HYDAC FILTER SYSTEMS CTM-EB 1000 Series Manual

CTM-EB
ContaminationTest Module -
Extraction Box
Operating and maintenance instructions
English (translation of original instructions)
Keep for future reference.
Documentation no.: 3456134c

Imprint
Imprint
Manufacturer / publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Industriestraße
66273 Sulzbach / Saar
Germany
Telephone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Homepage:
www.hydac.com
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:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
© HYDAC FILTER SYSTEMS GMBH
All rights reserved. No part of this work may be reproduced in any form (print,
photocopy or by other means) or processed, duplicated or distributed using
electronic systems without the written consent of the publisher.
These documents have been created and inspected with the greatest care.
However, errors cannot be ruled out completely.
The content of this manual is subject to change without notice.
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Content
Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................6
Technical Support........................................................................................6
Modifications to the Product ........................................................................6
Warranty......................................................................................................6
Using the documentation.............................................................................7
Safety information ........................................................................................8
Signal words and their meaning in the safety information and
instructions ..................................................................................................8
Structure of the safety information and instructions.....................................9
Warning signs used .....................................................................................9
Signs used for giving orders ......................................................................10
Used prohibitory signs ...............................................................................10
Used GHS symbols ...................................................................................11
Others used symbols.................................................................................11
Signs used for the required specialist personnel .......................................11
Specialist personnel – Mechanical .........................................................11
Specialist personnel – Electricity ............................................................12
Observe regulatory information .................................................................12
Proper/designated use...............................................................................13
Maximum permissible payload ...............................................................14
Improper Use or Use Deviating from Intended Use ...................................15
Qualifications of personnel / target group ..................................................16
Wear suitable clothing ...............................................................................18
Danger due to electrical power..................................................................18
Observe regulatory information .................................................................18
Stoppage in an emergency (EMERGENCY STOP)...................................19
Transporting the module............................................................................19
Storing the module .....................................................................................22
Decoding the model code label .................................................................23
Checking the scope of delivery .................................................................24
Module dimensions ....................................................................................25
Analysis chamber dimensions ..................................................................26
Preparing the module for operation ..........................................................27
Setting up the module................................................................................27
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Content
Hydraulic connection of the module...........................................................28
Electrical connection of the module........................................................28
Connecting the module with the CTM-SC supply module ......................29
Switching the module on and off...............................................................30
Module functional principle .......................................................................31
Performing manual spray extraction ..........................................................31
Achievable negative control values ..........................................................32
CTM-EB 12xx / 14xx / 16xx / 19xx.............................................................32
CTM-EB 1400 Q / 18xx..............................................................................32
CTM-EB 20xx ............................................................................................33
CTM-EB 46xx ............................................................................................33
Module components ...................................................................................34
Using the CTM-EB RC remote control ......................................................35
Two-handed control (optional) ...................................................................36
Two-handed control console (optional)....................................................37
Opening/closing the door...........................................................................38
Synchronizing the door drives ...................................................................38
Adjusting the working height......................................................................39
Starting up the module...............................................................................40
Cleaning the analysis chamber by means of inner chamber rinsing..........40
Conducting Contamination Testing............................................................42
Spray extraction .....................................................................................42
Test item holder / mount (optional) ...........................................................44
Waved mount ............................................................................................45
Operating filter membrane holder / Removing filter membrane .............46
Filter membrane holder with union nut ......................................................46
Filter membrane holder with clamp............................................................47
Cascading the filter membrane holder....................................................48
Filter membrane holder CTMH (ContaminationTest Membrane
Holder).......................................................................................................49
Cascading the filter membrane holder CTMH ........................................50
Labeling the filter membrane .....................................................................51
Performing maintenance............................................................................52
Maintenance work .....................................................................................53
Maintenance intervals for CTM-EB .....................................................53
Checking / Replacing hoses...................................................................54
Servicing the test liquid filters ....................................................................55
Changing the filter element........................................................................56
Clean the analysis chamber ...................................................................58
Cleaning the diffuser on the filter membrane holder...............................60
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Content
Cleaning the door...................................................................................60
Statically charged door...........................................................................61
Checking the gloves ..................................................................................62
Permeation of Protective Gloves According to EN 374-3:1994 ..............63
Installing gloves .........................................................................................64
Gloves — Electrostatic Discharging .......................................................64
Spare parts and accessories .....................................................................65
CTM-EB xxxx-… spare parts .....................................................................65
CTM-EB xxx0-… spare parts.....................................................................66
CTM-EB xxx1-… spare parts.....................................................................66
Accessories.................................................................................................66
Disk spare parts.........................................................................................67
Spare parts for light waved mount .............................................................68
Spare parts for medium waved mount.......................................................69
Spare parts for heavy waved mount ..........................................................70
Taking the unit out of operation ................................................................71
Shutting down the unit ...............................................................................71
Disposing of the unit ..................................................................................71
Technical data .............................................................................................72
Appendix .....................................................................................................73
Customer Service / Service .......................................................................73
Hydraulic diagram......................................................................................74
Model code ................................................................................................75
EC declaration of conformity......................................................................75
Explanation of terms and abbreviations.....................................................76
Index..........................................................................................................78
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Preface
Preface
This operating manual was made to the best of our knowledge. Nevertheless
and despite the greatest care, it cannot be excluded that mistakes could have
crept in. Therefore please understand that, in the absence of any provisions
to the contrary hereinafter, our warranty and liability – for any legal reasons
whatsoever – are excluded in respect of the information in these operating
instructions. In particular, we shall not be liable for lost profit or other financial
loss. This exclusion of liability does not apply in cases of intent and gross
negligence. Moreover, it does not apply to defects which have been
deceitfully concealed or whose absence has been guaranteed, nor in cases
of culpable harm to life, physical injury and damage to health. If we
negligently breach any material contractual obligation, our liability shall be
limited to foreseeable damage. Claims due to product liability shall remain
unaffected.
Technical Support
Contact our technical sales department if you have any questions on our
product. When contacting us, please always include the model code, serial
no. and part no. of the product:
Fax:
[phone]
E-mail:
[e-mail]
Modifications to the Product
We would like to point out that changes to the product (e.g., purchasing
options, etc.) may result in the information in the operating instructions no
longer being completely accurate or sufficient.
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.
Warranty
For the warranty provided by us, please refer to the terms of delivery of
HYDAC FILTER SYSTEMS GMBH.
You will find these under www.hydac.com -> Legal information.
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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.
WHERE can I find the information I’m looking for?
The documentation has a table of contents at the beginning. There, I select
the chapter I'm looking for and the corresponding page number.
de
HYDACFiltertechnikGmbH
BeWa123456ade
Se ite x
Produkt/Kapitel
200x-xx- xx
The documentation number with its index enables you to order another copy
of the operating and maintenance instructions. The index is incremented
every time the manual is revised or changed.
Chapter description
Page number
Edition date
Document language
Documentation No.
with Index /
File name
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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. They must
always be complete and legible.
Do not operate the unit unless all the safety devices are present.
Secure the hazardous areas which may arise between the unit and other
equipment.
Maintain the unit inspection intervals prescribed by law.
Document the results in an inspection certificate and keep it until the next
inspection.
Signal words and their meaning in the safety information and
instructions
In these instructions you will find the following signal words:
DANGER
DANGER – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result lethal or serious injury.
WARNING
WARNING – The signal word indicates a hazardous situation with a medium
level of risk, which, if not avoided, can result lethal or serious injury.
CAUTION
CAUTION – The signal word indicates a hazardous situation with a low level
of risk, which, if not avoided, can result in minor or moderate injury.
NOTICE
NOTICE – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result in damage to property.
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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:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert danger
Warning signs used
These signs are listed for all safety information and instructions in these
operating instructions which indicate particular hazards to persons, property
or the environment.
Danger point warning
Dangerous electrical voltage warning
Warning; Crushing of hands
Warning against crushing your hand
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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
operating instructions which indicate particular hazards to persons, property
or the environment.
Fires, naked lights and smoking prohibited
Procedure not permitted with loads
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Safety information
Used GHS symbols
These symbols are listed for all safety information and instructions in these
operating instructions which indicate particular hazards to persons, property
or the environment.
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 – Mechanical
Only specialist personnel with training as mechanics and
the following knowledge:
•Safe handling/use of tools
•Fitting and connection of hydraulic tubes and
connections
•Product-specific knowledge
•Knowledge about how to handle operating media.
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Safety information
Specialist personnel – Electricity
Only specialist personnel with training as electricians and
the following knowledge:
•Safe handling/use of tools
•Fitting and connection of electrical lines, electrical
machinery, sockets, etc.
•Checking the phase sequence
•Product-specific knowledge
•Knowledge about how to handle operating media.
Observe regulatory information
Observe the following regulatory information and directives:
•Legal and local regulations for accident prevention
•Legal and local regulations for environmental protection
•Country-specific regulations, organization-specific regulations
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Safety information
Proper/designated use
Use the unit only for the application described in the following.
The CTU-EB is an extraction unit specially designed to analyze the surface
cleanliness of components by taking wet samples. Quality standards can be
checked and documented by means of the determination of type, size and
quantity of the contamination, and the necessary optimization measures can
be implemented.
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 or designated use of the product extends to the following:
•Maintaining adherence to all the instructions contained herein
•Not operating the CTM-EB unless cover panels are installed
•Not operating the unit/performing extraction unless the analysis
chamber is closed.
•Performing requisite inspection and maintenance work.
•Operation with an impermissible test liquid only.
NOTICE
Impermissible test liquid
The module will be damaged.
►Use only test liquids which are compatible with the materials and the
sealing materials they come in contact with.
►Use G60 Spezial as the test liquid.
►CTM-EB 1xxx only
Do not use completely desalinated water as a test liquid.
Using water containing tensides (permissible pH values: 6 to 10) as a
test liquid is permitted.
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Safety information
Maximum permissible payload
NOTICE
Exceeding the permissible payload
The module will be damaged.
►Observe the maximum permissible payload.
►The payload is calculated as follows:
Payload = weight of test item + weight of mount + etc.
The payload can vary significantly depending on the module.
The maximum permissible payload is:
CTM-EB
Maximum permissible payload
120x
=
31.5 kg*
121x
=
100 kg*
14xx
=
150 kg*
1400 Q8
=
150 kg*
1400 S2
=
150 kg*
160x
=
100 kg*
161x
=
150 kg*
18xx
=
150 kg*
1900
=
100 kg*
200x
=
100 kg*
201x
=
150 kg*
460x
=
165 kg*
461x
=
150 kg*
*) for evenly distributed load, no point loading.
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Safety information
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 owner alone shall assume any and all
associated risk
Improper use or use deviating from intended use may result in hazards
and/or will damage the unit. Examples of improper use:
•Operation in potentially explosive atmospheres.
•Operation under impermissible operating conditions.
•Operation with an impermissible test liquid.
•Operation when the safety devices are defective or not activated.
•Modifications to the power unit made by the user or purchaser.
•Inadequate monitoring of parts that are subject to wear and tear.
•Improperly performed repair work.
•Exceeding the maximum payload
•Sampling test items that exceed the dimensions of the analysis
chamber
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Safety information
Qualifications of personnel / target group
Staff who work with the powerpack must be aware of the dangers involved,
must be over the age of 14 and must be without any physical impediments in
regard to the industrial environment.
These operating instructions are intended for:
Auxiliary personnel:
Such persons have been instructed about the product and informed about
potential hazards that can result from improper use.
Operating personnel: such persons have been instructed in power unit
operation and are aware of potential hazards due to improper use.
Operating personnel: such persons have been instructed in power unit
operation and are aware of potential hazards due to improper use.
Specialist personnel:
Such persons have 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 hazards.
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Safety information
Activity
Person
Knowledge
Transport / storage
Forwarding
agent
Specialist
personnel
•Proof of knowledge of cargo
securing instructions
•Safe handling/operation of
hoisting and lifting equipment
Hydraulic / electrical
installation,
First commissioning,
Maintenance,
Troubleshooting,
Repair,
Decommissioning,
Disassembly
Specialist
personnel
•Safe handling/use of tools
•Fitting and connection of
hydraulic tubes and
connections
•Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.
•Product-specific knowledge
Operation
Operations control
Specialist
personnel
•Product-specific knowledge
•Knowledge about how to
handle operating media.
•Knowledge about
contamination due to solids
and water
Disposal
Specialist
personnel
•Proper and environmentally-
friendly disposal of materials
and substances
•Decontamination of
contaminants
•Knowledge about reuse
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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. Note the safety data sheets of the test liquid.
You should replace damaged or worn gloves immediately.
•Wear close-fitting clothing.
•Do not wear any rings, chains or any other jewelry.
•Wear work safety shoes.
Danger due to electrical power
DANGER
Electric shock
Danger of fatal injury
►Any work involving electrical equipment may
only be done by a properly trained, certified
electrician.
►
Pull the power plug before performing work on
live parts.
•Regularly inspect the electrical connection cable for the unit.
•Fix any loose connections immediately.
•Always keep the control cabinet locked.
•Periodically inspect the module in accordance with the accident
prevention regulations of the German employers' liability insurance
associations (BGV A3).
Observe regulatory information
Observe the following regulatory information and directives:
•Legal and local regulations for accident prevention
•Legal and local regulations for environmental protection
•Country-specific regulations, organization-specific regulations
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Transporting the module
Stoppage in an emergency (EMERGENCY STOP)
I
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s
sw wi it tc ch h b by y 9 90 0° ° i in n a a c co ou un nt te er r- -c cl lo oc ck kw wi is se e d di ir re ec ct ti io on n t to o
s
sh hu ut t d do ow wn n t th he e e en nt ti ir re e u un ni it t. . T Th he e e en nt ti ir re e s sy ys st te em m
d
do ow wn ns st tr re ea am m o of f t th hi is s s sw wi it tc ch h w wi il ll l t th he en n b be e d de e- -
e
en ne er rg gi iz ze ed d. .
Transporting the module
The module is shipped from the factory in a wood box with the corresponding
securing devices. Pack the assembly for further transport in this wood box.
Alternatively, place the assembly on a pallet of sufficient size using a forklift.
Brace the assembly so that the steering rollers are not loaded.
When receiving and unpacking the unit, check it for damage in transit. Report
any damage to the forwarding agent immediately.
The module can be moved by pushing it on its casters. You can also use
hoisting equipment (e.g. a fork lift truck) to transport the module, provided its
load-carrying capacity is greater than the weight of the empty module.
To transport the module, all test liquid reservoirs and filter holders must be
drained.
All moveable components sensitive to vibration like the grating, spray gun,
etc., must be removed or secured.
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Transporting the module
NOTICE
Lifting the module by the sliding grip
The module / the analysis chamber will be damaged
►Use a fork lift truck to lift the module.
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