Honeywell EkoFlush-K572 Operation instructions

- 1 -
Wheeled Circuit Flushing Unit
EkoFlush-K572
USER OPERATING MANUAL

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Wheeled Circuit Flushing Unit
EkoFlush-K572
USER OPERATING MANUAL
1. Table of contents
Chapter 2. Safety Precautions Page 2
3.
Unit Description
3
4. Accessories 4
5. Technical Specifications 4
6. Main principles and interconnections 5
7. Flushing Procedure 7
8. Controlling 10
9. Completing Flushing 13
10. Exchange of SOLSTICE
®
PF-C solvent 14
11. Subprogram „distillation“ 14
12. Oil Change, Adding Oil 16
13. Waste Disposal 17
14. Risks Analysis 17
15. Failures, Possible Causes, Troubleshooting Guide 18
16. CE Conformity Declaration, Certificate Electro-technical Testing Institute 20
17. Safety guidelines 21
18. K572 Optional Accessories to order 22
The EkoFlush-K572 device is designed for qualified servicemen operating in the air conditioning and
refrigeration industry.
2. Safety Precautions
WARNING: Failure to follow these precautions can result in serious injury.
•This Operating Manual must be completely read and understood before operating this unit.
•Suitable skin and eye protective equipment should be worn while operating or maintaining the
EkoFlush unit.
•The use of flushing solvent is permitted only in cylinders equipped with a safety valve. Cylinders
can be filled up to a maximum of 70% of the available volume. Before beginning the flushing
procedure, please check the availability of the solvent by putting the cylinder on a scale.
•The flushing agent must be drained from the EkoFlush every time before transporting this Unit (“0”
bar or less should be shown on the low-pressure manometer).
•The EkoFlush-K572 unit can only be transported by transportation means if its solvent cylinder is
disconnected and transported separately. The main unit can be transported on wheels (properly
protected against moving), or laid down on its rear side leaning on its handle and wheels. Other
positions will result in damages to the EkoFlush machine.
•The EkoFlush unit must be protected against open flames and flying sparks.
•All repairs must be done by an authorized service or by the producer. Please consult your local
dealer.
•This Unit can be used only in compliance with EU regulations on manipulation of volatile matters.
•Material Safety Data Sheet must be according to the regulations located in the workshop. The
English version can be found on the website www.honeywell-solvents.com
CAUTION
Failure to observe precautions as outlined in this Operating Manual can result in damage to the
compressor, other components or even of the Unit as a whole, and cannot be supported or covered by
the warranty.

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3. Unit Description
3.1 The EkoFlush-K572 is a mobile flushing unit with wheels and rugged metal structure. The
solvent cylinder required to operate the machine must have a two-way valve and must be filled
only with the flushing agent SOLSTICE
®
PF-C by HONEYWELL, pressurized with nitrogen at 8
bar.
Please consult your local dealer on connectors to attach it to the circuit you need to clean.
3.2 IMPORTANT: This Unit was designed to operate exclusively with the flushing agent
SOLSTICE
®
PF-C by HONEYWELL. If other fluids will be used, the result will be a
significant damage to the Unit and injuries for the operator.
3.3 This Unit operates on the principle of pulsating pressurized flushing of the components or
systems to be cleaned. The EkoFlush has a patent certificate. The flushing agent SOLSTICE
®
PF-C is distilled during every flow and returns to the cylinder virtually pure, ready to be re-used
for another flushing. This ensures that the cleaned components are always flushed very
effectively and fast.
3.4 The cycle has four phases.
3.4.1 I – AIR SUCKING-OFF
After having safely connected the EkoFlush unit to the circuit to flush and the solvent cylinder
with SOLSTICE
®
PF-C, and having started the operations by switching the unit on and
selected the number of flushing cycles, the EkoFlush will remove the air from the dirty circuit.
Once this phase is completed, the EkoFlush begins the automatic flushing procedure.
3.4.2 II – FLUSHING
The flushing solvent is forced into the circuit to flush thanks to the high pressure of nitrogen
(6 – 8 bar) present in the cylinder. The high pressure, the speed of the solvent flow and the
pulsation ensure that the contaminants (oil, grease, particles, water, etc…) are also removed
from every hard-to-reach corner. The full volume of the dirty circuit is filled with SOLSTICE
®
PF-C. An accurate flushing is ensured by a special pulsating mode of the solvent flow. At the
end of this phase, the EkoFlush unit pushes SOLSTICE
®
PF-C from the circuit into its
distillation chamber. Each step automatically follows the previous one without manual
intervention of the operator.
3.4.3 III – REMOVING THE LIQUID PHASE OF SOLSTICE
®
PF-C
Nitrogen from the cylinder purges the flushed component at a pressure of 6 – 8 bar in order
to quickly remove the liquid SOLSTICE
®
PF-C.
The purge is repeated a number of times until there is no more liquid in the flushed circuit.
3.4.4 IV – SUCKING OFF THE VAPOR PHASE OF THE SOLSTICE
®
PF-C
In this last step, the vapor residues of SOLSTICE
®
PF-C are extracted from the circuit and
are returned clean to the storage cylinder. An acoustic signal announces the completion of
the automatic procedure. After hearing this signal, oils, greases and contaminants can be
drained from the distillation chamber.
Picture 1 - K572 Overview

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Your new unit is able to:
•Flush easily, automatically, quickly and effectively components of air conditioning and refrigerant
circuits, evaporators, condensers, as well as the pipework.
•Save money because SOLSTICE
®
PF-C flushing agent can be re-used up to 20 times (+1 open
flush – solvent vented to air).
•Clean and flush a complete circuit without impacting the environment, thanks to closed circuit
operations: you and your shop will remain clean!
4. Accessories
4.1 Standard accessories – delivered together with the Unit
•Hoses
-
1/4“ SAE x 90cm with valve – blue 1 piece to connect the solvent cylinder, vapor outlet (Blue)
to the inlet on the rear side of the EkoFlush Unit
(Nitrogen)
-
3/8“ SAE x 90cm with valve – red 1 piece to connect the solvent cylinder, liquid outlet (Red),
to the inlet on the rear side of the EkoFlush Unit
(Liquid)
-
3/8“ SAE x 180cm with valve – blue 1 piece to connect the EkoFlush front panel (OUT) to the
circuit to flush
-
3/8“ SAE x 180cm with valve – red 1 piece to connect the EkoFlush front panel (IN) to the
circuit to flush.
-
Flare adapter 3/8” Male SAE x 1/4”
Fem. SAE
1 piece Adapter for the vapor outlet valve on the solvent
cylinder (Blue)
-
Additional external filter P48 1 piece To intercept solid particles when flushing
particularly dirty circuits.
4.2 Additional accessories to order
•Please refer to your local supplier for the size of the cylinders of SOLSTICE
®
PF-C that best
suits your flushing operation.
5. Technical Specifications
• Voltage 110/230V, 50/60Hz
• Maximum power input 1850 W
• Compressor oil ester oil ISO VG 46
• Compressor oil filling 0,4 kg
• Connection to the flushed device 3/8“ SAE
• Connection to the refrigerant cylinder (liquid valve) 3/8“ SAE
• Connection to the refrigerant cylinder (vapor valve - nitrogen) 1/4“ SAE
•
Maximum operating overpressure of the Unit
8 bar
• Ambient temperature +5°C – +40°C
• Weight without the refrigerant cylinder 54 kg
•
Main dimensions (WxDxH)
570x605x950 (mm)
• Flushing agent for systems cleaning SOLSTICE
®
PF-C
!! WARNING !!
The Flushing Unit EkoFlush-K572 is designed to operate exclusively with
the SOLSTICE
®
PF-C flushing solvent produced by HONEYWELL.

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6. Main principles and interconnections
6.1 The circuit to flush must be tight, free from leaks and from internal blocks.
IMPORTANT!
Please check the absence of internal blocks by flowing some nitrogen or air through the circuit,
before starting the flushing operations. The pressure of the solvent and the EkoFlush unit may
not be sufficient to remove the blocks and the flushing operation will not be completed, resulting
in loss of solvent.
6.2 Connect the K572 directly to the circuit, by-passing the compressor.
IMPORTANT!
It is necessary to disconnect the compressor before flushing, or the oil present in the
compressor will be washed off!!
6.3 Large circuits need to be flushed in sections, especially circuits with several branches.
6.4 All throttling elements (capillary tubes, expansion valves, pressure limiters) need to be replaced
by standard pipes or “by-passed”.
6.5 Filters must be replaced by standard pipes; otherwise they will be immediately filled up with
impurities collected in the circuit.
6.6 Remove or turn upside-down the accumulators (receivers).
If portions of SOLSTICE
®
PF-C will end up in accumulators, the flushing procedure will become
longer or solvent will remain trapped inside.
6.7 The back side of the EkoFlush K572 unit and the solvent cylinder must to be connected with the
following hoses:
1/4“ SAE x 90 cm – blue - vapor outlet on the solvent cylinder – BLUE
3/8“ SAE x 90 cm – red - liquid outlet on the solvent cylinder - RED
NOTE: Depending on the cylinder you are using, you may need an adapter for these
connections. Please refer to your local supplier of SOLSTICE
®
PF-C.
NOTE: Hoses must be installed with the valve-end close to the cylinder of the solvent.
6.8 Use the belt to secure the solvent cylinder to the EkoFlush K572 and prevent it from falling onto
the operators.
6.9 For the flushing of complicated circuits, it’s kindly suggested to use a scale to check the quantity
of SOLSTICE
®
PF-C at the beginning of the operations and the solvent recuperated at the end
of the process. This check will confirm the total extraction of the solvent from the cleaned circuit.
6.10 Before starting the flushing, please verify that the pressure in the solvent cylinder is between 6
and 8 bar (max 8 bar). This check can be done after having connected the hoses, by looking at
the high-pressure manometer (pos. 13 – see Picture 4) without switching on the K572 Unit. The
valve on the liquid outlet of the cylinder and the relevant valve on the hose must be open when
this test is in progress. Maximum permissible pressure of 8 bar is indicated by a red line on the
high-pressure manometer (pos. 13)!
The refilling of nitrogen in the refrigerant cylinder is permitted using appropriate equipment.
Please consult your local supplier of the SOLSTICE® PC-C solvent in case of need.

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6.11 Check the oil level in the compressor sight-glass and refill if necessary. The level of the oil must
be between those two lines, indicated in the picture below.
Picture 2 - Sight-glass for compressor oil
WARNING! Any claim for malfunctioning caused by lack of oil won’t be accepted!!
6.12 Connect the front panel of the EkoFlush K572 to the circuit to flush, as follows:
-inlet into the flushed circuit to “IN”
-outlet from the flushed device “OUT”
The ends of the hoses with the valves must be near the flushing unit.
IMPORTANT
Whenever possible, in order to ensure easier flushing, please connect the inlet to the circuit to
be flushed in higher position than the outlet: gravity helps the cleaning process.

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7. Device flushing procedure
Picture 4 - K572 Control panel
Picture 5 - K572 Control panel with hoses
7.1 Ensure that the connections of all the hoses are tight (see chapter 6).
7.2 Open all valves both on the solvent cylinder and on the hoses.
Picture 5 here above describes the cylinder before and after the completion of the flushing
procedure.
High
Pressure
(from cylinder)
Pos.13
Low Pressure
(from circuit)
Pos.16
Outlet
Pos.6
OUTLET HOSE
with Valve
INLET HOSE
with Valve
Main Switch
Pos. 31
Inlet
Pos.7
Sight
Glasses
Manometers
Main Switch
Pos. 31
INLET HOSE
(to circuit)
with Valve
Low Pressure
Pos.16
High
Pressure
Pos.13
OUTLET HOSE
(from circuit)
with Valve
Picture
3
-
Cylinder of Solstice®
PF
-
C
Particles Filter
P48
Sight
Glass IN
(to circuit)
Red
Blue

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At the beginning of the flushing process, the unit automatically evacuates the circuit to clean
from the air, then automatically fills it with the solvent SOLSTICE
®
PF-C.
PLEASE NOTE
For circuits with more sections, the following steps are recommended:
- As soon as the sight glass (Picture 4 - Pos.6) is filled with the liquid, close the valve on the
hose connected to the outlet marked "OUT" (on the left in picture 3).
- The inlet sight glass (Picture 4 - Pos.7) enables the control of the filling of the complete
system to flush with the solvent SOLSTICE
®
PF-C.
- When the liquid stops to flow in the inlet sight glass (Picture 4 - Pos.7), the circuit is
completely filled and it is possible to open the valve on the outlet hose marked "OUT" (blue,
on the left side of the picture).
- The flushing procedure goes on automatically.
With simple circuits, the instructions above can be omitted.
7.3 The size of the solvent cylinder needs to be adapted to the size of the circuit to be flushed.
Please consult your local supplier for recommendations on the most suitable cylinders for your
flushing operations.
For best performance, the optimal internal diameter (Dn) of the circuits to flush should range
from 8 to 20 mm.
7.4 When the filter of the Outlet sight glass (Picture 4 - Pos. 6) is full of dirt and the current process
slows down or practically stops (the pressure on the low pressure gauge - Picture 4 - Pos. 16 is
increasing slower than normal or it doesn´t increase at all), please follow these instructions:
- Close the valve on the hose connected with the “OUT” outlet (Picture 4, on the left, in blue),
- Let the unit run until the pressure on the low pressure gauge (Picture 4 - Pos. 16) reaches 0
bar (equal to 1 bar of absolute pressure).
- Turn off the unit using the Main Switch (Picture 4 - pos. 31)
- Wait for several minutes. The pressure on the low pressure gauge (Picture 4 – Pos. 16)
should increase.
- If the pressure increases over 0 bar (1 bar of absolute pressure), repeat the process (turn on
the unit and wait for the pressure to drop).
- When the pressure does not increase after having turned off the unit, you can dismantle the
sight glass (Picture 4 – Pos.6) and clean the filter.
Using the external P48 Filter prevents the Sight Glass filter to accumulate dirt.
It’s important to follow the instructions here above to prevent injuries when disconnecting it
from the EkoFlush unit.
IMPORTANT!
The unit must be turned off while dismantling the sight glass or the P48 filter. At the
same time, the valve of the hose on the outlet marked “OUT” (Picture 5 – left side – in
blue) must be closed!!!

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After dismantling the upper part (No. 2, 3, 4), withdraw the blocking spring (No.4) and
dismantle all single parts (No.2, No.3 and No.4) and clean them, together with the
interior of the sight glass (No. 1).
CLEANING THE P48 FILTER
The cleaning of the P48 Filter is extremely simple:
-Open the external cartridge by unscrewing it
-extract the inner metal filter,
-blow it with compressed air or brush it
-put the filter back in its original position and close the cartridge.
NOTE: The metal filter inside the cartridge has an infinite life. In case it’s heavily clogged, you
can wash it with solvent.
7.5 After completing the flushing, it may happen (for many reasons) that the final pressure in the
cylinder is lower and that the quantity of recuperated SOLSTICE
®
PF-C is also less than at
start. If a cylinder of an appropriate size has been chosen for the flushing operation, in absence
of unexpected leaks, the quantity of the solvent should be sufficient to perform 20 cleanings.
Please consult your solvent supplier in case of problems.
WARNING!
A high loss of SOLSTICE
®
PF-C can indicate a problem of leakage in the flushed circuit.
Picture
6
-
Solvent
front sight
-
glass distmantled

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8. Unit controlling – work flow
G = green
Y = yellow
PB = button
LED = diode-signal light
DISPLAY or LEDS
8.1. Turn on the main switch. The display shows the number of remaining
flushing procedures three times. –see 10
8.1.1. Initial status. On display “1” and LED 1, LED 6
8.1.2. Select the number of flushing cycles (1 to 9), PB
2 increases, PB 3 decreases.
It is possible to change the number of cycles at any
time. With min. cycle count at „1“, just one
processing cycle will be completed.
On display “X” and LED 1, LED 6
“ X” = number of selected flushing procedures
8.1.3. Option to discharge the oil and sludge from
distillation chamber. – see 8.4.
On display “X” and LED 1,
LED 6 blinks.
8.2. Press PB 1 – start
8.2.1. Sucking-off (90 sec.) On display “X” and LED 2
8.2.2. Flushing (after filling the distillation chamber, 7min.
sucking-off)
Next cycle of flushing.
On display “X” and LED 3
LED7 lights up when the distillation chamber is
full.
On display X-1 and LED 3
NOTE
At any time during flushing, the number of flushing cycles PB 2 or PB 3 can be changed.
If
“1”
is selected
,
only
the
ongoing
processing cycle will be completed.
8.2.3. Sucking-off the liquid phase of SOLSTICE
®
PF-C
through nitrogen purge. 5 cycles made of 20 sec
nitrogen purging +
60s pause
On display “0” and LED 4
during the pause intervals: LED 4 blinks
8.2.4. Sucking-off the vapor phase of SOLSTICE
®
PF-C -
after the discharge of liquid is completed.
It is possible to blow-out the solvent with nitrogen
(20 sec) during this period – pressing PB 4
After 180 sec. 3 beeps will follow.
After this acoustic signal and at a pressure higher
than 0 bar on LP manometer, pressing PB 4 the
blow-out with nitrogen can be repeated up to 5
times.
On display “-” and LED 5,
LED 6
By pressing PB 4, LED 6 blinks
On display “-” and LED 5
blinks, LED 6
8.2.5 Within 15 min. from the acoustic signal, the
compressor turns off, the display goes blank.
Before PB 5 -“END” is pushed, nitrogen blow-out
may be repeated
up to
5 times by pushing PB 4.
LED 6, LED 5 blinks, on display “-”
NOTE:
During the flushing (8.2.2) the dist. chamber is filled and/or emptied with solvent and LED 7 blinking or
simply on.
When the procedure of par. 8.2.4 is in progress, the nitrogen purging process can be activated
for 20s by
pushing PB 4 (LED 6 blinks).
If the pressure on the low-pressure manometer is higher than 0 bar after the acoustic signal, repeat nitrogen
purging 5 times by pushing 1x PB 4.
Picture 7 - K572 Switchboard