Hydac CTU 2 Series Manual

CTU 2xxx series
Contamination Test
Unit
Operating and Maintenance Instructions
English (translation of original instructions)
Document No.: 3160738h
Keep for future reference.

Imprint
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Imprint
Manufacturer / publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Industriegebiet
66273 Sulzbach / Saar
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Homepage:
www.hydac.com
Court of Registration:
Saarbrücken, HRB 17216
Executive directors:
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.
The trademarks of other companies are exclusively used for the products of
those companies.

Content
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Content
Imprint............................................................................................................2
Documentation Representative...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................7
Technical Support........................................................................................7
Product modification....................................................................................7
Warranty......................................................................................................7
Using the documentation.............................................................................8
Safety information ........................................................................................9
Signal words and their meaning in the safety information and
instructions ..................................................................................................9
Structure of the safety information and instructions...................................10
Warning signs used...................................................................................10
Signs used for giving orders......................................................................11
Used prohibitory signs...............................................................................11
Others used symbols.................................................................................12
Signs used for the required specialist personnel.......................................12
Specialist personnel – Mechanical.........................................................12
Specialist personnel – Electricity............................................................12
Observe regulatory information .................................................................13
Proper/Designated Use .............................................................................13
Improper Use or Use Deviating from Intended Use...................................15
Qualifications of personnel / target group..................................................16
Wear suitable clothing...............................................................................17
Observe regulatory information .................................................................17
What to Do in Case of Emergency (EMERGENCY STOP) .......................17
Transporting the CTU.................................................................................18
Storing the CTU...........................................................................................18
Decoding the model code label.................................................................19
Checking the scope of delivery.................................................................20
Functional principle of the CTU.................................................................21
Clean-room conditions in the analysis chamber........................................23
Filling/refilling test fluid...............................................................................23
Automatic inner chamber cleaning/clean room cleaning ...........................23
Performing the contamination test.............................................................23
Achievable negative control values ...........................................................24
Parts of the CTU..........................................................................................25
Control elements on the operating panel...................................................26

Content
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Control elements on the operating console...............................................27
Preparing the CTU for operation ...............................................................28
Setting up the CTU....................................................................................28
Setting up the electrical connection of the CTU......................................29
Connecting the compressed air..............................................................30
Connecting an air extractor....................................................................31
Opening/closing the door ..........................................................................32
Door with several access holes.................................................................33
Door with gloves........................................................................................34
Installing gloves......................................................................................35
Use electro-statically conductive gloves..............................................35
Door with several access holes and small pane........................................36
Operating the filter membrane holder.......................................................37
Filter membrane holder CTMH (ContaminationTest Membrane
Holder).......................................................................................................37
Cascading filter membrane holder CTMH..............................................38
Filter membrane holder with union nut ......................................................39
Filter membrane holder with clamp............................................................40
Cascading filter membranes...................................................................41
Changing the filter membrane...................................................................42
Labeling the filter membrane.....................................................................44
Operating the text display TD 200 .............................................................45
CTU switching on ......................................................................................47
Selecting the operating mode....................................................................48
Stand-by.................................................................................................48
Operation ...............................................................................................48
Setting the vacuum for suctioning off the rinsing fluid................................49
Setting the pressure of the rinsing fluid......................................................49
Filling/refilling rinsing fluid..........................................................................50
Selecting the rinsing volume......................................................................53
Performing the contamination test.............................................................54
Cleansing the clean room automatically....................................................56
Automatic reservoir change-over...............................................................57
CTU switching off (Power Down)...............................................................58
Preparing the CTU for operation ...............................................................59
Clean-room conditions in the analysis chamber - Rinsing of the
inner chamber............................................................................................60
Performing the spray extraction method.................................................60
Performing maintenance............................................................................61
Maintenance work .....................................................................................62
Maintenance intervals.........................................................................62

Content
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Inspecting/cleaning the machine compartment..........................................63
Replacing hoses........................................................................................63
Selecting the rinsing fluid filter / return filter...............................................63
Changing the filter element – type LF.....................................................64
Changing the filter element – type MRF1...............................................67
Removing/fitting halogen lights (CTU up to manufacture year 2006) ........70
Light spare parts.....................................................................................72
Removing/fitting LED lights (CTU 2200 / 2400 from manufacture
year 2013) .................................................................................................73
Checking/maintaining the spray gun..........................................................74
Changing the spray nozzle.....................................................................74
Replacing the hose for the spray gun.....................................................75
Calibrating the flow rate meter................................................................76
Cleaning the analysis chamber..................................................................76
Clean the diffuser on the filter membrane holder....................................76
Cleaning the door......................................................................................77
Statically charged door...........................................................................77
Changing the clean-room filters.................................................................78
Replacing the prefilter mat .....................................................................78
Replacing the main filter.........................................................................79
Replacing the main filter of a CTU 2000 .............................................79
Replacing the main filter of a CTU 2200 / 2400...................................80
Emptying the intermediate pan..................................................................81
Changing the test fluid...............................................................................81
Draining the reservoirs...........................................................................82
Reservoir filling/refilling .......................................................................83
Checking the gloves..................................................................................83
Permeation of Protective Gloves According to EN 374-3:1994..............84
Checking the filter regulator.......................................................................86
Setting the filter regulator.......................................................................86
Draining the filter regulator.....................................................................86
Cleaning the filter elements of the filter regulator...................................86
Disassembling the filter regulator...........................................................87
Disassembling the top part..................................................................87
Disassembling the bottom part............................................................87
Assembling the filter regulator................................................................87
Assembling the bottom part.................................................................88
Assembling the top part ......................................................................88
Remedying error messages/malfunctions................................................89
Hydraulic circuit..........................................................................................91
Locating spare parts...................................................................................94
Disposing of the CTU .................................................................................96

Content
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Technical Data.............................................................................................97
Attachment..................................................................................................99
EC declaration of conformity......................................................................99
Customer Support/Service.........................................................................99
Model Code.............................................................................................100
Explanation of terms and abbreviations...................................................101
Index........................................................................................................103

Preface
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Preface
These operating instructions were made to the best of our knowledge.
Nevertheless and despite the greatest care taken, it may contain errors.
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
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
all 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 a face shield
Use protective gloves
Wear safety shoes
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

Safety information
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Others used symbols
The following symbols found you in this operation instructions.
Tip for handling the product
Required tools
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 lines 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.

Safety information
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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
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 ISO 18413).
DANGER
Only with soluble
test fluid: "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

Safety information
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Overloading the analysis chamber
The CTU can be damaged.
►Note the maximum load capacity of the test item of 50 kg for evenly
distributed load, no point loading.
NOTICE
Test fluids that cannot be used
The CTU can be damaged.
►Use only test fluids that are compatible with the materials and the
sealing materials they come in contact with.
►Use G60 Spezial as the test fluid.
►CTU 1xx1 only
Do not use completely demineralized water as a test fluid.
Using water containing tensides (permissible pH values: 6 to 10) as a
test fluid 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.
•Supervised operation.

Safety information
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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. This risk is borne solely by the owner.
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 fluid.
•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.
•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:
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 fluid 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 case of emergency, actuate the
EMERGENCY STOP button.
This will put the entire unit in a safe state.
The main switch is used to cut off the power
supply to the unit as a whole.

Transporting the CTU
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Transporting the CTU
To transport the CTU, proceed as follows:
1.
Empty the CTU completely (both reservoirs, rinsing fluid filter and
return filter).
2.
Remove all parts that are movable and sensitive to vibration, such
as the grate, gun, oil pan, etc. from/out of the CTU.
NOTICE
Risk of tipping during transport
The CTU can be damaged.
►Position the forks of the forklift truck as wide apart as possible during
lifting.
►Secure the CTU with suitable stopping means.
Storing the CTU
To store the CTU, proceed as follows:
1.
Empty the CTU completely (both reservoirs, rinsing fluid filter and
return filter).
2.
Pull power plug.
3.
Coil up the power cable and secure it at the CTU.
Store the CTU in a clean, dry room, 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)

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)
->
Type label for power unit
(2)
->
Model code; for details, see page 100.
(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

Checking the scope of delivery
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Checking the scope of delivery
The ContaminationTest Unit CTU is packed and delivered partially
assembled. Before commissioning, check the scope of delivery of the CTU to
make sure it has not been damaged during transport and that it is complete.
The following items are supplied:
Item
Qty
Designation
1
1
ContaminationTest Unit CTU 2xxx series
2
1
Air vent connection kit, consisting of:
1x blanking cover, 1x hose connecting piece, 2x seal,
fastening material
3
1
Four-sided hollow socket key, 6 mm
-
1
Spray gun including connection hose
-
1
Accessories for threefold membrane retainer:
2x support ring, 3x supporting sieve
-
1
Collecting pan
-
1
Documentation, consisting of:
- Operating and maintenance instructions (this document)
- Electrical circuit diagram
- CE Declaration of Conformity
- Other documents