HYDAC FILTER SYSTEMS CTU 1 3 Series Manual

CTU 1x3x series
CTU 1x4x series
Contamination Test Unit
Operating and Maintenance Instructions
English (translation of original instructions)
Document No.: 4093420e
(Valid from series no.: 0002S01495K000000192)
Keep for future reference.

Imprint
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Imprint
Manufacturer / publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Industriestraße
66280 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.

Contents
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Contents
Imprint............................................................................................................2
Documentation Representative...................................................................2
Contents ........................................................................................................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
Others used symbols.................................................................................10
Signs used for the required specialist personnel.......................................11
Specialist personnel – Mechanical.........................................................11
Specialist personnel – Electricity............................................................11
Observe regulatory information .................................................................11
Proper/Designated Use .............................................................................12
Improper Use or Use Deviating from Intended Use...................................13
Qualifications of personnel / target group..................................................14
Wear suitable clothing...............................................................................15
Observe regulatory information .................................................................15
What to Do in Case of Emergency (EMERGENCY STOP) .......................15
Transporting assembly ..............................................................................16
Storing the assembly..................................................................................19
Decoding the model code label.................................................................20
Checking the scope of delivery.................................................................21
CTU Dimensions.........................................................................................22
Outer dimensions ......................................................................................22
Analysis chamber dimensions...................................................................23
Preparing the CTU for operation ...............................................................24
Setting up the CTU....................................................................................24
Putting the CTU into operation ..................................................................25
Checking connections and contacts.......................................................25

Contents
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Air extraction within the unit......................................................................28
Note when using the test liquid G 60 Spezial ............................................28
Connecting an air extractor........................................................................29
Suctioning the machine room of the CTU 1x3x......................................29
Suctioning the machine room and analysis chamber of the CTU
1x4x........................................................................................................30
Setting up the electrical connection of the CTU......................................32
Connecting the compressed air..............................................................32
Connecting the foot switch.....................................................................33
Parts of the CTU..........................................................................................34
Operating console..................................................................................35
Functional principle....................................................................................36
Manual spray extraction.............................................................................36
Achievable negative control values ...........................................................37
Operating filter membrane holder / Removing filter membrane.............38
Filter membrane holder with union nut ......................................................38
Filter membrane holder with clamp............................................................39
Cascading the filter membrane holder....................................................40
Filter membrane holder CTMH (ContaminationTest Membrane
Holder).......................................................................................................41
Cascading filter membrane holder CTMH..............................................42
Opening / Closing door lock......................................................................44
CTU during operation.................................................................................45
CTU switching on ......................................................................................45
ConTeS Software......................................................................................46
Clean-Room Conditions in the Analysis Chamber - Rinsing of the
inner chamber............................................................................................46
Automatic cleansing of the analysis chamber ........................................47
Conducting Contamination Testing............................................................48
Spray extraction .....................................................................................48
Perform ultrasonic test (optional)............................................................50
Automatic reservoir switchover..................................................................52
CTU switching off ......................................................................................53
Changing the filter membrane...................................................................54
Labeling the removed filter membrane......................................................56
Performing inspection / maintenance.......................................................57
User information for the "products under pressure"................................58
Maintenance work overview ......................................................................58
Maintenance intervals for CTU 1xx0 with A III cleaner as the test
liquid.......................................................................................................59

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Maintenance intervals for CTU 1xx1 with A III cleaner as the test
liquid.......................................................................................................59
Maintenance intervals for CTU 1xx1 with water as the test liquid...........60
Checking / Replacing hoses...................................................................60
Changing the filter element.................................................................61
Calibrating the flow rate meter................................................................63
Calibrating the temperature sensor (ultrasound option only)..................64
Cleaning the analysis chamber..............................................................65
Clean the diffuser on the filter membrane holder....................................65
Cleaning the door...................................................................................66
Maintaining statically charged door.....................................................66
Change the test liquid.............................................................................67
Draining the test liquid.........................................................................67
Adding / Filling test liquid ....................................................................69
Checking the gloves..................................................................................72
Permeation of Protective Gloves According to EN 374-3:1994..............73
Installing gloves.........................................................................................75
Use electro-statically conductive gloves.................................................75
Spare parts list............................................................................................76
Accessories.................................................................................................77
Option/variant overview .............................................................................78
S2 - Switch vacuum...................................................................................78
Variant A – Add flushing............................................................................79
Variant -EA – Extraction Air.......................................................................80
Variant F – Flushing ..................................................................................81
Sensor to signal that the collecting pan is full (optional)............................82
Disposing of the CTU .................................................................................83
Technical details.........................................................................................84
Attachment..................................................................................................85
EC declaration of conformity......................................................................85
Customer Service/ Service........................................................................85
Model Code...............................................................................................86
Explanation of terms and abbreviations.....................................................87
Index..........................................................................................................89

Preface
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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/type
designation, 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 -> General terms and conditions.

Preface
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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
Seite 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

Safety Information
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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.

Safety Information
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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

Safety Information
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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
Others used symbols
The following symbols found you in this operation instructions.
Tip for handling the product
Tools required