hydac · we have made every endeavor to ensure the accuracy of the contents of this document....

CTM-EF 1200 ContaminationTest Module - Extraction Flushing

Operation Instructions English (translation of original instructions)

Documentation no.: 3509157

CTM-EF 1200 Trademarks

HYDAC Filter Systems GmbH en / 36

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Trademarks The trademarks of other companies are exclusively used for the products of those companies.

Copyright © 2009 by HYDAC Filter Systems GmbH all rights reserved

All rights reserved. This manual may not be reproduced in part or whole without the explicit written agreement from HYDAC Filter Systems. Contraventions are liable to compensation.

Exclusion of Liability We have made every endeavor to ensure the accuracy of the contents of this document. However, errors cannot be ruled out. Consequently, we accept no liability for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors. The content of the manual is checked regularly. Any corrections required will be incorporated in future editions. We welcome any suggestions for improvements.

All details are subject to technical modifications.

Technical specifications are subject to change without notice.

HYDAC Filter Systems GmbH Technische Dokumentation Postfach 12 51 66273 Sulzbach / Saar Germany

Documentation Representative Günter Harge

c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar

Telephone: ++49 (0)6897 509 1511

Fax: ++49 (0)6897 509 1394

E-mail: [email protected]

mailto:[email protected]

CTM-EF 1200 Content


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Content

Trademarks ...............................................................................................................2

Documentation Representative...............................................................................2

Content......................................................................................................................3

Preface ......................................................................................................................5 Technical Support...................................................................................................6 Modifications to the Product ...................................................................................6 Warranty .................................................................................................................6 Using the Documentation .......................................................................................7

Safety Information and Instructions .......................................................................7 Explanation of Symbols and Warnings, etc. ...........................................................7 Proper/Designated Use ..........................................................................................9 Hazards Posed by sing the Contamination Test Module........................................9 Training and Instruction of Personnel ...................................................................10 Protective Gear.....................................................................................................11 Maintenance, Servicing and Troubleshooting.......................................................11 Modifications.........................................................................................................11 General Remarks on This Operating Manual .......................................................11

Checking the scope of delivery.............................................................................12

Transportation, Packing and Disposal .................................................................13 Transporting the CTM-EF .....................................................................................13 Storing the CTM-EF..............................................................................................13 Disposing of the CTM-EF .....................................................................................13

Dimensions .............................................................................................................14

Hydraulic diagram ..................................................................................................15

Functional principle ...............................................................................................16

Negative control values .........................................................................................16

Parts of the CTM-EF ...............................................................................................17

Suitable Rinsing Fluids..........................................................................................18 CTM-EF 1xx0 ....................................................................................................18 CTM-EF 1xx1 ....................................................................................................18

Preparing the CTM-EF for operation.....................................................................19 Positioning the CTM-EF........................................................................................19 Connecting the CTM-EF .......................................................................................20

Filter membrane holder .........................................................................................21 Version with a union nut .......................................................................................21 Version with a clip.................................................................................................22

CTM-EF 1200 Content


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Cascading filter membranes .................................................................................23 CTM in operation ....................................................................................................24

Clean-Room Conditions in the Analysis Chamber................................................24 Automatic cleansing of the analysis chamber ...................................................24

Changing the filter membrane...............................................................................25 Carrying out the replacement ...............................................................................25 Labeling the filter membrane ................................................................................27

Performing Maintenance........................................................................................28 Maintenance work.................................................................................................29 Replace hoses ......................................................................................................29 Checking fluid level sensor settings......................................................................29

Spare Parts List ......................................................................................................30 Spare Parts...........................................................................................................30

Disposing of the CTM-EF.......................................................................................31

Customer service ...................................................................................................31

Technical data ........................................................................................................32

Model Code .............................................................................................................33

CTM-EF 1200 Preface


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Preface

For you, as the owner of a product manufactured by us, we have produced this manual, comprising the most important instructions for its operation and maintenance.

It will acquaint you with the product and assist you in using it as intended in an optimal manner.

Keep it in the vicinity of the product so it is always available.

Note that the information on the unit's engineering contained in the documentation was that available at the time of publication.There may be deviations in technical details, figures, and dimensions as a result.

If you discover errors while reading the documentation or have additional comments or suggestions, contact us at:

HYDAC Filter Systems GmbH Technische Dokumentation Postfach 12 51 66273 Sulzbach / Saar

Germany

We look forward to receiving your input.

“Putting experience into practice”

CTM-EF 1200 Preface


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Technical Support Contact our technical sales department if you have any questions on our product. When contacting us, please always include the model/type designation, serial no. and part-no. of the product:

Fax: ++49 (0) 6897 / 509 - 846


Modifications to the Product We would like to point out that changes to the product (e.g. purchasing additional options, etc.) may mean that the information in the operating instructions is no longer applicable or adequate.

After modification or repair work that affects the safety of the product has been carried out on components, the product may not be returned to operation until it has been checked and released by a HYDAC technician.

Please notify us immediately of any modifications made to the product whether by you or a third party.

Warranty For the warranty provided by us, please refer to the General Terms of Sale and Delivery of HYDAC Filter Systems GmbH.

Refer to these at www.hydac.com General terms and conditions.

http://www.hydac.com/

CTM-EF 1200 Safety Information and Instructions

Using the Documentation

Note that the method described for locating specific information does not release you from your responsibility of carefully reading these instructions prior to starting the unit up for the first time and 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.


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Chapter description

Page number

Edition date

Document language Documentation no.with index

/

file name

The documentation number with its index enables you to order another copy of the operating and maintenance instructions. The index is incremented every time the manual is revised or changed.

Safety Information and Instructions

Explanation of Symbols and Warnings, etc. The following symbols are used in this manual to designate hazards, etc.:


DANGER DANGER denotes situations which can lead to death if safety precautions are not observed.

WARNING WARNING denotes situations which can lead to death if safety precautions are not observed.

CAUTION CAUTION denotes situations which can lead to severe injuries if safety precautions are not observed.

NOTICE NOTICE denotes situations which can lead to property damage if safety precautions are not observed.

This symbol indicates that you are to wear suitable protective eyewear (e.g. goggles, full-face shields).

When dealing with rinsing liquids, gloves are to be worn which are suitable for the liquid involved.

Open flames are prohibited. This applies in particular when dealing with solvent-based rinsing liquids.


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Proper/Designated Use The CTM is a unit to test the surface cleanliness of components. Analyzing the type, size and quantity of contamination enables quality standards to be verified and documented, and the requisite optimization measures to be implemented.

Any use extending beyond or deviating therefrom shall not be considered intended use. HYDAC Filter Systems GmbH will assume no liability for any damage resulting from such use.

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.

Hazards Posed by sing the Contamination Test Module The CTM has been designed and constructed in accordance with the current state of the art and recognized safety regulations.

Nevertheless, hazards may be posed to the life and limb of the individual using the CTM or to third parties. Risk of damage may be posed to the product or other equipment and property.

The CTM is only to be used as follows:

- Solely for its intended use

- Only when in safe, perfect condition.

Any faults which might impair safety must immediately be remedied.



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Training and Instruction of Personnel The ContaminationTest Module may only be operated by properly trained and instructed personnel.

The owner is obliged to only let persons work on the CTM, who:

are thoroughly acquainted with the fundamental occupational safety and accident prevention regulations and have been properly instructed in the use of the CTM.

have read and understood these operating instructions.

The areas of responsibility of your staff must be established in a clear-cut manner.

Staff undergoing training may not use the ContaminationTest Module unless supervised by an experienced staff member.

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Activity

Packing Transportation X X X

Commissioning X X X

Operation X X X X

Troubleshooting/ locating the source of malfunction X X X

Remedying of mechanical faults X X

Remedying of electrical faults X X

Maintenance X X X X

Repair work X

Decommissioning/storage X X X X



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Protective Gear You must wear suitable protective gear and working clothes when using the CTM. Suitable working clothes means a sufficiently long laboratory coat with long sleeves, for example. Normal street clothing is not considered as suitable working clothes.

Depending on the test liquid you must wear protective gloves and suitable eye protection when using the CTM. Note the safety data sheets of the test liquid.

You should replace damaged or otherwise unusable gloves immediately.

Maintenance, Servicing and Troubleshooting The prescribed maintenance/servicing and inspection work is to be conducted in a timely fashion.

On the conclusion of any work, always check the safety equipment to ensure that it is working properly.

Modifications Immediately replace any faulty unit components.

Use only original spare parts (OEM). Parts from third party suppliers means that there is no guarantee that they have been designed and manufactured so as to comply with the required loading and safety requirements.

Do not make any modifications to the unit without the prior consent of the manufacturer.

General Remarks on This Operating Manual This operating and maintenance manual contains information on the transportation, installation, commissioning & decommissioning, and maintenance of the CTM.

The basic prerequisite for safe use of the CTM and for fault-free operation is to understand and comply with the safety precautions and regulations.

You must ensure that the operating instructions are kept close to the CTM.

In addition to the manual the general and the local regulations concerning accident prevention and environment (and conservation respectively) should be provided and observed.

Make sure that the safety and hazard symbols and warnings on the CTM are always in a legible condition.

CTM-EF 1200 Checking the scope of delivery


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Checking the scope of delivery The Contamination Test Module CTM comes packed and partially factory-assembled. Before starting up the CTM, check the contents of the delivery to make sure everything is present and undamaged.

The following items are supplied:

Item Qty. Description

1 1 ContaminationTest Module CTM-EF

1 Operation Instructions

CTM-EF 1200 Transportation, Packing and Disposal


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Transportation, Packing and Disposal

Transporting the CTM-EF The CTM comes wrapped in plastic sheeting or in a wood crate, the latter having to be specifically ordered.

When receiving and unpacking the unit, check it for damage in transit. Report any damage to the forwarding agent immediately.

The packing material is to be disposed of as specified by law or national regulations or be reused.

The CTM can be moved by pushing it on its casters. Lifting gear (e.g. a forklift) can also be used to transport the unit, provided its load-carrying capacity is greater than the empty CTM.

All moveable components sensitive to vibration must be removed/dismantled or secured.

Storing the CTM-EF The unit must be drained completely before extended storage (including the rinsing liquid and return filter).

Pull power plug.

Coil up the power cord and securely fasten it to the CTM.

The CTM may only be stored in a clean, dry rooms.

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)

Disposing of the CTM-EF When decommissioning and/or disposing of the unit, observe all local guidelines and regulations pertaining to occupational safety and environmental protection. This applies in particular to the analysis fluid in the unit, components covered with oil and electronic components.

After disassembling the unit and separating the various materials, reuse them or dispose of them properly in accordance with local regulations.

CTM-EF 1200 Dimensions

Dimensions

1816

646

420


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CTM-EF 1200 Hydraulic diagram

Hydraulic diagram

Item Description A Quick-action coupling "A" B Quick-action coupling "B" R Quick-action coupling "R" 1 Fluid level sensor 2 Reservoir 3 Air filters 4 Membrane holder 5 Test item


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CTM-EF 1200 Functional principle


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Functional principle The CTM-EF module is an extraction module for component sampling using rinse extraction. This module is used in conjunction with the CTM-SC supply module.

These components are rinsed off in a test liquid with a defined cleanliness.

At the end of the sampling process, the entire liquid with its particle load is sucked via the membrane retainer. The rinsing liquid (now called the analysis liquid) carrying the particulate soiling rinsed off the component, is sucked through the analysis membrane via connection "R" and flows back and flows back to the CTM-SC module.

The analysis membrane is then analyzed. 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.).

Negative control values The achievable baseline (negative control value) readings strongly depend on the ambient conditions and frequency of use. The following baselines can be achieved:

Ambience

Clean room 0.1 mg

Laboratory 0.1 mg

Separate sampling room 0.1 mg

Plant/factory shed 0.1 mg

Maximum particle size Requisite effort Cleansing time [h] after shutdown

70 µm* high 0.2

70 µm* middle 0.2

70 µm* low 0.2

* Applies to a maximum membrane load of 0.4 mg

CTM-EF 1200 Parts of the CTM-EF

Parts of the CTM-EF

AB

RX

5

6

4

3

8

7

1

2

Item Description

1 Reservoir

2 Filter membrane holder

3 Filter membrane holder support

4 Connection hoses with quick coupling (A / B / R)

5 Control connection plug

6 Fluid level sensor

7 Air filters

8 Collecting pan


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CTM-EF 1200 Suitable Rinsing Fluids


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Suitable Rinsing Fluids

CTM-EF 1xx0

NOTICE Impermissible rinsing liquids

The CTM-EF will be damaged

► Only use test liquids which are compatible to the installed materials and the sealing materials.

► Do not use test liquids with a flash point ≥60°C or with a lower explosion limit in excess of 0.6% by volume.

CTM-EF 1xx1

NOTICE Impermissible rinsing liquids

The CTM-EF will be damaged

► Only use test liquids which are compatible to the installed materials and the sealing materials.

► Do not use test liquids with a flash point ≥60°C or with a lower explosion limit in excess of 0.6% by volume.

► Water containing tensides (permissible pH values: 6-10) can be used as a test liquid.

► The use of demineralized water is not permitted.

CTM-EF 1200 Preparing the CTM-EF for operation

Preparing the CTM-EF for operation

Positioning the CTM-EF The CTM-EF can be moved into the required location on its own casters. The CTM-EF has 4 casters. Before pushing, release the hand brake on the swivel 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" rinsing / analysis liquid

Hazardous to health

► Makes sure that there is adequate ventilation

► Always wear protective gloves.

► Always wear eye protection.


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CTM-EF 1200 Preparing the CTM-EF for operation

Connecting the CTM-EF The CTM comes pre-installed. Before starting it up please note or check the following:

• Carefully read the operating and maintenance instructions for the CTM as well as the CTM software operating instructions.

• Take the support sieve supplied and put it in the membrane holder.


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• 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 16 .

Attach the CTM-EF control connection plug and hoses to the CTM-SC as shown in the following illustration.

AB

R

X

The test item to be examined is marked with an X.

To prevent the connector from working loose, secure it by screwing up the locking ring.

The hose quick connectors must be pressed firmly onto the nipples, so that the test liquid can flow.

CTM-EF 1200 Filter membrane holder

Filter membrane holder When the CTM-EF is delivered, you get the following two options to use the filter membrane holder.

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

Version with a union nut The fine thread on the union nut (1) means that the lower part (2) of the 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) counter-clockwise.


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Version with a clip

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 handles (1) of the clip together. Push the clip over the membrane holder (2). Carefully release the clip handles - the clip's spring force (3) will press the two halves of the membrane holder (with the intermediate ring) together.

Make sure that an intermediate ring and two supporting sieves are used when a clip is used.


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Cascading filter membranes Cascade filter membranes as shown in the following illustration.

Item Description

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



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

5.1

5.2

5.3

8

123

4

7

7

6

6

6

A

B

C


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CTM-EF 1200 CTM in operation


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CTM in operation

Clean-Room Conditions in the Analysis Chamber Before starting a contamination test series, the analysis chamber has to be 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 process of inner chamber rinsing, please see the CTM-SC software operating instructions.

CTM-EF 1200 Changing the filter membrane

Changing the filter membrane The ball valve on the filter membrane holder serves as an emergency isolation valve.

Carrying out the replacement Before you remove the filter membrane, the analysis liquid must have been completely used.

1. Hold the holder with one hand on the lower part.

With your other hand, undo the union nut counter-clockwise.

2. Put down the lower part together with

the filter membrane in its holder.


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3. Remove the filter membrane for analysis and label it as shown in the example on page 27.

4. Fit a new filter membrane on the

supporting sieve.

5. Position the lower part together with

the filter membrane underneath the upper part.


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6. Screw on the union nut clockwise.

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




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CTM-EF 1200 Performing Maintenance

Performing Maintenance

WARNING The system is pressurized

Bodily injury

► The system must be depressurized before performing any work on it.

CAUTION "G60 Spezial" rinsing / analysis liquid

Hazardous to health

► Makes sure that there is adequate ventilation

► Always wear protective gloves

► Always wear eye protection


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CTM-EF 1200 Performing Maintenance

Maintenance work The maintenance and servicing to be performed periodically is described here.The CTU’s serviceability, operational reliability and life substantially depend on performing maintenance and servicing work regularly and carefully. The CTM-EF’s serviceability, operational reliability and service life substantially depend on performing maintenance and servicing work regularly and carefully.

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Check all hoses for leaks or signs 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

Replace hoses The installed hoses are specially designed for use with the test liquid. The hoses must be checked regularly for brittleness.

After 2 years replace the hoses.

Checking fluid level sensor settings The fluid level sensors HNS can be parameterized.

M = Measurement range

D = LED display, 3-digit

D1 = LED D1

D2 = LED D2

T1 = Key T1

T2 = Key T2

When the CTM-EF is delivered, the fluid level sensor HNS is preset with all the required factory settings and is ready for operation.

During normal operation, additional settings do not need to be made on the fluid level sensor HNS.


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CTM-EF 1200 Spare Parts List


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Spare Parts List 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).

Spare Parts Description Part no. Qty.**

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

309376 1

Support screen (for membrane retainer PTFE-coated) ∅ 47 mm

6024224 1

Intermediate ring (for membrane retainer) 3122742 3 O-ring (for intermediate ring) 6023626 3 Air filters 306340 1 Guide roll 680885 4 Fluid level sensor (without factory setting for CTM-EF) 1 Fluid level sensor (programmed with factory setting) 1 Hoses 6023627 1 Quick-action coupling 6065601 1 Reservoir cover 3490920 1 *) on request, **) No. of items installed in the CTM-EF.

CTM-EF 1200 Disposing of the CTM-EF


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Disposing of the CTM-EF When decommissioning and/or disposing of the CTM, observe all local guidelines and regulations pertaining to occupational safety and environmental protection. This applies in particular to the oil in the unit, components covered with oil and electronical components.

After disassembling the unit and separating the various materials, reuse them or dispose of them properly in accordance with local regulations.

Customer service If you have any questions, suggestions, or encounter any problems of a technical nature, please contact:

HYDAC Filter Systems GmbH Industriegebiet 66280 Sulzbach / Saar

Germany

E-Mail: [email protected]

Fax: ++49 (0) 6897 509-846

For repair work or complaints/claims, please contact:

HYDAC Service GmbH Rehgrabenstraße, Werk 7 66125 Saarbrücken

Germany

Telephone: ++49 (0) 6897 509 883

Fax: ++49 (0) 6897 509 324


CTM-EF 1200 Technical data


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Technical data Height = 1816 mm

Width = 420 mm

Dimensions

Depth = 646 mm

Empty weight ≈ 53 kg»

Nominal volumes 5 liters

Voltage: 24 V DC

Wattage: 15 W

Protection class to DIN 400050 IP 54

Ambient temperature range: 15 – 28° C

Relative humidity: max. 80 % (non-condensing)

CTM-EF 1200 Model Code


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Model Code CTM - EF 12 0 0 - z - z - z / - Product CTM = ContaminationTest Module Series EF = Extraction Flushing Dimensions of analysis chamber 12 = Ø 200 x height 800 mm, volume 4.5 liters Filtration 0 = Without Test liquid 0 = Solvent class A III

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

1 = water containing tensides, permissible pH values: 6–10, no completely demineralized water

Supply voltage 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 process z = rinsing, medium pressure Supplementary details z = Series Modifications - = Without

HYDAC Filter Systems GmbH Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Phone: +49 (0) 6897 509 01 Central Fax: +49 (0) 6897 509 846 (Technical Department) Fax: +49 (0) 6897 509 577 (Sales Department) Internet: www.hydac.com E-Mail: [email protected]

hydac · we have made every endeavor to ensure the accuracy of the contents of this document....

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