wl Compact Series / L Operating Manual (original version) Type-No.: BO57RO1 | Comm-no.: 160716 | Year of construction: 2014 DILO. Sustainably tight. Made m GermanyTable of contents General safety notes Product description = Dimension sheet / Technical data Transport and installation Setting into operation Functional diagram with parts list Functional description * Removal and storage of SFs * Flooding of the gas compartment with ambient air * Evacuation of air from the gas compartment * Filling the gas compartment with SF * Filling of external bottles from an internal storage tank (only for devices with liquid storage) Gas removal from the service cart to transport pressure Fault correction Maintenance and functional test Circuit diagram with parts list Operating- and maintenance manuals for installed components ~_ © Ss "1 oa fF wo | Please read this operating manual before putting the device into operation. Thus operating faults can be avoided In case of nonobservance of the operating manual the manufacturer cannot assume any liability or warranty. The copyright of this documentation remains with DILO Armaturen und Anlagen GmbH, D-87727 Babenhausen. Any use not permitted by the author (multiplication, leaving to third persons ete.) is subject to penalty and indemnification. www dlla-ambh.com | COd2kosee=General safety notes SA Obligation to exercise due care The device has been designed and constructed bearing in mind the standards to be observed as well as. additional technical specifications. Safe use of the machine can only be achieved if all the necessary measures are followed. ‘The operator has to ensure that the device is only used for the purposes for which it is intended (see chapter 2 product description), the device is only operated in accordance with the instructions and in good condition and that the safety devices are regularly checked maintenance and repair personnel are issued with all the required safety and protective clothing, which shall always be used. complete and legible operating manuals are available on site. only qualified personnel operates or repairs the device. this personnel is regularly instructed in safety procedures and environmental protection and that this personnel is fully aware of the complete operating manuals and particularly in the safety notes. the safety and warning notes mounted on the device are legible and not removed. all obligatory registrations and tests prescribed by law are carried out on the devices in accordance with the local regulations (e. g. pressure vessel tests, test for electrical safety etc.) the safety data sheet on SF; (can be obtained from the SF. supplier) is available for the operating personnel, The instructions mentioned in the data sheet and safety precautions must be known and observed by the operating personnel. wwe dlla-ambh.com | 070386General safety notes SA Specific safety notes and standard symbols In the following operating manual specific safety wamings are given in order to draw your attention to residual risks which cannot be avoided during the operation of the device. These residual risks contain dangers for = Persons = Product and machine = The environment The symbols used in the operating manual should draw your attention specially tothe safety notes: This symbol refers to risks for persons (danger to life, danger of injury) Danger This symbol refers to risks for machines, material and the environment. Waring This symbol refers to electric shock ‘The most important aim of the safety notes is to prevent personal injuries. = Ifthe waming sign ,Danger", appears, danger from machines, materials and the environment are not excluded, = Ifthe warning sign ,Warning", appears, there is no danger for persons. The corresponding symbol which is used cannot replace the text of the safety note. Therefore the complete text must always be read. . This symbol is not for safety notes, but for information to understand the 1 device better Note wwe dlla-ambh.com | 070386General safety notes SA Basic safety measures during normal operation ° The equipment may only be operated throughout the EU by trained and 1 qualified persons who have been certified in accordance with EC 305/2008 regulations. Transition period until 30” June 2008. Note Only trained and authorized persons who are fully aware of the operating manuals should operate the device and should do so in accordance with the operating manuals, Before switching on the device ensure that = only authorized persons are present at the device = nobody can be hurt by the operation ofthe device ‘Whenever the device is started check for visible damage beforehand and ensure that it is operated in the correct conditions. Eliminate any damage immediately or inform your supervisor. Prior to each start check and make sure that the safety features are properly set. Check the U01 or FO2 cischarger (if available) installed in the control cabinet. In case the indication of the plug-in protection module is red, exchange the defective module. For concentrations of SF decomposition products of > 100 ppm, we recommend using a pre-filter unit to protect the device. In case of contamination, rinse the device (for at least 10 minutes) with pure Warming SFe-gas, e. g. by circulation. All gas compartments and vessels connected to the device via gas connecting coupling and connecting hose must be equipped with their own safety equipment against overpressure and vacuum. The safety equipment integrated in the device only serves for the self-protection of the device without consideration of the load-bearing capacity of the gas compartment connected. In case of non-observanee there Is the danger of implosion or explosion of the gas compartment if the device is not operated correctly. Danger wwe dlla-ambh.com | 070386General safety notes SA Installation of the device Position the device on level surface and hard subgrade only. The locking device of the wheels is not appropriate to put the device on hilly ground. Only operate the device in sufficiently large and ventilated compartments (room volume > 100 1?) so that the admissible SF. concentration in ambient air is not exceeded in case of leakages incurring suddenty. For operation in smaller compartments SF; waming devices must be available as well as the possibility to leave the compartment quickly. In case the device is burning the pressure vessel must be cooled down to prevent an inadmissible high increase in pressure. Personal protective equipment for operating personnel Safety gloves which allow the operation of the electrical operating elements. Ear protection is recommended for all devices with a sound power level of > 80 dB(A), As from 85 dB(A) the use of ear protection is compulsory. Safety shoes Wearing safety goggles is necessary in case hoses and tubes which are under pressure are opened (e. g. cylinder threads on SF;-gas bottles), as gas or fluid jet could escape. Basic safety measures during maintenance Follow inspection and maintenance periods described in the operating manuals. Follow maintenance and repair instructions for individual components in these operating manuals. Prior to carrying out maintenance and repair works turn off the main switch for the power supply and secure it with a padiock. The key for this lock must be in the hands of the person who carries out the repair works. If there is no main switch unplug the power supply cable at the plant and secure against it being plugged back in. When exchanging heavy machine parts only use suitable lifting devices in good working condition. Heavy components are to be secured against falling down by proper facilities. Prior to carrying out maintenance or repair works ensure that parts which may need to be handled have cooled down to room temperature. Dispose of grease, coolant or cleaning material in accordance with environmental regulations. If a device has been contaminated with SF; decomposition products additional safety measures are to be taken. Furthermore protective clothing and a dust mask depending on the degree of contamination is required. The working protection set is available under the order number: 3-442-RO01 wwe dlla-ambh.com | 070386¢ General safety notes Work on electrical equipment Only properly trained electricians should carry out repair works on the device electrical equipment. Regularly check the electrical equipment. Re-tighten loose connections. Replace damaged lines/cable immediately. Always keep the control cabinet closed. Only authorized persons with keyftools should work on the device. Never clean control cabinets and other electrical equipment housings using a water hose. Work on SF-gas filled equipment Only specially trained personnel should carry out maintenance and repair works on pressure gas filled equipment. Prior to maintenance and repair works depressurize the pressure gas filled equipment of the device. Replace hose lines for preventive purposes even if no damage is visible. (Follow recommendations of manufacturer). After having carried out maintenance and repair works and prior to putting back into service = check that loosened screw connections are property seated. = ensure that the tank caps, sieves or filters that have been removed have been re-installed. After having carried out the maintenance and repair works and before operation ensure that = all materials, tools and other equipment which were necessary for the maintenance or repair works have been removed from the working area of the device, = liquids that may have come out have been removed (wiped away) = all safety devices for the unit are property set and in working order. wwe dlla-ambh.com | 070386General safety notes SA Observe environmental standards ‘Whenever working on and with the device please observe legal requirements for waste handling and disposal. Particularly during installation, repair and maintenance works substances that cause water pollution such as: = lubricating greases and cil = hydraulic oils = cooling agents = cleansing liquors containing solvent must not contaminate the soil or flow into drains. These substances should be stored in suitable vessels, and removed and disposed of according to local regulations. ‘The equipment contains the greenhouse gas SF6 as stipulated in the Kyoto Protocol, with a global warming potential (GWP) of 22200. SF6 needs to be recovered and must not be released into the atmosphere. | When using and handling SF6 please observe IEC 62271-303 “High-voltage Danger | switchgear and control gear — Part 303 Use and handling of sulphur hexafluoride (sF6)". wwe dlla-ambh.com | 070386Product description SA Product description Correct use This service cart is designed for the recovery and putting into storage of SF.-gas from gas compartments. Gas compartments can also be flooded with air, evacuated and filed with SF.-gas. During each recovery and filling operation the SF.-gas passes through filters, which dry and purify the gas Donot use the cart to exhaust or compress liquids or other gases. Use of the SFe-gas service cart for any other purpose may not be safe. ‘The manufacturer will not accept any lability in case of Injury and damage caused by use of the cart for applications for which it was not intended. We recommend that all persons who are involved in the operation and repair of DILO devices are properly and specially trained. Construction and operation of the service cart The service cart consists of the following components: Sheet metal frame ‘evaporator (only for liquid storage) Compressor storage tank or storage bottles (option) ‘Vacuum compressor or suction pump particle filter / dry fiter Vacuum pump electric control ‘Sheet metal frame: The frame is of sheet metal construction. It is designed with provisions for fork lift loading and unloading. The standard version is equipped with fixing- and steerable rollers with brakes. The wheels on versions with a storage tank or SF.-bottle storage are bolted to the frame. This type of ‘wheel is not provided on road trailer versions. wwe dlla-ambh.com | 6200.6¢ Product description Compresso: The compressor is a dry running type and operates entirely without oil. itis available for different delivery rates and different final pressures (see technical data). The compressor housing is absolutely gastight, but the maintenance of the compressor can be carried out easily. The working overpressure is controlled by a pressure reducer and a contact gauge. The operating temperature of the motor winding and the cylinder heads are controlled by a thermistor. (Technical data and description see chapter 11 of the operating manuals for the compressor), Suction pump: (if included) The suction pump allows the recovery of gas down to Warming ‘Only operate the device indoors or in dry places outdoors. ‘Operation in humid places may cause corrosion of couplings and valves. For outdoor operation we recommend using a tarpaulin cover for protection. When using the device the tarpaulin must partially be raised to allow ventilation for cooling The ambient temperature during operation of the device should be in the range of +10°C to +40 °C. In case of temperatures from - 10 to + 10 °C the vacuum pump oil may need to be changed. (see operating manuals for vacuum pump) Electrical connection: > Danger > Pe Only trained and authorized personnel should connect the device! A three phase neutral and ground power supply must be used! Power supply must be protected via a residual current device (RCD) with a max. ‘operating current of 30mA. For operating voltage. fuse protection and recommended connecting cable: see chapter 2, technical data Electrical connection Connect the cable to the plug supplied. Note: Cable must be disconnected from the power socket Connect the 3 phases to terminals L1, L2, L3, the neutral to terminal N and the ground to the terminal marked with the symbol. However for the operation of the service cart no neutral is necessary. Power is supplied through the plug mounted on the control cabinet. Electrical accessories (€. g. remote control, bottle balance with switch contact) must also be connected to the service cart. ‘Checking for the correct power supply: Plug in the device. Turn on the main- or reversing switch (if available) The phase sequence relay installed in the device checks the connected mains supply for phase failure and the direction of rotation (for devices dependant on direction of rotation). The “Power, correct direction of rotation” lamp lights up if the power conneetion is correct The “Incorrect direction of rotation” lamp lights up if the power connection or direction of rotation is incorrect. Operation is blocked ‘Check the power connection or exchange the phase connections of the incoming power supply or reverse the reversing switch (if available). Attention: Disconnect the power plug beforehand! wwe dila-ambh.com | 0300.6¢ Setting into operation Prior to setting the device into operation check the following 1. Electrical supply that all necessary connections have been mace correctly. 2. il level of the vacuum pump (if installed) (see vacuum pump operating manuals) 3. Put the weighing device (if exists) in the working position (see chapter 9) After the initial start and prior to operation check that all safety equipment is operating correctly! Checking of safety equipment Only for devices with compressor: Check whether the pointer of the contact gauge (which controls the output pressure of the compressor) is adjusted to the red marking When exceeding the set pressure value the compressor must switch off by itself. Danger (see chapter 9 functional test) ww dila-ambh.com | 0400.6w All devices are filled with gas to a slight overpressure (~ pe 0.2 bar) in our works. Labels iving the correct details for transport are provided. Setting into operation Filling for transport Red label for devices filled with N. for transport Achtung/ Attention ; Ne- Transportfullung No- Filled for transport 1 Remplissage N. pour le transport Note Green label for devices filled with SF, for transport Achtung/ Attention After setting the device into operation SF - Transportfllung remove the label for transport filling. SF,- Filled for transport Remplissage SF, pour le transport Accessories, which are filled with SF.-gas (e. g. pre-fiter units) are provided with a green “SF -filled for transport” label. Accessories, which are filled with N--gas, (vacuum pump units) are provided with a red “Nefilled for transport’ label Accessories which are filled with air (e. g. hoses) are not provided with a label. Devices or accessories, which are filled with SFi-gas, can be put into operation without carrying out any additional preparatory operations. Devices or accessories, which are filled with N.-gas or air must be evacuated before use with SF.- gas otherwise the SF.-gas will be contaminated. For pressure tanks, which are installed by the customer observe the following: as the connecting hose is filled with air it must be evacuated after the installation, otherwise the SF-- gas could be contaminated. ww dila-ambh.com | 0400.6¢ Setting into operation into the working position Putting the weighing device Only for BO44R.. pressure tank There Is a hexagonal bolt (SW 30 mm) near the load cell of the tank which Is fixed with a pin so that it cannot be turned, = Pull out the pin. * Loosen screw (right hand thread) until the indicating instrument shows the weight. Then turn out the hexagonal bolt a further 10 mm so that there is enough freedom of movement to allow weighing. Only for B146R.. pressure tank and B145R.. / B147R.. bottle balance (4 bottles): There is a lever (with eccentric) near the load cell of the tank, which is fixed with a split pin Tum the lever clockwise until the indicating instrument shows the weight. ww dila-ambh.com | 0400.6Setting into operation SA Filling the pressure tank (if included) with SF.-aas Filling the pressure tank with SF.-qas until pressure compensation has been reached Connect the SF.-gas vessel (e. g. bottle) to coupling pos. 10. 2. Open ball valve pos.56, the ball valve to the pressure tank as well as the valves on the SF.- gas. vessel, 3. The SF» gas flows with overpressure in the pressure tank of the service cart. 4. When pressure compensation is reached uncouple the SF;- gas vessel from coupling pos. 10. Use the compressor for further filling of the pressure tank. Filling the pressure tank with SF,-qas (with the compressor’ 1. Connect the SF.z gas vessel (e. g. bottle) to coupling pos. 12, Attention: Connect max. 10 bar! ‘Connect the SF,-gas vessel via pressure reducer! (imma The device can be damaged by higher pressures! At special devices it is possible to connect higher pressures. (see label on coupling pos. 13). 2. Start the Removal and storage of SF.- gas" function. (see chapter 6) www dlla-ambh.com | C402hos0°wl Functional diagram Service cart L (liquid TM 5.0 B)Parts list for functional diagram SA Service cart L (liquid TM 5.0 B) Pos. |Designation Article-No. Piece 7 |G Vacuum pump (nominal suction capacity '3-690-ROO7 1 40 m3m, final vacuum <1 mbar) 1 | Vacuum pump (nominal suction capacity 3-745-R002 1 25 mM, final vacuum <2 x 10°3 mbar) ‘Small flange KF 25 with hose connection (angled) 3-370-R002 1 1 |G Vacuum pump (nominal suetion capacity 3-745-ROO4 1 40 m8m, final vacuum < 2 x 10°3 mbar) ‘Small flange KF40-DN20, angled 3-370-R001 1 2 |Dry-running compressor TM 5.0 B '4-200-00 i 3__ [Vacuum compressor unit BOOIROT 1 4 [Vacuum unit BO3SRO2 1 3_ [Valve unit (compressor) [BO64ROt 1 6 Evaporator |KO32RO1 1 7 Filter unit DN20 PN 64 bar BOO7R12 1 8/9 _[Ball valve DN20 3-383-RO01 P 2 10 {Coupling groove part VKIA-02/20 P 1 ‘Covering cap for groove part DN20 VK/KN-04/20 T 1 12/13 [Coupling groove part \VKIA-02/20 P 2 Covering cap for groove part DN20 VKIKN-04/20 T 2 74 [Ball valve DNé with hand wheel 3-365-R008 P. 1 15 _ [Filter with connection 3-337 1 16__|SF6-bottle balance KO91RO7_ 1 17 __|Wire braided hose 'SM0320L00600 1 18 [Particle filter DN20 3-377-ROO1 1 19 _|Rubber hose 'GS0320L00420 1 20 [Rubber hose (GS0120L00460 1 21 [Pressure reducer, set to pe 4 bar '3-300-R001 1 22__|Tubing elbow piece AD22 - AD22 KO18RO3, 1 23 [Rubber hose (GS0108L00700 1 24 [Rubber hose (Gs0108L00700 1 25 __|Rubber hose 1GS0108L01450 1 26 |Contact gauge NG100, 0-60 ber KO60RO9 1 27_|Rubber hose GS0108L00600 1 28__|Rubber hose 'GS0320L00670 1 29° [Tubing P038-01 1 30__|Ball valve DN20 '3-383-R001 P 1 31__|Tubing P038-02 1 32__|Ball valve DN20 3-383-ROOT P. 1 33__|Conical non return valve VR/A-02/20 P 4 34 [Rubber hose (GS0320L00670 1 35_|Solenoid valve DN20 PNEO 3-564-ROO1 1 37__|Rubber hose GS0308L00800 1 38 | Tubing 038-13 1 39 [Tubing P038-03, 1 40__|Rubber hose 'GS0108L00600 1 wwe dlla-ambh.com | 050'h901 basParts list for functional diagram SA Pos. [Designation Article-No. [Piece 41 _|Gauge NG100, 0-60 bar KOS9RO8 1 42_ [Overflow valve DN20 KO25R01 1 43 |Tubing P038-04 1 44 [Pressure reducer__pe 0-9 bar 3-300-ROO1 4 47 |Safety vavie pe = 10 bar (05-0110-R100 1 48_ [Tubing P038-11 1 1_|Tubing PO36-12 1 '52_ [Capillary tube KO81ROt 1 83 [Gauge NG100, -1/15 bar KOSSRO4 1 54 |Tubing 038-08 1 ‘85 _ [Ball valve DN20 '3-383-ROOT P 1 86_|Tubing P038-09 1 '57_ |Storage connection (6-1037-RO50 1 38 [Q Pressure tank 3001/50 bar B044R01 1 58 |Q Pressure tank 6001/50 bar B044R02 1 58 |C Weighing device for 4 SF6 bottles B147RO1 1 58 |G Weighing device for 4 SF6 bottles B147R02 1 58 |Q Stowage for 6 SF,- bottles BO45RO1 1 58__|O Stowage for 4 SF, bottles BOs6R11 1 89 |O Rubber hose (BO44R..) GS0108L01100 1 60/61 [Transition piece DN 8/20 3-240-ROO1 P 2 62_|Wire braided hose SM0320L00800 1 63_ [Transition piece DN 8/20 '3-240-ROO1 P 1 67_ [Rubber hose GS0108L00900 1 68 [Coupling groove part VK/A-02/20 P 1 Covering cap for groove part DN20 VK/KN-04/20 T 1 69_|Tubing Tee piece KO20R19 1 70 [Coupling groove part VKIA-02/20 P. 1 Covering cap for groove part DN20 VKIKN-04/20 T 1 71__|Tubing - Elbow piece AD22 - AD10 KO18RO2 1 72_ |Wire braided hose 'SM0108L01000 1 73_ |Copper seal (05-0568-RO06 1 74_ [Adapter G1/4- DNS 3-288 P 1 78_| Transition piece DN 20/8 [3-240-RO01 2 wwe dlla-ambh.com | 050'h901 basFunctional diagram Valve unit (TM5.0B/TM2.5) (BO64R01) | —~.] S6) (5.4) (5.7) — oq AS2 (3.1) (S.5) CI Pos. Designation Order-No. Piece 5.4 _ | Conical non retum valve ‘VRIA-02/20 P 1 5.2 | Conical non retum valve ‘VRIA-02/20 P 1 54 _ | Ball valve DN20 3383-RO01 P 1 5.5 Tubing P041-01 4 56 | Tubing Po4t-02 1 57 Tubing P041-03 4 wwe dllo-ambh.com | 505801. boeFunctional diagram Vacuum unit (B039R02) ¢ @ Pos. | Designation Order-no. Piece 44 Particle filter 3-377-RO01 1 42 Groove part without boring ML1-AD22-7 P 1 43 Solenoid valve DN20 PN6O (870 psi) 3-564-RO01 1 4.4 | Vacuum controller with mounting casing KO76R13, 1 45. Manostat pe 0.4 bar (5.8 psi ) KOS6RO6 1 46 Tubing Po27-01 1 47 Tubing K081RO1 1 www dlle-gmbh.com | BO32F02 noeFunctional diagram ¢ Pressure vessel BO44R01 (liquid) 9 6 aw FL 5 VV (AZ ’) 7 SH LT Ss " 8 12 rN 1 \! 47 A LI / LIN Pos. | Designation Article-no. Piece 1 [Pressure vessel, 3001 (10.5 cf), 50bar (725 psi), 3-817-R001 1 jin accordance with EC-Directive 97/23 2__|Pressure reader NG 160 |05-0465-RO06 4 3__| Tubing with pipe DN12 and filter 3-681-R001 4 4 _|Rubber hose GS0108L00700 4 5 |Full lift safety valve PE 50 3-298-R050 4 Gauge union AD10. M1-AD10-51 P- 1 Copper sealing }05-0091-ROO1 4 6 |Gauge NG100, 0-60 bar (0-870 psi} KOSSRO8 4 7__|Ball valve DN20 3-383-R001 P 1 8 | Tubing P045-05 4 9 | Tubing P045-02 4 410 _|Screw-in stub with O-ring ML1-AD22-13 P- 4 11_|Vent plug with O-ring WSTO3/M33x2_T 4 12_|Vent plug with O-ring WSTO3/M33x2 T 1 13 _|Vent plug with O-ring VSTO3/M33x2_T 4 14 |Tubing, elbow piece KO18RO2 4 www dlle-gmbh.com | BARD! noe¢ Functional description Recovery of composed or undefined SF; ‘When recovering decomposed or humid SF;-gas we recommend connecting the B007R1 1 pre-fiter unit upstream from the service cart. When recovering oll-contaminated SF.-gas, we recommend connecting the BO71R11 oil separating filter unit upstream from the service cart ‘warning ‘When recovering undefined SF.-gas we recommend connecting the BOO7R1 1 pre-fiter unit upstream from the service cart. ‘When recovering decomposed and cil-contaminated SF.-gas we recommend connecting the BO71R11 cil separating fiter unit and the BOO7R11 pre-fiter unit upstream from the service cart. . ‘After having recovered the contaminated or humid SF,-gas the gas in the service cart 1 should be dried of purified in the circuit for a short time. Note Economy and Mega service carts: Start the evaporator. Furthermore select and open the solenoid valves pos. 5.1, 5.2 and 5.4 via the keys on the operating panel. Start the “Compressor” function and circulate SF.-gas for about 10 minutes. ‘Compact service carts: Start the “Filling” function. Open the ball valve pos. 30. Close all other ball valves. Start the “Recovery — compressor” function and circulate SF<-gas for about 10 minutes. Piccolo service carts: The input pressure should be 2 -8 ber. The service cart could be damaged by higher pressures! amie Reduce the overpressure if necessary (see contact gauge). Connect the connecting hose between the input and output coupling, ‘Start the “Gas recovery” function of the compressor unit and make the SF.-gas circulate for about 10 minutes. ww dila-ambh.com | 0600.6¢ Functional description Removal and storage (liquid) of SF, oe |comporiment mee Ba OD cage am BEN, 3 SCE | 8 onecnoy ve a Bah In case it is necessary to open a gas compartment or gas should be exchanged the SF,-gas can be recovered with the "Gas recovery’ function and stored in a storage tank 1, Connect the gas compartment and the storage tank to the service cart as illustrated, Open the ball valve on the storage tank. Altematively, the gas compartment can also be connected to pos. 13. The connecting hoses must be evacuated or filled with SF,-gas! Waming 2. Tur the ball valves to the illustrated position. 3. Start the gas recovery function by pressing the green ,Gas recovery / Compressor" push-button. After having reached the required suction pressure stop the gas recovery function by pressing the red ,Gas recovery / Compressor * push-button Observe the fill weight of the storage tank (1 kg/l.). Waming ww dllo-ambh.com | 050'Ks\s6Functional description Flooding of the gas compartme ¢ it with ambient air |compartmen tcoueny cea kg Salah cove wy Se In case it is necessary to open a gas compartment for maintenance works it is under vacuum after the recovery process. The gas compartment is flooded with ambient air in accordance with the section "Elooding of the qas compartment” 1 The SF.-gas in the connecting hoses and in the pipework (see above figure, printed in bold type) should be recovered beforehand. 1. Connect the gas compartment to the service cart as illustrated above Altematively the gas compartment can also be connected to pos. 12 (open ball valves pos.8 and 9). 2. Open the venting ball valve and wait for pressure compensation. When pressure compensation is reached close the venting ball valve again otherwise the ‘SF gas is released into the atmosphere later on during gas handling. 1 Tote Aiter flooding uncouple the connecting hose from the gas compartment and evacuate to < ‘mbar (see chapter 6 "Evacuation of the gas compartment"). This is to avoid mixing ambient air in the hose with SF, later on during gas handling, ww dllo-ambh.com | 0502%cl86¢ Functional description Evacuation of air from the gas compartm p= git |comportment| L__| Brenna la BBY cone wa EE, es Sut ney whe Be Bll save To avoid mixing ambient air with SF.-gas the gas compartment must first be evacuated. 1, Connect the gas compartment to the service cart. Alternatively, itis also possible to connect the gas compartment to pos. 12. If there is SF,-gas overpressure (gauge pos. 53), the gas should be recovered beforehand (see chapter "Removal and storage of SF.) Warning 2. Turn the ball vaive to the illustrated position. 3. Start the evacuation function by pressing the green Evacuation" push-button. If there is a pressure > pe 0.4 bar the solenoid valve upstream from the vacuum pump does not open. Reduce the overpressure. (see chapter Gas recovery") 4. Evacuate the gas compartment until a stable vacuum has been reached (e.g. < pa 1 mbar). 5. After having reached the required final vacuum stop the evacuation function by pressing the red ,Evacuation" push-button. ww dllo-ambh.com | 0502%cl86¢ Functional description Filling the gas compartment with SF.-gas compartment Brcowning BRE a BEAD once aw GN SSRN, F onency ote ale Sn 1. Ifo storage tank is installed in the service cart, connect the SF,-bottle or external storage tank to pos.10 and open the ball valve on the storage tank. Do not yet connect any gas compartment. A The connecting hoses must be evacuated or filled with SFe. Warning, 2. Close the pressure reducer pos. 44 by turning anti-clockwise (minimum pressure), Turn the ball valves to the illustrated position. Press the green “Filling” push-button. (The evaporator heating is started. The solenoid valve upstream from the evaporator only opens after the evaporator has reached its operating temperature. The indicator light ‘Filling active” lights up”). 5. Adjust the pressure reducer to the required filling pressure. 6. Stop the “Filling” function by pressing the red push-button. 7. Connect the gas compartment to the service cart. Alternatively the gas compartment can also be connected to pos. 13. 8. Restart the “Filling” function. 9. When pressure compensation is reached start the “Gas recovery / Compressor” function by pressing the green push-button 10. After having reached the required filling pressure stop the functions manually by pressing the red push-button. ww dllo-ambh.com | 0stsislese¢ Functional description Filling of BH cowwing Gores” OM Sua) Gouge Seater 23 SET, bmw ake wa BEE 1. Connect the SF. 1.0 um 2. Revision intervals ‘The exchange of the filter cartridge in the particle filter should be carried out together with the exchange of the cartridge of the dry filter or when performing a revision of the compressor. xchange of the filter cartridge and disposal ‘Attention: Depressurize the particle fitter before dismantling the filter cartridge. Pay attention to the protective rules conceming the handling of SF. gas [1]. = Unscrew the filtering cone = Remove the filter cartridge = Clean the interior space of the filter cone with a fibreless piece of cloth = Slightly grease the o-ring in the new filter cartridge and the o-ing in the filter cone as well as the thread with @ suitable sliding means = Push the new filter cartridge on the guide pipe in the screw cap (do not forget the compressing spring!) = Screw in the filter cone until the stop Attention: The particle filter must be evacuated before putting it into operation. Attention: Ifthe filer cartridge is left until disposal it has to be put into a plastic packing and sealed tightly. Thus the decomposition products are no longer set free: www dlle-gmbh.com | ©256.07 | Page 112Particle filter revision | 3-377 SA The material is waste that must be controlled and for further disposal it has to be treated according to the regulations for the control of waste and recycling valid in your country. Furthermore it is possible to neutralize the filter cartridge and to dispose it afterwards, for this see our ‘working protection set 3-442. Note: Normally polluted or unused filter cartridges that are not charged with decomposition products are unrisky and can be disposed as usual rubbish. 4, Particle filter ITN ter cone Iker cantioye orderne. 3.87.08, guice pipe compression sping orderno, 3277-05 ong 613 ofderne.a5-0057-RO7S: input coup seraw ceo ibliography [1] SF--Anlagen, BG! 753 Berufsgenossenschaft der Feinmechanik und Elektrotechnik, Gustav-Heinemann-Ufer 130, Kéin www dlle-gmbh.com | £256.07 | Page 212Liste de piéces pour schéma des circuits | Control- and main circuit diagram | Esquema eléctrico Steuer- und Hauptstromlaufplan | a Sie SS =| SESS arog @) ° 1 te 2 n 22 Gd) i ; : uk Vien ub fed kde, tal, S 4 0 5 1 a ! ea ! ws| ser (Ua UU vay st sl el oor ye * ri Wwe e Z 3 = ¥ wwrw dlle-gmbh.com | 100th sprListe de piéces pour schéma des circuits | Control- and main circuit diagram | Esquema eléctrico Steuer- und Hauptstromlaufplan | ‘1304 ap vesascueg sesecdicy / wgoescny erence esr Ea censrioxz ie a pC A wae Zp wee (eymex ZO ne *) coca> im Toxt00e 33mm mates > CBee ees = vata Ez *F} es | Ff ro 6 "T0604 ow LE 7 3 ‘noxe1o1 3 ns rr. aw s z T o T Ss T + € wwrw dlle-gmbh.com | 100th spr6 "tox6t0Leg—E nl ser e0_NWie aay e108 wit Liste de piéces pour schéma des circuits | Control- and main circuit diagram | Esquema eléctrico Steuer- und Hauptstromlaufplan | @ wwrw dlle-gmbh.com | 100th sprParts list for circuit diagram (T™5,0B) Pos. [Designation Article- No. Piece B03 [Phase sequence rela} (05-1456-ROOT 1 Fit [Dold Protective contact relay 230V 05-0743-ROO1 7 F143 | Thermistor machinery protection (05-0228-R008 4 F51__ [Microprocessor controller (05-0701-R003 1 KiiM _ [KM Contactor 230 V (05-0722-RO02 1 KM Auxiliary contact module 05-0733-R104 4 K2iM__ [KM Contactor 230 V 05-0722-RO01 1 K31M__ [KM Contactor 230 V (05-0722-ROO1 1 KS1A__ [KM Contactor relay 230 V (05-0729-ROOS 4 K51E [KM Contactor 230 V 05-0722-RO01 1 1 P11-P31 [Working hours counter 230 V750 Hz (05-0400-ROO1 3 O P11-P31 |Working hours counter 230 V/60 Hz (05-0400-ROO2 3 01 [KM Motor protective circuit breaker (05-0891-ROO5 4 Q01.7 [KM Safety cutout (05-0725-RO03 1 11 [KM Motor protective circuit breaker (05-0891-RO11 1 KM Auxiliary contact 05-0723-R004 4 QIT1__ [Motor protective circuit breaker (05-0725-ROS2 1 Auxiliary contact 05-0725-RO5O 4 Q21 [KM Motor protective circuit breaker (05-0891-R008 1 KM Auxiliary contact 05-0723-R004 1 1G37__|KM Motor protective circuit breaker (40mm) (05-0891-R008 1 (031 |KM Motor protective circuit breaker (D25B) 05-0891-ROO7 1 KM Auxiliary contact 05-0723-R004 4 Q51__ [KM Motor protective circuit breaker 05-0891-RO10 1 KM Auxiliary contact 05-0723-R004 4 To1__|Wa. Universal transformer P. 200-550 V (05-0747-R005 1 To1.1 [Power unit 230V ~/ 24V- (05-1461-RO01 1 Voi [Discharger 05-1509-ROOT 4 X01 [ET Coupling 400 05-0751-R004 1 X02__ [ET Power plug (05-0752-R004 1 Range of operating voltage Control voltage: Compressor: TM 5.08 Vacuum compressor: 3-582 Vacuum pump: 40m‘ Q Vacuum pump: 25m‘ D258 Evaporator: KO32R01 Control: 380- 460V 230 5.00 KW 0.55 KW 4 (1.5) kW 0.75 kW 4.80 kW 0.32 kW ‘B0H2 140A 134 336A 22A T2A O9A www dlle-gmbh.com | 1001kck503.boeOperating panel SA Circuit diagram T019R01 Aa ww dllo-ambh.com | 1000%cl86Operating panel SA Parts list for circuit diagram T019R01 Pos. [Designation Type Article-No. Piece HO1 [Green indictor light_230V Ki02R12 4 H02 [Red indicator light 230V K102R13, 7 H53_|White indicator light 230V K102R11 4 ‘S11_|Double button 230V Ki01RO2 1 '$31_|Double button 230V. Ki01RO2 4 '$51_|Double button 230V K101RO2 4 ww dllo-ambh.com | 1000%cl86Dry-running compressor | TM 5.0 B Operating Manual (original version) Year of construction: 2014 > = ~ ak - DILO. Sustainably tight. . Germany =Dry-running compressor | TM 5.0B Product description Dimension sheet with technical data Functional diagram Safety notes Transport and installation Putting Into operation Fault correction Maintenance and functional test ¢ o 7/8/9/10 4 12113 14 15/16/17 118 Please read this operating manual before putting the device into operation. Thus operating faults can be avoided In case of nonobservance of the operating manual the manufacturer cannot assume any liability or warranty ‘The copyright of this documentation remains with DILO Armaturen und Antagen GmbH, D-87727 Babenhausen. Any use not permitted by the author (multiplication, leaving to third persons etc.) is indemnification. www allo-gmbn.com |¢ 1610-09 | Page 2/16 subject to penalty andDry-running compressor | TM 5.0B SA Product description Correct use ‘The compressor is designed for the recovery and compression of SF g-gas and SFg-gas mixtures, Do not use the device to exhaust or compress liquids or other gases. Use of the compressor for any other purpose may not be safe. The manufacturer will not accept any liability in case of injury or damage caused by Danger _ use Of the compressor for applications for which It was not intended. The TMS5.0B compressor is @ dry-running two-stage, low maintenance piston compressor and works entirely without oil ‘The compressor housing is enclosed and thus absolutely gastight. The position of the 2 cylinders guarantees a smooth running even at high back pressure. The gas is stored in gaseous of liquid form depending on the pressure. For cooling the compressor and the compressed SF:-gas with ambient air a ventilator and an intermediate cooler and after cooler are integrated, The operating overpressure is to be limited to max. pe 4 bar on the suction side by a pressure reducer. Furthermore, the output pressure has to be monitored by @ contact gauge (or pressure switch) which turns off the compressor in case the max. admissible operating pressure (pe 50 bar) is exceeded. The compressor is protected against overcurrent by a motor protection circuit breaker. Lead probes are installed in the motor winding and in each cylinder cap. ‘When exceeding the admissible temperature the compressor is switched off by the thermistor. In case the compressor is integrated in a device or system which is - in accordance with the legal regulations - liable to registration in the country of operation, the operator is responsible for commissioning and further tests. itis not allowed to expose the compressor to humid or corrosive substances permanently. However in case the compressor has been charged with moisture for a short time it must be rinsed with pure and dry gas for min. 30 minutes. For this purpose nitrogen can also be used if the rinsing gas is released into the atmosphere. Finally evacuate the compressor. Furthermore the compressor must not be operated with substances containing oil and oil mist as this ‘would damage the piston and guide rings. Do not switch on the compressor if the input or output pressure or pressure in the housing is < 100 mbar (absolute pressure). After evacuation flood the compressor with SF; before it is put into operation. Otherwise this could result in flashovers or leakage current on the grommet. www .llo-gmbn.com |¢ 1610-09 | Page 3/16¢ Dry-running compressor | TM 5.0B Dimension sI Length Width Height ~~ Weight mm mm mm 780 505 430 132 kg wwrw.dlle-gmbh.com | ¢ 1610-08 | Page 4! 18Dry-running compressor | TM 5.0B SA chnical data Dry running compress Number of cylinders 1. stage 1 2. stage 1 Theoretical delivery rate 5.7 mith (50 Hz) 6.8 mh (60 Hz) (at nominal speed) Direction of rotation right or left ‘Sound level 70 dB(A) Protection system Iraq Built-in motor; (standard version) Frequency 50/60 Hz Nominal speed 1460 / 1750 min’ Three phase short-circuit motor, 4 poles 5.0kW Operating voltage * 380-480 V (Y) / 208-240 V (A) Nominal current *99-44/17.3-21A Insulation class (VDE 0520) F For special voltage the data of the type plate marked with * are valid. Fan motor Frequency 50/60 Hz Single phase motor 2 poles 115/150 W Operating voltage 230V Nominal current 0.51/0.66A Admissible limiting values at continuous operation with SFe-aas (pressure indication in Pe) Suction pressure -0.5to 4 bar Max. back pressure 50 bar Admissible ambient temperature ~10°C to +45 °C ww w.lle-gmbh.com |¢ 1610-09 | Page 5! 16Dry-running compressor | TM 5.0B Functional diagram ¢ fan Be safely valve > non return valve HHH cooler iS ‘compression slage ww w.llo-gmbh.com |C 1610-09 | Page 6 16Dry-running compressor | TM 5.0B SA General safety notes = The compressor has been designed and constructed bearing in mind the standards to be observed as well as additional technical specifications. Safe use of the machine can only be achieved if all necessary measures are taken. = The operator has to ensure that = the device is only used for the purposes for which it is intended (see product description). = the device is only operated in accordance with the instructions and in good condition and that the safety devices are regularly checked. = maintenance and repair personnel are issued with all the required safety and protective clothing, which shall always be used = complete and legible operating manuals are available on site. = only qualified personnel operates or repairs the device. = this personnel is regularly instructed in safety procedures and environmental protection and that this personnel is fully aware of the complete operating manuals and particularly in the safety notes. = the safety and warning notes mounted on the device are legible and not removed. = all obligatory registrations and tests prescribed by law are carried out on the devices in accordance with the local regulations (e. g. pressure vessel tests, test for electrical safety etc.) = the safety data sheet on SF (can be obtained from the SF supplier) is available for the ‘operating personnel. The instructions mentioned in the data sheet and safety precautions must be known and observed by the operating personnel. www allo-gmbn.com | 1610-09 | Page 7/16Dry-running compressor | TM 5.0B SA Specific safety notes and standard symbols The symbals used in the operating manuals should draw your attention specially tothe safety notes This symbol refers to risks for persons (danger to life, danger of injury) Danger This symbol refers to risks for machines, material and the environment. ‘Warning, ‘The most important aim of the safety notes is to prevent personal injuries. = Ifthe warning sign "Danger’ appears, danger from machines, materials and the environment are not excluded = Ifthe warning sign "Waring" appears, there is no danger for persons, The corresponding symbol which is used cannot replace the text of the safety note. Therefore, the complete text must always be read! ww wallo-gmbh.com |C 1610-09 | Page 8 16Dry-running compressor | TM 5.0B SA Basic safety measures during normal operation Only trained and authorized persons who are fully aware of the operating manuals should ‘operate the device in accordance with the operating manuals. Before switching on the device ensure that = only authorized persons are present at the device = nobody can be hurt by the operation ofthe device ‘Whenever the compressor is started check for visible damage beforehand and ensure that it is operated in the correct conditions! Eliminate any damage immediately! Basic safety measures during maintenance Follow inspection and maintenance periods described in the operating manuals! Follow maintenance and repair instruction for individual components in these operating manuals! Prior to carrying out maintenance and repair works turn off the main switch for the power supply and secure it with @ padlock, The key for this lock must be in the hands of the person ‘who carries out the repair works, If there is no main switch unplug the power supply cable at the plant and secure it against being plugged in again ‘When exchanging heavy machine parts only use suitable lifting devices in good working condition, Prior to carrying out maintenance or repair works ensure that parts which may need to be touched have cooled down to room temperature! Dispose of grease, auxiliary or cleaning material in accordance with environmental regulations! ww w.lle-gmbh.com |C 1610-09 | Page 916¢ Dry-running compressor | TM 5.0B Work on electrical equipment = Only properly trained electricians should carry out repair works on the electrical equipment of the compressor. Regularly check the electrical equipment! * Rettighten loose connections! = Replace damaged lines/cables immediately! Works on equipment under overpressure = Only specially trained personnel should carry out maintenance and repair works on equipment which is under overpressure. "Prior to maintenance and repair works depressurize the compressor equipment which is under overpressure. = After having carried out maintenance or repair works and prior to putting the equipment back into service: = check whether loosened screw connections are properly sealed = ensure that the tank caps and components that have been removed have been re-installed! "After having carried out the maintenance or repair works and before operation ensure that = all materials, tools and other equipment which were necessary for the maintenance or repair works have been removed from the working area of the compressor, = all safety devices for the unit are properly set and in working order. Observe environmental standards = Whenever working on and with the compressor please observe legal requirements for waste handling and disposal. "Particularly during installation, repair and maintenance works substances that cause water pollution such as = lubricating grease = auxiliary material = cleansing liquors containing solvent must not contaminate the soil or flow into drains! ‘These substances should be stored and transported in suitable vessels and removed and disposed of according to local regulations! ww w.lo-gmbh.com | C 1610-09 | Page 19/19Dry-running compressor | TM 5.0B SA Transport To avoid damage to devices and life threatening injuries during transport: "= lifting slings must correspond to local health and safety regulations! = slings should be chosen in accordance with the weight of the device. (Weight see dimension sheet) Danger = Only qualified and authorized persons should carry out transport operations. Installation ‘The compressor is to be mounted on a frame correspondingly prepared. Level up unevenness on the frame by distance disks. ‘The screws or nuts must be fastened. Waring Connections Suction and back pressure side consist of a DILO union ML1-AD10-3 P. The suction pressure must not exceed the indicated suction pressure range. Therefore the suction pressure is to be reduced to its max. value by a pressure reducer before compressing Furthermore a pressure-controlled switching contact (e.g. contact gauge or manostat) should be installed on the back pressure side which tums off the compressor if the back pressure is too high. Dry running compressor Pressure reducer ‘ontact gauge Connecting proposal: ww walo-gmbn.com | C 1610-09 | Page 11/19¢ Dry-running compressor | TM 5.0B Setting into operation Prior to setting the compressor into operation check the following: 1, Electrical connection 2. SFi-gas connection After the initial start and prior to operation check that all safety equipment is operating correctly. Electrical connection Voltage indications on the compressor must be suitable for the existing electric network. For connecting the compressor remove the cover plate from the upper connecting case. The following terminals for the electrical connection are provided in the connecting case: Terminal U1, V1, W1, PE: connection of power supply for the compressor motor Terminal 1, 2: connection of the lead probes Terminal L1,N, PE: connection of the power supply for the fan ‘When connecting the power supply for the compressor motor observe the note in the connecting case for Y- and A-connection. Lead probes are installed (f1 to f5) in the motor winding and in each cylinder cap. Connect the lead probes to terminal T1 and 72 of the thermistor machinery protection (F'13). The electrical connection of the compressor motor contactor (K11M) must be done via the switching contact of the thermistor. Thus a thermal protection of the compressor is achieved, ww wlo-gmbh.com | C 1810-09 Page 12/19¢ Dry-running compressor | TM 5.0B Circuit diagram (wiring example) wt mca r compressor “Stan 13 Lead probe (in the motor winding of the compressor) 145, Lead probe (in the cylinder caps of the compressor) Ft Protective contact relay F13 Thermistor-machinery protection KIM Motor contactor P11 Working hours counters 01.1/Q11/011.2 Motor protective circuit breaker sit ‘On/Off button with indicator light Tot Transformer xot Coupling x02 Power plug 3 Contact gauge (the contact gauge must be connected to the output side of the compressor) ‘$Fe-gas connection ‘Check that connecting hoses are connected and tightened. Check whether the suction pressure is limited to its max. value by a pressure reducer. Verification of the safety equipment Check whether the red pointer of the contact gauge (or pressure switch) that controls the ‘output pressure of the compressor which is adjusted not higher than the max, admissible pressure of the compressor (pe 50 bar)! Danger ww w.ilo-gmbh.com | C 1810-09 Page 13/19Dry-running compressor | TM 5.0B SA Elimination of malfunctions In case of malfunction the operator has to inform his supervisor. The operator should not eliminate any damage on electrical equipment. To avoid danger to life by electric shock: "Only property trained electricians should carry out maintenance and repair works on. electrical equipment. * The operator should only eliminate faults, which result from operating or maintenance errors. Fault correction ‘The compressor is automatically switched off as soon as the lead probes (f1 — f3) in the motor winding or the cylinder caps (f4- 15) become too hot. As soon as this breakdown occurs the compressor is switched off by the control provided that the compressor has been connected in accordance with the circuit diagram. After cooling down the lead probes the compressor is to be restarted with the (S11) button. In case the motor protection circuit breaker (11.2) switches off due the defective fan the contactor (K11M) is turned off as well. ww w.llo-gmbn.com | C 1610-09 Page 14119¢ Dry-running compressor | TM 5.0B Maintenances All bearings are closed and provided with permanent lubrication The sliding surfaces of the cylinders are dry-running Do not lubricate the compressor with oil or grease. Only the O-rings are slightly greased with a special grease before installation. Maintenance Object Work interval Operating hours Weekly Noises Check Every 500 hours —_| Piston and guide or year rings Carry out pressure test with SF; Valve seats (See page 16) after 1500 h, Piston and guide _| Check, measure, exchange if necessary 4000h, 6500h, rings (see page 16 to 18) 9000h, (1 piece spare part kit - piston ring with O-ring kit, atticle no.: 6-1010-R013) Valve seats Check, exchange if necessary (see page 16 to 18) (1 piece spare part kit — valve seats with O-ring kit, article no.: 6-1010-R004) every 2500 h Crank gear Exchange (1 piece replacement crankcase mounted completely, article no.: 4-291-61) Non return valve | Check, exchange, if necessary (1 piece non retum valve, article no.: VR/A-02/8 P) ‘Within the specified maintenance interval the compressor can be operated completely maintenance-free. Examination in disassembled condition: Radial minimum thickness Dimension of new ring Piston ring, 9 64 mm 3.0mm 4.0mm. (Article no.: 05-1054-R012) Guide ring, 2 54 mm 3.4mm 35mm (Atticle no.: 05-1054-R013) High pressure piston ring, @ 23 mm. 4.0mm 5.0mm (Atticle no: 05-1054-R015) ww w.lo-gmbn.com | C 1810-09 Page 15/19Dry-running compressor | TM 5.0B SA Functional test (pressure test with SF.) Connect the gauge, then the check valve (ball valve or solenoid valve) to the compressor output (in case they are not already present downstream from the compressor in the service cart. If the compressor is installed in the service cart the exact procedure Is described in the operating manuals, chapter 9 “Maintenance and functional test of the compressor). Close the check valve and start the compressor (suction pressure should be about p. 0 bar) After a certain time a pressure of p 48 bar should be obtained, Turn off the compressor! If the compressor is turned off too late the compressed SF. is released in the atmosphere via the safety valve pe 55 bar (upstream from the compressor output). In case a pressure of p. 48 bar is not reached exchange the valve seats. After the exchange repeat the pressure test. Ifthe pressure is still not reached the piston and guide rings are to be exchanged. Verification and disassembly of the piston and quide rings and valve seats A Attention: Only carry out if the plant is depressurized and disconnected from the power supply! Danger ® Disassemble the front cover (2 pieces). = Disassemble all tubings on the cylinder caps. Then dismount all cylinder caps. ww walo-gmbn.com | C 1610-09 | Page 13/19Dry-running compressor | TM 5.0B = Remove the valve seats. = Tomeasure out the piston and guide rings disassemble the cylinders. = Exchange the wom-out piston and guide rings (radial minimum thickness page 15). Hf contamination is found in the compressor while exchanging the piston and guide rings and valve seats the compressor has to be disassembled and cleaned, ww wllo-gmbh.com | C 1810-09 Page 17/19Dry-running compressor | TM 5.0B SA Assembly of piston and quide rings and valve seats Prior to assembly, clean all O-rings and piston ring grooves, Exchange all O-rings and slightly grease them with silicone grease. Mount two tension springs per piston. Bend the guide and piston rings as little as possible and slide on to the piston. Mount the piston ring at about 180 degrees with respect to the tension spring (that means in case the open end of the tension spring is at the top the open end of the piston ring must be at the bottom) guide ing piston ing tension sping kL a Tum the piston and guide ring so that the open ends are 180 degrees out of position to each other (see photo down left). Do not grease the slide surface of the pistons neither with oil nor with grease. Assemble the cylinder. eT Clean the valve seats or exchange them if necessary and put them on the cylinders. Assemble the cylinder caps and hexagonal nuts and evenly thighten crosswise (35 Nm). Assemble the complete tubing to the cylinder caps. Carry out a leak test, Assemble the cylinder covers. wwrw.dlle-gmbh.com | C 1610-08 | Paye 10/18Vacuum compressor unit (installation) | BO01R01 =, Dimension sI I technical data () 440 nn_G7.6 330mm 432 i Weight: 43 kg (95 Ibs ) for further technical data see operating manual Paint: orange RAL 2004 ‘vacuum compressor 3-582 Electrical connection: power plug 18 A- connecting cable 4 x 2.5 mm2 wvrw dlle-gmbh.com | © 125006 Page 1/4Vacuum compressor unit (installation) | BO01R01 Functional diagram lL 31) Parts list for functional di on 5 A Pos. [Designation [Article-no. Piece 1 [Vacuum compressor* [3-582 1 2-3 [Rubber hose, nominal length 500mm (20 in) |Gs0108L00500 2 4-5 __|Conical non-retum valve \VRIA-02/20 P 2 g |Solenoid valve DN8 [3-297-ROOT 7 I7 Manostat pe 0,4 bar (6.8 psi) KOTER31 1 3 Manostat pe 1,5 bar (21.75 psi) KOTER32 1 i Tubing 001-01 1 10 |Transition piece DN 8/20 [3-240-RO01 P 1 11 [Tubing P001-06 1 = separate operating manual is enclosed wrw dlle-gmbh.com | © 125006 Page 2/4Vacuum compressor unit (installation) | BO01R01 Control- and main circuit diagram Electrical data see type plate wwrw dlle-gmbh.com | © 125006 Page 3/4Vacuum compressor unit (installation) | BO01R01 =, Description of the plant Electric control: This vacuum compressor unit is provided for the installation in plants or service carts. The vacuum compressor unit is controlled by a working hours counter and protected by electric protective devices thet are installed in the control cabinet of the service cart Vacuum compressor: ‘The vacuum compressor is a dry running type and is protected from inadmissible operating conditions by manostats, solenoid valve and non-return valves. Functional description: ‘With the vacuum compressor unit it is possible to suction gas compartments until pa <60 mbar (< 37.5mm Hg). The "Gas recovery’ function must be started and stopped with the on/off switch on the electric control cabinet of the service cart in which the vacuum compressor unit is installed The vacuum compressor unit switches on automatically. G ral The vacuum compressor and all control elements are installed into a stable frame. The standard version of the vacuum compressor unit is equipped with borings for mounting. All connecting lines are designed according to the well-proven DILO tightening principle and are absolutely tight. wrw dlle-gmbh.com | © 125006 Page 4Vacuum compressor | 3-582-RO001 —— 410 mm 6,4 ind 205 mm (82 inp Technical data delivery rate: 5.2 m3/n (184 cfh) final vacuum:< 50 mbar (37.5 mm Hg) final pressure max, : Pe = 1.5 bar (22 psi) Motor power: 0.55 kWspeed: 1425 rpm weight: 28 kg (62 Ibs) Description The vacuum compressor is @ dry running type and serves for compression, recovery and recirculation of ‘SFe-gas. The complete vacuum compressor is checked for gas density. The compression is effected absolutely “ollfree", because there are no lubricated parts in the compression chamber. The ball bearings of the motor and the piston rod have permanent lubrication. Thus, no maintenance works are necessary for a long time. ‘The vacuum compressor has two diaphragm heads which are connected in series. ww w.llo-gmbh.com [© 12006 |Page 1/4Vacuum compressor | 3-582-RO001 SA Installation and putting into operation ‘Observe that there is enough cooling air during the installation. Basically these devices are screwed on by vibration dampers. The vacuurn compressor can be operated in all positions. At electrical connection observe voltage and frequency indication at the type plate. In the terminal box cover plate there is a connecting diagram. In order to avoid overloading of the motor it is necessary to install into the supply line a motor protection that is adjusted to nominal current. The sense of rotation of the motor is arbitrary. Maintenance and repair Vacuum compressors are free of maintenance for a long time. The ball bearings are closed and permanently lubricated. At working load of the vacuum compressor of pe = 4 bar (14.5 psi) until pa = 50 mbar (37.5 mmHg) the diaphragm should be exchanged every 1500 working hours, however after 3 years at the latest. In case the delivery rate of the vacuum compressor decreases or even interrupts completely it is. Possible that the diaphragm and the valves must be exchanged. Exchange of the diaphragm and valves: At first the connecting tube between the two diaphragm heads must be disconnected. Unscrew the hexagon socket screws | A TA, Y i A Release the slotted screws B which Keon are secured by hexagon nut C — EN (picture 1). After having removed the diaphragm B head and the valve reed the diaphragm is accessible. In order to exchange it the motor shaft must be turned until the diaphragm reaches qj C{E—e _ its highest point. picture 1 ww w.lo-gmbh.com | C 12006 | Page 2/4Vacuum compressor | 3-582-RO001 picture 2 | —~.] Now, the superior bracket plate pos. 7 must be unscrewed with a special wrench (picture 2) Then the diaphragm pos. 1 can be exchanged ‘The superior bracket plate pos. 7 must carefully be tightened again with a special wrench (picture 3) On this occasion check valves and o-rings in the valve reed which should eventually be exchanged if they are damaged. Specially pay attention to the fact that there are no particles pressed on the valve seats as otherwise the delivery rate is reduced considerably, Pos. ] Pc. ] Designation ‘Order ho. diaphragm picture 3 ww w.llo-gmbh.com |C 12006 | Page 3/4 valve-suction side valve-pressure side ‘Oring ‘O-ring ‘O-ring ‘superior bracket plate [413 inferior bracket plate [5-6 piston rod 136 ball bearing 20 eccentric 15-6 driving plate BLB3|= [Sle] o|~fo]en]a}co}ns |] x3] p3]h2 rofns) prof. |ro no] na] oy fro] ‘screw Pos. 1 - 6 are included in the spare part set for the vacuum compressor, order-no, 6-1006-ROO1Vacuum compressor | 3-582-RO001 SA If it is necessary to continue to dismount the compressor take into consideration that the piston rod has to be installed again centric to the diaphragm support. This can be verified with a measure after screwing a bolt into the thread at the piston rod (picture 4 and picture 5 ). picture S terminal screw Note: Regarding all orders of spare parts the type as well as the serial number of the device must be indicated. www w.llo-gmbh.com | ¢ 12006 |Page-t/4Coe Installation and Operating Instructions Vacuum Pumps R 5 RA 0025 - 0040 F ce Busch Produktions GmbH Schauinslandstr. 1 79689 Maulburg Germany (0870190007 / e924) Madatons edTable of Contents Preface . Technical Data. || Produat Desaiption. Use Prinapk of Operation i Cirelation Coaling nfl Sitch Safety Intended Use Safety Notes Emssion of Ol Mist Robe Erission Transport Transport in Packoaing anata signe storage . Short Storage Canseristion Instalaton and Commissoning Inatllation Frerequctes ‘Mounting Postion and Space Suction Connection Gas Discharge Bectrical Connecion / Controls Instiletion Mounting Connecting Elecialy Connection Scheme Tre-Phose Mote. Connecting Lres/Pipes Filing O1 Recardig of Operational Parmeter Preface CCongretulations.n your purchase of he Buss vastus pump, Wie lwatthful obearvaten ofthe fald'srequiramants, innaveton and steady evelopment Busch delivers modern vacuum and pressure solutons wore These operating inructicne contain information for = protuct desertion, = safety, = vanepert = siorage, = instalaten and cammissioring, = maintenance, = ovethoul = troubleshooting and = spare parts ‘ofthe vacuum pump. For the purpose of these instructions, “handling” the vacuum pump rears the tareport, storage, metalation, carimsiaring, influeros on Speraing careltons, martenanc, roubleshootirg ar ovethat ot the vacuum pump Prior te handling the vacuum pump thes operating instructions shall beread and undeisiood I anything reman tobe cared please conladl your Burch representalivel Koup these operating Insitutions and, If applicable, other portnent ‘operating instructions avallable en sito, Technical Data Spartin tote TAME iis amr aicton capacity oh Seo Oil Return (S0Hz/60Hz} " RA 0040 F: ‘Conveying Condensable Vapours: Cres saaintnanea 5 . mouse 5 eee ey p ed Marlee Suen pasty sh hae Wek Monthy Umerate pressure weatemtad | gy Every 6 Moris tee fer Year rare Agee Fer) 300 = 2000 Operating Hour (9 Oi Life ie or nominal ating iE Chechingthe Ol to. |_| eoHevedh a mason: Greg the Level to Topping up i 10 | [tet goraralspeea oe ‘Checking the Colour of the Ci 10 (50Hz/60H2) 1800 / 1800 oll to TOE: ian Oi Fier change 10 |_| sound presure ve a3) ‘eset Dearing Usd OW fo | | NEOHSY Boiron.) wood Rushing the Vacuum Pump. 1 64/67 Checking the Rost Vee 11 | [ater vapourtotrance max hafembay | 40, Repvcng tne Od fker " Finn fed " Tags Exhaust Filter ‘Water vapour capacity Vh RA oogO Fr Checks durng Gpeition " vt Asreamert 3 Cesc East fie | | arate ease Scoag te St er a | | Bere wAoad thsring the Exhaust Fr 2 a2is0 vata 2 | "Oi" Removal from Sie 8 Teer tarnova mn Seen a cee arrose Reocarmstoring 8 Dismanting an Depo | | eitawotty 1 1 Troubleshooting. a4 wager Diloded Vien. Tae | | wees approx cowersttiy kg ea cout F SparePats 20 38 Spare Pats ks a Aectsoros 21 | £C-Doclaraton of Canformy. oe ve .23 ou. Sa | aiseh-arovertne Wore i indusy 2 Preface TaDGs O00 F page 2Product Description Use ‘The vacuum pumpis intended for = the ation of = sir and otter dry, nomaggreeive, nanstonic and noncexplosve gues Conveying media wih a higher denety than air eads to an ireased ‘hers! and mecheracl [aad an the vacuum purrpand is permisstle only after por aoradtaton wnt uch, Permissible temperaturerange ofthe inlet gas: see "OU", "Ambient femperatre range" In case the vacuum purp is equipped with a gas ballast (optional) wa se vapour urthin the gos fen sabe tolerated itn certin lite (9 Insalation and Camnissning & Operating Notes W Conveying CConvereatle Vapour). Tre corwyance of ether vapours shal be steed up vith Busch The vacuurn pumps inter forthe placement in arnan-patantally explosive envronment ‘Version with float valve 200) and oll rekum line: ‘The vacuum pumps thermally suable for consruous operation. ‘Version with allrotun valve if, 260): ‘The vacuum pumnpis thermally sulable for continuous operation (ob- save the rates ws Saregat to theo recreation, > Product Deze p= on MO Fecreulatian, > stallion ang Commussering 3 Operating Notes 8 Or Reoreveten Terminal box Directional aiow Gas discharge Suction connection Axa flow fan Oil return alee (version ‘yah tee salve only) Nameplate, drive motor il fiter Nameplete, vacuum pure Float valve with oll rtum line Gerson with Haat valve and al retum line only) eye belt | Oil fil plug rm Oilightelass Oil dain plug © Oil separator Exhaust filter 4g Eshauat vale 1 Vane Rotor & Cylinder us Demiter vil sump " Seroe cover ‘The vacuurn purmp i ulate presaure proof Principle of Operation ‘The wacuurn purnp wars onthe rotating vane pip A cx rotor (5, 14) ispos toned centrealy on the shaft ofthe svesuums punng. The shat of the vacuum pum ie driven By he oe rotor shaft ny means of « vibe ceusling 210), The rotor, 14) rotatesinan also cular, fixed onder th 1), the centraline af which soft from the cantreine of the rotor sich that the oter and the inner wall of the eyinder almost touch along Ine ‘anos, 22), dling in slots in the rotor, separate the spacelbetes ‘theroter and the eyinder into chambers. At any time gaste sched nd at almost any tne eecred. Therefore the vactnim pump mer ost pulssbonn fee In order to avoid the suction of solids, the vacuum pump is equipped wath a screen (261) in the suction connecter In arder to avoid reverse rotation ater switching ofthe vaoaum plenp 5 equiped witha nor-relum vale (257) Note: This valve shall note ured 93a nan-ratum valve asa of vale tothe vacuum system and isro reliable means to prevent suction ‘of al into the vacium system while the vacuum pump is shut dawn, Incase the vacuum pump is equipped with a gas ballast (optionad: ‘Trrough the gostoallastylve (4) «smal rnaunt of ambient ais sutked ino the puanp chamber and compressed together wit Fe pro: ‘cess 99, Thiscounteracs the acoumulation of condensates From the process gas inside te waeuury pur ( sallation an Commis soning M Operation Notes). ‘The gee lat ine ie seuppacl with sinter metal ker a onds - 000 F Product Description page 3