Hydac CTM-EF 3 Series User manual

CTM-EF 3xxx
ContaminationTest Module -
Extraction Flushing
Installation and Maintenance Instructions
English (translation of original instructions)
Keep for future reference.
Documentation no.: 4229881a

Imprint
Imprint
Manufacturer / publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Industriestraße
66280 Sulzbach / Saar
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
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.
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
Modifications to the Product ........................................................................5
Warranty......................................................................................................5
Using the documentation.............................................................................6
Safety Information ........................................................................................7
Signal words and their meaning in the safety information and
instructions ..................................................................................................7
Structure of the safety information and instructions.....................................8
Warning signs used .....................................................................................8
Signs used for giving orders ........................................................................9
Used prohibitory signs .................................................................................9
Used GHS symbols .....................................................................................9
Others used symbols.................................................................................10
Signs used for the required specialist personnel .......................................10
Specialist personnel – Mechanical .........................................................10
Specialist personnel – Electricity ............................................................10
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
Danger due to electrical power..................................................................15
Stoppage in an emergency (EMERGENCY STOP)...................................16
Transporting the module............................................................................16
Storing the module .....................................................................................16
Decoding the name plate ...........................................................................17
Checking the scope of delivery .................................................................18
Module dimensions ....................................................................................19
Preparing the module for operation ..........................................................20
Setting up the module................................................................................20
Connecting the EF module to the SC ........................................................21
Electrical connection of the module........................................................22
Switching the module on and off...............................................................23
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Content
Module functional principle .......................................................................24
Conducting the extraction..........................................................................24
Module components ...................................................................................26
Operating the filter membrane holder.......................................................27
Cascading filter membranes......................................................................29
Labeling the filter membrane..................................................................30
Connecting the test item............................................................................31
Starting up the module...............................................................................32
Clean-room conditions in the analysis chamber - Flushing of the
inner chamber............................................................................................32
Starting/stopping extraction on the CTM-SC module.................................32
Performing maintenance............................................................................33
Maintenance work .....................................................................................34
Checking / Replacing hoses ......................................................................35
Checking the collecting pan.......................................................................35
Cleaning the diffuser on the filter membrane holder...............................36
Hydraulic circuit..........................................................................................37
Spare parts and accessories .....................................................................38
CTM-EF 3xxx-… spare parts .....................................................................38
Taking the unit out of operation ................................................................39
Shutting down the unit ...............................................................................39
Disposing of the unit ..................................................................................39
Technical details.........................................................................................40
Annex ...........................................................................................................41
Customer Service / Service .......................................................................41
Model code ................................................................................................42
EC declaration of conformity......................................................................42
Explanation of terms and abbreviations.....................................................43
Index..........................................................................................................45
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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 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]
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 -> 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
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 heading
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.
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
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
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Safety Information
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
Used GHS 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.
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Safety Information
Health hazard
Others used symbols
The following symbols found you in this operation instructions.
Tip for handling the product
Tools required
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.
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Safety Information
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 CTU 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.
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.
Proper/designated use of the product extends to the following:
•Maintaining adherence to all the instructions contained herein.
•Not operating the CTM unless cover panels are installed.
•Performing requisite inspection and maintenance work.
•Operation with an impermissible test liquid only.
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-xx 3xx0
Only use G 60 Spezial as the test liquid
CTM-xx 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
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 or use deviating from intended may result in hazards and/or will
damage the unit. Examples of improper use:
•Operation in potentially explosive atmospheres.
•Operation under non-approved operational conditions.
•Operation with an impermissible test liquid.
•Operation when the safety devices are defective or not activated.
•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 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
Auxiliary
personnel
No specialist knowledge
required
Startup operation,
operation
Operations control
Specialist
personnel
Product-specific knowledge
Knowledge about how to handle
operating media.
troubleshooting,
maintenance,
Decommissioning,
Disassembly
Specialist
personnel
Safe handling/use of tools
Product-specific knowledge
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
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.
Depending on the test liquid, protective gloves and eye protection are to be
worn. Note the safety data sheets of the test liquid.
You should replace damaged or worn gloves immediately.
•Wear close-fitting clothing.
•Do not wear any rings, chains or any other jewelry.
•Wear protective work clothing/work safety shoes.
•Wear safety goggles and protective gloves.
Danger due to electrical power
DANGER
Electric shock
Danger of fatal injury
►Any work involving electrical equipment may
only be done by a properly trained, certified
electrician.
►
Pull the power plug before performing work on
live parts.
•Regularly inspect the electrical connection cable for the unit.
•Fix any loose connections immediately.
•Periodically inspect the module in accordance with the accident
prevention regulations of the German employers' liability insurance
associations (BGV A3).
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Transporting the module
Stoppage in an emergency (EMERGENCY STOP)
In the event of an emergency, turn the
emergency stop switch 90° in a counter-
clockwise direction to shut down the entire
system. The entire system downstream of this
switch will then be de-energized.
Transporting the module
The module comes wrapped in plastic sheeting or in a wood crate, the latter
having to be specifically ordered.
When receiving and unpacking the unit, check it for damage in transit. Report
any damage to the forwarding agent immediately.
The packing material is to be disposed of as specified by law or national
regulations or can be reused.
The module can be moved by pushing it on its casters. You can also use
hoisting equipment (e.g. a fork lift truck) to transport the module, provided its
load-carrying capacity is greater than the weight of the empty module. The
module must be secured to prevent it from tipping.
Seal all flexible hose connections using screw plugs.
Storing the module
Disconnect the power plug, connecting cable and hoses from the connected
modules.
Seal all flexible hose connections using screw plugs.
Store the completely emptied unit in a clean, dry room with the following
conditions:
Permitted storage
temperature range:
See chapter "Technical details", page 40.
Humidity:
max. 80 % (non-condensing)
Air:
dust-free, not 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
For identification details of the CTM-EF, see the name plate.
Item
->
Description
(1)
->
Name plate for module
(2)
->
Supply voltage, power supply, power consumption
Model
->
Model code; for details, see page 42
P/N
->
Part no.
S/N
->
Serial no.
Date
->
Week/year of manufacture
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Checking the scope of delivery
Checking the scope of delivery
The ContaminationTest Module CTM-EF comes packed and pre-assembled.
Before commissioning, please check the delivery to make sure it has not
been damaged during transport and that it is complete.
Qty
Designation
1
ContaminationTest Module CTM-EF
1
Supporting sieve for the filter membrane holder
1
Coded plug, 13-pin
4
Hoses, length 3 m (5 m length = optional)
1
Technical documentation, consisting of:
- Installation and maintenance instructions (this document)
- Electrical circuit diagram
- Additional documents
- CE declaration of conformity
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Module dimensions
Module dimensions
The module has the following dimensions.
All dimensions in mm.
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Preparing the module for operation
Preparing the module for operation
Setting up the module
The module has 4 casters. Before pushing, release the hand brake on the
casters. Push the module on the casters into the required position. Always
use the handles when pushing the CTM-EF.
When you have positioned and aligned the module, set the brakes on all the
casters.
Place the module on an even, level surface to the right of the CTM-SC.
Make sure that there is a minimum clearance of 0.5 m all around the CTM-
EF.
Make sure that the installation location provides proper laboratory conditions
with appropriate cleanliness and temperature of the air and environment.
CAUTION
"G60 Spezial" test liquid
Hazardous to health
►Make sure that there is adequate ventilation.
►Observe the information relating to personal
protection equipment in the safety data sheet
of the test liquid.
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