Contamination test module - extraction flushing (48 pages)
Summary of Contents for Hydac CTU 1000 Series
Page 1
CTU 1000 Series Contamination Test Unit Operating and Maintenance Instructions Document No.: 3229578p Valid from series no. up: 2481/2007 Keep for future reference.
Connecting an air extractor ................ 29 Electrical connection of the CTU ............30 Connecting the compressed air .............. 30 Connecting the foot switch ..............31 Parts of the CTU ..................32 CTU 1000 Series en(us) Page 3 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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Changing the CTU 1xx0 filter elements ..........62 Replacing/Reinstalling Filter Elements CTU 1xx1 ........64 Changing the filter elements on the CTU 1xx1 ........65 Calibrating the test liquid meter .............. 68 CTU 1000 Series en(us) Page 4 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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Spare Parts — CTU 1xx1 ................83 Customer Service ..................84 Disposing of the CTU ................. 84 Technical details ..................85 Model code ....................86 Index ......................87 CTU 1000 Series en(us) Page 5 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
After modification or repair work that affects the safety of the product has been carried out on components, the product may not be returned to operation until it has been checked and released by a HYDAC technician. Please notify us immediately of any modifications made to the product whether by you or a third party.
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. CTU 1000 Series en(us) Page 7 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
Danger due to electrical voltage / current Exposed electrical components Danger of electrical shock Danger due to operating pressure Risk of burns due to hot surfaces CTU 1000 Series en(us) Page 8 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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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 1000 Series en(us) Page 9 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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 1000 Series en(us) Page 10 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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.
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• Maintaining adherence to all the instructions contained herein. • Not operating unless the side paneling is fitted. • Not operating unless the analysis chamber is closed. • Performing requisite inspection and maintenance work. CTU 1000 Series en(us) Page 12 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
► media. 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. The user alone, shall assume any and all associated risk.
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 1000 Series en(us) Page 14 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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 1000 Series en(us) Page 15 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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 1000 Series en(us) Page 16 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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Transporting the CTU CTU 1000 Series en(us) Page 17 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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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 clean room of the CTU. CTU 1000 Series en(us) Page 18 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
Store the assembly 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 1000 Series en(us) Page 19 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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 1000 Series en(us) Page 20 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
The ContaminationTest Unit has the following outer dimensions: CTU10xx 985 1170 1290 1500 ≈ 1700 CTU12xx 910 1140 1160 1280 1750 ≈ 2070 All dimensions in mm. CTU 1000 Series en(us) Page 22 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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 1000 Series en(us) Page 23 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
"G60 Spezial" test liquid Hazardous to health Always make sure that there is adequate ► ventilation. Always wear protective gloves. ► Always wear eye protection. ► CTU 1000 Series en(us) Page 24 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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 1000 Series en(us) Page 25 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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Take the support sieve supplied and put it in the membrane holder. CTU 1000 Series en(us) Page 26 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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Experience shows that at least 12 rinsing cycles, using approx. 15 liters, will be required. CTU 1000 Series en(us) Page 27 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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 1000 Series en(us) Page 28 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
CTU. On delivery, a cover is fitted to the CTU extraction connection. CTU 1000 Series en(us) Page 29 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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 1000 Series en(us) Page 30 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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 1000 Series en(us) Page 31 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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 1000 Series en(us) Page 34 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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) counter- clockwise. CTU 1000 Series en(us) Page 36 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
(3) will press the two halves of the membrane holder (with the intermediate ring) together. Make sure that an intermediate ring and two supporting sieves are used when a clip is used. CTU 1000 Series en(us) Page 37 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
Intermediate ring The lower part of the filter membrane holder with a hose connection 1st cascade - coarse 2nd cascade - medium 3rd cascade - fine CTU 1000 Series en(us) Page 38 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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 1000 Series en(us) Page 39 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
Intermediate ring The lower part of the filter membrane holder with a hose connection 1st cascade - coarse 2nd cascade - medium 3rd cascade - fine CTU 1000 Series en(us) Page 40 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
Opening the door while the unit is operating will result in extraction immediately ceasing. Once the door is closed, extraction will continue. A status message will be output on the monitor. CTU 1000 Series en(us) Page 41 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
In the analysis chamber, use a the hose (1) to connect this to the external supply at front on analysis chamber. Install the angled pipe (2) with the outlet pointing down. CTU 1000 Series en(us) Page 42 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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 1000 Series en(us) Page 43 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
The warning can be reset by: Fixing the leak. Empty the collecting pan. Switching off the CTU at the main switch. CTU 1000 Series en(us) Page 44 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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 1000 Series en(us) Page 45 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
Only in this way can you ensure that contamination from the surrounding area is as minimal as possible. CTU 1000 Series en(us) Page 46 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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 information on controlling the process, please refer to CTU 1000 software operating instructions. CTU 1000 Series en(us) Page 47 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
Use the vacuum to suck the test/analysis liquid back into the reservoirs. You can use the "Fill CTU" function in the software. CTU 1000 Series en(us) Page 48 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
"Functional description" chapter. To run a test using spray extraction, the grating piece or another accessory such as the hanging basket can be used in the clean room. CTU 1000 Series en(us) Page 49 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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The test liquid is released by actuating the foot switch. Test liquid is delivered as long as you press the foot switch or the rinsing volume has not be reached. CTU 1000 Series en(us) Page 50 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
Use the vacuum to suck the test/analysis liquid back into the reservoirs. You can use the "Fill CTU" function in the software. CTU 1000 Series en(us) Page 51 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
For the ultrasonic test, replace the grating in the clean room with the proper device, such as a freely hanging basket. Hang the basket retaining frame [a] with the basket [b] in the corresponding thrust bolts in the clean room. CTU 1000 Series en(us) Page 52 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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Testing will be interrupted while the unit cools down. Close the ball valve on the filter membrane holder during the ultrasonic test. CTU 1000 Series en(us) Page 53 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
"No signal“, followed by the screen going dark. Switch off the CTU at the main switch. Wait for at least 20 seconds before you switch the CTU on again. CTU 1000 Series en(us) Page 54 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
Remove the filter membrane for analysis and label it as shown in the example on page Fehler! Textmarke nicht definiert.. CTU 1000 Series en(us) Page 55 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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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 1000 Series en(us) Page 56 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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 1000 Series en(us) Page 57 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
"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 1000 Series en(us) Page 58 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
Change return filters Calibrate the volume flow meter Calibrate the temperature sensor (ultrasound option only) Clean the analysis chamber Cleaning the diffuser for the filter membrane holder CTU 1000 Series en(us) Page 59 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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 1000 Series en(us) Page 60 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
Follow the instructions on page 62 for the element change. CTU 1xx0 CTU 12x0 Item Description [12] The fine filter for the test liquid [13] return line filter CTU 1000 Series en(us) Page 61 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
The filter bowl contains test liquid. Drain this into a suitable receptacle (> 1 liter) and dispose of it properly (in an CTU 1000 Series en(us) Page 62 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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CTU. Secure the two locks by turning them 90° in a clockwise direction using the four-sided hollow socket key. 11. The CTU is ready for operation. CTU 1000 Series en(us) Page 63 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
Replacing/Reinstalling Filter Elements CTU 1xx1 Change the filter elements as specified in the maintenance schedule. The filter dirt indicator is not triggered unless there is a flow through the filters. CTU 1000 Series en(us) Page 64 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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 1000 Series en(us) Page 65 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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Moisten the O-ring with the operating medium. For easy installation of the filter element, wet the O-ring on the filter element with the liquid in use. CTU 1000 Series en(us) Page 66 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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(1) Before screwing the union nut back on, apply lubricant to it. We recommend using white Vaseline as a lubricant HYDAC part no. 632391 (2) Screw the filter bowl over the coupling nut onto the filter head in a counterclockwise direction.
Calibrating the temperature sensor (ultrasound option only) Calibrate the temperature feeler for the ultrasound bath annually. Contact the HYDAC service department for this purpose. Cleaning the analysis chamber Clean the analysis chamber of the CTU1xx0 every week or the CTU1xx1 daily.
CAUTION Electrostatic charging Danger of uncontrolled electrical discharge Always clean the door with a moist, lint free ► cloth. Do not use a dry cloth. ► CTU 1000 Series en(us) Page 69 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
Appearance (greases, oils, preservatives, water have the effect of clouding the test liquid or giving it a yellow tint) See page 35 for achievable negative control values CTU 1000 Series en(us) Page 70 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
This process leaves a small amount of test liquid in the feed & return filters and in the lines. Max. capacity is approx. 20 liters. CTU 1000 Series en(us) Page 71 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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CTU. Close the two locks by turning them 90° in the clockwise direction using the four-sided hollow key. CTU 1000 Series en(us) Page 72 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
1. Start the "Fill system" operation. Service For controlling the process, please refer "CTU 1000 Software — User's Guide." FILL UNIT DRAIN UNIT MANUAL VALVE CONTROL CTU 1000 Series en(us) Page 73 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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5. Wait until the test liquid is completely suctioned out. Stop the "Fill system" process by pressing the stop key. 6. The filling of the system is completed. CTU 1000 Series en(us) Page 74 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
Check the gloves for leaks on a daily basis ► If you find signs of wear, replace the gloves ► immediately Replace the gloves every six months ► CTU 1000 Series en(us) Page 75 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
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 1000 Series en(us) Page 76 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
This information is not designed as a substitute for suitability testing conducted by the end user. Consequently, HYDAC assumes no liability or responsibility for the information provided in this list. Installing gloves Prepare the gloves before installing them in the CTU.
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 1000 Series en(us) Page 78 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
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 1000 Series en(us) Page 79 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
Insert the spring [5] onto the centering spigot of the piston [6]. Screw the upper assembly [3] onto the housing [8] (while doing this, secure the set screw) and securely tighten the upper assembly [3]. CTU 1000 Series en(us) Page 80 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc 2017-04-25...
Filter element for test liquid and return filter (12 / 13) 3510106 Model: N10FM-P001-PES1F, filter grade = 1 µm *) on request, **) Quantity of items included with the CTU. CTU 1000 Series en(us) Page 83 / 92 BeWa CTU1000 3229578p en-us 2017-04-25.doc...
Customer Service Customer Service If you have any questions, suggestions, or encounter any problems of a technical nature, please contact: HYDAC FILTER SYSTEMS GMBH Industriegebiet, Werk 6 D66280 Sulzbach/Saar Fax: +49 6897 509-9046 E-Mail: filtersystems@hydac.com For repair work or complaints/claims, please contact our central customer...
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