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

Safety Information
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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.
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 guidelines:
•Legal and local regulations for accident prevention
•Legal and local regulations for environmental protection
•Country-specific regulations, organization-specific regulations

Safety Information
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Proper/Designated Use
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 HYDAC is not responsible.
HYDAC is not responsible for the installation, integration, selection of
interfaces to / into your system nor for the use or functionality of your system.
Use the unit only for the application described in the following.
The ContaminationTest Unit CTU is a test bench for analyzing the technical
cleanliness of components and systems in accordance with directive VDA 19
(ISO 16232 or 18413).
DANGER
Only with soluble
test liquid: "G 60 Spezial"
Flammable gas-air mixture in the analysis
chamber, risk of ignition and fire
Danger of fatal injury from burns
►Open fires and smoking are prohibited.
NOTICE
Test liquids that cannot be used
The CTU can 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.
►CTU 1xx1 only
Do not use completely demineralized water as a test liquid.
Using water containing tensides (permissible pH values: 6 to 10) as a
test liquid is permitted.
Proper or designated use of the product extends to the following:
oMaintaining adherence to all the instructions contained herein.

Safety Information
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oNot operating unless the side paneling is fitted.
oNot operating unless the analysis chamber is closed.
oPerforming requisite inspection and maintenance work.
oSupervised operation.
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 user alone, shall assume any and all
associated risk
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 liquid.
•Operation under impermissible operating 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.

Safety Information
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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.
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.
Activity
Person
Knowledge
Transport / storage
Specialist
personnel
Knowledge of transport safety
required
Startup operation
operations control
Specialist
personnel
Product-specific knowledge
required.
Knowledge of how to handle
test liquid required.
troubleshooting,
maintenance,
decommissioning,
Disassembly
Specialist
personnel
Safe handling/use of tools.
Product-specific knowledge
required.
Disposal
Specialist
personnel
Knowledge of environmentally-
friendly disposal of materials
and matter is required.
Knowledge of decontamination
of contaminants is required.
Knowledge with regard to
recycling is required.

Safety Information
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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.
•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 operating fluid.
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
What to Do in Case of Emergency (EMERGENCY STOP)
In an emergency, switch the unit off at the
main on/off switch or unplug the power
connector.

Transporting assembly
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Transporting assembly
To transport the assembly, proceed as follows:
1.
Empty the assembly completely (both reservoirs, rinse and return
line filter).
2.
Remove all moveable components sensitive to vibration like the
grating, spray gun, PC, monitor, keyboard, etc. from the assembly.
Move the assembly by pulling or pushing the handle. Never lift the assembly
by the handle.
The assembly 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.

Transporting assembly
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Example of an illustration on a CTU10xx.

Transporting assembly
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NOTICE
Incorrect placement of the stops
The CTU can be damaged.
►Secure the CTU with suitable stopping means.
►Make sure that the stopping means are routed and stretched
exclusively over the body and not over the analysis chamber of the
CTU.

Storing the assembly
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Storing the assembly
To store the assembly, proceed as follows:
1.
Drain the assembly completely.
Both reservoirs, as well as the rinse and return line filters.
2.
Pull power plug.
3.
Coil up the power cable and secure it at the CTU.
4.
Dismantle the mounted parts like, for instance, the monitor, the
monitor holder, the keyboard with holder and the foot switch.
Store the system in clean and dry rooms, in an upright position under the
storage conditions, see chapter "Technical details" on page 84.

Decoding the model code label
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Decoding the model code label
Details for identifying the filtration unit can be found on the name plates on
the unit and the components.
Item
->
Description
(1)
->
Name plate for power unit
(2)
->
Model code; for details, see page 86.
(3)
->
Details of rated voltage / frequency / phases and power
consumption.
The following information can be found on the name plate of the unit:
Row
->
Description
Model
->
Model Code
P/N
->
Part number
S/N
->
Serial number / year of production
Date
->
Year/week of production