CTU 2xxx series Contamination Test Unit - HYDACCTU 2xxx series . Contamination Test Unit Operating and Maintenance Instructions . English (translation of original instructions) Document

CTU 2xxx series Contamination Test Unit

Operating and Maintenance Instructions

English (translation of original instructions)

Document No.: 3160738h Keep for future reference.

Imprint

CTU 2xxx series en-US Page 2 / 108

BeWa CTU2000 3160738h en-us 2018-11-15.docx 2018-11-15

Imprint

Manufacturer / publisher and responsible for the content: HYDAC FILTER SYSTEMS GMBH Industriegebiet 66273 Sulzbach / Saar Germany Phone: +49 6897 509 01 Fax: +49 6897 509 9046 E-mail: [email protected] 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: +49 6897 509 1511 Fax: +49 6897 509 1394 E-mail: [email protected]

© 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



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



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



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



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



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: +49 6897 509 9046 E-mail: [email protected]

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.

http://www.hydac.com/

Preface



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.

deHYDAC Filtertechnik GmbHBeWa 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 is revised or changed.

Chapter description

Page number Edition date

Document language Documentation no. with index/

file name

Safety information



Safety information

The unit was built according to the statutory provisions valid at the time of delivery and satisfies current safety requirements. Any residual hazards are indicated by safety information and instructions and are described in the operating instructions. Observe all safety and warning instructions attached to the unit. They must always be complete and legible. Do not operate the unit unless all the safety devices are present. Secure the hazardous areas which may arise between the unit and other equipment. Maintain the unit inspection intervals prescribed by law. Document the results in an inspection certificate and keep it until the next inspection.

Signal words and their meaning in the safety information and instructions

In these instructions you will find the following signal words:

DANGER DANGER – The signal word indicates a hazardous situation with a high level of risk, which, if not avoided, will result lethal or serious injury.

WARNING WARNING – The signal word indicates a hazardous situation with a medium level of risk, which, if not avoided, can result lethal or serious injury.

CAUTION CAUTION – The signal word indicates a hazardous situation with a low level of risk, which, if not avoided, can result in minor or moderate injury.

NOTICE NOTICE – The signal word indicates a hazardous situation with a high level of risk, which, if not avoided, will result in damage to property.

Safety information



Structure of the safety information and instructions All warning instructions in this manual are highlighted with pictograms and signal words. The pictogram and the signal word indicate the severity of the danger. Warning instructions listed before an activity are laid out as follows:

HAZARD SYMBOL

SIGNAL WORD

Type and source of danger

Consequence of the danger

Measures to avert danger

Warning signs used These signs are listed for all safety information and instructions in these operating instructions which indicate particular hazards to persons, property or the environment.

Danger point warning

Dangerous electrical voltage warning

Safety information



Signs used for giving orders These symbols are listed for all safety information and instructions in these operating instructions which indicate particular hazards to persons, property or the environment.

Follow the operating and maintenance instructions

Wear eye protection

Use 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



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



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



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


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



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



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



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



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


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



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



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

Functional principle of the CTU




The CTU is a specially designed test bench for analyzing the surface cleanliness of components. These components are rinsed off in a clean environment using a test fluid with a defined cleanliness. The particles carried by the test fluid are collected on a membrane for subsequent analysis. The results provide information on the type, size and mass of contamination. Knowing what type of contamination is involved enables measurements to be taken to prevent it (improved filtration, transportation, storage, etc.). After the CTU is filled, the rinsing fluid used is located in reservoir B1. The component to be analyzed is located in the clean room (30). As soon as the operating mode is switched from stand-by to operation, reservoir B1 is pressurized. After entering the desired amount of rinsing fluid and starting the contamination test via the text display, the rinsing fluid is conveyed from reservoir B1 into the analysis chamber via the rinsing fluid micronic filter (22) by actuating the spray gun (V12). The operator has to make sure that the surfaces of the component to be analyzed are rinsed. The contamination-particle-laden rinsing fluid is sucked via vacuum action through the analysis membrane (14) and flows into reservoir B2. The vacuum is produced by a vacuum generator (15) according to the Venturi principle. The fill level in reservoirs B1 and B2 is monitored via level sensors (12, 13). When the level in reservoir B1 reaches the lower threshold, the system automatically changes between reservoir B1 and reservoir B2 so that when processing continues, the rinsing fluid will be pumped from reservoir B2 to reservoir B1. The amount of rinsing fluid is calculated by a flow rate meter (23). Once the preset amount has been conveyed, the contamination test is automatically stopped. The analysis membrane can now be removed and analyzed.




1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1 3

2

B1 B2

1

2

1

2

Y10

11

10

15

Y30 Y31 Y40Y41 Y90 Y91

Y50 Y51 Y61 Y60

Y70

22

S5

Y81

2

1

43

16 17

9

6

7

8

V12

14

V11

5

31

1 2

1

2

1

2

1

2

12

V5 V7

V4

S4

V13

V8

33

V6

S2

A A

A A A A

A A

A

A

A A

V10

V1

V9

V21

V20

18 19

S3S1

30




Clean-room conditions in the analysis chamber The filter hood contains the clean-air module for supplying the analysis chamber with filtered air. The clean-air module produces an air curtain and overpressure in the analysis chamber, thereby preventing particles from getting in from the surrounding atmosphere. The air vent system is also located in the filter hood. This sucks away the air of the analysis chamber in the front section of the CTU and guides it to the air vent channels.

Filling/refilling test fluid Here, the rinsing fluid is filled in the analysis chamber of the CTU and sucked into reservoir B1 via vacuum action.

Automatic inner chamber cleaning/clean room cleaning The automatic cleaning of the inner chamber causes the inner walls of the clean room to be cleansed in a defined manner. The cleaning time can be set for this.

Performing the contamination test The contamination test can be used to rinse components or test objects in a defined manner.




Achievable negative control values The achievable blank (negative control value) readings strongly depend on the ambient conditions and frequency of use. Experience shows that the following negative control value readings may be obtained: Ambience CTU

2000 CTU 2200

CTU 2400

Clean room 0.4 … 0.6 0.4 … 0.7 0.6 … 1.0

Laboratory 0.5 … 0.8 0.5 … 0.9 0.6 … 1.4

Separate sampling room 0.5 … 1.0 0.5 … 1.1 0.8 … 1.6

Factory hall 0.8 … 1.2 0.8 … 1.4 3.0 … 5.0

Parts of the CTU



Parts of the CTU

Item Designation

1 Clean room

2 Front pane

3 Operating panel / control cabinet

4 Operating console

5 Pane fixture

6 Filter hood

7 Visual fluid level indicator

8 Rinsing fluid micronic filter [22]

9 Return filter [33]

10 Rinsing fluid reservoirs

Parts of the CTU



Control elements on the operating panel

Item Designation

31 Return-line vacuum indicator

32 Rinsing medium pressure indicator

33 Text display TD200

34 Reservoir change-over active indicator

35 "Operation" signal lamp

36 "Stand-by" signal lamp

37 Operating mode selector switch

38 Main switch

39 EMERGENCY STOP button

Parts of the CTU



Control elements on the operating console

Item Designation

41 Return-line rinsing fluid shut-off ball valve

42 Return-line vacuum setting

43 Rinsing fluid pressure setting

44 Vacuum shut-off ball valve

45 Threefold filter membrane holder

46 Compressed air shut-off ball valve

47 Compressed air supply

Preparing the CTU for operation




Setting up the CTU Make sure that the CTU is on a level, horizontal surface. Make sure that the CTU is at least 5 cm from the wall or devices located at the back, that there is enough space (≥ 0.5 m) between the suction filter and room ceiling and that the EMERGENCY STOP button, main switch and filter membrane holder are freely accessible at all times. Make sure that the cleanliness of the surrounding area, the ambient air and the temperature at the installation location are similar to laboratory conditions.

CAUTION

"G 60 Spezial" test fluid

Hazardous to health

Make sure that there is adequate ventilation. Always wear protective gloves. Always wear eye protection.




Setting up the electrical connection of the CTU The CTU is supplied with a power plug fitted.

DANGER

Dangerous electrical voltage warning

Danger of fatal injury

Any work involving the power supply may only be done by a properly trained, certified electrician.

Remove the power plug before undertaking any work.

Before plugging the CTU into the power socket, make sure that the voltage available corresponds to that specified on its type label.




Connecting the compressed air The inlet for the compressed air supply is located at the right on the operating console. The inlet is a standard connector nipple of the DN 7.2 low-pressure series.

The compressed air required must be dry, de-oiled and pre-cleaned to 5 µm. Additional conditions can be found in chapter "Technical Data" on page 97.




Connecting an air extractor The connection for discharging suctioned air to the outside or to a filter is located in the rear head section of the CTU. Screw the connecting piece [3] for a Ø 125 mm hose onto the top or rear port. Seal off the unused port with the blanking cover [1]. Fit an air vent hose (Ø 125 mm) via the connecting piece [3] and secure the air vent hose in place using a hose clamp.

Item Designation

[1] Blanking cover

[2] Seal

[3] Air vent connecting piece for Ø 125 mm air vent hose

Opening/closing the door



Opening/closing the door The door design varies depending on the model:

- Door with several access holes - Door with gloves - Door with several access holes and small pane

The door should only ever be moved using the handle provided.




Door with several access holes

CAUTION

Falling parts

Risk of injury to the feet

Wear safety shoes

The access holes in the door are sealed off with the covers provided. These are placed on the pane and remain there thanks to the integrated magnets. Ensure that the covers are properly fixed in place.

The covers can be taken off by pulling the handles.




Door with gloves The gloves are permanently attached and must be checked for damage at regular intervals. See chapter "Checking the gloves" on page 83 for more information.




Installing gloves Prepare the gloves before installation. To do so, roll up the gloves from the back for about 5 cm to form a roll, like in the following illustration.

Make sure that the text / labelling on the inside of the glove is on the side into which you put your hand. The text / labeling can come undone during sampling and lead to impairment of the analyses.

Introduce the gloves through the openings into the analysis chamber. Then, stretch the rolled end of the glove over the access opening from the outside. It is not necessary to additionally secure the gloves to the access opening. Use electro-statically conductive gloves When replacing the gloves, ensure that there is sufficient protection (i.e. conductivity) from electrostatic charge as specified in IDN EN 61340-5-1.

Rg = 2.0 x 108 Ω

Please make sure that resistance Rg (Ω) is between 7.5x105 ≤ Rg ≤ 1x1012 to EPA ground or a grounding point for gloves and finger stalls.




Door with several access holes and small pane

CAUTION

Falling parts

Risk of injury to the feet

Wear safety shoes

The access holes in the door are sealed off with the covers provided. These are placed on the pane and remain there thanks to the integrated magnets. Ensure that the covers are properly fixed in place.

The small pane must be mounted securely before every extraction procedure. Fix the pane in place using the split pins provided.

Operating the filter membrane holder



Operating the filter membrane holder When the CTU is delivered, you get the following two options to use the filter membrane holder.

Only close the ball valve (3) to prevent fluid from escaping.

Filter membrane holder CTMH (ContaminationTest Membrane Holder) The design presses the filter membrane in the lower part (2) of the filter membrane holder function-tight to the upper part.

The filter membrane holder CTMH 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 right is visible in order to insert the lower part into the upper part.




Cascading filter membrane holder CTMH Cascade filter membranes as shown in the following illustration: Item Designation

1 Coupling

2 Hose connection

3 Diffuser (A diffuser ensures that the analysis fluid is evenly distributed over the entire filter membrane)

4 Upper part of the filter membrane holder

5.1 Filter membrane, 100 µm



6 Supporting sieve

7 Intermediate ring

8 The lower part of the filter membrane holder with a hose connection

A 1st cascade - coarse

B 2nd cascade - medium

C 3rd cascade - fine




Filter membrane holder with union nut The fine thread on the union nut (1) means that the lower part (2) of the filter membrane holder is pressed against the upper part preventing leakage and ensuring that the membrane works properly.

1

2

3

To close the filter membrane holder, lift the lower part (2) up to the upper part and tighten the union nut (1) clockwise. Do not use a tool. The filter membrane holder is opened by turning the union nut (1) counterclockwise.




Filter membrane holder with clamp

NOTICE

Operation without an intermediate ring / supporting sieve

Leak in the filter membrane holder

The membrane holder only seals effectively when: - a vacuum is applied - a supporting sieve is inserted with a filter membrane

It is not possible to use two intermediate rings

Squeeze the clip together by the handles (1). Push the clip over the filter membrane holder (2). Carefully release the clip handles—the clip’s spring force (3) will press the two halves together with the intermediate ring of the filter membrane holder. Make sure that an intermediate ring and two supporting sieves are used when a clip is used.




Cascading filter membranes Cascade filter membranes as shown in the following illustration: Item Designation

5.1

5.2

5.3

8

123

4

7

7

6

6

6

A

B

C

1 Coupling

2 Hose connection

3 Diffuser (A diffuser ensures that the analysis fluid is evenly distributed over the entire filter membrane)

4 Upper part of the filter membrane holder

5.1 Filter membrane 100 µm



6 Supporting sieve

7 Intermediate ring

8 The lower part of the filter membrane holder with a hose connection

A 1st cascade - coarse

B 2nd cascade - medium

C 3rd cascade - fine

Changing the filter membrane



Changing the filter membrane The ball valve on the filter membrane holder serves as an isolation valve for ultrasonic operation or for emergencies. Ensure that the analysis fluid has been completely sucked away before you remove the filter membrane.

1. Hold the holder with one hand on the lower part. With your other hand, undo the union nut counterclockwise.

2. Put down the lower part together

with the filter membrane in its holder.

3. Remove the filter membrane for

analysis and label it as shown in the example on page 44.




4. Fit a new filter membrane on the supporting sieve.

5. Pick up the union nut.

Position the lower part together with the filter membrane underneath the upper part.

6. Screw on the union nut clockwise.

NOTICE Do not use any tools.




Labeling the filter membrane Label the filter membrane that you just removed using a clear & logical 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



Operating the text display TD 200



Operating the text display TD 200 Apart from setting the pressure and selecting the operating mode, you can control all functions using the text display. The functions in the top half of the buttons can be selected directly by pressing these buttons. To select the functions in the bottom half (black background), press the "SHIFT" button first.




Inscription

Buttons Function

ENTER

Confirming entries and selections

ESC

Cancelling entries or selections -> OPERATING MENU (password-protected) -> DIAGNOSTICS MENU (password-protected)

SHIFT

Switching the button assignment

+ / -

/

Selection buttons used to select individual functions

STOP

Canceling all functions

OK

Starting selected functions

SET

Settings menu for presetting the rinsing volume

CLEAN

Automatic cleaning of the clean room

SERVICE

Filling/refilling and draining the CTU with/of rinsing fluid

POWER DOWN

Shutting down the CTU




CTU switching on Turn the operating mode selector switch to "Stand-by" and switch the CTU on at the main switch. The text display will output the

following message…

…after approx. 10 seconds, this message will appear…

…the following message will then be

shown on the text display.

Switch the CTU to "Operation" using the operating mode selector switch…

…when you see the following

message on the text display, it means that the CTU is ready for operation.

Contamination Test Please wait

HYDAC FILTER SYSTEMS Contamination Test

S T A N D – B Y

Contamination Test Press OK button to start




Selecting the operating mode The operating mode is set using the selector switch at the front.

Stand-by When you switch the unit to stand-by:

• The compressed air line is blocked off.

• The reservoirs are adjusted to normal pressure and then sealed off.

• The fan power is reduced.

• The lighting is switched off. The clean room remains operational in stand-by mode.

Compressed air continues to flow via the vacuum generator. This does not represent a system defect!

Operation When you switch the unit to operation:

• The compressed air line is opened.

• The reservoirs are adjusted to operating pressure.

• The fan power is increased to operating power.

• The lighting is switched on.




Setting the vacuum for suctioning off the rinsing fluid To set this, proceed as follows: 1. Switch the shut-off ball valve of the compressed air supply to "on". 2.

To turn on the vacuum generator, press the button on the text display.

3. Set the "VACUUM return line" pressure control valve to 6 bar. 4.

Press the button on the text display. 5. The suction vacuum is now set.

Setting the pressure of the rinsing fluid To set this, proceed as follows: 1. Switch the shut-off ball valve of the compressed air supply to "on". 2. Set the pressure control valve to the desired pressure. Check the

pressure shown by the gauge on the operating panel. 3. The pressure is now set.




Filling/refilling rinsing fluid To fill or refill the CTU with rinsing fluid, the rinsing fluid is filled in the analysis chamber of the CTU and sucked into reservoir B1 via vacuum action.

CAUTION

Spraying "G60 Spezial" test fluid

Health hazard

Keep the door to the analysis chamber closed as far as possible during the spray extraction process.

Always wear a face shield. Always wear protective gloves.

To add rinsing fluid, follow all instructions and the following procedure.

NOTICE

Overfilling the unit

The reservoirs are overfilled.

Add only the required indicated fill quantity for the test fluid. If the unit is overfilled, contact the HYDAC Service Department.

Fill quantity during initial filling 20 liters




Check the fill levels of reservoirs B1 / B2 using the visual fluid level indicator.

Avoid overfilling the reservoirs.

Close the "RINSING FLUID return line" shut-off valve.

Remove the filter membrane from the filter membrane holder.

Message on text display.

Press the buttons.

Press the button.

Reservoirs 1 and 2 are being vented.

The reservoirs are vented to allow for precise filling.

This message appears once the reservoirs have been vented.

Please wait …

Fill rins. fl. = OK Vent res. 1/2 = +


Suctioning of rinsing fluid




Open the "RINSING FLUID return line" shut-off valve.

The lamp for the reservoir change-over lights up briefly. This goes out once the rinsing fluid can be suctioned.

Now fill the rinsing fluid in the drain pan of the clean room.

Press the button once the drain pan has been emptied through the suction action.

Press the button.

The basic setting will be displayed.

Check the fill levels of reservoirs B1 / B2 again.


Reservoirs full when pan empty: OK




Selecting the rinsing volume This menu allows you to predefine 10 different rinsing volumes so that you can call them up at a later point.

Message on text display.

Press the buttons.

Press the button.

Press the / buttons to scroll through the 10 rinsing volume programs and confirm the selection

by pressing the button.

To change the preset value, select

the value using . The selected value will flash and can be changed

by pressing the / buttons in 0.1 increments.

Once you have reached the desired

value, press to confirm.

Press the button to go to the main menu.

Rins. vol. 0: xx.x L Rins. vol. 1: xx.x L

Select rinsing volume Select OK


Rins. vol. 0: xx.x L

Rinsing volume no. 0: 10.0 L





Performing the contamination test The "Contamination Test" operating mode can be used to rinse components in a defined manner.

CAUTION


Health hazard



After switching on the CTU and switching to "Operation" mode, the following message appears on the display:

Pressing the button takes you to the main menu.

Press the button and .

Press the / buttons to scroll through the 10 rinsing volume programs. Confirm your selection

with the button.

Select the volume value by pressing

the button or change the

value by pressing the button. The value will flash and can be changed by pressing the


Select rins. 0-9 Rinsing volume no. 0

Rinsing volume no.: 0 Rinsing volume no.: 1

Volume = 0.1 L OK or up/down




/ buttons in increments. Confirm the selection by pressing the

button.

The rinsing volume predefined using "SET" is used again for the next contamination test.

Press the button. V = remaining volume (in liters) until the contamination test is completed Q = current flow rate (in liters/minute)

Rinse the test object using the handheld spray gun.

The rinsing fluid supply is automatically stopped once the set amount has been conveyed. If necessary, the rinsing fluid reservoir is changed over automatically (even during sampling).

The rinsed volume is displayed again

here. Press the button to confirm only once the entire volume has been suctioned from the clean room. The suctioning time is not limited.

To make it easier to remove the filter membrane, we recommend

only pressing the button after you have removed it.

Contamination Test V=xx.x L Q=y.y L/M



Volume = xx.x L Test completed: OK




Cleansing the clean room automatically

CAUTION

Spraying analysis fluid

Danger of eye injury

When cleaning the clean room, the door must remain firmly closed.

The automatic cleaning of the inner chamber causes the clean room to be cleansed in a defined manner. Select a cleaning duration ranging from 1 to 60 minutes.

Set the cleaning time to five minutes and repeat the cleaning cycle three to five times.

Press the buttons.

Press the button.

Press the button to confirm the length of time or press the

/ buttons to change the value in minute increments.

Press the button to confirm

the set time and press the button to start the cycle.

After starting the cleaning cycle, the remaining time is shown on the display.

By pressing , the cleaning cycle can be cancelled at any time


CTU cleaning: time Select OK

Duration: 0 MIN OK or up/down

Remaining time: x MIN Press STOP to cancel

Duration: 5 MIN OK or up/down




before the set cleaning time elapses.

There is still analysis fluid in the collecting pan after the cleaning time has elapsed.

Only press the button once the clean room has been completely emptied.

Automatic reservoir change-over During the contamination test or inner chamber cleaning, the fill levels of reservoirs B1 and B2 are continuously monitored. When the lower fill level is reached in one reservoir, the system automatically changes over to the other reservoir. This change-over takes some seconds and is indicated by the signal lamp.

- The "CHANGE-OVER reservoir" signal lamp flashes until the remaining

volume has been conveyed. - The test fluid supply is stopped. - The "CHANGE-OVER reservoir" signal lamp lights up until the change-

over is completed. - If the contamination test is completed before the remaining volume has

been consumed, the system will change over as soon as the contamination test is finished.

Cleaning completed Press OK to continue




CTU switching off (Power Down) To switch off the CTU, proceed as follows:

The display outputs the following message as a default.

Press the button and then the

button.

Here the compressed air line is blocked off and the rinsing fluid reservoirs are vented.

You can now either switch the CTU into STAND-BY mode or…

…switch it off at the main switch.

CTU can now be switched off

CTU Power Down Please wait







WARNING

When using "G 60 Spezial" as the test fluid

Warning of flammable substances

Open flames are prohibited near the CTU.

Proceed as follows for initial commissioning: 1. Take the supporting sieve supplied and put

it in the filter membrane holder. See page 32 for details.

2. Set the filter regulator to ≈ 6 bar. See page 30 for details. 3. Fill the CTU with test fluid. See page 50 for details. 4. Thoroughly clean the clean room by using

the rinsing of the inner chamber and the spray gun until a negative control value is achieved as listed in the table on page 24. For this purpose, rinse the CTU at least 20 times with approximately 20 liters.

See page 56 for details.




Clean-room conditions in the analysis chamber - Rinsing of the inner chamber

Before starting a series of contamination tests, cleanse the clean room of the CTU in a defined manner using the volume or time/duration in the rinsing program "Cleansing the clean room automatically". During operation, as well as between extractions, make sure that the clean room is always closed and is opened for only a short time for the insertion of the component to be analyzed. Only in this way can you ensure that contamination from the surrounding area is as minimal as possible.

Performing the spray extraction method

CAUTION


Health hazard



Manual spray extraction enables you to rinse components in a defined manner as described in the "Functional description" chapter.

Performing maintenance



Performing maintenance Perform the maintenance tasks described below.

WARNING

The system is pressurized

Danger of bodily injury

Depressurize the system before working on it. After being switched off, the system

depressurizes automatically.

WARNING

When using the "G 60 Spezial" as the test fluid

Warning of flammable substances

Open flames are prohibited near the CTU.

CAUTION

"G 60 Spezial" test fluid

Hazardous to health

Make sure that there is adequate ventilation in the room.

Always wear protective gloves. Always wear eye protection.




Maintenance work The maintenance and servicing to be performed periodically is described in the following. The CTU’s serviceability, operational reliability and life expectancy depend on performing maintenance and servicing work regularly and carefully.

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test

Check all hoses for leaks or signs of brittleness X

Visually inspect the electrics. Look for any damage to wires, connectors, sensors, cabling and electrical equipment in the switch cabinet.

X

Check all screwed connections and other connectors to ensure that they are firmly secured

X

Check that all of the shut-off valves are working properly

X

Maintenance intervals

Replace hoses

63

2 years for multi-shift operation; 6 years for single-shift operation

Change the rinsing fluid filter 63 12 months

Change the return filter 63 12 months

Calibrating the flow rate meter 76 X

Clean the clean room 76 X

Clean the diffuser on the filter membrane holder 76 X

Change the test fluid 81 X 1 month




Inspecting/cleaning the machine compartment As a result of air filters and leaks, test medium may collect at the bottom of the machine compartment in the CTU. If the machine compartment is opened, it must be well ventilated. Inspect and clean the collecting pan of the CTU on a weekly basis.

Replacing hoses The installed hoses are specially designed for use with the test fluid. The hoses must be checked regularly for brittleness. In the case of multi-shift operation, replace the hoses after two years. In the case of single-shift operation, replace the hoses after six years.

Selecting the rinsing fluid filter / return filter Change the filter elements of the rinsing fluid filter and return filter as per the maintenance schedule. The filter dirt indicator is not triggered unless there is a flow through the filters. Note the different versions of the rinsing fluid filter and return filter: - LF Filter housing See page 64 for details - MRF1 Filter housing See page 67 for details




Changing the filter element – type LF

LF in-line filter

3

4

1

2

56

Item Designation

1 Filter element including O-ring (2)

2 O-ring

3 O-ring

4 Support ring

5 Sealing ring

6 O-ring - Repair kit, consisting of:

O-ring [2], O-ring [3], support ring [4], sealing ring [5], O-ring [6]

- Wrench = 27 mm




To change the filter, proceed as follows:

1. Open both front doors.

2. Determine which filter housing needs to be changed. Unscrew the filter bowl in a counterclockwise direction using the A/F 27 wrench and remove it in a downward motion.

The filter bowl contains rinsing fluid. Collect this in a suitable container larger than 1 liter and dispose of it in an environmentally friendly manner.

3. Pull the filter element off the mounting pin

and dispose of it in an environmentally friendly manner.

4. Clean the filter bowl.

5. Check the filter bowl and filter head for mechanical damage. In particular, check the sealing surfaces and the thread.

6. Check the O-rings and support rings for damage and brittleness. If necessary, replace these parts.

7. Wet the thread and sealing surfaces on the filter bowl and filter head, including the O-ring on the filter bowl and filter element, with clean test fluid.

8. When installing the new filter

element, check to see whether the designation on the new element corresponds to the designation on the old one.




9. Slide the new filter element onto the mounting pin applying slight pressure and turning it.

When installing the new filter element, check to see whether the designation on the new element corresponds to the designation on the old one.

NOTICE Do not use a hammer, etc.

10. Screw in the filter bowl in a clockwise direction as far as it will go using the A/F 27 wrench and then screw it back a ¼ turn (90°) to release it slightly.

11. Close both front doors.

12. Start up the CTU again.

13. After operating for about 1 hour, check the filters for leaks.

14. The filter element change is now

complete.




Changing the filter element – type MRF1

- Strap wrench (for opening the union nuts)

- Allen wrench = 6 mm

To change the filter, proceed as follows:

1. Open both front doors.

2. Drain the test fluid from the filter housing. To do that, carefully unscrew the drain plug (2) at the bottom end of the filter bowl in a clockwise direction using a 6 mm Allen wrench.

The filter bowl contains approx. 1.5 liters test fluid. Catch the test fluid that drains out in a suitable container and put it in the clean room after changing the element.

3. Loosen the coupling nut (1) by turning it

in a clockwise direction and then remove the filter bowl (2).

Use a strap wrench to remove the coupling nut.

4. Remove the used filter element from the

element mount in a downward motion and dispose of it in an environmentally friendly manner.




5. Clean the filter bowl and sealing surface.

6. Clean the sealing surface on the filter

head. Check the O-ring for damage. Moisten the O-ring with the operating medium.

7. For easy installation of the filter element, wet the O-ring with the operating medium.




8. Carefully press the new filter element into the element mount by applying slight pressure, pressing it upwards and screwing it in.

NOTICE Do not use a hammer, etc.

9. (1) Before screwing the union nut back on, apply a lubricant. We recommend using white Vaseline as a lubricant HYDAC part no. 632391 (2) Screw the filter bowl over the union nut onto the filter head in a counterclockwise direction. When doing this, screw the union nut hand tight only.

10. Start up the CTU and rinse the inner

chamber using the automatic cleaning cycle with a volume of 5 ... 10 liters.

11. Check the changed filters for leakage.

12. Close both front doors.

13. The filter element change is now complete.




Removing/fitting halogen lights (CTU up to manufacture year 2006) The clean room is lit using three or four halogen lights.

Item Designation

1 Bulb holder with clips

2 Bulb

3 Clamping ring

4 Top part of light with glass and sealing ring




To change the halogen bulb, proceed as follows:

CAUTION

Hot surface

Danger of burns

Allow the halogen lights to cool down before removing them.

1. Switch the CTU off and allow the halogen lights to cool down.

2. Remove the halogen lights by pulling them out of the light rail. Pull the bulb socket off.

The halogen light is held in place in the rail by two clips. Carefully pull the halogen light out of the light rail.

3. Unscrew the bulb holder from the top part of the light.

4. Remove the clamping ring.

5. Insert the new bulb into the bulb holder.

6. Secure the bulb in the bulb holder using the clamping ring.

Screw the bulb holder with the fitted bulb and clamping ring into the top part of the light.




8. The halogen light is now assembled.

9. Plug the bulb socket in.

10. Push the clips of the halogen light together and slot the halogen light into the corresponding opening.

11. Switch the CTU on and check that the

halogen lights work.

Light spare parts

Only use the following light as a replacement:

Designation

Reflector light Ø 35 mm, GU 4, 20 W, 12 V




Removing/fitting LED lights (CTU 2200 / 2400 from manufacture year 2013)

The clean room is lit using four LED lights. These LED lights can only be replaced as a whole.




Checking/maintaining the spray gun

Item Designation

1.0 Spray gun handle piece

2.0 Filter holder (including filter)

3.0 Hose with screwed fittings, length 1.8 m

4.0 Spray nozzle

Changing the spray nozzle The following spray nozzles are available as accessories; see the list of spare parts and accessories. Designation Figure Standard nozzle

Long "ridged" nozzle

Long "round" nozzle

Long "open" nozzle




To change the spray nozzle, proceed as follows:

1. Switch the CTU off via the main switch. Direct the spray nozzle into the clean room and actuate it to relieve the pressure in the spraying system.

2. Unscrew the spray nozzle 4.0 from the filter holder 2.0 in a counterclockwise direction using a wrench.

3. Screw the spray nozzle 4.0 into the filter holder 2.0 by hand and tighten it slightly using a wrench.

4. The spray nozzle is now changed.

Replacing the hose for the spray gun

To change the hose, proceed as follows:

1. Switch the CTU off via the main switch. Direct the spray nozzle into the clean room and actuate it to relieve the pressure in the spraying system.

2. Unscrew the screwed hose fitting from the spray gun handle piece 1.0.

3. Unscrew the screwed hose fitting from the clean room.

4. Dispose of the old hose in an environmentally friendly manner.

5. Take the new hose.

6. Screw on the screwed hose fitting in the clean room.

7. Screw the screwed hose fitting onto the spray gun handle piece 1.0.

8. The replacement of the hose is now complete.

9. Switch the CTU on at the main switch and check the hose and screwed hose fittings for leaks during operation.




Calibrating the flow rate meter Calibrate the flow rate meter annually by gauging. To do so, proceed as follows: 1. On the filter regulator, set the rinsing pressure to 2 bar. 2. Have a measuring beaker that can hold a volume of 5 liters or more

ready. 3. Start a contamination test in the CTU software with a flushing

volume of 5 liters. 4. Fill the measuring beaker using the spray gun (nozzle) of the CTU

by operating the foot switch until the set volume has been completely discharged.

5. Read the volume on the measuring beaker. A deviation of +/- 5% (4.75 - 5.25 liters) is within the tolerance. The flow rate meter will need to be recalibrated if the deviation is greater. Contact the HYDAC Service Department.

6. The calibration by gauging is completed.

Cleaning the analysis chamber Clean the analysis chamber every week. For cleaning, we recommend a clean microfiber cloth.

Clean the diffuser on the filter membrane holder Clean the filter membrane holder at weekly intervals. If necessary, clean sooner. 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.




Cleaning the door Clean the see-through door regularly.

CAUTION

Electrostatic charging

Warning of uncontrolled electrical discharge

Always clean the door with a moist, lint-free cloth.

Do not use a dry cloth.

Statically charged door

In certain circumstances, the door can become statically charged. One possible cause of this is when two non-conducting substances, e.g., CTU gloves (neoprene), see-through door (Makrolon), cleaning cloths (cellulose or cotton), are rubbed against one another, thus causing static charge to build up. Discharging may be slowed down by the ambient conditions, such as dry air and low external temperatures. The "G 60 Spezial" test fluid (a hydrocarbon) results in an unusual effect: A film that looks like a pasty mass forms on the inside of the see-through door. The build-up of static charge counteracts the low surface tension of the hydrocarbon mixture. If the same fluid is transferred from the statically charged surface to a surface with no charge, the fluid will be distributed in the usual manner. Rinse down the inside of the door with more test fluid. Remedy:

• Adjust the humidity in the surroundings.

• Always clean the door of the CTU with damp cloths.

• If there is a lot of static, use a commercial anti-static product.




Changing the clean-room filters When the CTU is switched on, there is overpressure in the clean room. This overpressure is generated by a fan module above the clean room. This fan module contains a prefilter mat and a main filter to ensure clean supply air. Replace the prefilter and main filter regularly.

Replacing the prefilter mat We recommend changing the prefilter mat [2] every six months. Perform the following steps to change the prefilter / main filter.

Remove the fastening screws of the filter hood cover [1]. Take the filter hood cover [1] off. The prefilter mat is now freely accessible for you to remove it. Put the new prefilter mat [2] in place. Lay the filter hood cover [1] on top and secure it using the fastening screws.




Replacing the main filter When the prefilter mat is changed regularly, the main filter can be used for years without it requiring maintenance. To ensure trouble-free operation, we recommend replacing the main filter at least every two years. The main filter can be accessed and replaced via the analysis chamber. The main filter can be replaced without having to dismantle the entire filter.

Replacing the main filter of a CTU 2000 To replace the main filter, proceed as follows: Description Remove all halogen lights from the light

rail. See page 70 for details.

Remove the light rail by undoing the three hexagon socket screws under the installation openings for the halogen lights.

Undo the 10 screws at the bottom of the

filter.

Remove the four metal edge strips at the bottom of the filter.

Remove the filter element by pulling it down slightly. The cutting edge of the filter element will detach from the fluid seal in the housing as a result.

Fit the new filter element by pressing it firmly into the fluid seal.

Attach the four metal edge strips to the bottom of the filter using the 10 screws.

Fit the halogen light rail by tightening the three hexagon socket screws under the installation openings for the halogen lights.

Fit the halogen lights in the light rail. See

page 70 for details.

The replacement of the main filter is now




Description complete.

Replacing the main filter of a CTU 2200 / 2400

Description Switch the CTU off via the main switch

and allow the halogen lights to cool down.

Undo the 10 screws at the bottom of the filter.

Remove the four metal edge strips at the bottom of the filter.

Remove the filter element by pulling it down slightly. The cutting edge of the filter element will detach from the fluid seal in the housing as a result.

Fit the new filter element by pressing it firmly into the fluid seal.

Attach the four metal edge strips to the bottom of the filter using the 10 screws.

Switch the CTU on.




Emptying the intermediate pan When suctioning the air out of the analysis chamber, rinsing fluid may get suctioned along with this during a contamination test. This is collected in an intermediate pan under the analysis chamber. Empty this intermediate pan depending on the application conditions, however at least once a week. To do this, open the draining valve (Y) underneath.

Changing the test fluid Each use of the CTU differs from any other. This means that it is difficult to define fixed replacement intervals for the test fluid. Determine the replacement intervals for each application on an individual basis. Always observe the test fluid with regard to the following characteristics:

• Odor

• Appearance (greases, oils, preservatives, water have the effect of clouding the test fluid or giving it a yellow tint)

• Negative control values not achieved




Draining the reservoirs Select the "Contamination Test" operating mode and select a rinsing volume of approximately 20 liters. Remove the spray nozzle of the spray gun. Place a suitable container (≥ 20 liters) underneath to catch the old rinsing fluid.

Pressing the button takes you to the main menu.

Press the button and .

Select a rinsing volume program with approximately 20 liters. Confirm your selection with the

button.

Press the button. V = remaining volume (in liters) until the contamination test is completed Q = current flow rate (in liters/minute)

Spray the rinsing fluid into a suitable container.

The rinsing fluid supply is automatically stopped once the set amount has been conveyed. If necessary, the rinsing fluid reservoir is changed over automatically.

Press the button to confirm only once the entire volume has been suctioned off.


Select rins. 0-9 Rinsing volume no. 0

Rinsing volume no.: 0 Rinsing volume no.: 1




Volume = xx.x L Test completed: OK




Reservoir filling/refilling To fill/refill the reservoirs with test fluid, follow the instructions given on page 50.

Checking the gloves The gloves are subject to wear both mechanically and chemically. Mechanical wear - cuts and tears result from components with sharp edges and wear can be accelerated by components with rough surfaces. For details of wear due to chemical action, for example by permeation, please see page 84. Provided there is no mechanical damage to the surface, the gloves can be used for six months (with average use & single shift operation). The tests that we carried out were based on the "G 60 Spezial" analysis fluid. The service life depends on the nature of the analysis fluid used and can vary.

CAUTION

Worn gloves

Health hazard

Check the gloves for leaks on a daily basis If you find signs of wear, replace the gloves

immediately Replace the gloves every six months




Permeation of Protective Gloves According to EN 374-3:1994 This standard pertains to determining the resistance provided by the material of protective gloves against the permeation of nongaseous, potentially hazardous chemicals when subjected to continuous contact. For each chemical the combinations of protective glove and test chemical are classified according to their penetration/breakthrough time in which the glove prevents permeation. The protection index indicated is based on the penetration/breakthrough time determined during constant contact with the test chemical under customary laboratory conditions as specified in EN374-3. The actual duration of protection at the workplace may deviate considerably from this protection index. Pursuant to European standard EN 374-3:1994, permeation is classified according to a protection index, which is subdivided into six levels. EN 374-3:1994 — Specification of the Results: Assuming permeation takes place, the breakthrough time is indicated in minutes for each test sample. The average breakthrough time for each type of material is also indicated. The duration of testing is given if no breakthrough occurs.

Protection Index Class 1 Class 2 Class 3 Class 4 Class 5 Class 6

> 10 min. > 30 min. > 60 min. > 120 min. > 240 min. > 480 min. For example: For example: For example: For example: For example: For example: - Acetone Benzene Chloroform - Toluene

- Benzaldehyde Nitrobenzene

- Naphthabenzene Aniline

- n-Heptane Ethyl alcohol

- Isooctane Ethylenediamine

- Folic acid, 10% by vol. Ammonia, 10% by vol. Glycerin Potassium nitrate Sulfuric acid, 50% by vol.

This means that when the user is constantly exposed to the chemical it takes

a minimum of ²min1

cmg×m

to permeate the glove and come into contact with the user's skin. Standard EN374 subdivides gloves into six classes, class 6 being the highest and most resistant. During testing, the glove is completely immersed in the medium. No documentation of resistance in excess of 480 min. takes place.




This means that gloves which may provide for resistance to breakthrough for 1 month or longer are also categorized as class 6.

Chemical Example Neoprene (CR)

Hydrocarbon mixture, aliphatic C 11-13 G60 Spezial Class 6 The data in this test list was collected under laboratory conditions using new gloves without any mechanical action at room temperature. The gloves were continuously subjected to full contact. This information can only be used for orientation purposes as other and/or additional loading/exposure frequently occurs in practice which deviates from laboratory conditions. This information is not designed as a substitute for suitability testing conducted by the end user. Consequently, HYDAC assumes no liability or responsibility for the information provided in this list.




Checking the filter regulator The following tasks need to be carried out when setting and cleaning the filter regulator.

Setting the filter regulator To set the pressure desired at the filter regulator, pull the setting knob up and turn it until the pressure is below the new pressure to be set. Now turn the setting knob in the opposite direction and approach the desired pressure setting from the low pressure.

Draining the filter regulator

Depending on the condensation level in the reservoir, drain it by pressing the plastic knob against the reservoir => This causes the valve to open. The condensation level may never be allowed to rise above the maximum marking (applied to reservoir).

Cleaning the filter elements of the filter regulator When a substantial pressure drop is noticeable, clean the filter element and the reservoir. Clean the filter element using benzene, petroleum or similar agent, followed by air-flushing it from the inside to the outside. When reinserting the element make sure it is dry. The reservoir and the other plastic components may only be washed using warm water and dish washing liquid.




Disassembling the filter regulator

Only disassemble the filter regulator when the pneumatic system is depressurized. Remove the filter regulator to disassemble it.

Disassembling the top part Pull the setting knob [1] upwards and turn it all the way in a counterclockwise direction until it will go no further. Unscrew the upper assembly [3]. Remove the governor spring [5] and the set screw [4] Pull the piston [6] out of the housing [8] Pull the seal [7] out of the housing [8]

Disassembling the bottom part Taking the lower assembly apart is facilitated if you turn it so that the reservoir [14] is pointing upwards. Unscrew the receptacle [14]. Remove the tapered filter element [13] from the reservoir. Rotate the unit. Loosen the insert [12] using needle-nose pliers by turning it to the left and remove it from the housing [8]. Remove the pressure spring [11] from the housing [8] using needle-nose pliers. Pull the valve piston [10] out of the housing [8]. Remove the O-ring Ø 31x2 [9] from the housing.

Assembling the filter regulator

Remedying error messages/malfunctions



The filter regulator is re-assembled in reverse order. First the components of the lower assembly are replaced in the housing. The upper assembly is then put back together.

If new seals are used during re-assembly, thoroughly grease them prior to installation.

Assembling the bottom part Insert the O-ring Ø 31x2 [9] in the housing. Insert the valve piston [10] and the pressure spring [11] in the housing. Set the insert [12] in the housing [8] using needle-nose pliers (while doing this, make sure that the pressure spring [11] is centered; lock the insert in place by turning it to the right). Insert the filter element [13] into the mount for the baffle in the receptacle [14]. Screw the receptacle [14] back into the housing [8]; while doing this, center the filter element and tighten the receptacle [14] by hand.

Assembling the top part Insert the seal [7] in the hole of the housing so that the sealing lip points in the direction of the housing bottom (carefully insert it so that the sealing lip is not damaged). Center the valve piston [10] (already mounted in place). Pull the piston [6] out of the housing [8]. While doing this, make sure that the valve piston [10] and the piston [6] are properly centered. Insert the spring [5] onto the centering spigot of the piston [6]. Screw the upper assembly [3] onto the housing [8] (while doing this, secure the set screw) and securely tighten the upper assembly [3].





When operating the CTU, the following error messages may appear on the display: Error message Reason Rectification

EMERGENCY STOP The EMERGENCY STOP button was pressed.

Unlock the EMERGENCY STOP button.

Fresh air valve MPS The motor protection switch of the clean air fan has tripped. The electricity consumption of the motor was too high.

Switch the motor protection switch on again. If it trips several times, check the fan and motor.

Left exh. air valve MPS Right exh. air valve MPS

The motor protection switch of the exhaust air fan (right/left) has tripped. The electricity consumption of the motor was too high.

Switch the motor protection switch on again. If it trips several times, check the fan and motor.

Float B1.1-B1.2

The float switch in reservoir B1 is faulty.

Remove the float switch and check its functioning.

Float B2.1-B2.2

The float switch in reservoir B2 is faulty.

Remove the float switch and check its functioning.

Reservoirs B1 and B2 full

Reservoirs B1 and B2 are full. There is too much rinsing fluid in the CTU.

Drain ≥ 10 liters of rinsing fluid.

No air pressure There is no supply of compressed air.

Check the supply line and maintenance unit. Check the compressed air system for leaks.

Inlet filter clogged The rinsing fluid filter is clogged.

Replace the filter element.

Outlet filter clogged The return filter is clogged.

Replace the filter element.

No vacuum The vacuum generator is faulty.

Remove the vacuum generator and check its functioning.




Error message Reason Rectification

Fuse triggering F1-F11

There is excess current in the electrical circuit concerned (see the electrical circuit diagram).

Switch the fuse on again. Check the electricity consumption and look for the cause of the error.

Please top up rinsing fluid

Reservoirs B1 and B2 are empty. There is not enough rinsing fluid in the CTU.

Top up the rinsing fluid (see page 83).

Hydraulic circuit



Hydraulic circuit

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1 3

2

B1 B2

1

2

1

2

Y10

11

10

15

Y30 Y31 Y40Y41 Y90 Y91

Y50 Y51 Y61 Y60

Y70

22

S5

Y81

2

1

43

16 17

9

6

7

8

V12

14

V11

5

31

1 2

1

2

1

2

1

2

12

V5 V7

V4

S4

V13

V8

33

V6

S2

A A

A A A A

A A

A

A

A A

V10

V1

V9

V21

V20

18 19

S3S1

30

Hydraulic circuit



Item Designation

V1 Compressed air supply ball valve

V4 Output check valve B1

V5 Return check valve B1

V6 Output check valve B2

V7 Return check valve B2

V8 Return check valve

V9 Filter membrane holder ball valve

V10 Return ball valve

V11 Pan draining ball valve

V12 Spray gun

V13 Ball valve of ring main

V20 Pressure control valve (vacuum)

V21 Pressure control valve (pressure)

S2 Clogging indicator

S1 Pressure switch (optional)

S3 Pressure switch (optional)

S4 Clogging indicator

S5 Flow meter

Y30 Compressed air solenoid valve B1

Y31 Compressed air solenoid valve B2

Y40 B1 vacuum solenoid valve

Y41 B2 vacuum solenoid valve

Y50 Drain solenoid valve B2

Y51 Drain solenoid valve B2

Y60 Filler solenoid valve B1

Y61 Filler solenoid valve B1

Y70 Clean-room inlet solenoid valve

Y81 Inner chamber rinsing solenoid valve

Y90 B1 bleeding solenoid valve

Hydraulic circuit



Item Designation

Y91 B2 bleeding solenoid valve

1 Silencer

2 Silencer

3 Silencer

4 Silencer

5 Silencer

6 Pressure gauge (vacuum setting)




10 Compressed air filter

11 Compressed air filter

14 Filter membrane holder

16 Level switch B1

17 Level switch B2

30 Clean room

31 Compressed air supply

Locating spare parts



Locating spare parts Use only original spare parts and accessories. When ordering spare parts, always specify the designation of the unit (type, material no., serial no., year of manufacture).

Designation p/no.

CTU

20

00

CTU

22

00

CTU

24

00

Qty. Qty. Qty. Built-in light for analysis chamber lighting (without bulb and socket)

6028918 3 4 4

Socket for built-in light 6029142 3 4 4

Bulbs for built-in light 6029141 3 4 4

LED light (from manufacture year 2013) 6143675 - - 4

Clean-air module prefilter mat (by the meter, 2 m wide)

6028496 0.5 m

1 m 1.5 m

Clean-air module main filter 6031485 1 - -

Clean-air module main filter 6024934 - 1 1

Clean-air module main filter from manufacture year 2017

TBD - 1 -

Spray gun with standard nozzle, assembly 6022796 1 1 1

Hose incl. screwed fittings for spray gun, l=1.8 m

6040202 1 1 1

Spray gun with long "ridged" nozzle, l=100 mm

3227503 * * *

Spray gun with long "ridged" nozzle, l=500 mm

3178346 * * *

Spray gun with long "open" nozzle, l=100 mm

3227504 * * *

Spray gun with long "open" nozzle, l=500 mm

3178347 * * *

Spray gun with long "round" nozzle, l=100 mm

3227502 * * *

Spray gun with long "round" nozzle, l=500 mm

3178314 * * *

Locating spare parts



Designation p/no.

CTU

20

00

CTU

22

00

CTU

24

00

Qty. Qty. Qty. Spare parts set for spray gun including jet nozzle, fan nozzle, funnel nozzle (stainless steel)

6027105 1 1 1

Valve seal for spray gun 6042374 1 1 1

Filter regulator (without pressure gauge) 6004671 1 1 1

Pressure gauge for filter regulator 6006377 1 1 1

Filter insert 30 µm for filter regulator 6039258 1 1 1

3/2 directional valve (Y 10) 6022777 1 1 1

2/2 directional valve 6022707 12 12 12

Flow rate meter, type: SFL-122OR10 6022703 1 1 1

Flow rate meter, type: LSN45 6085694 1 1 1 Hose, transparent / soft 6023627 1.5

m 1.5 m

1.5 m

- 1-ear terminal 6069299 3 3 3

Plastic pipe, white / matt 6034766 10 m 10 m 10 m

- Insert sleeve 630116 24

- Cutting ring 608415 24

Pressure gauge for indicating return-line vacuum

6022772 1 1 1

Pressure gauge for indicating rinsing medium pressure

6022773 1 1 1

Filter element for rinsing fluid filter and return filter – type LF Type: 0060 D 003 BN3HC

1260901 2 2 2

Rinsing fluid filter / return filter – LF Repair kit consisting of: 4x O-ring, 1x support ring, 1x seal

305791 2 2 2

Filter element for rinsing fluid filter and return filter – type MRF Type: N10FM-P001-PES1F, filter grade = 1 µm

3510106 2 2 2

Disposing of the CTU



Designation p/no.

CTU

20

00

CTU

22

00

CTU

24

00

Qty. Qty. Qty. Vacuum generator 6024223 1 1 1

Float switches for reservoirs B1 and B2 6022887 2 2 2

Supporting sieve for membrane holder Ø 47 mm

6024224 1 1 1

Filter membrane 5 µm, Ø 47 mm Color: white, surface: smooth, 1 pckg contains 100

6020761 1 1 1

Analysis fluid G60 (30-liter container) 3205511 2 2 2

*) optional

Disposing of the CTU

Dispose of the packaging material in an environmentally friendly manner. Drain the CTU completely. Dispose of the test fluid in an environmentally friendly manner. Accordingly, follow the instructions in the safety data sheet for the test fluid. After dismantling the unit and separating the various materials, dispose of the unit in an environmentally friendly manner.

Technical Data



Technical Data Dimensions CTU 2000

Height = 2500 mm

Width = 1470 mm

Depth = 900 mm

Dimensions CTU 2200

Height = 2500 mm

Width = 2170 mm

Depth = 900 mm

Dimensions CTU 2400

Height = 3600 mm

Width = 2270 mm

Depth = 1595 mm

Weight when empty CTU 2000 ≈ 400 kg

CTU 2200 ≈ 550 kg

CTU 2400 ≈ 750 kg

Load capacity ≤ 50 kg For evenly distributed load, no point loading

Power supply 230 V AC, 50 Hz, 1 phase

Wattage 800 W max.

Permitted ambient temperature range

15 … 28°C

Permitted storage temperature range 0 … 50°C

Permitted ambient conditions for storage

dust-free, no salty air, not in the vicinity of oxidizing substances (flash rust, rust bloom)

Permitted relative air humidity ≤ 80% (non condensing)

Compressed air supply maximum 6 bar

Compressed air volume 60 l/min

Condition of compressed air

dry and filtered

Cleanliness of compressed air supply

≤ 5 µm

Technical Data



Suction speed of the analysis fluid

1.14 l/min at 0.7 bar vacuum

Collecting pan volume CTU 2000 = 30 liters CTU 2200 / CTU 2400 > 30 liters

Emission sound pressure level LPA

< 70 db(A)

Attachment



Attachment

EC declaration of conformity The CE declaration of conformity can be found in the Technical Documentation of the CTU.

Customer Support/Service If you have any questions, suggestions, or encounter any problems of 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: [email protected]

For repair work or complaints, please contact our central customer service department: HYDAC SYSTEMS & SERVICE GMBH Friedrichsthaler Straße 15, Werk 13 66540 Neunkirchen-Heinitz Phone: +49 6897 509 883 Fax: +49 6897 509 324 E-mail: [email protected]

Attachment



Model Code CTU 2 0 0 0 - M - Z - Z / -

Product CTU = Contamination Test Unit Series 1 = 2000 Series Size (height x width x depth) 0 = Clean-room dimensions

670 x 900 x 600 mm

2 = Clean-room dimensions 670 x 1600 x 600 mm

4 = Clean-room dimensions 1400 x 1700 x 1400 mm

Analysis 0 = with analysis membrane Ø 47 - 50 mm Test fluid 0 = Solvent class A III

(flash point > 60°C, explosion limit > 0.6% by volume)

Power supply K = 120 V AC / 60 Hz / 1 Ph USA / Canada

M = 230 V AC / 50 Hz / 1 Ph Europe

N = 240 V AC / 50 Hz / 1 Ph United Kingdom

O = 240 V AC / 50 Hz / 1 Ph Australia

P = 100 V AC / 50 Hz / 1 Ph Japan Extraction method Z = spraying, medium pressure Supplementary details Z = Series Modifications - = Without

Attachment



Explanation of terms and abbreviations An explanation of terms and abbreviations follows below:

°C Degrees Celsius

abs. Absolute (e.g. in pressure specifications)

AC Alternating current

Air Bleed Ventilation / air bleed port

Analysis fluid Test fluid loaded with particles up to the filter membrane after spray extraction.

Dosing calibration Set system / flow transmitter

BetrSichV German Industrial Safety Ordinance

BeWa Operating and Maintenance Instructions

Negative control value Inherent soiling value

cm Centimeters

ConTeS ContaminationTest Software

CTM ContaminationTest Module

CTMH ContaminationTest Membrane Holder

CTM-Ex ContaminationTest Module – Extraction Module

CTM-Fx ContaminationTest Module – Flushing Module

CTM-SC ContaminationTest Module – Supply Control

DC Direct current

DIN Deutsche Industrie Norm [German Industry Standard]

DN Nominal Diameter

Drain Drainage port

EC European Community

EU European Union

Solid particle contamination

Solid particles such as dirt, non-iron or metallic particles found in the fluid.

Flash point The flash point of a substance is the lowest temperature at which an ignitable vapor-air mix can form over a substance.

FPM (FKM / Viton®) Fluoroelastomer rubber

G60 Type of test fluid

Spray gun Spray gun with changeable nozzle for spray extraction

Attachment



IN Inlet

INLET Inlet

m Meter

MAX Maximum

mbar Millibar (1 mbar = 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 fluid Fluid for general operation. (Rinsing fluid / analysis fluid).

Sec. Second(s)

Rinsing fluid Test fluid for spray extraction.

A/F Wrench size for tools

Vent Ventilation / air bleed port

VE water Demineralized/Deionized water

Attachment



Index

A

Accessories 20 accident prevention 13, 17 Air vent 20, 31 ambient temperature 97 Analysis 96, 100, 101 Auxiliary personnel 16

B

bleeding 92, 93

C

care 2, 7 change-over 26, 52, 57 Changing the filter element 64, 67 cleaning 23, 46, 56, 57, 63, 69, 76, 77, 86 Cleanliness 97 Clogging indicator 92 collecting pan 57, 63 compressed air supply 30, 49, 97 connecting 20, 31 Content 3 ConTeS 101 Control 26, 27, 101

D

Date 19 Description 19, 79, 80 Dimensions 97 DIN 101 Disposal 16 Documentation Representative 2 drain plug 67 draining 46, 81, 92

E

EC declaration of conformity 99 Error 89 Error message 89

F

filling 50, 51, 83 Filter 15, 25, 37, 38, 39, 40, 41, 63, 64, 74, 92, 93, 95, 96 Filter element 64, 95 Filter housing 63 filtration 19, 21, 44

Flash point 101 Float switch 96 Flow rate 95

H

Hazard symbol 10 Hose connection 38, 41

I

Imprint 2 IN 102 In case of emergency 17 Inlet 89, 102 INLET 102 installation 12, 13, 28, 35, 68, 79, 88 installing 65, 66 ISO 13

L

Level switch 93

M

Main switch 26 Maintenance 1, 16, 62, 101 Maintenance interval 62 Maintenance intervals 62 Manufacturer 2 Measures 10 measuring 76 Model code 19 mounting 65, 66

O

OFF 102 operating 7, 8, 9, 10, 11, 12, 14, 16, 17, 21, 26, 27, 30,

45, 47, 48, 49, 54, 66, 68, 76, 82, 89 Operation 15, 26, 40, 47, 48, 54 Operations control 16 OUT 102 Outlet 89, 102 OUTLET 102

P

Pressure gauge 93, 95 Proper/Designated Use 13

Attachment



R

Remedy 77 replacement 72, 75, 79, 81

S

select 8, 45, 46, 53, 82 Service 50, 76, 99 setting 27, 45, 52, 86, 87, 93 Signal word 9, 10 signal words 9, 10 Size 100 Solid particle contamination 101 Spare part 95 Spare parts 95 Specialist personnel 12, 16 Storage temperature 18

switching off 58 switching on 47, 54

T

Transport 16 Troubleshooting 16 Type label 19

V

Vacuum 27, 96

W

Weight 97

HYDAC FILTER SYSTEMS GMBH Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Tel: +49 (0) 6897 509 01 Central Fax: +49 (0) 6897 509 9046 Technical Department Fax: +49 (0) 6897 509 577 Sales Internet: www.hydac.com E-mail: [email protected]

Documents

CTU 2xxx series Contamination Test Unit - HYDACCTU 2xxx series . Contamination Test Unit Operating and Maintenance Instructions . English (translation of original instructions) Document