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Related Manuals for HYDAC FILTER SYSTEMS CTM-SC 3 Series
Summary of Contents for HYDAC FILTER SYSTEMS CTM-SC 3 Series
- Page 1 CTM-SC 3xxx ContaminationTest Module - SupplyControl Operating and Maintenance Instructions English (translation of original instructions) Keep for future reference. Documentation no.: 4165698b...
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Page 2: Imprint
+49 6897 509 1394 E-mail: guenter.harge@hydac.com © HYDAC FILTER SYSTEMS GMBH All rights reserved. No part of this work may be reproduced in any form (print, photocopy or by other means) or processed, duplicated or distributed using electronic systems without the written consent of the publisher. -
Page 3: Table Of Contents
Content Content Imprint ......................2 Documentation Representative ..............2 Content ......................3 Preface ......................5 Technical Support ..................5 Product modification ..................5 Warranty ...................... 5 Using the documentation ................6 Safety Information ..................7 Hazard symbols ................... 7 Signal words and their meaning in the safety information and instructions .................... - Page 4 Content Remedying malfunctions ................29 Performing maintenance ................31 Maintenance intervals ................32 Checking / Replacing hoses ..............33 Maintaining membrane pump ..............33 Checking prefilter / bypass filter ..............34 Changing the filter element ..............35 Calibrate the volume flow meter ............. 38 Change the test liquid ................
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Page 5: Preface
Please notify us immediately of any modifications made to the product whether by you or a third party. 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. CTM-SC 3xxx series en(us) Page 5 / 56 BeWa CTM-SC 4165698b en-us 2017-05-10.docx... -
Page 6: Using The Documentation
Preface Using the documentation Note that the method described for locating specific information does not release you from your responsibility of carefully reading all these instructions prior to starting the unit up for the first time and at regular intervals in the future. What do I want to know? I determine which topic I am looking for. -
Page 7: Safety Information
Safety Information Safety Information The unit was built according to the statutory provisions valid at the time of delivery and satisfies current safety requirements. Any residual hazards are indicated by safety information and instructions and are described in the operating instructions. Observe all safety and warning instructions attached to the unit. - Page 8 Safety Information Risk of burns due to hot surfaces Substances that are health hazards or irritants This symbol indicates that you are to wear suitable protective eyewear (e.g., goggles, full-face shields). When dealing with fluids, suitable gloves are to be worn according to the type of liquid involved.
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Page 9: Signal Words And Their Meaning In The Safety Information And Instructions
Safety Information 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 serious injury. WARNING WARNING –... -
Page 10: Structure Of The Safety Information And Instructions
Safety Information Structure of the safety information and instructions All warning instructions in this manual are highlighted with pictograms and signal words. The pictogram and the signal word indicate the severity of the danger. Warning instructions listed before an activity are laid out as follows: SIGNAL WORD Type and source of danger HAZARD SYMBOL... -
Page 11: Proper/Designated Use
Safety Information Proper/Designated Use Use the unit only for the application described in the following. The CTM is an extraction unit specially designed to analyze the surface cleanliness of components by taking wet samples. Analyzing the type, size and quantity of contamination enables quality standards to be verified and documented, and the requisite optimization measures to be implemented. -
Page 12: Improper Use Or Use Deviating From Intended Use
Any use extending beyond this 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. -
Page 13: Qualifications Of Personnel / Target Group
Safety Information Qualifications of personnel / target group Persons who work on the power unit must be aware of the associated hazards when using the CTM. Operating and specialist personnel must have read and understood the operating instructions, in particular the safety information and instructions, and applicable regulations before beginning work. - Page 14 Safety Information Activity Person Knowledge Transport / storage Forwarding • Proof of knowledge of cargo agent securing instructions Specialist • Safe handling/operation of personnel hoisting and lifting equipment Hydraulic / electrical Specialist • Safe handling/use of tools installation, personnel • Fitting and connection of first commissioning, hydraulic lines and connections...
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Page 15: Wear Suitable Clothing
Safety Information Wear suitable clothing Loosely worn clothing increases the danger of getting caught or wound up in rotating parts and the danger of getting snagged on projecting parts. You can be severely injured or killed. • Wear close-fitting clothing. •... -
Page 16: Transporting The Ctm-Sc
Transporting the CTM-SC Transporting the CTM-SC The CTM-SC has 4 casters. Shift the CTM-SC by releasing the hand brakes on the casters. Remove all moving parts and parts sensitive to vibration, such as the monitor, keyboard and holder, for transportation. Supports must be placed under the CTM-SC to transport it on a pallet. -
Page 17: Checking The Scope Of Delivery
Checking the scope of delivery Checking the scope of delivery The ContaminationTest Module CTM comes packed and partially factory- assembled. Before starting up the CTM, check the delivery to make sure that it is complete and undamaged. The following items are supplied: Designation ContaminationTest Module –... -
Page 18: Ctm Characteristics
CTM characteristics CTM characteristics The CTM-SC is a specially designed supply module which only makes up an extraction unit to determine the surface cleanliness of components when used in combination with a corresponding CTM-E extraction module. Functional principle After entering the required analysis parameters in the CTM-SC software, you push the foot switch to pump the test liquid from a reservoir, via a purification filter, to one of the three valves with the corresponding connection (A / B / C ) on to the extraction module CTM-E. -
Page 19: Ctm-Sc Dimensions
CTM-SC dimensions CTM-SC dimensions The CTM-SC has the following dimensions: CTM-SC 3xxx series en(us) Page 19 / 56 BeWa CTM-SC 4165698b en-us 2017-05-10.docx 2017-05-10... -
Page 20: Ctm-Sc Components / Control Units
CTM-SC components / control units CTM-SC components / control units The CTM-SC has the following components / control units: CTM-SC 3xxx series en(us) Page 20 / 56 BeWa CTM-SC 4165698b en-us 2017-05-10.docx 2017-05-10... - Page 21 CTM-SC components / control units Item Designation Main switch Touchscreen monitor Touchscreen monitor holder RJ45 port, USB port, Schuko plug Foot switch Switch cabinet Connection panel, see page 26 Pull power plug Guide roll Pre-line filter Bypass filter Hood Body Sliding grip Stabler rail CTM-SC 3xxx series...
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Page 22: Preparing The Ctm-Sc For Operation
Preparing the CTM-SC for operation Preparing the CTM-SC for operation Positioning the CTM-SC The CTM-SC can be moved into the required location on its own casters. Only use the handle to push the CTM-SC. The CTM has 4 casters. Before pushing, release the hand brake on the casters. -
Page 23: Connecting Up / Testing The Ctm-Sc
Preparing the CTM-SC for operation Connecting up / testing the CTM-SC WARNING Electric shock Danger of fatal injury Any work involving the power supply may ► only be done by a properly trained, certified electrician. Unplug the unit from the power supply before ►... - Page 24 Preparing the CTM-SC for operation Figure 1: Installing the monitor CTM-SC 3xxx series en(us) Page 24 / 56 BeWa CTM-SC 4165698b en-us 2017-05-10.docx 2017-05-10...
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Page 25: Connecting The Ctm-Sc To The Electrical Supply
Preparing the CTM-SC for operation Connecting the CTM-SC to the electrical supply The CTM is supplied with a power plug fitted. DANGER Electric shock Danger of fatal injury Any work involving electrical equipment may ► only be done by a properly trained, certified electrician. -
Page 26: Ctm-Sc Connection Panel
Preparing the CTM-SC for operation CTM-SC Connection Panel Connecting the foot switch To prevent the connector from working loose, secure it by screwing up the locking ring. The connection plug for the foot switch is coded and will only fit into the correct socket. -
Page 27: Connecting The Ctm E Module
Preparing the CTM-SC for operation Connecting the CTM E module Attach the CTM-E electrical connector and hoses to the control unit as shown in the following illustration. Tighten the connection at the hose tightly to the screw connection on the CTM-SC. -
Page 28: Starting Up The Ctm
Starting up the CTM Starting up the CTM Once you have completed all of the steps listed in the chapter "Preparing the CTM-SC", switch it on at the main switch. If there is no test liquid in the CTM-SC, you must first fill up the system. -
Page 29: Remedying Malfunctions
Remedying malfunctions Remedying malfunctions In the following you can read which errors can arise at the device and how to fix them. Error Cause Remedy Permanent display of a Tank empty Fill tank tank volume of 0 liters. Level sensor (B1) set for Set level sensor (B1) for incorrect test liquid. - Page 30 Remedying malfunctions Boost pump faulty Replace pump if necessary No suctioning of the test Hose connected Check hose or connect / liquid from the pan incorrectly remount it Cable break Measure resistance, replace cable if necessary Valve faulty Replace valve Recirculating pump Clean or replace pump faulty...
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Page 31: Performing Maintenance
Performing maintenance Performing maintenance A liquid tank is built into the CTM-SC from which the test or analysis fluid is conveyed using a pump. This tank is not subject to the current Pressure Equipment Directive and does not represent system part which requires monitoring as per the national German ordinance on Industrial Safety Regulation. -
Page 32: Maintenance Intervals
Performing maintenance Maintenance intervals Check all hoses for leaks or signs of brittleness Visually inspect the electrics. Look for any damage to wires, connectors, sensors, cabling and electrical equipment in the switch cabinet. Check all screwed connections and other connectors to ensure that they are firmly secured. -
Page 33: Checking / Replacing Hoses
Performing maintenance Checking / Replacing hoses Replace the hydraulic hoses every six years at the latest. The six operating years include two years storage duration for normal requirements in accordance with the rules of the Employers Liability Insurance Association BGR 237 for normal requirements. Maintaining membrane pump The membrane pump is subject to wear. -
Page 34: Checking Prefilter / Bypass Filter
Performing maintenance Checking prefilter / bypass filter After opening the door, you can directly access the prefilter / bypass filter. Item Designation Pre-filter Bypass filter CTM-SC 3xxx series en(us) Page 34 / 56 BeWa CTM-SC 4165698b en-us 2017-05-10.docx 2017-05-10... -
Page 35: Changing The Filter Element
Performing maintenance Changing the filter element Tools needed: Strap wrench (for opening the union nuts) To change the filter element, proceed as follows: Drain the test liquid from the filter housing. To do that, carefully unscrew the drain plug (2) at the bottom end of the filter bowl in a clockwise direction using a 6 mm Allen wrench. - Page 36 Performing maintenance Clean the sealing surfaces on the filter head and filter bowl. Clean the sealing surface on the filter head. Check the O ring for visible signs of damage and, if necessary, replace it. Wet the O ring with hydraulic fluid and insert it.
- Page 37 Performing maintenance (1) Before screwing the union nut back on, apply a lubricant. We recommend using white Vaseline as a lubricant HYDAC part no. 632391 Screw the filter bowl (2) over the coupling nut (1) onto the filter head in a counterclockwise direction.
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Page 38: Calibrate The Volume Flow Meter
Performing maintenance Calibrate the volume flow meter Check the function of the volume meter yearly by means of measured flow. Measured flow of the volume meter is done as follows: 1. Detach a hose A / B / C at the CTM-E module. -
Page 39: Change The Test Liquid
Performing maintenance Change the test liquid Each use of the CTM differs from any other. This means that it is very difficult to define fixed replacement intervals for the test liquid. The intervals have to be determined by experience for each application. Permanently observe and check the test liquid for smell and appearance. - Page 40 Performing maintenance 1. Detach the return hose "R" at the CTM-E module. 2. Put the open end of the return hose into the container with the test liquid which is to be filled up. 3. Start the "Fill" process via the user interface.
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Page 41: Setting The Level Sensor (B1) To The Test Liquid / Checking Settings
Performing maintenance Setting the level sensor (B1) to the test liquid / Checking settings There is an electronic level sensor In the CTM-SC tank (B1). So that the level sensor works properly, it is necessary to set it up for the test liquid. Here, the following two settings are possible: G 60 Special Water... - Page 42 Performing maintenance Now press the key, appears on the display. Select between the keys until appears in the display, now confirm the key. You are now leaving the default settings menu. When exiting the menu will briefly appear on the display if default settings have been changed.
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Page 43: Removing/Installing The Hood
Performing maintenance Removing/Installing the hood To remove the hood, please proceed as follows: 1. Switch off the CTM-SC at the main switch. 2. Open the control cabinet door and unscrew the two screws (22) of the hand lever (18) using a 4mm Allen wrench 3. - Page 44 Performing maintenance To mount the hood, please proceed as follows: 1. Make sure that the CTM-SC is switched off at the main switch. 2. Connect the ground cable from the housing with the terminal of the cover. 3. Lift the hood (16) with 2 people (one left, one right) onto four bolts on the housing and slide the hood (16) approx.
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Page 45: Locating Spare Parts
Locating spare parts Locating spare parts Use only original spare parts to ensure safe operation of the attachment. When ordering spare parts, always indicate the unit designation (type, material no., serial no., year of manufacture). Designation Part no. Qty** Key to the electro-cabinet "G60 Spezial"... -
Page 46: Technical Data
Technical Data Technical Data 1.41 m Height (without touchscreen) Dimensions Width = 1.15 m Depth = 0.90 (with handle) Empty weight ≈ 250 kg Voltage 100 - 240 V AC (depending on the model code) Power consumption 1100 W Noise level ≤... -
Page 47: Annex
Annex Annex Contact Customer Service / Service For product information or technical support or if you have comments or suggestions concerning this manual, please contact: HYDAC FILTER SYSTEMS GMBH Phone: +49 6897 509 1174 Fax: +49 6897 509 9046 E-mail: filtersystems@hydac.com... -
Page 48: Model Code
Annex Model Code - SC Product CTM = ContaminationTest Module Series = Supply Control Series = Standard Test liquid = G 60 Special = water containing tensides, permissible pH values: 6-10, no completely demineralized water Power supply = 120 V AC / 60 Hz / 1 phase USA / Canada = 230 V AC / 50 Hz / 1 phase Europe... -
Page 49: Hydraulic Circuit
Annex Hydraulic circuit Temp P = 2bar P = 2bar CTM-SC 3xxx series en(us) Page 49 / 56 BeWa CTM-SC 4165698b en-us 2017-05-10.docx 2017-05-10... -
Page 50: Ec Declaration Of Conformity
Annex Item Designation Pre-line filter Bypass filter Breather filter Tank Level sensor Pressure sensor Flow sensor Return sensor M1/P1 Boost pump M2/P2 Suction pump Differential pressure switch Differential pressure switch Output A solenoid valve Output B solenoid valve Output C solenoid valve Return R solenoid valve Bypass solenoid valve Ball valve... -
Page 51: Explanation Of Terms And Abbreviations
Annex Explanation of terms and abbreviations An explanation of terms and abbreviations follows below: °C Degrees Celsius abs. Absolute (e.g. in pressure specifications) Alternating current Air Bleed Ventilation / air bleed port Analysis fluid After spray extraction load test liquid with particles up to the filter membrane. - Page 52 Annex Inlet INLET Inlet Meter Maximum mbar Millibar (1 mbar = 0.001 bar) Minimum Millimeter Nitrile rubber Newton meters (torque specification) Switched off Switched on Outlet OUTLET Outlet Test liquid Fluid for general operation. (flushing fluid / analysis fluid). sec. Second(s) Flushing fluid Test liquid for spray extraction.
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Page 53: Index
Annex Index accident prevention ........10, 15 Imprint ..............2 ambient temperature ..........46 IN 52 Analysis ..............51 Industrial Safety Regulation ........31 Inlet............... 52 INLET ..............52 Inspection ............. 17 installation ...........14, 22, 33, 36 Breather filter ............50 Level sensor .......... - Page 54 Annex select ............6, 38, 39 to shut down ............15 Sensor ..............29 Transport .............. 14 Service ............38, 47 transporting ............16 setting ..............27 troubleshooting ............. 14 Signal word ............9, 10 signal words............9, 10 Solid particle contamination ........51 Specialist personnel ........
- Page 56 HYDAC FILTER SYSTEMS GMBH Industriegebiet 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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