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Summary of Contents for Hydac CTM-EF 3 Series
- Page 1 CTM-EF 3xxx ContaminationTest Module - Extraction Flushing Installation and Maintenance Instructions English (translation of original instructions) Keep for future reference. Documentation no.: 4229881a...
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Page 2: Imprint
Court of Registration: Saarbrücken, HRB 17216 Executive director: Mathias Dieter, Dipl.Kfm. Wolfgang Haering Documentation Representative Mr. Günter Harge c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar Telephone: +49 6897 509 1511 Fax: +49 6897 509 1394 E-Mail: guenter.harge@hydac.com © HYDAC FILTER SYSTEMS GMBH All rights reserved. -
Page 3: Table Of Contents
Content Content Imprint ......................2 Documentation Representative ..............2 Content ......................3 Preface ......................5 Technical Support ..................5 Modifications to the Product ................ 5 Warranty ...................... 5 Using the documentation ................6 Safety Information ..................7 Signal words and their meaning in the safety information and instructions .................... - Page 4 Content Module functional principle ............... 24 Conducting the extraction ................24 Module components ................... 26 Operating the filter membrane holder ............27 Cascading filter membranes ..............29 Labeling the filter membrane ..............30 Connecting the test item ................31 Starting up the module ................32 Clean-room conditions in the analysis chamber - Flushing of the inner chamber ....................
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Page 5: Preface
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. -
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 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: 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 9: Signs Used For Giving Orders
Safety Information Signs used for giving orders These symbols are listed for all safety information and instructions in these operating instructions which indicate particular hazards to persons, property or the environment. Follow the operating and maintenance instructions Wear eye protection Use protective gloves Used prohibitory signs These signs are listed for all safety information and instructions in these... -
Page 10: Others Used Symbols
Safety Information Health hazard Others used symbols The following symbols found you in this operation instructions. Tip for handling the product Tools required Signs used for the required specialist personnel These symbols show the required training/knowledge for installation work and/or maintenance work. Specialist personnel –... -
Page 11: Observe Regulatory Information
Safety Information 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 en(us) CTM-EF 3xxx series Page 11 / 48 BeWa CTM-EF 3xxx 4229881a en-us 2018-03-06.docx 2017-03-06... -
Page 12: Proper/Designated Use
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. Proper/designated use of the product extends to the following: •... -
Page 13: Improper Use Or Use Deviating From Intended Use
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. The user alone, shall assume any and all associated risk. -
Page 14: 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 power unit. 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 15: Wear Suitable Clothing
Safety Information Wear suitable clothing Loose-fitting clothing increases the risk of being caught or being drawn in on rotating parts, and the risk of getting caught on protruding parts. You can be severely injured or killed. Depending on the test liquid, protective gloves and eye protection are to be worn. -
Page 16: Stoppage In An Emergency (Emergency Stop)
Transporting the module Stoppage in an emergency (EMERGENCY STOP) In the event of an emergency, turn the emergency stop switch 90° in a counter- clockwise direction to shut down the entire system. The entire system downstream of this switch will then be de-energized. Transporting the module The module comes wrapped in plastic sheeting or in a wood crate, the latter having to be specifically ordered. -
Page 17: Decoding The Name Plate
Decoding the name plate Decoding the name plate For identification details of the CTM-EF, see the name plate. Item -> Description -> Name plate for module -> Supply voltage, power supply, power consumption Model -> Model code; for details, see page 42 ->... -
Page 18: Checking The Scope Of Delivery
Checking the scope of delivery Checking the scope of delivery The ContaminationTest Module CTM-EF comes packed and pre-assembled. Before commissioning, please check the delivery to make sure it has not been damaged during transport and that it is complete. Designation ContaminationTest Module CTM-EF Supporting sieve for the filter membrane holder Coded plug, 13-pin... -
Page 19: Module Dimensions
Module dimensions Module dimensions The module has the following dimensions. All dimensions in mm. en(us) CTM-EF 3xxx series Page 19 / 48 BeWa CTM-EF 3xxx 4229881a en-us 2018-03-06.docx 2017-03-06... -
Page 20: Preparing The Module For Operation
Preparing the module for operation Preparing the module for operation Setting up the module The module has 4 casters. Before pushing, release the hand brake on the casters. Push the module on the casters into the required position. Always use the handles when pushing the CTM-EF. When you have positioned and aligned the module, set the brakes on all the casters. -
Page 21: Connecting The Ef Module To The Sc
Preparing the module for operation Connecting the EF module to the SC The module comes pre-installed. Before starting it up, please check the following: • Carefully read the operating and maintenance instructions for the CTM- SC and the software operating instructions for the CTM-EF. •... -
Page 22: Electrical Connection Of The Module
Preparing the module for operation Electrical connection of the module The module is supplied with a power plug fitted. DANGER Electric shock Danger of fatal injury Never connect the CTM-EF to a power outlet ► without a ground connection. Before plugging the module into the power socket, make sure that the voltage available corresponds to that specified on its name plate. -
Page 23: Switching The Module On And Off
Switching the module on and off Switching the module on and off When pairing the CTM-SC and the CTM EF, switch the EF module on first, using the main switch. Once you have done this, switch on the CTM-SC module. The SC module will automatically detect that an EF module is connected to it. -
Page 24: Module Functional Principle
Module functional principle Module functional principle The components are connected to the corresponding hoses and flushed out using a defined, clean test liquid. The particles carried by the test liquid are collected on a membrane for subsequent analysis. The results provide information on the type, size and mass of contamination. - Page 25 Module functional principle Remove the filter membrane from the filter membrane holder in order to analyze it. en(us) CTM-EF 3xxx series Page 25 / 48 BeWa CTM-EF 3xxx 4229881a en-us 2018-03-06.docx 2017-03-06...
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Page 26: Module Components
Module components Module components Item Designation Receiver tank Cover Ball valve Main switch Filter membrane holder Mains power cable with male connector Male interface connector for RJ45 control system Connection hoses (A/B/C/R) Sliding grip Guide roll Test item connection hoses (A'/C'/R') Filter membrane holder support en(us) CTM-EF 3xxx series... -
Page 27: Operating The Filter Membrane Holder
Operating the filter membrane holder Operating the filter membrane holder CAUTION Leaking analysis fluid Danger of eye injury/skin irritation Wear eye protection. ► Wear protective gloves. ► Before each extraction procedure, check the ► bayonet connection to ensure that it is seated correctly. - Page 28 Operating the filter membrane holder 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. en(us) CTM-EF 3xxx series Page 28 / 48 BeWa CTM-EF 3xxx 4229881a en-us 2018-03-06.docx 2017-03-06...
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Page 29: Cascading Filter Membranes
Operating the filter membrane holder Cascading filter membranes Cascade filter membranes as shown in the following illustration: Item Designation Coupling Hose connection Diffuser (A diffuser ensures that the analysis liquid is evenly distributed over the entire filter membrane) Upper part of the filter membrane holder Filter membrane, 100 µm Filter membrane, 20 µm... -
Page 30: Labeling The Filter Membrane
Operating the filter membrane holder Labeling the filter membrane Label the filter membranes that you have just removed using a clear and logical system. An example of labeling filter membranes: xyz-1-A-005 Current sample series, component designation Number of membranes created for a measurement series If several equivalent rinsing operations are to be performed for a component, A, B, C and Z are used for creating a random sample. -
Page 31: Connecting The Test Item
Operating the filter membrane holder Connecting the test item CAUTION Leaking analysis fluid Danger of eye injury/skin irritation Wear eye protection. ► Wear protective gloves. ► Always ensure that all ports that are not in ► use are sealed using screw plugs. Connect the test item (X) to ports A‘... -
Page 32: Starting Up The Module
Starting up the module Starting up the module CAUTION Leaking analysis fluid Danger of eye injury/skin irritation Wear eye protection. ► Wear protective gloves. ► Always ensure that all ports that are not in ► use are sealed using screw plugs. Clean-room conditions in the analysis chamber - Flushing of the inner chamber Clean the analysis chamber before beginning a contamination test series. -
Page 33: Performing Maintenance
Performing maintenance Performing maintenance CAUTION "G60 Spezial" test liquid Hazardous to health Make sure that there is adequate ventilation. ► Always wear protective gloves. ► Always wear eye protection. ► en(us) CTM-EF 3xxx series Page 33 / 48 BeWa CTM-EF 3xxx 4229881a en-us 2018-03-06.docx 2017-03-06... -
Page 34: Maintenance Work
Performing maintenance Maintenance work The maintenance and servicing to be performed periodically is described here. The CTM’s serviceability, operational reliability and service life substantially depend on performing maintenance and servicing work regularly and carefully. Check all hoses for leaks or signs of brittleness Visually inspect the electrics. -
Page 35: 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. Every 2 years for multi-shift operation. -
Page 36: Cleaning The Diffuser On The Filter Membrane Holder
Performing maintenance Cleaning the diffuser on the filter membrane holder Clean the filter membrane holder at least once a week. Open the coupling (1) and remove the diffuser (3). 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. -
Page 37: Hydraulic Circuit
Hydraulic circuit Hydraulic circuit B1 U C‘ A‘ R‘ Item Designation Supply port A Supply port B Supply port C Supply port R A‘ Test item port A' C‘ Test item port C' R‘ Test item port R' container Inner chamber flushing Breather filter Membrane holder Level sensor... -
Page 38: Spare Parts And Accessories
Spare parts and accessories Spare parts and accessories Use only original spare parts and accessories. When ordering spare parts, always specify the exact module designation (type, material no., serial no., year of manufacture). CTM-EF 3xxx-… spare parts Designation Part no. Qty.** Level sensor 922173... -
Page 39: Taking The Unit Out Of Operation
Taking the unit out of operation Taking the unit out of operation Drain the unit completely, including all of its components, before decommissioning. Pull out the power plug and securely fasten the hoses and power cord to the unit. Shutting down the unit See chapter "Taking the unit out of operation"... -
Page 40: Technical Details
Technical details Technical details CTM-EF34xx CTM-EF36xx Module dimensions See page 19 See page 19 Maximum test liquid filling volume 40 liter 60 liter Empty weight ≈ 110 kg ≈ 120 kg 230 V AC 230 V AC Power supply (depending on (depending on type) type) -
Page 41: Annex
+49 6897 509 9046 E-Mail: filtersystems@hydac.com Regular inspection and maintenance work is indispensable for ensuring trouble-free operation and long service life for your CTM. HYDAC SYSTEMS & SERVICES GMBH Friedrichsthaler Str. 15A, Werk 13 66540 Neunkirchen-Heinitz Germany Phone: +49 681 509 9518... -
Page 42: Model Code
Annex Model code - EF 0 - M - Z - Z / - Product CTM = ContaminationTest Module Series = Exctraction Flushing Dimensions analysis chamber = 40 liter = 60 liter Version = Standard Test liquid = G 60 Spezial = water containing tensides, permissible pH values: 6-10, no completely demineralized water... -
Page 43: 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 44 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 45: Index
Annex Index In case of emergency ........... 23 Inlet............... 44 INLET ..............44 installation ............10, 20 accident prevention ........11, 15 IP 40 ambient temperature ..........40 Analysis ..............43 Auxiliary personnel ..........14 Level sensor ........... 37, 38 Breather filter ............ - Page 48 HYDAC FILTER SYSTEMS GMBH Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Tel: +49 6897 509 01 Central Fax: +49 6897 509 9046 Technology Fax: +49 6897 509 577 Sales Department Internet: www.hydac.com E-mail: filtersystems@hydac.com...
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