Hydac CTU 15 Series Operating And Maintenance Instructions Manual
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Hydac CTU 15 Series Operating And Maintenance Instructions Manual

Contaminationtest unit
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CTU 1x5x
ContaminationTest Unit
Operating and Maintenance Instructions
English (translation of original instructions)
Document No. : 4603539
Follow these instructions for proper and safe use.
Keep for future reference.

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Summary of Contents for Hydac CTU 15 Series

  • Page 1 CTU 1x5x ContaminationTest Unit Operating and Maintenance Instructions English (translation of original instructions) Document No. : 4603539 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 Print date: 2/2/2022 ©...

  • 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 3.7 Components/operating elements ................ 39 3.7.1 Ports in the extraction chamber...............  40 3.7.2 Control panel .................... 41 4 Transporting / Storing the extraction unit................ 42 4.1 Transporting with a fork lift truck ................ 42 5 Setting up/assembling/commissioning ................ 44 5.1 Setting up the extraction unit.................. 44...
  • Page 5 HYDAC FILTER SYSTEMS GMBH Table of Contents 6.7.3 Option - Connecting external flushing ports ............  76 7 Eliminating errors...................... 77 8 Carrying out the maintenance / inspection ...............  80 8.1 Maintenance table..................... 81 8.2 Cleaning the extraction chamber ................ 83 8.2.1 Cleaning the extraction chamber in the case of a test liquid of water with surfac- tants.........................
  • Page 6 Table of Contents HYDAC FILTER SYSTEMS GMBH 9.3 Disposal / Recycling.................... 102 A Appendix.........................  103 A.1 Finding spare parts / accessories ................ 103 A.1.1 Finding accessories.................. 106 A.2 Contacting Customer Service ................. 107 A.3 EC declaration of conformity ................... 108 Glossary .........................  112 Index.......................... 114...

  • 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 1 | General HYDAC FILTER SYSTEMS GMBH Intermediate results are the consequence of activities; they are marked with an indented arrow. End results represent the end of an activity and are represented with a flag. An example for a procedural instruction with intermediate result and final result: 1.

  • 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 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 CAUTION Door is not correctly held Danger of crushing uHold the door with both hands and close it slowly. CAUTION Solvent cleaner as test liquid Health hazard uWear protective equipment. CAUTION Heavy test item Danger of crushing of feet/toes uWear safety shoes.
  • Page 22 2 | Safety HYDAC FILTER SYSTEMS GMBH Dangers with solvent cleaner as test liquid WARNING Static loading of components Discharge / Explosion uOnly use hoses/pipes with suitable conductivity. uEarth the test item if it is on a support that has an insulating ef- fect.
  • Page 23 HYDAC FILTER SYSTEMS GMBH Safety | 2 CAUTION Damaged / Worn protective gloves Health hazard uCheck the protective gloves for leaks on a daily basis. uIf you find signs of wear, replace the protective gloves immedi- ately. Only for Variant R...
  • Page 24 2 | Safety HYDAC FILTER SYSTEMS GMBH WARNING The extraction unit is under pressure Danger of bodily injury uSwitch off the extraction unit with the main switch. uThe extraction unit is depressurized after being switched off. CAUTION Hot surface at the solenoid valves...

  • Page 25: Safety Marking

    HYDAC FILTER SYSTEMS GMBH Safety | 2 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 26: Observing Regulatory Information

    2 | Safety HYDAC FILTER SYSTEMS GMBH 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 27: Shutdown In An Emergency (Emergency Stop)

    HYDAC FILTER SYSTEMS GMBH Safety | 2 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 28: Product And Technical Specifications

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

  • Page 29: Intended Use

    HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 3.2 Intended Use Use the extraction unit/module 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 30 3 | Product and technical specifications HYDAC FILTER SYSTEMS GMBH NOTICE Exceeding the permissible loading capacity/payload The extraction chamber will be damaged uNote the permissible loading capacity / payload of the test item for evenly distributed load, not for point loading.

  • Page 31: Improper Use Or Use Deviating From Intended Use

    HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 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 32: Technical Data

    3 | Product and technical specifications HYDAC FILTER SYSTEMS GMBH 3.4 Technical data Depending on the size and version, the CTU has varying technical data. Dimensions, CTU10xx Height = 1800 mm Width = 1000 mm Depth = 900 mm Dimensions, CTU12xx Height = 1800 mm Width = 1000 mm...

  • Page 33: Tab. 4 Technical Data - Ctu

    HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 Permissible ambient tempera- 15 … 28°C ture range 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...

  • Page 34: Decoding The Name Plate

    3 | Product and technical specifications HYDAC FILTER SYSTEMS GMBH 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 35 HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 Item -> Description Ambient -> Permissible ambient temperature temperatur Inlet pressure -> Permissible inlet pressure (compressed air) Max. level -> Filling volume, maximum Max. load -> Load-carrying capacity / payload Weight ->...

  • Page 36: Model Code

    3 | Product and technical specifications HYDAC FILTER SYSTEMS GMBH 3.5.1 Model Code The model code is created according to the following model code. CTU 1 0 5 0 - M - Z - Z / - Type CTU = ContaminationTest Unit...

  • Page 37: Dimensions

    HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 3.6 Dimensions Depending on the model, the ContaminationTest Unit has different outer dimensions and different dimensions of the extraction cham- The ContaminationTest Unit has the following outer dimensions: Fig. 6: Dimensions of the extraction unit...

  • Page 38: Fig. 7 Dimensions Of The Extraction Chamber

    3 | Product and technical specifications HYDAC FILTER SYSTEMS GMBH The ContaminationTest Unit has the following dimensions for the extraction chamber:: Fig. 7: Dimensions of the extraction chamber CTU10xx 2x Ø180 CTU12xx 2x Ø180 All dimensions in mm. 38 / 120 BeWa CTU1x5x 4603539 en-us web...

  • Page 39: Components/Operating Elements

    HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 3.7 Components/operating elements Fig. 8: Components/operating elements (example: CTU125x) 1 Extraction chamber with door 2 Ports in the extraction chamber, for details, see Ports in the extraction chamber [} 40] 3 Interventions with protective gloves...

  • Page 40: Ports In The Extraction Chamber

    3 | Product and technical specifications HYDAC FILTER SYSTEMS GMBH 13 Guide rolls with brake 14 Guide rolls with brake 15 Fork lift straps for transporting 3.7.1 Ports in the extraction chamber You will find the following ports in the extraction chamber.

  • Page 41: Control Panel

    HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 3.7.2 Control panel The control panel has the following operating elements. Fig. 10: Control panel 61 Quick fastener/terminal 62 Ball valve 63 Silencer 64 Compressed air supply 65 Main switch / E-STOP 67 Filter membrane holder, for details see Cascading the filter membranes / changing the filter membranes [} 66]...

  • Page 42: Transporting / Storing The Extraction Unit

    4 | Transporting / Storing the extraction unit HYDAC FILTER SYSTEMS GMBH 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 43: Fig. 12 Transport The Extraction Unit With A Fork Lift Truck. Example Illustration Ctu 105X

    HYDAC FILTER SYSTEMS GMBH Transporting / Storing the extraction unit | 4 CTU 105x CTU 125x Fig. 12: Transport the extraction unit with a fork lift truck. Example illus- tration CTU 105x / CTU 125x NOTICE Incorrect positioning of the slings The extraction unit will be damaged uSecure the extraction unit with suitable slings.

  • Page 44: 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 45: Making The Electrical Connections

    HYDAC FILTER SYSTEMS GMBH Setting up/assembling/commissioning | 5 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 46: Ultrasound Unit / Mounting/Connecting The Vibrator (Optional)

    5 | Setting up/assembling/commissioning HYDAC FILTER SYSTEMS GMBH 5.2.2 Ultrasound unit / mounting/connecting the vibrator (optional) This chapter contains information on the installation and connec- tion of the ultrasound generator and the ultrasonic vibrator. 1. Place the ultrasound generator in the switch cabinet at the bottom let in the corner.
  • Page 47 HYDAC FILTER SYSTEMS GMBH Setting up/assembling/commissioning | 5 During the suctioning operation, note the required flow rate and check the wiring of the entire ventilation system of the room. Note 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. 5.3.1.1 Suctioning of devices and extraction chamber If there is a suctioning system at the installation location, this can be attached to the connection on the CTU.

  • Page 49: Fig. 18 Suctioning The Extraction Chamber

    HYDAC FILTER SYSTEMS GMBH Setting up/assembling/commissioning | 5 Fig. 18: Suctioning the extraction chamber BeWa CTU1x5x 4603539 en-us web 49 / 120...

  • Page 50: Connecting The Compressed Air Connection

    5 | Setting up/assembling/commissioning HYDAC FILTER SYSTEMS GMBH 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 [} 32]. 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 51: Commissioning

    HYDAC FILTER SYSTEMS GMBH Setting up/assembling/commissioning | 5 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 [} 94].

  • Page 52: Operation

    6 | Operation HYDAC FILTER SYSTEMS GMBH 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 53: Switching The Extraction Unit On / Off

    HYDAC FILTER SYSTEMS GMBH Operation | 6 6.1 Switching the extraction unit on / off Switching on the extraction unit To switch on the extraction unit, proceed as follows: ü Before switching on, check that the plug is inserted and the pressurized air supply is open.

  • Page 54: Opening/Closing The Door

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.2 Opening/closing the door At each extraction, lock all the locks for the door to prevent the test liquid or aerosols from escaping. CAUTION Door is not correctly held Danger of crushing uHold the door with both hands and close it slowly.

  • Page 55: Selecting The Operating Modes

    HYDAC FILTER SYSTEMS GMBH Operation | 6 6.3 Selecting the operating modes Depending on the equipment, the extraction unit provides different operating modes as described in the following chapters. WARNING Solvent cleaner as test liquid - flammable gas-air mixture in the...

  • Page 56: Fig. 22 Extraction Chamber With Grating

    6 | Operation HYDAC FILTER SYSTEMS GMBH (A) Pen (B) Nozzle (C) Spray gun (D) Hose connection (E) Hose Nozzle type, nozzle diameter and the maximum pressure are matched to a low aerosol formation. Only use nozzles from the Spare parts or Accessories list.

  • Page 57: Fig. 23 Extraction Chamber With Basket Mount

    HYDAC FILTER SYSTEMS GMBH Operation | 6 Fig. 23: Extraction 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 [} 65]...
  • Page 58 6 | Operation HYDAC FILTER SYSTEMS GMBH 5. Then remove the filter membrane for analysis / evaluation. 6. Open the door and remove the test item. O The spray extraction is complete. 58 / 120 BeWa CTU1x5x 4603539 en-us web...

  • Page 59: Performing Air Extraction

    HYDAC FILTER SYSTEMS GMBH Operation | 6 6.3.2 Performing air extraction In this operating mode, the particles are blown off with a jet of compressed air. The released particles are in the extraction cham- ber and are later rinsed off the wall by the test liquid. .

  • Page 60: Fig. 24 Flushing The Interior Of The Extraction Chamber

    6 | Operation HYDAC FILTER SYSTEMS GMBH Fig. 24: Flushing the interior of the extraction chamber 60 / 120 BeWa CTU1x5x 4603539 en-us web...

  • Page 61: Preparing For Ultrasonic Extraction

    HYDAC FILTER SYSTEMS GMBH Operation | 6 6.3.4 Preparing for ultrasonic extraction Ultrasonic extraction is an optional operating mode which you can only perform if your CTU is equipped with ultrasound, for details see Model Code [} 36]. 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.

  • Page 62: Fig. 26 Extraction Chamber With Mounts

    6 | Operation HYDAC FILTER SYSTEMS GMBH NOTICE Ultrasonic extraction without a suitable device The extraction chamber will be damaged uFill adequate test liquid in the extraction chamber. uPlace the test item in the extraction chamber only with the cor- responding 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: Performing Ultrasonic Extraction

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.3.4.1 Performing ultrasonic extraction To perform the ultrasonic test in the ultrasonic bath, proceed as follows: ü Ultrasonic extraction has been prepared, for details, see Pre- paring for ultrasonic extraction [} 61]. ü Determine the Negative control value, for details, see Deter- mining the negative control value - Settings/parameters [} 65]...

  • Page 65: Determining The Negative Control Value - Settings/Parameters

    HYDAC FILTER SYSTEMS GMBH Operation | 6 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 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. 27 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: Operating The Filter Membrane Holder

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.5.2 Operating the filter membrane holder To remove the filter membrane, proceed as follows: Inserting the filter membrane ü Shut the ball valve upstream of the filter membrane holder. 1. Hold the holder by the lower part with one hand and release the lock at 90°...
  • 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 test liquid is completely suctioned out. 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 CTU1x5x 4603539 en-us web 71 / 120...

  • Page 72: 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 Marking Description Running test item series/running test item Number of the filter membranes provided When several flushing procedures are car- ried out on a test item A, B, C, etc.

  • Page 73: 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 74: Variante -Ea (Extraction Air)

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.7.2 Variante -EA (Extraction Air) The variant -EA (Extraction Air) is a variant in which compressed air is guided through port A into the extraction chamber. Air extrac- tion is performed by means of this port in the extraction compart- ment.
  • Page 75 HYDAC FILTER SYSTEMS GMBH Operation | 6 E2 Suction in the extraction chamber For details on the Extraction Air operating mode, see Performing air extraction [} 59]. BeWa CTU1x5x 4603539 en-us web 75 / 120...

  • Page 76: Option - Connecting External Flushing Ports

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6.7.3 Option - Connecting external flushing ports Only units with the model code CTU1xxx-x-x-R or CTU1xxx-x-x- A,have the Connecting external flushing ports option. It is possible, for example, to flush a test item outside the extrac- tion chamber using the external ports on the extraction chamber.

  • Page 77: Eliminating Errors

    HYDAC FILTER SYSTEMS GMBH Eliminating errors | 7 7 Eliminating errors The following errors can occur during operation: Malfunction/error Possible causes Solution To be car- ried out by The extraction unit The filling level of Check if the ball valve up-...
  • Page 78 7 | Eliminating errors HYDAC FILTER SYSTEMS GMBH Malfunction/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 79: Tab. 10 Eliminating Errors

    HYDAC FILTER SYSTEMS GMBH Eliminating errors | 7 Malfunction/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 80: Carrying Out The Maintenance / Inspection

    8 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 8 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 81: Maintenance Table

    HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 8 CAUTION Solvent cleaner as test liquid Health hazard uFollow all the instructions when handling the test liquid. Details on this can be found in the safety data sheet of the test liquid.
  • Page 82 8 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH Additional informa- tion Checking the screwed and plug connections Visual inspection of the electric com- ponents/cables 8.16 Checking that the pen is earthed 8.11 Checking the cali- bration of the flow...

  • Page 83: Cleaning The Extraction Chamber

    HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 8 8.2 Cleaning the extraction chamber The total surface area in the extraction chamber, the opening cy- cles, opening duration and the environment all influence the nega- tive control value to be achieved. The cleaning cycles of the ex- traction chamber depend on the test liquid used.

  • Page 84: Maintaining An Electrostatically Charged Door

    8 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH CAUTION Electrostatic charging of the door in the event of solvent cleaner as test liquid Danger of uncontrolled electrostatic discharge and ignition of a gas-air mixture. uClean the door with a moist, lint-free cloth and commonly avail- able antistatic materials.

  • Page 85: Dismounting / Installing The Side Cover

    HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 8 8.4 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 86 8 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH ü Switch on the extraction unit 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 87: Filling The Test Liquid / Filling The Extraction Unit

    HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 8 8.5.2 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 88: Avoiding The Mixing Of Test Liquids - Flushing The Extraction Unit

    8 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 8.5.3 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 89: Cleaning The Diffuser On The Filter Membrane Holder

    HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 8 Fit the cutting rings with a fitting aid. Details regarding this can be found in the DIN EN ISO 8434-1 standard NOTICE Assembly paste to assemble the screwed fittings The extraction unit will be contaminated/the analyses will become...
  • Page 90 8 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 2 Hose connection 3 Diffuser 4 Upper part of the filter membrane holder 5 Nut ü The test liquid in the extraction chamber is suctioned fully. ü Shut the ball valve on the filter membrane holder.

  • Page 91: 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. Contact the HYDAC department in this regard. O Checking the calibration of the flow meter is complete. BeWa CTU1x5x 4603539 en-us web...

  • Page 92: Checking The Protective Gloves

    8 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 8.12 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 93 HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 8 8.12.1 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 (permeation) of nongaseous, potentially hazardous chemicals when subjected to continuous contact.
  • Page 94 8 | 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 95 HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 8 Fig. 32: Preparing the protective gloves Insert the protective gloves through the inlet opening on the ex- traction chamber. Then stretch the led end of the glove over the in- let opening from the outside.

  • Page 96: Preparing For Changing The Filter Element

    8 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 8.14 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 [} 53]...
  • Page 97 HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 8 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 98 8 | 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 99 HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 8 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 100: Replacing The Pen With The Hose

    8 | Carrying out the maintenance / inspection HYDAC FILTER SYSTEMS GMBH 8.15 Replacing the pen with the hose The hose connected to the pen is a wear part that must be re- placed when necessary. Pens, which may only be used with water as the test liquid, are marked with WATER ONLY.

  • Page 101: Checking That The Pen Is Earthed

    HYDAC FILTER SYSTEMS GMBH Carrying out the maintenance / inspection | 8 8.16 Checking that the pen is earthed So that there is no electrostatic charge due to the hose, there is an electric conductor between the extraction chamber connector/ quick-action coupling and the pen.

  • Page 102: Decommissioning / Disposal

    9 | Decommissioning / Disposal HYDAC FILTER SYSTEMS GMBH 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 103: Finding Spare Parts / Accessories

    HYDAC FILTER SYSTEMS GMBH Appendix | A A Appendix This Appendix contains additional information on the product. A.1 Finding spare parts / accessories Use only original spare parts for a long and defect-free life cycle of the product. When ordering spare parts and accessories make sure to always indicate the exact model code and the serial num- ber.

  • Page 104: Tab. 13 Spare Parts List

    A | Appendix HYDAC FILTER SYSTEMS GMBH Description Part no. Quan- tity** Guide roll (CTU10xx) 680885 Guide roll (CTU12xx) 636560 Plastic pipe, Ø 6x1 mm 617539 0.5 m - Insert sleeve, Ø 6/4 mm, brass 612709 - Insert sleeve, Ø 6/4 mm, stainless steel 4258811 - Cutting ring, Ø 6 mm 6017174 Hose Tygothane Ø...

  • Page 105: Tab. 16 Spare Parts List For Safety-Related Components

    HYDAC FILTER SYSTEMS GMBH Appendix | A Spare parts with safety functions The following spare parts are safety-related components. Replace these after 20 years. Description Part no. Quan- tity** Pressure sensor (BP1 / BP2) 4622531 Temperature sensor (BT1 / BT2) 4622534 Proportional valve (QM85) 6066759 Tab. 16: Spare parts list for safety-related components...

  • Page 106: Finding Accessories

    A | Appendix HYDAC FILTER SYSTEMS GMBH A.1.1 Finding accessories The following accessories are available for the extraction unit. Please note that the selection of accessories depends on the test liquid used. Accessories list for water with surfactants as test liquid Description Part no.

  • Page 107: 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 108: Ec Declaration Of Conformity

    A | Appendix HYDAC FILTER SYSTEMS GMBH 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. 108 / 120 BeWa CTU1x5x 4603539 en-us web...
  • Page 109 HYDAC FILTER SYSTEMS GMBH Table of Illustrations Table of Illustrations Fig. 1 Overview / labeling of the title page ................ Fig. 2 Placement of safety symbols/pictograms..............25 Fig. 3 Minimum distance for fire fighting ................27 Fig. 4 Decoding the name plate ..................34 Fig.
  • Page 110 Table of Illustrations HYDAC FILTER SYSTEMS GMBH Fig. 32 Preparing the protective gloves................95 110 / 120 BeWa CTU1x5x 4603539 en-us web...
  • Page 111 Tab. 17 Accessories list for water with surfactants as test liquid ......... 106 Tab. 18 Accessories list for water with surfactants or solvent cleaners as test liquid ..106 Tab. 19 HYDAC Service Germany..................107 BeWa CTU1x5x 4603539 en-us web...

  • Page 112: Glossary

    Glossary HYDAC FILTER SYSTEMS GMBH Glossary ArbSchG and screwed connections based on their The Occupational Health and Safety Act geometrical shape in a simple, reliable (ArbSchG) is a German law implement- and safe way. ing EU directives on occupational health Extraction chamber and safety.
  • Page 113 HYDAC FILTER SYSTEMS GMBH Glossary Safety data sheet The safety data sheet is a document for communicating safety-related informa- tion on substances and mixtures, includ- ing information from the relevant chemi- cal safety report(s), across the supply chain to the downstream user. This is in-...

  • Page 114: Index

    Index HYDAC FILTER SYSTEMS GMBH Index Door Air extraction  59 Cleaning the  83 Ambient conditions  33 Contact switch  54 Ambient temperature range  33 Electrostatically charged  84 Maintaining the  84 Opening/closing  54 Circuit diagram Electrical  28 Hydraulic  28 EC declaration of conformity  28, 108...
  • Page 115 HYDAC FILTER SYSTEMS GMBH Index Branch offices  107 Spray/air extraction  32 General Terms and Conditions  13 Ultrasonic extraction  32 Product support  107  56 Service  107 Performing the Service partners  107 Performing ultrasonic extraction  64 Terms of delivery  13 Permeation time Hydraulic circuit diagram  28...
  • Page 116 Index HYDAC FILTER SYSTEMS GMBH Ageing characteristics  85 Changing the  85 Draining the  85 Filling quantity  32 Filling the  87 Solvent cleaners  32 Water containing surfactants  32 Ultrasonic Frequency  33 Performance  33 Ultrasonic bath  61 Warranty  13 116 / 120...
  • Page 120 www.hydac.com...

This manual is also suitable for:

Ctu10 seriesCtu12 seriesCtu 1000

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