Hydac CTU 1000 Operating And Maintenance Instructions Manual Download

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HYDAC FILTER SYSTEMS GMBH

Safety | 2

BeWa CTU1x5x 4603539 en-us web

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2.2 Hazard symbols / pictograms

The following are the safety symbols / pictograms in this manual.

They indicate specific dangers to persons, property or to the sur-

roundings. Observe these safety symbols / pictograms and act

with particular caution in such cases. Always keep all symbols /

pictograms intact and legible.

Used prohibitory signs

These marks can be found for all safety and warning instructions

in this manual which indicate particular dangers to persons, prop-

erty or the environment.

Fires, naked lights and smoking are prohibited

Warning signs used

These marks can be found for all safety and warning instructions

in this manual which indicate particular dangers to persons, prop-

erty or the environment.

Danger point warning

Dangerous electrical voltage warning

Signs used for giving orders

These symbols can be found for all safety and warning instructions

in this manual which indicate particular dangers to persons, prop-

erty or the environment.

Follow the direction.

Follow the instructions.

Pull the power plug before opening

Summary of Contents for CTU 1000

Page 1: ...x5x ContaminationTest Unit Operating and Maintenance Instructions English translation of original instructions Document No 4603539 Follow these instructions for proper and safe use Keep for future reference ...

Page 2: ... 509 9046 E mail filtersystems hydac com Homepage www hydac com Court of Registration Saarbrücken HRB 17216 Executive directors Mathias Dieter Dipl Kfm Wolfgang Haering Documentation Representative The contact data of the Documentation Representative is Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Germany Telephone 49 6897 509 1511 Fax 49 6897 509 1394 E mail guent...

Page 3: ...the general safety information 12 1 3 Exclusion of liability warranty 13 1 4 Notes on copyright 13 2 Safety 14 2 1 Target group Required personnel qualification 14 2 2 Hazard symbols pictograms 17 2 3 Danger notifications 20 2 4 Safety marking 25 2 5 Observing regulatory information 26 2 6 Observing environmental precautions 26 2 7 Wear personal protection equipment 26 2 8 Shutdown in an emergency...

Page 4: ...nd extraction chamber 48 5 4 Connecting the compressed air connection 50 5 5 Connecting the foot switch 50 5 6 Commissioning 51 6 Operation 52 6 1 Switching the extraction unit on off 53 6 2 Opening closing the door 54 6 3 Selecting the operating modes 55 6 3 1 Performing the spray extraction 55 6 3 2 Performing air extraction 59 6 3 3 Running Flushing of inner chamber 59 6 3 4 Preparing for ultra...

Page 5: ...ng the extraction unit 85 8 5 2 Filling the test liquid Filling the extraction unit 87 8 5 3 Avoiding the mixing of test liquids Flushing the extraction unit 88 8 6 Checking the screwed and plug connections 88 8 7 Visual inspection of the electric components cables 88 8 8 Checking the hoses 88 8 9 Replacing hoses plastic pipe 88 8 10 Cleaning the diffuser on the filter membrane holder 89 8 11 Chec...

Page 6: ...H vi BeWa CTU1x5x 4603539 en us web 9 3 Disposal Recycling 102 A Appendix 103 A 1 Finding spare parts accessories 103 A 1 1 Finding accessories 106 A 2 Contacting Customer Service 107 A 3 EC declaration of conformity 108 Glossary 112 Index 114 ...

Page 7: ...s manual are meant for gen eral illustration purposes Therefore representations and func tional options can deviate from the delivered product We reserve the right to modifications to the contents of this man ual without prior notice 1 1 Target group of the manual This manual was created for the following target group Target group Tasks Owner Keep this manual and the applicable docu ments at the i...

Page 8: ...duct name Operating and Maintenance Instructions Document no 12345678 English translation of original instructions Valid from from s no 1 5 2 4 3 Fig 1 Overview labeling of the title page 1 Short name of the product product name 2 Type of document 3 Language 4 Document no Index 5 Supplementary instructions regarding the validity of the man ual optional Please note that you can directly access info...

Page 9: ...presentation of procedural instructions In the case of procedural instructions there are the two following representations Procedural instructions with a fixed sequence Procedural instructions whose sequence must be complied with without fail are listed with sequential numbering 1 2 3 etc An example for procedural instructions with a fixed sequence 1 Remove the transport securing device 2 First fi...

Page 10: ...ities they are marked with an indented arrow End results represent the end of an activity and are represented with a flag An example for a procedural instruction with intermediate result and final result 1 Switch the product on ð The display lights up 2 Press the button O The product is now ready for use 1 2 3 4 5 6 7 8 9 A ...

Page 11: ...of the manual Tip for handling the product Required tool 1 2 6 Representation of warning general safety information All the warning general safety information in this manual are highlighted with pictograms and signal words The pictogram and the signal word give you information of the risk level of the danger Warning General Safety Information which is placed ahead of each activity are represented ...

Page 12: ...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 mod erate injury NOTICE NOTICE The signal word indicates a hazardous situation with a high level of risk which if not avoided will result in damage to property EN...

Page 13: ... of the information in these instructions In particular we shall not be liable for 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 negl...

Page 14: ... installation commissioning op eration maintenance work and also troubleshooting on the prod uct An owner is the person who operates the product himself herself for commercial or economic purposes or provides it to a third party for use application and bears the legal product responsibility to protect the user the personnel or the third party The obligations of the owner are To know and apply the ...

Page 15: ...ist personnel Electrical Safe handling use of tools Product specific knowledge is re quired Commissioning Specialist personnel Mechanical Specialist personnel Electrical Safe handling use of tools Product specific knowledge is re quired Handling operation operation monitoring Operating personnel General Product specific knowledge is re quired Knowledge about handling the operat ing fluid operating...

Page 16: ...f con taminants is required Knowledge of recy cling is required transport Commis sioning Operation Troubleshooting Maintenance Dis posal Specialist personnel Service Administra tor Service personnel Administrator HY DAC Service Extensive experience of the product Tab 2 Target group Required personnel qualification 1 2 3 4 5 6 7 8 9 A ...

Page 17: ...tructions in this manual which indicate particular dangers to persons prop erty or the environment Fires naked lights and smoking are prohibited Warning signs used These marks can be found for all safety and warning instructions in this manual which indicate particular dangers to persons prop erty or the environment Danger point warning Dangerous electrical voltage warning Signs used for giving or...

Page 18: ... warning instructions in this manual which indicate particular dangers to persons prop erty or the environment Hazardous to the environment Others symbols used These marks can be found for all safety and warning instructions in this manual which indicate a particular danger to persons prop erty or the environment Exposed electrical components Danger due to operating pressure 1 2 3 4 5 6 7 8 9 A ...

Page 19: ...recognize potential dangers Specialist personnel Electrician Such persons have specific specialist training and sev eral years work experience They are able to assess and perform the work assigned to them they are also able to recognize potential dangers Specialist personnel Mechanic Such persons have specific specialist training and sev eral years work experience They are able to assess and perfo...

Page 20: ...lifting accessories to raise or lash the extrac tion unit module uLift the extraction unit module only at the housing not by the attachments or components Life phase Commissioning Operation The following risks could arise during the commissioning opera tion life phase WARNING Solvent cleaner as test liquid flammable gas air mixture in the extraction chamber Danger of bodily injury uOpen fires or s...

Page 21: ...ent CAUTION Heavy test item Danger of crushing of feet toes uWear safety shoes NOTICE Exceeding the permissible loading capacity payload The extraction chamber will be damaged uNote the permissible loading capacity payload of the test item for evenly distributed load not for point loading The dangers arising during commissioning operation are mainly caused by the test liquid used Observe the chapt...

Page 22: ...r mixture uClean the door with a moist lint free cloth and commonly avail able antistatic materials CAUTION Solvent cleaner as test liquid Health hazard uFollow all the instructions when handling the test liquid Details on this can be found in the safety data sheet of the test liquid uWear your personal protective equipment Details on this can be found in the safety data sheet of the test liquid u...

Page 23: ... DANGER Aerosol formation in the extraction chamber by air extraction in the case of solvent cleaner as test liquid Risk of explosion uDo not perform air extraction on test items that have previously been flushed with solvent cleaner as test liquid uDo not point the air jet at nests consisting of the test liquid Life phase Maintenance Troubleshooting The following dangers could arise during the li...

Page 24: ...Allow the solenoid valves to cool down before any repair maintenance work CAUTION Solvent cleaner as test liquid Health hazard uFollow all the instructions when handling the test liquid Details on this can be found in the safety data sheet of the test liquid uWear your personal protective equipment Details on this can be found in the safety data sheet of the test liquid uMake sure that there is ad...

Page 25: ...n unit Replace the damaged or no more recognizable legible safety symbols pictograms imme diately Pull the safety symbol pictogram off the extraction unit re move 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 pictograms 1 2 3 4 5 6 7 8 9 A ...

Page 26: ...all measures to protect the environment Ensure that no op erating medium is released into the environment soil or water Environmentally tip Operating fluid operating medium is released into the soil or water Environmental hazard uRemove any escaped operating fluid operating medium imme diately and dispose of it in an environmentally sound manner 2 7 Wear personal protection equipment When handling...

Page 27: ...xtraction unit with the main switch The extraction unit is deenergized downstream of the main switch 2 9 Fire fighting measures Observe the measures relating to fire fighting given in the safety data sheet of the test liquid used Maintain a minimum safe distance from electrical components For a mains voltage of up to 1000 V the minimum safe distance is 1 m Fig 3 Minimum distance for fire fighting ...

Page 28: ... packed and delivered in a pre as sembled condition At the time of delivery before the commission ing please check the scope of delivery to ensure that it is com plete and undamaged The following items are included in the scope of delivery Qty Description 1 ContaminationTest Unit 1 Monitor including holder or foot 1 Keyboard with touchpad 1 Keyboard tray only for CTU125x 1 Foot switch with 1 m cab...

Page 29: ...Claims for defects or liability regardless of the legal foundation do not apply with incorrect or improper installation commissioning 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...

Page 30: ...lowing Follow all the instructions contained in the operating instruction Operation only with mounted cover panels Operation only with closed extraction chamber Complying with the requirements for repair and maintenance work Operation under supervision Operation only in closed rooms environmental cleanliness and air similar to that under laboratory conditions Horizontal installation surface The im...

Page 31: ...eviating from intended use are for ex ample Operation with an impermissible test liquid Operation under non permissible ambient and operational con ditions Operation with faulty safety devices Modifications to the product made by the user or purchaser Inadequate monitoring of parts that are subject to wear and tear Improperly performed repair work Unsupervised operation Non observance of the Opera...

Page 32: ... ultrasonic Load capacity payload for spray or air extraction 47 5 kg for evenly distributed surface load no point load Load capacity payload for ultra sonic extraction 0 5 kg in a suitable device e g hanging basket Nominal voltage See Model Code 36 Nominal power 600 W 800 W with ultrasound Emission sound pressure level LPA 70 db A CTU1xx0 Permissible test liquids 1 Solvent cleaner 2 Feroclean L26...

Page 33: ...f the compressed air dry and clean Required compressed air supply 5 µm Pressure adjustment range 0 7 6 bar Intended service life of the ma chine The intended service life of the machine is not limited if the ser vice and maintenance intervals are complied with Service life of the components of the machine with safety function 20 years see Finding spare parts acces sories 103 1 Test fluids that are...

Page 34: ...g the name plate Item Description 1 Name plate of the extraction unit 2 Model code for details see Decoding the name plate 34 The following information can be found on the name plate of the extraction unit Item Description Model Model code P N Part no S N Serial number Date Year week of production Power Details of the nominal voltage frequency phases and power consumption Fluid Permissible test li...

Page 35: ...eb 35 120 Item Description Ambient temperatur Permissible ambient temperature Inlet pressure Permissible inlet pressure compressed air Max level Filling volume maximum Max load Load carrying capacity payload Weight Weight when empty Noise level Emission sound pressure level 1 2 3 4 5 6 7 8 9 A ...

Page 36: ...e 120 V AC 60 Hz single phase 230 V AC 50 Hz single phase 240 V AC 50 Hz single phase 240 V AC 50 Hz single phase 100 V AC 50 Hz single phase USA Canada Europe UK Australia Japan Version 2020 Solvent cleaner flash point 60 C lower explosion limit 0 6 vol Water with surfactants permissible ph values 6 10 no fully demineralized water or solvent cleaner flash point 60 C lower explosion limit 0 6 vol ...

Page 37: ... the ContaminationTest Unit has different outer dimensions and different dimensions of the extraction cham ber The ContaminationTest Unit has the following outer dimensions Fig 6 Dimensions of the extraction unit B T H1 H2 H3 H4 CTU10xx 985 850 1170 1290 1500 1700 CTU12xx 910 1140 1160 1280 1750 2070 All dimensions in mm 1 2 3 4 5 6 7 8 9 A ...

Page 38: ...TU1x5x 4603539 en us web The ContaminationTest Unit has the following dimensions for the extraction chamber Fig 7 Dimensions of the extraction chamber B1 T1 H5 H6 H7 D CTU10xx 765 365 260 335 380 2x Ø180 CTU12xx 765 650 300 445 560 2x Ø180 All dimensions in mm 1 2 3 4 5 6 7 8 9 A ...

Page 39: ...ction chamber with door 2 Ports in the extraction chamber for details see Ports in the extraction chamber 40 3 Interventions with protective gloves 4 Switch cabinet 5 Monitor 6 Cable hole 7 USB A port for the keyboard 8 Keyboard with touchpad console only CTU 125x 9 Side paneling 10 Handle 11 Control panel for details see Control panel 41 12 Foot switch with connection cable 1 2 3 4 5 6 7 8 9 A ...

Page 40: ...s with brake 15 Fork lift straps for transporting 3 7 1 Ports in the extraction chamber You will find the following ports in the extraction chamber Fig 9 Ports in the extraction chamber A Port for pen with metering orifice B Flushing of inner chamber C Port for pen with metering orifice E2 Suction in the extraction chamber 1 2 3 4 5 6 7 8 9 A ...

Page 41: ...ing operating elements Fig 10 Control panel 61 Quick fastener terminal 62 Ball valve 63 Silencer 64 Compressed air supply 65 Main switch E STOP 67 Filter membrane holder for details see Cascading the filter membranes changing the filter membranes 66 68 Setting the filter regulator compressed air 69 Connection socket for the foot switch 1 2 3 4 5 6 7 8 9 A ...

Page 42: ...it module will be damaged uUse only suitable lifting accessories to raise or lash the extrac tion unit module uLift the extraction unit module only at the housing not by the attachments or components 4 1 Transporting with a fork lift truck The extraction unit is shipped from the factory in a wooden box with the appropriate securing devices Pack the assembly for fur ther transportation in this wood...

Page 43: ...20 CTU 105x CTU 125x Fig 12 Transport the extraction unit with a fork lift truck Example illus tration CTU 105x CTU 125x NOTICE Incorrect positioning of the slings The extraction unit will be damaged uSecure the extraction unit with suitable slings Fig 13 Packaging the extraction unit 1 2 3 4 5 6 7 8 9 A ...

Page 44: ...installed rollers The extraction unit must be set up on an even level surface When you have positioned and aligned the extraction unit press the brakes on all the guide rolls Make sure that the cleanliness of the surrounding area the am bient air and the temperature at the installation location are similar to laboratory conditions for details see Technical data 32 Make sure that there is a minimum...

Page 45: ...nit is electrically connected to the supply net work 5 2 1 Mounting connecting the monitor and keyboard This chapter contains information on the installation and connec tion of the monitor and keyboard to the extraction unit 1 Place the monitor at the top of the housing of the extraction unit 2 Connect the supply voltage and the signal data cable ac cording to the following figure 1 2 3 a c b 4 Fi...

Page 46: ...nerator 3 Ultrasound generator plug Ultrasonic converter 4 Mating connector XD3 in the switch cabinet 5 Extraction chamber a High frequency cable b Supply voltage for the ultrasound generator O The components are connected and operational 5 3 Suctioning the machine room The back of the extraction unit has a suction connection of Ø 100 mm for the machine room For this follow the safety data sheet o...

Page 47: ...t liquid being used CAUTION Solvent cleaner as test liquid Health hazard uFollow all the instructions when handling the test liquid Details on this can be found in the safety data sheet of the test liquid uWear your personal protective equipment Details on this can be found in the safety data sheet of the test liquid uMake sure that there is adequate air flow in the room Details on this can be fou...

Page 48: ...ing system at the installation location this can be attached to the connection on the CTU A cover is pre mounted to the Ø 100 mm CTU air exhaust port at the time of delivery The air is suctioned from the machine compartment using the con nection E1 Fig 17 Suctioning the machine compartment A partial current of the suctioning at the connection E1 is used for suctioning in the extraction chamber The...

Page 49: ...HYDAC FILTER SYSTEMS GMBH Setting up assembling commissioning 5 BeWa CTU1x5x 4603539 en us web 49 120 Fig 18 Suctioning the extraction chamber 1 2 3 4 5 6 7 8 9 A ...

Page 50: ... nipple of the low pressure series DN 7 2 on the extraction 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 the supply line O The pressure port is connected 5 5 Connecting the foot switch The foot switch is used to control the spray extraction depending on the setting The socket for the foot switch is located at th...

Page 51: ...g only a moist cloth of the appropriate language included in the scope of delivery and affix it to the lower right part of the border film of the door 3 Take the supporting sieve supplied and put it in the filter membrane holder 4 Fill the test liquid in the extraction unit for details see Filling the test liquid Filling the extraction unit 87 5 Clean the extraction chamber thoroughly using the Fl...

Page 52: ... level sensor When the lower fill level is reached in one container the system automatically switches over between the containers During the container switchover the message Contain ers being switched is displayed in the status line of the user inter face Additionally the status light will blink red The supply of test liquid is locked until the container switchover is complete The con tainer switc...

Page 53: ...monitor that the computer has started 2 After the loading of the Operating System the user interface of the extraction unit starts O Select the required operating mode or start an extraction Refer to the ConTeS software manual for details on the user in terface Switching the extraction module off To switch off the extraction unit proceed as follows 3 End the user interface 4 Shut down the computer...

Page 54: ...the door use the compression locks provided for this purpose Open the door with both hands on the compression locks Fig 20 Opening closing the door 1 Compression lock open 2 Compression lock closed The contact switch K monitors the position of the door The op erating modes can only start when the door is closed If the door is opened during operation an operating mode opera tion stops immediately a...

Page 55: ...ts Discharge Explosion uOnly use hoses pipes with suitable conductivity uEarth the test item if it is on a support that has an insulating ef fect uOnly use original spare parts CAUTION Solvent cleaner as test liquid Danger to health by spraying test liquid or aerosols uEnsure a closed extraction chamber during operation 6 3 1 Performing the spray extraction On the user interface select the spray e...

Page 56: ...n us web A Pen B Nozzle C Spray gun D Hose connection E Hose Nozzle type nozzle diameter and the maximum pressure are matched to a low aerosol formation Only use nozzles from the Spare parts or Accessories list Fig 22 Extraction chamber with grating 1 2 3 4 5 6 7 8 9 A ...

Page 57: ...hamber including the auxiliary equipment such as the hook in basket grating mounts for the test item etc 1 Place the test item to be sampled in the extraction chamber 2 Close the door and lock it 3 Select the required test parameters on the user interface and start the spray extraction 4 Spray the component surfaces to be analyzed evenly The test liquid loaded with the partially rinsed off particu...

Page 58: ...DAC FILTER SYSTEMS GMBH 58 120 BeWa CTU1x5x 4603539 en us web 5 Then remove the filter membrane for analysis evaluation 6 Open the door and remove the test item O The spray extraction is complete 1 2 3 4 5 6 7 8 9 A ...

Page 59: ...the door 4 Select the required analysis parameters for the spray extrac tion on the user interface 5 Start the extraction to spray the extraction chamber evenly 6 Wait until the test liquid has been fully suctioned through the filter membrane 7 End the spray extraction at the user interface 8 Then remove the filter membrane for analysis evaluation O The air extraction is concluded 6 3 3 Running Fl...

Page 60: ...6 Operation HYDAC FILTER SYSTEMS GMBH 60 120 BeWa CTU1x5x 4603539 en us web Fig 24 Flushing the interior of the extraction chamber 1 2 3 4 5 6 7 8 9 A ...

Page 61: ...ns of the ultrasonic vibration systems The vibrations transmitted to the test liquid cause microscopic cav ities to be formed constantly which then always implode This ef fect referred to as cavitation causes contamination to be removed and accelerates the physical process NOTICE Protective gloves in the ultrasonic bath The protective gloves will be damaged destroyed uRemove the protective gloves ...

Page 62: ...ponding jig uUse a suitable hanging basket uObserve the permissible load capacity payload for ultrasonic extraction For the ultrasonic test replace the grating in the extraction cham ber with a proper device such as a freely hanging basket Hang the basket retaining frame a with the basket b in the cor responding thrust bolts in the extraction chamber b a Fig 26 Extraction chamber with mounts a Thr...

Page 63: ...e ball valve on the filter membrane holder before beginning the ultrasonic extraction The temperature of the ultrasonic bath is continuously monitored If a temperature of 34 C is reached during ultrasonic extraction the monitor will switch off the ultrasonic converter and send a message to the monitor The extraction that is running will be in terrupted for the time cooling takes place and it must ...

Page 64: ...desired extraction parameters for ultrasonic ex traction in the user interface and start the ultrasonic extrac tion 4 Select the desired extraction parameter for rinsing the test item in the user interface and start the extraction 5 Select the desired extraction parameters for rinsing the ex traction chamber in the user interface and start the extrac tion 6 The test liquid loaded with the partiall...

Page 65: ...efore be ensured that the negative control value does not have a significant influence on the test result For this purpose the negative control value must first be recorded in a suitable manner In addition this value may only be in a special maximum ratio to the required technical cleanliness which is not exceeded The achievable negative control value depends very much on the ambient conditions of...

Page 66: ...or cas cading or changing the filter membranes varies The handling of different filter membrane holders is described below CAUTION Solvent cleaner as test liquid Health hazard uWear protective equipment 6 5 1 Creating cascades Cascade the filter membranes in the filter membrane holder ac cording to the following illustration example filter membrane holder with quick fastener 1 2 3 4 5 6 7 8 9 A ...

Page 67: ...m brane 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 The lower part of the filter membrane holder with a hose connection A Cascade coarse B Cascade medium C Cascade fine Tab 8 Cascading the filter membrane holder Due to the design the filter membrane in the lower part 8 of the filte...

Page 68: ...rt from the upper when the guide of the lower part is parallel to the lock guide 3 Pull down the lower part slightly Then pull it fully through the opening created 1 2 3 4 Place a single filter membrane or for cascading multiple fil ter membranes with different filtration ratings 1 coarse 2 medium 3 fine on the corresponding support sieve of the filter membrane holder 5 Place the lower part horizo...

Page 69: ... adjust the lower part for the suitable grid When assembling two cascades select the middle grid 8 When assembling three cascades select the upper grid 9 Seal the filter membrane holder by turning it clockwise by 90 NOTICE Do not use any tools O The insertion of the filter membrane is complete 1 2 3 4 5 6 7 8 9 A ...

Page 70: ...l down the lower part slightly Then pull it fully through the opening created 13 Remove the filter membranes from the cascade and mark them as given in Chapter Labeling the filter membrane 72 ð Pass these filter membranes on for analysis 14 Install the filter membrane holder 15 Place the lower part horizontally in the upper part together with the filter membrane 16 Lift the lower part vertically u...

Page 71: ...MS GMBH Operation 6 BeWa CTU1x5x 4603539 en us web 71 120 19 Seal the filter membrane holder by turning it clockwise by 90 NOTICE Do not use any tools O The removal of the filter membrane is complete 1 2 3 4 5 6 7 8 9 A ...

Page 72: ... xyz 1 A 005 Marking Description XYZ Running test item series running test item lot 1 Number of the filter membranes provided A When several flushing procedures are car ried out on a test item A B C etc For the establishment of the negative con trol value for the filter membrane Z 005 Rating of the filter membrane 005 5 µm 010 10 µm 100 100 µm Tab 9 Example Labeling the filter membrane 1 2 3 4 5 6...

Page 73: ...nly possible together with the modules of the CTM EB 1xxx or CTM EF 1xxx For this purpose connect the coding plug 1 1 from the scope of delivery of the modules into the female connector 1 2 Only when the coding or module plug 1 1 is connected are the external connections enabled Select the return port connection R using the changeover switch 2 Alternatively you can return the test liquid using the...

Page 74: ...he extraction compart ment Air extraction has been described in volume VDA19 1 since 2015 DANGER Aerosol formation in the extraction chamber by air extraction in the case of solvent cleaner as test liquid Risk of explosion uDo not perform air extraction on test items that have previously been flushed with solvent cleaner as test liquid uDo not point the air jet at nests consisting of the test liqu...

Page 75: ...FILTER SYSTEMS GMBH Operation 6 BeWa CTU1x5x 4603539 en us web 75 120 E2 Suction in the extraction chamber For details on the Extraction Air operating mode see Performing air extraction 59 1 2 3 4 5 6 7 8 9 A ...

Page 76: ...ge of test liquid under pressure Injury to the eyes uAlways wear eye protection Using the connection hose 1 in the extraction chamber establish a connection between the rinsing connection and the upper con nection piece at the front of the extraction chamber Install the pipe bend 2 with the outlet pointing down onto the lower connection piece Fig 30 Connecting external flushing ports 1 Connecting ...

Page 77: ...that the test liquid enters the extraction chamber Fill the test liquid see Filling the test liquid Filling the extraction unit 87 The extraction unit is overfilled with the test liquid You have added more than the dis played filling volume in the extraction chamber Shut the ball valve above the filter membrane holder Open the filter membrane holder and place a suitable container under it to colle...

Page 78: ...let pressure Connect the compressed air line to the extraction unit see Connecting the com pressed air connection 50 Set the pressure control valve to 6 5 bar The cable to the pressure sensor is broken Replace the faulty cable The pressure sensor is faulty Replace the pressure sen sor The solenoid valve is faulty Replace the solenoid valve The Venturi nozzle is faulty Replace the Venturi nozzle Fl...

Page 79: ...aulty cable The proportional valve is faulty Replace the proportional valve The proportional valve is not receiv ing an impulse Contact the HYDAC service department Level display skips 3 liters Cable break to the level sensor Replace the faulty cable The level sensor is faulty Replace the level sensor The collecting pan is full A leak within the system has caused the collecting pan to fill Empty t...

Page 80: ...vely in case of maintenance repair and assemble it immediately after completion of the work WARNING The extraction unit is under pressure Danger of bodily injury uSwitch off the extraction unit with the main switch uThe extraction unit is depressurized after being switched off WARNING Solvent cleaner as test liquid flammable gas air mixture in the extraction chamber Danger of bodily injury uOpen f...

Page 81: ...sure equipment on the market the in stalled containers are pressure equipment according to Article 4 Paragraph 3 of the same Directive and therefore excluded from its field of application As part of the overall product covered by and compliant with the European Directive 2006 42 EC on machinery there is no obliga tion to perform periodic inspections in accordance with 15 and 16 of the Industrial S...

Page 82: ... of the electric com ponents cables 4 8 16 Checking that the pen is earthed 4 8 11 Checking the cali bration of the flow meter 1 8 8 Checking the hoses 2 8 14 Preparing for changing the filter element 3 8 15 Replacing the pen with the hose 3 8 15 Replacing the pen with the hose 4 8 9 Replacing hoses plastic pipe 3 8 9 Replacing hoses plastic pipe 3 1 Operating personnel 2 Service personnel 3 Speci...

Page 83: ... following chapters For cleaning the extraction chamber we recommend a moist clean commercial microfiber cloth Finish cleaning the extraction chamber with a long Flushing of inner chamber 8 2 1 Cleaning the extraction chamber in the case of a test liquid of water with surfactants Clean the extraction chamber when using a water based test liq uid due to self contamination daily 8 2 2 Cleaning the e...

Page 84: ...ellulose cotton are rubbed against one another Static charges of the materials arise thereby A discharge may be accel erated by the ambient conditions such as dry air and low external temperatures One visual feature which comes about when using solvent clean ers as a test liquid is that a film that looks like a pasty mass forms on the inside of the door The static charge counteracts the low surfac...

Page 85: ...s complete 8 5 Changing the test fluid Fixed change intervals of the test liquid are difficult to define due to different parameters such as sampling interval type and surface of the test items etc Define the change interval individually for each application The following characteristics of the test liquid change with increas ing use Check the test liquid cyclically for Appearance Greases oils pre...

Page 86: ... ball valve is closed tightly by hand 4 Start the Empty system process in the user interface To control the process see ConTeS 5 This process leaves a small amount of test liquid in the rinse return line filters and in the lines Max capacity is approx 20 liters Level 1 liter 6 Put the drain ball valve into the Operation position Wind up the hose and place it back in the extraction unit NOTICE Owin...

Page 87: ... the extraction unit to top up the test liquid proceed as fol lows ü Have the container with the test liquid ready 1 Detach the plug with the hydraulic silencer from the ball valve 2 Attach the filling hose to the ball valve and turn the ball valve to the Vent position 3 Start the Fill system menu item in the user interface ð The extraction unit is filled Overfilling is not possible the software a...

Page 88: ... results in non representative faulty measure ment results 8 6 Checking the screwed and plug connections Screwed and plug connections can become loose due to shaking or vibrations Check all the screwed and plug connections regu larly for correct seating 8 7 Visual inspection of the electric components cables Electrical components and cables can be damaged Check the electrical components and cables...

Page 89: ...lyses will become unusable uDo not use any assembly paste to assemble the screwed fit tings To replace the hoses the plastic pipe you will need the following tool Hose cutter Fork wrench 14 mm Fork wrench 17 mm Fork wrench 19 mm Always use original spare parts which have the corresponding conductivity with the use of solvent cleaners 8 10 Cleaning the diffuser on the filter membrane holder Clean t...

Page 90: ...est liquid in the extraction chamber is suctioned fully ü Shut the ball valve on the filter membrane holder 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 in the filter membrane holder and tighten the coupling 1 by hand O The cleaning of the diffuser on the filter membrane holder is complete 1 2 3 4 5 6 7 8 9 A ...

Page 91: ...pressure to 2 bar ü Have a measuring beaker that can hold a volume of 5 liters ready 1 Start a spray extraction with a flushing volume of 5Mess becherliters 2 Fill the measuring beaker using the pen until the set filling volume according to the user interface has been completely conveyed 3 Now check the conveyed filling volume on the scale on the measuring beaker A deviation of 5 4 75 5 25 liters ...

Page 92: ...uIf you find signs of wear replace the protective gloves immedi ately Mechanical wear includes for example Cuts and tears which re sult from burrs sharp edges on components and excessive wear through components with rough surfaces Chemical wear comes about as a result of for example perme ation For details refer to chapter Permeation time according to EN 374 3 93 Provided there is no mechanical da...

Page 93: ... 374 3 Specification of the results Assuming permeation takes place the penetration time is given in minutes for each test sample The average penetration time for each type of material is also indicated The duration of testing is given if no penetration occurs This means that when the user is constantly exposed to the chem ical it takes a minimum of 1 µg minute x cm to permeate the glove and come ...

Page 94: ...ns with new gloves without mechanical action at room temper ature There was full and continuous contact Since in practice other and or additional loads often occur which differ from labora tory conditions this information can only be an orientation guide They do not replace suitability tests by the end user For this rea son we do not assume any obligation or liability in connection with the inform...

Page 95: ...lly se cure the protective gloves to the inlet opening Using electrostatically conductive protective gloves When replacing the protective gloves ensure that there is suffi cient electrostatic conductivity as specified in DIN EN 61340 5 1 Rg 2 0 x 10 8 Ω Make sure that the resistance Rg Ω to EPA ground or to a grounding pint is between 7 5x10 5 Rg 1x10 12 for protective gloves and fingerstalls Remo...

Page 96: ...ion unit with the main switch For de tails see Switching the extraction unit on off 53 2 Remove the side paneling see Dismounting Installing the side cover 85 8 14 1 Changing the filter element MRF1 E The chapter describes how to change the filter element on the fil ter housing MRF1 E 1x Allen wrench 6 mm 1x strap wrench 1x lint free cloth ü The following activities refer to a filter unit filter h...

Page 97: ...nd drain the filter housing fully with the help of the drain plug 6 mm on the floor of the filter housing The ca pacity is 2 liters Screw the drain plug again into the filter bowl after draining 2 Loosen the union nut 1 by turning it in the clockwise direc tion and then remove the filter bowl 2 NOTICE Use a strap wrench to remove the union nut 1 3 Remove the used filter element from the element mo...

Page 98: ...ck the O ring on the cover for damage and replace it if necessary 7 Coat the O ring on the filter bowl lightly with the operating medium 8 For easy installation of the filter element wet the O ring on the filter element with the operating medium 9 Apply pressure to the new filter element by screwing it in slightly upwards into the element mount NOTICE Do not use any striking tools 1 2 3 4 5 6 7 8 ...

Page 99: ...less steel nut lubricant containing a slip additive MoS2 11 Screw the filter bowl over the union nut onto the filter head 2 in the counterclockwise direction 12 When doing this screw the union nut hand tight only 13 Fill the filter housing slowly to avoid pressure surges 14 Check the filter for leaks O The changing of the filter element is complete After the commissioning check the filter housing ...

Page 100: ...TER ONLY For the replacement proceed as follows ü The extraction unit is switched off ü The door is open 1 Loosen the quick action coupling on the connection in the extraction chamber 2 Pull off the quick coupling connected to the pen with the hose 3 Insert the new pen with hose through the quick action cou pling onto the connection in the extraction chamber 4 Check that the pen is earthed see Che...

Page 101: ...re is an electric conductor between the extraction chamber connector quick action coupling and the pen Check the resistance every 3 months Multimeter ü Carry out the measurement on all the mounted pens 1 Using the multimeter measure the resistance between the pen and the quick coupling 2 A resistance of R 10 Ω is O K If the resistance is higher replace the hose O The test is concluded 1 2 3 4 5 6 ...

Page 102: ...hut down permanently proceed as follows Empty the product fully including all the components before the shutdown Fully disconnect the product from the surrounding units Slacken or remove the electric pneumatic or hydraulic connec tions insofar as they are present 9 3 Disposal Recycling Dismount and recycle the product that cannot be used any more not as a whole unit but in individual parts and acc...

Page 103: ...e gloves black size 9 3204299 2 Protective gloves white size 9 4644608 2 Test liquid G60 Spezial 30 liters 3205511 1 Test liquid Feroclean L261 CTF1300 P F 30 liters 4434287 1 Air filters 1284372 1 Grating for extraction chamber CTU10xx 3325329 1 Grating for extraction chamber CTU12xx 3448167 1 Level sensor container CM1 CM2 6283457 2 Piston check valve RM1 RM2 RM3 RM4 6034256 4 3 2 directional va...

Page 104: ...s 632391 1 Filter element for test liquid and return line filter CTU1xx0 3559783 2 Filter element for test liquid and return line filter CTU1xx1 3510106 2 Filter element for additional module CTU1xxx x x A x 1346006 3 Pen replacement set with hose and con nector fittings 4614551 1 Tab 13 Spare parts list On request Quantity installed Description Part no Qty Filter membrane 5 µm Ø 47 mm Color white...

Page 105: ...unctions The following spare parts are safety related components Replace these after 20 years Description Part no Quan tity Pressure sensor BP1 BP2 4622531 2 Temperature sensor BT1 BT2 4622534 2 Proportional valve QM85 6066759 1 Tab 16 Spare parts list for safety related components 1 2 3 4 5 6 7 8 9 A ...

Page 106: ...uan tity Flat fan nozzle 6263519 1 Round nozzle Ø 2 5 mm 3918070 1 Round nozzle Ø 3 mm 3942320 1 Round nozzle Ø 4 mm 3259932 1 Round nozzle Ø 5 mm 3868777 1 Tab 17 Accessories list for water with surfactants as test liquid Accessories list for water with surfactants or solvent cleaners as test liquid Description Part no Quan tity Flat fan nozzle 6275263 1 Round nozzle Ø 2 5 mm 4094689 1 Round nozz...

Page 107: ...ine product support Customer Service Branches service partners for maintenance repair and spare parts can be found always updated on our homepagewww hydac com HYDAC SYSTEMS SERVICES GMBH Friedrichsthaler Str 15 Werk 13 66450 Neunkirchen Heinitz Germany Telephone 49 6897 509 01 Fax 49 6897 509 324 E mail service hydac com Homepage www hydac com Tab 19 HYDAC Service Germany 1 2 3 4 5 6 7 8 9 A ...

Page 108: ...MS GMBH 108 120 BeWa CTU1x5x 4603539 en us web A 3 EC declaration of conformity The EC declaration of conformity can be found in the technical documentation that is part of the scope of delivery for the product 1 2 3 4 5 6 7 8 9 A ...

Page 109: ...ck Example illustration CTU 105x CTU 125x 43 Fig 13 Packaging the extraction unit 43 Fig 14 Moving using the handle 44 Fig 15 Connecting the components 45 Fig 16 Connecting the ultrasonic unit vibrator 46 Fig 17 Suctioning the machine compartment 48 Fig 18 Suctioning the extraction chamber 49 Fig 19 Connecting the foot switch 50 Fig 20 Opening closing the door 54 Fig 21 Pen A 55 Fig 22 Extraction ...

Page 110: ...Table of Illustrations HYDAC FILTER SYSTEMS GMBH 110 120 BeWa CTU1x5x 4603539 en us web Fig 32 Preparing the protective gloves 95 ...

Page 111: ...the filter membrane holder 67 Tab 9 Example Labeling the filter membrane 72 Tab 10 Eliminating errors 77 Tab 11 Volume calculation 87 Tab 12 Protection index according to EN 374 3 93 Tab 13 Spare parts list 103 Tab 14 Spare parts for the filter membrane holder Ø 47 mm all 104 Tab 15 Spare parts for the filter membrane holder Ø 47 mm CTMH 104 Tab 16 Spare parts list for safety related components 10...

Page 112: ... 24 cone connectors These in accordance with DIN EN ISO 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 Extraction chamber This is a closed chamber in which the sampling of the test items is carried out General Terms and Conditions The Genera...

Page 113: ... at work and protection of the environment Test item Component for sampling component cleanliness analysis contamination test Test liquid do not use any more Liquid for spray extraction 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 c...

Page 114: ...nsions Extraction chamber 38 Extraction unit 32 37 Directives 2006 42 EC 81 2014 68 EU 81 VDA 19 29 Disposal Disposal 102 Recycling 102 Documentation 28 Documentation Representative 2 Door Cleaning the 83 Contact switch 54 Electrostatically charged 84 Maintaining the 84 Opening closing 54 E EC declaration of conformity 28 108 Electrical circuit diagram 28 Empty weight 32 Exclusion of Liability 13 ...

Page 115: ...r ultrasonic extraction 62 ultrasonic extraction 64 Owner information Containers under pressure 81 P Payload 21 30 35 Spray air extraction 32 Ultrasonic extraction 32 Pen 56 Performing the Performing ultrasonic extraction 64 Permeation time Protective gloves 94 Preparing Preparing for ultrasonic extraction 62 Protective gloves checking 92 Conductivity 95 Installing the 94 Permeation 94 Permeation ...

Page 116: ... CTU1x5x 4603539 en us web Ageing characteristics 85 Changing the 85 Draining the 85 Filling quantity 32 Filling the 87 Solvent cleaners 32 Water containing surfactants 32 U Ultrasonic Frequency 33 Performance 33 Ultrasonic bath 61 W Warranty 13 ...

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