HYDAC FILTER SYSTEMS CTM-SC 3 Series Manual

CTM-SC 3xxx
ContaminationTest Module -
SupplyControl
Operating and Maintenance Instructions
English (translation of original instructions)
Keep for future reference.
Documentation no.: 4165698b

Imprint
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Phone:
[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
Phone:
[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.
All details are subject to technical modifications. Technical specifications are
subject to change without notice.
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Content
Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................5
Technical Support........................................................................................5
Product modification ....................................................................................5
Warranty......................................................................................................5
Using the documentation.............................................................................6
Safety Information ........................................................................................7
Hazard symbols...........................................................................................7
Signal words and their meaning in the safety information and
instructions ..................................................................................................9
Structure of the safety information and instructions...................................10
Observe regulatory information .................................................................10
Proper/Designated Use .............................................................................11
Improper Use or Use Deviating from Intended Use ...................................12
Qualifications of personnel / target group ..................................................13
Wear suitable clothing ...............................................................................15
Observe regulatory information .................................................................15
Stoppage in an emergency (EMERGENCY STOP)...................................15
Transporting the CTM-SC ..........................................................................16
Storing the CTM-SC ....................................................................................16
Checking the scope of delivery .................................................................17
CTM characteristics....................................................................................18
Functional principle....................................................................................18
CTM-SC dimensions ...................................................................................19
CTM-SC components / control units .........................................................20
Preparing the CTM-SC for operation.........................................................22
Positioning the CTM-SC ............................................................................22
Connecting up / testing the CTM-SC .........................................................23
Connecting the CTM-SC to the electrical supply .......................................25
CTM-SC Connection Panel .......................................................................26
Connecting the foot switch .....................................................................26
Connecting the CTM E module..................................................................27
Checking setting at the level sensor / Setting test liquid............................27
Starting up the CTM....................................................................................28
Switching off the CTM-SC .........................................................................28
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Content
Remedying malfunctions ...........................................................................29
Performing maintenance............................................................................31
Maintenance intervals................................................................................32
Checking / Replacing hoses ......................................................................33
Maintaining membrane pump ....................................................................33
Checking prefilter / bypass filter.................................................................34
Changing the filter element ....................................................................35
Calibrate the volume flow meter.............................................................38
Change the test liquid................................................................................39
Draining the test liquid............................................................................39
Filling test liquid......................................................................................39
Setting the level sensor (B1) to the test liquid / Checking settings ...........41
Removing/Installing the hood ....................................................................43
Locating spare parts...................................................................................45
Taking the unit out of operation ................................................................45
Disposing of the unit ..................................................................................45
Technical Data.............................................................................................46
Annex ...........................................................................................................47
Contact Customer Service / Service..........................................................47
Model Code ...............................................................................................48
Hydraulic circuit .........................................................................................49
EC declaration of conformity......................................................................50
Explanation of terms and abbreviations.....................................................51
Index..........................................................................................................53
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Preface
Preface
These operating instructions were 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]
Product modification
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
all 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.
Hazard 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.
Observe these instructions and act with particular caution in such cases.
Pass all safety information and instructions on to other users.
General hazard
Danger due to electrical voltage / current
Exposed electrical components
Danger of electrical shock
Danger due to operating pressure
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Safety Information
Risk of burns due to hot surfaces
Substances that are health hazards or irritants
This symbol indicates that you are to wear suitable
protective eyewear (e.g., goggles, full-face shields).
When dealing with fluids, suitable gloves are to be worn
according to the type of liquid involved.
This symbol indicates that you are to wear suitable hearing
protection.
Open fires are prohibited. This particularly applies when
dealing with test liquids which contain solvents.
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Safety Information
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
Observe regulatory information
Observe the following regulatory information and guidelines:
•Legal and local regulations for accident prevention.
•Legal and local regulations for environmental protection.
•Country-specific regulations, organization-specific regulations.
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Safety Information
Proper/Designated Use
Use the unit only for the application described in the following.
The CTM is an extraction unit specially designed to analyze the surface
cleanliness of components by taking wet samples. Analyzing the type, size
and quantity of contamination enables quality standards to be verified and
documented, and the requisite optimization measures to be implemented.
Proper/designated use of the product extends to the following:
•Operation with CTM-ES only.
•Observing all instructions contained in the operating instructions.
•performing inspection and maintenance work.
NOTICE
Test liquids that cannot be used
The CTM will be damaged
►Only use test liquids which are compatible with the installed materials
and the sealing materials.
Depending on the version (see model code), the CTM may only be used for
the following media (see model code):
CTM-SC 3xx0
Only use G 60 Spezial as the test liquid
CTM-SC 3xx1
Only use G 60 Spezial as the test liquid
or
water containing tensides (permissible pH values: 6-10)
as a test liquid can be used
The use of demineralized water is not permitted.
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Safety Information
Improper Use or Use Deviating from Intended Use
NOTICE
Test liquids that cannot be used
The CTM will be damaged
►Only use test liquids which are compatible with the installed materials
and the sealing materials.
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. This risk is borne solely by the owner.
Improper use or use deviating from intended may result in hazards and/or will
damage the unit. Examples of improper use:
•Operation with a non-approved medium.
•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.
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Safety Information
Qualifications of personnel / target group
Persons who work on the power unit must be aware of the associated
hazards when using the CTM.
Operating and specialist personnel must have read and understood the
operating instructions, in particular the safety information and instructions,
and applicable regulations before beginning work.
The operating instructions and applicable regulations are to kept so they are
accessible for operating and specialist personnel.
These operating instructions are intended for:
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 with 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 lines 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
Loosely worn clothing increases the danger of getting caught or wound up in
rotating parts and the danger of getting snagged on projecting parts. You can
be severely injured or killed.
•Wear close-fitting clothing.
•Do not wear any rings, chains or any other jewelry.
•Wear work safety shoes.
•Wear gloves.
•Observe the information relating to personal protection equipment in
the safety data sheet of the test liquid.
Observe regulatory information
Observe the following regulatory information and guidelines:
•Legal and local regulations for accident prevention
•Legal and local regulations for environmental protection
•Country-specific regulations, organization-specific regulations
Stoppage in an emergency (EMERGENCY STOP)
In the event of an emergency, turn the main
switch by 90° in a counter-
clockwise direction to
shut down the entire unit. The entire unit
downstream of this switch is voltage-free and
depressurized.
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Transporting the CTM-SC
Transporting the CTM-SC
The CTM-SC has 4 casters. Shift the CTM-SC by releasing the hand brakes
on the casters.
Remove all moving parts and parts sensitive to vibration, such as the
monitor, keyboard and holder, for transportation.
Supports must be placed under the CTM-SC to transport it on a pallet. The
casters must be free of load.
Observe the maximum fork distance of 670 cm when transporting with a
forklift truck.
Storing the CTM-SC
Pull power plug. Coil up the power cable and fix it to the CTM.
Drain the reservoirs and filters of the CTM completely before putting it into
extended storage.
Store the CTM in a clean and dry room under the corresponding storage
conditions, see chapter "Technical Data" on page 46.
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Checking the scope of delivery
Checking the scope of delivery
The ContaminationTest Module CTM comes packed and partially factory-
assembled. Before starting up the CTM, check the delivery to make sure that
it is complete and undamaged.
The following items are supplied:
Qty
Designation
1
ContaminationTest Module – Supply and Control, CTM SC
1
Touchscreen monitor
1
Touchscreen monitor holder
1
Foot switch
1
Four-sided hollow socket key, 6 mm
1
Technical documentation, consisting of:
- Operating and maintenance instructions (this document)
- Electrical circuit diagram
- Additional documents
- Certificates / Inspection logs
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CTM characteristics
CTM characteristics
The CTM-SC is a specially designed supply module which only makes up an
extraction unit to determine the surface cleanliness of components when
used in combination with a corresponding CTM-E extraction module.
Functional principle
After entering the required analysis parameters in the CTM-SC software, you
push the foot switch to pump the test liquid from a reservoir, via a purification
filter, to one of the three valves with the corresponding connection (A / B / C )
on to the extraction module CTM-E.
The test liquid, (now called the analysis liquid) carrying the particles washed
off of the component, is sucked through the analysis membrane using a
diaphragm pump and flows back through the connection (R) into the
reservoir.
The level in the reservoir is constantly monitored. If the fill level of the
reservoir drops to the lower limit, the extraction process will be interrupted.
The set test liquid volume is measured using a volume flow meter. Once the
preset amount is reached, the intake is stopped.
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CTM-SC dimensions
CTM-SC dimensions
The CTM-SC has the following dimensions:
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CTM-SC components / control units
CTM-SC components / control units
The CTM-SC has the following components / control units:
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