Summary of Contents for HYDAC FILTER SYSTEMS CTU 1x3x Series
Page 1
CTU 1x3x Series Contamination Test Unit Operating and Maintenance Instructions English (translation of original instructions) Document no.: 3631694d (Valid until serial number: 0002S01495K000000191) Keep for future reference.
Connecting an air extractor ................ 30 Electrical connection of the CTU ............31 Connecting the compressed air .............. 31 Connecting the foot switch ..............32 Parts of the CTU ..................33 CTU 1x3x Series en(us) Page 3 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Page 4
Calibrating the temperature sensor (ultrasound option only) ....64 Cleaning the analysis chamber .............. 65 Clean the diffuser on the filter membrane holder........65 Cleaning the door ................... 66 CTU 1x3x Series en(us) Page 4 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Page 5
EC declaration of conformity ..............83 Customer Service / Service ............... 83 Model Code ....................84 Explanation of terms and abbreviations ............. 85 Index ......................87 CTU 1x3x Series en(us) Page 5 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Warranty For the warranty provided by us, please refer to the terms of delivery of HYDAC FILTER SYSTEMS GMBH. You will find these under www.hydac.com -> Legal information. Using the documentation Note that the method described for locating specific information...
Page 7
The documentation number with its index enables you to order another copy of the operating and maintenance instructions. The index is incremented every time the manual is revised or changed. CTU 1x3x Series en(us) Page 7 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Pass all safety information and instructions on to other users. General hazard Danger due to electrical voltage / current Exposed electrical components Danger of electrical shock Danger due to operating pressure CTU 1x3x Series en(us) Page 8 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Page 9
Fire hazard Harmful to the environment Wear eye protection. Wear protective gloves. Wear hearing protection. Do not use any open fire or open flame while in operation. CTU 1x3x Series en(us) Page 9 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Warning instructions listed before an activity are laid out as follows: SIGNAL WORD Type and source of danger HAZARD SYMBOL Consequence of the danger Measures to avert danger ► CTU 1x3x Series en(us) Page 10 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Flammable gas-air mixture in the analysis chamber Risk of burns Use only test liquids with a flash point ≥ 60°C ► or with a lower explosion limit > 0.6% by volume. CTU 1x3x Series en(us) Page 11 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Page 12
Maintaining adherence to all the instructions contained herein. o Not operating unless the side paneling is fitted. o Not operating unless the analysis chamber is closed. o Performing requisite inspection and maintenance work. CTU 1x3x Series en(us) Page 12 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Any use extending beyond or deviating therefrom shall not be considered intended use. HYDAC Filter Systems GmbH will assume no liability for any damage resulting from such use. This risk is borne solely by the owner. Improper use or use deviating from intended may result in hazards and/or will damage the unit.
Knowledge of environmentally- personnel friendly disposal of materials and matter is required. Knowledge of decontamination of contaminants is required. Knowledge with regard to recycling is required. CTU 1x3x Series en(us) Page 14 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
What to Do in Case of Emergency (EMERGENCY STOP) In an emergency, switch the unit off at the main on/off switch or unplug the power connector. CTU 1x3x Series en(us) Page 15 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Pack the CTU for further transport in this wood box. Alternatively, place the CTU on a pallet of sufficient size using a forklift. Brace the CTU so that the steering rollers are not loaded. CTU 1x3x Series en(us) Page 16 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Page 17
Transporting the CTU Example illustration on a CTU10xx. CTU 1x3x Series en(us) Page 17 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Page 18
Secure the CTU with suitable stopping means. ► Make sure that the stopping means are routed and stretched ► exclusively over the body and not over the analysis chamber of the CTU. CTU 1x3x Series en(us) Page 18 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Store the CTU in a clean, dry room, upright with the following conditions: Storage temperature: 0 … 50°C Humidity: max. 80%, non-condensing Air: dust-free, no salty air, not in the vicinity of oxidizing substances (flash rust, rust bloom) CTU 1x3x Series en(us) Page 19 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
The following information can be found on the name plate of the unit: -> Description Model -> Model Code -> Part number -> Serial number / year of production Date -> Year/week of production CTU 1x3x Series en(us) Page 20 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Outer dimensions The ContaminationTest Unit has the following outer dimensions: CTU10xx 1170 1290 1500 ≈ 1700 CTU12xx 1140 1160 1280 1750 ≈ 2070 All dimensions in mm. CTU 1x3x Series en(us) Page 22 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
CTU dimensions Analysis chamber dimensions The ContaminationTest Unit has the following dimensions for the analysis chamber: CTU10xx 2x Ø180 CTU12xx 2x Ø180 All dimensions in mm. CTU 1x3x Series en(us) Page 23 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Make sure that the cleanliness of the surrounding area, the ambient air and the temperature at the installation location are similar to laboratory conditions. CTU 1x3x Series en(us) Page 24 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Page 25
"G60 Spezial" test liquid Vapors hazardous to health Make sure that there is adequate ventilation. ► Always wear protective gloves. ► Always wear eye protection. ► CTU 1x3x Series en(us) Page 25 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Put the monitor and the keyboard on the CTU. Check and connect the power and signal/data cables as shown in the following illustrations. CTU 1x3x Series en(us) Page 26 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Page 27
Preparing the CTU for operation (optional) Mount the monitor holder onto the housing. Then fasten the monitor onto the monitor holder. Power supply connection CTU 1x3x Series en(us) Page 27 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Page 28
36. Experience shows that at least 12 rinsing cycles, using approx. 15 liters, will be required. CTU 1x3x Series en(us) Page 28 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Minimum volumetric flow of the air extraction 150 m³/h Maximum ambient temperature 28 °C Maximum permitted temperature of the ventilation equipment 200 °C and its components CTU 1x3x Series en(us) Page 29 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
CTU. On delivery, a cover is fitted to the CTU extraction connection. CTU 1x3x Series en(us) Page 30 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
The compressed air required must be dry, de-oiled and pre-cleaned to 5 µm. Required atmospheric pressure Maximum 6 bar Required air flow rate ≈ 60 l/min CTU 1x3x Series en(us) Page 31 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
The socket for the foot switch is located at the lower right part of the operating console. Insert the plug into the socket and turn the locking ring to hold it in place. CTU 1x3x Series en(us) Page 32 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Directional valve (Y81) is closed once the preset quantity has been conveyed. Wait until the analysis fluid has been completely sucked through the membrane. Then remove the analysis membrane and evaluate it. CTU 1x3x Series en(us) Page 35 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
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. CTU 1x3x Series en(us) Page 37 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
(3) will press the two halves together with the intermediate ring of the filter membrane holder. Make sure that an intermediate ring and two supporting sieves are used when a clip is used. CTU 1x3x Series en(us) Page 38 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Intermediate ring The lower part of the filter membrane holder with a hose connection 1st cascade - coarse 2nd cascade - medium 3rd cascade - fine CTU 1x3x Series en(us) Page 39 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
To seal the filter membrane holder it is sufficient to turn the upper part 90°. Note that the wrench size at the lower part to the left and right is visible in order to insert the lower part into the upper part. CTU 1x3x Series en(us) Page 40 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Intermediate ring The lower part of the filter membrane holder with a hose connection 1st cascade - coarse 2nd cascade - medium 3rd cascade - fine CTU 1x3x Series en(us) Page 41 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Install the angled pipe (2) with the outlet pointing down onto the lower screw connection. CTU 1x3x Series en(us) Page 42 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Operating the filter membrane holder Operating the door lock Lock the door using the clamps [2]. To undo the clamps, lift the lever [1]. CTU 1x3x Series en(us) Page 43 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Switch on the CTU at the main switch. After switching on the CTU, the PC self-test will be displayed on the monitor after approx. 5 … 8 seconds. CTU 1x3x Series en(us) Page 44 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Only in this way can you ensure that contamination from the surrounding area is as minimal as possible. CTU 1x3x Series en(us) Page 45 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
CTU to be cleansed in a defined manner. The nozzle to clean the inner chamber is located in the middle of the analysis chamber. For controlling, please refer to the ConTeS operating manual. CTU 1x3x Series en(us) Page 46 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
• Use the vacuum to suck the test/analysis liquid back into the reservoirs. You can use the "Fill CTU" function in the software. CTU 1x3x Series en(us) Page 47 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Note the maximum weight of the test item of 0.5 kg when using the ► hanging basket. Using spray extraction, you can spray/rinse off components in a defined way as described in the "Functional description" section. CTU 1x3x Series en(us) Page 48 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Page 49
The test liquid is released by actuating the foot switch. Test liquid is delivered as long as you press the foot switch or the flushing volume has not be reached. CTU 1x3x Series en(us) Page 49 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
• Use the vacuum to suck the test/analysis liquid back into the reservoirs. You can use the "Fill CTU" function in the software. CTU 1x3x Series en(us) Page 50 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Hang the basket retaining frame [a] with the basket [b] in the corresponding thrust bolts in the analysis chamber. CTU 1x3x Series en(us) Page 51 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Page 52
Testing will be interrupted while the unit cools down. Close the ball valve on the filter membrane holder during the ultrasonic test. CTU 1x3x Series en(us) Page 52 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
"No signal“, followed by the screen going dark. Switching off the CTU at the main switch. Wait for at least 20 seconds before you switch the CTU on again. CTU 1x3x Series en(us) Page 53 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Put down the lower part together with the filter membrane in its holder. Remove the filter membrane for analysis and label it as shown in the example on page 56. CTU 1x3x Series en(us) Page 54 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Page 55
Pick up the union nut. Position the lower part together with the filter membrane underneath the upper part. Screw on the union nut clockwise. Do not use any tools. CTU 1x3x Series en(us) Page 55 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
A, B, C and Z are used for creating a random sample. Membrane filtration fineness, 5 µm Membrane filtration fineness, 20 µm Membrane filtration fineness, 100 µm CTU 1x3x Series en(us) Page 56 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
"G60 Spezial" test liquid Hazardous to health Make sure that there is adequate ventilation ► in the room. Always wear protective gloves ► Always wear eye protection ► CTU 1x3x Series en(us) Page 57 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Check all screwed connections and other connectors to ensure that they are firmly secured. Check that all of the shut-off valves are working properly CTU 1x3x Series en(us) Page 58 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Calibrating the flow rate meter Calibrate the temperature sensor (ultrasound option only) Cleaning the analysis chamber Cleaning the diffuser for the filter membrane holder Change the test liquid 1 month CTU 1x3x Series en(us) Page 59 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Replace hoses The installed hoses are specially designed for use with the test liquid. The hoses must be checked regularly for brittleness. After 2 years replace the hoses. CTU 1x3x Series en(us) Page 60 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Loosen the coupling nut (1) by turning it in a clockwise direction and then remove the filter bowl (2). Use a strap wrench to remove the coupling nut. CTU 1x3x Series en(us) Page 61 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Page 62
Check the O-ring for damage. Replace it if necessary. Moisten the O-ring lightly with operating medium. Lightly wet the O-ring on the filter element with operating medium. CTU 1x3x Series en(us) Page 62 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Page 63
5 to 10 liters. 14. Remove the membrane from the filter membrane holder. 13. Check the changed filters for leaks. CTU 1x3x Series en(us) Page 63 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
The calibration by gauging is completed. Calibrating the temperature sensor (ultrasound option only) Calibrate the temperature feeler for the ultrasound bath annually. Contact the HYDAC Service department in this regard. CTU 1x3x Series en(us) Page 64 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Clean the diffuser (3) by blowing it out with compressed air. Put the diffuser into the filter membrane holder and screw the coupling (1) finger tight. CTU 1x3x Series en(us) Page 65 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
• Adjust the humidity in the surroundings. • Always clean the door with a moist cloth. • If there is a lot of static, use a commercial anti-static product. CTU 1x3x Series en(us) Page 66 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
This process leaves a small amount of test liquid in the rinse & return line filters and in the lines. Max. capacity is CTU 1x3x Series en(us) Page 67 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Page 68
CTU. Close the two locks by turning them 90° in the clockwise direction using the four-sided hollow key. 7. Draining the test liquid has completed. CTU 1x3x Series en(us) Page 68 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
CTU software. 3. Pour the previously determined and measured test liquid into the analysis chamber of the CTU. Maximum capacity is approx. 20 liters. CTU 1x3x Series en(us) Page 69 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Page 70
• Open the ball valve above the membrane holder and drain the residual amount from the analysis chamber. 7. The filling of the system is completed. CTU 1x3x Series en(us) Page 70 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Danger from test liquids, which can be hazardous to your health Check the gloves for leaks on a daily basis. ► If you find signs of wear, replace the gloves ► immediately. CTU 1x3x Series en(us) Page 71 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
The data in this test 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 CTU 1x3x Series en(us) Page 72 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Ω Please make sure that resistance R (Ω) is between 7.5x10 ≤ R ≤ 1x10 EPA ground or a grounding point for gloves and finger stalls. CTU 1x3x Series en(us) Page 73 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
When reinserting the element make sure it is dry. The reservoir and the other plastic components may only be washed using warm water and dish washing liquid. CTU 1x3x Series en(us) Page 74 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
• Remove the pressure spring [11] from the housing [8] using needle-nose pliers. • Pull the valve piston [10] out of the housing [8]. • Remove the O-ring Ø 31x2 [9] from the housing. CTU 1x3x Series en(us) Page 75 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
The following accessories are available to this CTU: Designation Part no. Flat nozzle 3274841 Round nozzle, Ø 1 mm 3907026 Round nozzle, Ø 2 mm 3979373 Round nozzle, Ø 3 mm 4087268 CTU 1x3x Series en(us) Page 78 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
CTU. S2 - Switch vacuum Switch the vacuum either to the filter membrane holder (standard) (1) or to the additional connection in the analysis chamber (2). CTU 1x3x Series en(us) Page 79 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
The warning can be reset by: • Fix the leak in the CTU. Empty the collecting pan. • Switching off the CTU at the main switch. CTU 1x3x Series en(us) Page 80 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Accordingly, follow the instructions in the safety data sheet for the analysis fluid. After dismantling the unit and separating the various materials, dispose of the unit in an environmentally-friendly manner. CTU 1x3x Series en(us) Page 81 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx...
Documentation of the CTU. Customer Service / Service If you 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...
® FPM (FKM / Viton Fluoroelastomer rubber Type of test liquid Spray gun Spray gun with changeable nozzle for spray CTU 1x3x Series en(us) Page 85 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Page 86
Fluid for general operation. (flushing fluid / analysis fluid). sec. Second(s) Flushing fluid Test liquid for spray extraction. Wrench size for tools Vent Ventilation / air bleed port VE water Demineralized/Deionized water CTU 1x3x Series en(us) Page 86 / 92 BeWa CTU1x3x 3631694d en-us 2017-03-13.docx 2017-03-13...
Need help?
Do you have a question about the CTU 1x3x Series and is the answer not in the manual?
Questions and answers