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BeWa CTU2000 3160738h en-us 2018-11-15.docx

2018-11-15

Inspecting/cleaning the machine compartment .......................................... 63

Replacing hoses ........................................................................................ 63

Selecting the rinsing fluid filter / return filter ............................................... 63

Changing the filter element – type LF ..................................................... 64

Changing the filter element – type MRF1 ............................................... 67

Removing/fitting halogen lights (CTU up to manufacture year 2006) ........ 70

Light spare parts ..................................................................................... 72

Removing/fitting LED lights (CTU 2200 / 2400 from manufacture
year 2013) ................................................................................................. 73

Checking/maintaining the spray gun .......................................................... 74

Changing the spray nozzle ..................................................................... 74

Replacing the hose for the spray gun ..................................................... 75

Calibrating the flow rate meter................................................................ 76

Cleaning the analysis chamber .................................................................. 76

Clean the diffuser on the filter membrane holder.................................... 76

Cleaning the door ...................................................................................... 77

Statically charged door ........................................................................... 77

Changing the clean-room filters ................................................................. 78

Replacing the prefilter mat ..................................................................... 78

Replacing the main filter ......................................................................... 79

Replacing the main filter of a CTU 2000 ............................................. 79

Replacing the main filter of a CTU 2200 / 2400................................... 80

Emptying the intermediate pan .................................................................. 81

Changing the test fluid ............................................................................... 81

Draining the reservoirs ........................................................................... 82

Reservoir filling/refilling ....................................................................... 83

Checking the gloves .................................................................................. 83

Permeation of Protective Gloves According to EN 374-3:1994 .............. 84

Checking the filter regulator ....................................................................... 86

Setting the filter regulator ....................................................................... 86

Draining the filter regulator ..................................................................... 86

Cleaning the filter elements of the filter regulator ................................... 86

Disassembling the filter regulator ........................................................... 87

Disassembling the top part .................................................................. 87

Disassembling the bottom part ............................................................ 87

Assembling the filter regulator ................................................................ 87

Assembling the bottom part................................................................. 88

Assembling the top part ...................................................................... 88

Remedying error messages/malfunctions ................................................ 89

Hydraulic circuit .......................................................................................... 91

Locating spare parts ................................................................................... 94

Disposing of the CTU ................................................................................. 96

Summary of Contents for CTU 2 Series

Page 1: ...CTU 2xxx series Contamination Test Unit Operating and Maintenance Instructions English translation of original instructions Document No 3160738h Keep for future reference ...

Page 2: ...Documentation Representative Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar 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 ...

Page 3: ...Specialist personnel Mechanical 12 Specialist personnel Electricity 12 Observe regulatory information 13 Proper Designated Use 13 Improper Use or Use Deviating from Intended Use 15 Qualifications of personnel target group 16 Wear suitable clothing 17 Observe regulatory information 17 What to Do in Case of Emergency EMERGENCY STOP 17 Transporting the CTU 18 Storing the CTU 18 Decoding the model cod...

Page 4: ...older CTMH 38 Filter membrane holder with union nut 39 Filter membrane holder with clamp 40 Cascading filter membranes 41 Changing the filter membrane 42 Labeling the filter membrane 44 Operating the text display TD 200 45 CTU switching on 47 Selecting the operating mode 48 Stand by 48 Operation 48 Setting the vacuum for suctioning off the rinsing fluid 49 Setting the pressure of the rinsing fluid...

Page 5: ...ing the door 77 Statically charged door 77 Changing the clean room filters 78 Replacing the prefilter mat 78 Replacing the main filter 79 Replacing the main filter of a CTU 2000 79 Replacing the main filter of a CTU 2200 2400 80 Emptying the intermediate pan 81 Changing the test fluid 81 Draining the reservoirs 82 Reservoir filling refilling 83 Checking the gloves 83 Permeation of Protective Glove...

Page 6: ...US Page 6 108 BeWa CTU2000 3160738h en us 2018 11 15 docx 2018 11 15 Technical Data 97 Attachment 99 EC declaration of conformity 99 Customer Support Service 99 Model Code 100 Explanation of terms and abbreviations 101 Index 103 ...

Page 7: ...l obligation our liability shall be limited to foreseeable damage Claims 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 ...

Page 8: ...etermine which topic I am looking for WHERE can I find the information I m looking for The 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 mai...

Page 9: ...nspection intervals prescribed by law Document the results in an inspection certificate and keep it until the next inspection Signal words and their meaning in the safety information and instructions In these instructions you will find the following signal words DANGER DANGER The signal word indicates a hazardous situation with a high level of risk which if not avoided will result lethal or seriou...

Page 10: ...e signal word indicate the severity of the danger Warning instructions listed before an activity are laid out as follows HAZARD SYMBOL SIGNAL WORD Type and source of danger Consequence of the danger Measures to avert danger Warning signs used These signs are listed for all safety information and instructions in these operating instructions which indicate particular hazards to persons property or t...

Page 11: ... which indicate particular hazards to persons property or the environment Follow the operating and maintenance instructions Wear eye protection Use a face shield Use protective gloves Wear safety shoes Used prohibitory signs These signs are listed for all safety information and instructions in these operating instructions which indicate particular hazards to persons property or the environment Fir...

Page 12: ...ialist personnel Mechanical Only specialist personnel with training as mechanics and the following knowledge Safe handling use of tools Fitting and connection of hydraulic lines and connections Product specific knowledge Knowledge about how to handle operating media Specialist personnel Electricity Only specialist personnel with training as electricians and the following knowledge Safe handling us...

Page 13: ...ning usage handling storage maintenance repair use of unsuitable components or other circumstances for which HYDAC is not responsible HYDAC is not responsible for the installation integration selection of interfaces to into your system nor for the use or functionality of your system Use the unit only for the application described in the following The ContaminationTest Unit CTU is a test bench for ...

Page 14: ...with the materials and the sealing materials they come in contact with Use G60 Spezial as the test fluid CTU 1xx1 only Do not use completely demineralized water as a test fluid Using water containing tensides permissible pH values 6 to 10 as a test fluid is permitted Proper or designated use of the product extends to the following Maintaining adherence to all the instructions contained herein Not ...

Page 15: ...esulting from such 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 Inadeq...

Page 16: ...hazards due to improper use Specialist personnel Such persons have corresponding specialist training and several years work experience They are able to assess and perform the work assigned to them they are also able to recognize potential hazards Activity Person Knowledge Transport storage Specialist personnel Knowledge of transport safety required Startup operation Operations control Specialist p...

Page 17: ...es Wear gloves Observe the information relating to personal protection equipment in the safety data sheet of the operating fluid 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 What to ...

Page 18: ...pping during transport The CTU can be damaged Position the forks of the forklift truck as wide apart as possible during lifting Secure the CTU with suitable stopping means Storing the CTU To store the CTU proceed as follows 1 Empty the CTU completely both reservoirs rinsing fluid filter and return filter 2 Pull power plug 3 Coil up the power cable and secure it at the CTU Store the CTU in a clean ...

Page 19: ...can be found on the name plates on the unit and the components Item Description 1 Type label for power unit 2 Model code for details see page 100 3 Details of rated voltage frequency phases and power consumption The following information can be found on the name plate of the unit Row Description Model Model Code P N Part number S N Serial number year of production Date Year week of production ...

Page 20: ...t is complete The following items are supplied Item Qty Designation 1 1 ContaminationTest Unit CTU 2xxx series 2 1 Air vent connection kit consisting of 1x blanking cover 1x hose connecting piece 2x seal fastening material 3 1 Four sided hollow socket key 6 mm 1 Spray gun including connection hose 1 Accessories for threefold membrane retainer 2x support ring 3x supporting sieve 1 Collecting pan 1 ...

Page 21: ...rized After entering the desired amount of rinsing fluid and starting the contamination test via the text display the rinsing fluid is conveyed from reservoir B1 into the analysis chamber via the rinsing fluid micronic filter 22 by actuating the spray gun V12 The operator has to make sure that the surfaces of the component to be analyzed are rinsed The contamination particle laden rinsing fluid is...

Page 22: ...2018 11 15 docx 2018 11 15 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 3 2 B1 B2 1 2 1 2 Y10 11 10 15 Y30 Y31 Y40 Y41 Y90 Y91 Y50 Y51 Y61 Y60 Y70 22 S5 Y81 2 1 4 3 16 17 9 6 7 8 V12 14 V11 5 31 1 2 1 2 1 2 1 2 1 2 V5 V7 V4 S4 V13 V8 33 V6 S2 A A A A A A A A A A A A V10 V1 V9 V21 V20 18 19 S3 S1 30 ...

Page 23: ...t system is also located in the filter hood This sucks away the air of the analysis chamber in the front section of the CTU and guides it to the air vent channels Filling refilling test fluid Here the rinsing fluid is filled in the analysis chamber of the CTU and sucked into reservoir B1 via vacuum action Automatic inner chamber cleaning clean room cleaning The automatic cleaning of the inner cham...

Page 24: ...lank negative control value readings strongly depend on the ambient conditions and frequency of use Experience shows that the following negative control value readings may be obtained Ambience CTU 2000 CTU 2200 CTU 2400 Clean room 0 4 0 6 0 4 0 7 0 6 1 0 Laboratory 0 5 0 8 0 5 0 9 0 6 1 4 Separate sampling room 0 5 1 0 0 5 1 1 0 8 1 6 Factory hall 0 8 1 2 0 8 1 4 3 0 5 0 ...

Page 25: ...018 11 15 docx 2018 11 15 Parts of the CTU Item Designation 1 Clean room 2 Front pane 3 Operating panel control cabinet 4 Operating console 5 Pane fixture 6 Filter hood 7 Visual fluid level indicator 8 Rinsing fluid micronic filter 22 9 Return filter 33 10 Rinsing fluid reservoirs ...

Page 26: ...ntrol elements on the operating panel Item Designation 31 Return line vacuum indicator 32 Rinsing medium pressure indicator 33 Text display TD200 34 Reservoir change over active indicator 35 Operation signal lamp 36 Stand by signal lamp 37 Operating mode selector switch 38 Main switch 39 EMERGENCY STOP button ...

Page 27: ... 15 Control elements on the operating console Item Designation 41 Return line rinsing fluid shut off ball valve 42 Return line vacuum setting 43 Rinsing fluid pressure setting 44 Vacuum shut off ball valve 45 Threefold filter membrane holder 46 Compressed air shut off ball valve 47 Compressed air supply ...

Page 28: ...the back that there is enough space 0 5 m between the suction filter and room ceiling and that the EMERGENCY STOP button main switch and filter membrane holder are freely accessible at all times Make sure that the cleanliness of the surrounding area the ambient air and the temperature at the installation location are similar to laboratory conditions CAUTION G 60 Spezial test fluid Hazardous to hea...

Page 29: ...s supplied with a power plug fitted DANGER Dangerous electrical voltage warning Danger of fatal injury Any work involving the power supply may only be done by a properly trained certified electrician Remove the power plug before undertaking any work Before plugging the CTU into the power socket make sure that the voltage available corresponds to that specified on its type label ...

Page 30: ...ng the compressed air The inlet for the compressed air supply is located at the right on the operating console The inlet is a standard connector nipple of the DN 7 2 low pressure series The compressed air required must be dry de oiled and pre cleaned to 5 µm Additional conditions can be found in chapter Technical Data on page 97 ...

Page 31: ...utside or to a filter is located in the rear head section of the CTU Screw the connecting piece 3 for a Ø 125 mm hose onto the top or rear port Seal off the unused port with the blanking cover 1 Fit an air vent hose Ø 125 mm via the connecting piece 3 and secure the air vent hose in place using a hose clamp Item Designation 1 Blanking cover 2 Seal 3 Air vent connecting piece for Ø 125 mm air vent ...

Page 32: ...00 3160738h en us 2018 11 15 docx 2018 11 15 Opening closing the door The door design varies depending on the model Door with several access holes Door with gloves Door with several access holes and small pane The door should only ever be moved using the handle provided ...

Page 33: ...l access holes CAUTION Falling parts Risk of injury to the feet Wear safety shoes The access holes in the door are sealed off with the covers provided These are placed on the pane and remain there thanks to the integrated magnets Ensure that the covers are properly fixed in place The covers can be taken off by pulling the handles ...

Page 34: ... en US Page 34 108 BeWa CTU2000 3160738h en us 2018 11 15 docx 2018 11 15 Door with gloves The gloves are permanently attached and must be checked for damage at regular intervals See chapter Checking the gloves on page 83 for more information ...

Page 35: ...ne during sampling and lead to impairment of the analyses Introduce the gloves through the openings into the analysis chamber Then stretch the rolled end of the glove over the access opening from the outside It is not necessary to additionally secure the gloves to the access opening Use electro statically conductive gloves When replacing the gloves ensure that there is sufficient protection i e co...

Page 36: ... parts Risk of injury to the feet Wear safety shoes The access holes in the door are sealed off with the covers provided These are placed on the pane and remain there thanks to the integrated magnets Ensure that the covers are properly fixed in place The small pane must be mounted securely before every extraction procedure Fix the pane in place using the split pins provided ...

Page 37: ... membrane holder CTMH ContaminationTest Membrane Holder The design presses the filter membrane in the lower part 2 of the filter membrane holder function tight to the upper part The filter membrane holder CTMH has three height positions for threefold cascading Select the height according to your desired cascading To seal the filter membrane holder it is sufficient to turn the upper part 90 Note th...

Page 38: ...signation 1 Coupling 2 Hose connection 3 Diffuser A diffuser ensures that the analysis fluid is evenly distributed over the entire 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 The lower part of the filter membrane holder with a hose connection A 1st cascade coarse B ...

Page 39: ...nion nut 1 means that the lower part 2 of the filter membrane holder is pressed against the upper part preventing leakage and ensuring that the membrane works properly 1 2 3 To close the filter membrane holder lift the lower part 2 up to the upper part and tighten the union nut 1 clockwise Do not use a tool The filter membrane holder is opened by turning the union nut 1 counterclockwise ...

Page 40: ...y seals effectively when a vacuum is applied a supporting sieve is inserted with a filter membrane It is not possible to use two intermediate rings Squeeze the clip together by the handles 1 Push the clip over the filter membrane holder 2 Carefully release the clip handles the clip s spring force 3 will press the two halves together with the intermediate ring of the filter membrane holder Make sur...

Page 41: ... 2 3 4 7 7 6 6 6 A B C 1 Coupling 2 Hose connection 3 Diffuser A diffuser ensures that the analysis fluid is evenly distributed over the entire 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 The lower part of the filter membrane holder with a hose connection A 1st casc...

Page 42: ...lve for ultrasonic operation or for emergencies Ensure that the analysis fluid has been completely sucked away before you remove the filter membrane 1 Hold the holder with one hand on the lower part With your other hand undo the union nut counterclockwise 2 Put down the lower part together with the filter membrane in its holder 3 Remove the filter membrane for analysis and label it as shown in the...

Page 43: ...TU2000 3160738h en us 2018 11 15 docx 2018 11 15 4 Fit a new filter membrane on the supporting sieve 5 Pick up the union nut Position the lower part together with the filter membrane underneath the upper part 6 Screw on the union nut clockwise NOTICE Do not use any tools ...

Page 44: ...gical system An example of labeling filter membranes xyz 1 A 005 xyz Current sample series component designation 1 Number of membranes created for a measurement series A If several equivalent rinsing operations are to be performed for a component A B C and Z are used for creating a random sample 005 Membrane filtration fineness 5 µm 020 Membrane filtration fineness 20 µm 100 Membrane filtration fi...

Page 45: ...ing the text display TD 200 Apart from setting the pressure and selecting the operating mode you can control all functions using the text display The functions in the top half of the buttons can be selected directly by pressing these buttons To select the functions in the bottom half black background press the SHIFT button first ...

Page 46: ...tions OPERATING MENU password protected DIAGNOSTICS MENU password protected SHIFT Switching the button assignment Selection buttons used to select individual functions STOP Canceling all functions OK Starting selected functions SET Settings menu for presetting the rinsing volume CLEAN Automatic cleaning of the clean room SERVIC E Filling refilling and draining the CTU with of rinsing fluid POWER D...

Page 47: ...play will output the following message after approx 10 seconds this message will appear the following message will then be shown on the text display Switch the CTU to Operation using the operating mode selector switch when you see the following message on the text display it means that the CTU is ready for operation Contamination Test Please wait HYDAC FILTER SYSTEMS Contamination Test S T A N D B...

Page 48: ...s blocked off The reservoirs are adjusted to normal pressure and then sealed off The fan power is reduced The lighting is switched off The clean room remains operational in stand by mode Compressed air continues to flow via the vacuum generator This does not represent a system defect Operation When you switch the unit to operation The compressed air line is opened The reservoirs are adjusted to op...

Page 49: ... turn on the vacuum generator press the button on the text display 3 Set the VACUUM return line pressure control valve to 6 bar 4 Press the button on the text display 5 The suction vacuum is now set Setting the pressure of the rinsing fluid To set this proceed as follows 1 Switch the shut off ball valve of the compressed air supply to on 2 Set the pressure control valve to the desired pressure Che...

Page 50: ...UTION Spraying G60 Spezial test fluid Health hazard Keep the door to the analysis chamber closed as far as possible during the spray extraction process Always wear a face shield Always wear protective gloves To add rinsing fluid follow all instructions and the following procedure NOTICE Overfilling the unit The reservoirs are overfilled Add only the required indicated fill quantity for the test fl...

Page 51: ...irs Close the RINSING FLUID return line shut off valve Remove the filter membrane from the filter membrane holder Message on text display Press the buttons Press the button Reservoirs 1 and 2 are being vented The reservoirs are vented to allow for precise filling This message appears once the reservoirs have been vented Please wait Fill rins fl OK Vent res 1 2 Contamination Test Press OK button to...

Page 52: ...hange over lights up briefly This goes out once the rinsing fluid can be suctioned Now fill the rinsing fluid in the drain pan of the clean room Press the button once the drain pan has been emptied through the suction action Press the button The basic setting will be displayed Check the fill levels of reservoirs B1 B2 again Contamination Test Press OK button to start Reservoirs full when pan empty...

Page 53: ...s to scroll through the 10 rinsing volume programs and confirm the selection by pressing the button To change the preset value select the value using The selected value will flash and can be changed by pressing the buttons in 0 1 increments Once you have reached the desired value press to confirm Press the button to go to the main menu Rins vol 0 xx x L Rins vol 1 xx x L Select rinsing volume Sele...

Page 54: ...a face shield Always wear protective gloves After switching on the CTU and switching to Operation mode the following message appears on the display Pressing the button takes you to the main menu Press the button and Press the buttons to scroll through the 10 rinsing volume programs Confirm your selection with the button Select the volume value by pressing the button or change the value by pressing...

Page 55: ...he handheld spray gun The rinsing fluid supply is automatically stopped once the set amount has been conveyed If necessary the rinsing fluid reservoir is changed over automatically even during sampling The rinsed volume is displayed again here Press the button to confirm only once the entire volume has been suctioned from the clean room The suctioning time is not limited To make it easier to remov...

Page 56: ...minutes Set the cleaning time to five minutes and repeat the cleaning cycle three to five times Press the buttons Press the button Press the button to confirm the length of time or press the buttons to change the value in minute increments Press the button to confirm the set time and press the button to start the cycle After starting the cleaning cycle the remaining time is shown on the display By...

Page 57: ...irs B1 and B2 are continuously monitored When the lower fill level is reached in one reservoir the system automatically changes over to the other reservoir This change over takes some seconds and is indicated by the signal lamp The CHANGE OVER reservoir signal lamp flashes until the remaining volume has been conveyed The test fluid supply is stopped The CHANGE OVER reservoir signal lamp lights up ...

Page 58: ...lay outputs the following message as a default Press the button and then the button Here the compressed air line is blocked off and the rinsing fluid reservoirs are vented You can now either switch the CTU into STAND BY mode or switch it off at the main switch CTU can now be switched off CTU Power Down Please wait Contamination Test Press OK button to start Contamination Test Press OK button to st...

Page 59: ...l commissioning 1 Take the supporting sieve supplied and put it in the filter membrane holder See page 32 for details 2 Set the filter regulator to 6 bar See page 30 for details 3 Fill the CTU with test fluid See page 50 for details 4 Thoroughly clean the clean room by using the rinsing of the inner chamber and the spray gun until a negative control value is achieved as listed in the table on page...

Page 60: ...een extractions make sure that the clean room is always closed and is opened for only a short time for the insertion of the component to be analyzed Only in this way can you ensure that contamination from the surrounding area is as minimal as possible Performing the spray extraction method CAUTION Spraying G60 Spezial test fluid Health hazard Keep the door to the analysis chamber closed as far as ...

Page 61: ...er of bodily injury Depressurize the system before working on it After being switched off the system depressurizes automatically WARNING When using the G 60 Spezial as the test fluid Warning of flammable substances Open flames are prohibited near the CTU CAUTION G 60 Spezial test fluid Hazardous to health Make sure that there is adequate ventilation in the room Always wear protective gloves Always...

Page 62: ... hoses for leaks or signs of brittleness X Visually inspect the electrics Look for any damage to wires connectors sensors cabling and electrical equipment in the switch cabinet X Check all screwed connections and other connectors to ensure that they are firmly secured X Check that all of the shut off valves are working properly X Maintenance intervals Replace hoses 63 2 years for multi shift opera...

Page 63: ...specially designed for use with the test fluid The hoses must be checked regularly for brittleness In the case of multi shift operation replace the hoses after two years In the case of single shift operation replace the hoses after six years Selecting the rinsing fluid filter return filter Change the filter elements of the rinsing fluid filter and return filter as per the maintenance schedule The ...

Page 64: ...11 15 docx 2018 11 15 Changing the filter element type LF LF in line filter 3 4 1 2 5 6 Item Designation 1 Filter element including O ring 2 2 O ring 3 O ring 4 Support ring 5 Sealing ring 6 O ring Repair kit consisting of O ring 2 O ring 3 support ring 4 sealing ring 5 O ring 6 Wrench 27 mm ...

Page 65: ...ironmentally friendly manner 3 Pull the filter element off the mounting pin and dispose of it in an environmentally friendly manner 4 Clean the filter bowl 5 Check the filter bowl and filter head for mechanical damage In particular check the sealing surfaces and the thread 6 Check the O rings and support rings for damage and brittleness If necessary replace these parts 7 Wet the thread and sealing...

Page 66: ...heck to see whether the designation on the new element corresponds to the designation on the old one NOTICE Do not use a hammer etc 10 Screw in the filter bowl in a clockwise direction as far as it will go using the A F 27 wrench and then screw it back a turn 90 to release it slightly 11 Close both front doors 12 Start up the CTU again 13 After operating for about 1 hour check the filters for leak...

Page 67: ... drain plug 2 at the bottom end of the filter bowl in a clockwise direction using a 6 mm Allen wrench The filter bowl contains approx 1 5 liters test fluid Catch the test fluid that drains out in a suitable container and put it in the clean room after changing the element 3 Loosen the coupling nut 1 by turning it in a clockwise direction and then remove the filter bowl 2 Use a strap wrench to remo...

Page 68: ...n us 2018 11 15 docx 2018 11 15 5 Clean the filter bowl and sealing surface 6 Clean the sealing surface on the filter head Check the O ring for damage Moisten the O ring with the operating medium 7 For easy installation of the filter element wet the O ring with the operating medium ...

Page 69: ...rewing the union nut back on apply a lubricant We recommend using white Vaseline as a lubricant HYDAC part no 632391 2 Screw the filter bowl over the union nut onto the filter head in a counterclockwise direction When doing this screw the union nut hand tight only 10 Start up the CTU and rinse the inner chamber using the automatic cleaning cycle with a volume of 5 10 liters 11 Check the changed fi...

Page 70: ...60738h en us 2018 11 15 docx 2018 11 15 Removing fitting halogen lights CTU up to manufacture year 2006 The clean room is lit using three or four halogen lights Item Designation 1 Bulb holder with clips 2 Bulb 3 Clamping ring 4 Top part of light with glass and sealing ring ...

Page 71: ...ts to cool down 2 Remove the halogen lights by pulling them out of the light rail Pull the bulb socket off The halogen light is held in place in the rail by two clips Carefully pull the halogen light out of the light rail 3 Unscrew the bulb holder from the top part of the light 4 Remove the clamping ring 5 Insert the new bulb into the bulb holder 6 Secure the bulb in the bulb holder using the clam...

Page 72: ...ight is now assembled 9 Plug the bulb socket in 10 Push the clips of the halogen light together and slot the halogen light into the corresponding opening 11 Switch the CTU on and check that the halogen lights work Light spare parts Only use the following light as a replacement Designation Reflector light Ø 35 mm GU 4 20 W 12 V ...

Page 73: ...es en US Page 73 108 BeWa CTU2000 3160738h en us 2018 11 15 docx 2018 11 15 Removing fitting LED lights CTU 2200 2400 from manufacture year 2013 The clean room is lit using four LED lights These LED lights can only be replaced as a whole ...

Page 74: ...m Designation 1 0 Spray gun handle piece 2 0 Filter holder including filter 3 0 Hose with screwed fittings length 1 8 m 4 0 Spray nozzle Changing the spray nozzle The following spray nozzles are available as accessories see the list of spare parts and accessories Designation Figure Standard nozzle Long ridged nozzle Long round nozzle Long open nozzle ...

Page 75: ...zle is now changed Replacing the hose for the spray gun To change the hose proceed as follows 1 Switch the CTU off via the main switch Direct the spray nozzle into the clean room and actuate it to relieve the pressure in the spraying system 2 Unscrew the screwed hose fitting from the spray gun handle piece 1 0 3 Unscrew the screwed hose fitting from the clean room 4 Dispose of the old hose in an e...

Page 76: ...he set volume has been completely discharged 5 Read the volume on the measuring beaker A deviation of 5 4 75 5 25 liters is within the tolerance The flow rate meter will need to be recalibrated if the deviation is greater Contact the HYDAC Service Department 6 The calibration by gauging is completed Cleaning the analysis chamber Clean the analysis chamber every week For cleaning we recommend a cle...

Page 77: ...against one another thus causing static charge to build up Discharging may be slowed down by the ambient conditions such as dry air and low external temperatures The G 60 Spezial test fluid a hydrocarbon results in an unusual effect A film that looks like a pasty mass forms on the inside of the see through door The build up of static charge counteracts the low surface tension of the hydrocarbon mi...

Page 78: ...er mat and a main filter to ensure clean supply air Replace the prefilter and main filter regularly Replacing the prefilter mat We recommend changing the prefilter mat 2 every six months Perform the following steps to change the prefilter main filter Remove the fastening screws of the filter hood cover 1 Take the filter hood cover 1 off The prefilter mat is now freely accessible for you to remove ...

Page 79: ...lights from the light rail See page 70 for details Remove the light rail by undoing the three hexagon socket screws under the installation openings for the halogen lights Undo the 10 screws at the bottom of the filter Remove the four metal edge strips at the bottom of the filter Remove the filter element by pulling it down slightly The cutting edge of the filter element will detach from the fluid ...

Page 80: ...n lights to cool down Undo the 10 screws at the bottom of the filter Remove the four metal edge strips at the bottom of the filter Remove the filter element by pulling it down slightly The cutting edge of the filter element will detach from the fluid seal in the housing as a result Fit the new filter element by pressing it firmly into the fluid seal Attach the four metal edge strips to the bottom ...

Page 81: ...g on the application conditions however at least once a week To do this open the draining valve Y underneath Changing the test fluid Each use of the CTU differs from any other This means that it is difficult to define fixed replacement intervals for the test fluid Determine the replacement intervals for each application on an individual basis Always observe the test fluid with regard to the follow...

Page 82: ...lection with the button Press the button V remaining volume in liters until the contamination test is completed Q current flow rate in liters minute Spray the rinsing fluid into a suitable container The rinsing fluid supply is automatically stopped once the set amount has been conveyed If necessary the rinsing fluid reservoir is changed over automatically Press the button to confirm only once the ...

Page 83: ... be accelerated by components with rough surfaces For details of wear due to chemical action for example by permeation please see page 84 Provided there is no mechanical damage to the surface the gloves can be used for six months with average use single shift operation The tests that we carried out were based on the G 60 Spezial analysis fluid The service life depends on the nature of the analysis...

Page 84: ...ng to a protection index which is subdivided into six levels EN 374 3 1994 Specification of the Results Assuming permeation takes place the breakthrough time is indicated in minutes for each test sample The average breakthrough time for each type of material is also indicated The duration of testing is given if no breakthrough occurs Protection Index Class 1 Class 2 Class 3 Class 4 Class 5 Class 6...

Page 85: ...st list was collected under laboratory conditions using new gloves without any mechanical action at room temperature The gloves were continuously subjected to full contact This information can only be used for orientation purposes as other and or additional loading exposure frequently occurs in practice which deviates from laboratory conditions This information is not designed as a substitute for ...

Page 86: ... low pressure Draining the filter regulator Depending on the condensation level in the reservoir drain it by pressing the plastic knob against the reservoir This causes the valve to open The condensation level may never be allowed to rise above the maximum marking applied to reservoir Cleaning the filter elements of the filter regulator When a substantial pressure drop is noticeable clean the filt...

Page 87: ... the governor spring 5 and the set screw 4 Pull the piston 6 out of the housing 8 Pull the seal 7 out of the housing 8 Disassembling the bottom part Taking the lower assembly apart is facilitated if you turn it so that the reservoir 14 is pointing upwards Unscrew the receptacle 14 Remove the tapered filter element 13 from the reservoir Rotate the unit Loosen the insert 12 using needle nose pliers ...

Page 88: ...s centered lock the insert in place by turning it to the right Insert the filter element 13 into the mount for the baffle in the receptacle 14 Screw the receptacle 14 back into the housing 8 while doing this center the filter element and tighten the receptacle 14 by hand Assembling the top part Insert the seal 7 in the hole of the housing so that the sealing lip points in the direction of the hous...

Page 89: ...has tripped The electricity consumption of the motor was too high Switch the motor protection switch on again If it trips several times check the fan and motor Float B1 1 B1 2 The float switch in reservoir B1 is faulty Remove the float switch and check its functioning Float B2 1 B2 2 The float switch in reservoir B2 is faulty Remove the float switch and check its functioning Reservoirs B1 and B2 f...

Page 90: ...tion Fuse triggering F1 F11 There is excess current in the electrical circuit concerned see the electrical circuit diagram Switch the fuse on again Check the electricity consumption and look for the cause of the error Please top up rinsing fluid Reservoirs B1 and B2 are empty There is not enough rinsing fluid in the CTU Top up the rinsing fluid see page 83 ...

Page 91: ...2018 11 15 Hydraulic circuit 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 3 2 B1 B2 1 2 1 2 Y10 11 10 15 Y30 Y31 Y40 Y41 Y90 Y91 Y50 Y51 Y61 Y60 Y70 22 S5 Y81 2 1 4 3 16 17 9 6 7 8 V12 14 V11 5 31 1 2 1 2 1 2 1 2 1 2 V5 V7 V4 S4 V13 V8 33 V6 S2 A A A A A A A A A A A A V10 V1 V9 V21 V20 18 19 S3 S1 30 ...

Page 92: ...Spray gun V13 Ball valve of ring main V20 Pressure control valve vacuum V21 Pressure control valve pressure S2 Clogging indicator S1 Pressure switch optional S3 Pressure switch optional S4 Clogging indicator S5 Flow meter Y30 Compressed air solenoid valve B1 Y31 Compressed air solenoid valve B2 Y40 B1 vacuum solenoid valve Y41 B2 vacuum solenoid valve Y50 Drain solenoid valve B2 Y51 Drain solenoid...

Page 93: ...noid valve 1 Silencer 2 Silencer 3 Silencer 4 Silencer 5 Silencer 6 Pressure gauge vacuum setting 7 Pressure gauge vacuum setting 8 Pressure gauge vacuum setting 9 Pressure gauge vacuum setting 10 Compressed air filter 11 Compressed air filter 14 Filter membrane holder 16 Level switch B1 17 Level switch B2 30 Clean room 31 Compressed air supply ...

Page 94: ... 6029141 3 4 4 LED light from manufacture year 2013 6143675 4 Clean air module prefilter mat by the meter 2 m wide 6028496 0 5 m 1 m 1 5 m Clean air module main filter 6031485 1 Clean air module main filter 6024934 1 1 Clean air module main filter from manufacture year 2017 TBD 1 Spray gun with standard nozzle assembly 6022796 1 1 1 Hose incl screwed fittings for spray gun l 1 8 m 6040202 1 1 1 Sp...

Page 95: ...22707 12 12 12 Flow rate meter type SFL 122OR10 6022703 1 1 1 Flow rate meter type LSN45 6085694 1 1 1 Hose transparent soft 6023627 1 5 m 1 5 m 1 5 m 1 ear terminal 6069299 3 3 3 Plastic pipe white matt 6034766 10 m 10 m 10 m Insert sleeve 630116 24 Cutting ring 608415 24 Pressure gauge for indicating return line vacuum 6022772 1 1 1 Pressure gauge for indicating rinsing medium pressure 6022773 1...

Page 96: ...rane 5 µm Ø 47 mm Color white surface smooth 1 pckg contains 100 6020761 1 1 1 Analysis fluid G60 30 liter container 3205511 2 2 2 optional Disposing of the CTU Dispose of the packaging material in an environmentally friendly manner Drain the CTU completely Dispose of the test fluid in an environmentally friendly manner Accordingly follow the instructions in the safety data sheet for the test flui...

Page 97: ... CTU 2400 750 kg Load capacity 50 kg For evenly distributed load no point loading Power supply 230 V AC 50 Hz 1 phase Wattage 800 W max Permitted ambient temperature range 15 28 C Permitted storage temperature range 0 50 C Permitted ambient conditions for storage dust free no salty air not in the vicinity of oxidizing substances flash rust rust bloom Permitted relative air humidity 80 non condensi...

Page 98: ...ge 98 108 BeWa CTU2000 3160738h en us 2018 11 15 docx 2018 11 15 Suction speed of the analysis fluid 1 14 l min at 0 7 bar vacuum Collecting pan volume CTU 2000 30 liters CTU 2200 CTU 2400 30 liters Emission sound pressure level LPA 70 db A ...

Page 99: ...have any questions suggestions or encounter any problems of a technical nature please contact HYDAC FILTER SYSTEMS GMBH Justus von Liebig Str Werk 20 66280 Sulzbach Saar Fax 49 6897 509 9046 E mail filtersystems hydac com For repair work or complaints please contact our central customer service department HYDAC SYSTEMS SERVICE GMBH Friedrichsthaler Straße 15 Werk 13 66540 Neunkirchen Heinitz Phone...

Page 100: ... dimensions 670 x 1600 x 600 mm 4 Clean room dimensions 1400 x 1700 x 1400 mm Analysis 0 with analysis membrane Ø 47 50 mm Test fluid 0 Solvent class A III flash point 60 C explosion limit 0 6 by volume Power supply K 120 V AC 60 Hz 1 Ph USA Canada M 230 V AC 50 Hz 1 Ph Europe N 240 V AC 50 Hz 1 Ph United Kingdom O 240 V AC 50 Hz 1 Ph Australia P 100 V AC 50 Hz 1 Ph Japan Extraction method Z spray...

Page 101: ...iling value cm Centimeters ConTeS ContaminationTest Software CTM ContaminationTest Module CTMH ContaminationTest Membrane Holder CTM Ex ContaminationTest Module Extraction 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 EC European Com...

Page 102: ...1 bar MIN Minimum mm Millimeter NBR Nitrile rubber Nm Newton meters torque specification OFF Switched off ON Switched on OUT Outlet OUTLET Outlet Test fluid Fluid for general operation Rinsing fluid analysis fluid Sec Second s Rinsing fluid Test fluid for spray extraction A F Wrench size for tools Vent Ventilation air bleed port VE water Demineralized Deionized water ...

Page 103: ...raining 46 81 92 E EC declaration of conformity 99 Error 89 Error message 89 F filling 50 51 83 Filter 15 25 37 38 39 40 41 63 64 74 92 93 95 96 Filter element 64 95 Filter housing 63 filtration 19 21 44 Flash point 101 Float switch 96 Flow rate 95 H Hazard symbol 10 Hose connection 38 41 I Imprint 2 IN 102 In case of emergency 17 Inlet 89 102 INLET 102 installation 12 13 28 35 68 79 88 installing...

Page 104: ...81 S select 8 45 46 53 82 Service 50 76 99 setting 27 45 52 86 87 93 Signal word 9 10 signal words 9 10 Size 100 Solid particle contamination 101 Spare part 95 Spare parts 95 Specialist personnel 12 16 Storage temperature 18 switching off 58 switching on 47 54 T Transport 16 Troubleshooting 16 Type label 19 V Vacuum 27 96 W Weight 97 ...

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Page 108: ...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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