CTR Group Proch One Manual

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