Hydac CTU 1 3 Series Operating And Maintenance Instructions Manual
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Hydac CTU 1 3 Series Operating And Maintenance Instructions Manual

Hydac CTU 1 3 Series Operating And Maintenance Instructions Manual

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CTU 1x3x / CTU 1x4x
ContaminationTest Unit
Operating and Maintenance Instructions
English (translation of original instructions)
Document No. : 4093420f
Follow these instructions for proper and safe use.
Keep for future reference.

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Summary of Contents for Hydac CTU 1 3 Series

  • Page 1 CTU 1x3x / CTU 1x4x ContaminationTest Unit Operating and Maintenance Instructions English (translation of original instructions) Document No. : 4093420f Follow these instructions for proper and safe use. Keep for future reference.
  • Page 2 Executive directors: Mathias Dieter, Dipl.Kfm. Wolfgang Haering Documentation Representative The contact data of the Documentation Representative is: Günter Harge c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar Germany Telephone: +49 6897 509 1511 Fax: +49 6897 509 1394 E-mail: guenter.harge@hydac.com Date of printing: 9/3/2021 ©...

  • Page 3: Table Of Contents

    HYDAC FILTER SYSTEMS GMBH Table of Contents Table of Contents 1 General.......................... 7 1.1 Target group of the manual.................. 7 1.2 Illustrations in the manual ................... 8 1.2.1 Illustration on the title page................ 8 1.2.2 Representation of requirements ................  9 1.2.3 Representation of procedural instructions ............ 9 1.2.4 Representation of intermediate results/results ..........
  • Page 4 Table of Contents HYDAC FILTER SYSTEMS GMBH 3.4 Technical data...................... 31 3.5 Decoding the name plate .................. 33 3.5.1 Model Code .....................  34 3.6 Dimensions ....................... 35 3.7 Components/operating elements ................ 37 3.7.1 Control panel .................... 38 4 Transporting / Storing the extraction unit................ 39 4.1 Transporting with a fork lift truck ................ 40...
  • Page 5 HYDAC FILTER SYSTEMS GMBH Table of Contents 6.5.1 Creating cascades...................  66 6.5.2 Filter membrane holder with quick fastener - Operating the CTMH .... 68 6.5.3 Filter membrane holder with a screw cap............ 72 6.5.4 Operating the filter membrane holder with clamp.......... 74 6.6 Labeling the filter membrane .................. 76...
  • Page 6 Table of Contents HYDAC FILTER SYSTEMS GMBH 7.10 Calibrating the temperature probe (optional with ultrasonic)........ 95 7.11 Cleaning the diffuser on the filter membrane holder .......... 96 7.12 Checking the calibration of the flow meter .............. 97 7.13 Checking the protective gloves ................. 98 7.13.1 Permeation time according to EN 374-3............

  • Page 7: General

    HYDAC FILTER SYSTEMS GMBH General | 1 1 General Before you use this product for the first time, read this manual at least up to the chapter "Operation". If you would like to carry out maintenance or troubleshooting, you can find the procedure in the respective chapters.

  • Page 8: Illustrations In The Manual

    1 | General HYDAC FILTER SYSTEMS GMBH 1.2 Illustrations in the manual You will find illustrations in this manual. You can find details re- garding these in the following chapters. 1.2.1 Illustration on the title page You will find the following information on the title page of this man-...

  • Page 9: Representation Of Requirements

    HYDAC FILTER SYSTEMS GMBH General | 1 The document no. with the index (4) is meant for identifying and reordering the manual. The index is incremented every time the manual is revised or changed. The manual contains a table of contents, a list of tables and fig- ures, an index and a glossary.

  • Page 10: Representation Of Intermediate Results/Results

    1 | General HYDAC FILTER SYSTEMS GMBH 1.2.4 Representation of intermediate results/results In the case of some activities, it is necessary to carry out work steps with intermediate results and end results. Intermediate results are the consequence of activities; they are marked with an indented arrow.

  • Page 11: Supplementary Symbols

    HYDAC FILTER SYSTEMS GMBH General | 1 1.2.5 Supplementary symbols You will find the following symbols in the manual as additional de- tails: u ## Cross reference to a page / a chapter / a section or another document. Glossary Terms in grey are explained in detail in the glossary, a chapter at the end of the manual.

  • Page 12: Signal Words And Their Meaning In The General Safety Information

    1 | General HYDAC FILTER SYSTEMS GMBH 1.2.7 Signal words and their meaning in the general safety information 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.

  • Page 13: Exclusion Of Liability / Warranty

    HYDAC FILTER SYSTEMS GMBH General | 1 1.3 Exclusion of liability / warranty For the warranty provided by us, please refer to our terms of deliv- ery. They are made available to you at the conclusion of the con- tract at the latest. In addition, you will find these under www.hydac.com ->...

  • Page 14: Safety

    2 | Safety HYDAC FILTER SYSTEMS GMBH 2 Safety The product is designed as safe. In spite of that, there is danger in some actions that can only be avoided by using the right proce- dures. These correct procedures and points, which must be followed, are described in this manual.
  • Page 15 HYDAC FILTER SYSTEMS GMBH Safety | 2 – To provide the necessary protective equipment to the person- Personnel who work with the product must be aware of the dan- gers involved in handling it, must be over 14 years of age and must be without any physical impediments in regard to the indus- trial environment.

  • Page 16: Tab. 2 Target Group / Required Personnel Qualification

    2 | Safety HYDAC FILTER SYSTEMS GMBH Activity Personnel Knowledge Knowledge of decon- tamination of con- taminants is required. Knowledge of recy- cling is required. transport Commis- Specialist personnel - Service personnel / sioning, Operation, Service / Administra- Administrator / HY- Troubleshooting DAC Service.

  • Page 17: Hazard Symbols / Pictograms

    HYDAC FILTER SYSTEMS GMBH Safety | 2 2.2 Hazard symbols / pictograms The following are the safety symbols / pictograms in this manual. They indicate specific dangers to persons, property or to the sur- roundings. Observe these safety symbols / pictograms and act with particular caution in such cases.
  • Page 18 2 | Safety HYDAC FILTER SYSTEMS GMBH Pull the power plug before opening Wear eye protection. Use protective gloves. Wear safety shoes. Used GHS symbols These symbols can be found for all safety and warning instructions in this manual which indicate particular dangers to persons, prop- erty or the environment.
  • Page 19 HYDAC FILTER SYSTEMS GMBH Safety | 2 Signs used for the required specialist personnel These symbols show the required training/knowledge for installa- tion work and/or maintenance work. Specialist personnel / operators Such persons have had the 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 dangers.

  • Page 20: Danger Notifications

    2 | Safety HYDAC FILTER SYSTEMS GMBH 2.3 Danger notifications The following residual risks can occur in the various life phases of the product: Life phase - Transport / Storage The following risks could arise during the commissioning / opera-...
  • Page 21 HYDAC FILTER SYSTEMS GMBH Safety | 2 Dangers with test liquid G60 Spezial / Feroclean L261 WARNING Static loading of components Discharge / Explosion uOnly use hoses with suitable conductivity. uGround the test item if it is on a support that has an insulating effect.
  • Page 22 2 | Safety HYDAC FILTER SYSTEMS GMBH CAUTION Door is not correctly held Danger of crushing uHold the door with both hands and close it slowly. Only for Variant R CAUTION Leakage of test liquid under pressure Injury to the eyes uAlways wear eye protection.
  • Page 23 HYDAC FILTER SYSTEMS GMBH Safety | 2 WARNING The test bench is pressurized Danger of bodily injury uSwitch off the extraction unit at the main switch. uThe extraction unit is depressurized after being switched off. CAUTION Test liquid G60 Spezial or Feroclean L261 Health hazard uFollow all the instructions when handling the test liquid.

  • Page 24: Safety Marking

    2 | Safety HYDAC FILTER SYSTEMS GMBH 2.4 Safety marking In this chapter, you will find information on the placement of safety symbols/pictograms on the extraction unit. Replace the damaged or no more recognizable/legible safety symbols/pictograms imme- diately. Pull the safety symbol/pictogram off the extraction unit, re- move possible present adhesive residues with a cleaner suitable for that purpose.

  • Page 25: Observing Regulatory Information

    HYDAC FILTER SYSTEMS GMBH Safety | 2 2.5 Observing regulatory information Observe the following regulatory information and directives: – Legal and local regulations for accident prevention – Legal and local regulations for environmental protection and environmental requirements – Country-specific regulations, organization-specific regulations –...

  • Page 26: Shutdown In An Emergency (Emergency Stop)

    2 | Safety HYDAC FILTER SYSTEMS GMBH 2.8 Shutdown in an emergency (EMERGENCY STOP) In an emergency, disconnect the extraction unit and any modules from the power supply. Switch off the extraction unit with the main switch. The extraction unit is deenergized downstream of the main switch.

  • Page 27: Performance And Product Description

    HYDAC FILTER SYSTEMS GMBH Performance and product description | 3 3 Performance and product description The CTU is an extraction unit for the determination of the surface cleanliness of components and systems. The components are flushed in a closed analysis chamber using a specifically clean test liquid.

  • Page 28: Intended Use

    3 | Performance and product description HYDAC FILTER SYSTEMS GMBH 3.2 Intended Use Use the unit only for the application described in the following. The ContaminationTest Unit CTU is an extraction unit for analyz- ing the technical cleanliness of components and systems in accor-...
  • Page 29 HYDAC FILTER SYSTEMS GMBH Performance and product description | 3 NOTICE Exceeding the permissible loading capacity / payload The the analysis chamber will be damaged uNote the permissible loading capacity / payload of the test item for evenly distributed load, not for point loading.

  • Page 30: Improper Use Or Use Deviating From Intended Use

    3 | Performance and product description HYDAC FILTER SYSTEMS GMBH 3.3 Improper use or use deviating from intended Any other use or extended use shall not be considered intended use. The manufacturer does not accept any liability for damage re- sulting from such use.

  • Page 31: Technical Data

    HYDAC FILTER SYSTEMS GMBH Performance and product description | 3 3.4 Technical data Depending on the size and version, the CTU has varying technical data. Dimensions, CTU 10xx Height = 1800 mm Width = 1000 mm Depth = 900 mm Dimensions, CTU 12xx Height = 1800 mm...

  • Page 32: Tab. 4 Technical Data - Ctu

    3 | Performance and product description HYDAC FILTER SYSTEMS GMBH Permissible storage temperature 0 … 50°C range Permissible ambient conditions Air and temperature similar to laboratory conditions, ade- quately ventilated room Permissible air conditions during Dust-free, salt-free air, not near storage oxidizing substances (rust film) Permitted relative air humidity ≤ 80% (non condensing)

  • Page 33: Decoding The Name Plate

    HYDAC FILTER SYSTEMS GMBH Performance and product description | 3 3.5 Decoding the name plate You will find identification details of the extraction unit on the name plate. Fig. 4: Decoding the name plate Item -> Description -> Name plate of the extraction unit ->...

  • Page 34: Model Code

    3 | Performance and product description HYDAC FILTER SYSTEMS GMBH 3.5.1 Model Code The model code is created according to the following model code. CTU 1 0 3 0 - M - Z - Z / - Type CTU = ContaminationTest Unit...

  • Page 35: Dimensions

    HYDAC FILTER SYSTEMS GMBH Performance and product description | 3 3.6 Dimensions Depending on the model, the ContaminationTest Unit has different outer dimensions and different dimensions of the analysis cham- ber. The ContaminationTest Unit has the following outer dimensions: Fig. 6: Dimensions - CTU...

  • Page 36: Fig. 7 Dimensions Of The Analysis Chamber Of The Ctu

    3 | Performance and product description HYDAC FILTER SYSTEMS GMBH The ContaminationTest Unit has the following dimensions for the analysis chamber: Fig. 7: Dimensions of the analysis chamber of the CTU CTU10xx 2x Ø180 CTU12xx 2x Ø180 All dimensions in mm. 36 / 124...

  • Page 37: Components/Operating Elements

    HYDAC FILTER SYSTEMS GMBH Performance and product description | 3 3.7 Components/operating elements The extraction unit has the following operating elements/compo- nents: Fig. 8: Components/operating elements (example: CTU1200) 1 Analysis chamber with door 2 Connection for the spray extraction/Flushing of inner cham-...

  • Page 38: Control Panel

    3 | Performance and product description HYDAC FILTER SYSTEMS GMBH 11 Control panel, for details see Control panel [} 38] 12 Foot switch with connection cable 13 Guide rolls with brake 14 Guide rolls with brake 15 Forklift lugs for transport (only CTU 12xx) 3.7.1 Control panel...

  • Page 39: Transporting / Storing The Extraction Unit

    HYDAC FILTER SYSTEMS GMBH Transporting / Storing the extraction unit | 4 4 Transporting / Storing the extraction unit Through correct handling during transportation and storage, you will maintain the life cycle of the extraction unit. Move the extraction unit by pulling or pushing the handle.

  • Page 40: Transporting With A Fork Lift Truck

    4 | Transporting / Storing the extraction unit HYDAC FILTER SYSTEMS GMBH 3. Disconnect the power plug and all the electric/hydraulic con- nections, wind up the cables/hoses and fasten them to the extraction unit. 4. Remove all moveable, loose and components sensitive to vi- bration e.g.

  • Page 41: Fig. 12 Packaging The Extraction Unit

    HYDAC FILTER SYSTEMS GMBH Transporting / Storing the extraction unit | 4 NOTICE Incorrect positioning of the slings The extraction unit will be damaged uSecure the extraction unit with suitable slings. uWhen doing this, ensure that the slings are routed and stretched only over the body and not over the analysis cham- ber / drip tray.

  • Page 42: Setting Up/Assembling/Commissioning

    5 | Setting up/assembling/commissioning HYDAC FILTER SYSTEMS GMBH 5 Setting up/assembling/commissioning This chapter provides instructions on the setting up, assembly and commissioning of the extraction unit. 5.1 Setting up the extraction unit In order to set up the extraction unit, observe the following points: –...

  • Page 43: Fig. 13 Moving Using The Handle

    HYDAC FILTER SYSTEMS GMBH Setting up/assembling/commissioning | 5 Fig. 13: Moving using the handle BeWa CTU1x3x-CTU1x4x 4093420f en-us web 43 / 124...

  • Page 44: Making The Electrical Connections

    5 | Setting up/assembling/commissioning HYDAC FILTER SYSTEMS GMBH 5.2 Making the electrical connections The extraction unit is delivered ready for connection with a power plug. 1. Before plugging in the power plug, compare the voltage in- formation provided on the name plate of the extraction unit with the available voltage from the power supply.

  • Page 45: Installing / Connecting The Components

    HYDAC FILTER SYSTEMS GMBH Setting up/assembling/commissioning | 5 5.2.2 Installing / Connecting the components This chapter contains information on the installation and connec- tion of all the associated components to the extraction unit. 1. Place the monitor at the top of the housing of the extraction unit.

  • Page 46: Fig. 16 Signal Cable Of The Pc <-> Monitor, Keyboard, Etc

    5 | Setting up/assembling/commissioning HYDAC FILTER SYSTEMS GMBH Fig. 16: Signal cable of the PC <-> monitor, keyboard, etc. 4. The installation and connection of all the components is complete. 46 / 124 BeWa CTU1x3x-CTU1x4x 4093420f en-us web...

  • Page 47: Suctioning The Machine Room

    HYDAC FILTER SYSTEMS GMBH Setting up/assembling/commissioning | 5 5.3 Suctioning the machine room The back of the extraction unit has a suction connection of Ø 100 mm for the machine room. For this, follow the safety data sheet of the test liquid being used.

  • Page 48: Connecting An Air Extractor

    5 | Setting up/assembling/commissioning HYDAC FILTER SYSTEMS GMBH 5.3.1 Connecting an air extractor The scope of delivery and the type of extraction vary depending on the model. Please note the following descriptions for the respec- tive model. 5.3.1.1 Suctioning the machine room of the CTU 1x3x If there is an air extraction system at the installation location, this can be attached to the connection on the rear side of the CTU.

  • Page 49: Suctioning The Machine Room And Analysis Chamber Of The Ctu1X4X

    HYDAC FILTER SYSTEMS GMBH Setting up/assembling/commissioning | 5 5.3.1.2 Suctioning the machine room and analysis chamber of the CTU1x4x If there is an extraction system at the installation location, this can be attached to the connection on the CTU. At the time of delivery of the CTU 1x4x, the air exhaust port of Ø 100 mm is pre-...

  • Page 50: Fig. 19 Suctioning Of The Analysis Chamber Of The Ctu1X4X

    5 | Setting up/assembling/commissioning HYDAC FILTER SYSTEMS GMBH Fig. 19: Suctioning of the analysis chamber of the CTU1x4x 50 / 124 BeWa CTU1x3x-CTU1x4x 4093420f en-us web...

  • Page 51: Connecting The Compressed Air Connection

    HYDAC FILTER SYSTEMS GMBH Setting up/assembling/commissioning | 5 5.4 Connecting the compressed air connection The extraction unit requires a compressed air connection for oper- ation. For the compressed air requirements, see Technical data [} 31]. 1. Connect the quick-action coupling of the compressed air supply to the standard connection nipple of the low-pressure series DN 7.2 on the extraction unit.

  • Page 52: Commissioning

    5 | Setting up/assembling/commissioning HYDAC FILTER SYSTEMS GMBH 5.6 Commissioning ü All the previously described work is required for commission- ing. The subsequent steps for commissioning given below. 1. Install the protective gloves from the scope of delivery, for details see Installing / Removing the protective gloves [} 100].

  • Page 53: Operation

    HYDAC FILTER SYSTEMS GMBH Operation | 6 6 Operation Select the different operating modes with the different parameters on the user interface and start them by approving them on the op- erator display or using the foot switch depending on the setting.

  • Page 54: Switching The Extraction Unit On / Off

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.1 Switching the extraction unit on / off The extraction unit has a PC for controlling and documenting the extraction. This means that it is necessary to start up and shut down the extraction unit. The procedure for switching the extrac- tion unit on and off properly is described below.

  • Page 55: Opening/Closing The Door

    HYDAC FILTER SYSTEMS GMBH Operation | 6 6.2 Opening/closing the door When taking samples, lock the door with all the door locks to pre- vent the test liquid from leaking. The design of the door with door locks varies depending on the model.

  • Page 56: Selecting The Operating Modes

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.3 Selecting the operating modes Depending on the equipment, the extraction unit provides different operating modes as described in the following chapters. WARNING Test liquid G60 Spezial or Feroclean L261 - Flammable gas-air mixture in the analysis chamber Danger of bodily injury uOpen fires or smoking are prohibited in the vicinity.

  • Page 57: Fig. 22 Spray Gun (A) With Nozzle (B)

    HYDAC FILTER SYSTEMS GMBH Operation | 6 Fig. 22: Spray gun (A) with nozzle (B) (A) Spray gun (B) Nozzle Fig. 23: Analysis chamber with grating BeWa CTU1x3x-CTU1x4x 4093420f en-us web 57 / 124...

  • Page 58: Fig. 24 Analysis Chamber With Basket Mount

    6 | Operation HYDAC FILTER SYSTEMS GMBH Fig. 24: Analysis chamber with basket mount The dimensions of the hook-in basket are 220 x 110 x 40 mm. Mesh width = 4 mm. Proceed as follows for spray extraction: ü Determine the negative control value; for details, see Deter- mining the negative control value - Settings/parameters [} 64]...
  • Page 59 HYDAC FILTER SYSTEMS GMBH Operation | 6 5. Then remove the filter membrane for analysis / evaluation. 6. Open the door and remove the test item. O The spray extraction is complete. BeWa CTU1x3x-CTU1x4x 4093420f en-us web 59 / 124...

  • Page 60: Running Flushing Of Inner Chamber

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.3.2 Running Flushing of inner chamber Flush the inner chamber /analysis chamber in a defined manner using the Flushing of inner chamber operating mode. This operat- ing mode always precedes a sampling to determine the negative control value.

  • Page 61: Ultrasonic Extraction (Optional)

    HYDAC FILTER SYSTEMS GMBH Operation | 6 6.3.3 Ultrasonic extraction (optional) The principle of ultrasonic effect is the conversion of the electrical energy generated by the high-frequency generator into mechanical vibrations by means of the ultrasonic vibration systems. The vibrations transmitted to the test liquid cause microscopic cav- ities to be formed constantly, which then always implode.

  • Page 62: Fig. 27 Analysis Chamber With Mounts

    6 | Operation HYDAC FILTER SYSTEMS GMBH NOTICE Ultrasonic extraction without a suitable device The the analysis chamber will be damaged uFill adequate test liquid in the analysis chamber. uPlace the test item in the analysis chamber only with the corre- sponding jig.
  • Page 63 HYDAC FILTER SYSTEMS GMBH Operation | 6 The minimum fill quantity of the test liquid for ultrasonic extraction is defined by the defined minimum value of the filling quantity on the user interface. Shut the ball valve on the filter membrane holder before beginning the ultrasonic extraction.

  • Page 64: Determining The Negative Control Value - Settings/Parameters

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.4 Determining the negative control value - Settings/parameters Determining the negative control value is an indispensable part of the measurement technology analysis within a decay measure- ment. This value represents the sum of all impurities not originat- ing from the component and is therefore of significant importance.

  • Page 65: Tab. 7 Effort To Achieve The Negative Control Value

    HYDAC FILTER SYSTEMS GMBH Operation | 6 Requisite effort Particle size Cleaning time Cleaning time [h] after shut- [h] after shut- down ≤ 24 h down > 24 h High ≤ 100 µm* 1.5 … 4 3 … 5 Tab. 7: Effort to achieve the negative control value BeWa CTU1x3x-CTU1x4x 4093420f en-us web...

  • Page 66: Cascading The Filter Membranes / Changing The Filter Membranes

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.5 Cascading the filter membranes / changing the filter membranes Depending on the filter membrane holder, the procedure for cas- cading or changing the filter membranes varies. The handling of different filter membrane holders is described below.

  • Page 67: Fig. 28 Cascading The Filter Membrane Holder

    HYDAC FILTER SYSTEMS GMBH Operation | 6 Item Description Coupling Hose connection Diffuser The diffuser - allows for the even distribution of the test liquid over the entire surface of the filter mem- brane. Upper part of the filter membrane holder Filter membrane, 100 µm...

  • Page 68: Filter Membrane Holder With Quick Fastener - Operating The Ctmh

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.5.2 Filter membrane holder with quick fastener - Operating the CTMH To remove the filter membrane, proceed as follows: Inserting the filter membrane ü Shut the ball valve upstream of the filter membrane holder.
  • Page 69 HYDAC FILTER SYSTEMS GMBH Operation | 6 7. If additional cascades are required, adjust the lower part for the suitable grid. When assembling two cascades, select the middle grid. 8. When assembling three cascades, select the upper grid. 9. Seal the filter membrane holder by turning it clockwise by 90°.
  • Page 70 6 | Operation HYDAC FILTER SYSTEMS GMBH Removing the filter membrane ü Wait until the analysis fluid has been fully extracted. ü End the extraction via the user interface. ü Shut the ball valve upstream of the filter membrane holder.
  • Page 71 HYDAC FILTER SYSTEMS GMBH Operation | 6 19. Seal the filter membrane holder by turning it clockwise by 90°. NOTICE! Do not use any tools O The removal of the filter membrane is complete. BeWa CTU1x3x-CTU1x4x 4093420f en-us web 71 / 124...

  • Page 72: Filter Membrane Holder With A Screw Cap

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.5.3 Filter membrane holder with a screw cap To remove the filter membrane, proceed as follows: ü Wait until the analysis fluid has been fully extracted. ü End the extraction via the user interface.
  • Page 73 HYDAC FILTER SYSTEMS GMBH Operation | 6 4. Fit a new filter membrane onto the supporting sieve. 5. Lift the union nut. Position the lower part together with the filter membrane flush underneath the upper part. 6. Turn the union nut tightly in the clockwise direction.

  • Page 74: Operating The Filter Membrane Holder With Clamp

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.5.4 Operating the filter membrane holder with clamp To insert the filter membrane, proceed as follows: Inserting the filter membrane ü Shut the ball valve upstream of the filter membrane holder. 1. Squeeze the handles (1) of the clip together.
  • Page 75 HYDAC FILTER SYSTEMS GMBH Operation | 6 NOTICE Operation without an intermediate ring / supporting sieve in the fil- ter membrane holder Leak in the filter membrane holder uThe filter membrane holder is sealed effectively only when: - vacuum is applied - a supporting sieve with a filter membrane is inserted uIt is not possible to use two intermediate rings.

  • Page 76: Labeling The Filter Membrane

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.6 Labeling the filter membrane Label the filter membranes that you have just removed using a clear and logical system. For example: xyz-1-A-005 Tab. 9: Example - Marking of filter membranes Marking Description Running test item series/running test item...

  • Page 77: Overview Of The Variants / Options

    HYDAC FILTER SYSTEMS GMBH Operation | 6 6.7 Overview of the variants / options The operation / description of additional optional variants for the CTU is given below. Note the model code of the extraction unit when referring to it.

  • Page 78: Fig. 29 Variant A - Add Flushing

    6 | Operation HYDAC FILTER SYSTEMS GMBH Fig. 29: Variant A - Add flushing 78 / 124 BeWa CTU1x3x-CTU1x4x 4093420f en-us web...

  • Page 79: Variant F - Flushing

    HYDAC FILTER SYSTEMS GMBH Operation | 6 6.7.2 Variant F - Flushing In variant F, ports A, B, C, R are connected externally to the exter- nal port panel (2). Use the Info window of the operating software to check. CTM-E…...

  • Page 80: Variante -Ea - Extraction Air

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.7.3 Variante -EA - Extraction Air The EA variant is a variant in which compressed air is guided through port A into the analysis chamber. Air extraction is per- formed by means of this port in the analysis room. Air extraction has been described in volume VDA19-1 since 2015.

  • Page 81: Fig. 31 Variant -Ea

    HYDAC FILTER SYSTEMS GMBH Operation | 6 Fig. 31: Variant –EA BeWa CTU1x3x-CTU1x4x 4093420f en-us web 81 / 124...

  • Page 82: Variant S2 - Changing Over The Vacuum

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.7.4 Variant S2 - Changing over the vacuum Switch the vacuum either to the filter membrane holder (standard) (1) or to the additional connection in the analysis chamber (2) to empty the test item.

  • Page 83: Fig. 34 External Flushing Connections

    HYDAC FILTER SYSTEMS GMBH Operation | 6 6.7.5 Option - Connecting external flushing ports (only CTU1xxx-x-x-R) It is possible, for example, to flush a test item outside the analysis chamber using the external ports on the analysis chamber. CAUTION Leakage of test liquid under pressure Injury to the eyes uAlways wear eye protection.

  • Page 84: Option - Sensor To Signal That The Collecting Pan Is Full

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.7.6 Option - Sensor to signal that the collecting pan is full The optional sensor (1) is connected electrically to the float switch (2) in the collecting pan. If there is a leak in the extraction unit, the test liquid will collect in the collecting pan and the float switch will trigger the warning contact for the visual / acoustic sensor.

  • Page 85: Carrying Out The Maintenance / Inspection

    HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 7 7 Carrying out the maintenance / inspection This chapter contains the description of the required maintenance activities and the qualifications of the staff needed to carry out these tasks.

  • Page 86: Maintenance Table

    7 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH Owner's information on the "products under pressure" According to Diagram 3, Annex II of the European Directive 2014/68/EU on placing pressure equipment on the market, the in- stalled containers are pressure equipment according to Article 4, Paragraph 3 of the same Directive and therefore excluded from its field of application.

  • Page 87: Cleaning The Analysis Chamber

    HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 7 Additional informa- tion 7.12 Checking the cali- bration of the flow meter Checking the hoses 7.15 Preparing for changing the filter element 7.10 Calibrating the temperature probe (optional with ultra-...

  • Page 88: Cleaning The Analysis Chamber In The Case Of Test Liquid - Water With Surfactants

    7 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH For cleaning the analysis chamber, we recommend a moist, clean, commercial microfiber cloth. Finish cleaning the analysis chamber with a long Flushing of inner chamber. 7.2.1 Cleaning the analysis chamber in the case of test...

  • Page 89: Maintaining An Electrostatically Charged Door

    HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 7 CAUTION Electrostatic charging of the door with test liquid G60 Special/Fe- roclean L261 Danger of uncontrolled electrostatic discharge and ignition of a gas-air mixture. uAlways clean the door with a moist, lint-free cloth and com- monly available antistatic materials.

  • Page 90: Dismounting / Installing The Side Cover

    7 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 7.4 Dismounting / Installing the side cover Proceed as follows to dismount the side cover: 1. Loosen the two twist locks by 90° counterclockwise. 2. Tip the cover ≈ 15° to the top away from the housing.
  • Page 91 HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 7 ü Switch on the test bench and select "Empty system" in the user interface. Have a collection container (≈ 20 liters) ready to collect the test liquid. 1. Dismount the right side paneling.

  • Page 92: Filling The Test Liquid / Filling The Extraction Unit

    7 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 7.5.2 Filling the test liquid / Filling the extraction unit The extraction unit must be filled during initial start-up and during operation if the test liquid level is too low.
  • Page 93 HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 7 Filling the CTU1x4x/CTU1x5x To fill the extraction unit/to top up the test liquid, proceed as fol- lows: ü Have the container with the test liquid ready. 5. Detach the plug with the breather filter from the ball valve.

  • Page 94: Avoiding The Mixing Of Test Liquids - Flushing The Extraction Unit

    7 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 7.5.3 Avoiding the mixing of test liquids - Flushing the extraction unit If you want to use the same test liquid for operation as in the previ- ous operation, the mixing of test liquids is not critical.

  • Page 95: Replacing Hoses/Plastic Pipe

    HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 7 7.9 Replacing hoses/plastic pipe Replace the hoses/plastic pipe at least once every 2 years when working multiple shifts 24/7 or at least once every 6 years for sin-...

  • Page 96: Cleaning The Diffuser On The Filter Membrane Holder

    7 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 7.11 Cleaning the diffuser on the filter membrane holder Clean the diffuser on the filter membrane holder at least once a week. Fig. 36: Cleaning the diffuser 1 Coupling...

  • Page 97: Checking The Calibration Of The Flow Meter

    A deviation of +/- 5 % (4.75 … 5.25 liters) is below the error limit. If the deviation is larger, calibration will be required. To do this, contact HYDAC Service. O Checking the calibration of the flow meter is complete. BeWa CTU1x3x-CTU1x4x 4093420f en-us web...

  • Page 98: Checking The Protective Gloves

    7 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 7.13 Checking the protective gloves The gloves are subject to wear due to both mechanical and chemi- cal use. Therefore, it is imperative to check them regularly and to replace them.
  • Page 99 HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 7 7.13.1 Permeation time according to EN 374-3 The EN 374-3 standard pertains to determining the resistance pro- vided by the material of protective gloves against the permeation of nongaseous, potentially hazardous chemicals when subjected to continuous contact.
  • Page 100 7 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH Protection Index Class 1 Class 2 Class 3 Class 4 Class 5 Class 6 > 10 min- > 30 min- > 60 min- > 120 > 240 > 480 utes utes utes minutes minutes...

  • Page 101: Installing / Removing The Protective Gloves

    HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 7 Fig. 37: Preparing the protective gloves Insert the protective gloves through the inlet opening on the analy- sis chamber. Then stretch the led end of the glove over the inlet opening from the outside.

  • Page 102: Preparing For Changing The Filter Element

    7 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 7.15 Preparing for changing the filter element To prepare to change the filter element, proceed as follows: 1. Switch off the extraction unit with the main switch. For de- tails, see Switching the extraction unit on / off [} 54]...
  • Page 103 HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 7 1. Have a suitable container (1) ready to collect any leaking op- erating medium. Carry out the pressure release of the filter housing. To do this, carefully open the drain plug (2) on the filter bowl...
  • Page 104 7 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 4. Clean the filter bowl and sealing surface. 5. Clean the sealing surface on the filter head. 6. Check the O-ring on the cover for damage and replace it if necessary.
  • Page 105 HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 7 10. Before installing the union nut, coat the thread with lubricant (1). Recommended lubricant: -Plastic nut -> Vaseline, white - Stainless steel nut -> lubricant containing a slip additive (MoS2) 11.

  • Page 106: Eliminating Errors

    8 | Eliminating errors HYDAC FILTER SYSTEMS GMBH 8 Eliminating errors The following errors can occur during operation: Error Possible causes Solution To be car- ried out by The extraction unit The filling level of Check if the ball valve up-...
  • Page 107 HYDAC FILTER SYSTEMS GMBH Eliminating errors | 8 Error Possible causes Solution To be car- ried out by Set the pressure control valve to 6.5 bar. The cable to the Replace the faulty cable. pressure sensor is broken. The pressure sensor Replace the pressure sen- is faulty.

  • Page 108: Tab. 12 Eliminating Errors

    8 | Eliminating errors HYDAC FILTER SYSTEMS GMBH Error Possible causes Solution To be car- ried out by The door contact is Replace the door contact. faulty. The compressed air Cable break to the Replace the faulty cable. control is not work- proportional valve.

  • Page 109: Decommissioning / Disposal

    HYDAC FILTER SYSTEMS GMBH Decommissioning / Disposal | 9 9 Decommissioning / Disposal In the following chapters, you will be provided with information re- garding temporary shutdown/final decommissioning and disposal of the product. 9.1 Temporary shutdown If the product is being temporarily shut down, the following mea- sures are adequate: 1.

  • Page 110: A Appendix

    A | Appendix HYDAC FILTER SYSTEMS GMBH A Appendix This Appendix contains additional information on the product. A.1 Finding spare parts / accessories Use only original spare parts and accessories. When ordering spare parts, always specify the exact product designation (type, part number, serial number, year of manufacture).

  • Page 111: Tab. 13 Spare Parts List - Ctu1Xxx

    HYDAC FILTER SYSTEMS GMBH Appendix | A Designation Part no. Quan- tity** - Cutting ring, Ø 6 mm 6017174 Tygothane hose, Ø 6.4x9.6 mm 6023627 1.5 m - 1-ear terminal 6069299 Plastic pipe, Ø 8x1 mm 6034766 10 m - Insert sleeve Ø 8/6 mm 630116 - Cutting ring, Ø 8 mm...

  • Page 112: Tab. 16 Spare Parts For The Filter Membrane Holder Ø 47 Mm, Ctmh

    A | Appendix HYDAC FILTER SYSTEMS GMBH Description Part no. Qty. O-ring 604122 Tab. 16: Spare parts for the filter membrane holder Ø 47 mm, CTMH 112 / 124 BeWa CTU1x3x-CTU1x4x 4093420f en-us web...

  • Page 113: Finding Accessories

    HYDAC FILTER SYSTEMS GMBH Appendix | A A.1.1 Finding accessories The following accessories are available for the product. Please note that the selection of accessories depends on the test liquid used. Designation Part no. Quan- tity** Flat fan nozzle 6263519 Round nozzle, Ø...

  • Page 114: Contacting Customer Service

    Hotline, product support, Customer Service, Branches, service partners for maintenance, repair and spare parts can be found, always updated, on our homepagewww.hydac.com. HYDAC SYSTEMS & SERVICES GMBH Friedrichsthaler Str. 15, Werk 13 66450 Neunkirchen - Heinitz Germany...

  • Page 115: Ec Declaration Of Conformity

    HYDAC FILTER SYSTEMS GMBH Appendix | A A.3 EC declaration of conformity The EC declaration of conformity can be found in the technical documentation that is part of the scope of delivery for the product. BeWa CTU1x3x-CTU1x4x 4093420f en-us web...
  • Page 116 Table of Illustrations HYDAC FILTER SYSTEMS GMBH Table of Illustrations Fig. 1 Overview / labeling of the title page ................ Fig. 2 Placement of safety symbols/pictograms..............24 Fig. 3 Minimum distance for fire fighting ................26 Fig. 4 Decoding the name plate ..................33 Fig.
  • Page 117 HYDAC FILTER SYSTEMS GMBH Table of Illustrations Fig. 27 Analysis chamber with mounts................62 Fig. 28 Cascading the filter membrane holder ..............67 Fig. 29 Variant A - Add flushing ..................78 Fig. 30 Variant F........................79 Fig. 31 Variant –EA ......................81 Fig.
  • Page 118 Tab. 17 Accessories list (for water as test liquid) ..............113 Tab. 18 Accessories list (for water or G60 / L261 as test liquid) .......... 113 Tab. 19 HYDAC Service Germany..................114 118 / 124 BeWa CTU1x3x-CTU1x4x 4093420f en-us web...

  • Page 119: Glossary

    HYDAC FILTER SYSTEMS GMBH Glossary Glossary ArbSchG DIN EN ISO 8434-1 The Occupational Health and Safety Act Metallic tube connections for fluid power (ArbSchG) is a German law implement- and general use - Part 1: Screwed con- ing EU directives on occupational health nections with 24°...
  • Page 120 Glossary HYDAC FILTER SYSTEMS GMBH Test liquid health. The safety concept contained in it is applicable to all hazards arising from Flushing fluid / analysis fluid for spray work equipment. Source: Wikipedia. extraction. ISO 16232 VDA 19 directive The ISO 16232 is the international coun- The Industrieverbund Technische terpart to the VDA 19 Directive.

  • Page 121: Index

    HYDAC FILTER SYSTEMS GMBH Index Index 2006/42/EC  86 2014/68/EU  86 Ambient conditions  32 VDA 19  28 Ambient temperature range  31 Disposal Analysis chamber Disposal  109 Cleaning the  87 Recycling  109 Documentation Representative  2 Door Checking the scope of delivery  27 Cleaning the  88...
  • Page 122 Index HYDAC FILTER SYSTEMS GMBH Connecting the  51 Owner information Forklift lugs  38 Containers under pressure  86 Hotline  114 Payload  29, 31 HYDAC Permeation time  100 Branch offices  114 Protective gloves General Terms and Conditions  13 Checking the  98 Product support  114...
  • Page 123 HYDAC FILTER SYSTEMS GMBH Index Ageing characteristics  90 Changing the  90 Draining the  90 Filling quantity  31 Filling the  92 Permissible  31 Ultrasonic Frequency  32 Power  32 Ultrasonic bath  61 Warranty  13 Weight when empty  31 BeWa CTU1x3x-CTU1x4x 4093420f en-us web...
  • Page 124 www.hydac.com...

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