HYDAC FILTER SYSTEMS CTM-SC 3 Series Operating And Maintenance Instructions Manual Download Page 51

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Annex

Explanation of terms and abbreviations

An explanation of terms and abbreviations follows below:
°C

Degrees Celsius

abs.

Absolute (e.g. in pressure specifications)

Alternating current

Air Bleed

Ventilation / air bleed port

Analysis fluid

After spray extraction load test liquid with particles

up to the filter membrane.

Dosing calibration

Set system / flow transmitter

BetrSichV

German Industrial Safety Ordinance

Operation and

Maintenance

Instructions

Operating and Maintenance Instructions

Negative control value

Inherent soiling value

Centimeters

CTM-SC Software

ContaminationTest Software

CTM

ContaminationTest Module

CTM-Ex

ContaminationTest Module – Exctractions Module

CTM-Fx

ContaminationTest Module – Flushing Module

CTM-SC

ContaminationTest Module – Supply Control

Direct current

DIN

Deutsche Industrie Norm [German Industry

Standard]

Nominal Diameter

Drain

Drainage port

European Community

European Union

Solid particle

contamination

Solid particles such as dirt, non-iron or metallic

particles found in the fluid.

Flash point

The flash point of a substance is the lowest

temperature at which an ignitable vapor-air mix

can form over a substance.

FPM (FKM / Viton

)

Fluoroelastomer rubber

G60

Type of test liquid

Spray gun

Spray gun with changeable nozzle for spray

extraction

CTM-SC 3xxx series

en(us)

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BeWa CTM-SC 4165698b en-us 2017-05-10.docx

2017-05-10

Summary of Contents for CTM-SC 3 Series

Page 1: ...CTM SC 3xxx ContaminationTest Module SupplyControl Operating and Maintenance Instructions English translation of original instructions Keep for future reference Documentation no 4165698b ...

Page 2: ...aar Phone 49 6897 509 1511 Fax 49 6897 509 1394 E mail guenter harge hydac com HYDAC FILTER SYSTEMS GMBH All rights reserved No part of this work may be reproduced in any form print photocopy or by other means or processed duplicated or distributed using electronic systems without the written consent of the publisher These documents have been created and inspected with the greatest care However er...

Page 3: ... 15 Observe regulatory information 15 Stoppage in an emergency EMERGENCY STOP 15 Transporting the CTM SC 16 Storing the CTM SC 16 Checking the scope of delivery 17 CTM characteristics 18 Functional principle 18 CTM SC dimensions 19 CTM SC components control units 20 Preparing the CTM SC for operation 22 Positioning the CTM SC 22 Connecting up testing the CTM SC 23 Connecting the CTM SC to the elec...

Page 4: ... liquid 39 Filling test liquid 39 Setting the level sensor B1 to the test liquid Checking settings 41 Removing Installing the hood 43 Locating spare parts 45 Taking the unit out of operation 45 Disposing of the unit 45 Technical Data 46 Annex 47 Contact Customer Service Service 47 Model Code 48 Hydraulic circuit 49 EC declaration of conformity 50 Explanation of terms and abbreviations 51 Index 53 ...

Page 5: ...ims due to Product Liability shall remain unaffected Technical Support Contact our technical sales department if you have any questions on our product When contacting us please always include the model code serial no and part no of the product Fax 49 6897 509 9046 E mail filtersystems hydac com Product modification We would like to point out that changes to the product e g purchasing options etc m...

Page 6: ...e documentation has a table of contents at the beginning There I select the chapter I m looking for and the corresponding page number de HYDAC Filtertechnik GmbH BeWa 123456a de Seite x Produkt Kapitel 200x xx xx The documentation number with its index enables you to order another copy of the operating and maintenance instructions The index is incremented every time the manual is revised or change...

Page 7: ...nd other equipment Maintain the unit inspection intervals prescribed by law Document the results in an inspection certificate and keep it until the next inspection Hazard symbols These symbols are listed for all safety information and instructions in these operating instructions which indicate particular hazards to persons property or the environment Observe these instructions and act with particu...

Page 8: ...es full face shields When dealing with fluids suitable gloves are to be worn according to the type of liquid involved This symbol indicates that you are to wear suitable hearing protection Open fires are prohibited This particularly applies when dealing with test liquids which contain solvents CTM SC 3xxx series en us Page 8 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 9: ...NG 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 hazardous situation with a high level of risk which if not avoided will r...

Page 10: ...are laid out as follows HAZARD SYMBOL SIGNAL WORD Type and source of danger Consequence of the danger Measures to avert danger Observe regulatory information Observe the following regulatory information and guidelines Legal and local regulations for accident prevention Legal and local regulations for environmental protection Country specific regulations organization specific regulations CTM SC 3xx...

Page 11: ...all instructions contained in the operating instructions performing inspection and maintenance work NOTICE Test liquids that cannot be used The CTM will be damaged Only use test liquids which are compatible with the installed materials and the sealing materials Depending on the version see model code the CTM may only be used for the following media see model code CTM SC 3xx0 Only use G 60 Spezial ...

Page 12: ...y damage resulting from such use This risk is borne solely by the owner Improper use or use deviating from intended may result in hazards and or will damage the unit Examples of improper use Operation with a non approved medium 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...

Page 13: ...pplicable regulations are to kept so they are accessible for operating and specialist personnel These operating instructions are intended for Operating personnel such persons have been instructed in power unit operation and are aware of potential hazards due to improper use Specialist personnel such persons with corresponding specialist training and several years work experience They are able to a...

Page 14: ...ing and connection of hydraulic lines and connections Fitting and connection of electrical lines electrical machinery sockets etc Product specific knowledge Operation Operations control Specialist personnel Product specific knowledge Knowledge about how to handle operating media Knowledge about contamination due to solids and water Disposal Specialist personnel Proper and environmentally friendly ...

Page 15: ...y data sheet of the test liquid Observe regulatory information Observe the following regulatory information and guidelines Legal and local regulations for accident prevention Legal and local regulations for environmental protection Country specific regulations organization specific regulations Stoppage in an emergency EMERGENCY STOP In the event of an emergency turn the main switch by 90 in a coun...

Page 16: ... a pallet The casters must be free of load Observe the maximum fork distance of 670 cm when transporting with a forklift truck Storing the CTM SC Pull power plug Coil up the power cable and fix it to the CTM Drain the reservoirs and filters of the CTM completely before putting it into extended storage Store the CTM in a clean and dry room under the corresponding storage conditions see chapter Tech...

Page 17: ...items are supplied Qty Designation 1 ContaminationTest Module Supply and Control CTM SC 1 Touchscreen monitor 1 Touchscreen monitor holder 1 Foot switch 1 Four sided hollow socket key 6 mm 1 Technical documentation consisting of Operating and maintenance instructions this document Electrical circuit diagram Additional documents Certificates Inspection logs CTM SC 3xxx series en us Page 17 56 BeWa ...

Page 18: ...s with the corresponding connection A B C on to the extraction module CTM E The test liquid now called the analysis liquid carrying the particles washed off of the component is sucked through the analysis membrane using a diaphragm pump and flows back through the connection R into the reservoir The level in the reservoir is constantly monitored If the fill level of the reservoir drops to the lower...

Page 19: ...CTM SC dimensions CTM SC dimensions The CTM SC has the following dimensions CTM SC 3xxx series en us Page 19 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 20: ... SC components control units CTM SC components control units The CTM SC has the following components control units CTM SC 3xxx series en us Page 20 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 21: ...holder 5 RJ45 port USB port Schuko plug 6 Foot switch 8 Switch cabinet 10 Connection panel see page 26 11 Pull power plug 13 Guide roll 14 Pre line filter 15 Bypass filter 16 Hood 17 Body 18 Sliding grip 19 Stabler rail CTM SC 3xxx series en us Page 21 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 22: ...an even level surface Make sure that there is a gap of at least 5 cm between the CTM SC and the wall or other equipment behind the unit Make sure that the installation location provides proper laboratory conditions with appropriate cleanliness and temperature of the air and environment CAUTION G60 Spezial test liquid Hazardous to health Make sure that there is adequate ventilation Observe the info...

Page 23: ...please do the following Keep the box containing the software licenses and Operation and maintenance Instructions near the CTM SC Carefully read the operating and maintenance instructions for the CTM SC as well as the CTM SC software operating instructions Install the holder for the monitor on the CTM SC see Fig 1 Install the monitor on the holder see Fig 1 Attach the power supply connect the signa...

Page 24: ...Preparing the CTM SC for operation Figure 1 Installing the monitor CTM SC 3xxx series en us Page 24 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 25: ...ic shock Danger of fatal injury Any work involving electrical equipment may only be done by a properly trained certified electrician Check or compare the local mains voltage and frequency specifications with the specifications on the unit s name plate CTM SC 3xxx series en us Page 25 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 26: ...oot switch To prevent the connector from working loose secure it by screwing up the locking ring The connection plug for the foot switch is coded and will only fit into the correct socket CTM SC 3xxx series en us Page 26 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 27: ...he type of extraction module some of the screw connections may not be required Block any unnecessary screw connections using screw plugs Checking setting at the level sensor Setting test liquid There is an electronic level sensor In the CTM SC tank B1 So that the level sensor works properly it is necessary to set it up for the test liquid Check the settings at the level sensor as described in the ...

Page 28: ...M SC using the touchscreen monitor The user interface provides you with self explanatory menu items Details about the menu points can be found directly in the user interface Switching off the CTM SC 1 End all running processes like extraction suctioning test liquid etc 2 Switch off the CTM SC at the main switch 3 Wait at least 30 seconds before switching the CTM SC back on again CTM SC 3xxx series...

Page 29: ...ndicator Plug loose Check or tighten plug Cable break Measure resistance replace cable if necessary Sensor faulty Replace sensor Pan float switch tripped Pan filled with test liquid Empty pan find and repair leaky area s Cable break Measure resistance replace cable if necessary Motor protection switch tripped Electric motor of the pump retransfer pump overloaded Switch on motor protection in the E...

Page 30: ...ndicator Plug loose Check or tighten plug Cable break Measure resistance replace cable if necessary Pressure sensor faulty Replace pressure sensor No display on the touchscreen Device not switched on Check power plug connection switch on device at the main switch DVI connection loose Tighten DVI connection Power supply loose Fasten power supply No reaction when touching the touchscreen USB connect...

Page 31: ... on it CAUTION Hot surfaces of valves pumps Risk of burns Let the system cool down before performing any maintenance work CAUTION G60 Spezial test liquid Hazardous to health Make sure that there is adequate ventilation Observe the information relating to personal protection equipment in the safety data sheet of the test liquid The maintenance and servicing to be performed periodically is described...

Page 32: ...ll of the shut off valves are working properly X Check the tank for damage and leaks visual inspection 5 years Maintenance intervals for CTM 3xx0 Replace hoses 33 X Replace prefilter element 34 X Replace bypass filter element 34 X Change return line filters 34 X Calibrate the volume flow meter 38 X Change the test liquid 39 1 month Maintenance intervals for CTM 3xx1 Replace hoses 33 X Replace the ...

Page 33: ...n BGR 237 for normal requirements Maintaining membrane pump The membrane pump is subject to wear If the pump line eases off perform maintenance according to the manufacturer s information For details view the operation and installation instructions of the pump manufacturer Remove the screw in supports at the inlet and outlet of the membrane pump with a maximum torque of 5 Nm CTM SC 3xxx series en ...

Page 34: ...refilter bypass filter After opening the door you can directly access the prefilter bypass filter Item Designation 14 Pre filter 15 Bypass filter CTM SC 3xxx series en us Page 34 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 35: ... 6 mm Allen wrench The drain plug has ventilation slots Catch the approximately 1 5 liters of test liquid that drain out in a suitable container 2 Undo union nut 1 in a clockwise direction and then remove filter bowl 2 downwards and place it on the shelf intended for this purpose in the CTM You can use a strap wrench to remove the union nuts 3 Remove the used filter element from the element mount ...

Page 36: ...he O ring with hydraulic fluid and insert it 6 For easy installation of the filter element wet the O ring on the filter element with the liquid in use 7 Carefully press the new filter element into the element mount by applying slight pressure pressing it upwards and screwing it in Do not use excessive force or a hammer etc CTM SC 3xxx series en us Page 36 56 BeWa CTM SC 4165698b en us 2017 05 10 d...

Page 37: ... the user interface Note that the software constantly monitors the level and will stop the filling process once the maximum level has been reached 11 To begin the filling process press the Start button 12 The test liquid is pumped into the tank using the membrane pump 13 Once the container is empty stop the filling process or put the filler hose into another container of test liquid to completely ...

Page 38: ... vessel available Insert the hose into the measuring vessel Hold onto the hose while draining the unit 4 Start the process on the user interface 5 Once the selected rinsing volume has been reached on the monitor or once no more test liquid comes out of the spray gun read off the amount of liquid issued on the measuring vessel scale A tolerance of 5 is acceptable If the deviation is greater the met...

Page 39: ...M E module 2 In the user interface select the detached hose as the outlet 3 Make sure that a suitable container is available for the drained liquid Insert the hose into the container Hold onto the hose while draining the unit Note that this draining process will leave residual test liquid in the reservoirs the filters and the lines 4 Start the Drain process on the user interface and press the foot...

Page 40: ...ed up 3 Start the Fill process via the user interface 4 Once the minimum allowed volume in the tank has been reached the control of the user interface switches the Fill process off 5 Screw the return hose onto the R connection on the CTM E module 6 Filling the CTM SC is complete CTM SC 3xxx series en us Page 40 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 41: ...proceed as follows 1 Take off the hood Details regarding this can be found in the Removing Installing the hood chapter on page 43 2 Unplug the level sensor connector The level sensor is now without power 3 Keep the key pressed and attach the plug to the level sensor 4 After approx three seconds appears on the display 5 Keep pressing the key until such a time that the menu item is visible on the di...

Page 42: ...g the menu will briefly appear on the display if default settings have been changed Afterwards the level will be shown in cm 10 Install the hood Details regarding this can be found in the Removing Installing the hood chapter on page 43 11 Changing the settings of the test liquid at the level switch has now finished CTM SC 3xxx series en us Page 42 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017...

Page 43: ...ew the two screws 22 of the hand lever 18 using a 4mm Allen wrench 3 Close the control cabinet door 4 Now with two people one left one right slide the hood 16 approx 30 mm forward and then lift it up and off 5 Remove the ground cable from the terminal 6 The removal of the hood is now complete CTM SC 3xxx series en us Page 43 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 44: ...he hood 16 with 2 people one left one right onto four bolts on the housing and slide the hood 16 approx 30 mm to the rear into the housing 4 Open the control cabinet door 5 Screw on the two screws 22 of the handle 18 with an Allen key 4 mm and tighten them 6 Close the control cabinet door 7 Mounting the hood is now complete CTM SC 3xxx series en us Page 44 56 BeWa CTM SC 4165698b en us 2017 05 10 ...

Page 45: ...e roll 680885 4 Filter element for prefilter bypass filter 3559783 2 Hose set replacement set 1 on request Quantity installed in the CTM SC Taking the unit out of operation Drain the unit completely including all of its components the same way as is done before putting it into storage Pull out the power plug and securely fasten the hoses and power cord to the unit Store the unit in a clean dry non...

Page 46: ... Power consumption 1100 W Noise level 67 dBA Permitted ambient temperature range 15 28 C Permitted relative air humidity maximum 80 non condensing Permitted storage temperature range 0 50 C Air quality dust free no salty air not in the vicinity of oxidizing substances flash rust rust bloom CTM SC 3xxx series en us Page 46 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 47: ...Regular inspection and maintenance work is indispensable for ensuring trouble free operation and long service life for your CTM Our HYDAC Service Center offers you these tasks within agreed upon time frames and at fixed prices HYDAC SERVICE GMBH Friedrichsthaler Str 15A Werk 13 66540 Neunkirchen Heinitz Germany Phone 49 681 509 9518 Fax 49 681 509 2324 E mail service hydac com CTM SC 3xxx series e...

Page 48: ...taining tensides permissible pH values 6 10 no completely demineralized water Power supply K 120 V AC 60 Hz 1 phase USA Canada M 230 V AC 50 Hz 1 phase Europe N 240 V AC 50 Hz 1 phase United Kingdom O 240 V AC 50 Hz 1 phase Australia P 100 V AC 50 Hz 1 phase Japan CTM SC 3xxx series en us Page 48 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 49: ...aulic circuit M M Niv B1 V1 B2 B3 V2 Y5 Y4 Y1 Y2 Y3 B4 M1 M2 1 2 S2 S1 Q I A B R C P I 3 I Niv Temp P1 P2 4 P 2bar P 2bar CTM SC 3xxx series en us Page 49 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 50: ...ch S2 Differential pressure switch Y1 Output A solenoid valve Y2 Output B solenoid valve Y3 Output C solenoid valve Y4 Return R solenoid valve Y5 Bypass solenoid valve V1 Ball valve V2 Pressure relief valve EC declaration of conformity The CE declaration of conformity can be found in the Technical Documentation of the CTM SC CTM SC 3xxx series en us Page 50 56 BeWa CTM SC 4165698b en us 2017 05 10...

Page 51: ...ftware CTM ContaminationTest Module CTM Ex ContaminationTest Module Exctractions Module CTM Fx ContaminationTest Module Flushing Module CTM SC ContaminationTest Module Supply Control DC Direct current DIN Deutsche Industrie Norm German Industry Standard DN Nominal Diameter Drain Drainage port EG European Community EU European Union Solid particle contamination Solid particles such as dirt non iron...

Page 52: ...witched off ON Switched on OUT Outlet OUTLET Outlet Test liquid Fluid for general operation flushing fluid analysis fluid sec Second s Flushing fluid Test liquid for spray extraction SW Wrench size for tools Vent Ventilation air bleed port VE water Demineralized Deionized water CTM SC 3xxx series en us Page 52 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 53: ...gent 14 H Hazard symbol 7 10 I Imprint 2 IN 52 Industrial Safety Regulation 31 Inlet 52 INLET 52 Inspection 17 installation 14 22 33 36 L Level sensor 29 45 50 M Main switch 21 Maintenance 1 32 51 Maintenance interval 32 Maintenance intervals 32 Measure 29 30 Measures 10 measuring 38 Motor protection switch 29 N Noise level 46 O OFF 52 operating 5 6 7 11 13 14 23 33 Operation 11 12 14 23 51 Operat...

Page 54: ...gnal word 9 10 signal words 9 10 Solid particle contamination 51 Specialist personnel 13 14 T to shut down 15 Transport 14 transporting 16 troubleshooting 14 U USB 21 23 30 CTM SC 3xxx series en us Page 54 56 BeWa CTM SC 4165698b en us 2017 05 10 docx 2017 05 10 ...

Page 55: ......

Page 56: ...riegebiet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Tel 49 0 6897 509 01 Central Fax 49 0 6897 509 9046 Technical Department Fax 49 0 6897 509 577 Sales Internet www hydac com E mail filtersystems hydac com ...

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