CTR Logika Use And Maintenance Manual

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LOGIKA

USE AND MAINTENANCE GUIDE

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CTR Group thanks you for having chosen this product from its range and recommends that you read this guide carefully. It contains all the information you will need for correctly using this model. We therefore recommend that you follow all the safety instructions and read all sections of this guide before using the machine. We would also advise that you keep the guide in a safe place for future reference. The contents of this guide are subject to change without warning, nor is the company under any obligation to incorporate changes and improvements to the parts already printed. Reproduction or unauthorised translation of any part of this guide is severely prohibited without written permission from the Company. During the full warranty period, CTR is responsible for all manufacturing defects, which it undertakes to eliminate in the shortest possible time.

WARRANTY

The warranty period, under current legislation, is for 12 months from the date of purchase. The warranty only covers the right to replacement of any faulty part of the machine. The warranty is not valid in the event that the machine is used for a purpose other than that for which it was intended, or is tampered with by persons not authorised by our company or, in any case, using non-compliant methods or parts.

DECLARATION OF COMPLIANCE

Directive 89/392 and 89/336 and subsequent modications and integrations

The Company CTR s.p.a. Via T. ed E. Manzini, 9 - 43100 Parma (Italy) in the name of its Legal Representative, declares, under its sole responsibility, that the machine System for managing conditioning and refrigerating plants, Model LOGIKA, complies with the provisions

of directive 89/392 and directive 89/336 and subsequent modications and integrations.

The Company further declares that:

- the year of manufacture is printed on the label (with CE marking) to be found on the machine;

- the technical manufacturing documentation attesting manufacture in compliance with the Directive is available at our company;

- the machine serial number (if present, in that it is not mandatory) can be found on the machine.

Parma

....................................................

Signature of authorised representative.

CTR s.p.a.

Inspection is certied by the plate

with the CE marking, as illustrated, positioned on the machine.

Via T. ed E. Manzini n° 9 43100 Parma Made inItaly

modello

LOGIKA

N° matricola

00/ L000

Tensione

230V A/C-50 HZ

Assorbimento A5Potenza assorbita W

1000

Logika - use and maintenance guide

Anno di fabbricazione

0000

refrigerante

R-134a

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PAR. INDEX PAGE

Declaration of compliance 1

Index - Symbols key 2

1 Introduction 3

2 Technical characteristics 4

3 Warning 5

4 Electricity supply

5 Handling and transport

6 Controls 7

7 Menu structure - Error codes 8

8 Manual operation RECOVERY 9

9 Manual operation VACUUM 10

10 Manual operation CHARGING oil and refrigerant 11

11 AUTOMATIC operation 12

12 Refrigerant topping up 13

13 Recharging of the gas storage cylinder

14 Refrigerant transfer from the unit to an external container

15 General maintenance

15.1 Topping up or changing oil in the vacuum pump

15.2 Changing oil in the compressor and changing lters

15.3 Oil containers

15.4 Charging and service hoses

15.5 Spare parts

16 Labels

SYMBOLS KEY

The key below illustrates the meaning of symbols used in this guide.

DANGER: indicates situations 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.

NO!: do not carry out the operations indicated, as they may compromise the correct working of the machine.

IMPORTANT: indicates that important instructions of a general nature should be

noted but that they do not compromise personal safety or the correct working of the machine.

CORRECT OPERATION: indicates that this operating method used is correct.

NON CORRECT OPERATION: indicates that this operating method used is NOT

correct.

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1. Introduction

The machine described in this user and maintenance guide is an automatic, multifunctional digital-setting system for operation with vehicle air conditioning (A/C) plants with functions for gas recovery, used oil discharge, vacuum, leakage control, oil injection and gas injection, all managed by a microprocessor and an electronic precision scale.

• Electronic management system: it allows the whole process to be administered through a microprocessor.

• Electronic precision scale for weighing of gas: it can weigh up to a maximum of 10 Kg. of refrigerant with a margin of error of 10 grams and is programmed to interrupt the RECOVERY and CHARGING functions if pre-set for this purpose or should the quantity of gas exceed the set limits.

• Electronic precision scale for weighing of oil injection: it can weigh up to a maximum of 500 grams with a margin of error of 10 gr.

• Compressor for refrigerant gas recovery.

• Anti-acid and dehydration lters (n. 3) with hight absorption capacity of water

guaranteeing excellent autonomy.

• Infeed gas still with automatic regulation of refrigerant ow and separated oil coming

from the A/C system with discharge of oil coming from the same.

• Oil separator: positioned immediately after the compressor with automatic oil return at the end of the cycle.

• Cylinder for refrigerant gas recovery, equipped with an electronically controlled thermostatic resistor and discharge of incondensable gases.

• Two-stage high-performance vacuum pump.

• Control panel with digital commands.

• Analogic pressure gauges.

• Refrigerant service valve (Ref. Service): allows refrigerant contained in the internal

cylinder of the unit to be sent to a suitable outside container for the purpose.

• Solenoid valve for the discharge of the incondensable gas which are in the bottle.

• Discharge valve for oil coming from the A/C system.

• High-performance exible hoses (n. 2) with rapid coupling and with manual opening

(screw mechanism) for R134a and R12.

• Oil dosing devices (n. 2) 500 cc.

Do not use the machine for any purpose other than which it was designed. In the case of demolition or hauling away, check the legislation codes that are

applicable in your Country (note that the machine contains refrigerant uids and

we therefore recommend demolition by specialised operators).

The machine is supplied with two distinct models for two types of refrigerant.

Do not use the same model for both types of uids.

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2. Technical characteristics

The technical specications in the chart below are given for the models according to the type

of refrigerant used.

Description

Unit

Measure

R12

Values

R134a

Values

Max. absorbed power W 800 800

Net weight Kg 81 81

Overall dimensions (HxLxP) Mm

1040x540x600 1040x540x600

Fully charged weight kg 100 100

Vacuum ow rate lt/min 66 66

Max. vacuum mbar 0.01 0.01

Filter absorption capacity (rate) gr H2O 80 80

System recovery rate gr/min 400 400

Refrigerant cylinder capacity kg 10 10

Supply voltage V 220/240 220/240

Supply frequency Hz 50 50

Max. absorbed current A 5,0 5,0

Coupling diameter on vehicle (Low Pressure LP) mm 11 13

Coupling diameter on vehicle (High pressure HP) mm 11 16

Max. operating temperature °C 50 50

Min. operating temperature °C 5 5

Max. pressure pneumatic circuit bar 18 18

For supply voltage, always use the value indicated on the machine plate.

The acoustic pressure value for the machine is below 70dBA and therefore no special precautions need to be taken by the operator even in the case of continuous use (standard ISO 3746). However, it is the responsibility of the employer to evaluate noise level exposure of workers in compliance with the directives concerning work hygiene and safety.

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3. Warning

This gure 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.

When the machine is operating, check the level of oil in the two tanks making

sure that it does not overow.

We remind you that maintenance and repair carried out by not qualied staff

change the standard of security of the machine and expose the worker to serious risks.

NEVER disconnect the HP and LP hoses, unless expressly stated in this guide.

Do not manually action the manual lling valves during normal operating phases

unless expressly stated in the instructions.

Always wait some minutes after having switched off the machine to allow the system to be correctly reset (temperature and pressure).

In no case should the operator use combustible or ammable liquids or detergents

for cleaning the machine.

The machine is delivered with the cylinder correctly positioned in its seating on the weighing

scale and already xed with

brackets (n. 2) for this purpose.

During maintenance work do not contaminate the environment with eventual residual waste products and always follow the prescribed directives in force regarding disposal.

NEVER disassemble the cylinder.

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4. Electricity supply

The electrical connections to the machine should be carried out following the instructions supplied by CTR s.p.a. which, in any case, is not responsible for connections. Check that the connection point to the main supply is equipped with the prescribed safety devices in accordance with the relevant codes in force (differential circuit-breaker mechanism and earthing (grounding system). We advise you to follow the instructions below to correctly connect up the electrical circuit.

• In the workshop it is necessary to connect the machine up to the mains using the

apposite plug that comes with the machine, checking that the supply voltage corresponds to the value on the machine plate.

• If you are using an extension cable, check that the cable core section is proportioned

to the length of the cable and that it is positioned where it cannot be damaged in any way (avoid areas where it can be walked on or damp surfaces).

• In the event of a component breaking, please only contact our after-sales technical

service.

In case of power-down due to a shortage of feeding, wait for approx. 10 seconds

before restarting the machine to allow sufcient time for the electronic components

to be correctly reset.

5. Handling and transport

Use the wheels on the bottom of the machine to push it by hand.

Always use the four wheels to move the machine. Avoid to tilt it even for short move.

To lift the machine at a distance, use a fork lift suitable to take the machine weight (see the section on technical characteristics) inserting the forks as

illustrated in the gure

above.

Switch off the machine and disconnect it from the electric system.

Please keep original packaging (pallet, box and polystyrene) for possible future

shipments.

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6. Controls

This section describes the main functions present on the machine control panel:

1 ON/OFF Emergency switch 8 Oil injection valve (OIL INJECTION)

2 Control panel 9 Oil discharge valve (OIL DISCHARGE)

3 Low pressure gauge 10 bar 10 Used oil discharge tank connection

4 High pressure gauge 30 bar 11 Ref. Service coupling

5 LP valve (low pressure) 12 Low pressure connection (Blue)

6 HP valve (high pressure) 13 High pressure connection (Red)

7 Oil injection tank connection

During the normal working of the machine keep the valve no. 8 completely open and

the valve no. 9 open to approx. 45°.

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7. Menu structure

SEL

WEIGHT

RECOVERY

VACUUM

CHARGING

AUTO

1800

OIL

0030

T200 T60

T300

GAS

00.70

Whole gas recovered.

End

operation

0000

End

operation

OIL IN

AUTOMATIC

OIL

GAS

00.70

0030

RECOVERY

AUTO

VACUUM

1800

CHARGING

0000

End

operation

GAS IN

Possible error codes:

E0 = Cylinder full. It is not possible to recover gas. E1 = Excessive quantity of gas programmed for recovery. E2 = Recovery time expired. E3 = Pressure present in the system at the start or during the vacuum cycle. E4 = Time to achieve vacuum expired. E5 = Leaks found in vacuum control cycle. E6 = Insufcient quantity of refrigerant for programmed charge. E7 = Refrigerant/oil charge time expired. E9 = Insufcient quantity of oil injection.

0000

End

operation

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8. Manual operation “RECOVERY”

1- Quantity of gas during the recovery

2- Wait

3- Oil discharge

4- End of operation (Ex. 1,5 Kg. gas recovered)

1) LP and HP valves open 2) LP valve closed and HP valve open

- Connect up the high and low pressure hoses with the A/C plant.

- Open the two high and low pressure valves HP-LP (ex. 1) or, in case of only one service point, open the corresponding valve (ex. 2).

- Use the SEL key to select RECOVERY, indicated by the side led light.

- The display visualizes the word AUTO. By pressing the key OK, the unit will recover the entire refrigerant in the circuit. It is possible to pre-set the quantity of refrigerant to be recovered by using the “+” and “-” keys. In that case, the times T200 and T60 will be deactivated.

- During this operation, it is possible to monitor the partial weight of gas recovered on the display.

- Terminated the pressure in the A/C system, the display visualizes T200 (seconds) for eventual refrigerant still blocked in the system in the form of micro-frozen granules of oil and humidity.

- At the end, the machine discharges the oil recovered for 60 seconds. Once the oil discharge phase has terminated, the recovery phase begins if pressure is present. At the end of this phase the total quantity of refrigerant recovered is visualized and is followed by an acoustic signal indicating the end of the operation. The data of the complete operation will be automatically printed.

Possible error codes:

E0 = Cylinder full. It is not possible to recover gas. E1 = Excessive quantity of gas programmed for recovery. E2 = Recovery time expired.

The RECOVERY operation must be carried out with the engine switched off.

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9. Manual operation “VACUUM”

1- Time for vacuum expired

2- Leakage control

3- End of vacuum phase

1) LP and HP valves open 2) LP valve open and HP valve closed

3a- Leak presence

- Connect up the high and low-pressure hoses with the A/C plant.

- Open the two high and low pressure valves HP-LP (ex. 1) or, in case of only one service

point, open the corresponding valve (ex. 2).

- Use the SEL key to select VACUUM, indicated by the lateral led light.

- The display visualizes the pre-set time of 1800 seconds (30 minutes) that can be

changed by using the “+” and “-” keys.

- Press the OK key to proceed with the vacuum function. If the pre-set time doesn’t

decrease, after 10 minutes the function will stop and the error code E4 will appear (time to achieve vacuum expired).

- Check leaks: using the countdown function for a maximum of 300 seconds (5 minutes).

In case of leaks the operation will stop and the display will visualize the error code E5 indicating a leak in the plant.

- If this phase ends without problems, then the display will visualize “four zeros” (0000)

indicating that the vacuum phase has been completed.

Possible error codes:

E3 = Pressure present in the system at the start or during the vacuum cycle. E4 = Time to achieve vacuum expired. E5 = Leaks found in vacuum control cycle.

The VACUUM operation must be carried out with the engine switched off.

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10. Manual operation “CHARGING”

This function of the system allows refrigerant liquid and oil to be injected into the system according to a pre-programmed quantity.

1- Setting oil charging

- Connect up the high and low pressure hoses.

- We advice you to open only the HP valve.

- If the HP service point is not present, the charge must be carried out in LP. At the end

wait for three minutes before starting the A/C system.

- Use the SEL key to select CHARGING, indicated by the lateral led light (g. 1).

- Once the CHARGING operation has been selected, the led OIL position on the display

lights on and the programmed quantity 30 gr. (indicated as 0030) of fresh oil appears on the display (g. 1). This quantity can be changed by using the “+” and “-” keys.

- Press the OK key to conrm.

- The led light OIL disappears and the led GAS position lights on. The programmed

quantity of 700 gr. (indicated as 00.70 kg.) appears on the display (g. 2) and it can

be changed by using the “+” and “-” keys.

- Press the OK key to conrm.

- The led light GAS disappears and the led START lights on to start the charging operation (g. 3).

- During the oil and gas charging the display visualizes the grams with a margin of error of 10 gr.

- Oil will be charged only after the vacuum operation has been carried out in the A/C system.

- If the quantity of oil and refrigerant are lower than the min. quantity, the error codes E6-E9 will be visualized to indicate that you must restore the levels before starting the operation. Then re-select the CHARGING phase.

- Acoustic sound of end operation and data printing.

- Wait for three minutes before starting the A/C system.

2- Setting gas charging 3- Start operation

Possible error codes:

E6 = Insufcient quantity of refrigerant for programmed charge. E7 = Refrigerant/oil charge time expired. E9 = Insufcient quantity of oil injection.

Min. level of refrigerant in the cylinder = 1 Kg. Min. level of fresh oil in the container = 100 gr.

Sometimes, at the end of charging, you could hear a pressure leak and a countdown will appear on the display. This is the automatic function of air discharge or incondensable gases from the cylinder.

The CHARGING operation must be carried out with the engine switched off.

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How to empty the hoses of the unit:

- After having carried out the charging procedure, maintain the high and low pressure hose connections but close the two HP-LP valves, start the vehicle engine and wait a few minutes until the A/C plant is fully running.

- In case of only one service point, close the HP or LP valve used and disconnect the hose from the vehicle.

- In case of two service points, disconnect the high pressure (HP) hose from the vehicle and open the two valves HP-LP on the control panel to allow the gas contained in the hoses to be discharged through the low pressure terminal to the vehicle. Wait until HP and LP fall to about 2 bar, then disconnect the remaining low-pressure hose (LP). Switch off the engine.

11. “AUTOMATIC” operation

This procedure allows the system to carry out gas recovery, recovered oil discharge, vacuum, leakage control, oil charge and gas charge in a completely automatic mode and with invariable times for each operation respect to the manual mode.

1- Setting oil charging

2- Setting gas charging

3- Start operation

- Connect up the high and low pressure hoses.

- Open the HP and LP valves; we advice you to close the LP valve at the end of the vacuum phase. If at the end of this phase it is not possible to close the LP valve, once the charging operation has come to an end, wait for three minutes before starting the A/C system, or, in case of only one service point, open the corresponding valve.

- Use the SEL key to select AUTOMATIC, indicated by the lateral led light (g. 1).

- Once the AUTOMATIC operation has been selected, the led OIL position on the display lights on and the programmed quantity 30 gr. (indicated as 0030) of fresh oil appears on the display (g. 1). This quantity can be changed by using the “+” and “-” keys.

- Press the OK key to conrm.

- The led light OIL disappears and the led GAS position lights on. The programmed quantity 700 gr. (indicated as 00.70 kg) appears on the display and it can be changed by using the “+” and “-” keys (g. 2).

- Press the OK key to conrm.

- The led GAS disappears and the led START lights on to start the Automatic operation (g. 3).

- If the quantity of oil and refrigerant are lower than the minimum quantity, the error codes E6-E9 will be visualized to indicate that you must restore the levels before starting the operation, then re-select the AUTOMATIC phase.

- During the operation, the display will visualize times, quantities and errors of the different phases.

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- Acoustic sound of end operation and data printing.

- Wait for three minutes before starting the A/C system.

How to empty the hoses of the unit:

- After having carried out the charging procedure, maintain the high and low pressure

hose connections but close the two HP-LP valves, start the vehicle engine and wait a few minutes until the A/C plant is fully running.

- In case of only one service point, close the HP or LP valve used and disconnect the hose

from the vehicle.

- In case of two service points, disconnect the high pressure (HP) hose from the vehicle

and open the two valves HP-LP on the control panel to allow the gas contained in the hoses to be discharged through the low pressure terminal to the vehicle. Wait until HP and LP fall to about 2 bar, then disconnect the remaining low-pressure hose (LP). Switch off the engine.

Possible error codes:

The AUTOMATIC operation must be carried out with the engine switched off.

12. 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 start the vehicle engine and wait a few minutes until the A/C plant is fully running.

- Connect the low-pressure hose (blue).

- Partly open the low pressure valve LP.

- Press the SEL key and select the CHARGING function on the control panel.

- Set the oil quantity at ZERO grams and press OK.

- Programme the desired quantity of gas by using the “+” or “-”.

- Press the OK key to start topping up.

This is the only phase to be carried out with the engine running.

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13. Recharging of the gas storage cylinder

Take the red high-pressure hose HP; remove the rapid coupling at its end, connect the hose to an external cylinder containing refrigerant and carry out the recovery procedure (see the section Manual operation “RECOVERY”).

If the external cylinder is not equipped with an internal pick-up tube, it should be turned upside down so that the gas flows out in a liquid state. We would recommend that the pressure value be maintained at approximately 3 bar at this stage of recovery visible on the HP pressure gauge by partially opening the valve on the external cylinder. When the desired quantity has been reached, close the

valve of the external bottle and wait for the end of recovery operation. Then disconnect the hose and re-screw the rapid coupling.

14. Refrigerant transfer from the unit to an external container

To carry out emptying of the cylinder the operator should:

- Switch on the machine, connect a service hose with the Ref. Service valve and the other

end of the hose with a bottle or another external container; open the valves.

- Once the transfer has come to an end, close the valves and carry out the recovery

operation of the gas left in the hose.

15. General maintenance

Periodically:

- Check the oil level in the vacuum pump every three months.

- Change the oil in the vacuum pump every six months even when the unit is not used regularly.

- Check the calibration of the scale.

The station is equipped with a recovery cycle counter; when the lters are saturated, every time the unit is switched on, a display with the

word “FILT” will indicate that they need to be changed shortly. Contact our after-sales service centre.

15.1 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) and top up with sufcient oil to the level of the screw of

the indicator light. Finally, replace the cap on the vent. To do a complete oil change it is necessary to:

- run the pump for 10 minutes;

- disconnect the machine from the power supply;

- disassemble the drainage cap positioned on the underside of the

pump; wait until all the oil has drained out, and replace the cap;

- unscrew the vent cap and ll up with new oil until the level is

halfway up the spyglass;

- replace the vent cap.

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15.2 Changing oil in the compressor and changing lters

Qualied personnel should only carry out this operation.

We recommend that you contact our after-sales technical service centre.

15.3 Oil containers

The machine is supplied with one oil container for new oil injection. If it is necessary to use more than one type of oil, then separate containers should be requested for each different oil type.

Never mix different types of lubricant. Always check the type of oil that should

be used by a specic A/C plant (according to the type of compressor installed).

CTR s.p.a. will be happy to provide technical sheets, on request.

15.4 Charging and service hoses

The machine is supplied with connecting hoses to the A/C plant of length equal to 1800 mm.

Should the standard tubing not be of sufcient length for your requirements, tubing length

equal to 3000 mm. is available at our authorised distributors.

15.5 Spare parts

All spare parts for LOGIKA are available at our authorised dealers and are distributed by CTR s.p.a.

16 Labels and markings

This is a list of the meanings of the labels present on the machine:

Indicates the type of refrigerant

R134a

compatible for the type of machine.

Lightening symbol on bright yellow background (indicates parts carrying high voltage with an electric-shock hazard).

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CTR Group s.p.a. - Via T. ed E. Manzini, 9 - 43100 Parma - Italy

Tel. +39 0521 957611 - Fax. +39 0521 957677

internet: http://www.ctrgroup.it • e-mail: [email protected]