HYDAC FILTER SYSTEMS CTM-EF 3 3 Series Operating And Maintenance Instructions Manual Download Page 59

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HYDAC FILTER SYSTEMS GMBH

Glossary

BeWa CTM-EF3x3x 4436386 en-us lq

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8434-1 and DIN 2353 standardized com-

ponents for hydraulic connection tech-

nology, create seals for hydraulic pipes

and screwed connections based on their

geometrical shape in a simple, reliable

and safe way.

DM water

DM water = completely demineralized

water Water always tries to saturate it-

self with minerals. That is why we never

find absolutely pure water in nature.

When one removes all the dissolved

substances from water, then one gets

pure H2O or what is called DM water.

Distilled water is still the most common

term used as completely demineralized

water was produced through distillation,

in the past. As this process is very ex-

pensive, reverse osmosis and ion ex-

changers are generally used to produce

DM water. The designations DI water,

deionate, deionized water, or demineral-

ized water always describe the quality of

DM water. This kind of water is also de-

scribed in VDE 0510, DIN 13060 or DIN

EN 50272.

General Terms and Conditions

The General Terms and Conditions are

available at our home page www.hy-

dac.com -> General Terms and Condi-

tions.

ISO 16232

The ISO 16232 is the international coun-

terpart to the VDA 19 Directive. Both

standards are fully compatible with one

another.

Negative control value

Contamination/particles that originate

from the environment, the extraction unit

or auxiliary devices and that can be

measured during the analysis.

Test fluid

Flushing fluid/analysis fluid for spray ex-

traction.

Test item

Component for testing/component clean-

liness analysis/contamination test

VDA 19 directive

The Industrieverbund Technische

Sauberkeit (TecSa) (industrial associa-

tion for technical cleanliness) prepared a

comprehensive set of regulations in the

period 2001 ... 2004. It lays down how

cleanliness checks on products of the

automobile industry must be carried out.

It defines: the extraction process, the

analysis process and the documentation

of the test results. The set of regulations

was given the name "VDA Volume 19

Summary of Contents for CTM-EF 3 3 Series

Page 1: ...ionTest Module Extraction Flushing Operating and Maintenance Instructions English translation of original instructions Document No 4436386 9 25 2019 Follow these instructions for proper and safe use Keep for future reference ...

Page 2: ...nformation 9 1 5 6 Signal words and their meaning in the general safety information 10 1 6 Supplementary symbols 11 1 7 Exclusion of liability warranty 11 1 8 Notes on copyright 11 1 9 Validity of this manual 11 2 Safety information 12 2 1 Placement of safety symbols pictograms 15 2 2 Fire fighting measures 16 2 3 Stoppage in an emergency EMERGENCY STOP 16 3 Overview 17 3 1 Checking the scope of d...

Page 3: ...he extraction module on and off 37 6 2 Connecting the test item 38 6 3 Cascading filter membranes replacing filter membranes 39 6 3 1 Creating cascades 39 6 3 2 Filter membrane holder with quick fastener 40 6 4 Labeling the filter membrane 44 6 5 Conducting the extraction 45 6 5 1 Changing the direction of flushing 45 6 5 2 Draining the test item 45 7 Performing inspection maintenance 46 7 1 Maint...

Page 4: ...Table of Contents HYDAC FILTER SYSTEMS GMBH iv BeWa CTM EF3x3x 4436386 en us lq Finding a Customer Service team 54 EC declaration of conformity 55 Glossary 58 Index 61 ...

Page 5: ...ata of the person authorized with the documentation is Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Germany Phone 49 6897 509 1511 Fax 49 6897 509 1394 E mail guenter harge hydac com Tab 2 Documentation Representative 1 3 Purpose of this manual Before you use this product for the first time or if you have been asked to carry out other work on the product please ...

Page 6: ...on of the prod uct and also for later use Ask the employees to read and follow the manual and the associated documents in particular the safety and warning instructions Observe the additional product related instructions and requirements Specialist personnel Read observe and follow this manual and the associ ated documents in particular the safety and warning instructions Tab 3 Target group 1 5 Il...

Page 7: ...that you can directly access information through the directories However this does not release you from the obligation to read this manual fully before commissioning The document no with the index 4 is meant for identifying and reordering the manual The index is incremented every time the manual is revised or changed The manual contains a table of contents a list of tables and figures an index and...

Page 8: ... the product on Procedural instructions with a random sequence Procedural instructions that have a random sequence are listed as bullet points An example of a procedural instruction with a random sequence Clean the display Rinse the product 1 5 4 Representation of intermediate results results In the case of some activities it is necessary to carry out work steps with inter mediate results and end ...

Page 9: ... information in this manual are highlighted with pictograms and signal words The pictogram and the signal word give you an in dication of the severity of the danger Warning general safety information which are placed ahead of each activity are represented as follows CAUTION Type and source of danger Hazard symbol Consequence of the danger Measures to avert danger ...

Page 10: ...which if not avoided will result lethal or serious injury WARNING WARNING The signal word indicates a hazardous situation with a medium level of risk which if not avoided can result lethal or serious injury CAUTION CAUTION The signal word indicates a hazardous situation with a low level of risk which if not avoided can result in minor or moderate injury NOTICE NOTICE The signal word indicates a ha...

Page 11: ...lost profit or other financial loss This exclusion of liability does not apply in cases of intent and gross negligence Moreover it does not apply to defects which have been deceitfully concealed or whose absence has been guaranteed nor in cases of culpable harm to life physical injury and damage to health If we negligently breach any material con tractual obligation our liability shall be limited ...

Page 12: ...ded use test liquid Bodily injury and damage to property u The extraction unit may only be used with the permissible test liquid u Use only test fluids that are compatible with the materials and the sealing materials they come in contact with WARNING Test liquid G60 Spezial or Feroclean L261 Flammable gas air mixture in the analysis chamber Danger of fatal injury from burns u Open fires or smoking...

Page 13: ...et u Make sure that there is adequate exchange of air in the room You will find details in the safety data sheet CAUTION Operating pressure Danger of bodily injury u Remove disconnect the compressed air supply from the excraction unit be fore all work CAUTION Hot surface at the solenoid valves Danger of burns u Allow the solenoid valves to cool down before all repairs maintenance work NOTICE Imper...

Page 14: ...Lift the extraction module only at the housing not at attachments or compo nents The following are the safety symbols pictograms in this manual They indicate specific dangers to persons property or to the environment Observe these safety symbols pictograms and act with particular caution in such cases Al ways keep all symbols pictograms intact and legible Fires naked lights and smoking are prohibi...

Page 15: ...s pic tograms on the extraction unit Replace the damaged or no more recognizable legible safety symbols pictograms immediately Pull the safety symbol pic togram off the extraction unit remove possible present adhesive residues with a cleaner suitable for that purpose Then affix the new stick on safety symbol pic togram at the same place on the extraction unit Fig 2 Placement of safety symbols pict...

Page 16: ...n a minimum safe distance from electrical components For a mains volt age of up to 1000 V the minimum safe distance is 1 m Fig 3 Minimum distance for fire fighting 2 3 Stoppage in an emergency EMERGENCY STOP In an emergency disconnect the extraction unit and modules that may be present from the power supply Switch off the extraction unit at the main switch The extraction unit is deenergized downst...

Page 17: ...er membrane and then analysed with regard to the quantity of particles and their type 3 1 Checking the scope of delivery The ContaminationTest Module CTM EF comes packed and pre assembled At delivery before commissioning please check the scope of delivery to make sure it has not been damaged during transport and that it is complete The following items are included in the scope of delivery Qty Tool...

Page 18: ...missioning usage handling storage maintenance repair use of unsuitable components or other circumstances for which the manufacturer is not responsible The manufacturer assumes no responsibility for determining the interfaces for installation in a system or the installation use or functionality of the product in this system The intended use of the product extends to the following Operation only tog...

Page 19: ...h use This risk is borne solely by the owner Improper use may result in hazards and or will damage the unit Improper use or use deviating from intended use are for example Operation with an impermissible test fluid Operation under non approved operational conditions Operation when the safety devices are defective Modifications to the power unit made by the user or purchaser Inadequate monitoring o...

Page 20: ...equately ventilated Permissible ambient temperature range 15 28 C Permissible relative air humidity 80 non condensing Permissible storage temperature range 0 50 C Required compressed air supply 5 6 bar Required cleanliness of compressed air ISO8573 1 7 4 4 Permissible air conditions during stor age Dust free salt free air not near oxidiz ing substances rust film Permitted relative air humidity 80 ...

Page 21: ... 34xx CTM EF 36xx Clean room 0 2 mg 0 3 mg Laboratory 0 2 mg 0 3 mg Separate sampling room 0 2 mg 0 3 mg Plant factory shed 0 2 mg 0 3 mg Tab 6 Achievable negative control values particle size metallic Requisite effort Cleansing time af ter a brief shut down 24 h Cleansing time af ter a longer shut down 24 h 100 µm High 1 4 h 1 4 h 150 µm Medium 1 2 h 1 2 h 200 µm Low 0 5 h 0 5 h Tab 7 Requisite e...

Page 22: ...e model code to the permissible test liquid Use only test fluids that are compatible with the materials and the sealing mate rials they come in contact with Extraction device Permissible test liquids CTM SC 3xx0 CTM EF 3xx0 G60 Spezial or Feroclean L261 CTM SC 3xx1 CTM EF 3xx1 G60 Spezial or Feroclean L261 or water containing tensides permissible ph value 6 10 No demineralized water completely dem...

Page 23: ...ind identification details of the extraction unit on the name plate Fig 4 Decoding the type label Item Description 1 Name plate of the extraction unit 2 Supply voltage power supply power consumption Model Model code for details see Chapter Model code 24 P N Part number S N Serial number Date Year week of production ...

Page 24: ...lean L261 or water containing tensides permissible ph values 6 10 no completely demineralized water or G60 Spezial or Feroclean L261 0 1 ExtractionFlushing Series Volume storage container 4 6 40 liters nominal 60 liters nominal Extraction method Supplementary details Modifications spraying medium pressure Series Series z z With integrated extraction for recovery of the test liquid after the extrac...

Page 25: ...DAC FILTER SYSTEMS GMBH Overview 3 BeWa CTM EF3x3x 4436386 en us lq 25 64 3 6 Dimensions The ContaminationTest Module CTM EB has the following outer dimensions Fig 6 Dimensions CTM EF All dimensions in mm ...

Page 26: ...aulic circuit AIR Compressed air supply A Supply port B Supply port C Supply port R Supply port A Test item port C Test item port R Test item port 1 Receiver tank 2 Inner chamber flushing 3 Breather filters 4 Filter membrane holder B1 Level detector V1 Ball valve X Test item Y10 1 2 2 directional valve Y10 2 2 2 directional valve Y20 2 2 directional valve Y30 3 2 directional control valve ...

Page 27: ...HYDAC FILTER SYSTEMS GMBH Overview 3 BeWa CTM EF3x3x 4436386 en us lq 27 64 Y31 2 2 directional valve Y40 2 2 directional valve Y50 3 2 directional control valve Y51 2 2 directional valve ...

Page 28: ...lements components Fig 8 CTM EF 3x3x components operating elements 1 Reservoir 2 Cover 3 Ball valve 4 Main switch E STOP 5 Filter membrane holder 6 Connection cable with power plug 7 Control system interface plug RJ45 8 Ports A B C R 10 Sliding grip 11 Steering castor 12 Test item connection hoses A C R 13 Filter membrane holder support 14 Compressed air supply ...

Page 29: ...ift the extraction module only at the housing not at attachments or compo nents ü In order to transport store the extraction unit proceed as follows 1 Completely empty the extraction unit all the tanks and lines Dispose of the draining test fluid in an environmentally friendly way Im mediately remove the test fluid that has drained 2 Remove the compressed air supply 3 Disconnect the power plug and...

Page 30: ...shipped from the factory in a wooden box with the corre sponding securing devices Pack the assembly for onward transport in this wooden box Alternatively place the assembly on a pallet of sufficient size us ing a forklift Brace the extraction unit so that the steering rollers are not loaded Secure the extraction unit against tipping See also 2 Technical Data 20 ...

Page 31: ... following points Release the brakes on the steering rollers and move the extraction unit into the desired position with the installed rollers The extraction unit must be set up on an even level surface When you have positioned and aligned the extraction unit set the brakes on the casters Make sure that the cleanliness of the surrounding area the ambient air and the temperature at the installation...

Page 32: ...a compressed air connection for operation The compressed air requirements can be found in Chapter Technical Data 20 1 Connect the quick action coupling of the compressed air supply to the standard connection nipple of the low pressure series DN 7 2 on the ex traction unit 2 Open the shut off valves that may be present in the supply line 3 Check the state and the setting of the maintenance unit in ...

Page 33: ... assembling commissioning 5 BeWa CTM EF3x3x 4436386 en us lq 33 64 Fig 9 Connecting CTM SC3xxx CTM EF3xxx Screw the spigot nuts of the hoses onto the supports of the module and tighten them Shut the ports that are not required with a plug ...

Page 34: ...hecking the installation ü You have successfully completed all the works described earlier in Chap ter Setting up assembling commissioning 31 1 Connect the ports A and R with a connection piece 2 Switch on the extraction module at the main switch 3 Switch on the supply module at the main switch ð After 2 minutes the user interface appears on the touch screen The software detects the connected extr...

Page 35: ...the installation Marking the discharge points Connection Volume Flow Discharge point A 1 liter 6 l min 1 A change of di rection 1 liter 6 l min 2 B 1 liter 6 l min 3 Tab 9 Test parameter 1 Connection Volume Flow Discharge point C 1 liter 6 l min 1 Tab 10 Test parameter 2 See also 2 Setting up assembling commissioning 31 ...

Page 36: ...ow rate meter If the set volume has been conveyed the directional valve is closed The test liquid in the analysis chamber is drawn through the filter membrane in the filter membrane holder by a vacuum The filling level of the test liquid in the storage container is monitored by a level sensor If the max filling level is reached in the storage container the flow through the CTM SC module is stopped...

Page 37: ... the operating system the user interface of the sup ply module starts and detects the connected extraction module O Select the required operating mode or start an extraction You will find details regarding the user interface in the online help for the ConTeS software Switching the extraction module off To switch off the extraction module proceed as follows ü Finish all extractions 3 Switch off the...

Page 38: ...6 2 Connecting the test item Connect the test item X to the suitable screwed fittings at the ports A or C and R Fig 11 Connecting the test item A Connecting hose B Connecting hose C Connecting hose R Connecting hose A Test item port C Test item port R Test item port X Test item ...

Page 39: ...ane holder with quick fastener Fig 12 Cascading the filter membrane holder Item Tool 1 Coupling 2 Hose connection 3 Diffuser The diffuser allows for the even distribution of the test liquid over the entire surface of the filter membrane 4 Upper part of the filter membrane holder 5 1 Filter membrane 100 µm 5 2 Filter membrane 20 µm 5 3 Filter membrane 5 µm 6 Supporting sieve 7 Intermediate ring 8 T...

Page 40: ... ü End the extraction through the user interface ü Wait until analysis fluid is completely evacuated ü Shut the ball valve upstream of the filter membrane holder 1 Hold the holder with one hand on the lower part 2 Use your other hand to release the lock by 90 upper part 3 Disengage the lower part from the upper when the guide of the lower part is parallel to the lock guide ...

Page 41: ...wn the lower part slightly Then pull it fully through the opening cre ated 5 Remove the filter membranes from the cascade and mark them as given in Chapter Labeling the filter membrane 44 ð Pass these filter membranes on for analysis 6 Fit a new filter membrane onto the supporting sieve ...

Page 42: ... the lower part horizontally in the upper part together with the filter membranes 8 Lift the lower part vertically under the upper part The position of the screen must match the number of cascades 9 If further cascades are required the lower part must be adjusted for the matching block ...

Page 43: ... CTM EF3x3x 4436386 en us lq 43 64 10 During the assembly of three cascades select the top block 11 Seal the filter membrane holder by turning it clockwise by 90 NOTICE Do not use any tools O The replacemeent of the filter membrane is complete ...

Page 44: ...em For example xyz 1 A 005 Tab 12 Example Marking of filter membranes Marking Description XYZ Running test item series running test item lot 1 Number of the filter membranes provided A When several flushing procedures are carried out on a test item A B C Z for the establishment of the negative control value for the filter membrane 005 Rating of the filter membrane 005 5 µm 010 10 µm 100 100 µm ...

Page 45: ... the analysis fluid carrying the particulate con tamination flushed off the component is sucked through the filter mem brane with the help of a membrane pump via connection R and flows back to the CTM SC supply module ð The membrane pump will continue running once extraction is complete The message Pause wait until test liquid has been extracted will appear on the user interface 3 Remove the test ...

Page 46: ...se tasks 7 1 Maintenance table Weekly Every three months Annually Every 2 years Every 6 years Additional informa tion 7 6 Clean the diffuser on the filter mem brane holder 1 7 2 Checking the screwed and plug connections 3 7 3 Visual inspection of the electric com ponents cables 4 7 4 Checking hoses 2 7 5 Replacing hoses plastic pipe 3 7 5 Replacing hoses plastic pipe 3 1 Operating personnel 2 Serv...

Page 47: ...all the screwed and plug connections regularly for correct seating 7 3 Visual inspection of the electric components cables Electric components and cables can be damaged Check the electric compo nents and cables on the device and in the switch cabinet through regular visual inspections 7 4 Checking hoses The installed hoses are specially designed for this application Check the hoses once a year for...

Page 48: ...n of the hoses the plastic pipe Fit the cutting rings with a fitting aid Details regarding this can be found in the DIN EN ISO 8434 1 standard NOTICE Assembly paste to assemble the screwed fittings The extraction unit will be contaminated the analyses will become unusable u Do not use any assembly paste to assemble the screwed fittings To replace the hoses the plastic pipe you will need the follow...

Page 49: ...pper part of the filter membrane holder ü The test liquid in the analysis chamber is completely extracted 1 Open the coupling 1 and remove the diffuser 3 2 Clean the diffuser 3 by blowing it out with compressed air 3 Put the diffuser into the filter membrane holder and screw the coupling 1 finger tight O The cleaning of the diffuse on the filter membrane holder is complete ...

Page 50: ...es not flow into the storage container The CTM SC module is incorrectly connected Check the connection hoses be tween the CTM SC and CTM EF module A directional valve in the CTM SC module or a hose is defective Replace the directional valve or the hose The gear pump in the CTM SC is defective Replace the gear pump The incorrect outlet was selected Select another outlet The test liquid is not ex tr...

Page 51: ...ubleshooting remedying malfunctions 8 BeWa CTM EF3x3x 4436386 en us lq 51 64 Malfunction error Possible causes Solution To be carried out by The membrane pump in the CTM SC is defec tive Replace the membrane pump Tab 13 Error list ...

Page 52: ...mmissioning Disconnect or remove the electric pneumatic or hydraulic connections Dispose of the packaging material in an environmentally friendly manner Dispose of the fluid operating medium that has been drained in an environ mentally friendly manner After dismantling the product and separating its various materials into cate gories dispose of all parts in an environmentally friendly manner ...

Page 53: ...20 1 CTM EF 36xx level sensor 4437221 1 Solenoid valve Y10 1 6235930 1 Solenoid valve Y10 2 Y20 Y40 6187217 1 Solenoid valve Y31 Y51 6124865 1 Solenoid valve Y30 Y50 6022777 1 Hose set consisting of plastic pipe Ø 15 9 mm cutting rings support bushing spigot nut air hose 4458807 1 Tab 14 Spare parts list CTM EF 3x3x available on request Description Part no Qty Filter membrane 5 µm Ø 47 mm Color wh...

Page 54: ...he hotline product support customer service branch offices service part ners for servicing repair and spare parts can be found always updated at our homepage www hydac com HYDAC SYSTEMS SERVICES GMBH Friedrichsthaler Str 15 Werk 13 66450 Neunkirchen Heinitz Germany Phone 49 6897 509 01 Fax 49 6897 509 324 E mail service hydac com Homepage www hydac com Tab 17 Customer service in Germany ...

Page 55: ...TEMS GMBH Appendix BeWa CTM EF3x3x 4436386 en us lq 55 64 EC declaration of conformity The ED declaration of conformity can be found in the Technical Documentation that is part of the scope of delivery for the product ...

Page 56: ...istance for fire fighting 16 Fig 4 Decoding the type label 23 Fig 5 Model code 24 Fig 6 Dimensions CTM EF 25 Fig 7 CTM EF 3x3x hydraulic circuit 26 Fig 8 CTM EF 3x3x components operating elements 28 Fig 9 Connecting CTM SC3xxx CTM EF3xxx 33 Fig 10 Checking the installation Marking the discharge points 35 Fig 11 Connecting the test item 38 Fig 12 Cascading the filter membrane holder 39 Fig 13 Clean...

Page 57: ...1 Tab 7 Requisite effort cleansing time for negative control values 21 Tab 8 Permissible test liquids 22 Tab 9 Test parameter 1 35 Tab 10 Test parameter 2 35 Tab 11 Cascading the filter membrane holder 39 Tab 12 Example Marking of filter membranes 44 Tab 13 Error list 50 Tab 14 Spare parts list CTM EF 3x3x 53 Tab 15 Spare parts for the filter membrane holder Ø 47 mm all 53 Tab 16 Spare parts for t...

Page 58: ...e gases and vapors 1 Charged insolating equip ment 2 Conductive grounded object with a curvature radius of above approx 5 mm 3 Brush discharge 4 Conduc tive grounded needle shaped object with a radius of curvature of less than 0 5 mm 5 Corona discharge Source TRGS727 DGUV213 060 CTM EF ContaminationTest Module Extraction Flushing DGUV DGUV is the abbreviation for the Deutsche Gesetzliche Unfallver...

Page 59: ...ater This kind of water is also de scribed in VDE 0510 DIN 13060 or DIN EN 50272 General Terms and Conditions The General Terms and Conditions are available at our home page www hy dac com General Terms and Condi tions ISO 16232 The ISO 16232 is the international coun terpart to the VDA 19 Directive Both standards are fully compatible with one another Negative control value Contamination particles...

Page 60: ...Glossary HYDAC FILTER SYSTEMS GMBH 60 64 BeWa CTM EF3x3x 4436386 en us lq Checking technical cleanliness Particle contamination of function relevant auto motive parts ...

Page 61: ...eclaration of conformity 17 Electrical circuit diagram 17 Empty weight 20 Environmental conditions 20 exclusion of liability 11 H Hotline 54 Hydraulic circuit 17 I Imprint 5 Intended use 18 L Life expectancy 20 M manufacturer 5 N Nominal power 20 O Operating elements 28 Operation and maintenance Instructions 17 P Person authorized with the documentation 5 R Rated voltage 20 Relative air humidity 2...

Page 62: ...Index HYDAC FILTER SYSTEMS GMBH 62 64 BeWa CTM EF3x3x 4436386 en us lq T Technical data 20 Technical documentation 17 Terms and Conditions 11 Terms of Delivery 11 W warranty 11 ...

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