Hydac CTM-EF-1 Series, Operating And Maintenance Instructions Manual

Page 1: ...CTM EF 1x3x ContaminationTest Module Extraction Flushing Operating and Maintenance Instructions English translation of original instructions Keep for future reference Documentation no 4365310 ...

Page 2: ...lfgang Haering Documentation Representative Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Phone 49 6897 509 1511 Fax 49 6897 509 1394 E mail guenter harge hydac com 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 witho...

Page 3: ...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 16 Danger due to electrical power 16 Observe regulatory information 16 Transp...

Page 4: ...acement 31 Labeling the filter membrane 35 Starting up the module 36 Clean Room Conditions in the Analysis Chamber Rinsing of the inner chamber 36 Automatic cleansing of the analysis chamber 36 Performing maintenance 37 Maintenance work 38 Checking Replacing hoses 38 Clean the diffuser on the filter membrane holder 39 Finding spare parts 40 Decommissioning the product 41 Shutting down the product ...

Page 5: ...l 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 49 6897 509 9046 E mail filtersystems hydac com Modifications to the Pr...

Page 6: ... 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 HYDAC Filtertechnik GmbH BeWa 123456a de 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 i...

Page 7: ... inspection certificate and keep it until the next inspection 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 ...

Page 8: ...e 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 t...

Page 9: ...or the environment 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 operati...

Page 10: ... 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 handli...

Page 11: ...s 2018 06 06 docx 2018 06 06 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 ...

Page 12: ...viating therefrom shall not be considered intended use HYDAC FILTER SYSTEMS GMBH will assume no liability for any damage resulting from such use Proper or designated use of the product extends to the following Maintaining adherence to all the instructions contained herein Performing requisite inspection and maintenance work Operation with an impermissible test liquid only NOTICE Impermissible test...

Page 13: ...ting from such use The user alone shall assume any and all associated risk Improper use may result in hazards and or will damage the module 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 module...

Page 14: ...erating 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 tr...

Page 15: ...ooting Repair Decommissioning Disassembly Specialist personnel Safe handling use of tools Fitting and connection of hydraulic tubes and connections Fitting and connection of electrical lines electrical machinery sockets etc Product specific knowledge Operation Operations control Specialist personnel Product specific knowledge Knowledge about how to handle operating media Knowledge about contaminat...

Page 16: ...fety shoes 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 Always keep the control cabinet locked Periodically in...

Page 17: ...y damage to the respective forwarding agent immediately 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 To transport the module all test liquid reservoirs and filter holders must be drained Storing the module Disconnect the connec...

Page 18: ...ecoding 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 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 number Date Year week of production ...

Page 19: ...odule CTM EF comes packed and ready to be connected Before commissioning please check the scope of delivery to make sure it has not been damaged during transport and that it is complete Qty Designation 1 ContaminationTest Module CTM EF 1 Technical documentation consisting of Operating and maintenance instructions this document Circuit diagram Additional documents Certificates ...

Page 20: ...Module dimensions CTM EF 1x3x Series en Page 20 52 BeWa CTM EF 1x3x 4365310 en us 2018 06 06 docx 2018 06 06 Module dimensions All dimensions in mm ...

Page 21: ... end of the sampling process the entire liquid with its particle load is sucked via the membrane retainer The rinsing liquid now referred to as the analysis liquid that carries the rinsed off dirt particles is drawn through the analysis membrane by means of vacuum and returned through connection R to CTM SC 1xxx CTU 1x4x x x F CTU 1x4x x x A The analysis membrane is then analyzed The results provi...

Page 22: ...bar Nozzle Volume in l Pressure bar Nozzle CTM EF 12xx 20 5 Center nozzle eliminated CTM EF 14xx 20 5 Center nozzle eliminated CTM EB 12xx 30 5 Center nozzle 14 4 Flat spray CTM EB 14xx 30 5 Center nozzle 20 4 Flat spray CTM EB 14xx Q8 30 5 Center nozzle 22 4 Flat spray CTM EB 16xx 30 5 Center nozzle 20 4 Flat spray CTM EB 18xx 30 5 Center nozzle 20 4 Flat spray CTM EB 19xx 30 5 Center nozzle 20 4...

Page 23: ...anes in µm Gravimetric analysis in mg 0 particles X µm CTM EF 12xx 3 3 Center nozzle 5 0 1 70 CTM EF 14xx 3 3 Center nozzle 5 0 1 70 CTM EB 12xx 4 5 3 Flat spray 5 0 2 100 CTM EB 14xx 6 5 3 Flat spray 5 0 2 150 CTM EB 14xx Q8 8 5 3 Flat spray 5 0 3 180 CTM EB 16xx 6 5 3 Flat spray 5 0 3 180 CTM EB 18xx 6 5 3 Flat spray 5 0 2 150 CTM EB 19xx 6 5 3 Flat spray 5 0 2 150 CTM EB 20xx 8 5 3 Flat spray 5...

Page 24: ...e Installation size Volume in l Pressure bar Nozzle CTM EF 12xx 3 3 Center nozzle CTM EF 14xx 3 3 Center nozzle CTM EB 12xx 4 5 3 Flat spray CTM EB 14xx 6 5 3 Flat spray CTM EB 14xx Q8 8 5 3 Flat spray CTM EB 16xx 6 5 3 Flat spray CTM EB 18xx 6 5 3 Flat spray CTM EB 19xx 6 5 3 Flat spray CTM EB 20xx 8 5 3 Flat spray CTM EB 46xx 8 5 3 Flat spray ...

Page 25: ...65310 en us 2018 06 06 docx 2018 06 06 Components of the module Item Designation 1 Reservoir 2 Cover 3 Ball valve 4 Filter membrane holder 5 Control plug 6 Connection hoses A I B I R 7 Sliding grip 8 Caster 9 Connections hoses of test item A I R 10 Filter membrane holder support ...

Page 26: ...se the hand brake on the casters When you have positioned and aligned the CTM EF set the brakes on the casters Make sure that the CTM EF is on a level horizontal surface to the right next to the CTM SC 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 Health hazard M...

Page 27: ...x x x F CTU 1x4x x x A software carefully Take the support sieve supplied and put it in the membrane holder Clean the clean room by using the rinsing of the inner chamber until a negative control value is achieved as listed in the table on page 22 Attach the connector to the control unit and the connection hoses of CTM EF to CTM SC 1xxx CTU 1x4x x x F CTU 1x4x x x A as shown below The test item to...

Page 28: ...r The design presses the filter membrane in the lower part 2 of the filter membrane holder function tight to the upper part The CTMH filter membrane holder has three height positions for threefold cascading Select the height according to your desired cascading To seal the filter membrane holder it is sufficient to turn the upper part 90 Note that the wrench size at the lower part to the left and r...

Page 29: ...8 06 06 CAUTION G60 Spezial test liquid Health hazard Make sure that there is adequate ventilation Always wear protective gloves Always wear eye protection NOTICE Test liquid flows out Danger of slipping and falling Check before each test procedure that the membrane holder is mounted correctly Check the drip tray daily and empty if required ...

Page 30: ...ion Item Designation 1 Coupling 2 Hose connection 3 Diffuser A diffuser ensures that the analysis liquid is evenly distributed over the entire filter membrane 4 Upper part of the filter membrane holder 5 1 Filter membrane 100 µm 5 2 Filter membrane 20 µm 5 3 Filter membrane 5 µm 6 Supporting sieve 7 Intermediate ring 8 The lower part of the filter membrane holder with a hose connection A 1st casca...

Page 31: ...serves as an emergency isolation valve Carrying out the replacement Before you remove the filter membrane the analysis liquid must have been completely sucked away 1 Hold the holder with one hand on the lower part Use your other hand to release the lock 90 in the counterclockwise direction 2 Disengage the lower part from the upper when the guide of the lower part is parallel to the lock guide ...

Page 32: ... en us 2018 06 06 docx 2018 06 06 3 Pull down the lower part slightly Then pull it fully through the opening created 4 Remove the filter membranes from the cascade for further analysis and mark them as given in the chapter on page 35 5 Fit a new filter membrane onto the supporting sieve ...

Page 33: ...6 Place the lower part horizontally in the upper part together with the filter membranes Lift the lower part vertically under the upper part The position of the screen must match the number of cascades 7 If two cascades are mounted the screen must be moved to the center The lower part remains assembled as described above ...

Page 34: ... 1x3x Series en Page 34 52 BeWa CTM EF 1x3x 4365310 en us 2018 06 06 docx 2018 06 06 8 If three cascades are mounted the screen must be moved to the uppermost position 9 Tighten the lock 90 in the clockwise direction Do not use any tools ...

Page 35: ...ogical system An example of labeling filter membranes xyz 1 A 005 xyz Current sample series component designation 1 Number of membranes created for a measurement series A If several equivalent rinsing operations are to be performed for a component A B C and Z are used for creating a random sample 005 Membrane filtration fineness 5 µm 020 Membrane filtration fineness 20 µm 100 Membrane filtration f...

Page 36: ... cleaned in a defined manner by volume or time using the inner chamber rinsing program Automatic cleansing of the analysis chamber The automatic cleaning of the inner chamber causes the inner walls of reservoir to be cleansed in a defined manner The nozzle to clean the inner chamber is located in the middle of the analysis chamber It is activated via connection B For information on controlling the...

Page 37: ...system is pressurized Danger of bodily injury The system must be depressurized before performing any work on it WARNING G60 Spezial test liquid Fire hazard Fires naked lights and smoking prohibited CAUTION G60 Spezial test liquid Hazardous to health Make sure that there is adequate ventilation Always wear protective gloves Always wear eye protection ...

Page 38: ... of brittleness X Visually inspect the electrics X Check all screwed connections and other connectors to ensure that they are firmly secured X Cleaning the diffuser for the filter membrane holder X Check that all of the shut off valves are working properly X Replace hoses 2 years Checking Replacing hoses The installed hoses are specially designed for use with the test liquid The hoses must be chec...

Page 39: ...8 06 06 Clean the diffuser on the filter membrane holder Clean the filter membrane holder at least once a week 1 Open the coupling 1 and remove the diffuser 3 2 Clean the diffuser 3 by blowing it out with compressed air 3 Put the diffuser into the filter membrane holder and screw the coupling 1 finger tight ...

Page 40: ... 1 Supporting sieve 47 mm stainless steel for the filter membrane holder 6177739 1 Sealing ring for membrane holder 611942 1 O ring for filter membrane holder 604122 1 Breather filter 306340 1 Caster 4 Level sensor 1 Level sensor programmed for CTM EF 1xxx 3986722 1 Hoses 6023627 1 Quick action coupling 6065601 1 Reservoir cover 3490920 1 on request Quantity installed in the CTM EF 1x3x Accessorie...

Page 41: ...y including all the components before decommissioning Pull out the power plug and securely fasten the hoses and power cord to the product Shutting down the product See chapter Decommissioning the product Disposing of the product After dismantling the product and separating its various materials into categories dispose of all parts in an environmentally friendly manner ...

Page 42: ...mensions Height 1448 mm Width 500 mm Depth 500 mm Empty weight 53 kg Nominal volume EF 1230 5 liters EF 1430 8 liters Voltage 24 V DC Wattage 15 W Protection class to DIN 400050 IP 54 Permitted ambient temperature range 15 28 C Permitted storage temperature range 0 50 C Permitted relative air humidity Max 80 non condensing ...

Page 43: ...f a technical nature please contact HYDAC FILTER SYSTEMS GMBH Justus von Liebig Str Werk 20 66280 Sulzbach Saar Fax 49 6897 509 9046 E mail filtersystems hydac com For repair work or complaints please contact our central customer service department HYDAC SYSTEMS SERVICES GMBH Friedrichsthaler Straße 15 Werk 13 66540 Neunkirchen Heinitz Phone 49 6897 509 883 Fax 49 6897 509 324 E mail service hydac...

Page 44: ...Attachment CTM EF 1x3x Series en Page 44 52 BeWa CTM EF 1x3x 4365310 en us 2018 06 06 docx 2018 06 06 Hydraulic diagram ...

Page 45: ... 2018 06 06 docx 2018 06 06 Item Designation A Quick action coupling A B Quick action coupling B R Quick action coupling R A Test item port A R Test item port R 1 Reservoir 2 Inner chamber flushing 3 Breather filter 4 Membrane holder B1 Level sensor V1 Ball valve X Test item ...

Page 46: ...ash point 60 C explosion limit 0 6 by volume 1 water containing tensides permissible pH values 6 10 no completely demineralized water Power supply K 120 V AC 60 Hz 1 phase USA Canada M 230 V AC 50 Hz 1 phase Europe N 240 V AC 50 Hz 1 phase United Kingdom O 240 V AC 50 Hz 1 phase Australia P 100 V AC 50 Hz 1 phase Japan Z without Extraction methods Z Flushing medium pressure Supplementary details Z...

Page 47: ...rol value Inherent soiling value cm Centimeters ConTeS ContaminationTest Software CTM ContaminationTest Module CTMH ContaminationTest Membrane Holder CTM EB ContaminationTest Module Extraction Box CTM EF ContaminationTest Module Extraction Flushing CTM SC ContaminationTest Module Supply Control DC Direct current DIN Deutsche Industrie Norm German Industry Standard DN Nominal Diameter Drain Drainag...

Page 48: ...0 001 bar MIN Minimum mm Millimeter NBR Nitrile rubber Nm Newton meters torque specification OFF Switched off ON Switched on OUT Outlet OUTLET Outlet Test liquid Fluid for general operation flushing fluid analysis fluid Sec Second s Flushing fluid Test liquid for spray extraction SW Wrench size for tools Vent Ventilation air bleed port VE water Demineralized Deionized water ...

Page 49: ...mity 46 Empty weight 42 F Filter 13 25 28 30 40 filtration 18 21 35 Flash point 47 Forwarding agent 15 H Hazard symbol 8 Hose connection 30 Hydraulic diagram 44 I Imprint 2 IN 48 Inlet 48 INLET 48 installation 10 15 26 27 IP 42 L Level sensor 40 45 M Maintenance 1 15 38 47 Manufacturer 2 Measures 8 Model code 18 46 O OFF 48 operating 5 6 7 8 9 10 14 15 36 Operation 12 13 15 47 Operations control 1...

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Page 52: ... Industriegebiet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Tel 49 6897 509 01 Board no Fax 49 6897 509 9046 Technology Fax 49 6897 509 577 Sales Internet www hydac com E mail filtersystems hydac com ...