HYDAC FILTER SYSTEMS CTU 1x3x Series Manual

CTU 1x3x Series
Contamination Test Unit
Operating and Maintenance Instructions
English (translation of original instructions)
Document no.: 3631694d
(Valid until serial number: 0002S01495K000000191)
Keep for future reference.

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.
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Content
Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................6
Technical Support........................................................................................6
Product modification ....................................................................................6
Warranty......................................................................................................6
Using the documentation.............................................................................6
Safety information ........................................................................................8
Hazard symbols...........................................................................................8
Signal words and their meaning in the safety information and
instructions ................................................................................................10
Structure of the safety information and instructions...................................10
Proper/Designated Use .............................................................................11
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 the CTU .................................................................................16
Storing the CTU...........................................................................................19
Decoding the name plate ...........................................................................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
Connecting the CTU ..................................................................................26
Checking connections and contacts.......................................................26
Air extraction within the unit......................................................................29
Note when using the test liquid G 60 Spezial ............................................29
Connecting an air extractor........................................................................30
Electrical connection of the CTU ............................................................31
Connecting the compressed air..............................................................31
Connecting the foot switch .....................................................................32
Parts of the CTU........................................................................................33
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Content
Operating console ..................................................................................34
Functional principle....................................................................................35
Manual spray extraction.............................................................................35
Achievable negative control values ...........................................................36
Operating the filter membrane holder.......................................................37
Version with a union nut ............................................................................37
Version with a clip......................................................................................38
Cascading the filter membrane holder.......................................................39
Filter membrane holder CTMH CTMH
(ContaminationTest Membrane Holder).....................................................40
Cascading the filter membrane holder CTMH............................................41
Using external rinsing connections (CTU1xxx-x-x-R only) .....................42
Operating the door lock..........................................................................43
CTU in operation .........................................................................................44
Switching on CTU......................................................................................44
ConTeS Software ......................................................................................45
Clean-Room Conditions in the Analysis Chamber - Rinsing of the
inner chamber............................................................................................45
Automatic cleansing of the analysis chamber ........................................46
Automatic reservoir switchover ...........................................................47
Conducting Contamination Testing............................................................48
Spray extraction .....................................................................................48
Automatic reservoir switchover ...........................................................50
Perform ultrasonic test (optional)............................................................51
Switching the CTU 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
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
Replace hoses........................................................................................60
Changing filter element .......................................................................61
Calibrating the test liquid meter..............................................................64
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
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Content
Maintaining statically charged door.....................................................66
Change the test liquid.............................................................................67
Draining the test liquid.........................................................................67
Adding / Filling test liquid ....................................................................69
Checking the gloves ..................................................................................71
Permeation of Protective Gloves According to EN 374-3:1994 ..............72
Installing gloves .........................................................................................73
Use electro-statically conductive gloves.................................................73
Checking the filter regulator.......................................................................74
Setting the filter regulator .......................................................................74
Draining the filter regulator .....................................................................74
Filter regulator - Cleaning the filter elements..........................................74
Removing the filter regulator ..................................................................75
Removing the top part.........................................................................75
Removing the bottom part...................................................................75
Mounting the filter regulator....................................................................76
Mounting the bottom part ....................................................................76
Mounting the top part ..........................................................................76
Spare parts list............................................................................................77
Accessories.................................................................................................78
Options / Variants .......................................................................................79
S2 - Switch vacuum...................................................................................79
Sensor to signal that the collecting pan is full (optional) ............................80
Disposing of the CTU .................................................................................81
Technical Data.............................................................................................82
Attachment ..................................................................................................83
EC declaration of conformity......................................................................83
Customer Service / Service .......................................................................83
Model Code ...............................................................................................84
Explanation of terms and abbreviations.....................................................85
Index..........................................................................................................87
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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
additional options, etc.) may mean that the information in the operating
instructions is no longer applicable or adequate.
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.
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
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Preface
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
Fire hazard
Harmful to the environment
Wear eye protection.
Wear protective gloves.
Wear hearing protection.
Do not use any open fire or open flame while in
operation.
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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.
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
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Safety information
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 ISO18413).
DANGER
Only with soluble
test liquid: "G 60 Spezial"
Flammable gas-air mixture in the analysis
chamber
Risk of burns
►Use only test liquids with a flash point ≥60°C
or with a lower explosion limit > 0.6% by
volume.
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Safety information
NOTICE
Test liquids that cannot be used
The CTU is damaged
►Use only test liquids which are compatible with the materials and the
sealing materials they come in contact with.
►Use only test liquids with a flash point ≥
60°C or with a lower explosion
limit > 0.6% by volume.
►CTU 1xx1 only
Do not use completely desalinated water as a test liquid.
►CTU 1xx1 only
Using water containing surfactants (permissible pH values: 6 … 10) as
a test liquid is permitted.
Proper/designated use of the product extends to the following:
oMaintaining adherence to all the instructions contained herein.
oNot operating unless the side paneling is fitted.
oNot operating unless the analysis chamber is closed.
oPerforming requisite inspection and maintenance work.
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Safety information
Improper Use or Use Deviating from Intended Use
DANGER
Danger due to unanticipated use of the unit
Risk of bodily injury due to fire
►
Never operate the unit in potentially explosive
atmospheres.
►The unit is only to be used with permissible
media.
Any use extending beyond or deviating therefrom shall not be considered
intended use. HYDAC Filter Systems GmbH will assume no liability for any
damage resulting from such use. 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 an impermissible test liquid.
•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 power unit.
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.
Activity
Person
Knowledge
Transport / storage
Specialist
personnel
Knowledge of transport safety
required
Startup operation,
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.
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Safety information
Wear suitable clothing
Loose-fitting clothing increases the risk of being caught or being drawn in on
rotating parts, and the risk of getting caught on protruding parts. You can be
severely injured or killed.
•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.
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Transporting the CTU
Transporting the CTU
To transport the CTU, proceed as follows:
1.
Empty the CTU completely (both tanks, rinsing liquid and return
filter).
2.
Remove all moveable components sensitive to vibration like the
grating, nozzle, PC, monitor, keyboard, etc. from the CTU.
Move the CTU by pulling or pushing the handle. Never lift the CTU by the
handle.
The CTU is shipped from the factory in a wood box with the corresponding
securing devices. Pack the CTU for further transport in this wood box.
Alternatively, place the CTU on a pallet of sufficient size using a forklift.
Brace the CTU so that the steering rollers are not loaded.
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Transporting the CTU
Example illustration on a CTU10xx.
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Transporting the CTU
NOTICE
Bottle placement of the stops
The CTU is 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.
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Storing the CTU
Storing the CTU
To rinse the CTU, proceed as follows:
1.
Drain the CTU completely.
Both reservoirs, as well as the flush and return line filters.
2.
Pull power plug.
3.
Coil up the power cable and fix it to 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 CTU in a clean, dry room, upright with the following conditions:
Storage temperature:
0 … 50°C
Humidity:
max. 80%, non-condensing
Air:
dust-free, no salty air, not in the vicinity of
oxidizing substances (flash rust, rust bloom)
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Decoding the name plate
Decoding the name plate
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 84.
(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
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