Hydac CTU 1000 Series Manual

CTU 1000 Series
Contamination Test Unit
Operating and Maintenance Instructions
E
En ng gl li is sh h ( (t tr ra an ns sl la at ti io on n o of f o or ri ig gi in na al l i in ns st tr ru uc ct ti io on ns s) )
Document No.: 3229578p
Valid from series no. up: 2481/2007
Keep for future reference.

Imprint
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
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.
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Contents
Contents
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Contents ........................................................................................................3
Preface...........................................................................................................6
Technical Support........................................................................................6
Modifications to the Product ........................................................................6
Warranty......................................................................................................6
Using the documentation.............................................................................6
Safety Information ........................................................................................7
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 assembly..................................................................................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 ..................................................................................25
Checking connections and contacts.......................................................25
Air extraction within the unit......................................................................28
Note when using the test liquid G 60 Spezial ............................................28
Connecting an air extractor........................................................................29
Electrical connection of the CTU ............................................................30
Connecting the compressed air..............................................................30
Connecting the foot switch .....................................................................31
Parts of the CTU........................................................................................32
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Contents
Operating console ..................................................................................33
Manual spray extraction.............................................................................34
Achievable negative control values ...........................................................35
Operating the filter membrane holder.......................................................36
Version with a union nut ............................................................................36
Version with a clip......................................................................................37
Cascading filter membranes......................................................................38
Filter membrane holder CTMH (ContaminationTest Membrane
Holder).......................................................................................................39
Cascading filter membrane holder CTMH ..............................................40
Door contact switch ................................................................................41
Using external rinsing connections (CTU1xxx-x-x-R only) .....................42
Operating the door lock ..........................................................................43
Sensor to signal that the collecting pan is full (optional).........................44
CTU in operation .........................................................................................45
Switching on CTU......................................................................................45
CTU software.............................................................................................46
Clean-Room Conditions in the Analysis Chamber.....................................46
Automatic cleansing of the analysis chamber ........................................47
Automatic reservoir switchover ...........................................................48
Conducting Contamination Testing............................................................49
Spray extraction .....................................................................................49
Automatic reservoir switchover ...........................................................51
Perform ultrasound test (optional) ..........................................................52
Switching the CTU Off ...............................................................................54
Changing the filter membrane ...................................................................55
Labeling the removed filter membrane ......................................................57
Performing inspection / maintenance.......................................................58
User information for the "products under pressure"................................59
Maintenance work overview ......................................................................59
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 .............................................................................................60
Maintenance intervals for CTU 1xx1 with water as the test
liquid....................................................................................................60
Replace hoses........................................................................................60
Micronic filter / return-line filter ...............................................................61
Changing the CTU 1xx0 filter elements...............................................62
Replacing/Reinstalling Filter Elements CTU 1xx1 ..................................64
Changing the filter elements on the CTU 1xx1....................................65
Calibrating the test liquid meter..............................................................68
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Contents
Calibrating the temperature sensor (ultrasound option only)..................68
Cleaning the analysis chamber ..............................................................68
Cleaning the diffuser for the filter membrane holder...............................69
Cleaning the door...................................................................................69
Statically charged door...........................................................................70
Change the test liquid.............................................................................70
Draining the test liquid / Draining unit..................................................71
Adding test liquid / Filling system ........................................................73
Checking the gloves ..................................................................................75
Permeation of Protective Gloves According to EN 374-3:1994 ..............76
Installing gloves .........................................................................................77
Gloves electrically conductive ................................................................77
Checking the filter regulator.......................................................................78
Setting the filter regulator .......................................................................78
Draining the filter regulator .....................................................................78
Cleaning the filter elements....................................................................78
Removing the filter regulator ..................................................................79
Removing the top part.........................................................................79
Removing the bottom part...................................................................79
Mounting the filter regulator....................................................................80
Mounting the bottom part ....................................................................80
Mounting the top part ..........................................................................80
Hydraulic diagram.......................................................................................81
Spare parts list............................................................................................82
Spare Parts — CTU 1xxx ..........................................................................82
Spare Parts — CTU 1xx0 ..........................................................................83
Spare Parts — CTU 1xx1 ..........................................................................83
Customer Service .......................................................................................84
Disposing of the CTU .................................................................................84
Technical details.........................................................................................85
Model code ................................................................................................86
Index ............................................................................................................87
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Preface
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 General Terms of Sale
and 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
these instructions prior to starting the unit up for the first time and
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Safety Information
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.
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.
Chapter heading
Page number
Edition date
Document language
Documentation no.
with Index /
File name
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Safety Information
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
Risk of burns due to hot surfaces
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Safety Information
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 18413).
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 in excess of
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 in excess of 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 or designated use of the product extends to the following:
•Maintaining adherence to all the instructions contained herein.
•Not operating unless the side paneling is fitted.
•Not operating unless the analysis chamber is closed.
•Performing 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. The user alone, shall assume any and all
associated risk.
Improper use 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 be 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
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
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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 clean room of the CTU.
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Storing the assembly
Storing the assembly
To store the assembly, proceed as follows:
1.
Drain the assembly 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 assembly 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 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
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