ACS 400

ACS 450

Repair instructions
EN A/C service unit
 en ACS 400/450

1 689 973 193 (2006-09-18)

Robert Bosch GmbH
ACS 400/450
1. Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Test equipment and resources . . . . . . . . . . . . . . . . . 4
3. General and component overview . . . . . . . . . . . . . . 4
3.1 General overview...........................................................................4
3.1.1 Electronics compartment.............................................................4
3.1.2 Cold chamber.................................................................................5
3.2 Component overview....................................................................5
3.2.1 Valve block......................................................................................5
3.2.2 Preparation unit..............................................................................6
3.2.3 Control PCB...................................................................................6
3.2.4 Refrigerant cylinder.......................................................................6
4. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 According to function and error messages.............................7
4.1.1 Function messages.......................................................................7
4.1.2 Error messages..............................................................................7
4.2 According to symptoms...............................................................8
5. Calling up calibration and service menu (0000) 10
6.1 Overview of sub-menus.............................................................10
6.2 Calling up sub-menu...................................................................10
7. Description of sub-menu . . . . . . . . . . . . . . . . . . . . . 11
7.1 Calibrating scales (000l)...........................................................11
7.2 Resetting maintenance counter (0005)..................................11
7.3 Function and component test (00l5)......................................12
7.4 Printer configuration (0050)......................................................12
7.5 System parameter menu (0567)...............................................12
8. Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8.1 Functional testing of operating / display unit........................13
8.2 Testing pressure switch..............................................................13
8.3 Check pressure sensor..............................................................13
Robert Bosch GmbH
en 
9. Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
9.1 Opening and closing ACS 400 / ACS 450..........................14
9.1.1 Electronics compartment...........................................................14
9.1.2 Cold chamber...............................................................................14
9.2 Replacing control PCB..............................................................15
9.3 Operating / display unit..............................................................16
9.3.1 Replacing operating / display unit...........................................16
9.3.2 Checking operating / display unit............................................16
9.4 Scales for refrigerant cylinder...................................................16
9.4.1 Replacing force sensor..............................................................16
9.4.2 Calibrating scales........................................................................17
9.5 Valve block....................................................................................18
9.5.1 Replacing valve block.................................................................18
9.5.2 Calibrating pressure sensor......................................................19
9.6 Pressure sensor...........................................................................19
9.6.1 Replacing pressure sensor.......................................................19
9.6.2 Calibrating pressure sensor......................................................19
9.7 Replacing vacuum pump.......................................................... 20
9.8 Replace the preparation unit.....................................................21
9.8.1 Removing preparation unit........................................................21
9.8.3 Installing preparation unit...........................................................21
9.9 Replacing pressure switch....................................................... 22
10. Piping connection diagram . . . . . . . . . . . . . . . . . . . 23
11. Pneumatic circuit diagram . . . . . . . . . . . . . . . . . . . 24
12. Electrical connection diagram . . . . . . . . . . . . . . . . 25
12.1 General connection diagram................................................... 25
12.2 Wiring harness connection diagram...................................... 26
12.2.1 Connecting to control PCB..................................................... 26
12.2.2 Connecting to valve block........................................................ 26
1 689 973 193 (2006-09-18)
 en ACS 400/450

1. Important notes 3. General and component overview

Installation and/or repair may only be performed by trained 3.1 General overview
and instructed Service personnel at Robert Bosch GmbH
3.1.1 Electronics compartment
or by organizations appointed to do such work by Robert
Bosch GmbH. If the devices are opened or modified by 7
unauthorized persons, then all warranty claims will be
5 6
rendered null and void.
Electrical systems and resources may only be put into
operation when in proper operating condition (see hereto
also Inspection and testing information 0108_084). This Kg/g

min/s

requirement is deemed to have been fulfilled, if after

mbar

LP

1
HP
R134a
V

R134a

modification or repair (initial test) it has been ascertained

that requirements as specified by the electrotechnical rules
have been adhered to. To this end tests as under the type and
4
scope of the measures defined by the electrotechnical rules 3 2
(e.g. in Germany BGV A2) are to be conducted. The type 459786-5
and scope of tests are specified in VDE 0701/0702 Section 1
within Germany. Corresponding national specifications are Fig. 1: Component overview in electronics compartment
to be adhered to. 1. Terminal box with control PCB
2. Valve block
3. Operating / display unit
4. Low pressure (LP) and high pressure tap (HP)
2. Test equipment and resources 5. Pressure gauge LP
# General tools for electricians and mechanics. 6. Pressure gauge HP
# Digital multimeter. 7. Printer (Szb.)
# Pipe sealing compound with PTFE (e.g. RODI-DOS-
PTFE from Würth).
# Cleaning agent (e. g. brake cleaner).
# Weights for calibration of scales:
− 10 kg
− 5 kg
− 2 kg
− 2 kg

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ACS 400/450 en 

3.1.2 Cold chamber 3.2 Component overview

3.2.1 Valve block

1 6 7 8 9 10

11

2
4
3

6-4 5 4 3 2
78
4 59

459786_7

Fig. 3: Valve block overview

Fig. 2: Component overview in cold chamber 1. Hose line for return and feed lines
1. Refrigerant cylinder (reservoir) 2. Solenoid valve (OUT L) for oil injection phase
2. Scales 3. Solenoid valve (OUT R) for filling phase
3. Vacuum pump 4. Solenoid valves (OUT A) for recovery / recycling phase
4. Preparation unit 5. Solenoid valves (OUT B) for vacuum phase
6. Pressure sensor
7. Terminal to vacuum pump
8. Terminal to preparation unit
9. Terminal to refrigerant cylinder
10. Terminal to oil separator
11. Nonreturn valve

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 en ACS 400/450

3.2.2 Preparation unit 3.2.3 Control PCB

! Any change to the setting of the expansion valve 7
(Pos. 11) may impair the functional capability of the PRINTER

1
ACS 400 / ACS 450.

OUT HP
IN CMP
IN PMP
V +18

V +18
GND

GND
13

IN 8
IN 6
IN 4
IN 3
IN 1
IN 7
F1 J2 2

200 mA T
12

1 6 F2

3
LINE IN

11
BN
BN
BU
BU

2 TERRA
YE/GN
OUT 8 OUT 7 OUT 6 OUT 4 OUT 3 OUT 1 PUMP PUMP
PROTECT.

COMPRESS.
F3
YE/GN BN BN BN BN BN BN BN BN BN

TERRA BU BU BU BU BU BU BU BU BU

YE/GN YE/GN YE/GN YE/GN YE/GN YE/GN YE/GN YE/GN YE/GN YE/GN

3
4 5 4 459786_6
5
10

Fig. 5: Overview of control PCB

1. Printer supply voltage (special accessories)
6 2. Operating / display unit connection
7 3. Pressure switch supply voltage
4. ACS component supply voltage
5. F3 (10 AT) safety fuse for mains connection
8 6. F2 (10 AT) safety fuse for mains connection
7. F1 (200 mAT) safety fuse for 12 Volt supply

3.2.4 Refrigerant cylinder

4

9
1
2
6-4
59
78 3
4

Fig. 4: Component overview of preparation unit

1. Feed hose to preparation system
2. Coarse filter
3. Moisture and oil separator
4. Oil separator
5. Feed hose for refrigerant cylinder
6. Feed hose for used-oil tank
7. Solenoid valve (OUT S) for oil drain
8. Condenser with fan
9. Compressor
10. Filter and desiccator cartridge
11. Expansion valve
12. Nonreturn valve
13. Pressure switch

459786_9

Fig. 6: Component overview of refrigerant cylinder

1. Safety valve (excess pressure)
2. Safety valve (for non-compressible gases)
3. LP fitting terminal
4. HP fitting terminal
1 689 973 193 (2006-09-18)
Robert Bosch GmbH
ACS 400/450 en 

4. Troubleshooting
4.1 According to function and error messages
4.1.1 Function messages

Message Description Problem solution

Maintenance message. Maintenance deadline reached. No
-5WWE- Perform maintenance and reset counter (see Operating
instructions 1 689 979 930 Chapter 14).
Acknowledge message with key E (> 3 sec.).

Insufficient refrigerant volume in internal refrigerant cylinder. # Fill refrigerant cylinder.

noWWFL
# Operating / display unit faulty. Replace operating / display unit.

Excess pressure in refrigerant cylinder. # Open shutoff valves and shutoff cocks on internal refrigerant
Excess pressure in path between compressor and refrigerant cylinder.
cylinder. # Switch off ACS 400/450 and wait for 30 minutes. Following
-HWWP-
this start the recovery / recycling phase again.
# Check nonreturn valve in feed hose to refrigerant cylinder.
# Check pressure switch.

-PWWM- Maximum permissible net weight (10 kg for ACS 400, 20 kg # Reduce refrigerant in refrigerant cylinder.
for ACS 450) of refrigerant cylinder is reached.

Weight limit reached. Weight limit can be set in the recovery / # Reduce refrigerant in refrigerant cylinder.
-PWWL- recycling phase.
Acknowledge message with key E  .

4.1.2 Error messages

Message Description Problem solution

Absolute pressure in the vehicle A/C system is less than 1.4 bar. Start and run recovery / recycling phase.
-EWWE-
Acknowledge message with key E (> 3 sec.).

Maximum permissible time to evacuate vehicle A/C system Read off pressure on pressure gauge.
reached. # Pressure available:
Solenoid valves for recovery / recycling phase fail to open:
$ Check solenoid valves.
$ Check actuation of solenoid valves.
-EWWl- # Pressure not available:
Vehicle A/C system leaks
or
leakage in preparation unit
$ Search terminal connections for signs of leaks.
$ Check solenoid valve for oil drain.

Pressure increase during pressure loss measurement # Check vehicle A/C system for leakage.
-EWW2- (leakage test) in vacuum phase. # Check connections and condition of filling hoses.
# Check connections and condition of quick-release couplings.

Maximum permissible time for filling reached. Absolute # Open low pressure (LP) and high pressure tap (HP).
-EWW3- pressure in vehicle A/C system and in refrigerant cylinder # Open valve taps on refrigerant cylinder.
probably have identical values. # Check filling capacity in refrigerant cylinder and fill if necessary.

Absolute pressure in vehicle A/C system is too high for the oil # Perform vacuum phase.
-EWW4- injection phase.

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 en
4.2 According to symptoms
Error pattern
The digital display does not
light up.
The recovery and recycling phase
is slow or does not run at all.
The recovery and recycling phase
ends prematurely or not at all.
The gauge pressure rises after the
recovery and recycling phase.
The vacuum phase does not start.
The leakage test at the end of the
vacuum phase failed.
Filling in the filling phase is very
slow or is interrupted before the
set quantity has been filled.
1 689 973 193 (2006-09-18)
Cause
Power supply interrupted.
The control / display unit or the control
printed circuit board is defective.
Wrong working position of the external
refrigerant cylinder when filling.
Low pressure valve and/or high pressure Open the valve in question.
valve is/are closed.
Flow in the hose lines may be faulty.
Excess pressure in internal refrigerant
cylinder.
Compressor defective.
Filter and drier cartridge is saturated.
Ice in expansion valve due to aspirated
water.
Do not switch OUT A solenoid valves.
Incorrectly calibrated or faulty pressu-
re sensor.
Valve pistons for the recovery and recy-
cling phase are leaking.
The valve pistons for the filling phase
are leaking.
The vacuum pump does not start.
Duration of the vacuum phase is too
short.
Leaking vehicle air conditioning system.
ACS is leaking internally.
Insufficient refrigerant in the internal re- Fill internal refrigerant cylinder with fresh refrigerant.
frigerant container.
Pressure in the internal refrigerant cylin- Fill internal refrigerant cylinder with fresh refrigerant.
der is too low.
ACS 400/450
Troubleshooting and correction
Check mains input voltage.
Check fuse F1 on the control printed circuit board.
Replace defective fuse.
Replace the control / display unit or control printed circuit
board.
Correct the working position of the external refrigerant cy-
linder (see operating instructions).
Check external and hose lines, whether the sealing rings
have become deformed due to tightening of the hose lines,
thereby possibly blocking the flow of the refrigerant. Care-
fully loosen hose lines and tighten them again by hand. Re-
place misshapen seals if necessary.
Reduce pressure in the internal refrigerant cylinder by pull-
ing the metal ring on the safety valve for excess pressure
(see Chap. 3.2.4, Item 1).
Replace processing unit.
Replace the filter and drier cartridge.
Heat expansion valve and replace all refrigerant from the
ACS with fresh refrigerant.
Check relay on the control printed circuit board. If the re-
lay has blown, replace the control printed circuit board.
Check electrical connection to the solenoid valves.
Check connecting lines to the solenoid valves for continui-
ty. Replace defective connecting line.
Connecting lines to the solenoid valves have been swap-
ped. Check connection against connection diagram / wi-
ring harness (see Chap. 12.2).
Connecting lines to control printed circuit board have be-
en swapped. Check connection against connection dia-
gram / wiring harness (see Chap. 12.2).
Check pressure sensor (see Chap. 8.3).
Check condition (contamination, wear) of the valve pistons
in the valve block.
Caution: Close the shutoff valve on the internal refrige-
rant cylinder before testing.
Check condition (contamination, wear) of the valve pistons
in the valve block.
Check fuses F2 and F3 on the control PCB.
Check relay on the control printed circuit board. If the re-
lay has blown, replace the control printed circuit board.
The vacuum pump is mechanically blocked. Replace vacu-
um pump.
Vacuum phase duration: approx. 30 min. for vehicles
(for larger systems, e.g. commercial vehicles, set a corre-
spondingly longer vacuum time).
Repair the vehicle's air conditioning system.
Check external filling hoses and their connections
(e. g. are seals present?).
Check condition (contamination, wear) of the valve pistons
in the valve block.
Optimum amount: approx. 7 kg.
Optimum pressure: approx. 6-7 bar.
Robert Bosch GmbH
ACS 400/450 en 

Error pattern Cause Troubleshooting and correction

The quantity filled does not match Scale is not calibrated.
the set amount.
Compressor will not start.
White smoke escapes from the va-
cuum pump.
Mechanical malfunction in the scale mo-
vement.
Power supply interrupted.
Aspirated ambient air.
Check scale with a known weight. If the value does not
match, calibrate the scale (see Chap. 9.4.2).
Check whether the movement of the scale and the refrige-
rant cylinder is blocked mechanically by other components.
Check fuses F2 and F3 on control PCB. Replace defective
fuse.
Check relay on the control printed circuit board. If the re-
lay has blown, replace the control printed circuit board.
Inspect the vehicle air conditioning system and ACS for
leaks and repair. Small quantities of smoke in the first mi-
nutes of the vacuum phase are permitted.

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10 en ACS 400/450

5. Calling up calibration and service menu 6.1 Overview of sub-menus

(0000)
The following sub-menus are available for selection:
The calibration and service menu includes several sub
menus which can be called up for configuration, repair or
for a function test following repair work. Menunr. Description
000l Menu for calibration of scales for refrigerant.
Procedure:
0005 Menu for resetting maintenance counter.

i The net weight of the internal refrigerant cylinder may 00l5 Menu for checking functions and components.
vary. Before initial startup of an ACS 400 or ACS 450 0050 Menu for configuration of printer (Szb.).
the net weight indicates a negative value (ACS 400 =
0567 Menu for entering or changing system parameters.
approx. -00.800; ACS 450 = -01.400).
1. Connect mains cable. Tab. 3: Sub-menus
2. Switch on main switch on rear panel of ACS 400 /
ACS 450. Following switch-on the following messages 6.2 Calling up sub-menu
are successively displayed on the operating / display
Procedure:
unit:
 In the calibration and service menu 0000 enter the
Display Comments number of the sub-menu required (e. g. 0050):
UWE:l:0 Software version number is displayed (approx. 1 se-
cond).
Display Key
-PWWA- Operating interval (approx. 1 second).
0000 Set value 0050.
Net weight of internal refrigerant cylinder is displa- E Press key.
04:960 0050
yed in kilograms.
Print
Tab. 1: Display after switching on
Tab. 4: Example: Input in menu for configuration of printer
3. Call up calibration and service menu (0000):
r Sub-menu 0050 selected.

Display Key
E Press and hold key.
04:960
04:960 Press key.
04:960 Press and hold key.
E Release key.
04:960
04:960 Release key.
0000

Tab. 2: Input in calibration and service menu

r The calibration and service menu 0000 has been

called up.6. Sub-menus

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ACS 400/450 en 11

7. Description of sub-menu 7.2 Resetting maintenance counter (0005)

7.1 Calibrating scales (000l) Upon reaching the maximum operating time a signal is
sounded each time the ACS 400 / ACS 450 is switched
Menu for calibration of scales for refrigerant cylinder.
on with the message -5WWE-. As from this point in
Procedure: time maintenance must be performed on the ACS 400
/ ACS 450. To do so see Chapter 14 "Maintenance" in
Display Key operating instructions for "A/C service device" with order
Set value 0001.
number: 1 689 979 930. Once the ACS 400 /450 has been
0000
E Press key.
serviced the maintenance counter is reset.
000l
E
P---0
P---F Place 10 kg weight onto scales.
E
P---F
9.976 Set value of weight 10.000.
E Remove weight.
l0:000
Place weight onto scales:
P---t For ACS 400 = 9 kg
For ACS 450 = 17 kg
E
P---t
E Remove weight.
-End-

Tab. 5: Calibration procedure for scales

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Robert Bosch GmbH
12 en ACS 400/450

7.3 Function and component test (00l5) 7.5 System parameter menu (0567)
Menu for testing functions and components (LED test, Configuration menu for ACS system parameters.
display test etc.) for ACS 400 / ACS 450.
! Changes to programmed values may impair the
The following testing options are available: functional capability of the ACS 400 / ACS 450 or
damage it.
Menunr. Description
Testing of display segments of operating / display Code Value Unit Description
tE5tw1 unit.
P-t02 60 No details
tE5tw2 LED testing of operating / display unit.
Testing of control keys and supply voltage of com- Duration of pressure measurement in
P-t03 l80 sek
pressor and fan for condenser. Following selection recovery / recycling phase
the compressor and fan start to run cyclically. The Compressor operating time after pres-
tE5tw4 control keys are tested by selecting the keys. Fol- P-t04 60 sek
sure measurement (P-t03).
lowing selection a display segment is shown in the
display. P-t05 45 No details

The weight of the scales for the refrigerant is dis- Duration of pressure loss during vacu-
tE5tw5 P-t06 04 min
played. um phase.

tE5tw6 Pressure sensor shows the pressure display in mV. P-t07 05 No details

tE5tw7 Without function P-t08 02 No details

tE5tw8 Without function P-t09 60 No details

tE5tw9 Printer test printout (Szb.) P-tl0 00 No details

-End- Exit sub-menu. P-tll 09 No details

P-tl2 60 No details
Tab. 6: Menu description
P-tl3 05 No details

P-tl4 240 No details

7.4 Printer configuration (0050)
P-tl5 05 No details
This menu can be used to activate the printer (special
Compressor switches off once abso-
accessory) after installation.
P-udL u0:700 bar lute pressure is reached during reco-
very phase.
Compressor does not switch on again
once absolute pressure is reached du-
P-udH ul:400 bar ring the pressure measurement in the
recovery / recycling phase until the
pressure P-udL is reached.
Limit in vacuum phase. If the pressure
P-udl u0:l20 bar lies +1 bar absolute above this value,
then error message -E2- is displayed.

P--Fd l:000 No details

rE5 No details

l0:000 For ACS 400

20:000 kg For ACS 450
P--Lb Maximum permissible net weight of
refrigerant.

t--AL 3600 min Maintenance counter operating time.

Menu for calibration of pressure sen-
u---F sor.
l9:500 For ACS 400
P---M 38:500 kg For ACS 450
No details

rE5 No details
Default value for filling quantity during
P-CFd 00:700 kg filling phase.

-End- out Configuration menu output.

Tab. 7: System parameter menu

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ACS 400/450 en 13

8. Testing 8.3 Check pressure sensor

8.1 Functional testing of operating / display unit Procedure:
Procedure: 1. Plug in power plug.
2. Switch on ACS 400 / ACS 450.
1. Call up calibration and service menu 0000 (see
3. Remove quick release coupling from hose line LP.
Chapter 5).
4. Open low pressure valve completely.
2. Call up sub-menu 00l5 (see Chapter 6).
5. Call calibration and customer service menu 0000 (see
3. Call up function tests tE5tWl, tE5tW2, tE5tW4 one
Chapter 5).
after the other and then run (see Chapter 7.3).
6. Call submenu 00l5 (see Chapter 6).
7. Call and run function tests tE5tW6W (see Chapter 7.3).
8.2 Testing pressure switch
8. Read result. Pressure must be approx. 1000 bar.
9. Exit calibration and customer service menu.
Danger - Danger of electric current
10. Remount quick release coupling.
Touching voltage-carrying parts on the main switch
11. Close low pressure valve.
and on the control PCB may result in severe physical
12. Start vacuum phase.
injury or a fatality.
13. Cancel vacuum phase after approx. 45 seconds.
e Detach power plug.
12. Call calibration and customer service menu 0000 (see
e Disconnect main switch using a padlock.
Chapter 5) and read result. Pressure must be < 0.050
bar.
The pressure switch interrupts the supply voltage of the
compressor where the system has excess pressure. Pressure
If one of the two measurement values lies outside the
switch testing is done by means of a continuity test between
specified setpoints, calibrate the pressure sensor (see
Pin 1 and Pin 2.
Chapter 9.5.2) and check it again. If the measurement
Procedure: values are still outside the setpoints, replace the pressu-
re sensor (see Chapter 9.6.1).
i During the test procedure there must be no pressure in
the preparation unit.
1. Open terminal box.
2. Detach both supply lines of pressure switch from
control PCB.
3. Connect continuity tester to both supply lines.
4. Check pressure switch for continuity:
# Continuity given - Pressure switch OK.
# Continuity not given - Check connecting lines.
Replace pressure switch (see Chapter 9.8).

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14 en ACS 400/450

9. Repair 9.1.2 Cold chamber

Warning - Risk of frostbite

When performing repair work on the ACS 400 /
ACS 450 refrigerant may escape in liquid or gaseous Kg/g

min/s

form and cause frostbite on the body. LP

R134a
V

HP

e Close valves on refrigerant cylinder.

e Wear safety glasses.
e Wear protective gloves.

9.1 Opening and closing ACS 400 / ACS 450

9.1.1 Electronics compartment
1 2
-13
79
5 97
4
B OSC
2 H
ACS
400

1 1

Fig. 8: Cold chamber

Open cold chamber:

1. Remove hexagon socket screws (Pos. 2).
2. Slide on front cover (Pos. 1).
Close cold chamber:
Kg/g

min/s

1. Slide on front cover (Pos. 1).

mbar

R134a

LP V

HP
2. Use four hexagon socket screws (Pos. 2) to fasten front
cover in place.

3 459786/12

Fig. 7: Electronics compartment

Open electronics compartment:

1. Remove four sheet-metal screws (Pos. 1).
2. Mount cover (Pos. 2) back and lift upwards and out.
Close electronic compartment:
1. Mount cover (Pos. 2) and slide forward and under the
control panel (Pos. 3).
2. Fasten cover using four sheet-metal screws (Pos. 1) into
place.

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ACS 400/450 en 15

9.2 Replacing control PCB 11. Connect wiring harness (see Chapter 12.2).
12. Mount housing cover (Pos. 1) onto terminal box and
Danger - Danger of electric current fasten in place.
Touching voltage-carrying parts on the main switch 13. Mount cover onto electronics compartment.
and on the control PCB may result in severe physical
injury or a fatality.
e Detach power plug.
e Disconnect main switch using a padlock.

Procedure:
1. Switch off ACS 400 / ACS 450 at main switch.
2. Detach power plug.
3. Remove cover of electronics compartment.

3
8
86_1
4597

2
Fig. 9: Terminal box

4. Mount housing cover (Pos. 1) from terminal box

(Pos. 2).
5. Detach all connecting lines from control PCB (Pos. 3).

4 4

459786_26

Fig. 10: Terminal box

6. Undo fastening screws (Pos. 4).

7. Remove control PCB (Pos. 5).
8. Insert new control PCB into terminal box.
9. Fit control PCB in place using fastening screws
(Pos. 4).
10. Connect operating / display unit connecting line and,
where applicable plug connecting cable onto printer.
(see Chapter 12.1)

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16 en ACS 400/450

9.3 Operating / display unit 9.4 Scales for refrigerant cylinder

9.3.1 Replacing operating / display unit 9.4.1 Replacing force sensor
Procedure: Procedure:
1. Switch off ACS 400 / ACS 450 at main switch. 1. Switch off ACS 400 / ACS 450 at main switch.
2. Detach power plug. 2. Detach power plug.
3. Remove cover of electronics compartment. 3. Remove covers on electronics compartment and cold
chamber.
4
6 2 3
7

1, 2
5

1
5

4
459786_11
3
1, 2

Fig. 11: Operating / display unit

3. Plug connecting lines (Pos. 3 to Pos. 5) onto rear panel 459786_15

of operating / display unit (Pos. 6).
4. Undo hexagon nuts (Pos. 1) and washers (Pos. 2). Fig. 12: Refrigerant cylinder
5. Remove operating / display unit from control panel
4. Close shutoff taps (Pos. 2) and shutoff valves (Pos. 4).
(Pos. 7).
5. Remove both hose lines (Pos. 3).
6. Insert new operating / display unit into control panel
6. Undo fastening screw (Pos. 1) for refrigerant cylinder.
(Pos. 7).
7. Remove refrigerant cylinder (Pos. 5) from scales.
7. Fasten operating / display unit using hexagon nuts
(Pos. 1) and washers (Pos. 2).
8. Plug connecting lines (Pos. 3 to Pos. 5) onto operating /
display unit (see Chapter 12.1).
The following work must also be performed after
replacement:
 Calibrate scales (see Chapter 7.1).
 Calibrate pressure sensor (see Chapter 9.5.2).
 Connect printer (if given) (see Chapter 7.4).

9.3.2 Checking operating / display unit

Procedure:
1. Perform function test (see Chapter 8.1).
2. If the ACS 400 / ACS 450 passes the test mount the cover 6
back onto the electronics compartment. 459786_16

Fig. 13: Operating and display unit

8. Detach connecting line (Pos. 6) from operating / display

unit.

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ACS 400/450 en 17

9.4.2 Calibrating scales

Procedure:
1. Call up calibration and service menu 0000 (see
6 Chapter 5).
2. Calibrate scales (see Chapter 7.1).
3. Mount refrigerant cylinder onto scales.
4. Fasten refrigerant cylinder using fastening screw
(see Fig. 12, Pos. 1) into place.
5. Remove pipe sealing compound’s coarse residue from
connection thread of refrigerant cylinder for the hose
lines and clean using a suitable cleaning agent (e. g. brake
cleaner).
6. Apply thin coating of pipe sealing compound to
-14
connection thread of refrigerant cylinder.
86
97
45 7. Connect hose lines.
8. Open shutoff taps (see Fig. 12, Pos. 2) and shutoff valves
(see Fig. 12, Pos. 4) on refrigerant cylinder.
Fig. 14: Scales 9. Mount covers to electronics compartments and cold
chamber.
9. Remove scales (Pos. 7) completely from ACS 400 /
ACS 450.

459786-17

Fig. 15: Force sensor

10. Remove force sensor (Pos. 8).

11. Mount new force sensor.
12. Insert scales into mounting bores in ACS 400 / ACS 450
and fasten in place.
13. Plug connecting line of fuel sensor onto operating /
display unit.
14. Fasten connecting line in place with cable ties.

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18 en ACS 400/450

9.5 Valve block

9.5.1 Replacing valve block

Warning - Risk of frostbite! 7

8
When performing repair work on the ACS 400 /
ACS 450 refrigerant may escape in liquid or gaseous 4
form and cause frostbite on the body. 3
e Close valves on refrigerant cylinder. 6
e Wear safety glasses. 5
e Wear protective gloves.
4597
86_1
9

Warning - Risk of burn injuries!

Hot surfaces on the valve block may cause severe
burn injuries to the hands.
e Allow valve block to cool down.
e Wear protective gloves.

Procedure:
2
1. Switch off ACS 400 / ACS 450 at main switch.
2. Detach power plug.
Fig. 17: Valve block
3. Remove covers on electronics compartment and cold
chamber.
6. Undo hexagon screws (Pos. 2) with washers.
4. Close shutoff taps and shutoff valves on refrigerant
7. Connect hose line (Pos. 7) from HP terminal (red) of
cylinder.
refrigerant cylinder.
8. Slide hose lines (Pos. 5 and Pos. 6).
9. Undo union nut of hose lines (Pos. 3 and Pos. 4).
1 10. Slide hose lines (Pos. 3 and Pos. 4) from connecting
pipe.

4597
86_2
0

Fig. 16: Solenoid valve connector

5. Detach all solenoid valve connectors (Pos. 1).

9 459786_22

Fig. 18: Operating / display unit

11. Detach pressure sensor connecting line (Pos. 9).

12. Remove valve block (Pos. 8).
13. Insert new valve block.

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ACS 400/450 en 19

9.6 Pressure sensor

9.6.1 Replacing pressure sensor
Procedure:
11
4597
86_2 10
1 1. Switch off ACS 400 / ACS 450 at main switch.
2. Detach power plug.
Fig. 19: Connecting pipe 3. Remove covers from electronics compartment.
4. Remove valve block (see Chapter 9.5.1).
14. Apply thin coating of pipe sealing compound onto 2
thread of connecting pipe (Pos. 10 and Pos. 11).
15. Screw on hose lines (Pos. 5 and Pos. 6) (see Fig. 17). 1
16. Slide hose lines (Pos. 3 and Pos. 4) with union nut onto
connecting pipe and fasten in place.
17. Connect hose line (Pos.7) to HP (red) terminal of
refrigerant cylinder.
4597
18. Fasten valve block using hexagon screws and washers in 86-2
8
place.
19. Fit connectors to solenoid valves (see Chapter 12.2.1). Fig. 20: Removing pressure sensor
20. Connect pressure sensor connecting line to operating /
5. Unscrew pressure sensor (Pos. 2).
display unit (see chapter 12.1).
6. Apply thin coating of pipe sealing compound to internal
21. Open shutoff taps and shutoff valves on refrigerant
thread of new pressure sensors.
cylinder.
7. Screw pressure sensor into valve block (Pos. 1).
22. Mount covers.
8. Install valve block (see Chapter 9.5.1).
9.5.2 Calibrating pressure sensor
9.6.2 Calibrating pressure sensor
Procedure:
See Chapter 9.5.2
1. Plug-in power plug.
2. Switch on ACS 400 / ACS 450.
3. Remove quick-release coupling from LP hose line.
4. Open low pressure tap completely.
5. Call up calibration and service menu 0000 (see
Chapter 5).
6. Call up sub menu 0567 (see Chapter 6) and proceed as
follows:

Display Key
0000 Set value 0567.
E
0567
P-t02 V x22 x 22
E
u---F
E
u0.988
u1.005 Set current ambient pressure (1.005 bar).
E
u1.005
-End- V x22
E Exit sub-menu.
-End-

Tab. 8: Pressure sensor calibration

7. Remove pipe sealing compound’s coarse residue from

internal thread of quick-release coupling and clean
using a suitable cleaning agent (e. g. brake cleaner).
8. Apply thin coating of pipe sealing compound to internal
thread of quick-release coupling.
9. Screw quick-release coupling onto LP hose line and
tighten.

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20 en ACS 400/450

9.7 Replacing vacuum pump

Warning - Risk of burn injuries!

Hot surfaces on the vacuum pump may lead to severe
burns to the hands.
e Allow vacuum pump to cool down.
e Wear protective gloves.

Procedure:
1. Switch off ACS 400 / ACS 450 at main switch.
2. Detach power plug.
3. Remove cold chamber cover.
4. Close shutoff taps and shutoff valves on refrigerant
cylinder.
5. Place collector for used oil under the opening in the base 45
97
86
_2
5

of the trolley.

1 8

Fig. 23: Vacuum pump removal

14. Undo hexagon screws (Pos. 8).

15. Remove vacuum pump.
16. Insert new vacuum pump and tighten in place.
2 17. Remove pipe sealing compound’s coarse residue from
4597
86-2 thread on threaded socket (Pos. 4) and clean using a
3
suitable cleaning agent (e. g. brake cleaner).
18. Apply thin coating of pipe sealing compound to thread
Fig. 21: Vacuum pump
of threaded socket (Pos. 4).
19. Screw threaded socket (Pos. 4) into connecting pipe of
6. Close oil drain screw (Pos. 2) of vacuum pump and
vacuum pump.
allow oil to be completely drained off.
20. Connect hose line (Pos. 3).
i Dispose of used oil at appropriate return points. 21. Remove lid of terminal box for vacuum pump.
22. Route connecting line (Pos. 7) through cable
7. Close oil drain screw (Pos. 2) of vacuum pump.
connection.
3 23. Join connecting line to engine line according to
4 following connection diagram:
5
6
7 Connecting line Engine line
GN/YE lead GN/YE lead
BU lead BK lead
BN lead RD lead
4
459786_2

24. Tighten cable connection.

Fig. 22: Vacuum pump
8. Remove lid for terminal box (Pos. 5) of vacuum
pump.
9. Open cable connection (Pos. 6).
10. Route connecting line (Pos. 7) and remove from cable
connection (Pos. 6).
11. Open union nut of hose line (Pos. 3).
12. Connect hose line (Pos. 3).
13. Screw threaded socket (Pos. 4).
25. Close terminal box.
26. Undo screw plug (Pos. 1) for oil-filling orifice.
27. Fill with vacuum pump oil according to the
amount stated in the ACS 400 / ACS 450 operating
instructions.
28. Close oil-filling orifice with screw plug.
29. Open shutoff taps and shutoff valves on refrigerant
cylinder.
30. Mount cold chamber cover.

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ACS 400/450 en 21

9.8 Replace the preparation unit

Warning - Risk of frostbite!

When detaching hoses or when replacing a pressure
switch, refrigerant will escape in liquid or gaseous 1 2
form and may cause severe frost bite on the body.
e Wear safety glasses.
e Wear protective gloves.

9.8.1 Removing preparation unit

Procedure:
i The replacement processing unit is delivered without a
pressure switch. When replacing the processing unit, the
pressure switch must therefore be removed from the old 45
97
86
-30

processing unit and fitted on the new one.

1. Switch off ACS 400 / ACS 450 at main switch.
2. Detach power plug.
Fig. 24: Preparation unit removal
3. Remove cold chamber cover.
4. Close shutoff taps and shutoff valves on refrigerant 11. Remove sheet-metal screws (Pos. 1).
cylinder. 12. Lift preparation unit (Pos. 2) out of trolley.
5. Detach hose line, which runs from the preparation 13. Remove pressure switch (see chapter 9.9).
unit’s condenser to the refrigerant cylinder, at blue
terminal on refrigerant cylinder. 9.8.3 Installing preparation unit
6. Detach hose line on preparation unit’s coarse filter.
Procedure:
7. Detach hose line on solenoid valve for oil drain.
6. Detach electrical line in terminal box of vacuum 1. Fit pressure switch (see Chapter 9.9).
pump. 2. Install preparation unit into trolley in reverse sequence
7. Detach electrical line in terminal box of condenser. to the one described in Chapter 9.8.1.
8. Remove ground lead on base of retaining panel on 3. Fasten electrical connecting lines in place using cable
preparation unit. ties.
9. Remove connecting lines from solenoid valve for oil
drain and on pressure switch.
10. Detach connecting line from fan of condenser.

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22 en ACS 400/450

9.9 Replacing pressure switch

Warning - Risk of frostbite!

When detaching hoses or when replacing a pressure
switch, refrigerant will escape in liquid or gaseous
form and may cause severe frost bite on the body.
e Wear safety glasses.
e Wear protective gloves.

Procedure:

4
5
459786_31

Fig. 25: Pressure switch removal

1. Remove processing unit (see Chapter 9.8.1).

2. Unscrew pressure switch (Pos. 3) while counterholding
hexagon (Pos. 5).
3. Remove pipe sealing compound’s coarse residue from
connection thread (Pos. 4) and clean using a suitable
cleaning agent (e. g. brake cleaner).
4. Apply thin coating of pipe sealing compound to
connection thread (Pos. 4).
5. Screw pressure switch into connection and tighten by
counterholding connection thread.
6. Reinstall processing unit (see Chapter 9.8.2).

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ACS 400/450 en 23

10. Piping connection diagram

Kg/g

min/s

mbar

LP
R134a
V

HP
R134a

-3
86
97
45

Fig. 26: Piping connection diagram

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24 en ACS 400/450

11. Pneumatic circuit diagram

-1 - 34 bar

HP

-1 - 15 bar

LP

0 - 10 bar
P
U

OUT B OUT A OUT R OUT L

11,9/15 bar (ACS 400)

16/19,5 bar (ACS 450)

16 bar (ACS 400) 12,8 bar (ACS 400)

20 bar (ACS 450) 16 bar (ACS 450)

OUT S

459786-1

Fig. 27: Pneumatic circuit diagram

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ACS 400/450 en 25

12. Electrical connection diagram

12.1 General connection diagram

1 2
OUT HP

IN CMP
IN PMP

V +18

GND
IN 7

IN 6

IN 1
IN 3
IN 4

DRUCKER
PRINTER

PRINTER

OUT HP
IN CMP
IN PMP
V +18

V +18
GND

GND
IN 8
IN 6
IN 4
IN 3
IN 1
IN 7
J2
F1
200 mA T

8
11,9/15 bar (ACS 400)
F2
16/19,5 bar (ACS 450)
LINE IN
U BN
230 V BU P
N
50/60 Hz GN/YE PROTECT.
TERRA
F3
OUT 8 OUT 7 OUT 6 OUT 4 OUT 3 OUT 1 PUMP PUMP COMPRESS.
3
TERRA

M C 4
OUT C

7
OUT S
M P 5
OUT P

U
P 459786-2

OUT R OUT L OUT A OUT B

Fig. 28: General connection diagram

1. Operating / display unit 5. Vacuum pump

2. Scales 6. Valve block
3. Pressure switch 7. Solenoid valve for oil drain
4. Compressor 8. Master switch
9. Control PCB

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26 en ACS 400/450

12.2 Wiring harness connection diagram

12.2.1 Connecting to control PCB

459786_27a

LINE IN BN
BN
BU
BU
PROTECT.
YE/GN OUT 8 OUT 7 OUT 6 OUT 4 OUT 3 OUT 1 PUMP PUMP COMPRESS.
TERRA BN BN BN BN BN BN BN BN BN
YE/GN
BU BU BU BU BU BU BU BU BU
PROT
LINE TERRA
YE/GN YE/GN YE/GN YE/GN YE/GN YE/GN YE/GN YE/GN YE/GN
YE/GN

OUT 6 OUT 4 OUT 3 OUT 1 POM2 POM1 COMP

Fig. 29: Wiring harness connection to control PCB

12.2.2 Connecting to valve block

POM2C OUT 1A

459786_29

POM2 OUT 1 OUT 4 OUT 3

Fig. 30: Wiring harness connection to valve block

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Robert Bosch GmbH
ACS 400 0 684 350 400
ACS 450 0 684 350 450

Robert Bosch GmbH

Automotive Aftermarket
Test Equipment
Franz-Oechsle-Str. 4
D 73207 Plochingen
www.bosch.com
e-Mail: Bosch.Prueftechnik@de.bosch.com

Printed in Germany - Imprimé en Allemagne

1 689 973 193 (2006-09-18)