CTR Kheos Plus User manual

Instruction Booklet
ENGLISH
KHEOS PLUS
EN
Carefully read this use and maintenance manual before using the unit.
CTR S.R.L. Via T.ed E. Manzini n° 9, 43126 Parma (Italy)
Tel. [phone] - Fax. [phone]
Internet:www.ctr-srl-com E-mail: [email protected]
Revision number 1.0 code 330080 Date 08/02/2016

EN

Instruction Booklet
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KHEOS PLUS
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CTR S.R.L. would like to thank you for buying a product from its range and invites you to read this manual. Inside this manual you
will find all the information you need for correctly using the unit; please follow the instructions contained in this manual carefully and
read through every section. You should also store the manual carefully to keep it in good readable condition. The content of this
manual may be modified without prior notice, nor further obligations, in order to include changes and improvements to the
instructions already provided. No part of this manual may be reproduced or translated without prior written consent of the owner.
CTR S.R.L. shall be responsible for any manufacturing defect that may arise during the entire warranty period and undertakes to
correct any defect as promptly as possible.
WARRANTY
The warranty is valid for 12 months from the date of purchase. The warranty covers only the replacement of faulty parts. The
warranty shall be invalidated if the equipment is found to have been improperly used or tampered with by people not authorized
by us or if nonconforming components or techniques have been used.
LABELLING
Model Kheos Automatica
CTR S.R.L.
via T. ed E. Manzini,9
43126 - PARMA ITALY MADE IN ITALY
Model
KHEOS AUTOMATICA
Voltage
Serial N°: Adsorption A Absorbed power W
Max pressure. Min Temperature. Max temperature.
Refrigerant
R134a
Year of manufacture Risk category under
97/23/CE I
This label is merely indicative. The complete data label is afxed onto the unit.

Instruction Booklet KHEOS PLUS
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Declaration of Conformity
Directive EEC 2006/42 – “Machine Directive”
Directive EEC 2014/30 – “Low voltage directive”
Directive EEC 2014/35 – “Electromagnetic compatibility directive”
PED European Directive 97/23/EC
We: CTR S.R.L. Via T. ed E. Manzini n° 9, 43126 Parma (Italy) represented by its Legal Representative, declare on our sole
responsibility that the product:
Management System for air-conditioning and cooling systems
Model: Kheos Automatica
complies with the requirements of directive 2006/42/EC, 2014/30/EC and 2014/35/EC and associated implementation provisions;
furthermore the pressure circuit complies with directive 97/23/EC as amended, and it is classified respectively:
• category I for the Kheos Automatica model.
We hereby specify that the maximum permissible limits for correct operation of the Kheos Automatica unit are:
• Maximum working pressure: 16 bar
• Maximum working temperature: +50°C
• Minimum working temperature: +5°C
We also point out that:
• the year of manufacture is indicated on the label (with CE marking) affixed onto the unit;
• the technical construction file is kept at our company by the legal representative.
COMPONENTS INCLUDED IN THE PRODUCT
COMPONENT PED CLASSIFICATION / PROCEDURE OF
CONFORMITY EVALUATION
Recovery Compressor Art.3 par. 3
Cylinder Cylinder I (D1 module)
Solenoid valves Art.3 par. 3
Hoses and ttings Art.3 par.3
Safety valve IV (B+D modules)
PARMA February 2016
Eng. Aldo Adamo
(General Manager)

Instruction Booklet
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POSTCODE PAGE OF CONTENTS PAGE
Declaration of conformity 3
CE label 4
1Symbols Introduction 6
1.1 Spare parts 7
1.2 List of functions 7
2Technical characteristics 8
3Safety precautions 8
3.1 Work environment 9
3.2 Preliminary checks 9
3.3 Disposal of electrical material 9
3.4 Use 10
3.5 Maintenance 10
3.6 Power supply 11
4Handling and transport 11
4.1 Mechanical cylinder retainer 12
5General operating rules 13
5.1 Main panel 13
5.2 Operating phases 13
5.3 Use 14
5.4 “Automatic” operation 15
5.5 “Recovery” operation 16
5.6 “Vacuum” operation 18
5.7 “Charge to vehicle” operation (gas, oil-UV Tracer) 18
5.8 Pipe drainage procedure 20
5.9 Refrigerant topping-up 21
5.10 “Recharge cylinder” operation 21
5.11 A/C system flushing 22
6“Service” menu 22
6.1 “Operator” service menu 22
6.2 “Technical staff” service menu 23
7 Refrigerant transfer from unit to external container 24
8Routine Maintenance 25
8.1 Refrigerant filter replacement 25
8.2 Vacuum pump replacement 26
9Adhesive labels 26
10 SD card database update 27
11 Printer (Optional) 27
12 Troubleshooting 29
13 List of error messages 30
14 Fuses 30

Instruction Booklet KHEOS PLUS
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SYMBOLS
The following is a list of the symbols used with a brief explanation.
DANGER: draws your attention to situations or problems that may cause injury or risk of death.
WARNING: draws your attention to situations or problems connected with the efficiency of the unit that do not
involve a risk to the safety of people.
PROHIBITION: do not perform the operations indicated as they would affect the level of efficiency of the unit
IMPORTANT: draws your attention to important information of a general nature that does not compromise
personal safety or proper functioning of the unit.
1. Introduction
The unit described in this use and maintenance manual is an automatic multifunctional system with digital setting, with a database
for first-installation automotive air conditioning systems and performs the following operations: gas recovery, used oil discharge,
vacuum phase, leak test, new oil refill and gas recharge. All these operations are controlled by a microprocessor with electronic
precision scales.
Listed below are the main components and their functions:
• Electronic control: controls the entire process by means of a microprocessor.
• 1) Electronic gas weighing scale: can weigh up to 25 kg refrigerant, with 5 g resolution and interrupt the RECOVERY and CHARGE
functions if the quantities entered or reached during the operation cannot be handled.
• 2) 12cc refrigerant gas recovery compressor.
• 3) One anti-acid recovery filter and a new-concept dehydrator with reduced environmental impact, featuring low cost and ease
of replacement.
• 4) Input gas distiller with automatic flow regulator for separated oil and refrigerant coming from the A/C system with oil
discharge.
• 5) Oil separator, located directly behind the compressor, with automatic return during the recovery cycle.
• 6) 12-litre cylinder for refrigerant gas recovery fitted with safety valve.
• 7) Vacuum pump with high vacuum degree.
• 8) Digital control panel.
• 9) Multi-language high-contrast display for use in poor or excessive light conditions.
• 10) 80 mm analogue pressure gauges (Class 1.0) with pulse-free movement for A/C diagnosis.
• 11) T
wo 2.5 m highly reliable flexible hoses with quick-coupling valves and manual opening (screw fitting) for R134a.
• 12) T wo 250 cc beakers with raised graduations for new oil, used oil
The unit is equipped with 2.5 m hoses for connection with A/C system.
If the length of the hoses supplied is not sufficient for your operating and functional needs, please note that 3
and 6 m hoses are available from our point of sale.
The unit is supplied with two containers for feeding oil and UV tracer and one for oil discharge. If you need to
use different types of oil, you will need to keep a different container for each type of oil.
Make absolutely sure that different kinds of lubricants are not mixed together. Always check what type of oil you
need to use in the various A/C systems (depending on compressor type used); oil types can be identified by
means of specific technical data sheet.

Instruction Booklet
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1.1 Spare parts
All Kheos Plus spare parts are sold by CTR S.R.L. and can be requested from our points of sale.
Spare parts must be installed by your local dealer’s specialized technicians.
1.2 List of functions
• Recovery: allows the unit to recover both the refrigerant and part of the oil mixed in it, automatically separating and storing
them. The polluted oil is recovered in an external graduated container. After regeneration through the filters, the refrigerant is
stored in a dedicated cylinder. Quantification is performed automatically by the system’s scale.
• Vacuum: the A/C system can be brought to the maximum vacuum level within the preset time and kept in this condition. This
makes it possible to completely evacuate moisture and check vacuum seal for possible leaks.
• Recharge to vehicle:
the regenerated refrigerant can be recycled (after adding new oil if needed) using the methods indicated
by the operator. You can also add the desired quantity of new refrigerant fluid, new oil and UV tracer .
• Recharge cylinder: this function is used to fill the internal cylinder and is controlled by an electronic process.
• Automatic cycle: performs the sequence of all the operations required to restore the system to the correct levels of refrigerant
and oil without operator intervention.
Do not use the unit for purposes other than those for which it was designed. When scrapping the machine, you
must comply with current regulations in force locally (bear in mind that the unit contains refrigerant fluids; use
the services of specialized firms).
The unit is supplied with the type of refrigerant indicated in the CE label. Do not refrigerants other than the one
indicated.
The Nordik unit is designed to perform the operations of recovery, vacuum and charge of R134a refrigerant con-
tained in automotive air conditioning systems.
The Nordik unit must not be used to transfer fluids and/or recharge other liquids. Do not fluids other than R134a,
in particular use with flammable liquids is prohibited.
In case of improper use of the station with resulting contamination of the R134s refrigerant and/or of the vacuum
pump oil (e.g. recovery of gas other than R134a, vacuum on circuits containing oils other than the vacuum pump
oil), switch the unit off immediately and contact our technical service department.
Before using the unit, operators must be suitably trained and assisted by technical staff trained by our com-
pany.
Operator: person trained to use the machine (trained directly/indirectly by CTR staff)
Specialized technician: person trained and authorized by CTR to perform technical procedures.
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2. Technical characteristics
The technical specifications shown below refer to the specific models.
Description Unit of measure Nordik
Max absorbed power W 900
Net weight Kg 60
Overall dimensions (HxWXD) cm 104X48X58
Weight (fully charged) kg 75
Vacuum pump flow rate l/min 100
Final vacuum mbar 0.1
System recovery capacity g/min 400
Refrigerant cylinder capacity l 12
Power supply voltage V 220/240
Power supply frequency Hz 50
Max absorbed current A 4
Vehicle coupling diameter (LP – Low pressure) mm 11
Vehicle coupling diameter (HP – High pressure) mm 16
Max operating temperature °C 50
Min operating temperature °C 5
Maximum pneumatic circuit pressure bar 16
For the connection voltage value, instructions are provided on the label on the unit.
The sound pressure value measured is less than 70 dBA therefore the operator does not need to take any particular protection
measure even in case of continuous use (ISO 3746). Nonetheless, the employer is responsible for evaluating the level of noise the
workers are exposed to in accordance with workplace hygiene and safety regulations currently in force.
3. Safety precautions
We recommend you read through every section of this use and maintenance manual carefully before procee-
ding and to make yourself familiar with the unit’s controls.
In case of need, contact only our Technical Service Department (in particular for components repair and repla-
cement).
Do not perform any repair operations. Repair operations performed by inexperienced staff may affect the safety
level of the unit.
Do not place any objects on the unit; the unit must not be used as a support surface or means of transport.
Connection hoses (A/C system) and feed hoses should be positioned in a way that will not cause hindrance and
prevent them from being damaged.
For refrigerant recovery do not use (pressurized) containers that are unfit for the purpose, in terms of material
type and pressure level.

Instruction Booklet
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Current workplace hygiene and safety regulations must be observed at all times. Always refer to the safety data
sheet and comply with its instructions. Never leave the unit unattended in the workplace, even in case of auto-
matic operation.
3.1 Work environment
Only responsible adults must be allowed to use the unit. Make sure that the control device is not used by chil-
dren.
Do not move close to the unit with naked flames or anything else that might cause overheating of the refilling
circuit (with consequent fire hazard). Do not use the unit in places where there is a risk of explosion or fire.
Do not smoke in the area where the work phases are performed.
Operate the unit in places with adequate lighting.
Make sure that there is adequate ventilation. Operate and store the unit in a dry place, protected from the weather
(in general avoid harsh environmental conditions).
For correct use of the unit, read through the essential safety rules for the operator contained in this manual:
Wear safety gloves and goggles. Do not expose to rain or direct sunlight. Before you use the unit, read the car’s
operation and maintenance manual to identify the type of refrigerant.
3.2 Preliminary checks
If the unit is switched off due to a power failure, wait about 10 seconds before restarting it, so that the electronic
part can reset the unit correctly.
The electrical/electronic material must be disposed of separately in accordance with current regulations.
3.3 Disposal of electrical material
When disposing the unit, you must:
1. separate the unit’s parts by type (e.g. plastic, dangerous liquids, metal, etc.) in particular, any waste from
electrical/electronic parts must not be disposed of as urban waste but is to be collected separately;
2. disposal must be through public or private collection systems as required by local regulations;
3. this unit may contain dangerous substances: improper use or incorrect disposal could have negative effects on
human health and on the environment;
3.4 USE
Take special care with possible ejections of refrigerant because:
- contact with eyes may cause serious injury;
- contact with the skin (given the extremely low boiling temperature) may cause burns.
If refrigerant is splashed into your eyes or onto your skin, rinse with plenty of water and immediately seek medical
assistance.

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The unit has been designed for specific use with refrigerant R134a.
The type of refrigerant (R134-a) to be used is indicated on a specific label.
After switching the unit on, allow at least five minutes before performing any operation. If the work cycle is inter-
rupted for whatever reason (e.g. power failure), the operation must be restarted from the beginning.
In case of emergency press the red push button in the panel to remove power completely
The external container used for refilling must be type approved for pressure levels of at least 35
bars and equipped with a safety valve (the valve must comply with the regulations for pressurized
containers).
The refrigerant storage container must NEVER be filled to over 80% its total capacity to prevent drops in efficiecy.
During operation, check fill level of oil containers and ensure they are not overfilled to prevent sudden drops in
efficiency. Do not use these containers with different types of materials.
Live parts
EMERGENCY PUSH BUTTON POWER SOCKET
The unit is designed for use by a single operator. Other persons should keep at a safe distance during operation
as well as during adjustment and maintenance.
Always connect the high and low pressure ducts (red and blue) with the parts supplied and do not use them for
purposes other than those specified.
During operation, check the level in the oil tanks to prevent overflowing .
You must NEVER disconnect the HP and LP hoses, unless specifically requested in this manual. Do not open the
manual valves during normal operation unless expressly requested in the instructions.
3.5 Maintenance
Do not, under any circumstance, use flammable liquids or detergents to clean the unit. Use only neutral deter-
gents; failure to do so will invalidate the warranty for damaged parts.
Always allow a few minutes after switch off to enable the system to return to its rest condition (temperature and
pressure).
During maintenance procedures, do not discard any residues into the environment, but comply with current
disposal regulations.
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Fig. 1 Fig. 2