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Mega

DILO Armaturen und Anlagen GmbHFrundsbergstr. 36D-87727 Babenhausen

Tel.: (49) 8333/302-0Fax.: (49) 8333/302-52

0000mea.bae

Operating instructions

for

Series: Mega

Typ-No.: B2000R01

Comm.-No.: 108951

Year of construction: 2008

Please read this operating instruction before putting the device into operation. Thus operatingfaults can be avoided. In case of nonobservance of the operating instruction the manufacturercannot 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 thirdpersons etc.) is subject to penalty and indemnification

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Table of contents R

Mega

DILO D-87727 Babenhausen 0000mea.bae

General safety notes 1

Product description 2Dimension sheet / Technical data

Transport and installation 3

Setting into operation 4

Functional diagram with parts list 5

Functional description: Removal and storage of SF6 6

Flooding of the gas compartment withambient air

Evacuation of air f rom the gascompartment

Filling the gas compartment withSF6-gas

Filling of external bottles from aninternal storage tank

Gas removal from the service cart to transport pressure 7

Fault correction 8Maintenance and functional test 9

Circuit diagram and parts list 10

Operating- and maintenance instructions for 11 installed components

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General safety notes R

DILO D-87727 Babenhausen 0100.bae

Obligation to exercise due care

The device has been designed and constructed bearing in mind the standards to beobserved 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 productdescription).

- the device is only operated in accordance with the instructions and in good condition andthat the safety devices are regularly checked.

- maintenance and repair personnel are issued with all the required safety and protectiveclothing, which shall always be used.

- complete and legible operating instructions are available on site.

- only qualified personnel operates or repairs the device.

- this personnel is regularly instructed in safety procedures and environmental protection andthat this personnel is fully aware of the complete operating instructions and particularly in thesafety notes.

- the safety and warning notes mounted on the device are legible and not removed.

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Specific safety notes and standard symbols

In the following operating instructions specific safety warnings are given in order to draw yourattention 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 instructions should draw your attention specially to thesafety notes:

This symbol refers to risks for persons (danger to life, danger ofinjury)

This symbol refers to risks for machines, material and the

environment.

This symbol refers to electric shock

The most important aim of the safety notes is to prevent personal injuries.

- If the warning sign „Danger“ , appears, danger from machines, materials and theenvironment are not excluded.

- If the 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 thedevice better.

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Basic safety measures dur ing normal operation

Only trained and authorized persons who are fully aware of the operating instructions shouldoperate the device and should do so in accordance with the operating instructions.

Before switching on the device ensure that

only authorized persons are present at the device

nobody can be hurt by the operation of the device

Whenever the device is started check for visible damage beforehand and ensure that it isoperated in the correct conditions. Eliminate any damage immediately or inform yoursupervisor.

Prior to each start check and make sure that the safety features are properly set.

Basic safety measures during maintenance

Follow inspection and maintenance periods described in the operating instructions.

Follow maintenance and repair instructions for individual components in these operatinginstructions.

Prior to carrying out maintenance and repair works turn off the main switch for the powersupply and secure it with a padlock. The key for this lock must be in the hands of the personwho carries out the repair works. If there is no main switch unplug the power supply cable atthe plant and secure against it being plugged back in.

When exchanging heavy machine parts only use suitable lifting devices in good workingcondition.

Prior to carrying out maintenance or repair works ensure that parts which may need to behandled have cooled down to room temperature.

Dispose of grease, coolant or cleaning material in accordance with environmentalregulations.

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Work on electrical equipment

Only properly trained electricians should carry out repair works on the device electricalequipment.

Regularly check the electrical equipment.

Re-tighten loose connections.

Replace damaged lines/cable immediately.

Always keep the control cabinet closed. Only authorized persons with key/tools

should work on the device.Never clean control cabinets and other electrical equipment housings using a

water hose.

Work on pneumatic equipment

Only specially trained personnel should carry out maintenance and repair workson pneumatic equipment.Prior to maintenance and repair works depressurize the device pneumaticequipment. Replace hose lines for preventive purposes even if no damage isvisible. (Follow recommendations of manufacturer). After having carried out maintenance and repair works and prior to putting backinto service

- check that loosened screw connections are properly 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 operationensure that all materials, tools and other equipment which were necessary forthe maintenance or repair works have been removed from the working area ofthe device.Liquids that may have come out have been removed (wiped away) All safety devices for the unit are properly set and in working order.

Observe environmental standardsWhenever working on and with the device please observe legal requirementsfor waste handling and disposal.Particularly during installation, repair and maintenance works substances thatcause water pollution such as:- lubricating greases and oil- hydraulic oils- cooling agents- cleansing liquors containing solventmust not contaminate the soil or flow into drains.These substances should be stored in suitable vessels, and removed anddisposed of according to local regulations.

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Product description


Product description

Correct use

This service cart is designed for the recovery and putting into storage of SF6-gas from gascompartments. Gas compartments can also be flooded with air, evacuated and filled with SF6-gas.During each recovery and filling operation the SF6-gas passes through filters, which dry andpurify the gas.Do not use the cart to exhaust or compress liquids or other gases.

Use of the SF6-gas service cart for any other purpose may not be safe.

The manufacturer will not accept any liability in case of injury anddamage caused by use of the cart for applications for which it was notintended.

We recommend that all persons who are involved in the operation and repair of DILO devicesare 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 filterVacuum 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 isequipped with fixing- and steerable rollers with brakes.The wheels on versions with a storage tank or SF6-bottle storage are bolted to the frame. Thistype of wheel is not provided on road trailer versions.

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Product description


Compressor:

The compressor is a dry running type and operates entirely without oil. It is available for differentdelivery rates and different final pressures (see technical data).The compressor housing is absolutely gastight, but the maintenance of the compressor can becarried out easily. The working overpressure is controlled by a pressure reducer and a contactgauge. The operating temperature of the motor winding and the cylinder heads are controlled bya thermistor.

(Technical data and description see chapter 11 of the operating instructions for thecompressor).

Suction pump: (if included)

The suction pump allows the recovery of gas down to < pa 1 mbar (absolute). The suction pumpis a dry-running type, which operates entirely without oil. It is protected from inadmissibleoperating conditions by a pressure switch, pressure sensor, solenoid valves and regulatingvalve. The suction pump only switches on automatically at pressures of about pe = 0,1 bar.The pressure on the output side of the suction pump is controlled by a pressure sensor. Theregulating valve on the suction side prevents a too high output pressure by throttling on theinput side.The output pressure is regulated to about pa 1000- 1050 mbar by the regulating valve on theoutput of the suction pump so that the compressor behind the suction pump cannot generateany depression and cause ambient air to be sucked in.

Do not connect any gas compartment with overpressure to the suction sidewhile the suction pump is running as the suction pump can be damaged byoverpressure.

(Technical data and description see chapter 11 of the operating instructionsfor the suction pump).

Vacuum compressor: (if included)

The vacuum compressor allows the recovery of gas down to < pa 50 mbar.The vacuum compressor is a dry-running type and is protected from inadmissible operatingconditions by manostat, solenoid valve and return valves.The vacuum compressor switches on automatically during the gas recovery process.

(Technical data and description see chapter 11 of the operating instructions for the vacuumcompressor).

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Product description


Vacuum pump:

The vacuum pump allows the evacuation of air from gas compartments.To avoid any damage to the vacuum pump it must be protected from overpressure. Thesolenoid valve upstream from the vacuum pump only opens if there is no overpressure on thesuction side. Reduce the SF6-overpressure with the compressor and vacuum compressor orsuction pump as described under the operating description “Gas recovery”.Release air or nitrogen via the venting ball valve.The vacuum pump only exhausts into the atmosphere.

(Technical data and description see chapter 11 of the operating instructions for vacuum pump).

Evaporator: (only for devices with liquid storage)

The evaporator consists of a special steel housing with electric heating coils inside. It serves toensure vaporisation of liquid SF6.The temperature is regulated via a control unit.

Storage tank:The SF6-gas is stored in gaseous form or at higher pressure in liquid form. We distinguishbetween storage in a pressure tank in gaseous form up to 25 bar and in liquid form up to 50 bar.(Attention! Do not use these pressure tanks for transport of SF6-gas).Check the pressure rating of the tank to confirm gaseous or liquid storage. If gas is stored intransport bottles (in liquid form), please ensure the maximum fill weight stamped on the bottle isnot exceeded.Only use bottles registered for SF6-gas.

For transport of tanks with weight indication the weight must be takenoff the load cell prior to weighing i t.Pressure vessels must not be worked on mechanically, welded orheated. The type plate must not be removed or made illegib le.

Pressure vessels (e. g. SF6-tank, dry f ilter 64bar) should be approvedby the local technical control organisation.

The pressure vessels are produced and approved in accordance withthe corresponding regulations. (e.g. 97/23 EC).The operator is responsible for approval and repeating checks.

Particle filter/ Dry filter:The SF6-gas is purified and dried with the particle filter and dry filter installed in the system.During each gas handling process the SF6-gas passes through these filters.(see chapter 9 dry filter or particle filter)

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Product description Mega


Functional description of the Mega service cart:

Electric control:

Power is supplied through the plug mounted on the control cabinet.(The correct phase sequence is checked by a device monitoring the direction of rotation). All components are protected by motor protective circuit breakers.The control circuits are powered at 24V DC. All other electrical components (contactor, working hours counter, temperature regulation etc.)are supplied at 230V AC.Both voltages (230 V AC and 24V DC) are generated from the connected supply voltage with atransformer or a power supply unit.The running times are indicated by working hours counters installed in the control cabinet.

The operating panel has two functions:1. Indication of the gas flow of the preset automatic functions.2. Manual opening of the valves via lighted push-buttons.

General information:

All operating elements and control monitoring systems are well arranged on the front panel.

All connecting lines are produced according to the well-proved DILO metal-to-metal sealprinciple and are absolutely tight.

The gas flow can be controlled very well on the clearly arranged operating panel during thedifferent operations.

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Automat ic funct ion:

The following automatic functions can be carried out on the operating panel:1. Evacuation 2. Gas recovery 3. Filling

Each function must first be preselected by pressing the white push-button. (The correspondingsolenoid valves and white push-button on the operating panel light up).The preselected function can be started by pressing the green push-button. (The correspondingsolenoid valves and the green push-button on the operating panel light up, the white push-

button is then extinguished).The green push-button can only be started if the white push-button has already been pressed.The corresponding unit starts and the preselected solenoid valves open.The started function can be stopped by pressing the red push-button. A preselected function (blue LED lights up) can also be reset by pressing the red push-button.If the manual operation is started (e. g. vacuum pump, compressor, preselected or openedsolenoid valves), the automatic operation cannot be started or preselected.

Note - Parallel operation: A parallel operat ion is only possib le if bal l valve pos. 42 is closed, that means besides the"Evacuation" function at coupling pos. 13 or pos. 17 either the "Gas recovery" or "Filling"

function at coupling pos. 10 can be carried out.The "Filling" and "Gas recovery" function cannot be carried out at the same time. For the"Filling" function the compressor can be started or stopped manually by pressing the"Compressor" push-button.

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Manual operation:

The manual operation is only provided for special functions (e. g. “Gas removal to transportpressure” or “Evacuation of filters”).

If an automatic function is preselected or started, the solenoid valves cannot be opened or thevacuum pump cannot be started manually.Each solenoid valve can be preselected by the lighted push-buttons on the operating panel(LED's light up).

If an incorrect solenoid valve is preselected all preset solenoid valves can be reset by the"Reset valves" push-button (LED’s are then extinguished).The preselected solenoid valves are opened by pressing the green "Open valves" push-button.(LED’s light up). All opened solenoid valves can be closed by pressing the red "Reset valves" push-button(LED’s are then extinguished).The solenoid valve upstream from the evaporator only opens if the evaporator has reached itsoperating temperature (LED lights up as long as the solenoid valve does not open).The solenoid valve upstream from the vacuum pump only opens, if there is no overpressure onthe suction side (LED lights up as long as the solenoid valve does not open).

In case of manual operation the operator is responsible for correct gas handling byhimself.

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Dimension sheet / Technical dataR

Mega

DILO D-87727 Babenhausen 0203mel.bae

B2000R01

Pressure tank: Max. admissible pressure Test pressure Operating temperature

50 bar 71.5 bar -10 bis +50 °CPressure tank: Storage

volume:Storagecapacity

Lengthmm

Widthmm

Heightmm

Netweight

B146R01 300 l. 280 kg 2420 1150 1900 1320 kg

Compressor: Theoretical deliveryrate

Final pressuremax. pe

Differentialpressure max.

B110R11 17,0 m3/h (50Hz) 50 bar 50 bar

Suction pump: Theoretical delivery rate: Final vacuum:

30 m3/h

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Transport and installation R


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. (for

weight see dimension sheet).

Version with lifting eyes:

Check that fork lift truck forks are long enough.If the device is equipped with lifting eyes then a crane can be used.Ensure slings are of the correct length and that chains do not cause

damage to the device.- Do not stand underneath the load.

- Only qualified and authorized persons should carry out transport

operations.

Notes for transport of DILO devices with a weighing device (load cell)

The weight must be taken off the load cell prior to transport of the device.

(Danger of vibration/shock for the measuring system)(see chapter 9 weighing device)

Transport regulations for DILO service carts

European Transport Regulations:

SF6 (Sulphur hexafluoride) service carts are exempt from “Hazardous Goods TransportRegulations” as long as the gas pressure in a tank or vessel at 15 deg C is not more than2 bar above atmospheric pressure and it remains in a gaseous state during transport. Thisexemption covers all kinds of vessels and tanks as well as machinery (motors, pumps etc.)(see ADR annex A 1.1.3.2 c – exemptions with regard to the transport of gases).

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Transport and installation R


Installation: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 raised to allow ventilationfor cooling.The ambient temperature during operation of the device should be inthe range of 10- 40 °C.In case of temperatures from - 10 to + 10 °C the vacuum pump oil mayneed to be changed.(see operating instructions for vacuum pump)

Electrical connection:

Only trained and authorized personnel should connect the device! A three phase neutral and ground power supply must be used!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 andthe ground to the terminal marked with the symbol.Power is supplied through the plug mounted on the controlcabinet. Electrical accessories (e. g. remote control, bottle balance withswitch 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 connectedmains supply for phase failure and the direction of rotation (for devicesdependant on direction of rotation).The “Power, correct direction of rotation“ lamp lights if the power connectionis correct.The “Incorrect direction of rotation” lamp lights if the power connection ordirection of rotation is incorrect. Operation is blocked.Check the power connection or exchange the phase connections of theincoming power supply or reverse the reversing switch (if available). At tention: Disconnect the power plug beforehand!

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Setting into operation R


Prior to setting the device into operation check the following:

1. Electrical supplythat all necessary connections have been made correctly.

2. Oil level of the vacuum pump (if installed)(see vacuum pump operating instructions)

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 outputpressure of the compressor) is adjusted to the red marking.When exceeding the set pressure value the compressor must switch off by

itself.(see chapter 9 functional test)

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Filling for transport

All devices are filled with gas to a slight overpressure (~ pe 0.2 bar) in our works. Labels givingthe correct details for transport are provided.

Red label for device filled with N2 for transport

Achtung/ Attention N2 - Transportfüllung

N2 - Filled for transportRemplissage N2 pour le transport

Green label for devices filled with SF6 for transport

Achtung/ Attention SF6 - Transportfüllung

SF6 - Filled for transportRemplissage SF6 pour le transport

Accessories, which are filled with SF6-gas (e. g. pre-filter units) are provided with a green“SF6-filled for transport” label.

Accessories, which are filled with N2-gas, (vacuum pump units) are provided with a red“N2-filled 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 SF6-gas, can be put into operation withoutcarrying out any additional preparatory operations.

Devices or accessories, which are filled with N2-gas or air must be evacuated before usewith SF6-gas otherwise the SF6-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, otherwisethe SF6-gas could be contaminated.

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Putting the weighing device (if fitted ) into the working posit ion

Only for B044R… pressure tank

There is a hexagonal bolt (SW 30 mm) near the load cell of the tank which is fixed with a pin sothat 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 ofmovement 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.- Turn the lever clockwise until the indicating instrument shows the weight.

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Setting into operation Mega


Filling the pressure tank (if included) with SF6 gas

Filling the pressure tank with SF6 gas until pressure compensation has been reached

1. Connect the SF6-gas vessel (e. g. bottle) to coupling pos. 11.

2. Open the ball valve to the pressure tank and the valves on the SF6-gas vessel.

3. The SF6-gas flows with overpressure in the pressure tank of the service cart.

4. When pressure compensation is reached uncouple the SF6 gas vessel from coupling

pos. 11.Use the compressor for further filling of the pressure tank.

Filling the pressure tank with SF6-gas (with the compressor)

1. Connect the SF6-gas vessel (e.g. bottle) to coupling pos. 10.

Warning: Connect max. 10 bar!Connect the SF6-gas vessel via pressure reducer!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 „Gas recovery“ function (see chapter 6).

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Functional diagramR

Mega


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Parts list for functional diagram R

Mega

DILO D-87727 Babenhausen 0501mel-s01.bae

Pos. Desígnation Order-No. Piece

1 Vacuum pump (nominal suction capacity40 m3/h, final vacuum < 1 mbar)

3-690-R007 1

1 Vacuum pump (nominal suction capacity

63 m3/h, final vacuum < 1 mbar)

3-690-R008 1

1 Vacuum pump (nominal suction capacity

100 m3/h, final vacuum

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Mega


Pos. Designation Order-No. Piece

29 Tubing B2000R01P10 1

30 Tubing B2000R01P09 1

31 Tubing B2000R01P02 1

32 Tubing B2000R01P03 1

33 Wired braided hose SM0340L00800 1

34 Wired braided hose (3-690-R..) B2000R01P11 1

34 Wired braided hose (3-745-R..) SM0340L00600 1

35 Tubing Tee-piece 3x AD22 K020R17 1

36 Tubing Tee-piece 3x AD22 B2000R01P04 1

37 Rubber hose GS0308L01000 1

38 Tubing B2000R01P12 1

39 Storage connecting hose 6-1037-R050 1

40 Solenoid valve DN40, PN60 3-563-R001 1

41 Pressure switch pe 0,4 bar K016R01 1

42 Ball valve DN40 3-679-R001 P 1

43 Pressure reducer 20 bar 3-300-R001 144 Tubing B2000R01P05 1

45 Tubing P045-04 1

46 Safety valve, 10 bar 05-0110-R100 1

48 Gauge NG100, -1 / 9 bar K059R12 1

49 Particle filter DN40, PN16 K072R01 1

50 Tubing K013R01 1

51 Coupling groove part DN20 VK/A-02/20 P 1

54 Solenoid valve DN20, PN60 3-564-R001 1


57 Pressure switch pe 5 bar K016R04 1

58 Vacuum controller 0-100 mbar K076R13 1

59 Tubing B2000R01P06 1

60 Elbow piece DN40 K018R07 1

76/77 Capillary tube K081R01 2

78 Tubing B2000R01P08 1

79 Disk with hole 1mm ML1-10-8 P 1


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Mega


81 Dry filter 64bar 3-899-R002 1

82 Particle filter DN20 3-377-R001 1

83 Intermediate piece DN20 3-311-R001 P 1

84 Tubing Tee-piece K020R25 1

85 Wired braided hose SM018L01200 1

86 Intermediate piece DN8/20 3-240-R001 P 1

87 Coupling groove part DN20 VK/A-02/20 P 1

90 Pressure tank 300l, 50bar B146R01 1

90 Pressure tank 600l, 50bar B146R02 1

90 Pressure tank 1000l, 50bar (SQL) B146R82 1

90 Stowage for 4 SF 6- bottles B145R11 1

90 Weighing device for 4 SF6-bottles B145R12 1

90 Stowage for 4 SF6- bottles B145R01 1

90 Weighing device for 4 SF6-bottles B145R02 1

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Functional diagram / L R

DILO D-87727 Babenhausen B038R01.bae

Solenoid valve uni t 60 bar (870 psi) (B038R01)

Pos. Designation Order-no. Piece

5.1 Solenoid valve DN20 PN60 (870 psi) 3-564-R001 15.2 Solenoid valve DN20 PN60 (870 psi) 3-564-R001 1

5.3 Solenoid valve DN20 PN60 (870 psi) 3-564-R001 1

5.4 Solenoid valve DN20 PN60 (870 psi) 3-564-R001 1

5.5 Pressure reducer, set to pe 4 bar (58 psi) 3-301-R001 1

5.6 Non return valve VR/A-02/20 P 1

5.7 Non return valve VR/A-02/20 P 1

5.8 Overflow valve, set to 10 bar (145 psi) K025R01 1

5.9 Pressure switch pe 20 bar (290 psi) K056R03 1

5.10 Safety valve pe 40 bar (580 psi) 05-0110-R400 1

5.11 Tubing elbow piece AD22 - AD22 K018R04 1

5.12 Tubing P028-03 1

5.13 Tubing P028-04 1

5.14 Tubing P028-05 1

5.15 Tubing P028-07 1

5.16 Tubing P028-01 1

5.17 Tubing P028-02 1

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Functional diagramR

Mega


Pressure tank B146R01 / B146R11

Pos. Designation Art icle-No. Piece

1 Pressure tank, 300l, 50bar, in accordance with97/23/EC directive

3-811-R001 1

2 Load cell NG 160 05-0465-R006 1

3 Fitting with ascending pipe DN12 and filter 3-681-R001 1


5 Full lift safety valve PE 50 3-298-R050 1Gauge fitting AD10 3-328-R001 P 1

Copper seal KD-01G1/2A 16 Gauge NG100, 0-60 bar K059R08 1

7 Ball valve DN20 3-383-R001 P 1

8 Tubing P045-01 1

9 Tubing P045-02 1

10 Screw in stub with o-ring ML1-AD22-13 P 1

11 Vent plug with o-ring VST03/M33x2 T 1




15 Tubing P045-04 1

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Functional descriptionR


Recovery of decomposed or undefined SF6

When recovering decomposed or humid SF6-gas we recommend connectingthe B007R11 pre-filter unit upstream from the service cart.

When recovering oil-contaminated SF6-gas, we recommend connecting theB071R11 oil separating filter unit upstream from the service cart.

When recovering undefined SF6-gas we recommend connecting the B007R11pre-filter unit upstream from the service cart.

When recovering decomposed and oil-contaminated SF6-gas we recommend

connecting the B071R11 oil separating filter unit and the B007R11 pre-filter unitupstream from the service cart.

After having recovered the contaminated or humid SF6-gas the gas in theservice cart should be dried or purified in the circuit for a short time.

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 theoperating panel.Start the “Compressor“ function and circulate SF6-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 SF6-gas for about 10 minutes.

Piccolo service carts:

The input pressure should be 2 -8 bar.The service cart could be damaged by higher pressures!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 SF6-gas circulate forabout 10 minutes.

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Mega


Removal and storage of SF6

In case it is necessary to open a gas compartment or gas should be exchanged the SF6-gascan be recovered with the “Gas recovery” function. The SF6-gas can then be stored in a storagetank.

1. Connect the gas compartment and the storage tank to the service cart as illustrated. Openthe ball valve on the storage tank. Alternatively, it is also possible to connect the gascompartment to pos. 13 or 17.

The connecting hoses must be evacuated or fil led with SF6-gas!

2. Turn the ball valves to the illustrated position.

3. Press the white “Gas recovery” push-button (The solenoid valves illustrated above as openedand the white push-button on the operating panel light up).

4. Press the green “Gas recovery” push-button.(The solenoid valves illustrated above open and the compressor starts running. The LED’s ofthe opened solenoid valves and the green “Gas recovery” push-button light up).

5. After having reached the required suction pressure stop the gas recovery function bypressing the red „Gas recovery“ push-button.

Observe the fill weight of the storage tank (1 kg/l.).

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Mega


Flooding of the gas compartment with ambient air

In case it is necessary to open a gas compartment for maintenance works pay attention tothe faxt that it is under vacuum after the recovery process. The gas compartment is flooded withambient air with "Flooding of the gas compartment" function.

The SF6-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. Alternatively the gas compartment can also be connected to pos. 10 (open ball valve pos.42) or to pos. 17.

2. Open the venting ball valve and wait for pressure compensation.

3. When pressure compensation is reached close the venting ball valve again otherwise theSF6 gas is released into the atmosphere later on during gas handling.

After flooding uncouple the connecting hose from the gas compartment andevacuate to < 1 mbar (see chapter 6 "Evacuation of the gas compartment").This is to avoid mixing ambient air in the hose with SF6 later on during gas

handling.

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Evacuation of air from the gas compartment

To avoid mixing ambient air with SF6-gas the gas compartment must first be evacuated.

1. Connect the gas compartment to the service cart. Alternatively, it is also possible to connectthe gas compartment to pos. 10 or 17.

If there is SF6-gas overpressure (gauge pos.48), the gas must first be recovered.(see chapter "Removal and storage of SF6")

2. Turn the ball valve to the illustrated position.

3. Press the white “Evacuation” push-button. (The solenoid valves illustrated above as openedand the white push-button on the operating panel light up).

4. Start the evacuation function by pressing the green „Evacuation" push-button. If there is apressure > 0.4 bar the solenoid valve upstream from the vacuum pump does not open.The LED for the solenoid valve on the operating panel lights up. Reduce the overpressure.(see chapter „Gas recovery“)

5. Evacuate the gas compartment until a stable vacuum has been reached (e. g. < 1 mbar).

6. After having reached the required final vacuum stop the evacuation function by pressing the

red „Evacuation“ push-button.

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Filling the gas compartment with SF6 –gas

1. If no storage tank is installed in the service cart, connect the SF6-bottle or external

storage tank to pos.11 and open the ball valve on the storage tank. Do not yet connectany gas compartment.

The connecting hoses must be evacuated or fi lled with SF6.

2. Close the pressure reducer by turning anti-clockwise (minimum pressure).


4. Press the white “Filling” push-button. (The solenoid valves illustrated above as openedand the white push-button on the operating panel light up).

5. Press the green “Filling” push-button. (The evaporator heating is started. The solenoidvalves illustrated open. The solenoid valve upstream from the evaporator only opensafter the evaporator has reached its operating temperature. The LED’s of the openedsolenoid valves and the green “Filling” push-button on the operating panel light up).

6. Adjust the pressure reducer to the required filling pressure.

7. Stop the “Filling” function by pressing the red push-button.

8. Connect the gas compartment to the service cart. Alternatively, it is also possible toconnect the gas compartment to pos. 13 or 17.

9. Restart the “Filling” function.

10. When pressure compensation is reached start the “Compressor” function by pressing the

green „Compressor“ push-button.11. After having reached the required filling pressure stop the functions manually by pressing

the red push-buttons.

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Filling of external bottles from the internal storage tank

1. Connect the SF6-gas bottle to coupling pos. 87. Open the ball valve on the storage tank.

The connecting hoses must be evacuated or fi lled with SF6-gas.

2. Press the green “Evaporator” push-button. (The evaporator heating is started).

3. Select the solenoid valves pos. 5.1 and 5.4 by pressing the corresponding push buttons onthe operating panel (The LED’s will start flashing).

4. Press the „Open solenoid valves“ push-button. The solenoid valve pos 5.1 only opens if the

evaporator has reached its operating temperature (LED still lights up).The LED’s of the opened solenoid valves on the operating panel light up.

5. Start the compressor by pressing the green „Compressor“ push-button.

Observe the fill weight of the SF6-bottles (1 kg/l).

6. After having reached the required filling weight in the SF6-bottle close the solenoid valve bypressing the “Reset solenoid valves” push-button and stop the “Compressor” and“Evaporator” function by pressing the red push-button.

7. Uncouple the storage bottle.8. Reduce the pressure downstream from the compressor by opening the solenoid valves.

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Gas removal from the service cart to transport pressure

For the transport of service carts on roads the SF6-overpressure should be reducedbeforehand.

1. Connect the SF6-bottle or storage tank via the storage connecting hose to coupling pos. 51as illustrated above. Open the ball valve on the storage tank.


3. Start the evaporator by pressing the green “Evaporator” push button.

4. Select the solenoid valves pos. 5.1, 5.2 and 5.3 by pressing the corresponding push-buttonson the operating panel. (LED’s will start flashing)

5. Press the "Open solenoid valves" push button.(The selected solenoid valves open, the corresponding LED’s light up)

6. Start the compressor by pressing the green „Compressor“ push button.

7. After having reached the atmospheric pressure (gauge pos.48) stop the „Compressor“ and„Evaporator“ function by pressing the red push button, close the solenoid valves by pressingthe „Reset solenoid valves“ push button.

8. Close the bottle valve and the ball valve of the storage connecting hose.9. For pressure compensation open all solenoid valves.

10. Disconnect the storage connecting hose.

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Fault correction R

Mega


In case of malfunction or if the device cannot be started only authorized and qualified personnel

should carry out maintenance and repair works.

Inform your supervisor. Only trained and authorized personnel should eliminate malfunctions onelectrical equipment (see chapter 1).

To avoid danger to li fe by electrical shock:

- Only properly trained electricians should carry out maintenance andrepair works on electrical equipment.

- The operator should only eliminate faults, which result fromoperating or maintenance errors.

Fault list :

Fault Possible cause Correction

Indication"Incorrect direction ofrotation"

Phase failure,incorrect direction of rotation

Defective phase sequence relay

Check power supply

Exchange phase sequence relay

No function can be

started, but the solenoidvalves can be opened.

A motor protective circuit breaker

has switched off.

Due to excess temperature of thecompressor, the thermistor hasswitched off (red LED in thethermistor lights up)

Check the motor protective circuit

breaker for correct position.

Check the temperature of thecompressor and let the compressorcool down if necessary.Check the thermistor

The “Gas recovery” and“Compressor” function

cannot be started.

The contact gauge has switchedoff.

Reduce the pressure or put thecontactpointer upwards

The compressor doesnot reach any highoutput pressure

The incorrect solenoid valves orball valves are opened.

Defective piston rings and valveplates

Check the position of the solenoidvalves or ball valves.

Check the compressor accordingto the operating instruction of thecompressor chapter “Pressure test”

Fault Possible cause Correction

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Fault correction R

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The indicated final

vacuum of pa 50 mbaror 1 mbar is notreached during therecovery process

The solenoid valves or ball

valves on the suction side areclosed.

Burst membrane(vacuum compressor)

Vacuum compressor or suctionpump does not switch on.

Check the position of the solenoid

valves or ball valves.

Exchange the membrane

Check the corresponding pressureswitches

The vacuum pump doesnot reach the finalvacuum

Solenoid valve or ball valveupstream from the vacuum pumpis closed

Not enough oil

Incorrect oil

Humidity in the oil(white colour of the oil)

Defective vacuum controller orsensor

Check the position of the solenoidvalves or ball valves.

Refill oil

Exchange oil and filter

Exchange vacuum controller orsensor

„1999" indication on thetemperature regulatingdevice

Interruption or short-circuit in thetemperature sensor or in theconnecting cable

Check the resistance of theconnected PT-100-sensor

(~ 100Ω at 20°C )

The evaporator doesnot heat

Due to excess temperature thesafety temperature limiterhas switched off

Press in the blue button of thesafety temperature limiter (seelabel in the terminal box of theevaporator) until it snaps in byusing a screwdriver.Check the temperature control ofthe evaporator.

SPS-control:Normally, the LEDs „Run“ and „Battery“ light up.

The „Not ready“ and„Battery“ LED light up.

EEPROM not in correct position.

Defective EEPROM

Ensure that the EEPROM and thegrey clip are properly seated. (evenwith the upper edge of the control).

Exchange the EEPROM.

Only the „Ready“ and„Battery“ LED light up.

The control is in „Run Mode“(Operating condition).

Open the grey front cover of theSPS and press the „Reset“ push-button.

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Maintenance and functional test R


MaintenanceOnly authorized personnel should carry out purification, lubrification andmaintenance works in accordance with maintenance instructions andregulations for the prevention of accidents.In case of non compliance this could result in injury or death and alsoconsiderable damage to the equipment.

Carry out maintenance works only if the device is switched off.

- Touch hot components (e. g. evaporator, pump parts) only after theyhave cooled down!

- Ensure that used oils and filter materials are disposed of in accordancewith local environment regulations.

- Exchange filters which contain or are saturated with decompositionproducts.

- When working with harmful materials (e. g. filter cartridge) the workingprotection set should be used (DILO-working protection set 3-442-R...)

Preventive maintenance

Component Maintenance works Recommended control interval

Compressor

(if installed)

valve plate, piston rings,

guide rings

check condition every 500 operating hours

and exchange if necessary

see operating instructions for compressor

Vacuum compressor

(if installed)

exchange the

membranes and valves

every 1500 operating hours or every 3 years

see operating instructions for vacuum

compressor

Vacuum pump /

Rotary pump

(if necessary)

check the oil level daily or before every operation

Vacuum pump only 1. Oil exchange

further oil exchanges

after 100 operating hours

every 500-2000 or every six months

see operating instructions for the vacuum

pump

Dry filter

(if installed)

Filter cartridge

Exchange filter content

after filtration of contaminated gas

after saturation of the filter

(Measurement upstream of the filter)

Particle filter

(if installed)

Exchange filter cartridge Check condition each time the dry filter is

exchanged. Exchange of the particle filter if

necessary

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General operating instructions for hoses

1. From time to time the hoses used for service carts should be checked for leak tightness. Forthis purpose the following two tests should be carried out:

a) Pressure test

Connect the hose so that there is a pressure indication on the gauge. The hose must bepressurized. Look at the gauge, no pressure drop should occur.

b) Vacuum test

Connect the hose to the vacuum pump. Interconnect suitable vacuum gauge. Producevacuum. After having switched off the vacuum pump, the vacuum indication should remainunchanged at constant room temperature.

2. The DILO-coupling tongue parts DN 8 and DN 20 are equipped with an O-ring which is toprovide an external seal during the coupling process. As the O-ring is used for each couplingprocess and because of abrasion, it should be replaced from time to time.

O-ring for coupling tongue part DN 8:order no.: 1-05-057-R024

dimension: ID 13.95 x W 2.62 EPDM

O-ring for coupling tongue part DN 20:order no.: 1-05-057-R010dimension: ID 20.29 x W 2.62 EPDM

O-ring for coupling tongue part DN 40:order no.: 1-05-057-R141dimension: ID 44.12 x W 2.62 EPDM

3. In order to protect the connecting hose and the piping system from contamination bydecomposition products, we recommend using a pre-filter unit.

o-ring

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Weighing device (only for pressure tank with liquid storage)

Adjustment of the indicating gaugeThe weight indicated on the gauge is always the effective filling weight of the stored gas. Toobtain the correct indication the net weight of the storage tank has to be considered. Thisbasic adjustment is carried out by DILO. If re-adjustment is necessary, it has to be donewithin the vessel empty as follows:Glycerine filled*: Completely remove the gauge and empty the glycerine* through the

feed opening into a clean vessel or: leave the glycerine* in thegauge and put the device flat on the ground.

Open gauge: At the front ring of the gauge there is a bayonet union which isopened by turning anticlockwise.

Pointer adjustment: Next to the pointer axis there is a little slotted screw. With a suitablescrewdriver, the pointer can be adjusted to the zero-point by turningthis screw.

Re-installation After adjustment attach the front ring (ensuring thecorrect position of the seal!), and if necessary, refill device withglycerine * and mount the gauge onto its support again.

Regarding weighing devices for 4 SF6-steel cylinders please take the following intoconsideration dependant on the version:

on the German SF6-cylinder there is a red marking at the indication

gauge at 160 kg and on US-standard SF6-steel cylinders (type B)**

at 390 lbs (176 kg) = filling factor 62 lbs SF6/cf (1 kg SF6/liters.).

Do not exceed this marking when filling the cylinders as

otherwise the pressure may exceed allowable values.

4) Function of the weighing device:The load cell works according to the principle of a hydraulic pressure cylinder. The weight of thepressure tank is transmitted by a hydraulic instrument to an indicating instrument. The fillingweight of the pressure vessel can be read on the indicating instrument. It is a closed system thatmust not be opened. The indicating gauge is filled with glycerine in order to protect themeasuring system. Only 90 % of the housing is filled. The feed opening is at the top side of thegauge. The sealing screw is equipped with a pressure compensation device.

* not applicable on indication gauges with contacts** cylinders other than type B may only be used if they have the same dimensions and the same weight.

Prior to moving the device the weight must be taken off the load cell (which is under thepressure tank)

(only for B044R…storage tank)For this purpose, screw in the (SW30 mm) bolt up to the stop,until the weight is taken off the load cell, and secure it with a pin.

(only for B146R… storage tank,B145R…/B147R…bottle balance (4 bottles)For this purpose turn the lever (with eccentric) anti-clockwise (the weight is taken off the

load cell). Then secure the lever with a split pin.

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Functional test of the service cart

We recommend checking the service cart functions and for faults once a year or not later thanthe maintenance interval indicated.Maintenance interval: see operating instructions of the corresponding components.

Compressor: Verification of the output pressure:

Connect the SF6-gas storage tank to coupling pos. 11 so that the compressor receives SF6-

gas for compression.

For this purpose heat up the evaporator and start the “Filling” function.

If the evaporator is heated up stop the “Filling” function.Close the solenoid valve on the pressure side of the compressor.

Open the solenoid valve upstream from the evaporator.

Start the “Compressor” function.

Observe the increase of pressure on contact gauge pos. 8 at the compressor output.

The contact pointer must be adjusted to the red marking.

When exceeding the adjusted pressure value on the contact gauge the compressor must

switch off.

Restarting of the compressor is only possible after pressure reduction.

After having executed the test reduce the pressure by opening the solenoid valves.If the indicated final pressure is not reached during the functional test the valve plates and

piston rings must be checked (see operating instructions of the compressor).

Suction pump unit: (if installed) Verification of the function and the final vacuum

Do not connect any gas compartment.

Start the “Gas recovery” function.

If the suction pressure is less than pe 0.1 bar the suction pump starts running and thesolenoid valve downstream from the suction pump opens. When exceeding one of these

switching points the suction pump switches off and the solenoid valves close.

The gas flow is reduced by the regulating valve on the suction side so that no inadmissibleoverpressure can be produced on the pressure side.

The lower the output pressure the more the regulating valve opens. If the regulating valve iscompletely open the symbol on the surface shows the flow direction.

Check the final vacuum on the vacuum controller and stop the gas recovery function..

If the indicated final vacuum (< pa 1 mbar) is not reached also follow the instructions inchapter 8 “Fault correction” and the operating instructions for the suction pump unit chapter

11.

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Vacuum compressor (if installed):

Start the “Gas recovery” function. The vacuum compressor is ready for operation.

The vacuum compressor and the solenoid valve on the suction side are controlled by 2

manostats on the suction- and pressure side; they are started when pressure falls

below these switching points.

The vacuum compressor switches off and the solenoid valve closes when one of these

switching points is exceeded.

Check the final vacuum on the vacuum controller.

Also follow the instructions in the operating instructions for the vacuum pump chapter 11).

Vacuum pump and vacuum contro ller:

Uncouple the connecting hose from the service cart.

Start the “Evacuation” function.

Open filling pressure reducer pos. 12. (Adjust max. filling pressure).

The vacuum pump and the vacuum controller must have reached their operating

temperatures (operating time about 15 minutes).

If the vacuum is less than 1 mbar (0.75 mm Hg) stop the function.

Observe the vacuum on the vacuum controller. After 15 minutes the increase of pressure

with the vacuum pump being stopped should be less than 5 mbar (3.75 mm Hg).

Evaporator:

To allow the temperature probe in the evaporator to react quickly on the temperature

changes there should be SF6-gas overpressure in the evaporator and no vacuum.

Start the “Filling” function.

The evaporator heating is controlled by a temperature regulating device.

The solenoid valve at the input of the evaporator which releases the gas flow is also

controlled via the temperature regulating device. (The solenoid valve opens as soon as the

evaporator has reached its adjusted temperature).

The LED on the operating panel indicates the opened solenoid valve.If the solenoid valve closes during the heating process the LED lights up.

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Spare parts list:

Piece Designation Art icle-No.

B110R11/R12 Compressor 6-1091-R...see operating instructions of the B110R11/R12 compressor

3-690-R007 Vacuum pump (40m³/h, < 1mbar)1 Filter spare part kit includes 6-1047-R011

1 Oil filter OC 21 Pos. 1001 Exhaust filter element Pos. 1201 O-ring 34x4 Pos. 121

1 1 litre SAE30 vacuum pump oil 3-690-R201for 3-690-R007 vacuum pump

1 Spare part kit includes 6-1047-R0011 Oil filter OC 21 Pos. 1001 Exhaust filter element Pos. 1201 O-ring 34x4 Pos. 1211 Valve plate Pos. 251

1 Guide for valve seat Pos. 2521 O-ring Pos. 2531 Pressure spring Pos. 254

3-690-R008/ R009 Vacuum pump (63/ 100m³/h, < 1mbar)1 Filter spare part kit includes 6-1047-R012

1 Oil filter OC 21 Pos.1002 Exhaust filter element Pos. 1202 O-ring 34x4 Pos. 121

2 1 litre SAE30 Vacuum pump oil 3-690-R201for 3-690-R008 and 3-690-R009 vacuum pump

1 Spare part kit includes 6-1047-R0021 Oil filter OC 21 Pos. 1002 Exhaust filter element Pos. 1202 O-ring 34x4 Pos. 1211 Valve plate Pos. 2511 Guide for valve seat Pos. 2521 O-ring Pos. 2531 Pression spring Pos. 254

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Piece Designation Art icle-No.

3-745-R004/ R006 Vacuum pump (40/ 65m³/h, < 2x10-3mbar)1 Seals 6-1049-R002

3 1 litre N62 vacuum pump oil 3-745-R2013-745-R004 / 3-745-R006 for vacuum pump

3-899-R002 Dry filter 1 Spare filter cartridge for dry filter 3-899-06

3-377-R001 Part icle fi lter 1 (2) Spare filter cartridge for particle filter DN20 3-377-08

(the version with the vacuum compressor includes two filters)

K072R011 (0) Spare filter cartridge for particle filter DN40 K072-03

(only for the version with suction pump)

1 Spare part kit for general parts of the Mega Series 2000 6-1048-R016includes1 Solenoid valve DN20, PN60bar 3-564-R0012 Rectifier for solenoid valve DN20/ DN40 05-0494-R1021 Solenoid valve DN40, PN30bar 3-563-R0012 O-ring 44,12 x 2,62 for VK/F-01/40 05-0057-R1411 Coupling groove part DN20 VK/A-02/20 P1 Coupling tongue part DN20 VK/F-02/20 P5 O-ring 20,29 x 2,62 for VK/F-02/20 05-0057-R010

1 Conical non-return valve DN20 VR/A-02/20 P

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Recovery of the filters for f ilter revision

To open the filters for filter revision the filters must first be depressurized. Checkthe pressure on contact gauge pos. 8. For this purpose open the solenoid valvedownstream from the compressor (pos.5.4) manually.

Danger to life! Do not open the filters under pressure!

1. Connect the storage tank or SF6-bottle to coupling pos. 51 as illustrated above.

2. Turn the ball valve to the above illustrated position.

3. Open pressure reducer pos. 12 all the way (Max. filling pressure).

4. Select the solenoid valve pos. 5.3 by pressing the corresponding push-button on the

operating panel (LED of the selected solenoid valve lights up).5. Press the green "Open solenoid valves" push-button. (The preset solenoid valve opens,

the corresponding LED lights up).

6. Start the "Compressor" function by pressing the green push button.

7. At a pressure of < pa 500 mbar stop the „Compressor“ function by pressing the red pushbutton.

8. Uncouple the SF6-bottle.

9. Then open ball valves pos. 14 and 42. Flood the filters with ambient air until atmosphericpressure has been reached.

11. Check the pressure on gauge pos.48. Close the solenoid valves.

12. Open the filters and exchange them only if there is no overpressure (see revision).

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Evacuation of the filters after filter revision

After having exchanged the filters, the air should be evacuted from the filters.

Otherwise, SF6-gas is mixed with ambient air.


2. Open the pressure reducer pos.12 all the way (Max. filling pressure).

3. Select the solenoid valves pos. 40 and 5.3 by pressing the corresponding push-buttonson the operating panel. (The LED’s of the preset solenoid valves light up).

4. Press the green "Open solenoid valves“ push-button.(The preset solenoid valves open, the corresponding LED’s light up).

5. Start the "Vacuum pump" function by pressing the green push button.6. The evacuation should continue until a vacuum < pa 1 mbar has been reached. To

achieve this vacuum, continue running the pump for a while even after the vacuum gaugehas indicated < 1 mbar (due to expected vacuum raise).

7. Reset the solenoid valves (by pressing the red “Reset solenoid valves” push-button) andstop the “Vacuum pump” function by pressing the red push-button.

8. Open the solenoid valve pos. 5.3.

9. Observe the vacuum on the vacuum controller. Within 15 minutes after turning the pumpoff, the indicated vacuum should be 5 mbar or less. If the vacuum raise exceeds 5 mbar,repeat the above steps.

10. After evacuating refill the filters with SF6-gas. For this purpose connect the SF6-storagevessel to pos.11 and start the „Filling the gas compartment“ function (see chapter 6).

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Evacuation of the service cart

Evacuate the service cart only if there is air in the service cart (e. g. after maintenance works).

1. Connect the connecting hose as illustrated above.


3. Open pressure reducer pos.12 all the way (Max. filling pressure)

4. Open the door of the control cabinet and turn on the “Evacuation of the service cart”switch. (All solendoid valves open, the corresponding LED’s on the operating panel lightup).

5. Start the “Vacuum pump” function by pressing the green push-button.

6. If there is overpressure in the service cart the solenoid valves do not open (LED’s lightup).

7. Release air or N2-overpressure into the atmosphere via the venting ball valve.

8. The evacuation should continue until a vacuum of < pa 1mbar has been reached. Toachieve this vacuum continue to running the pump for a while even after the vacuumgauge has indicated < 1 mbar (due to expected vacuum raise).

9. Reset the solenoid valves and stop the “Vacuum pump” function by pressing thered push-button.

10. Open all solenoid valves except pos. 40.

11. Observe the vacuum on the vacuum controller. Within 15 minutes after turning the pumpoff, the indicated vacuum should be 5 mbar or less. If the vacuum raise exceeds 5 mbar,repeat the above steps.

12. After evacuating refill the device with SF6-gas. For this purpose connect the SF6-storagevessel to pos.11 and start the „Filling the gas compartment“ function (see chapter 6).

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Dry filter revision 3-899

Operating instructions Page 1 of 8

DILO D-87727 Babenhausen C 1978-01

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Use of the filter

The dry filter is provided for treating sulphur hexafluoride (SF6). The use for other purposesshould be agreed with the manufacturer.

max. operating pressure see type platemax. operating temperature see type plate

The dry filter is a pressure vessel and is subject to the Pressure Vessels Directive CE 97/23.It is classified in the category II in accordance with the Directive (if it is used for the purposes forwhich it is intended). Prior to setting the filter into operation it should be equipped with the

required safety equipment such as gauge and safety valve or connected to non-blockable tubelines. These parts are not included in the scope of supply.Prior to setting the filter into operation it must be approved in accordance with the legalregulations which are in effect. The operator is responsible for carrying out regular checksaccording to local laws and regulations which are in effect. Only use the filter under theindicated pressure and temperature limiting values. These values must not exceed or be lowerthan the limiting values.

Installation instructions

The flow direction of the filter should be observed.

The filter can be installed in a vertical or horizontal position.

The filter is to be installed and fixed so that it will not be damaged by vibrations. Furthermore,there should not be any tensile force on the filter housing and the tube lines.

The filter housing must not be exposed to fluids or very humid and corrosive medium. If so,exchange the desiccative immediately and check the housing parts for corrosion and replacethem if necessary. Carefully remove the penetrated humidity from the housing parts. Ifdecomposed SF6 is in the filter it could be warmed by physical and chemical reactions. In this

case the flow should be blocked or reduced so that the temperture of the filter housing does notexceed the admissible operating temperature.

The housing parts which are under pressure must not be worked on mechanically and welded.The type plate should not be modified, made illegilbe or removed.

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1. Description

The dry filter serves for adsorbing moisture and decomposition products out of SF6-gas. An exchangeable filter cartridge is installed in the dry filter.The filter cartridge consists of a tube filled with approx. 2.3 kg (5 lbs) desiccative. At the inputside there is the aluminium oxide, at the output side the molecular sieve.

1.7 kg (3.8 lbs) aluminium oxide Al 2O3 pore size 20-50 Angström, granular size 2 - 5 mm0.6 kg (1.3 lbs) molecular sieve pore size 4 Angström (0.08 to 0.2 in)

This filter mixture proved to be the best for the adsorption of moisture and decompositionproducts.

With the filter cartridge a dew point temperature of below -50 °C (-58 °F) can be obtained withinone drying process.

The throughput is one of the decisive factors for the optimum drying effect. As the filtering is based on the adsorption the adsorbability for humidity and decompositionproducts depends on the concentration of these substances on the input, on the contact timewith the filter as well as on the degree of saturation of the filter.

The throughput of a filter unit is raised by using several filter units in parallel, however not inseries because the filter material needs a minimum contact time with the gas, in order to enablean adsorption.

The desiccative can absorb approx. 120 g (4.2 ounzes) water without the residual moisture of thegas behind the filter exceeding 10 ppmm (= -44 °C dew point temperature at pa = 1 bar).(= -77.2 °F dew point temperature at atmosphere)

SF6 gas molecules can decompose to fluoride and sulphur-fluoride compounds because ofdischarges or high temperatures. Normally these substances recombine to SF6 again. However,if water and other substances exist at the same time the recombination is not complete andgaseous residues, the decomposition products, are left behind. If metals exist also metallicfluorides can arise in form of dust. The following gaseous decomposition products appear mostfrequently beside others in used SF6-gas:

HF hydrogen fluorideSO2 sulphur dioxideSOF2 thionyl fluorideSO2F2 sulfuryl fluorideSF4 sulfur tetrafluoride

With the dry filter 3-899 these gaseous decomposition products can be adsorbed.

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The solid particles that can be found in the decomposed SF6 like tungsten trioxide (WO 3), cupric

fluoride (CuF2) and others are effectively retained in particle filters 3-377-R001 that are placedbehind.

The absorbing capacity of the filter cartridge for decomposition products is different anddepends on the substance. For sulphur dioxide (SO2) and thionyl fluoride (SOF2) it is about 15-20 % by weight, that means 90-120 g (2.6 - 3.9 ounces) for each filter cartridge.

Note:

The absorption of humidity and decomposition products generates an exothermic reaction in thefilter. Therefore a dry filter can become hot if these substances are fed in high concentrations.

2. Revision intervals

There is no formula to determine the revision intervals generally as it depends on thesubstances the filter is fed with. Therefore it is important to control the efficiency of the dry filterfrom time to time using a moisture measuring device and a decomposition products measuringdevice.

a) If it is known that the dry filter had been admitted with decomposed SF6 the filter cartridgemust be exchanged in any case.

b) Example: When drying SF6 a dew point temperature of less than -50 C (-58 °F) is obtainedwith a practically new filter cartridge. A dew point temperature of -20 °C (-4 °F) is measured for SF 6-gas, filled into a storage tank.Now the question is: How much SF6 can be dried to a dew point temperature of less than-50 °C (-58 °F) with one filter cartridge?

A dew point temperature of -20 C (-4 °F at atmosphere) at 1 bar is 1000 ppmV and

thus1000

8 1123 5

,,= ppm m. Thus the moisture content of the gas is 123.5 mg/kg. With one

filter cartridge can therefore be dried a gas quantity of120

0 1235

971g

gkg

,

= kg (2140 lbs) .

c) If the filter had been charged with decomposed SF6 as a consequence of max. 1.700 kJ arcenergy (= arc current x arc voltage x duration of the arc) the filter cartridge must beexchanged.Investigations showed that SOF2 is the most abundant decomposition product as aconsequence of electric arcs and spark discharge. Other decomposition products appear inconsiderably lower concentrations. The production rate of SOF2 directly depends on the arcenergy that affects the SF6.If SF6 that was exposed to such an arc energy had been led over a dry filter the filtercartridge has to be exchanged.

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d) If a moisture of more than -50°C (-58 °F) dew point temperature is detected at a throughput

of not more than 1 kg/min (2.205 lbs/min) the filter cartridge must be exchanged as the dryfilter will soon be exhausted if only a small quantity of moisture is additionally absorbed.

The proof that decomposition products are retained in the filter cartridge can be furnished by acomparison measurement between the input and the output side with a decomposition productsmeasuring device. If it is already known that the SF6 the filter is fed with contains decompositionproducts a measurement at the output of the filter is sufficient in order to detect the retaining.

If decomposition products (more than some ppmv) are detected at the output the filter cartridgemust immediately be exchanged as the filter will soon be exhausted in case of further

absorption of decomposition products.

Note:

We recommend not to effect a regeneration of aluminium oxide or molecular sieve by heatingup or vacuum drying as vapours that are injurious to health and ecologically harmful can be setfree. Furthermore this method is very cost-intensive and there is no proportion to the use of newmaterial.

3. State at delivery, control , storage:

The filter cartridge is delivered airtight sealed.

Before using the filter cartridge check if the covering caps are still tight and not damaged. Onlyuse filter cartridges which are delivered in perfect packing.

Store the filter cartridges in dry rooms. Remove packing and sealing caps only short time beforethe installation.

Scope of supply of the filter cartridge

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4. Exchange of the filter cartridge

At tention: Depressurize the dry filter before dismounting the filter cartridge.

Pay attention to the protective regulations concerning the handling of SF6 gas [1].

c: Remove the sealing caps of the new filter cartridge.

d: Exchange both O-rings. Slightly grease threads and O-rings with a suitable sliding means(e.g. silicone grease).

e: Put the filter cartridge with compression spring in the screw cap as illustrated.

f: Screw in the filtering cone until the stop.

At tention: The dry filter must be evacuated before putting it into operation.

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5. Exchange of the desiccative of the filter cartridge

At tent ion: When exchanging the used desiccative avoid any contact.Do not blow up dust. Work in a well ventilated room or outdoors. Before openingthe filter cartridge corresponding protective measures have to be taken, see our workingprotection set 3-442.

Please observe:• The DILO-refilling device 3-834-R002 should be used

for the exchange of the used desiccative(to be ordered separately).

• Remove the sealing caps (pos. 7).• Remove the spring (pos. 2).• Unscrew the threaded ring (pos. 3) by using a strap wrench

1-05-1196-R001 (to be ordered separately)• Remove the perforated plate (pos. 4).• Fill the desiccative into a plastic packing and seal it tightly.

Observe that for this the perforated plate (pos. 8) is removed andwill be kept until refilling.

• Clean the interior space of the filter cartridge with a fibreless pieceof cloth.

• Fill with new desiccative in a dry room. Dust abrasion andabsorption of moisture by ambient air are avoided if one lets flowN2 with slight overpressure (max. pe 0.5 bar) from the bottomthrough the filter cartridge that is put upright during the fillingprocess.

• Filling process:Fill 1/3 of the cartridge with molecular sieve (pos. 5). Compressthe desiccative by slightly knocking (rubber mallet) until it does nolonger sink.Then insert the perforated plate (pos. 8).Fill in aluminium oxide (pos. 6) until the top edge of the cartridge,

compress and refill until it does no longer sink.(Desiccative - packed in tins - can be ordered under the followingorder-no.: 3-899-07.)

• Clean the thread (lubricate with the "Molykote" spray D-321R)• Put on the perforated plate (pos. 4) and screw on the threaded

ring (pos. 3).• Insert the spring (pos. 2).

• If the installation into the dry filter is carried out later the sealingcaps (pos. 7) must be plugged on to avoid that ambient moisture isabsorbed.

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6. Disposal of filter cartridge and desiccative

At tention: If the used filter cartridge is left until disposal both sealing caps must beplugged on so that decomposition products cannot desorb because of absorptionof air moisture in the course of time.

The material is waste that must be controlled and for further disposal it has to be treatedaccording to the regulations for the control of waste and recycling valid in your country.

Furthermore it is possible to neutralize the desiccative and to dispose it afterwards, for this see

our working protection set 3-442.

7. Bibliography:

[1] SF6-Anlagen, BGI 753 07/99Berufsgenossenschaft der Feinmechanik und Elektrotechnik,Gustav-Heinemann-Ufer 130, Köln

Conversion for SF6 gas

8.1 ppmv = 1 ppm m

1 ppmm = 1 mg/kg

1 Angström = 10-10m

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Particle filter revision 3-377

Operating instruction Page 1 of 2


1. Filter cartr idge

The particle filter is intended for filtering solid particles and solid decomposition products out ofSF6 gas. Gaseous decomposition products can be adsorbed by a dry filter 3-376.

The filter cartridge is folded to a cylinder with star-shape section.

The result of this arrangement of the surface is a large filtration surface (0.12 m2 / 1.3 sq. f.),that makes possible a long service life.

A retention rate of 100% is obtained from a particle size of ≥ 1.0 µm


The exchange of the filter cartridge in the particle filter should be carried out together with theexchange of the cartridge of the dry filter or when performing a revision of the compressor.

3. Exchange of the filter cartridge and disposal

At tention: Depressurize the particle filter before dismantling the filter cartridge.Pay attention to the protective rules concerning the handling of SF6 gas [1].

• Unscrew the filtering cone

• Remove the filter cartridge

• Clean the interior space of the filter cone with a fibreless piece of cloth

• S l i g h t l y grease the o-ring in the new filter cartridge and the o-ring in the filter coneas well as the thread with a suitable sliding means

• Push the new filter cartridge on the guide pipe in the screw cap (do not forget thecompressing spring!)

• Screw in the filter cone until the stop

At tention: The particle filter must be evacuated before putting it into operation.

At tention: If the filter cartridge is left until disposal it has to be put into a plasticpacking and sealed tightly. Thus the decomposition products are no longer set free.

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Particle filter revision 3-377

Operating instruction Page 2 of 2


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 thissee our working protection set 3-442.

Note:

Normally polluted or unused filter cartridges that are not charged with decomposition productsare unrisky and can be disposed as usual rubbish.

4. Particle fil ter

filter cartridge

filter cone

order no.

guide pipe

order no.compression spring

order no.o-ring 67x3

output

screw cap

input

3-377-08

3-377-05

05-0057-R075

5. Bibliography

[1] SF6-Anlagen, BGI 753

Berufsgenossenschaft der Feinmechanik und Elektrotechnik,Gustav-Heinemann-Ufer 130, Köln

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Particle filter revision K072R01



1. Candle fil ter

The particle filter is intended for filtering solid particles and solid decomposition products out ofSF6 gas. The candle filter is folded to a cylinder with star-shape section.

The result of this arrangement of the surface is a large filtration surface, that makes possible along service life.

A retention rate of 100% is obtained from a particle size of ≥ 1.0 µm


The exchange of the candle filter in the particle filter should be carried out together with theexchange of the cartridge of the dry filter or when performing a revision of the compressor.

3. Exchange of the candle filter and disposal

At tention: Depressurize the particle filter before dismantling the candle filter.

Pay attention to the protective rules concerning the handling of SF6 gas [1].

• Unscrew the filter cone

• Remove the candle filter

• Clean the interior space of the filter cone with a fibreless piece of cloth

• S l i g h t l y grease the o-ring in the new candle filter and the o-ring in the filter coneas well as the thread with a suitable sliding means (e. g. Molykote)

• Put the new candle filter into the screw cap

• Screw in the filter cone until the stop

At tention: The particle filter must be evacuated before putting it into operation.

At tention: If the candle filter is left until disposal it has to be put into a plasticpacking and sealed tightly. Thus the decomposition products are no longer set free.

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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 candle filter and to dispose it afterwards, for this seeour working protection set 3-442.

Note:

Normally polluted or unused candle filters that are not charged with decomposition products areunrisky and can be disposed as usual rubbish.

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4. Particle fil ter

5. Bibliography

[1] Merkblatt SF 6-Anlagen, Ausgabe 10/92

Berufsgenossenschaft der Feinmechanik und Elektrotechnik,Gustav-Heinemannn-Ufer 130, Köln

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Steuer und HauptstromlaufplanControl- and main circuit diagram

Liste de pièces pour schéma des circuits

Esquema eléctrico R

Mega

DILO D-87727 Babenhausen 1001mel-4-spr

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Parts list for control- and

main circuit diagram R

Mega


Pos. Designation Order-no. Piece

B03 Phase sequence relay 05-1456-R001 1D03 Compact controller with memory module 05-0671-R020 1D03.1, Extension module F.EM4-201 05-0671-R022 1D03.2,D03.3 Extension module F.EM4-201 05-0671-R025 2D03.4 Extension module F.EM4-201 05-0671-R023 1

F13 Thermistor-machinery protection 05-0228-R006 1

F51 Microprocessor controller 05-0701-R003 1

K11M Contactor, DILM25-10 05-0722-R008 1

K21M, K31M Contactor, DILM9-10 05-0722-R001 2

K51E Contactor, DILM9-10 05-0722-R002 1

P11-P31 Working hours counter 230V / 50Hz 05-0400-R001 3

P11-P31 Working hours counter 230V / 60Hz 05-0400-R002 3

Q01 Motor protective circuit breaker PKZM0-6,3 05-0891-R009 1

Q01.1 Cutout FAZB 6 05-0725-R003 1

Q11 Motor protective circuit breaker PKZ 2 05-0721-R014 1

Trip block, ZM-32-PKZ 2 05-0721-R016 1 Auxiliary contact, NHI 11-PKZM2 05-0723-R002 1

Q11.1 Motor protective circuit breaker FAZ-Z2/1 05-0725-R054 1 Auxiliary contact, FAZ-XH/11 05-0725-R050 1

Q21 Motor protective circuit breaker PKZM0-4 05-0891-R008 1 Auxiliary contact 05-0723-R004 1

Q31 Motor protective circuit breaker (40m3/h, 63m3/h) 05-0891-R010 1 Q31 Motor protective circuit breaker (100m3/h, D40/

65B)05-0891-R011 1

Auxiliary contact 05-0723-R004 1

Q51 Motor protective circuit breaker PKZM0-16 05-0891-R011 1 Auxiliary contact 05-0723-R004 1

S100 Flip switch 1 pole 05-0467-R001 1

T01 Universal transformer, WA-U 1000 05-0747-R009 1

T01.1 AC power unit 230V/24V DC 05-1461-R001 1

U01 Discharger 05-1509-R001 1

X01 Coupling CCW 563/9h 230V 05-0751-R009 1X02 Power plug CGW 563/9h 230V 05-0752-R009 1

Range of operating voltage 208-240V 50Hz 60HzControl voltage 230V

Compressor B110R11 (R12) 10 (7.5) kW 36,0 A 29,5 ASuction pump unit B131R02 0.6 kW 2.7 A 2.8 AEvaporator K032R01 4,8 kW 12,5 A 12,5 A Vacuum pump 40m³/h 1,5 (1,1) kW 7,2- 4,8 A 6,8 A Vacuum pump 63m³/h 2,2 (1,5) kW 9,6- 6,6 A 9,2 A Vacuum pump 100m³/h 3,0 (2,2) kW 13,6-9,4 A 13,2 A Vacuum pump 40 m³/h D40B 2,2 kW 9,9 A 10,1 A Vacuum pump 65 m³/h D65B 2,2 kW 11,8 A 10,0 A

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Circuit diagram / Operating panel R

Mega


(T135R02)

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Mega


Parts list for c ircuit diagram of operating panel

Pos. Designation Art icle-no. Piece

H01 Signal lamp 05-1136-R004 1Green cover 05-1136-R042 1Green LED 05-1136-R052 1

H02 Signal lamp 05-1136-R004 1Red cover 05-1136-R041 1Red LED 05-1136-R051 1

S01-S05 Lighted push-button 05-1136-R004 5Transparent cover 05-1136-R043 5Yellow LED 05-1136-R053 5

S11,S13,S15,S17

Lighted push-button 05-1136-R004 4

b2000r01 e

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