HYDAC FILTER SYSTEMS CTM-EF 3 3 Series Manual

CTM-EF 3x3x
ContaminationTest Module -
Extraction Flushing
Operating and Maintenance Instructions
English • (translation of original instructions)
Document No. : 4436386 • 9/25/2019
Follow these instructions for proper and safe use.
Keep for future reference.

Table of Contents HYDAC FILTER SYSTEMS GMBH
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Table of Contents
1 General.............................................................................................................................................................5
1.1 Imprint.......................................................................................................................................................5
1.2 Documentation Representative ................................................................................................................5
1.3 Purpose of this manual .............................................................................................................................5
1.4 Target group of the manual ......................................................................................................................6
1.5 Illustrations in the manual .........................................................................................................................6
1.5.1 Illustration on the title page ........................................................................................................... 6
1.5.2 Representation of requirements.................................................................................................... 7
1.5.3 Representation of procedural instructions .................................................................................... 8
1.5.4 Representation of intermediate results/results.............................................................................. 8
1.5.5 Representation of warning/general safety information.................................................................. 9
1.5.6 Signal words and their meaning in the general safety information ............................................. 10
1.6 Supplementary symbols .........................................................................................................................11
1.7 Exclusion of liability/warranty..................................................................................................................11
1.8 Notes on copyright..................................................................................................................................11
1.9 Validity of this manual.............................................................................................................................11
2 Safety information...........................................................................................................................................12
2.1 Placement of safety symbols/pictograms ...............................................................................................15
2.2 Fire-fighting measures ............................................................................................................................16
2.3 Stoppage in an emergency (EMERGENCY STOP) ...............................................................................16
3 Overview.........................................................................................................................................................17
3.1 Checking the scope of delivery...............................................................................................................17
3.2 Proper/designated use............................................................................................................................18
3.3 Improper Use or Use Deviating from Intended Use................................................................................19
3.4 Technical Data........................................................................................................................................20
3.4.1 Achievable negative control values............................................................................................. 21
3.4.2 Permissible test liquid ................................................................................................................. 22
3.5 Decoding the type label ..........................................................................................................................23
3.5.1 Model code ................................................................................................................................. 24
3.6 Dimensions .............................................................................................................................................25
3.7 Hydraulic circuit ......................................................................................................................................26

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3.8 Components/operating elements............................................................................................................28
4 Transporting/storing the extraction unit ..........................................................................................................29
4.1 Transport with a forklift ...........................................................................................................................30
5 Setting up/assembling/commissioning ...........................................................................................................31
5.1 Setting up the extraction unit ..................................................................................................................31
5.2 Electrical connection...............................................................................................................................32
5.3 Connecting the compressed air supply...................................................................................................32
5.4 Connecting the CTM-EF extraction unit to the GTM-SC supply module ................................................32
5.5 Flushing the extraction unit - Avoiding the mixing of test liquids ............................................................34
5.6 Checking the installation.........................................................................................................................34
6 Operation........................................................................................................................................................36
6.1 Switching the extraction module on and off ............................................................................................37
6.2 Connecting the test item .........................................................................................................................38
6.3 Cascading filter membranes/replacing filter membranes........................................................................39
6.3.1 Creating cascades ...................................................................................................................... 39
6.3.2 Filter membrane holder with quick fastener ................................................................................ 40
6.4 Labeling the filter membrane ..................................................................................................................44
6.5 Conducting the extraction .......................................................................................................................45
6.5.1 Changing the direction of flushing............................................................................................... 45
6.5.2 Draining the test item .................................................................................................................. 45
7 Performing inspection / maintenance .............................................................................................................46
7.1 Maintenance table ..................................................................................................................................46
7.2 Checking the screwed and plug connections .........................................................................................47
7.3 Visual inspection of the electric components/cables ..............................................................................47
7.4 Checking hoses ......................................................................................................................................47
7.5 Replacing hoses/plastic pipe ..................................................................................................................48
7.6 Clean the diffuser on the filter membrane holder....................................................................................48
8 Troubleshooting/remedying malfunctions.......................................................................................................50
9 Decommissioning / Disposal ..........................................................................................................................52
Appendix.........................................................................................................................................................53
Finding spare parts / accessories ...........................................................................................................53

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Finding a Customer Service team ..........................................................................................................54
EC declaration of conformity...................................................................................................................55
Glossary .........................................................................................................................................................58
Index...............................................................................................................................................................61

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1 General
In this chapter, you will find helpful notes on handling these instructions.
1.1 Imprint
Manufacturer / publisher and responsible for the content:
Address of the manufacturer Contact address
HYDAC FILTER SYSTEMS GMBH
Industriegebiet
66280 Sulzbach / Saar
HYDAC FILTER SYSTEMS GMBH
Justus-von-Liebig-Str., Werk 20
66280 Sulzbach / Saar
Germany Germany
E-mail: [email protected]
Homepage: www.hydac.com
Court of Registration: Saarbrücken , HRB 17216
Executive directors: Mathias Dieter ,
Dipl.Kfm. Wolfgang Haering
Tab.1: Impressum
1.2 Documentation Representative
The contact data of the person authorized with the documentation is:
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Tab.2: Documentation Representative
1.3 Purpose of this manual
Before you use this product for the first time or if you have been asked to carry
out other work on the product, please read this manual.
The use and the handling of the product described in the following, as well as its
use, are not self-explanatory and are described in detail in this manual and the
associated technical documentation.
This manual will help you to use the product as intended, properly, effectively,
and safely. Therefore, you are requested to read the following chapters atten-
tively and carefully. Please refer to it every time you require decisive details.

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This manual informs and warns you of risks, against which the risk reduction
through the design and protective measures may not be effective or not fully ef-
fective.
1.4 Target group of the manual
This manual was created for the following target group.
Target group Tasks
Owner This manual and the associated documents must be
kept accessible at the installation location of the prod-
uct and also for later use.
Ask the employees to read and follow the manual
and the associated documents, in particular, the
safety and warning instructions.
Observe the additional product-related instructions
and requirements.
Specialist personnel Read, observe and follow this manual and the associ-
ated documents, in particular, the safety and warning
instructions.
Tab.3: Target group
1.5 Illustrations in the manual
You will find illustrations in this manual. You can find details regarding these in
the following chapters.
1.5.1 Illustration on the title page
You will find the following information on the title page of this manual:

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Short name of the product
Product name
Operating and Maintenance Instructions
12345678 ● ##.##.####
English (translation of original instructions)
Valid from: - from s/no. - ... ... - ... ...
1
5
2
4
3
Fig.1: Overview / labeling of the title page
1 Short name of the product / product name
2 Type of document
3 Language
4 Document no./Index ● Date of printing
5 Supplementary instructions regarding the validity of the manual (op-
tional)
Please note that you can directly access information through the directories.
However, this does not release you from the obligation to read this manual fully
before commissioning.
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 figures, an index
and a glossary.
1.5.2 Representation of requirements
These are absolutely required for carrying out a work activity on the product and
are marked with a check mark and are in bold in the text.
An example for the representation of requirements:
ühe product is assembled and connected.

1 | General HYDAC FILTER SYSTEMS GMBH
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üThe product is switched off.
1. Switch the product on.
1.5.3 Representation of procedural instructions
In the case of procedural instructions, there are the two following representa-
tions:
Procedural instructions with a fixed sequence
Procedural instructions, whose sequence must be complied with without fail are
listed with sequential numbering (1., 2., 3., etc.).
An example for procedural instructions with a fixed sequence:
1. Remove the transport securing device.
2. First fill the product.
3. Switch the product on.
Procedural instructions with a random sequence
Procedural instructions that have a random sequence are listed as bullet points
(-).
An example of a procedural instruction with a random sequence:
– Clean the display.
– Rinse the product.
1.5.4 Representation of intermediate results/results
In the case of some activities, it is necessary to carry out work steps with inter-
mediate results and end results.
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. Switch the product on.
ðThe display lights up.
2. Press the button.
OThe product is now ready for use.

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1.5.5 Representation of warning/general safety information
All the warning / general safety information in this manual are highlighted with
pictograms and signal words. The pictogram and the signal word give you an in-
dication of the severity of the danger.
Warning / general safety information, which are placed ahead of each activity,
are represented as follows:
CAUTION
Type and source of danger
Hazard symbol
Consequence of the danger
Measures to avert danger
►

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1.5.6 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.
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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1.6 Supplementary symbols
You will find the following symbols in the manual as additional details:
Tip for handling the product
Required tools
1.7 Exclusion of liability/warranty
For the warranty provided by us, please refer to the Terms of Delivery. They are
made available to you at the conclusion of the contract at the latest. You will
also find these under www.hydac.com -> General Terms and Conditions (T&C).
This manual was prepared to the best of our knowledge. Nevertheless and de-
spite 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 con-
trary hereinafter, our warranty and liability – for any legal reasons whatsoever –
are excluded in respect of the information in this manual. 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 con-
tractual obligation, our liability shall be limited to foreseeable damage. Claims
due to the Product Liability shall remain unaffected.
1.8 Notes on copyright
All copyrights for this manual lies with the manufacturer. No part of this manual
may be reproduced in any form or processed, duplicated or distributed using
electronic systems without the written consent of the manufacturer. Any in-
fringements of the above shall be liable to damage compensation.
1.9 Validity of this manual
The diagrams and visualizations in this manual are meant for general illustration
purposes. Therefore, representations and functional options can deviate from
the delivered product.
We reserve the right to changes to the contents of this manual without prior no-
tice.

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2 Safety information
The General Safety Information provides important information on handling the
device. A prerequisite for safe work is the maintenance of all stated General
Safety Instructions and precautions. In addition, the local accident prevention
specifications and general safety regulations that apply for the area of operation
of the device must be observed.
The following dangers could occur when handling/operating the extraction unit:
DANGER
Danger due to unintended use/test liquid
Bodily injury and damage to property
uThe extraction unit may only be used with the permissible test liquid.
uUse only test fluids that are compatible with the materials and the sealing
materials they come in contact with.
WARNING
Test liquid G60Spezial or FerocleanL261 - Flammable gas-air mixture
in the analysis chamber
Danger of fatal injury from burns
uOpen fires or smoking are prohibited in the vicinity.
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.
WARNING
Brush discharge/corona discharge
Bodily injury due to the ignition of an explosive atmosphere.
uConnect the test item to a potential-free earth.

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CAUTION
Test liquid G60Spezial or Feroclean L261
Health hazard
uObserve all the notices when handling the test liquid. You will find details in
the safety data sheet.
uWear your personal protective equipment. You will find details in the safety
data sheet.
uMake sure that there is adequate exchange of air in the room. You will find
details in the safety data sheet.
CAUTION
Operating pressure
Danger of bodily injury
uRemove/disconnect the compressed air supply from the excraction unit be-
fore all work.
CAUTION
Hot surface at the solenoid valves
Danger of burns
uAllow the solenoid valves to cool down before all repairs/maintenance work.
NOTICE
Impermissible test liquid
The extraction unit will be damaged.
uThe extraction unit is only to be used together with the permissible test liq-
uid.

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NOTICE
Lifting the extraction module at the components
The extraction unit will be damaged
uUse suitable lifting accessories to lift the extraction module.
uLift the extraction module only at the housing, not at attachments or compo-
nents.
The following are the safety symbols / pictograms in this manual. They indicate
specific dangers to persons, property or to the environment. Observe these
safety symbols / pictograms and act with particular caution in such cases. Al-
ways keep all symbols / pictograms intact and legible.
Fires, naked lights and smoking are prohibited
Wear eye protection.
Use protective gloves.

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2.1 Placement of safety symbols/pictograms
In this chapter, you will find information on the placement of safety symbols/pic-
tograms on the extraction unit. Replace the damaged or no more recognizable/
legible safety symbols/pictograms immediately. Pull the safety symbol/pic-
togram off the extraction unit, remove possible present adhesive residues with a
cleaner suitable for that purpose. Then, affix the new stick-on safety symbol/pic-
togram at the same place on the extraction unit.
Fig.2: Placement of safety symbols/pictograms

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2.2 Fire-fighting measures
Observe the measures relating to fire fighting given in the safety data sheet of
the test liquid used.
Maintain a minimum safe distance from electrical components. For a mains volt-
age of up to 1000V, the minimum safe distance is 1m.
Fig.3: Minimum distance for fire fighting
2.3 Stoppage in an emergency (EMERGENCY
STOP)
In an emergency, disconnect the extraction unit and modules that may be
present from the power supply. Switch off the extraction unit at the main switch.
The extraction unit is deenergized downstream of the main switch.

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3 Overview
The CTM-EF3xxx is an extraction module, which can only be operated together
with the CTM-SC3xxx supply module of the same series, for analyzing the sur-
face cleanliness of components.
The components are connected to the corresponding hoses and flushed out us-
ing a defined, clean test liquid. You can change the direction of flushing with the
CTM-EF3x3x.
The particles carried by the test liquid are fed over a filter membrane and then
analysed with regard to the quantity of particles and their type.
3.1 Checking the scope of delivery
The ContaminationTestModule CTM-EF comes packed and pre-assembled. At
delivery/before commissioning, please check the scope of delivery to make sure
it has not been damaged during transport and that it is complete.
The following items are included in the scope of delivery:
Qty Tool
1 ContaminationTestModule CTM-EF
1 Supporting sieve for the filter membrane holder
4 Hoses
1 RJ45 patch cable
1 Technical documentation, consisting of:
- Operation and maintenance Instructions (this document)
- Electrical circuit diagram
- EC declaration of conformity, certificates, etc.
Tab.4: Scope of delivery

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3.2 Proper/designated use
Use the unit only for the application described in the following.
The ContaminationTest Module CTM-E… is the extraction module that can only
be used together with a CTM-SC… supply module of the same series. The
analysis of components and systems with regard to their technical cleanliness is
based on the VDA 19 directive (ISO 16232 and ISO18413).
Quality standards can be checked and documented by means of a microscopic
and gravimetric analysis of the type, size and quantity of the contamination, and
the necessary optimization measures can be implemented.
Claims for defects or liability, regardless of the legal foundation, do not apply
with incorrect or improper installation, commissioning, usage, handling, storage,
maintenance, repair, use of unsuitable components or other circumstances for
which the manufacturer is not responsible.
The manufacturer assumes no responsibility for determining the interfaces for
installation in a system or the installation, use or functionality of the product in
this system.
The intended use of the product extends to the following:
– Operation only together with the ContaminationTestModule CTM-SC3xxx.
– Follow all the notices contained in the operating instructions.
– Operation only with mounted cover panels.
– Not operating unless the analysis chamber is closed.
– Complying with the requirements for repair and maintenance work.
– Operation under supervision.
– Operation only in closed rooms, environmental cleanliness and air similar to
that under laboratory conditions.
– Horizontal installation surface
– The immobilization brakes on all the rollers have been set.
– Minimum distance to the wall at the rear ≥5cm
– Adequate ventilation in the room.

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3.3 Improper Use or Use Deviating from
Intended Use
Any use extending beyond this or deviating therefrom shall not be considered
intended use. The manufacturer does not accept any liability for damage result-
ing from such use. This risk is borne solely by the owner.
Improper use may result in hazards and/or will damage the unit. Improper use
or use deviating from intended use are, for example:
– Operation with an impermissible test fluid.
– Operation under non-approved operational conditions.
– Operation when the safety devices are defective.
– 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.
– Unsupervised operation.

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3.4 Technical Data
Depending on the size and version, the CTM-EF has varying technical data.
CTM-EF343x CTM-EF363x
Test liquid volume 40liters 60liters
Empty weight ≈110kg ≈110kg
Dimensions 600 x 600 x 1550mm
Rated voltage 85…265VAC, 50/60Hz
Nominal power 100W
Tab.5: Technical data - CTM-EF3x3x
Protection class according to
EN60529/DIN40050
IP44
Permissible environmental conditions Air and temperature similar to labora-
tory conditions, the room is adequately
ventilated
Permissible ambient temperature
range
15…28°C
Permissible relative air humidity ≤80% (non condensing)
Permissible storage temperature range 0…50°C
Required compressed air supply 5…6bar
Required cleanliness of compressed
air
ISO8573-1 [7:4:4]
Permissible air conditions during stor-
age
Dust-free, salt-free air, not near oxidiz-
ing substances (rust film)
Permitted relative air humidity ≤80% (non condensing)
Design life expectancy of the device The design life expectancy of the de-
vice is not limited if the service and
maintenance intervals are complied
with.
Life expectancy of the components of
the device with safety functions.
Semtron load disconnector/emergency
stop switch 3LD2122-0TK13: Maxi-
mum switching cycles, 50per hour