CTR Group Proch One Manuale

Proch One

Use and Maintenance handbook

The safest, most convenient solution for quick cleaning of A/C systems

Read this handbook carefully prior to starting use; pay special attention to the safety

information section.

PROCHONE can be used with flammable liquids. We recommend reading this handbook

carefully and abiding by sanitary and safety regulations.

PROCH ONE – A/C FLUSHING SYSTEM

INDEX

1. INTRODUCTION

1.1 FEATURES

1.2 COMPONENTS

1.3 NOISE LEVEL

2. DELIVERY, TRANSPORT AND ASSEMBLING

2.1 DELIVERY AND ASSEMBLING

2.2 TRANSPORT

3. SAFETY INFORMATION

3.1 WORKING ENVIRONMENT

3.2 PRELIMINARY CHECK

3.3 USE

1.1 MAINTENANCE

4. CONNECTION TO THE A/C SYSTEM

4.1 USE

5. TROUBLE-SHOOTING

6. REPLACING SPARE PARTS

7. SUPPLIED ACCESSORIES

8. CONTROLS

8.1 FUSE

8.2 HYDRAULIC CONNECTIONS

8.3 CABLES

9. USE

9.1 FILLING THE TANK

10. FAILURES

10.1 HYDRAULIC SYSTEM

11. MAINTENANCE

11.1 CLEANING THE BODY

11.2 MAINTENANCE OF QUICK FITTINGS

11.3 DISPOSAL

12 ELECTRICAL DIAGRAMS

13. SPLIT-UP DRAWING

SAFETY INFORMATION (SEE ALSO SAFETY DATA SHEET)

1. AVOID CONTACT WITH SKIN. WEAR PROTECTIVE GOGGLES AND SUITABLE

GLOVES

2. ALWAYS KEEP AN EXTINGUISHER (FOR FUEL) BY YOUR SIDE

3. IF PAINTED PARTS HAVE COME IN CONTACT WITH THE PRODUCT

IMMEDIATELY RINSE WITH WATER

4. USE IN WELL VENTILATED ROOM

5. DO NOT SMOKE NEAR THE MOTOR NOR PROCHONE IN ORDER TO AVOID

FIRES

6. FEEDING TO THE VEHICLE MUST BE OILTIGHT. CHECK FOR ANY LEAKAGE

PRIOR TO STARTING THE PROCESS

7. WATCH OVER THE VEHICLE WHEN THE PROCESS IS BEING CARRIED OUT

8. FEEDING TO PROCHONE MUST BE AT 12 V CC (VEHICLE BATTERY)

9. PROTECT ALL HOT OR PAINTED PARTS FROM PRODUCT SPLASHING WHEN

THE PROCESS IS BEING CARRIED OUT

1.INTRODUCTION

1.1 DESCRIPTION

1. PROCHONE allows effective cleaning of vehicle A/C systems

2. Pressure can be rated from 1-10 bar with high precision

3. PROCHONE can be powered by any 12V vehicle battery; no other supply source is

needed

4. The liquid moves inside a closed circuit, therefore there can be no spill of cleaning

product from the tank

5. The pump’s considerably high flow (180 l/h), makes it suitable for all A/C systems

6. The process can be stopped at any time: this increases safety of the system.

7. Connection to the A/C system is quick and easy. The accessories PROCHONE is

equipped with allow you to connect all parts of the A/C system to the cleaning unit at any

position

PROCHONE was designed for the functions stated herewith. Read safety data sheet carefully

and abide by it. PROCHONE was thought to be used with indicated components. Contact our

authorized distributor in case of need.

1.2 COMPONENTS

FRONT BACK

1) Fitting (quick connection) for RED hose to be connected to the A/C system inlet.

2) Pressure gauge (0-12 bar / 0-170 PSI).

3) Precision pressure regulator:

•For higher pressure rotate clockwise

•For lower pressure rotate counter-clockwise

4) Cleaning liquid tank

5) Fitting (quick connection) for BLUE hose to be connected to the A/C system outlet.

6) ON/OFF I/O switch for A/C system cleaning unit.

7) Filter

8) Air inlet fitting

9) Screw cover for tank filling

10)Fuse holder with 10AT fuse (timed)

11)3-pin connection for electrical cable

12)Cable with battery pliers

13)CE label

1.3 NOISE LEVEL

Produced noise level (Sound pressure level) is extremely low (<70dBA). However, it is up to

the employer to evaluate every single worker’s exposure to noise

2. DELIVERY, TRANSPORT AND ASSEMBLING

2.1 DELIVERY AND ASSEMBLING

The user shall:

•Unload according to sanitary and safety regulations in force

•Remove packing without dumping it into the environment

Always check status of components and appliances. Should the need arise, contact our

authorized distributor

2.2 TRANSPORT

Transport must be carried out according to the following instructions:

•Follow sanitary and safety regulations in force (especially concerning total weight about

Kg. 20)

•Remove accessory devices or other objects which can get in the way

•If you lift PROCHONE with your hands make sure you hold on to it tightly

•Keep other employees at a distance

For transport by vehicle, make sure the carton is stable prior to moving

3. SAFETY INFORMATION

3.1 WORKING ENVIRONMENT

PROCHONE is meant to be used with flammable and aggressive liquids, therefore you are

recommended to: - work in an environment which is compliant to sanitary and safety

regulations in force; make sure the room is adequately ventilated and free from ignition

sources.

Make sure you have easy access to fire-fighting devices close to PROCHONE and that such

devices are compliant to sanitary and safety regulations in force.

PROCHONE must be located so as not to be of hindrance to employees. Do not place

PROCHONE where employees move about.

Use under proper lighting. Avoid harsh environmental conditions.

3.2 PRELIMINARY CHECK

The system has been tested with flammable liquids (flammability point about 20 °C). Make

sure you have a safety data sheet for the liquid you use and you follow its instructions (ex.

Wear protective garments such as gloves and goggles, refrain from smoking, avoid polluting

the environment).

Special care must be taken during filling of the tank. Carry out the process cautiously until the

tank is full (MAX 3 l). In case of spill clean immediately.

Arrange connecting hose out of other employees’ way.

Prior to starting the process verify that there is no leak either in the components or in the

connections to the system.

Plug the system only to 12 V DC supply line.

3.3 USE

Never leave PROCHONE unattended during functioning. Strictly follow the instructions here

below. PROCHONE must be used on a horizontal surface.

PROCHONE is meant to be used by a single reliable adult. All other people are recommended

to keep at a distance from the functioning appliance. Always wear protective garments (ex.

Gloves). Always request the safety data sheet of the products you use and follow its

instructions.

3.4 MAINTENANCE

Do not carry out any maintenance operations when the system is connected to the vehicle and

to the supply line.

Do not carry out any maintenance operations which are not mentioned in this handbook

During maintenance, you are recommended to use protective garments. Do not dump any

residue into the environment and abide by the regulations in force.

A/C SYSTEM -------------------- FOR WASHING PROCEDURES

LOW PRESSURE SIDE HIGH PRESSURE SIDE

FILTER COMPRESSOR

4. CONNECTION TO THE A/C SYSTEM

4.1 USE

Ill.1

Universal adapter for connection to the A/C system

Ill. 2

Connection sequence to common A/C hose. The system allows assembling to fittings, hose as

well as to A/C components such as radiator or evaporator.

Ill. 3

View of a correctly assembled universal adapter and hose to be treated. WARNING: Hand-

grip must be adequately tightened.

•Place Proch One on a horizontal surface next to the A/C system.

•Connect red hose to the system at the left quick fitting discharge line (PRESSURE) and

connect the other end of the hose to the universal adapter, which in turn is connected to

the A/C system to be cleaned (See Ill. 1,2,3)

•Connect blue hose to the system at the right quick return fitting (RETURN) and connect

the other end of the hose to the universal adapter, which in turn is connected to the A/C

system to be cleaned (See Ill. 1,2,3)

•Check level of the liquid inside the tank (operating level 2-3 l), considering the size of the

component to be cleaned (it must be completely filled throughout the whole process). In

case of need top up the tank with some extra liquid.

WARNING: PROCHONE cannot work if liquid level is lower than needed.

WARNING: All filling and topping up operations must be carried out when PROCHONE is

disconnected from the supply line. Avoid use near open flame and contact with heat.

Ill. 4

•Connect the supply cable connector to the joint at the back of the unit

•Connect black and red pliers to the positive and negative poles of the battery respectively.

WARNING: PROCHONE only works at 12V direct current

Ill. 5

•Turn pressure regulator on the control board counter-clockwise completely.

WARNING: Starting PROCHONE with the flow regulator turned clockwise can damage the

A/C components (the system can deliver up to 12 bar).

•Check that the taps on the universal adapters are completely open

•Start PROCHONE by pressing the green switch (I) of the (O/I) main switch on the control

board

WARNING: splashes of product could come in contact with overheated parts. Protect all

overheated parts and wait for them to cool down

•Check for any leakage in the hydraulic connections.

•Increase pressure by rotating the pressure regulator clockwise (Ill. 5) so that it reaches

correct values

•7/8 bar: Hoses or hydraulic connections

•7/8 bar: A/C system components (condensers, evaporators, piping)

•If pressure strives to reach wanted values, operate on the blue hose tap (outlet) until you

obtain recommended pressure.

•Leave process on for about 20 min.

•Turn PROCHONE off by pressing the red switch (I) of the (O/I) main switch on the

control board

Ill. 6

•Start clearing of Proch One

•Screw fitting with yellow tap (supplied with PROCHONE) into the “AIR IN” fitting on

the control board.

•Check that the tap is closed

•Connect compressed air hose to the fitting you just screwed in

•Open yellow tap gently and keep it open until the hydraulic circuit of Proch One is

completely cleared

•This way all the liquid in the circuit of Proch One will be collected inside the tank

•Close compressed air inlet yellow tap.

•Disconnect supply cable from the battery of the vehicle

•Disconnect compressed air hose

•Disconnect fitting with yellow tap from Proch One

•Remove universal fittings from the A/C system

5. PROBLEMS, CAUSES AND SOLUTIONS

Proch One Trouble-shooting Guide

ACTION FAILURE PROBABLE CAUSE

SOLUTION

•Connect pliers of

PROCHONE to

the battery.

•Press Button 1

•The pump does

not work

•The pump works

but the manometer

shows no pressure

•Burnt fuse

•Electrical contacts

are cut off

⇒to the main

connection

⇒to supply

cables

•

Pliers have little

contact with

battery poles.

•

Battery is not

powerful enough

•

The switch is

broken

•

Pressure of the

liquid has

exceeded 12 bar

and the safety

device has come

on.

•Replace fuse

•Restore contacts

•Check

•Clean poles

•Recharge battery

•Replace battery

•Press “O” switch

Wait till motor has

come to a

complete stop.

Open pressure

regulator

completely

(counter-

clockwise). Press

“1” switch

•Slowly rotate

precision

regulator in order

to increase

pressure

•Pressure increases

irregularly

•Pressure does not

increase or

increases very

little

•The regulator is

open and pressure

is quite high

•The pump is

damaged

•The manometer or

regulator is faulty

•The regulator is

loose

•Viscous liquid in

the circuit (the

product has

remained inside

the system too

•Replace pump

•Replace

manometer or

regulator

•Remove regulator

and clean it

•Clean the system

with solvent and

short-circuit suck

and discharge. Let

the pump work for

long and has

become oxidized)

(PROCHONE has

not been correctly

emptied)

•There is a break in

between the

manometer and

pressure outlet

•Resistance in the

regulator

•Faulty regulator

The hose is broken at

the regulator inlet or

outlet

5 minutes

•Open the system

and replace hose

•Remove regulator

repair or replace

•Replace hose if

necessary

WARNING: for any maintenance operation not mentioned in this handbook contact our after

sale technical service. The above operations must be carried out by skilled technicians.

6. REPLACING COMPONENTS

How to replace some of the components

FUSE

•Unscrew fuse holder cover at the back and remove fuse

•Check whether the wire is cut off.

•If necessary replace fuse with a new one (10AT – Timed) (one is included in the package)

MANOMETER

•Disconnect hydraulic connections

•Remove adapter on the manometer

FILTER

•Disconnect hydraulic connections

•Release the two quick fittings with the supplied spanner by loosening the blocks

•Remove filter

•Replace filter with new one (one is included in the package)

•Check that both ends of the filter are fitted completely into the junctions

WARNING: For all operations to be carried out inside PROCHONE:

•Disconnect from battery

•Disconnect from any A/C system

•Unscrew and remove cap

•Remove cover

7. SUPPLIED ACCESSORIES

Connection hoses to A/C system

10 AT fuse

Spare external filter

Spanner for filter removal

Supply cable with pliers for connection to the battery

8. CONTROLS

8.2 FUSE

The 10 AT Timed fuse can be replaced by unscrewing the fuse holder at the back of

PROCHONE.

8.3 HYDRAULIC CONNECTIONS

Both hydraulic connections on the front board (PRESSURE and RETURN) are equipped with

quick fittings.

The red hose is for pressure, the blue one for return.

8.4 ELECTRICAL CABLES

The only electrical cable of PROCHONE is the supply cable. It is 4 m long and equipped with

two terminals suitable for connection to the battery.

•Black terminal to be connected to negative pole

•Red terminal to be connected to positive pole

9. USE

9.1 Filling the tank

Unscrew tank cap, check level and top up with product if necessary; screw cap back on.

WARNING: all filling and top up operations must be carried out when PROCHONE is

disconnected from the supply line. Do not use near open fire and sources of heat.

10. FAILURES

10.1 Hydraulic system

In order to replace the components, proceed as follows: unscrew self-closing fittings at the

end of the hoses connected to the part you need to replace. Remove part and hose from

PROCHONE; it will be easier to remove hose from the part and replace the part.

11. MAINTENANCE

WARNING: all maintenance operations are to be carried out when PROCHONE is

disconnected from the supply line and the vehicle. Wear protective garments and follow

sanitary and safety regulations in force.

11.1 Cleaning the body

Do not use aggressive or abrasive products; we suggest mild detergents or surface cleaning

products. Do not use solvents as they can damage the paint.

11.2 Maintenance of quick fittings

Quick fittings contain moving parts. Movement can cause ageing of metals and gaskets.

Quick fittings must be replaced after some time.

The following factors reduce life of quick fittings:

1. Connecting and disconnecting them several times

2. Long term contact of cleaning products with fittings. The liquid becomes oxidized and

develops a viscous film.

3. Atmospheric hazards: water, salt and acids damage metals. Dust and dirt are abrasive for

moving parts.

How can we avoid these problems ?

•Never remove PRESSURE and RETURN hoses from PROCHONE

•Do not expose PROCHONE to atmospheric agents such as rain, saltiness, etc.

•Lubricate quick fittings prior to using them if they have sat unused for a long time

11.3 DISPOSAL

In case of scrapping, follow the regulations in force in the country where the operation is

carried out.

12. ELECTRICAL DIAGRAMS

13. SPLIT-UP DRAWING

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