CTR Group PRATIKA User And Maintenance Manual
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CTR Group PRATIKA User And Maintenance Manual

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ECOLOGICAL MACHINE DIVISION
User and Maintenance Guide
___________________________________________
PRATIKA
P/N 4018014
Please fully read this User and Maintenance Guide before using the machine.
C.T.R. s.r.l. Via Via T.ed E. Manzini n° 9, 43100 Parma (Italy)
Tel. +39 0521/957611 - Fax. + 39 0521/957677

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  • Page 1 ECOLOGICAL MACHINE DIVISION User and Maintenance Guide ___________________________________________ PRATIKA P/N 4018014 Please fully read this User and Maintenance Guide before using the machine. C.T.R. s.r.l. Via Via T.ed E. Manzini n° 9, 43100 Parma (Italy) Tel. +39 0521/957611 - Fax. + 39 0521/957677...
  • Page 2 The Company C.T.R. s.r.l Via G.Di Vittorio, 78 43044 Lemignano di Collecchio (PR - Italy), in the name of its Legal Representative, declares, under its sole responsibility, that the machine System for managing conditioning and refrigerating plants, Model PRATIKA, complies with the provisions of directive 89/392 and directive 89/336 and subsequent modifications and integrations.

  • Page 3: Table Of Contents

    PRATIKA INTRODUCTION......................... 6 TECHNICAL CHARACTERISTICS..................7 IMPORTANT SAFETY INSTRUCTIONS................. 8 WORK ENVIRONMENT ......................8 PRELIMINARY CHECKS BEFORE USE ................. 9 USE............................. 9/10 3.4 MAINTENANCE............................. 11 3.5 ELECTRICITY SUPPLY........................11 INSTALLATION AND PRELIMINARY CHECKS............12/13 5- ELECTRICITY SUPPLY ........................14 HANDLING AND TRANSPORT ....................
  • Page 4 PRATIKA 9- PROBLEMS, CAUSES AND REMEDIES..................... 30 9 ERROR CODE LIST..........................31 10- STANDARD ACCESSORIES ....................... 31 11- OPTIONAL ACCESSORIES ........................ 32 11.1 OIL CONTAINERS..........................32 11.2 CHARGING AND SERVICE TUBES ....................32 11.3 LEAK DETECTOR..........................32 11.4 CLEANING OF VEHICLE A/C PLANT.................... 33 12- SPARE PARTS............................
  • Page 5 PRATIKA SYMBOLS KEY The key below illustrates the meaning of symbols used in this Guide. DANGER: indicates a situation or problems that can be a safety risk and an accident or life-threatening hazard for people. CAUTION: indicates situations or problems that are connected with the correct running of the machine but are not a safety hazard for people.

  • Page 6: Introduction

    R12 (model Pratika/12) or with R134-a (model Pratika/134). The PRATIKA system, thanks to the digitally controlled unit means that all operations can be carried out while fully respecting the environment.

  • Page 7: Technical Characteristics

    PRATIKA 2 – T E C H I C A L C H A R A C T E R I S T I C S The technical specifications in the chart below are given for the models according to the type of refrigerant used.

  • Page 8: Important Safety Instructions

    PRATIKA 3 – I M P O R T A N T S A F E T Y I N S T R U C T I O N S We recommend that you carefully read all sections of this guide before using the machine and become familiar with the workings of controls and settings on the machine.

  • Page 9: Preliminary Checks Before Use

    PRATIKA 3.2 PRELIMINARY CHECKS BEFORE USE In the event of a temporary power blackout, wait a minute (normally approx. 50-sec) before switching the machine back on, so that the electronic component has sufficient time to be reset. 3.3 USE Always use the machine with all safety devices correctly positioned. During normal operations, wear suitable protective gear in compliance with the directives in force (protective face mask, eye goggles, overalls and gloves).
  • Page 10 PRATIKA This figure indicates the areas on the machine where there may be a safety hazard during operations: 1) area where refrigerant may be ejected 2) components carrying live current ig.1 The use of the machine is for one operator only. We recommend that other persons present should be kept at a safe distance from the machine when operating and during setting and maintenance work.

  • Page 11: Maintenance

    PRATIKA 3.4 MAINTENANCE In no case should the operator use combustible or flammable liquids or detergents for cleaning the machine. Always wait a few minutes after switching the machine off so that the machine system has time to re-establish non-operational conditions (temperature and pressure).

  • Page 12: Installation And Preliminary Checks

    PRATIKA 4 – I N S T A L L A T I O N A N D P R E L I M I N A R Y C H E C K S Th machine is delivered packed in its protective packing material and sealed in a plastic cover.
  • Page 13 PRATIKA This description is a general overview of the machine functions and does not represent actual function on the machine. Fig.2 The machine is delivered with the cylinder correctly positioned in its seating on the weighing machine and already fixed with brackets (n.3) for this purpose.

  • Page 14: 5- Electricity Supply

    PRATIKA 5 - E L E C T R I C I T Y S U P P L Y The electrical connections to the machine should be carried out following the instructions supplied by C.T.R. s.r.l. which, in any case, is not responsible for connections. The machine safety mechanisms are only guaranteed when it is correctly connected to an electricity supply.

  • Page 15: Handling And Transport

    PRATIKA H A N D L I N G A N D T R A N S P O R T Before moving the machine, check that the machine is stable (when the machine is at rest, the braking mechanism blocking the machine located on the front wheels should be activated.

  • Page 16: 7-General Instructions For Use

    PRATIKA 7 - G E N E R A L I N S T R U C T I O N S F O R U S E 7.1 CONTROL PANEL This section describes the main functions present on the machine control panel. To fully understand all functions, we strongly advise reading the whole chapter in which the numbered figure below is fully explained.
  • Page 17 PRATIKA Description of number-key ON/OFF-Emergency switch Used oil discharge tank connection Control panel Oil injection tank connection Low pressure gauge Oil discharge valve (OIL DISCHARGE) High pressure gauge Oil injection valve (OIL INJECTION) LP valve (low pressure) HP valve (high pressure)

  • Page 18: Setting-Up The Unit

    PRATIKA 7.2 SETTING-UP THE UNIT To correctly connect up the machine, the operator should make sure that the machine is not plugged in to the mains supply (if plugged in) and unscrew the four screws positioned on the sides of the station and the two screws positioned above (on the sides of the mains panel board) the station, then lift up and slide out the plastic housing by gently pulling it towards him.

  • Page 19: Operating Phases

    PRATIKA Partially open (to approx. 45° degrees) the OIL DISCHARGE valve. This valve should always be keep in the partially shut position throughout all unit operating phases to avoid excessive pressure at discharge causing oil to be ejected out of the vent tube.

  • Page 20: Manual Mode Recovery Operation

    PRATIKA 7.4 Manual mode RECOVERY operation The aim of this operation is to recover and recycle all gas present in the A/C plant, separating it from oil and other impurities present. 7.4/1 Preliminary operations The operator should: - switch on the vehicle engine with the bonnet closed for a few minutes.

  • Page 21: Instructions For Carrying Out Gas Recovery

    PRATIKA 7.4/2 Instructions for carrying out gas recovery The aim of this operation is to recover and recycle all gas present in the A/C plant and separate it from oil and other impurities present. The maximum time required for this operation is 15 minutes (900 sec.)

  • Page 22: Manual Mode Vacuum Operation

    PRATIKA 7.5 Manual mode VACUUM operation This operation sets up a vacuum inside the A/C plant in a pre-set time permitting seals to be checked and subsequently to carry out recharging. The phases of this operation are the following: - Achieve Vacuum : by using a vacuum pump a minimum depression of –0.75 bar in a maximum time of 10 minutes (600 seconds) is achieved.

  • Page 23: Manual Mode Charging Operation

    PRATIKA 7.6 Manual mode CHARGING operation This function of the system permits refrigerant liquid and oil to be injected into the system according to a pre-programmed quantity and within a pre-set maximum time limit of 600 seconds (10 minutes). The programme contains two separate functions: recharging after having totally emptied the system and topping up (this is the only way of injecting the correct quantity of refrigerant in the system).

  • Page 24: Refrigerant Topping Up

    PRATIKA 7.6/2 Refrigerant topping up If refrigerant is already present in the A/C plant, the only way to inject gas is by TOPPING UP. To carry out this phase, it is necessary, after having connected up the unit to the A/C plant, to switch on the vehicle engine and wait a few minutes until the A/C plant is fully operational.

  • Page 25: Automatic Mode Complete Recovery And Vacuum Operation (Automatic Procedure)

    PRATIKA 7.7 Automatic mode complete recovery and vacuum operation (AUTOMATIC PROCEDURE) -This procedure allows the following operations to be carried out in sequence: -Gas recovery, recovered oil discharge, vacuum phase and vacuum seal check with pre- programmed, invariable times for each operation respect to the manual mode.

  • Page 26: Refrigerant Transfer From The Unit To An External Container

    PRATIKA 7.9 REFRIGERANT TRANSFER FROM THE UNIT TO AN EXTERNAL CONTAINER To carry out emptying of the cylinder the operator should: Connect the terminal of the yellow service tube (part without valve) supplied with the unit, to the Ref. Service valve.

  • Page 27: 8- Maintenance

    PRATIKA 8 - M A I N T E N A N C E Maintenance operations (unless otherwise specified in the instructions given in this user and maintenance guide) should always be carried out with the machine switched off and disconnected from the mains power supply.

  • Page 28: Topping Up Or Changing Oil In The Vacuum Pump

    PRATIKA 8.2 TOPPING UP OR CHANGING OIL IN THE VACUUM PUMP To top up or change oil in the vacuum pump, the operator should use oils that are designed for use in vacuum pumps. To top up, the operator should unscrew the cap of the vent (see illustration opposite) and top up with sufficient oil to the level of the screw of the indicator light.

  • Page 29: Recharging Of The Gas Storage Cylinder

    PRATIKA 8.4 RECHARGING OF THE GAS STORAGE CYLINDER We recommend never filling the recovery cylinder to more than 80% of its maximum capacity. We advise, to avoid excessive overheating of the compressor, not to recover an excessive quantity of gas at one time, but to wait a few minutes between operations,...

  • Page 30: 9- Problems, Causes And Remedies

    PRATIKA 9 - P R O B L E M S , C A U S E S A N D R E M E D I E S To carry out repairs, maintenance or adjustment operations that have not been described in the previous paragraphs, we recommend contacting qualified operators (In any other case, C.T.R.

  • Page 31: Error Code List

    PRATIKA Unit does not connect Unit model is not Check labelling for type Operator up with A/C plant compatible with type of of refrigerant refrigerant ERROR CODE LIST Cylinder full Excessive quantity of gas programmed for recovery Recovery time expired...

  • Page 32: 11- Optional Accessories

    C.T.R is Yokogawa’s exclusive authorised distributor. The method for tracking leaks can be briefly summed up as follows: Use the PRATIKA station to create a vacuum inside the A/C circuit. Inject tracer additives to the A/C system and carry out a refrigerant charging cycle (the...

  • Page 33: Cleaning Of Vehicle A/C Plant

    1 2 - S P A R E P A R T S All spare parts for PRATIKA are available at our authorised dealers and are distributed by C.T.R. 1 3 - L A B E L S A N D M A R K I N G S...

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