CTR Group PRATIKA Operating instructions

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. [phone] - Fax. + 39 0521/957677

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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.
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.
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.
Lemignano di Collecchio (PR)
.................................................
Stamp and signature of authorised representative
Inspection is certified by the plate
with the CE marking, as illustrated,
positioned on the machine.
DECLARATION OF COMPLIANCE
DIRECTIVE 89/392 AND 89/336 AND SUBSEQUENT MODIFICATIONS AND
INTEGRATIONS
Insert photo
with plate

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1INTRODUCTION......................................................................................................................... 6
2 TECHNICAL CHARACTERISTICS......................................................................................... 7
3 IMPORTANT SAFETY INSTRUCTIONS................................................................................. 8
3.1 WORK ENVIRONMENT............................................................................................................. 8
3.2 PRELIMINARY CHECKS BEFORE USE ................................................................................. 9
3.3 USE............................................................................................................................................. 9/10
3.4 MAINTENANCE..................................................................................................................................... 11
3.5 ELECTRICITY SUPPLY....................................................................................................................... 11
4 INSTALLATION AND PRELIMINARY CHECKS........................................................... 12/13
5- ELECTRICITY SUPPLY ........................................................................................................................ 14
6. HANDLING AND TRANSPORT .............................................................................................. 15
7-GENERAL INSTRUCTIONS FOR USE ................................................................................................ 16
7.1 CONTROL PANEL............................................................................................................................ 16/17
7.2 SETTING-UP THE UNIT....................................................................................................................... 18
7.3 OPERATING PHASES........................................................................................................................... 19
7.4 MANUAL MODE RECOVERY OPERATION ................................................................................................ 20
7.4/1 Preliminary operations ........................................................................................................................... 20
7.4/2 Instructions for carrying out gas recovery.............................................................................................. 21
7.5 MANUAL MODE VACUUM OPERATION .................................................................................................... 22
7.6 MANUAL MODE CHARGING OPERATION................................................................................................. 23
7.6/1 Charging ................................................................................................................................................. 23
7.6/2 Refrigerant topping up............................................................................................................................ 24
7.7 AUTOMATIC MODE COMPLETE RECOVERY AND VACUUM OPERATION (AUTOMATIC PROCEDURE). . 25
7.8 END OF WORK CYCLE........................................................................................................................ 25
7.9 REFRIGERANT TRANSFER FROM THE UNIT TO AN EXTERNAL CONTAINER ................. 26
8- MAINTENANCE ...................................................................................................................................... 27
8.1 GENERAL MAINTENANCE ................................................................................................................ 27
8.2 TOPPING UP OR CHANGING OIL IN THE VACUUM PUMP ....................................................... 28
8.3 CHANGING OIL IN THE COMPRESSOR AND CHANGING FILTERS....................................... 28
8.4 RECHARGING OF THE GAS STORAGE CYLINDER .................................................................... 29

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9- PROBLEMS, CAUSES AND REMEDIES............................................................................................. 30
9ERROR 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........................................................................................................................................ 33
13- LABELS AND MARKINGS.................................................................................................................. 33
For instructions on use of accessories (optional), please read the relevant section of
this Guide.

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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.
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 a semi-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, gas injection and discharge of
incondensable gases, all managed by a microprocessor and an electronic precision weighing
machine. It is equipped with analogic pressure gauges with silicon absorber pads with a
diagnostics section for monitoring operating pressures of any type of conditioning or refrigerant
plant installed on vehicles working with 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.
•Recovery: allows recovery both of the refrigerant fluid as well as part of the oil that it
contains, automatically overseeing separation of the two components and relative storage. The
contaminated oil is recovered in an apposite outside graduated container, while the fluid following
reprocessing by dehydration filters, is stored in a cylinder for the purpose. The electronic precision-
weighing machine automatically determines the quantities.
•Re-injection: the reprocessed refrigerant fluid can be recycled (after injection with new oil)
using the method adopted by the operator. It is also possible to add new refrigerant fluid as
required.
•Vacuum: it is possible to depressurise the A/C plant to the maximum level in the set time,
maintaining a vacuum. In this way, it is possible to completely eliminate any humidity present in the
system and check the vacuum seal for possible leaks.
The machine comes complete with connection cables for connection and liquid injection inside the
A/C plant.
Do not use the machine for any other 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 fluids 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 fluids.

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2 – TECHICAL CHARACTERISTICS
The technical specifications in the chart below are given for the models according to the type of
refrigerant used.
Description Unit
Measure
R12
Values
R134-a
Values
Max. absorbed power W 800 800
Net weight Kg 81 81
Overall dimensions (HxWXD) Mm 1050x600x4
40
1050x600x4
40
Fully charged weight kg 100 100
Vacuum flow rate lt/min 67 67
Filter absorption capacity (rate) gr H2O120 120
System recovery rate gr/min 400 400
Refrigerant cylinder capacity kg 10 10
Supply voltage V 220/230 220/230
Supply frequency Hz 50 50
Max. absorbed current A 4,0 4,0
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 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 – IMPORTANT SAFETY INSTRUCTIONS
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.
If you need service, please only contact our after-sales service department (for repairs
or spare parts).
Do not carry out repairs. Repairs carried out by unqualified staff may create a safety
hazard on the machine.
Do not place or leave things on the machine. The machine is not a surface for storing
neither things nor a means of transport.
Avoid putting the connecting tubes (A/C plant) in a position where they could become
an obstacle or could be damaged.
For the recovery of refrigerant do not use (pressurised) containers that are made of
unsuitable materials or unapproved pressure levels.
Follow hygiene and safety prevention at work directives. Make sure you have an up-
dated copy of them and follow the instructions in the safety prevention sheets. Never
leave the machine unattended even when it is operating in automatic mode.
3.1 WORK ENVIRONMENT
We recommend that responsible adults only use the machine. Always watch that
children do not operate the ON/OFF device.
Never approach the machine with naked flames or any other source that could cause
overheating (with consequent fire hazard) of the recharging circuit. Never use the
machine in locations where there is a risk of fire or explosions.
Do not smoke in the room when the machine is working or while work is being carried
out.
We recommend using the machine in a well-lit working environment.
Always work in a well-ventilated environment. Operate and store the machine in a dry
place protected from rain (and generally protected from unfavourable atmospheric
conditions).

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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). Do not tamper with the
machine in any way.
Pay particular attention to possible refrigerant liquid being ejected by the machine in that:
-contact with the eyes can cause serious damage.
-contact with the skin (given the extremely low boiling point of the fluid) can cause
burns.
For this reason, it is necessary when using the machine to wear suitable protective gear
such as gloves and goggles. In the event of fluid coming into contact with eyes or skin,
rinse with plenty of running water and seek immediate medical advice.
The machine is designed to be used specifically with the refrigerants R12 or R134-a (for
use in two distinct models). It is important to avoid mixing the fluids or using them in a
promiscuous way. The type of refrigerant (R12 or R134-a) for which the machine
has been equipped, is clearly indicated.
!After the machine has been switched on, wait at least five minutes before carrying out
any operation. In the event that the work cycle is interrupted for any reason (e.g. lack of
electricity supply), then it is always necessary to repeat operations from the beginning of
the cycle.
Do not fill any container with refrigerant liquid that is not approved for pressures
of at least 35 bar and that is not equipped with a safety valve (the valve should be
in compliance with the directives regulating pressure vessels).
The container used to store the refrigerant should NEVER be filled to more than 80%
total capacity to avoid performance shortfalls. Check the filling of the oil containers
during machine operation, ensuring that they are not overfull thereby avoiding abrupt
losses in machine performance. Do not use these containers for other types of fluids or
materials.

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This figure indicates the areas on the machine where there may be a safety hazard during
operations:
1) area where refrigerant may be ejected
V
2) components carrying live current
Fig.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.
Always use the piping that comes with the machine for connecting up high and low
pressure connections (red and blue) and do not use it for other purposes other than that
for which it was designed.
When the machine is operating, check the level of oil in the two tanks making sure that it
does not overflow.
NEVER disconnect the HP and LP tubes, unless expressly stated in this guide. Do not
manually action the manual filling valves during normal operating phases unless
expressly stated in the instructions.
1
2

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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).
!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.
Do not carry out repairs or maintenance work while the machine is operating or is
connected up to the electricity supply.
Only carry out the maintenance operations and repairs indicated in the relevant sections
of this guide. We stress that work carried out on the machine by unqualified staff can
compromise the overall safety level of the machine and expose the operator to serious
safety hazards.
3.5 ELECTRICITY SUPPLY
In the case that extension cords are used, check that the cord core section is in
proportion to the length of the cord and that the position of the cord is not subject to
damage of any kind (avoid areas where the cord could be walked on or wet surfaces).
Check that the connection to the mains supply is equipped with safety devices as
prescribed by the directives in force governing the subject (grounding system and
differential circuit-breaker).

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4 – INSTALLATION AND PRELIMINARY
CHECKS
Th machine is delivered packed in its protective packing material and sealed in a plastic cover.
To unload the machine, a small forklift stable enough to take the weight of the machine is sufficient
(See the technical specifications for machine weight).
Unload the machine and remove the packing (we recommend disposing of waste packing
materials following the local codes in force in your Country), avoiding litter hazards. Check that the
machine is not damaged in any way and that all components are intact. If this is not the case, then
please immediately contact our authorised distributor.
The machine is equipped with the following main elements (see list below):
•Electronic Management system: allowing the whole process to be administered through a
microprocessor.
•Electronic precision weighing machine for weighing of gas: it can weigh up to a maximum of
10 Kg of refrigerant with a margin of error of 10 g 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.
•Compressor for refrigerant gas recovery.
•Anti-acid and dehydration filters (n. 3) with total absorption capacity of 160 g of water
guaranteeing excellent autonomy.
•Infeed gas still with automatic regulation of refrigerant flow 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 with silicon absorber pads that check abrupt pressure changes.
•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.
•Discharge valve for oil coming from the A/C system.
•High-performance flexible tubing (n.2) with rapid coupling for R134-a, and with manual
opening (screw mechanism) for R12.
•Service tube for refrigerant transfer operations (n. 1) with ball valve 3/8 SAE x 3/8 SAE for
R134-a and 1/4 SAE x1/4 SAE with ball valve for R12.
•Oil dosing devices (n.2) 500 cc.
The following section describes operations to be carried out to set up the machine for correct
working (please also read the section under Control Panel).

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!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. Make sure that
the cylinder rests on the weighing machine free
of obstructions.

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5- ELECTRICITY SUPPLY
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. 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. We advise that you follow the instructions below to correctly connect up the
electrical circuit:
-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)
-check that the connection point to the mains supply is equipped with the prescribed safety
devices in accordance with the relevant codes in force (differential circuit-breaker mechanism and
earthing (grounding) system).
-In the event of a component breaking, please only contact our after-sales technical service.
Should you need to replace the supply plug, please contact our technical service
beforehand, and do not attempt to replace it unless you have received specific
authorisation in writing from our office in charge. In any other case, C.T.R. s.r.l. will not
be liable for damage to persons or things caused by an electricity hazard.

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6. HANDLING AND TRANSPORT
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. Also check the degree of incline of the surface where it is positioned).
Before moving the machine, remove the components that were installed after the
machine was delivered to avoid possible damage (See section on Installation).
During this phase we recommend:
-correctly storing all accessories to avoid breakage from accidental falling or other
damage during transport.
-transport at low speed and watching out for possible points that may cause instability.
-keeping at a safe distance.
Particular caution should be used when moving the machine in the work place. Avoid
areas where there are steps, tight corners or other obstacles. Incorrect transport could
compromise the exact calibration of the settings.
Fig.6
Fig.7
The operator transporting the machine can use
the wheels on the front of the machine base to
push it by hand.
The operator, to lift the machine at a distance,
should use a fork lift suitable to take the
machine weight (see the section on technical
characteristics) inserting the forks as illustrated
in the figure above,

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7-GENERAL INSTRUCTIONS FOR USE
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. The display visualises different information according to the working
mode selected. The machine is equipped with an emergency stop push button. In the event of an
emergency, by pressing this button the machine comes to an immediate halt, in which case it is
necessary to wait for approx. 50 sec before restarting the machine to allow sufficient time for the
electronic component to be correctly reset.
We recommend that you only follow the instructions and indications explained in the
following sections and that you always apply the safety instructions that will be outlined
further on, or have been illustrated in the previous sections. Please read carefully the
following sections to fully understand how the machine works and the operating modes.
When switching on the machine, wait at least five minutes.
1
1
2
1
3
7
2
1
0
1
1
9
8
4
3
65
Fig 8

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Description of number-key
1. ON/OFF-Emergency switch 10. Used oil discharge tank connection
2. Control panel 11. Oil injection tank connection
3. Low pressure gauge 12. Oil discharge valve (OIL
DISCHARGE)
4. High pressure gauge 13. Oil injection valve (OIL
INJECTION)
5. LP valve (low pressure)
6. HP valve (high pressure)
7. High pressure connection (Red)
8. Low pressure connection (Blue)
9. Ref. Service coupling

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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.
We advise checking that the cylinder junctions are tightly blocked.
The phases to be carried out are described below.
Fig.10
-check that the cylinder is correctly fixed in its seating.
-connect the unit to the mains electricity supply following the instructions in the section on
Electricity supply.

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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.
7.3 OPERATING PHASES
This section describes all the phases that should be carried out by the operator to obtain excellent
working results in absolute safety, illustrating the manual and automatic machine modes. The
machine is equipped with an intelligent monitoring device that indicates any machine malfunction
by visualising a number code that can be read by the operator, an acoustic signal at the beginning
of machine operations indicating that the machine set for a particular function and is functioning
correctly and a second acoustic signal indicating that the operation has been terminated.
Before carrying out the operations described below, to achieve optimum operating conditions from
the system (both in terms of saving energy and time), we advise switching on the vehicle engine so
that the conditional plant runs for a few minutes and the A/C system is fully running as in normal
conditions.
!Before carrying out the recovery procedure, we advise checking the state of the
refrigerant in the A/C system by following the GAS ANALYSIS* operation to avoid
eventual contamination of the gas present inside the unit.
!If you are unsure of any point or have further questions, please do not hesitate to contact
our after-sales technical service or authorised distributor for advice.
Remember that during the recharging operations a certain quantity of refrigerant will be
present in the connecting tubes. To empty these tubes, follow the instructions under the
section End of work cycle.
!At the end of the various work phases, various residual products will be present in the
containers. Dispose of these waste materials following the codes in force in your
Country.
All recovery, vacuum and recharging operations should be carried out with the vehicle
and the conditioning plant switched off (with the compressor disconnected from the
power supply).
N.B.
•To test the quality of the gas to be recovered, our authorised dealers sell the Yokogawa gas analysis unit
specifically designed for the purpose, and for which C.T.R. srl is the exclusive distributor.

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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.
-set the A/C plant ventilator to max. position. Let the vehicle engine idle (800-1200 rpm) for at
least ten/fifteen minutes to facilitate the flow of oil mixed with the refrigerant through the system,
and using the heating effect of the engine to eliminate micro-granules of frozen liquid that might still
be in the system when carrying out the recovery operation.
-during the recovery phase the vehicle engine should be switched off.
The cylinder can contain up to max. 10 kg, we therefore recommend checking the initial
amount of gas in the cylinder before beginning the recovery operation, thereby avoiding
interrupting the recovery process to empty excess gas. Always check before starting
operations the correct quantity of refrigerant.
On delivery the cylinder is obviously empty. When filling the cylinder for the first time, it is
necessary to connect the machine up to an outside cylinder to carry out a recovery
operation to provide for filling.
Remember that during the recharging operations a certain quantity of refrigerant will
remain in the connecting tubes. To completely empty the tubes follow the instructions
under the section End of work cycle.
For the type of oil to be used for injection in the refrigerant, please contact qualified
technical operators for information.
Never mix different types of lubricants. Always check beforehand the type of oil that
should be used in the different A/C plants (depending on the type of compressor
installed). C.T.R srl will be pleased to provide technical specifications.