Hydac CTU 1 3 Series Manual

CTU 1x3x / CTU 1x4x
ContaminationTest Unit
Operating and Maintenance Instructions
English (translation of original instructions)
Document No. : 4093420f
Follow these instructions for proper and safe use.
Keep for future reference.
Valid from series no. up 0002S01495K000000192

Imprint
Manufacturer/ Publisher and responsible for the content:
Address of the manufacturer Contact address
HYDAC FILTER SYSTEMS GMBH HYDAC FILTER SYSTEMS GMBH
Industriegebiet Justus-von-Liebig-Str., Werk 20
66280 Sulzbach / Saar 66280 Sulzbach / Saar
Germany Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Homepage: www.hydac.com
Court of Registration: Saarbrücken, HRB 17216
Executive directors: Mathias Dieter, Dipl.Kfm. Wolfgang Haering
Documentation Representative
The contact data of the Documentation Representative is:
Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Date of printing: 9/3/2021
© HYDAC FILTER SYSTEMS GmbH
Subject to technical modifications.

HYDAC FILTER SYSTEMS GMBH Table of Contents
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Table of Contents
1General............................................................................................................................... 7
1.1 Target group of the manual.........................................................................................7
1.2 Illustrations in the manual ...........................................................................................8
1.2.1 Illustration on the title page................................................................................ 8
1.2.2 Representation of requirements ........................................................................ 9
1.2.3 Representation of procedural instructions ......................................................... 9
1.2.4 Representation of intermediate results/results ................................................ 10
1.2.5 Supplementary symbols .................................................................................. 11
1.2.6 Representation of warning / general safety information .................................. 11
1.2.7 Signal words and their meaning in the general safety information .................. 12
1.3 Exclusion of liability / warranty ..................................................................................13
1.4 Notes on copyright ....................................................................................................13
2Safety ............................................................................................................................... 14
2.1 Target group / Required personnel qualification .......................................................14
2.2 Hazard symbols / pictograms....................................................................................17
2.3 Danger notifications ..................................................................................................20
2.4 Safety marking ..........................................................................................................24
2.5 Observing regulatory information ..............................................................................25
2.6 Observing environmental precautions.......................................................................25
2.7 Wear personal protection equipment ........................................................................25
2.8 Shutdown in an emergency (EMERGENCY STOP) .................................................26
2.9 Fire-fighting measures ..............................................................................................26
3Performance and product description............................................................................... 27
3.1 Checking the scope of delivery .................................................................................27
3.2 Intended Use.............................................................................................................28
3.3 Improper use or use deviating from intended use.....................................................30

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3.4 Technical data...........................................................................................................31
3.5 Decoding the name plate ..........................................................................................33
3.5.1 Model Code ..................................................................................................... 34
3.6 Dimensions ...............................................................................................................35
3.7 Components/operating elements ..............................................................................37
3.7.1 Control panel ................................................................................................... 38
4Transporting / Storing the extraction unit.......................................................................... 39
4.1 Transporting with a fork lift truck ...............................................................................40
5Setting up/assembling/commissioning ............................................................................. 42
5.1 Setting up the extraction unit.....................................................................................42
5.2 Making the electrical connections .............................................................................44
5.2.1 Checking the terminal strip in the switch box .................................................. 44
5.2.2 Installing / Connecting the components........................................................... 45
5.3 Suctioning the machine room....................................................................................47
5.3.1 Connecting an air extractor ............................................................................. 48
5.3.1.1 Suctioning the machine room of the CTU 1x3x........................................ 48
5.3.1.2 Suctioning the machine room and analysis chamber of the CTU1x4x..... 49
5.4 Connecting the compressed air connection ..............................................................51
5.5 Connecting the foot switch ........................................................................................51
5.6 Commissioning..........................................................................................................52
6Operation.......................................................................................................................... 53
6.1 Switching the extraction unit on / off .........................................................................54
6.2 Opening/closing the door ..........................................................................................55
6.3 Selecting the operating modes..................................................................................56
6.3.1 Performing the spray extraction....................................................................... 56
6.3.2 Running Flushing of inner chamber................................................................. 60
6.3.3 Ultrasonic extraction (optional) ........................................................................ 61
6.4 Determining the negative control value - Settings/parameters .................................64
6.5 Cascading the filter membranes / changing the filter membranes ............................66

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6.5.1 Creating cascades........................................................................................... 66
6.5.2 Filter membrane holder with quick fastener - Operating the CTMH ................ 68
6.5.3 Filter membrane holder with a screw cap........................................................ 72
6.5.4 Operating the filter membrane holder with clamp............................................ 74
6.6 Labeling the filter membrane ....................................................................................76
6.7 Overview of the variants / options .............................................................................77
6.7.1 Variant A – Add flushing .................................................................................. 77
6.7.2 Variant F - Flushing ......................................................................................... 79
6.7.3 Variante -EA - Extraction Air............................................................................ 80
6.7.4 Variant S2 - Changing over the vacuum.......................................................... 82
6.7.5 Option - Connecting external flushing ports (only CTU1xxx-x-x-R)................. 83
6.7.6 Option - Sensor to signal that the collecting pan is full.................................... 84
7Carrying out the maintenance / inspection ....................................................................... 85
7.1 Maintenance table.....................................................................................................86
7.2 Cleaning the analysis chamber .................................................................................87
7.2.1 Cleaning the analysis chamber in the case of test liquid - Water with surfactants
......................................................................................................................... 88
7.2.2 Cleaning the analysis chamber in the case of test liquid - G60Spezial/Fero-
cleanL261 ....................................................................................................... 88
7.3 Cleaning the door......................................................................................................88
7.3.1 Maintaining an electrostatically charged door ................................................. 89
7.4 Dismounting / Installing the side cover......................................................................90
7.5 Changing the test fluid ..............................................................................................90
7.5.1 Draining the test liquid / Emptying the extraction unit...................................... 90
7.5.2 Filling the test liquid / Filling the extraction unit ............................................... 92
7.5.3 Avoiding the mixing of test liquids - Flushing the extraction unit ..................... 94
7.6 Checking the screwed and plug connections............................................................94
7.7 Visual inspection of the electric components/cables.................................................94
7.8 Checking the hoses...................................................................................................94
7.9 Replacing hoses/plastic pipe.....................................................................................95

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7.10 Calibrating the temperature probe (optional with ultrasonic).....................................95
7.11 Cleaning the diffuser on the filter membrane holder .................................................96
7.12 Checking the calibration of the flow meter ................................................................97
7.13 Checking the protective gloves .................................................................................98
7.13.1 Permeation time according to EN374-3.......................................................... 99
7.14 Installing / Removing the protective gloves.............................................................100
7.15 Preparing for changing the filter element ................................................................102
7.15.1 Changing the filter element – MRF1 E........................................................... 102
8Eliminating errors............................................................................................................ 106
9Decommissioning / Disposal .......................................................................................... 109
9.1 Temporary shutdown ..............................................................................................109
9.2 Permanent shutdown ..............................................................................................109
9.3 Disposal / Recycling................................................................................................109
AAppendix......................................................................................................................... 110
A.1 Finding spare parts / accessories ...........................................................................110
A.1.1 Finding accessories....................................................................................... 113
A.2 Contacting Customer Service .................................................................................114
A.3 EC declaration of conformity ...................................................................................115
Glossary ......................................................................................................................... 119
Index............................................................................................................................... 121

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1 General
Before you use this product for the first time, read this manual at
least up to the chapter "Operation". If you would like to carry out
maintenance or troubleshooting, you can find the procedure in the
respective chapters.
The use and the handling of the product as well as its use are not
self-explanatory and are described in detail in this manual.
This manual will help you to use the product as intended, properly,
effectively, and safely. Please refer to it every time you require
specific details or actions.
Validity of this manual
The diagrams and visualizations in this manual are meant for gen-
eral illustration purposes. Therefore, representations and func-
tional options can deviate from the delivered product.
We reserve the right to modifications to the contents of this man-
ual without prior notice.
1.1 Target group of the manual
This manual was created for the following target group:
Target group Tasks
Owner Keep this manual and the applicable docu-
ments at the installation location of the prod-
uct and also for later use.
Ask the employees to read and follow the
manual and the associated documents, in
particular, the safety and warning instruc-
tions.
Additionally, please observe the product-re-
lated instructions and requirements.
Operator, specialist
personnel:
Read, observe and follow this manual and
the associated documents, in particular, the
safety and warning instructions.
Tab.1: Target group
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1.2 Illustrations in the manual
You will find illustrations in this manual. You can find details re-
garding these in the following chapters.
1.2.1 Illustration on the title page
You will find the following information on the title page of this man-
ual:
Short name of the product
Product name
Operating and Maintenance Instructions
Document no.: 12345678
English (translation of original instructions)
Valid from: - from s/no. - ... ... - ... ...
1
5
2
4
3
Fig.1: Overview / labeling of the title page
1 Short name of the product / product name
2 Type of document
3 Language
4 Document no. / Index
5 Supplementary instructions regarding the validity of the man-
ual (optional)
Please note that you can directly access information through the
directories. However, this does not release you from the obliga-
tion to read this manual fully before commissioning.
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The document no. with the index (4) is meant for identifying and
reordering the manual. The index is incremented every time the
manual is revised or changed.
The manual contains a table of contents, a list of tables and fig-
ures, an index and a glossary.
1.2.2 Representation of requirements
These are absolutely required for carrying out a work activity on
the product and are marked with a check mark and are in bold in
the text.
An example for the representation of requirements:
ühe product is assembled and connected.
üThe product is switched off.
1. Switch the product on.
1.2.3 Representation of procedural instructions
In the case of procedural instructions, there are the two following
representations:
Procedural instructions with a fixed sequence
Procedural instructions, whose sequence must be complied with
without fail are listed with sequential numbering (1., 2., 3., etc.).
An example for procedural instructions with a fixed sequence:
1. Remove the transport securing device.
2. First fill the product.
3. Switch the product on.
Procedural instructions with a random sequence
Procedural instructions that have a random sequence are listed as
bullet points (-).
An example of a procedural instruction with a random sequence:
– Clean the display.
– Rinse the product.
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1.2.4 Representation of intermediate results/results
In the case of some activities, it is necessary to carry out work
steps with intermediate results and end results.
Intermediate results are the consequence of activities; they are
marked with an indented arrow.
End results represent the end of an activity and are represented
with a flag.
An example for a procedural instruction with intermediate result
and final result:
1. Switch the product on.
ðThe display lights up.
2. Press the button.
OThe product is now ready for use.
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1.2.5 Supplementary symbols
You will find the following symbols in the manual as additional de-
tails:
[ ]
u##
Cross reference to a page / a chapter / a section or
another document.
Glossary
Terms in grey are explained in detail in the glossary, a
chapter at the end of the manual.
Tip for handling the product.
Required tool.
1.2.6 Representation of warning / general safety
information
All the warning / general safety information in this manual are
highlighted with pictograms and signal words. The pictogram and
the signal word give you information of the risk level of the danger.
Warning/General Safety Information, which is placed ahead of
each activity, are represented as follows:
CAUTION
Type and source of danger
Hazard symbol
Consequence of the danger
Measures to avert danger
►
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1.2.7 Signal words and their meaning in the general safety
information
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 mod-
erate 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.
ENVIRONMENTALLY TIP
ENVIRONMENTALLY TIP – The signal word indicates a haz-
ardous situation without a high level of risk, which, if not avoided,
will result in environmental contamination.
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1.3 Exclusion of liability / warranty
For the warranty provided by us, please refer to our terms of deliv-
ery. They are made available to you at the conclusion of the con-
tract at the latest. In addition, you will find these under
www.hydac.com -> General terms and conditions .
This manual was prepared to the best of our knowledge. Never-
theless and despite the greatest care, it is possible that it may con-
tain 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 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 con-
tractual obligation, our liability shall be limited to foreseeable dam-
age. Claims due to the product liability shall remain unaffected.
1.4 Notes on copyright
All copyrights for this manual lies with the manufacturer. No part of
this manual may be reproduced in any form or processed, dupli-
cated or distributed using electronic systems without the written
consent of the manufacturer. Any infringements to the above shall
be liable to damage compensation.
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2 Safety
The product is designed as safe. In spite of that, there is danger in
some actions that can only be avoided by using the right proce-
dures.
These correct procedures and points, which must be followed, are
described in this manual.
The following dangers could occur in the handling / operation of
the extraction unit.
2.1 Target group / Required personnel
qualification
These instructions are intended for owners, project engineers,
startup engineers, machine operators, service and maintenance
personnel.
The instructions explain the proper handling of the product to the
abovementioned target group. These instructions provide the tar-
get group with an overview of the installation, commissioning, op-
eration, maintenance work and also troubleshooting on the prod-
uct.
An owner is the person who operates the product himself/herself
for commercial or economic purposes or provides it to a third party
for use / application and bears the legal product responsibility to
protect the user, the personnel or the third party.
The obligations of the owner are:
– To know and apply the applicable health and safety regulations
– To determine the hazards arising at the operating site in the
risk assessment
– To create a user manual for the operation
– To regularly check if the user manual is consistent with the cur-
rent rules
– *To clearly lay down and define the responsibilities for the in-
stallation, operation, troubleshooting, maintenance and clean-
ing
– To ensure that all the employees have read and understood
the instructions
– To train the personnel at regular intervals and to inform them of
the hazards
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– To provide the necessary protective equipment to the person-
nel
Personnel who work with the product must be aware of the dan-
gers involved in handling it, must be over 14 years of age and
must be without any physical impediments in regard to the indus-
trial environment.
These instructions are intended for:
Activity Personnel Knowledge
Transport, storage Specialist personnel -
General
Knowledge of trans-
port safety is re-
quired
Installation Specialist personnel -
Mechanical
Specialist personnel -
Electrical
Safe handling/use of
tools.
Product-specific
knowledge is re-
quired.
Commissioning Specialist personnel -
Mechanical
Specialist personnel -
Electrical
Safe handling/use of
tools.
Product-specific
knowledge is re-
quired.
Handling, operation,
operation monitoring
Operating personnel
- General
Product-specific
knowledge is re-
quired.
Knowledge about
handling the test liq-
uid is required
Troubleshooting
Maintenance Decom-
missioning, Disas-
sembly
Specialist personnel -
Mechanical
Specialist personnel -
Electrical
Safe handling/use of
tools.
Product-specific
knowledge is re-
quired.
Disposal Specialist personnel -
General
Knowledge of envi-
ronmentally friendly
disposal of materials
and matter is re-
quired.
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Activity Personnel Knowledge
Knowledge of decon-
tamination of con-
taminants is required.
Knowledge of recy-
cling is required.
transport Commis-
sioning, Operation,
Troubleshooting
Maintenance Dis-
posal
Specialist personnel -
Service / Administra-
tor
Service personnel /
Administrator / HY-
DAC Service.
Extensive experience
of the product.
Tab.2: Target group / Required personnel qualification
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2.2 Hazard symbols / pictograms
The following are the safety symbols / pictograms in this manual.
They indicate specific dangers to persons, property or to the sur-
roundings. Observe these safety symbols / pictograms and act
with particular caution in such cases. Always keep all symbols /
pictograms intact and legible.
Used prohibitory signs
These marks can be found for all safety and warning instructions
in this manual which indicate particular dangers to persons, prop-
erty or the environment.
Fires, naked lights and smoking are prohibited
Warning signs used
These marks can be found for all safety and warning instructions
in this manual which indicate particular dangers to persons, prop-
erty or the environment.
Danger point warning
Dangerous electrical voltage warning
Signs used for giving orders
These symbols can be found for all safety and warning instructions
in this manual which indicate particular dangers to persons, prop-
erty or the environment.
Follow the direction.
Follow the instructions.
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Pull the power plug before opening
Wear eye protection.
Use protective gloves.
Wear safety shoes.
Used GHS symbols
These symbols can be found for all safety and warning instructions
in this manual which indicate particular dangers to persons, prop-
erty or the environment.
Hazardous to the environment
Others symbols used
These marks can be found for all safety and warning instructions
in this manual which indicate a particular danger to persons, prop-
erty or the environment.
Exposed electrical components
Danger due to operating pressure
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Signs used for the required specialist personnel
These symbols show the required training/knowledge for installa-
tion work and/or maintenance work.
Specialist personnel / operators
Such persons have had the 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 dangers.
Specialist personnel - Electrician
Such persons have specific specialist training and sev-
eral years' work experience. They are able to assess
and perform the work assigned to them, they are also
able to recognize potential dangers.
Specialist personnel - Mechanic
Such persons have specific specialist training and sev-
eral years' work experience. They are able to assess
and perform the work assigned to them, they are also
able to recognize potential dangers.
Specialist personnel - Service / Administrator
These persons have been trained by the manufacturer
and are authorized to perform service.
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2.3 Danger notifications
The following residual risks can occur in the various life phases of
the product:
Life phase - Transport / Storage
The following risks could arise during the commissioning / opera-
tion life phase:
NOTICE
Lifting the extraction module by the components
The extraction unit will be damaged
uUse suitable lifting accessories to lift the extraction module.
uLift the extraction module only by the housing, not by the at-
tachments or components.
Life phase - Commissioning / Operation
The following risks could arise during the commissioning / opera-
tion life phase:
WARNING
Test liquid G60Spezial or FerocleanL261 - Flammable gas-air
mixture in the analysis chamber
Danger of bodily injury
uOpen fires or smoking are prohibited in the vicinity.
WARNING
Danger due to unintended use / test liquid
Bodily injury / Damage to property
uThe extraction unit may only be used with the permitted test liq-
uid.
The dangers arising during commissioning/operation are mainly
caused by the test liquid used. Observe the chapter on the test
liquid you are using.
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