B2000R01 e

Mega
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 operating
faults can be avoided. In case of nonobservance of the operating instruction 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 etc.) is subject to penalty and indemnification
DILO Armaturen und

Anlagen GmbH
Frundsbergstr. 36
D-87727 Babenhausen
Tel.:
Fax.:
(49) 8333/302-0
(49) 8333/302-52
0000mea.bae
Table of contents
Mega
R
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 SF6
Flooding of the gas compartment with

ambient air
Evacuation of air from the gas
compartment
Filling the gas compartment with
SF6-gas
Filling of external bottles from an
internal storage tank
Gas removal from the service cart to transport pressure
Fault correction
Maintenance and functional test
Circuit diagram and parts list
10
Operating- and maintenance instructions for

installed components
11
DILO D-87727 Babenhausen
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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 instructions 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 instructions and particularly in the
safety 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 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 instructions should draw your attention specially to the
safety notes:
This symbol refers to risks for persons (danger to life, danger of

injury)
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 the
environment 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 the
device better.
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Basic safety measures during normal operation

Only trained and authorized persons who are fully aware of the operating instructions should
operate 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 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.
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 operating
instructions.
Prior to carrying out maintenance and repair works turn off the main switch for the power
supply and secure it with a 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 against it being plugged back in.
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
handled have cooled down to room temperature.
Dispose of grease, coolant or cleaning material in accordance with environmental
regulations.
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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 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 works
on pneumatic equipment.
Prior to maintenance and repair works depressurize the device pneumatic
equipment. 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 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 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 properly set and in working order.
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 oil
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.
0100.bae
Product description
Product description
Correct use
This service cart is designed for the recovery and putting into storage of SF6-gas from gas
compartments. Gas compartments can also be flooded with air, evacuated and filled with SF6gas.
During each recovery and filling operation the SF6-gas passes through filters, which dry and
purify 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 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 filter
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 SF6-bottle storage are bolted to the frame. This
type of wheel is not provided on road trailer versions.
0200.bae
Product description
Compressor:
The compressor is a dry running type and operates entirely without oil. It is 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 instructions for the
compressor).
Suction pump: (if included)
The suction pump allows the recovery of gas down to < pa 1 mbar (absolute). The suction pump
is a dry-running type, which operates entirely without oil. It is protected from inadmissible
operating conditions by a pressure switch, pressure sensor, solenoid valves and regulating
valve. 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. The
regulating valve on the suction side prevents a too high output pressure by throttling on the
input side.
The output pressure is regulated to about pa 1000- 1050 mbar by the regulating valve on the
output of the suction pump so that the compressor behind the suction pump cannot generate
any depression and cause ambient air to be sucked in.
Do not connect any gas compartment with overpressure to the suction side
while the suction pump is running as the suction pump can be damaged by
overpressure.
(Technical data and description see chapter 11 of the operating instructions
for 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 operating
conditions 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 vacuum
compressor).
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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. The
solenoid valve upstream from the vacuum pump only opens if there is no overpressure on the
suction side. Reduce the SF6-overpressure with the compressor and vacuum compressor or
suction 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 to
ensure 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 distinguish
between 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 in
transport bottles (in liquid form), please ensure the maximum fill weight stamped on the bottle is
not exceeded.
Only use bottles registered for SF6-gas.
For transport of tanks with weight indication the weight must be taken
off the load cell prior to weighing it.
Pressure vessels must not be worked on mechanically, welded or
heated. The type plate must not be removed or made illegible.
Pressure vessels (e. g. SF6-tank, dry filter 64bar) should be approved
by the local technical control organisation.
The pressure vessels are produced and approved in accordance with
the 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 a
transformer 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 seal
principle and are absolutely tight.
The gas flow can be controlled very well on the clearly arranged operating panel during the
different operations.
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Product description
Mega
Automatic function:
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 corresponding
solenoid valves and white push-button on the operating panel light up).
The preselected function can be started by pressing the green push-button. (The corresponding
solenoid valves and the green push-button on the operating panel light up, the white pushbutton 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 opened
solenoid valves), the automatic operation cannot be started or preselected.
Note - Parallel operation:
A parallel operation is only possible if ball 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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Product description
Mega
Manual operation:
The manual operation is only provided for special functions (e. g. Gas removal to transport
pressure or Evacuation of filters).
If an automatic function is preselected or started, the solenoid valves cannot be opened or the
vacuum 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 (LEDs are then extinguished).
The preselected solenoid valves are opened by pressing the green "Open valves" push-button.
(LEDs light up).
All opened solenoid valves can be closed by pressing the red "Reset valves" push-button
(LEDs are then extinguished).
The solenoid valve upstream from the evaporator only opens if the evaporator has reached its
operating 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 on
the 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 by
himself.
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Mega
R
B2000R01
Pressure tank:
Max. admissible pressure

50 bar
Pressure tank:
B146R01
Compressor:
B110R11
Suction pump:
Vacuum pump:
3-745-R004
Storage
volume:
300 l.
Theoretical delivery
rate
17,0 m3/h (50Hz)
Length
mm
2420
Operating temperature
-10 bis +50 C
Width
mm
1150
Final pressure
max. pe
50 bar
Theoretical delivery rate:

30 m3/h
Theoretical nominal suction capacity:
40 m3/h
Height
mm
1900
Net
weight
1320 kg
Differential
pressure max.
50 bar
Final vacuum:
< 1 mbar
Final vacuum:
< 2 x 10-3 mbar
< 82 dB(A)
orange RAL 2004
three phase current 220V 60 Hz
Sound level:
Paint:
Operating voltage:
Electical connection:
Operating voltage:
Fuse protection:
Conductor diameter:
Power plug:
Storage
capacity
280 kg
Test pressure
71.5 bar
208-240V, 50/60 Hz
50-63 A time delay
16 mm (AWG 5)
63 A
380-500V, 50/60 Hz
32-50 A time delay
10 mm (AWG 7)
63 A
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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 Transport
Regulations as long as the gas pressure in a tank or vessel at 15 deg C is not more than
2 bar above atmospheric pressure and it remains in a gaseous state during transport. This
exemption 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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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 ventilation
for cooling.
The ambient temperature during operation of the device should be in
the range of 10- 40 C.
In case of temperatures from - 10 to + 10 C the vacuum pump oil may
need 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 and
the ground to the terminal marked with the
symbol.
Power is supplied through the plug
mounted on the control
cabinet. Electrical accessories (e. 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 if the power connection
is correct.
The Incorrect direction of rotation lamp lights 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!
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Prior to setting the device into operation check the following:

1.
Electrical supply
that 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 output
pressure 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 giving
the correct details for transport are provided.
Red label for device filled with N2 for transport
Achtung/ Attention
N2 - Transportfllung
N2 - Filled for transport
Remplissage N2 pour le transport
Green label for devices filled with SF6 for transport
Achtung/ Attention
SF6 - Transportfllung
SF6 - Filled for transport
Remplissage 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 without
carrying out any additional preparatory operations.
Devices or accessories, which are filled with N2-gas or air must be evacuated before use
with 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, otherwise
the SF6-gas could be contaminated.
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Putting the weighing device (if fitted ) into the working position
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 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/B147Rbottle 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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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 diagram
Mega
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0501mel.bae
Parts list for functional diagram
Mega
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Pos.
Desgnation
Vacuum pump (nominal suction capacity
40 m3/h, final vacuum < 1 mbar)
40 m3/h, final vacuum < 2 x 10-3 mbar
Vacuum pump ( nominal suction capacity
65 m3/h, final vacuum < 2 x 10-3 mbar
Small flange KF40-DN40, angled
Order-No.
3-690-R007
Piece
3-690-R008
3-690-R009
3-745-R004
3-745-R006
3-370-R005
Dry-running compressor
B110R11
Oilfree suction pump unit
B131R02
Vacuum controller 0-100 mbar
K076R13
Solenoid valve unit, 60 bar
B038R01
Evaporator unit, PN64 bar
K032R01
Contact gauge NG100, 0-60 bar
K060R09
Gauge NG100, 0-60 bar
K059R08
10/11
Coupling groove part DN20
VK/A-02/20 P
12
Pressure reducer, range of adjustment 0-9 bar
3-302-R002
13
VK/A-02/20 P
14
Ball valve DN8
3-365-R001 P
15
Filter with connection
3-337
16
SF6-bottle balance
K091R07
17
Flange coupling groove part DN40
VK/A-01/40 E
18
Wired braided hose
SM0340L00900
19
Rubber hose
GS0320L00700
20
Rubber hose
GS0320L01400
21
Rubber hose
GS0320L01700
22
Rubber hose
GS0308L00900
23
Wired braided hose
SM0320L00450
24
Wired braided hose
SM0320L00450
25
Tubing
B2000R01P07
26
Rubber hose
GS0320L02000
27
Wired braided hose
SM0120L00600
28
Tubing
B2000R01P01
1
1
1
1
1
0501mel-s01.bae
Mega
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Pos.
Designation
Order-No.
29
Tubing
B2000R01P10
30
Tubing
B2000R01P09
31
Tubing
B2000R01P02
32
Tubing
B2000R01P03
33
Wired braided hose
SM0340L00800
34
Wired braided hose (3-690-R..)
B2000R01P11
34
Wired braided hose (3-745-R..)
SM0340L00600
35
Tubing Tee-piece 3x AD22
K020R17
36
Tubing Tee-piece 3x AD22
B2000R01P04
37
Rubber hose
GS0308L01000
38
Tubing
B2000R01P12
39
Storage connecting hose
6-1037-R050
40
Solenoid valve DN40, PN60
3-563-R001
41
Pressure switch pe 0,4 bar
K016R01
42
Ball valve DN40
3-679-R001 P
43
Pressure reducer 20 bar
3-300-R001
44
Tubing
B2000R01P05
45
Tubing
P045-04
46
Safety valve, 10 bar
05-0110-R100
48
Gauge NG100, -1 / 9 bar
K059R12
49
Particle filter DN40, PN16
K072R01
50
Tubing
K013R01
51
VK/A-02/20 P
54
Solenoid valve DN20, PN60
3-564-R001
55
Rubber hose
GS0120L00400
57
Pressure switch pe 5 bar
K016R04
58
Vacuum controller 0-100 mbar
K076R13
59
Tubing
B2000R01P06
60
Elbow piece DN40
K018R07
76/77
Capillary tube
K081R01
78
Tubing
B2000R01P08
79
Disk with hole 1mm
ML1-10-8 P
80
Rubber hose
GS0108L00450
Piece
0501mel-s01.bae
Mega
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81
Dry filter 64bar
3-899-R002
82
Particle filter DN20
3-377-R001
83
Intermediate piece DN20
3-311-R001 P
84
Tubing Tee-piece
K020R25
85
Wired braided hose
SM018L01200
86
Intermediate piece DN8/20
3-240-R001 P
87
VK/A-02/20 P
90
Pressure tank 300l, 50bar
B146R01
90
Pressure tank 600l, 50bar
B146R02
90
Pressure tank 1000l, 50bar (SQL)
B146R82
90
Stowage for 4 SF6- bottles
B145R11
90
Weighing device for 4 SF6-bottles
B145R12
90
Stowage for 4 SF6- bottles
B145R01
90
Weighing device for 4 SF6-bottles
B145R02
0501mel-s01.bae
Functional diagram / L
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Solenoid valve unit 60 bar (870 psi) (B038R01)
Pos.
Designation
Order-no.
5.1
Solenoid valve DN20 PN60 (870 psi)
3-564-R001
5.2
3-564-R001
5.3
3-564-R001
5.4
3-564-R001
5.5
Pressure reducer, set to pe 4 bar (58 psi)
3-301-R001
5.6
Non return valve
VR/A-02/20 P
5.7
Non return valve
VR/A-02/20 P
5.8
Overflow valve, set to 10 bar (145 psi)
K025R01
5.9
Pressure switch pe 20 bar (290 psi)
K056R03
5.10
Safety valve pe 40 bar (580 psi)
05-0110-R400
5.11
Tubing elbow piece AD22 - AD22
K018R04
5.12
Tubing
P028-03
5.13
Tubing
P028-04
5.14
Tubing
P028-05
5.15
Tubing
P028-07
5.16
Tubing
P028-01
5.17
Tubing
P028-02
Piece
B038R01.bae
Functional diagram
Mega
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Pressure tank B146R01 / B146R11
Pos. Designation
1 Pressure tank, 300l, 50bar, in accordance with
97/23/EC directive
2 Load cell NG 160
3 Fitting with ascending pipe DN12 and filter
4 Rubber hose
5 Full lift safety valve PE 50
Gauge fitting AD10
Copper seal
6 Gauge NG100, 0-60 bar
7 Ball valve DN20
8 Tubing
9 Tubing
10 Screw in stub with o-ring
11 Vent plug with o-ring
14 Rubber hose
15 Tubing
Article-No.
3-811-R001
Piece
1
05-0465-R006
3-681-R001
GS0320L01600
3-298-R050
3-328-R001 P
KD-01G1/2A
K059R08
3-383-R001 P
P045-01
P045-02
ML1-AD22-13 P
VST03/M33x2 T
VST03/M33x2 T
VST03/M33x2 T
GS0120L01300
P045-04
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0503mel.bae
Functional description
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Recovery of decomposed or undefined SF6

When recovering decomposed or humid SF6-gas we recommend connecting
the B007R11 pre-filter unit upstream from the service cart.
When recovering oil-contaminated SF6-gas, we recommend connecting the
B071R11 oil separating filter unit upstream from the service cart.
When recovering undefined SF6-gas we recommend connecting the B007R11
pre-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 unit
upstream from the service cart.
After having recovered the contaminated or humid SF6-gas the gas in the
service 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 the
operating 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 for
about 10 minutes.
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Removal and storage of SF6
In case it is necessary to open a gas compartment or gas should be exchanged the SF6-gas
can be recovered with the Gas recovery function. The SF6-gas can then be 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. Alternatively, it is also possible to connect the gas
compartment to pos. 13 or 17.
The connecting hoses must be evacuated or filled 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 opened
and 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 LEDs of
the 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 by
pressing the red Gas recovery push-button.
Observe the fill weight of the storage tank (1 kg/l.).
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Flooding of the gas compartment with ambient air
In case it is necessary to open a gas compartment for maintenance works pay attention to
the faxt that it is under vacuum after the recovery process. The gas compartment is flooded with
ambient 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 the
SF6 gas is released into the atmosphere later on during gas handling.
After flooding uncouple the connecting hose from the gas compartment and
evacuate 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 connect
the 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 opened
4. Start the evacuation function by pressing the green Evacuation" push-button. If there is a
pressure > 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 SF6gas
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 connect
any gas compartment.
The connecting hoses must be evacuated or filled with SF6.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Close the pressure reducer by turning anti-clockwise (minimum pressure).

Turn the ball valves to the illustrated position.
Press the white Filling push-button. (The solenoid valves illustrated above as opened
Press the green Filling push-button. (The evaporator heating is started. The solenoid
valves illustrated open. The solenoid valve upstream from the evaporator only opens
after the evaporator has reached its operating temperature. The LEDs of the opened
solenoid valves and the green Filling push-button on the operating panel light up).
Adjust the pressure reducer to the required filling pressure.
Stop the Filling function by pressing the red push-button.
Connect the gas compartment to the service cart. Alternatively, it is also possible to
connect the gas compartment to pos. 13 or 17.
Restart the Filling function.
When pressure compensation is reached start the Compressor function by pressing the
green Compressor push-button.
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 filled 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 on
the operating panel (The LEDs 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 LEDs 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 by
pressing 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 reduced
beforehand.
1. Connect the SF6-bottle or storage tank via the storage connecting hose to coupling pos. 51
as illustrated above. Open the ball valve on the storage tank.
2. Turn the ball valves to the illustrated position.
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-buttons
on the operating panel. (LEDs will start flashing)
5. Press the "Open solenoid valves" push button.
(The selected solenoid valves open, the corresponding LEDs 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 pressing
the 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
Mega
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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 on
electrical equipment (see chapter 1).
To avoid danger to life by electrical shock:
- Only properly 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 list:
Fault
Indication
"Incorrect direction of
rotation"
Possible cause
Phase failure,
incorrect direction of rotation
Correction
Check power supply
Defective phase sequence relay Exchange phase sequence relay

No function can be
A motor protective circuit breaker Check the motor protective circuit
started, but the solenoid has switched off.
breaker for correct position.
valves can be opened.
Due to excess temperature of the Check the temperature of the
compressor, the thermistor has
compressor and let the compressor
switched off (red LED in the
cool down if necessary.
thermistor lights up)
Check the thermistor
The Gas recovery and
Compressor function
cannot be started.
The compressor does
not reach any high
output pressure
Fault
The contact gauge has switched

off.
Reduce the pressure or put the

contactpointer upwards
The incorrect solenoid valves or

ball valves are opened.
Check the position of the solenoid

valves or ball valves.
Defective piston rings and valve

plates
Check the compressor according

to the operating instruction of the
compressor chapter Pressure test
Possible cause
Correction
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Fault correction
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The indicated final

vacuum of pa 50 mbar
or 1 mbar is not
reached during the
recovery process
The solenoid valves or ball

valves on the suction side are
closed.

Burst membrane
(vacuum compressor)
Exchange the membrane
Vacuum compressor or suction

pump does not switch on.
The vacuum pump does Solenoid valve or ball valve
not reach the final
upstream from the vacuum pump
vacuum
is closed
Check the corresponding pressure

switches
Not enough oil
Refill oil
Incorrect oil
Exchange oil and filter
Humidity in the oil

(white colour of the oil)
Defective vacuum controller or
Exchange vacuum controller or
sensor
sensor
1999" indication on the Interruption or short-circuit in the Check the resistance of the
temperature regulating temperature sensor or in the
connected PT-100-sensor
device
connecting cable
(~ 100 at 20C )
The evaporator does
not heat
Due to excess temperature the

safety temperature limiter
has switched off
Press in the blue button of the

safety temperature limiter (see
label in the terminal box of the
evaporator) until it snaps in by
using a screwdriver.
Check the temperature control of
the evaporator.
SPS-control:
Normally, the LEDs Run and Battery light up.
The Not ready and
Battery LED light up.
Only the Ready and

Battery LED light up.
EEPROM not in correct position. Ensure that the EEPROM and the
grey clip are properly seated. (even
with the upper edge of the control).
Defective EEPROM
The control is in Run Mode
(Operating condition).
Exchange the EEPROM.

Open the grey front cover of the
SPS and press the Reset pushbutton.
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Maintenance
Only authorized personnel should carry out purification, lubrification and
maintenance works in accordance with maintenance instructions and
regulations for the prevention of accidents.
In case of non compliance this could result in injury or death and also
considerable 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 they
have cooled down!
- Ensure that used oils and filter materials are disposed of in accordance
with local environment regulations.
- Exchange filters which contain or are saturated with decomposition
products.
- When working with harmful materials (e. g. filter cartridge) the working
protection set should be used (DILO-working protection set 3-442-R...)
Preventive maintenance
Component
Maintenance works
Compressor
(if installed)
valve plate, piston rings, check condition every 500 operating hours
guide rings
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
Recommended control interval
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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. For
this 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 be
pressurized. Look at the gauge, no pressure drop should occur.
b) Vacuum test
Connect the hose to the vacuum pump. Interconnect suitable vacuum gauge. Produce
vacuum. After having switched off the vacuum pump, the vacuum indication should remain
unchanged at constant room temperature.
2. The DILO-coupling tongue parts DN 8 and DN 20 are equipped with an O-ring which is to
provide an external seal during the coupling process. As the O-ring is used for each coupling
process and because of abrasion, it should be replaced from time to time.
o-ring
O-ring for coupling tongue part DN 8:

order no.:
1-05-057-R024
dimension:
ID 13.95 x W 2.62 EPDM
order no.:
1-05-057-R010
dimension:
ID 20.29 x W 2.62 EPDM
order no.:
1-05-057-R141
dimension:
ID 44.12 x W 2.62 EPDM
3. In order to protect the connecting hose and the piping system from contamination by
decomposition products, we recommend using a pre-filter unit.
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Weighing device (only for pressure tank with liquid storage)

Adjustment of the indicating gauge
The weight indicated on the gauge is always the effective filling weight of the stored gas. To
obtain the correct indication the net weight of the storage tank has to be considered. This
basic adjustment is carried out by DILO. If re-adjustment is necessary, it has to be done
within 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 the
gauge and put the device flat on the ground.
Open gauge:
At the front ring of the gauge there is a bayonet union which is
opened by turning anticlockwise.
Pointer adjustment:
Next to the pointer axis there is a little slotted screw. With a suitable
screwdriver, the pointer can be adjusted to the zero-point by turning
this screw.
Re-installation
After adjustment attach the front ring (ensuring the
correct position of the seal!), and if necessary, refill device with
glycerine * and mount the gauge onto its support again.
Regarding weighing devices for 4 SF6-steel cylinders please take the following into
consideration 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 the
pressure tank is transmitted by a hydraulic instrument to an indicating instrument. The filling
weight of the pressure vessel can be read on the indicating instrument. It is a closed system that
must not be opened. The indicating gauge is filled with glycerine in order to protect the
measuring system. Only 90 % of the housing is filled. The feed opening is at the top side of the
gauge. 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 the
pressure tank)
(only for B044Rstorage 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/B147Rbottle 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 than
the 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 SF6gas 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 the
solenoid 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 inadmissible
overpressure can be produced on the pressure side.
The lower the output pressure the more the regulating valve opens. If the regulating valve is
completely 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 in
chapter 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 controller:
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
Article-No.
B110R11/R12 Compressor
see operating instructions of the B110R11/R12 compressor
6-1091-R...
3-690-R007 Vacuum pump (40m/h, < 1mbar)

Filter spare part kit includes
1
Oil filter OC 21
Pos. 100
1
Exhaust filter element
Pos. 120
1
O-ring 34x4
Pos. 121
6-1047-R011
1 litre SAE30 vacuum pump oil

for 3-690-R007 vacuum pump
3-690-R201
Spare part kit includes

1
Oil filter OC 21
1
1
O-ring 34x4
1
Valve plate
1
Guide for valve seat
1
O-ring
1
Pressure spring
6-1047-R001
3-690-R008/ R009 Vacuum pump

Filter spare part kit includes
1
Oil filter OC 21
2
2
O-ring 34x4
Pos. 100
Pos. 120
Pos. 121
Pos. 251
Pos. 252
Pos. 253
Pos. 254
(63/ 100m/h, < 1mbar)
6-1047-R012
Pos.100
Pos. 120
Pos. 121
1 litre SAE30 Vacuum pump oil

for 3-690-R008 and 3-690-R009 vacuum pump
3-690-R201
Spare part kit includes

1
Oil filter OC 21
2
2
O-ring 34x4
1
Valve plate
1
Guide for valve seat
1
O-ring
1
Pression spring
6-1047-R002
Pos. 100
Pos. 120
Pos. 121
Pos. 251
Pos. 252
Pos. 253
Pos. 254
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Piece
Designation
3-745-R004/ R006 Vacuum pump (40/ 65m/h, < 2x10-3mbar)

Seals
Article-No.
1 litre N62 vacuum pump oil

3-745-R004 / 3-745-R006 for vacuum pump
6-1049-R002
3-745-R201
3-899-R002 Dry filter

Spare filter cartridge for dry filter
3-899-06
1 (2)
3-377-R001 Particle filter

Spare filter cartridge for particle filter DN20
(the version with the vacuum compressor includes two filters)
3-377-08
1 (0)
K072R01
Spare filter cartridge for particle filter DN40
(only for the version with suction pump)
K072-03
Spare part kit for general parts of the Mega Series 2000
includes
1
Solenoid valve DN20, PN60bar
2
Rectifier for solenoid valve DN20/ DN40
1
Solenoid valve DN40, PN30bar
2
O-ring 44,12 x 2,62 for VK/F-01/40 05-0057-R141
1
1
Coupling tongue part DN20
5
O-ring 20,29 x 2,62 for VK/F-02/20
1
Conical non-return valve DN20
6-1048-R016
3-564-R001
05-0494-R102
3-563-R001
VK/A-02/20 P
VK/F-02/20 P
05-0057-R010
VR/A-02/20 P
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Recovery of the filters for filter revision
1.
2.
3.
4.
5.
6.
7.
8.
9.
11.
12.
To open the filters for filter revision the filters must first be depressurized. Check
the pressure on contact gauge pos. 8. For this purpose open the solenoid valve
downstream from the compressor (pos.5.4) manually.
Danger to life! Do not open the filters under pressure!
Connect the storage tank or SF6-bottle to coupling pos. 51 as illustrated above.
Turn the ball valve to the above illustrated position.
Open pressure reducer pos. 12 all the way (Max. filling pressure).
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).
Press the green "Open solenoid valves" push-button. (The preset solenoid valve opens,
the corresponding LED lights up).
Start the "Compressor" function by pressing the green push button.
At a pressure of < pa 500 mbar stop the Compressor function by pressing the red push
button.
Uncouple the SF6-bottle.
Then open ball valves pos. 14 and 42. Flood the filters with ambient air until atmospheric
pressure has been reached.
Check the pressure on gauge pos.48. Close the solenoid valves.
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
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
After having exchanged the filters, the air should be evacuted from the filters.
Otherwise, SF6-gas is mixed with ambient air.
Turn the ball valve to the illustrated position.
Open the pressure reducer pos.12 all the way (Max. filling pressure).
Select the solenoid valves pos. 40 and 5.3 by pressing the corresponding push-buttons
on the operating panel.
(The LEDs of the preset solenoid valves light up).
Press the green "Open solenoid valves push-button.
(The preset solenoid valves open, the corresponding LEDs light up).
Start the "Vacuum pump" function by pressing the green push button.
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 gauge
has indicated < 1 mbar (due to expected vacuum raise).
Reset the solenoid valves (by pressing the red Reset solenoid valves push-button) and
stop the Vacuum pump function by pressing the red push-button.
Open the solenoid valve pos. 5.3.
Observe the vacuum on the vacuum controller. Within 15 minutes after turning the pump
off, the indicated vacuum should be 5 mbar or less. If the vacuum raise exceeds 5 mbar,
repeat the above steps.
After evacuating refill the filters with SF6-gas. For this purpose connect the SF6-storage
vessel 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.
2.
Turn the ball valve to the illustrated position.
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 LEDs on the operating panel light
up).
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 (LEDs light
up).
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. To
achieve this vacuum continue to running the pump for a while even after the vacuum
gauge has indicated < 1 mbar (due to expected vacuum raise).
9.
Reset the solenoid valves and stop the Vacuum pump function by pressing the
red push-button.
10.
Open all solenoid valves except pos. 40.
11.
Observe the vacuum on the vacuum controller. Within 15 minutes after turning the pump
off, 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-storage
vessel to pos.11 and start the Filling the gas compartment function (see chapter 6).
0900mel.bae
Dry filter revision 3-899

Page 1 of 8
C 1978-01
Page 2 of 8
Use of the filter
The dry filter is provided for treating sulphur hexafluoride (SF6). The use for other purposes
should be agreed with the manufacturer.
max. operating pressure
max. operating temperature
see type plate

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 for
which 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 tube
lines. 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 legal
regulations which are in effect. The operator is responsible for carrying out regular checks
according to local laws and regulations which are in effect. Only use the filter under the
indicated pressure and temperature limiting values. These values must not exceed or be lower
than 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 replace
them if necessary. Carefully remove the penetrated humidity from the housing parts. If
decomposed 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 not
exceed 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.
C 1978-01

Page 3 of 8
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 input
side there is the aluminium oxide, at the output side the molecular sieve.
1.7 kg (3.8 lbs) aluminium oxide Al2O3
0.6 kg (1.3 lbs) molecular sieve
pore size 20-50 Angstrm, granular size 2 - 5 mm

pore size 4 Angstrm
(0.08 to 0.2 in)
This filter mixture proved to be the best for the adsorption of moisture and decomposition
products.
With the filter cartridge a dew point temperature of below -50 C (-58 F) can be obtained within
one 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 decomposition
products depends on the concentration of these substances on the input, on the contact time
with 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 in
series because the filter material needs a minimum contact time with the gas, in order to enable
an adsorption.
The desiccative can absorb approx. 120 g (4.2 ounzes) water without the residual moisture of the
gas 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 of
discharges 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 and
gaseous residues, the decomposition products, are left behind. If metals exist also metallic
fluorides can arise in form of dust. The following gaseous decomposition products appear most
frequently beside others in used SF6-gas:
HF
SO2
SOF2
SO2F2
SF4
hydrogen fluoride
sulphur dioxide
thionyl fluoride
sulfuryl fluoride
sulfur tetrafluoride
With the dry filter 3-899 these gaseous decomposition products can be adsorbed.
C 1978-01

Page 4 of 8
The solid particles that can be found in the decomposed SF6 like tungsten trioxide (WO3), cupric
fluoride (CuF2) and others are effectively retained in particle filters 3-377-R001 that are placed
behind.
The absorbing capacity of the filter cartridge for decomposition products is different and
depends on the substance. For sulphur dioxide (SO2) and thionyl fluoride (SOF2) it is about 1520 % 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 the
filter. 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 the
substances the filter is fed with. Therefore it is important to control the efficiency of the dry filter
from time to time using a moisture measuring device and a decomposition products measuring
device.
a) If it is known that the dry filter had been admitted with decomposed SF6 the filter cartridge
must be exchanged in any case.
b) Example: When drying SF6 a dew point temperature of less than -50 C (-58 F) is obtained
with a practically new filter cartridge.
A dew point temperature of -20 C (-4 F) is measured for SF6-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
1000
thus
= 123, 5 ppmm. Thus the moisture content of the gas is 123.5 mg/kg. With one
8,1
120g
= 971 kg (2140 lbs) .
filter cartridge can therefore be dried a gas quantity of
g
0,1235
kg
c) If the filter had been charged with decomposed SF6 as a consequence of max. 1.700 kJ arc
energy (= arc current x arc voltage x duration of the arc) the filter cartridge must be
exchanged.
Investigations showed that SOF2 is the most abundant decomposition product as a
consequence of electric arcs and spark discharge. Other decomposition products appear in
considerably lower concentrations. The production rate of SOF2 directly depends on the arc
energy that affects the SF6.
If SF6 that was exposed to such an arc energy had been led over a dry filter the filter
cartridge has to be exchanged.
C 1978-01

Page 5 of 8
d) If a moisture of more than -50C (-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 dry
filter 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 a
comparison measurement between the input and the output side with a decomposition products
measuring device. If it is already known that the SF6 the filter is fed with contains decomposition
products 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 cartridge
must 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 heating
up or vacuum drying as vapours that are injurious to health and ecologically harmful can be set
free. Furthermore this method is very cost-intensive and there is no proportion to the use of new
material.
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. Only
use filter cartridges which are delivered in perfect packing.
Store the filter cartridges in dry rooms. Remove packing and sealing caps only short time before
the installation.
Scope of supply of the filter cartridge
C 1978-01

Page 6 of 8
4. Exchange of the filter cartridge

Attention: 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.
Attention: The dry filter must be evacuated before putting it into operation.
C 1978-01

Page 7 of 8
5. Exchange of the desiccative of the filter cartridge

Attention: When exchanging the used desiccative avoid any contact.
Do not blow up dust. Work in a well ventilated room or outdoors. Before opening
the filter cartridge corresponding protective measures have to be taken, see our working
protection 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 and
will be kept until refilling.
Clean the interior space of the filter cartridge with a fibreless piece
of cloth.
Fill with new desiccative in a dry room. Dust abrasion and
absorption of moisture by ambient air are avoided if one lets flow
N2 with slight overpressure (max. pe 0.5 bar) from the bottom
through the filter cartridge that is put upright during the filling
process.
Filling process:
Fill 1/3 of the cartridge with molecular sieve (pos. 5). Compress
the desiccative by slightly knocking (rubber mallet) until it does no
longer 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 following
order-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 sealing
caps (pos. 7) must be plugged on to avoid that ambient moisture is

absorbed.
C 1978-01

Page 8 of 8
6. Disposal of filter cartridge and desiccative

Attention: If the used filter cartridge is left until disposal both sealing caps must be
plugged on so that decomposition products cannot desorb because of absorption
of air moisture in the course of time.
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 desiccative and to dispose it afterwards, for this see
our working protection set 3-442.
7. Bibliography:
[1] SF6-Anlagen, BGI 753 07/99
Berufsgenossenschaft der Feinmechanik und Elektrotechnik,
Gustav-Heinemann-Ufer 130, Kln
Conversion for SF6 gas

8.1 ppmv = 1 ppmm
1 ppmm = 1 mg/kg
1 Angstrm = 10-10m
C 1978-01
Particle filter revision 3-377

Operating instruction
Page 1 of 2
1. Filter cartridge
The particle filter is intended for filtering solid particles and solid decomposition products out of
SF6 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 m
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.
3. Exchange of the filter cartridge and disposal
Attention: 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 cone
as 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 the
compressing spring!)
Screw in the filter cone until the stop
Attention: The particle filter must be evacuated before putting it into operation.
Attention: If the filter 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.
C 266-07
Particle filter revision 3-377
Page 2 of 2
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
filter cone
filter cartridge
order no.
3-377-08
guide pipe
compression spring
o-ring 67x3
input
order no.
3-377-05
order no.
05-0057-R075
output
screw cap
5. Bibliography
[1]
SF6-Anlagen, BGI 753

Gustav-Heinemann-Ufer 130, Kln
C 266-07
Particle filter revision K072R01

Page 1 of 3
1. Candle filter
The particle filter is intended for filtering solid particles and solid decomposition products out of
SF6 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 a
long service life.
A retention rate of 100% is obtained from a particle size of 1.0 m
The exchange of the candle filter 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.
3. Exchange of the candle filter and disposal

Attention: 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 cone
as 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
Attention: The particle filter must be evacuated before putting it into operation.
Attention: If the candle filter 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.
C 1799-00

Page 2 of 3
Furthermore it is possible to neutralize the candle filter and to dispose it afterwards, for this see
our working protection set 3-442.
Note:
Normally polluted or unused candle filters that are not charged with decomposition products are
unrisky and can be disposed as usual rubbish.
C 1799-00

Page 3 of 3
4. Particle filter
5. Bibliography
[1]
Merkblatt SF6-Anlagen, Ausgabe 10/92

Gustav-Heinemannn-Ufer 130, Kln
C 1799-00
Steuer und Hauptstromlaufplan

Control- and main circuit diagram
Liste de pices pour schma des circuits
Esquema elctrico
Mega
R
1001mel-4-spr

Esquema elctrico
Mega
R
1001mel-4-spr

Esquema elctrico
Mega
R
1001mel-4-spr

Esquema elctrico
Mega
R
1001mel-4-spr

Esquema elctrico
Mega
R
1001mel-4-spr

Esquema elctrico
Mega
R
1001mel-4-spr
Parts list for control- and
Mega
main circuit diagram

Pos.
B03
D03
D03.1,
D03.2,D03.3
D03.4
F13
F51
K11M
K21M, K31M
K51E
P11-P31
P11-P31
Q01
Q01.1
Q11
Q11.1
Q21
Q31
Q31
Q51
S100
T01
T01.1
U01
X01
X02
Designation
Phase sequence relay
Compact controller with memory module
Extension module F.EM4-201
Thermistor-machinery protection
Microprocessor controller
Contactor, DILM25-10
Contactor, DILM9-10
Contactor, DILM9-10
Working hours counter 230V / 50Hz
Working hours counter 230V / 60Hz
Motor protective circuit breaker PKZM0-6,3
Cutout FAZB 6
Motor protective circuit breaker PKZ 2
Trip block, ZM-32-PKZ 2
Auxiliary contact, NHI 11-PKZM2
Motor protective circuit breaker FAZ-Z2/1
Auxiliary contact, FAZ-XH/11
Motor protective circuit breaker PKZM0-4
Auxiliary contact
Motor protective circuit breaker (40m3/h, 63m3/h)
Motor protective circuit breaker (100m3/h, D40/
65B)
Auxiliary contact
Motor protective circuit breaker PKZM0-16
Auxiliary contact
Flip switch 1 pole
Universal transformer, WA-U 1000
AC power unit 230V/24V DC
Discharger
Coupling CCW 563/9h 230V
Power plug CGW 563/9h 230V
Order-no.
05-1456-R001
05-0671-R020
05-0671-R022
05-0671-R025
05-0671-R023
05-0228-R006
05-0701-R003
05-0722-R008
05-0722-R001
05-0722-R002
05-0400-R001
05-0400-R002
05-0891-R009
05-0725-R003
05-0721-R014
05-0721-R016
05-0723-R002
05-0725-R054
05-0725-R050
05-0891-R008
05-0723-R004
05-0891-R010
05-0891-R011
Piece
1
1
1
2
1
1
1
1
2
1
3
3
1
1
1
1
1
1
1
1
1
1
1
05-0723-R004
05-0891-R011
05-0723-R004
05-0467-R001
05-0747-R009
05-1461-R001
05-1509-R001
05-0751-R009
05-0752-R009
1
1
1
1
1
1
1
1
1
Range of operating voltage

Control voltage
208-240V
230V
50Hz
60Hz
Compressor B110R11 (R12)

Suction pump unit B131R02
Evaporator K032R01
Vacuum pump 40m/h
Vacuum pump 63m/h
Vacuum pump 100m/h
Vacuum pump 40 m/h D40B
Vacuum pump 65 m/h D65B
10 (7.5) kW
0.6 kW
4,8 kW
1,5 (1,1) kW
2,2 (1,5) kW
3,0 (2,2) kW
2,2 kW
2,2 kW
36,0 A
2.7 A
12,5 A
7,2- 4,8 A
9,6- 6,6 A
13,6-9,4 A
9,9 A
11,8 A
29,5 A
2.8 A
12,5 A
6,8 A
9,2 A
13,2 A
10,1 A
10,0 A
1001mel-s01.bae
Circuit diagram / Operating panel
Mega
R
(T135R02)
1010mel.bae
Mega
R
1010mel.bae
Mega
R
Parts list for circuit diagram of operating panel

Pos.
H01
H02
S01-S05
S11,S13,
S15,S17
S12,S14,
S16,S18
Designation
Signal lamp
Green cover
Green LED
Signal lamp
Red cover
Red LED
Lighted push-button
Transparent cover
Yellow LED
Lighted push-button
Article-no.
05-1136-R004
05-1136-R042
05-1136-R052
05-1136-R004
05-1136-R041
05-1136-R051
05-1136-R004
05-1136-R043
05-1136-R053
05-1136-R004
Piece
1
1
1
1
1
1
5
5
5
4
Green cover
Green LED
Push-button
05-1136-R042
05-1136-R052
05-1136-R004
4
4
4
05-1136-R041
05-1136-R004
05-1136-R043
05-1136-R054
05-1136-R004
05-1136-R042
05-1136-R052
05-1136-R004
05-1136-R041
4
3
3
3
3
3
3
3
3
Red cover
S21,S31,S41 Lighted push-button
Transparent cover
Blue LED
S22,S32,S42 Lighted push-button
Green cover
Green LED
S23,S33,S43 Red push-button,
Red Cover
1010mel.bae
for
Dry running compressor B110R11/R12
Year of construction: 2008

Please read this operating instruction before putting the device into operation. Thus operating
faults can be avoided. In case of nonobservance of the operating instruction the manufacturer
cannot assume any liability or guarantee.
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 etc.) is subject to penalty and indemnification
DILO Armaturen und

Anlagen GmbH
Frundsbergstr. 36
D-87727 Babenhausen
Tel.:
Fax.:
(49) 8333/302-0
(49) 8333/302-52
C 2616-01

Page 2 of 30
Table of contents
Page
Product description
Dimension sheet with technical data
3
4-5
Functional diagram
Safety notes
Fault correction
6
7-10
11
12-13
14
15-17
Spare parts list
18-30
C 2616-01

Page 3 of 30
Product description
Correct use
The compressor is designed for the recovery and compression of SF6-gas and SF6-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 use of the compressor for applications for which it was not
intended.
The compressor type B110R11/R12 is a dry-running two-stage piston compressor, which

operates entirely without oil.
The compressor housing is enclosed and thus absolutely gastight.
The position of the 3 cylinders guarantees a steady running even at high back pressure.
The drive train is equipped with an oilfree bearing.
The gas is stored in gaseous or liquid form depending on the pressure.
The compressor is equipped with a cooling unit for cooling the compressor and the compressed
SF6-gas. The cooling unit is air-cooled by a fan.
The operating overpressure is to be limited to max. pe 4 bar on the suction side by a pressure
reducer.
The output pressure is controlled by a contact gauge so that the compressor is switched off in
case the max admissible pressure (50 bar) is exceeded.
The compressor is protected against overcurrent by a motor protective circuit breaker, which is
installed in our works.
PTC (positive temperature coefficient) resistors are installed in the motor winding and in each
cylinder cap. When exceeding the admissible temperature the compressor is switched off by
the thermistor.
C 2616-01
Page 4 of 30
Dimension sheet
Length
mm
900
Width
mm
640
Height
mm
670
Weight
340 kg
C 2616-01
Page 5 of 30
Technical data
Dry running compressor:
Number of cylinders
Diameter of cylinder
Piston stroke
Piston capacity
1st Stage
2nd Stage
2
1
1st Stage
54 mm
42 mm
96.2 cm
2nd Stage
32 mm
42 mm
33.8 cm
Theoretical delivery rate

(at nominal speed)
Direction of rotation
Sound level
17.0 m/h (50 Hz)
13.4 m/h (60 Hz)
Built-in motor: (Standard version)

Frequency
Nominal speed
Three phase short-circuit motor
Operating voltage
Nominal current
Insulation class (VDE 0530)
System of protection
B110R11
B110R12
50 Hz (4 poles)
60 Hz (6 poles)
1470 U/min
1160 U/min
10 kW
7.5 kW
* 380-460 V (Y) / 208-240 V ()
* 20/36 A
16.5-15.5/29.5-27 A
F
IP54
right or left
70 dB(A)
For special voltage the data of the type plate marked with * are valid.
Fan motor:
Frequency
Single phase motor
Operating voltage
Nominal current
50/60 Hz
230/350 W
230 V
1.1 A / 1.55 A
Admissible limiting values at continuous operation with SF6-gas

(pressure indications in pabsolute)
Suction pressure
Max. back pressure
Admissible ambient temperature
p1
p2
RT
= 0.8 to 5 bar (for short time to 0.5 bar)

= 50 bar
= -10 C to +45 C
C 2616-01
Page 6 of 30
Functional diagram
Crankcase
Fan
Safety valve
Non-return valve
Cooler
Compressor
step
C 2616-01

Page 7 of 30

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 compressor is only used for the purposes for which it is intended.
the compressor is only operated in accordance with the instructions and in good condition
and that the safety devices are regularly checked.
complete and legible operating instructions of the device are available on site.
only qualified personnel operates or repairs the compressor and carries out maintenance
works.
this personnel is regularly instructed in safety procedures and environmental protection and
that this personnel is fully aware of the complete operating instructions and particularly the
safety notes.
C 2616-01

Page 8 of 30
Specific safety notes and standard symbols

The symbols used in the operating instructions should draw your attention specially to the
safety notes
This symbol refers to risks for persons (danger to life, danger

of injury)
This symbol refers to risks for machines, material and the environment.
The most important aim of the safety notes is to prevent personal injuries.
-
If the warning sign "Danger" appears, danger from machines, materials and the environment
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!
C 2616-01

Page 9 of 30
Basic safety measures during normal operation

Only trained and authorized persons who are fully aware of the operating instructions should
operate the device 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 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 instructions!
Follow maintenance and repair instructions for individual components in these operating
instructions!
Prior to carrying out maintenance and repair works turn off the main switch for the power
supply and secure it with a 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!
C 2616-01

Page 10 of 30
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!
Re-tighten 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 reinstalled!
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!
C 2616-01

Page 11 of 30
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)
- 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.
Connections
Suction and back pressure side consist of a DILO union ML1-AD22-13 P or ML1-AD22-3 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 on the back pressure side a pressure-controlled switching contact (e. g. contact
gauge or manostat) should be installed which turns off the compressor if the back pressure is
too high.
Connecting proposal:
1 = Dry running compressor
2 = Pressure reducer
3 = Contact gauge
4 = Hose
5 = Hose
C 2616-01

Page 12 of 30

Prior to setting the compressor into operation check the following:
1. Electrical connection
2. SF6-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 and cap from the connecting
case of the compressor motor and the cooling unit.
In the connecting case the following terminals for the electrical connection are provided:
Compressor motor:
Terminal U1, V1, W1, PE: connection of power supply for the compressor motor
Terminal 1, 2: connection of the leadprobes
When connecting the power supply for the compressor motor observe the note in the
connecting case for - and -connection.
Cooling unit:
Terminal L1, N, PE: Connection of the power supply for the fan motor.
Leadprobes are installed (f1 to f6) in the motor winding and in each cylinder cap.
Connect the leadprobes to terminal T1 and T2 of the thermistor machinery protection (F13).
The 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.
C 2616-01

Page 13 of 30
Circuit diagram (Wiring example)
Compressor
f1-f3
f4-f6
F11
F13
K11M
P11
Q01.1/Q11/Q11.1
S11
T01
X01
X02
3
Fan
Leadprobe (in the motor winding of the compressor)

Leadprobe (in the cylinder caps of the compressor)
Contact relay
Thermistor-machinery protection
Contactor
Working hours counter
Motor protection circuit breaker
ON/OFF push-button with indicator light
Transformer
Coupling
Power plug
Contact gauge (The contact gauge must be connected to the output side of
the compressor).
SF6-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 (50 bar)!
C 2616-01

Page 14 of 30
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 properly 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 leadprobes (f1 f3)
in the motor winding or the cylinder caps (f4- f6) 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 leadprobes the compressor is to be restarted with the (S11)
button.
In case the motor protection circuit breaker (Q11.1) switches off due to a defective fan the
contactor (K11M) is turned off as well.
C 2616-01
Page 15 of 30
Maintenance:
All bearings are provided with permanent lubrication.
The sliding surfaces of the cylinders are dry-running.
Do not lubricate the compressor with oil or fat.
Only the O-rings are slightly greased with a special fat before installation.
Maintenance
Object
Work
Noises
Check
interval
Operating hours
Weekly
Every 500 hours All piston and

or after 1 year
guide rings
Check, measure and replace if necessary (see

pressure output test)
(1 pc. spare part kit - piston rings: 6-1091-R002)
(1 pc. spare part kit - O-rings: 6-1091-R021)
Valve plates
(2 pcs. spare part kit low pressure valve plate:

6-1091-R011)
(1 pc. spare part kit high pressure valve plate:
6-1091-R012)
After 2500 hours Drive trains

or 3 years,
then every
500 hours or after
1 year
Check or replace if necessary

(2 pcs. spare part kit low pressure drive train:
6-1091-R041)
(1 pc. spare part kit - high pressure drive train:
6-1091-R042)
(1 pc. spare part kit housing O-ring: 6-1091-R022)
Within the specified maintenance interval the compressor can be operated completely
maintenance-free.
Examination in disassembled condition:
Piston ring, 54 mm
(Article no.: 05-1054-R012)
Guide ring, 54 mm
(Article no.: 05-1054-R013)
High pressure piston ring,
32 mm
(Article no.: 05-1054-R016)
Radial minimum
thickness
3.0 mm
Dimension of
new ring
4.0 mm
3.1 mm
3.5 mm
4.0 mm
5.0 mm
C 2616-01

Page 16 of 30
Functional test (Pressure output test)

Depressurize the compressor beforehand. Disconnect the hose from the suction side of the
compressor so that air can be sucked in.
Connect the shut-off valve and pressure gauge to the pressure side of the compressor.
Close the shut-off valve and start the compressor.
After max. 90 seconds a pressure of 50 bar should be reached on the gauge.
Switch off the compressor.
If a pressure of 50 bar is not reached exchange the valve plates.
Then repeat the output test. If the pressure is not yet reached exchange the piston and guide
rings. If contamination is found in the compressor housing while exchanging the valve plates the
compressor has to be disassembled and cleaned.
Disassembly and Assembly
Only to be carried out if the plant is depressurized.

Verification and disassembly of piston rings, guide rings and valve plates:
Disassemble the front covers (3 pieces).
Disassemble the complete tubing at the cylinder caps.
Disassemble all cylinder caps.
Remove the valve plates and check the valve.
Check the piston rings. If there is no air gap between piston and cylinder bore
(piston sits close to the cylinder) the piston and guide rings must be exchanged.
To measure out the piston rings disassemble the cylinders.
Exchange the worn-out piston rings. (see page 15 radial min. thickness).
Assembly of piston rings, guide rings and valve plates
Prior to assembly, clean all O-rings and piston ring grooves.
Exchange all O-rings and slightly grease them with silicone grease.
Set guide rings and piston rings by carefully bending and sliding them around piston.
Transfer oblique push of the piston ring around 180.
Do not grease the slide face of the pistons neither with oil nor with grease.
Assemble the cylinder.
Clean valve plates or exchange them if necessary and mount with new O-rings.
Assemble cylinder cap and evenly tighten crosswise.
Assemble the complete tubing at the cylinder caps.
Carry out the leak test.
Assemble the covers.
C 2616-01

Page 17 of 30
Spare parts list

Compressor B110R11/R12
C 2616-01

Parts list for B110R11/R12 compressor
Pos. Designation
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Crankcase mounted completely

Rubber metal buffer M12
Set screw M12x20
Disk A13
Lock washer A12
Hexagonal screw M12x25
Thermo sensor 100 C
Terminal block 1.5-2.5 mm, 125 C
Temperature probe connection
Set clip 107/D Pg13.5
Incisive ring 107/B Pg13.5
Bushing M20-M12
Pressing screw 164/Pg7
Flexible control line 2x1 mm; 4.3 m
Red end sleeve for strands 1.0 mm,
Wire tie 100x2,5
Compressor tubing
Cooling unit
Sheet metal cover of the compressor
Cap with sealing
Cylinder screw M4x12
Screw cable gland M32
Flexible connecting line 4x6 mm; 1.5 m
Crimp type sockets
Screwed cable gland M16
Flexible control line 2x1 mm; 1.5 m
Strand H07V-K 4,0 mm,; 0.42 m, black
Crimp type socket
Indication plate
Plate with symbol for earth
Label
Ring nut M16
Suspension
Disk A17
Drive train complete (50 Hz)
Drive train complete (60 Hz)
Threaded rod M16
Lock washer A16
Hexagonal nut M16
Fixture rail
Front fixture rail
Page 18 of 30
Article-no.
B115R20
05-0207-R010
05-0344-R030
05-0306-R090
05-0309-R060
05-0354-R218
05-1121-R001
05-0757-R070
4-091-02
05-1115-R006
05-1115-R001
05-0693-R023
05-1220-R001
05-0659-R001
05-1052-R004
05-0168-R001
B113R11
B118R11
B111R01
B110-01
05-0300-R040
05-0693-R006
05-0659-R010
05-1052-R036
05-0693-R004
05-0659-R022
05-1051-R047
05-1052-R031
05-1217-R001
05-1218-R001
05-1295-R001
05-0333-R010
B112-04
05-0306-R110
B114R01
B114R02
05-1169-R001
05-0309-R070
05-0357-R130
B112-03
05-0354-R220
B112-05
05-0354-R230
Piece
1
4
4
7
7
4
3
8
3
6
3
3
3
1
10
10
1
1
1
1
8
1
1
10
4
1
1
4
1
1
1
1
1
9
1
1
4
8
8
1
1
1
2
C 2616-01

Page 19 of 30
B113R11 Compressor tubing
C 2616-01
Page 20 of 30
Parts list for B113R11 compressor tubing
Pos.
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Designation
Distribution block
Screw-in stub with O-ring
Safety valve pe 10 bar
Copper sealing
Screw-in stub with O-ring
Lock washer A8
Disk A8.4
Support
Lock washer A8
Disk A8.4
Distribution block
Copper sealing
Tubing
Rubber ring
Copper sealing
Connecting piece
Non-return valve
Tubing
Tubing
Tubing
Tubing
Tubing
Tubing
Tubing
Piece of hose
Tubing DN8
Screw-in stub
Copper sealing
Label
Article-no.
B113-05
ML1-AD22-13 P
05-0110-R100
KD-01/G1/4A G
3-845-R002
05-0354-R100
05-0309-R040
05-0306-R060
B113-17
05-0354-R090
05-0309-R040
05-0306-R060
B113-19
05-0237-R025
KD-01/G3/8A G
B113-07
3-298-R052
05-0741-R010
KD-01/G1/2A G
M1-10-51 P
3-994-R001
B113-08
B113-09
B113-10
B113-20
B113-21
B113-13
B113-14
05-0439-R005
B113-16
ML1-AD10-4 P
KD-01/M16x1,5
05-1295-R001
Piece
1
1
1
1
2
2
2
2
1
2
2
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
30 mm
1
1
1
2
C 2616-01
Page 21 of 30
B114R01/R02 Complete drive train
Parts list for B114R01/R02 complete drive train

Pos. Designation
1 Crankcase
2 Rotor (50 Hz)
Rotor (60 Hz)
3 Cap piece of the bearing crankcase
4 Stator, 10.0 kW (50 Hz)
Stator, 7.5 kW (60 Hz)
5 Grommet
6 Insulating disk
8 Grooved ball bearing
9 Safety clip 80x2.5
10 Safety clip 40x1.75
11 Parallel key A10x8x28
12 Threaded rod M6x8
13 Cylinder notch pint 5x12
14 O-ring 234.54x3.53
15 Cylinder screw with hexagon socket- M6x30
16 Disk A6.4
17 Lock washer A6
Article-no.
B114-01
B114-02
B114-09
B114-03
05-1053-R001
05-1219-R001
4-130-00
B114-07
05-1055-R003
05-0421-R047
05-0533-R028
05-0923-R020
05-0349-R010
05-0436-R045
05-0057-R137
05-0339-R140
05-0306-R050
05-0309-R030
Piece
1
1
1
1
1
1
1
1
2
2
2
1
1
2
1
2
2
2
C 2616-01

Page 22 of 30
B115R20 Crankcase mounted completely
C 2616-01

Page 23 of 30
Parts list for B115R20 crankcase mounted completely

Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Designation
Crankcase
Intermediate flange
Cap piece of the crankcase
Low pressure cylinder
High pressure cylinder
Intermediate ring (l=9 mm)
Flywheel
Eccentric gear
Crankcase bolt
Motor shaft
Retaining clip
Intermediate ring (l=12 mm)
Long state bolt
Short state bolt
Hexagon screw M14x1.5x80
Low pressure drive train
High pressure drive train
Counterweight
Cylinder screw with hexagon socket - M12x125
Solid clutch
Grooved ball bearing
Lock washer 12
Screw M5x10
Lock washer A14
Straight pin 6m6x24
Straight pin 6m6x24
Lock washer A10
Lock washer A12
Lock washer A8
Straight pin 8m6x40
O-ring 221.84x3.53
O-ring 228.19x3.53
Parallel key A12x8x32
Set-screw M6x8
Screw in stub
Copper sealing
Article-no.
B115-01
B115-02
B115-03
B115-04
B115-05
B115-18
B115-07
B115-17
B115-20
B115-21
B115-11
B115-19
B115-13
B115-14
05-0352-R017
B116R01
B117R01
B115-16
05-0339-R328
B114-06
05-1055-R002
05-0309-R061
05-0354-R003
05-0309-R065
05-0339-R298
05-0339-R320
05-0339-R220
05-0377-R024
05-0377-R024
05-0309-R050
05-0309-R060
05-0309-R040
05-0377-R037
05-0057-R135
05-0057-R136
05-0923-R030
05-0349-R010
ML1-AD10-4 P
KD-01/M16x1,5
Piece
1
1
1
3
1
1
2
1
1
1
1
3
4
8
1
2
1
2
2
1
2
2
4
1
6
6
6
2
2
6
6
6
2
1
1
1
1
1
1
C 2616-01

Pos.
40
41
42
43
44
45
46
47
48
49
50
52
53
54
55
56
57
58
59
Designation
O-ring 94.92x2.62
O-ring 75.92x1.78
High pressure valve plate (50 bar)
O-ring 66.4x1.78
O-ring 33.05x1.78
High pressure cylinder cap
O-ring 82.27x1.78
Hexagon nut M10
Lock washer A10
Disk A10.5
Screw in stub with O-ring
Screw in stub of temperature sensor
Copper sealing
Low pressure valve plate (25 bar)
O-ring 75.92x1.78
O-ring 44.17x1.78
Low pressure cylinder cap
O-ring 101.32x1.78
O-ring 247.24x3.53
Page 24 of 30
Article-no.
05-0057-R058
05-0057-R052
05-1057-R001
05-0057-R148
05-0057-R147
B115-06
05-0057-R134
05-0357-R100
05-0309-R050
05-0306-R070
3-845-R002
4-091-01
KD-01/G1/4A G
05-1057-R002
05-0057-R052
05-0057-R044
B115-15
05-0057-R059
05-0057-R138
Piece
3
1
1
1
1
1
1
12
12
12
6
3
3
2
2
2
2
2
1
C 2616-01

Page 25 of 30
B116R01 Low pressure drive train
Parts list for B116R01 low pressure drive train

Pos.
1
2
3
4
5
6
7
8
Designation
Connecting rod
Safety clip 100x3
Needle bearing
Piston
Clamping spring
Piston ring, 54 mm
Guide ring, 54 mm
Article-no.
B116-01
05-1055-R001
05-0421-R050
05-1415-R001
B155R01
4-000-15
05-1054-R012
05-1054-R013
Piece
1
1
1
1
1
2
2
2
C 2616-01

Page 26 of 30
B117R01 High pressure drive train
Parts list for B117R01 high pressure drive train

Pos.
1
2
3
4
5
6
7
8
9
Designation
Connecting rod
Safety clip 100x3
Needle bearing
High pressure piston
Clamping spring
Piston ring, 54 mm
Guide ring, 54 mm
High pressure piston ring, 32 mm
Article-no.
B116-01
05-1055-R001
05-0421-R050
05-1415-R001
B156R01
4-000-15
05-1054-R012
05-1054-R013
05-1054-R016
Piece
1
1
1
1
1
2
2
2
8
C 2616-01

Page 27 of 30
B118R11 cooling unit
C 2616-01

Page 28 of 30
Parts list for B118R11 cooling unit

Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Designation
Fixing rail
Hexagon screw M12x25
Lock washer A12
Radiator
Pipe clip
Cylinder screw with hexagon thread - M6x35
Disk A6.4
Pipe clip
Spacer
Front mounting rail
Rear mounting rail
Cylinder screw with hexagon screw - M6x75
Lock washer A6
Axial fan 230 V
Wall plate
Edge protection profile; 1.7 m
Conduit
Hexagon screw M6x16
Large disk - A6.4
Hexagon nut M6
Complete handle piece
Hexagon screw M8x16
Lock washer A8
Hexagon nut M8
Hexagon screw M8x30
Disk A8,4
Mounting bracket
Motor condensor 8 F
Junction box
Slotted cylinder screw M4x12
Large disk - A4,3
Lock washer A4
Hexagon nut M4
Label
Mounting rail; 75 mm
Sheet metal screw B4,8x13
Terminating clamp
Grey terminal box
Article-no.
B118-10
05-0354-R218
05-0309-R060
B118-09
05-0282-R001
05-0339-R150
05-0306-R050
05-0282-R002
B118-08
B118-11
B118-12
05-0339-R185
05-0309-R030
05-1056-R010
05-1056-R011
05-0719-R001
05-0741-R010
05-0354-R035
05-0390-R004
05-0357-R080
B118-14
05-0354-R080
05-0309-R040
05-0357-R090
05-0354-R110
05-0306-R060
B118-13
05-1056-R012
05-0655-R001
05-0300-R040
05-0390-R002
05-0309-R010
05-0357-R030
B118-15
05-1010-R001
05-0381-R010
05-0757-R015
05-0757-R001
Piece
1
1
1
2
16
48
50
8
4
1
1
4
10
1
1
1
2
6
8
6
1
4
8
4
4
4
1
1
1
2
4
2
2
1
1
2
2
3
C 2616-01

Pos.
39
40
41
42
43
44
45
46
47
Designation
Terminal plate
Yellow green terminal box
3x1 mm; 2 m long flexible connecting line
1.0 mm crimp connector red
M25 stabilizing nut
M25/M16 reducer
M16 cord grip
2x1.0 mm, red twin crimp connector
Spacer
Page 29 of 30
Article-no.
05-0757-R031
05-0757-R002
05-0659-R001
05-1052-R004
05-1014-R013
05-1014-R032
05-0656-R010
05-1052-R014
B118-04
Piece
1
1
1
5
1
1
1
2
4
C 2616-01

Page 30 of 30
Piece
Designation
Article-no.
Spare part kit: piston rings

consisting of:
6 pcs. piston ring, 54 mm
6 pcs. guide ring, 54 mm
8 pcs. high pressure piston ring, 32 mm
6-1091-R002
05-1054-R012
05-1054-R013
05-1054-R016
Spare part kit: O-ring kit,

consisting of:
1 pc O-ring (B115R20 pos. 46)
2 pcs. O-ring (B115R20 pos. 58)
3 pcs. O-ring (B115R20 pos. 41, 55)
1 pc. O-ring (B115R20 pos. 44)
6-1091-R021
Spare part kit: Low pressure valve plate

consisting of
1 pc. Low pressure valve plate
6-1091-R011
05-0057-R134
05-0057-R059
05-0057-R044
05-0057-R052
05-0057-R147
05-0057-R148
05-0057-R058
05-1057-R002
05-0057-R059
05-0057-R044
05-0057-R052
Spare part kit: High pressure valve plate

consisting of:
1 pc. High pressure valve plate
6-1091-R012
Spare part kit: Low pressure drive train (1 piece)
6-1091-R041
Spare part kit: High pressure drive train (1 piece)
6-1091-R042
Spare part kit: Housing O-ring (B115R20 pos. 34)
Spare part kit: Low pressure cylinder (1 piece)
6-1091-R051
Spare part kit: High pressure cylinder (1 piece)
6-1091-R052
Spare part kit: coupling,

consisting of:
1 pc. solid clutch
1 pc. Parallel key A12x8x32
1 pc. Parallel key A10x8x28
2 pcs. Thread pin M6x8
6-1091-R061
05-1057-R001
05-0057-R134
05-0057-R147
05-0057-R148
6-1091-R022
B114-06
05-0057-R138
05-0923-R030
05-0923-R020
05-0349-R01
C 2616-01
Suction pump unit B131R01/R02/R03

Table of contents
Page 1 of 8
Page
Suction pump
Maintenance
Disposal
Suction pump unit

Description of the device
B131R01/R03 functional diagram with parts list
B131R02 functional diagram with parts list
Circuit diagram with B131R01 parts list
7, 8
Fault correction
C 2635-01

Page 2 of 8
Maintenance
Introduction
The suction pump has been designed in such a way as to only require little maintenance by
the user. Carry out the following checks for maintenance of your vacuum system.
Inspection of the sieve
Whenever the pump is disconnected from the vacuum system
blow the sieve with compressed air and check it for damage.
To disassemble the sieve remove the four screws, the suction flange and finally the sieve.
After that insert the suction flange again. Then evacuate the air penetrated from the opened
tubing.
Performance test
We recommend carrying out the following gas recovery test once a year.
Connect the evacuated rubber hose (DN20 about 5 meter long) to the suction coupling of
the service cart and fill with SF6-gas to pe 0 bar.
Start the Gas recovery function.
After about 2 minutes a vacuum of < 1 mbar must be obtained at the vacuum controller.
Repeat the test several times if necessary.
Service
To guarantee safe operation of the pump we recommend carrying out maintenance works at
least every 2500 operating hours or every 5 years. For this the pump must be disassembled
and returned to DILO.
To avoid long decommissioning times we recommend replacing the pump body by
exchanging it.
For more details please contact DILO.
Disposal
Dispose of the pump and its components safely in accordance with the local and national
safety and environmental requirements. Take particular care of components which have
been contaminated with dangerous process substances.
C 2635-01

Page 3 of 8
Description of the unit

General information:
The suction pump unit consists of a suction pump, solenoid valves, Regulating valve, pressure
switch, pressure sensor and electric control. All components are mounted on a sheet metal
frame and are connected with each other by hoses or tubings. The suction pump is a dry
running type and operates entirely without oil.
It is protected from inadmissible operating conditions by pressure switch, pressure sensor,
solenoid valves and regulating valve.
The suction pump unit allows to recover gas compartments to pa < 1 mbar.
Function:
If the SF6-gas recovery function is started on the service cart with the integrated gas recovery
unit the suction pump is ready for operation.
The SF6-gas flows through the by-pass solenoid valve of the suction pump.
The suction pump only switches on at a pressure of about pe = 0.1 bar.
The by-pass solenoid valve closes a short time later. The pressure on the output side of the
suction pump is controlled via a pressure sensor.
The regulating valve on the suction side prevents a too high output pressure by throttling on the
input side of the suction pump. The regulating valve on the output of the suction pump regulates
the output pressure to about pa 1000- 1050 mbar to avoid that the compressor behind the
suction pump generates any depression and causes ambient air to be sucked in.
If the Gas recovery function is stopped the suction pump stops running. All solenoid valves
and the regulating valve on the suction side close.
Attention:
Do not connect any gas compartment with overpressure to the suction side while the suction
pump is running as the suction pump can be damaged by overpressure.
Electric control *):
The suction pump unit is equipped with an electric control with integrated programmed control.
All valves and pressure switches are connected to the control.
The motor protective circuit breaker, contactor and working hours counter of the suction pump
are installed in the control cabinet of the service cart.
Evacuation of the suction pump unit:
In case the air should be evacuated from the suction pump unit (after maintenance works) the
solenoid valves can be opened with the Open solenoid valves function.
For this purpose a red push-button is installed in the electric housing of the
suction pump unit *).
If this push-button is pressed once the solenoid valves and the regulating valves open.
The solenoid valves are activated if the LEDs of the K02 and K03 relays light up.
The solenoid valves are closed again by pressing this push-button.
After 5 minutes all valves are closed automatically for safety reason. If this time is not sufficient
for the evacuation process the solenoid valves must be opened once again.
*) only for B131R01
C 2635-01

Page 4 of 8
(Illustration: B131R02)
Length:
Width:
Height:
540 mm
480 mm
605 mm
Weight:
Paint:
100 kg
orange (RAL 2004)
Admissible ambient temperature:

Theoretical final vacuum:
Theoretical suction volume 50 Hz:
Theoretical suction volume 60 Hz:
Nominal motor capacity of the suction pump 50/ 60 Hz:
Rotational speed of the suction pump 50 Hz:
Rotational speed of the suction pump 60 Hz.
Electrical data:
0 to 40C
1x10-2 mbar, 1 Pa
30mh-1 (17.6 ftmin-1)
36mh-1 (21.2 ftmin-1)
0.60 kW (0.80 hp)
1500 min -1
1800 min -1
see type plate of the suction pump
C 2635-01
Page 5 of 8
B131R01/R03
Functional diagram

Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Designation
30 m3/h oilfree suction pump
Regulating valve DN20
Pressure transformer pe 0-0.4 bar
Gauge union DN8
Copper sealing
Solenoid valve DN20 PN60
Pressure switch pe 0.1 bar
Tubing with hose
Tubing with hose
Tubing
Rubber hose
Tubing
Tubing
Tubing, angular piece 2x AD22
Tubing with hose
Article-No.
B105R31
K066R03
05-0495-R301
3-328-R001 P
05-0091-R001
3-564-R001
K016R01
3-564-R001
K016R01
P205-01
P205-16
P205-03
GS0108L00700
P205-04
P205-05
3-564-R001
K066R03
K018R09
P205-17
Piece
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
C 2635-01
Page 6 of 8
B131R02
Functional diagram

Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Designation
30 m3/h oilfree suction pump
Regulating valve DN40 (230V)
Pressure transformer pe 0-0.4 bar
Tubing with hose
Tubing with hose
Tubing
Rubber hose
Tubing
Tubing
Tubing
Tubing with hose
Article-No.
B105R31
B083R12
05-0495-R301
3-564-R001
K016R01
3-563-R001
K016R01
P205-08
P205-16
P205-06
GS0108L00700
P205-04
P205-07
3-564-R001
K066R03
K018R09
P205-17
Piece
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
C 2635-01

Page 7 of 8
Control and main circuit diagram B131R01
C 2635-01
Page 8 of 8
Parts list for control- and circuit diagram B131R01
Pos.
D03
F08
Designation
Compact control
Safety clamp
Cap
Safety plug
Fine fuse
K01-K03 Relay 24 VK04 Relay 230 V
K05-K06 Relay 24 VS02 Red push-button
T01.1 Power plug 230V/ 24V-
Article-No.
05-0671-R020
05-0745-R004
05-0745-R005
05-0745-R001
05-0103-R065
05-0729-R010
05-0729-R011
05-0729-R010
05-0764-R002
05-1461-R001
Piece
1
1
1
1
1
3
1
2
1
1
Fault correction
No. Fault
1
No vacuum
Cause / Check
Incorrect direction of motor rotation
Suction line is blocked
Leakage of suction line
Sieve is contaminated
Correction
Reverse polarity of the power
supply
Clean gas recovery line
Check the gas recovery line,
exchange if necessary
Clean or replace sieve
Check density
Pump check see page 2 Service
Bad final pressure
Leakage in the vacuum system

Defective seals
Overload
The back pressure of pump is too Check outlet line

Exchange of bearing
high
Defective bearings
Pump contaminated by process
residuals
Heating of the pump
Insufficient ventilation of the pump

residuals
Outlet line is blocked
Motor failure
Ambient temperature is too high
Improve the ventilation

Check the outlet line
Check the motor
Check the ambient temperature
Abnormal noise of the Outlet line is blocked

pump
Incorrect direction of motor rotation
residuals
Check the outlet line and clean it

if necessary
Reverse the polarity of the power
supply
C 2635-01
OPERATING INSTRUCTIONS
GA01203_1102
TRIVAC B
D 40 B / D 65 B
Rotary Vane Vacuum Pump
Cat. No.
113 46/47
113 56/57
vacuum
Contents
Section
Page
Important Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GA01203_1102 - 07/2005
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2
Supplied Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.4.1
Motor Related Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1
Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2
Connection to the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4
Areas of Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.1
Pumping of Non-Condensable Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.2
Pumping of Condensable Gases and Vapours . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.3
Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.1
Shutdown through Monitoring Components . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.3.2
Failure of the Control System or the Mains Power. . . . . . . . . . . . . . . . . . . . . . 23
Contents
Section
5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.1
Checking the Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1.1
Checking the Condition of N 62 Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.3
Cleaning the Inlet Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.4
Removing and Fitting the Internal Demister . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.5
Disassembly and Reassembly of the Electric Motor . . . . . . . . . . . . . . . . . . . . 28
5.6
Replacing the Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.7
Removing and Remounting the Pump Module . . . . . . . . . . . . . . . . . . . . . . . . 32
5.7.1
Removing the Pump Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.7.2
Remounting the Pump Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.8
Service by Leybold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.8.1
Waste Disposal of Used Pump Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.9
Storing the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.10
Maintenance Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
EEC Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
EEC Manufacturers Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Declaration of Contamination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
GA01203_1102 - 07/2005
Notes
Leybold Service
If a pump is returned to Leybold indicate whether the pump is free of substances damaging to health or whether it is contaminated.
If it is contaminated also indicate the nature of the hazard. Leybold must
return any pumps without a Declaration of Contamination to the senders
address.
Disposal of Waste Oil

Owners of waste oil are entirely self-responsible for proper disposal of this
waste.
Waste oil from vacuum pumps must not be mixed with other substances or
materials.
Waste oil from vacuum pumps (Leybold oils which are based on mineral
oils) which are subject to normal wear and which are contaminated due to
the influence of oxygen in the air, high temperatures or mechanical wear
must be disposed of through the locally available waste oil disposal system.
Waste oil from vacuum pumps which is contaminated with other substances must be marked and stored in such a way that the type of contamination is apparent. This waste must be disposed of as special waste.
European, national and regional regulations concerning waste disposal
need to be observed. Waste must only be transported and disposed of by
an approved waste disposal vendor.
Figures
The references to diagrams, e.g. (1/2) consist of the Fig. No. and the Item
No. in that order.
We reserve the right to modify the design and the specified data. The illustrations are not binding.
GA01203_1102 - 07/2005
Notes
The vacuum pumps from the TRIVAC B system from Leybold ensure
when properly used and when observing the information provided in
these Operating Instructions, safe and reliable operation. Please read all
safety related notes provided in this section and the remaining part of the
Operating Instructions with care and ensure compliance. The pump must
only be operated and maintained by trained staff while in the proper
state and as described in these Operating Instructions. Please also
note local and government requirements and regulations. Should you
have any questions relating to safety, operation or maintenance of the
equipment, please get in touch with your nearest Leybold Vacuum office.
The icon indicates procedures that must be strictly observed to prevent

hazards to persons.
Warning
This special icon warns about dangers caused by high electric voltages.
Touching parts at a high voltage can result in immediate death.
Covers which are marked with this icon must only be removed by trained
electricians after having reliably disconnected the electric power source.
Warning
Indicates procedures that must strictly be observed to prevent damage

to, or destruction of the equipment.
Caution
Emphasises additional application information and other useful information provided within these Operating Instructions.
Note
GA01203_1102 - 07/2005
Safety information
Important Safety
Information
Warning
Non-compliance with the following precautions can result in
severe injury!
Before beginning with any maintenance or service work on the

TRIVAC B, disconnect the pump from all power supplies.
Do not operate the pump with any of the covers removed.
Serious injury may result.
If exhaust gases must be collected or contained, do not allow the
exhaust line to become pressurised.
Make sure that the gas flow from the exhaust port is not
blocked or restricted in any way.
The standard version of the TRIVAC B is not suited for operation in
explosion hazard areas. For this purpose there are special TRIVAC B
Atex Pumps. Contact us before planning to use the pump
under such circumstances.
Before starting up for the first time, the motor circuit must be
equipped with a suitable protective motor switch. Please take
note of the information in these Operating Instructions or on
the electric motor (wiring diagram).
The TRIVAC B is not suited for pumping of:
combustile and explosive gases and vapours
radioactive and toxic substances
pyrophorous substances
Avoid exposing any part of the human body to the vacuum.
Never operate the TRIVAC B without a connected intake line
or blank flange at the intake port.
The location at which the TRIVAC B (including its accessories)
is being operated should be such that angles over 10 from
the vertical are avoided.
The location of the TRIVAC B should be such that all controls
are easily accessible.
Under certain ambient conditions the TRIVAC B may attain a
temperature of over 70 C (158 F). There then exists the
danger of receiving burns.
Note the symbols on the pump pointing to the hazards, and in the
case of a hot pump wear the required protective clothing.
The noise level of the TRIVAC B is between 52 and 62 dB(A). Introduce
suitable hearing protection.
Warning
Before pumping oxygen (or other highly reactive gases) at concentrations exceeding the concentration in the atmosphere (> 21 % for
oxygen) it will be necessary to use a special pump. Such a pump will
have to be modified and degreased, and an inert special lubricant
(like PFPE) must be used.
Before commissioning the TRIVAC B, make sure that the
media which are to be pumped are compatible with each
other so as to avoid hazardous situations. All relevant safety
standards and regulations must be observed.
GA01203_1102 - 07/2005
Safety information
It is recommended to always operate the TRIVAC B with a
suitable exhaust line which is properly connected. It must
slope down and away from the pump.
When moving the TRIVAC B always use the allowed means only.
A lifting eye is provided as standard on the pump.
Do not allow the ingestion of small objects (screws, nuts,
washers, pieces of wire, etc.) through the inlet port. For this
reason always use the inlet screen which is supplied as
standard.
Caution
Non-compliance with the following precautions can cause
damage to the pump!
Do not use the pump for applications that produce abrasive or

adhesive powders or condensable vapours that can leave
adhesive or high viscosity deposits. When planning to pump
vapours other than water vapour please contact our sales or
service department for advice.
This pump is suited for pumping water vapour within the
specified water vapour tolerance limits.
Avoid vapours that can condense into liquids when being compressed inside the pump, if these substances exceed the vapour
tolerance of the pump.
Before pumping vapours the TRIVAC B should have attained its
operating temperature. This will be the case approximately 30
minutes after having started the pump. During this warming
up phase, the pump should be separated from the process, by a
blocking valve in the intake line, for example.
In the case of wet processes we recommend the installation
of liquid separators upstream and downstream of the pump as
well as the use of the gas ballast.
The exhaust line should be laid so that it slopes down and
away from the pump so as to prevent condensate from backstreaming into the pump.
The entry of particles and fluids must be avoided under all
circumstances.
Reactive or aggressive substances in the pump chamber may
impair the operating oil or modify it. In addition, such
substances may be incompatible with the materials of the
pump (Viton, grey cast iron, aluminium, steel, resins, glass etc.).
Corrosion, deposits and cracking of oil within the pump are not
allowed.
Normal amounts of humidity within the range of the pumps water
vapour tolerance will not significantly affect pump performance when
the gas ballast is active.
This information serves the

purpose of making optimum
use of the pump!
In the case of custom pumps (with a part number deviating from

that stated in the EC Declaration of Conformity) please note the
information provided in the supplementary sheet.
Caution
GA01203_1102 - 07/2005
Description
Key to Fig. 1
1 Oil filter OF 40-65
2 Roots pump adapter
3 Exhaust filter AF 40-65
Fig. 1 TRIVAC B with accessories
Description
TRIVAC B pumps are oil-sealed rotary vane pumps. The TRIVAC D 40 B

and D 65 B are dual-stage pumps. The number in the type designation (40
or 65) indicates the pumping speed in m3 h-1.
TRIVAC B pumps are capable of pumping gases and vapours and evacuating vessels or vacuum systems down into with the medium vacuum range.
The standard versions of the pump are not suited for pumping of oxygen
exceeding the concentration as found in the atmosphere, and are also not
suited for pumping of hazardous gases or extremely aggressive or corrosive media.
The drive motor of the TRIVAC B is directly flanged to the pump at the coupling housing. The pump and motor shafts are directly connected by a flexible coupling. The bearing points of the pump module are force lubricated
sliding bearings. All controls as well as the oil-level glass and the nameplate are arranged on the front. All connections are to be found at the sides of
the pump. The oil-level glass is provided with prisms for better observation
of the oil level.
The pump module consists of assembly parts which are pin-fitted so as to
allow easy disassembly and reassembly. The pump module can be easily
removed without special tools.
GA01203_1102 - 07/2005
Description
Key to Fig. 2
1 Intake port
2 Inlet screen
3 Anti-suckback valve
4 Intake channel
5 Vane
6 Pump chamber
7 Rotor
8 Cover plate, connection for inert gas ballast
9 Exhaust channel
10 Exhaust valve
11 Internal demister
12 Spring buckles
13 Cover plate, connection for oil filter
Fig. 2 Sectional drawing of the TRIVAC B
1.1
Function
The rotor (2/7), mounted eccentrically in the pump housing (2/6), has two
radially sliding vanes (2/5) which divide the pump chamber into several
compartments. The volume of each compartment changes periodically
with the rotation of the rotor.
Operating Principle
As a result, gas is sucked in at the intake port (2/1). The gas passes
through the dirt trap sieve (2/2), flows past the open anti-suckback valve
(2/3) and then enters the pump chamber (2/6). In the pump chamber, the
gas is passed on and compressed, after the inlet aperture is closed by the
vane.
The oil injected into the pump chamber is used for sealing and lubricating.
The slap noise of the oil in the pump which usually occurs when attaining
the ultimate pressure is prevented by admitting a very small amount of air
into the pump chamber.
The compressed gas in the pump chamber is ejected through the exhaust
valve (2/10). The oil entrained in the gas is coarsely trapped in the internal
demister (2/11); there the oil is also freed of mechanical impurities. The gas
leaves the TRIVAC B through the exhaust port.
Oil filter
During compression, a controlled amount of air - the so-called gas ballast

- can be allowed to enter the pump chamber by opening the gas ballast
valve (position I). The gas ballast stops condensation of vapours in the
pump chamber up to the limit of water vapour tolerance as specified in the
technical data for the pump.
Operating with gas ballast
The gas ballast valve is opened (position I) and closed (position 0) by turning the gas ballast knob (7/5) on the front.
GA01203_1102 - 07/2005
Description
Lubrication system
To enable the TRIVAC B to be used at intake pressures as high as 1,000

mbar, a special lubricating system was developed featuring force-lubrication of the sliding bearings.
An oil pump (3/6) pumps the oil from the oil reservoir (3/5) into a pressurelubrication system which supplies oil to all bearing points (3/2). From there
the oil enters the pump chamber area (2/6) of the vacuum pump.
The oil pump is fitted in the front end plate on the coupling side of the pump
module. The oil suction line is placed low, resulting in a large usable oil
reservoir.
Seperation of oil and gas
The oil is separated from the gas in the TRIVAC B in two steps as described above. First, small droplets are coalesced into large drops in the internal demister (2/11) fitted above the exhaust valve (2/10). Then, the large
drops fall into the oil reservoir as the exhaust gas is diverted by the inner
walls of the oil case. Thus a low loss of oil is obtained. This and the large
usable oil reservoir ensure long intervals between oil changes even at high
intake pressures.
Anti-suckback valve
The vacuum is maintained by the TRIVAC B by an integrated hydropneumatic anti-suckback valve (2/3) which is controlled via the oil pressure.
During operation of the TRIVAC B the control piston (4/3) remains sealed
against a spring (4/2) by the oil pressure. The valve disc (4/6) of the antisuckback valve is held at the lower position by its own weight (valve open).
When the pump stops (because it has been switched off or because of a
failure), the oil pressure drops and the spring (4/2) presses the control
piston (4/3) up. Thus a connection is provided between the oil case or the
oil reservoir (4/1) and the piston (4/4) of the anti-suckback valve. Due to the
pressure difference between the oil case and the intake port the oil presses
the piston (4/4) up and the valve plate (4/6) against the valve seat (4/5). The
quantity of oil in the oil reservoir (4/1) prevents the entry of air into the intake port (2/1) at the beginning of this process.
After the oil has flowed out from the reservoir and when the valve plate rests
on the valve seat, air follows in, which vents the pump chamber and forces
the valve disc (4/6) against its seat. This effectively prevents backstreaming
of oil. The anti-suckback valve (2/3) operates independently of the operating mode of the pump, i.e. also with gas ballast.
10
GA01203_1102 - 07/2005
Description
Key to Fig. 3
1 Accessories
2 Bearings
3 Non-return valve
4 Pump chamber of the TRIVAC
5 Oil reservoir
6 Oil pump
Fig. 3 Schematic of the lubricating system
Key to Fig. 4
1 Oil reservoir
2 Spring
3 Control piston
4 Anti-suckback piston
5 Valve seat
6 Valve disk
7 Gas inlet
Fig. 4 Hydropneumatic anti-suckback valve
1.2
Supplied Equipment
The equipment supplied with the TRIVAC B pump includes:

Pump with motor, including initial filling of N 62.
1 centering ring,
1 centering ring with inlet screen,
2 clamping rings DN 40 KF.
As protection during shipment, the connection ports are each blanked off
by rubber diaphragms and supporting rings.
The switch, motor protection switch, mains cable etc. are not included.
GA01203_1102 - 07/2005
11
Description
1.3
Accessories
Kat.-Nr./Best.-Nr.
Seperator AK 40-65, DN 40 KF
188 16
Exhaust filter AF 40-65, DN 40 KF
189 16
Drain trap for Seperator, exhaust-filter, oil drain of the pump,

vacuum tight
oil tight
190 90
190 91
Exhaust filter with lubricant return

AR 40-65, DN 40 KF
189 22
Exhaust filter with lubricant return

ARS 40-65
189 57
Inlet screen
186 15
Medium vacuum adsorption trap

(with zeolithe)
187 15
adsorption trap
(with aluminium oxide)
854 16
Oil filter OF 40-65
101 92
Chemical filter CF 40-65
101 97
Chemical filter with safety cut-off valve CFS 40-65
101 77
Adapter for RUVAC Roots pumps 151/251
168 30
Adapter fr gas ballast port

M 16 x 1,5 - DN 16 KF
M 16 x 1,5 - 3/8 inch NPT
Oil N 62
168 40
99 175 011
1l
177 01
5l
177 02
20 l
177 03
1 qt
98 198 006
12 qt case
98 198 049
1 gal
98 198 007
5 gal
98 198 008
(order from LH Cologne, Germany)
Oil HE-200
(order from LHVP, Export Pa., USA)
The oil grades N 62 and HE-200 are interchangeable.

Caution
12
GA01203_1102 - 07/2005
Only use the kind of oil specified by Leybold. Alternative types of oil are
specified upon request.
Description
1.4
Technical Data
Nominal pumping speed

Pumping speed
1)
1)
Ultimate partial pressure without gas ballast

Ultimate total pressure without gas ballast
Ultimate total pressure with gas ballast
Water vapor tolerance
1)
1)
1)
1)
TRIVAC D 40 B
two-stage
TRIVAC D 65 B
two-stage
m3 h-1
46
75
m3 h-1
40
65
mbar
< 1 10-4
mbar
< 2 10-3
mbar
< 5 10-3
mbar
40
gm h-1
Water vapor capacity

Oil filling, min./max.
Noise level to DIN 45 635,

(without/with gas ballast)
1184
1925
1.7 / 2.6
2.0 / 3.3
dB (A)
57 - 59
Admissible ambient temperature
12 - 40
Motor rating
2200
min-1
Nominal speed
Type of protection
IP
Weight
kg
Connections, intake and exhaust side

1)
1500/1800
54
68
80
DN
40 KF
To DIN 28 400 and subsequent numbers
Note
1.4.1
Motor Related Data
D 40 B
P/N
We can only guarantee that the pump will meet its specifications when
using the type of lubricant which has been specified by us.
D 65 B
l
W (kg)
(mm)
P/N
l
W (kg)
(mm)
113 47
670
69
113 57
748
80
113 46
410
50
113 56
488
61
10
Saugvermgen
Pumping
speed
3~, 200/346 V 10 %, 50/60 Hz
Motor
power
Rated
current
Speed
Motornoise level
P/N
motor
2200 W
10,5/6,0 A
9,5/5,5 A
1380
1660
55 dB(A)
59 dB(A)
200 10 412
without motor
10
10
Ultimate partial pressure without gas ballast

Ultimate total pressure without gas ballast
Ultimate total pressure with gas ballast
D 65 B
D 40 B
m3 . h-1
10
Motor connections
voltage, frequency
-1
-5
10
-4
10
-3
10
-2
10
10
-1
10
10
mbar
10
Pressure
Druck
Fig. 5 Pumping speed characteristics of the TRIVAC D 40 B and TRIVAC D 65 B, 50 Hz operation, SI units
GA01203_1102 - 07/2005
13
Transportation and Storage
DN
b2
h1
Type
h2
o
b1
DN
D 40 B (P/N 113 47)
40 KF
135
b1
b2
h1
h2
670
D 40 B (P/N 113 57)
40 KF
213
750
Dimensions in mm
Fig. 6 Dimensional drawing for the TRIVAC rotary vane pumps (Dimensions a, l, b to b2 and h1 are approximate)
Transportation and
Storage
Caution
Pumps which are filled with operating agents must only be

moved while standing upright. Otherwise oil may escape.
Avoid any other orientations during transport.
Warning
Check the pump for the presence of any oil leaks, since there
exists the danger that someone may slip on spilt oil.
When lifting the pump you must make use of the crane eyes provided on the pump for this purpose; also use the recommended type
of lifting device.
14
GA01203_1102 - 07/2005
Installation
Key to Fig. 7
1 Eye for moving the pump
2 Intake port
3 Exhaust port
4 Oil-level glass
5 Gas ballast knob
6 Threaded connection
M 16 x 1.5 for inert gas ballast
7 Adapter
8 Cover plate
9 Cover plate; connection for oil filter
1
2
3
9
4
8
5
7
Fig. 7 Connections and controls
Installation
The standard pump is not suited for installation in the explosion hazard
areas. Contact us before planning to use the pump under such circumstances.
3.1
Warning
Placement
The TRIVAC B pump can be set up on a flat, horizontal surface. Rubber feet
under the coupling housing ensure that the pump can not slip.
If you wish firmly install the pump in place, insert bolts through bore holes
in the rubber feet.
Max. tilt for the pump (without further attachment) with possibly fitted
standard accessories is 10 from the vertical.
Caution
The rubber feet act as vibration absorbers. They must therefore not be
compressed by screws. When installing the TRIVAC B pump, make sure
that the connections and controls are readily accessible.
The site chosen should allow adequate air circulation to cool the pump
(keep front and rear unobstructed). The ambient temperature should not
exceed +40 C (104 F) and not drop below +12 C (55 F) (see Section
4.2.3).
The max. amount of heat given off approximately corresponds to the
rated motor power.
GA01203_1102 - 07/2005
15
Installation
3.2
Connection to the System
Before connecting the TRIVAC B, remove the shipping seals from the
connection flanges (7/2) and (7/3).
Caution
Retain the shipping seals in case you need to store the pump in the future.
The pump is shipped with intake and exhaust flanges mounted for horizontal connection of the connecting lines. You can easily convert the ports
for vertical connection by removing the four capscrews, rotating the flanges
as required, and reinstalling the capscrews.
Connect the intake and exhaust lines with a centering ring and a clamping
ring each. Use the centering ring with dirt trap for the intake port.
Connect the intake and exhaust line using anti-vibration bellows, without
placing any strain on the pump.
The intake line must be clean. Deposits in the intake line may outgas and
adversely affect the vacuum. The connecting flanges must be clean and
undamaged.
The maximum throughput of the pump is equivalent to the pumping speed
of the pump (see Section 1.4).
Caution
The cross-section of the intake and exhaust lines should be at least the
same size as the connection ports of the pump. If the intake line is too
narrow, it reduces the pumping speed. If the exhaust line is too narrow,
overpressures may occur in the pump; this might damage the shaft seals
and cause oil leaks. The maximum pressure in the oil case must not
exceed 1.5 bar (absolute).
When pumping vapours, it is advisable to install condensate traps on the
intake and exhaust sides.
Install the exhaust line with a downward slope (lower than the pump) so
as to prevent condensate from flowing back into the pump. If this is not
possible, insert a condensate trap.
The exhaust gases from the vacuum pump must be safely led away and
subjected to post-treatment as required. In order to reduce the emission
of oil vapours we recommend the installation of an additional exhaust filter (Leybold accessory).
Depending on the type of application or the kind of pumped media, the
corresponding regulations and information sheets must be observed.
The pumps may be operated with an inert gas ballast via a connection
which is provided for this purpose. The cover plate (7/8) can be removed
to gain access to this M 16 x 1.5 threaded port (7/6). Matching connectors
are available (see Section 1.3).
In inlet pressure for the gas ballast should be about 1000 mbar (absolute)
and sufficient quantities of gas must be available (about 1/10 of the pumping
speed).
Warning
Never operate the pump with a sealed exhaust line. There is the danger
of injury.
Before starting any work on the pump, the personnel must be informed
about possible dangers first. All safety regulations must be observed.
16
GA01203_1102 - 07/2005
Installation
3.3
Electrical Connections
Before wiring the motor or altering the wiring, ensure that mains supply
for the pump is off and that it can not be applied inadvertently.
Warning
In order to prevent the pump from running up unexpectedly after a mains

power failure, the pump must be integrated in the control system in such
a way that the pump can only be switched on again manually. This
applies equally to emergency cut-out arrangements.
The connections must only be provided by a trained electrician or must
be supervised by a trained electrician working in accordance with the currently valid IEC (International), EN (European) or national guidelines.
Observe all safety regulations.
TRIVAC B pumps with a three-phase motor are supplied without accessories for electrical connection. They must be connected via the appropriate
cable, and a suitable motor protection switch. Set the switch in accordance with the rating on the motor nameplate.
Fig. 8 shows the connection for pumps with 230/400 V, 50 Hz motors.
Please also observe the motor wiring diagram in the junction box and the
information given on the nameplate of the motor.
After connecting the motor and after every time you alter the wiring,
check the direction of rotation. To do so, briefly switch on the motor and
check whether a suitable cover (e. g. a blank flange) is sucked on at the
intake port. If not, interchange two phases of the connection.
Caution
Observe the direction arrow on the coupling housing.
GA01203_1102 - 07/2005
17
Installation
Star circuit
Delta circuit
Fig. 8 Connection diagram for TRIVAC B with 50 Hz 3-phase motor
3.4
Warning
Areas of Application
Before pumping oxygen (or other highly reactive gases) at concentrations

exceeding the concentration in the atmosphere (> 21 % for oxygen) it will
be necessary to use a special pump. Such a pump will have to be modified and de-greased, and an inert special lubricant (like PFPE) must be
used.
The TRIVAC B is not suited for pumping of:
ignitable and explosive gases or vapours
Oxidationsmitteln
pyrophoren Gasen
Caution
The pumps are not suited for pumping of liquids or media which carry
large quantities of dust. Corresponding protection devices need to be
provided.
Warning
The standard pump is not suited for pumping of hazardous gases or

vapours.
Our technical sales department is available for further advice in these
matters.
18
GA01203_1102 - 07/2005
Operation
Operation
4.1
Start-up
Each time before starting up check the oil level.

On the initial start-up, and each time after having made changes to the
mains power connection of the pump, check the direction of rotation of the
pump equipped with a three-phase motor (for this refer to Section 3.3.1).
On initial start-up, after prolonged idle periods or after an oil change, the
specified ultimate pressure cannot be attained until the oil is degassed. This
can be done by running the pump for approx. 30 min. with the intake line
closed and the gas ballast valve (7/5) open.
Before starting the pump ensure that the pump and the fitted accessories meet the requirements of your application and that safe operation
can be guaranteed.
Warning
Avoid exposure of any part of the body to the vacuum. There is the danger of injury. Never operate the pump with an open intake port. Vacuum
connections as well as oil-fill and oil-drain openings must never be opened during operation.
The safety regulations which apply to the application in each case must
be observed. This applies to installation, operation and during maintenance (service) as well as waste disposal and transportation.
4.2
Operation
TRIVAC B pumps can pump condensable gases and vapours, provided

that the gas ballast valve (7/5) is open and the pump has attained its
operating temperature.
4.2.1
Pumping of Non-Condensable Gases

and Vapours
If the process contains mainly permanent gases, the TRIVAC B may be

operated without gas ballast (position 0), provided that the saturation
vapour pressure at operating temperature is not exceeded during compression.
If the composition of the gases to be pumped is not known and if condensation in the pump cannot be ruled out, run the pump with the gas ballast
valve open in accordance with Section 4.2.2.
GA01203_1102 - 07/2005
19
Operation
4.2.2
Pumping of Condensable Gases and

Vapours
With the gas ballast valve open (position I) and at operating temperature,
TRIVAC B pumps can pump pure water vapour up to the water vapour tolerance specified by the technical data. If the vapour pressure increases
above the permissible level, the water vapour will condense in the oil of the
pump.
When pumping vapours ensure that the gas ballast valve is open and that
the pump has been warmed up for approximately 30 minutes with the
intake line closed.
Caution
Vapour phases may only be pumped up to the permissible limit after the
pump has attained its operating temperature.
During pumping, vapours may dissolve in the oil. This changes the oil
properties and thus there is a risk of corrosion in the pump. Therefore,
dont switch off the pump immediately after completion of the process.
Instead, allow the pump to continue operating with the gas ballast valve
open and the intake line closed until the oil is free of condensed vapours.
We strongly recommend operating the TRIVAC B in this mode for about
30 minutes after completion of the process.
In cyclic operation, the TRIVAC B should not be switched off during the
intervals between the individual working phases (power consumption is
minimal when the pump is operating at ultimate pressure), but should continue to run with gas ballast valve open and intake port closed (if possible
via a valve).
Once all vapours have been pumped off from a process (e.g. during
drying), the gas ballast valve can be closed to improve the attainable
ultimate pressure.
4.2.3
Operating Temperature
Proper operation of the TRIVAC B is ensured in the ambient temperature

range between 12 C to 40 C (55 F to 104 F).
At operating temperature, the surface temperature of the oil case may lie
between 40 C and over 70 C (104 F and 156 F), depending on the load.
Warning
The surface temperature of the TRIVAC B pumps may rise above 70 C.

There is the danger of receiving burns.
20
GA01203_1102 - 07/2005
Operation
4.3
Shutdown
Under normal circumstances, all that you need do is to electrically switch

off the TRIVAC B.
No further actions will be required.
When pumping condensable media let the pump continue to operate with
the gas ballast valve open and the intake line closed before switching off
(see Section 4.2.2).
When pumping aggressive or corrosive media, let the pump continue to
operate even during long non-working intervals (e.g. overnight) with the
intake line closed and the gas ballast valve open. This avoids corrosion
during idle periods.
If the TRIVAC B is to be shutdown for an extended period after pumping
aggressive or corrosive media or if the pump has to be stored, proceed as
follows:
When having pumped harmful substances, take adequate safety precautions.
Warning
Our technical sales department is available for further advice in these matters.
Drain the oil (see Section 5.2).
Add clean oil until the oil-level is at the min mark (see Section 5.2) and let
the pump operate for some time.
Then drain the oil and add clean oil until the oil level is at the max mark
(see Section 5.2).
Seal the connection ports. Special conservation or anti-corrosion oils arent
necessary.
Please also take note of the information given in Section 5.9 (Storing the
Pump).
4.3.1
Shutdown through Monitoring

Components
When the pump has been switched off due to overheating sensed by the
motor coil protector or other monitoring components at the pump (e. g.
thermal sensor), the pump must only be started manually after the pump
has cooled down to the ambient temperature and after having removed
the cause first.
4.3.2
Caution
Warning
Controller/Mains Power Failure
In order to prevent the pump from running up unexpectedly after a mains

power failure, the pump must be integrated in the control system in such
a way that the pump can only be switched on again manually. This
applies equally to emergency cut-out arrangements.
Warning
GA01203_1102 - 07/2005
21
Maintenance
5
Warning
Maintenance
Disconnect the electrical connections before disassembling the pump.
Make absolutely sure that the pump cannot be accidentally started.
If the pump has pumped harmful substances, contrary to what has been
stated in Section 3.4, ascertain the nature of hazard and take adequate
safety measures.
Contamination
Whenever you send a pump to Leybold, indicate whether the pump is contaminated or is free of substances which could pose a health hazard. If it is
contaminated, specify exactly which substances are involved. You must
use the form we have prepared for this purpose; we will forward the form
on request.
Form
A copy of the form is printed at the end of these operating instructions:

Declaration of contamination of vacuum equipment and components.
Another suitable form is available from the Leybold homepage:
http://www.leybold.com under the headline Support & Download.
Attach the form to the pump or enclose it with the pump.
This statement detailing the contamination is required to satisfy legal requirements and for the protection of our employees.
Pumps which are not accompanied by a contamination statement will be
returned to the sender.
Caution
When disposing of used oil, you must observe the applicable environmental regulations.
Due to the design concept, TRIVAC B pumps require very little maintenance when operated under normal conditions. The work required is described
in the sections below. In addition to this, a maintenance plan is provided in
Section 5.10.
Caution
All work must be carried out by suitably trained personnel. Maintenance

or repairs carried out incorrectly will affect the life and performance of the
pump and may cause problems when filing warranty claims.
LEYBOLD offers practical courses on the maintenance, repair, and testing
of TRIVAC B pumps. Further details are available from LEYBOLD on
request.
Caution
If the TRIVAC B is used in ambient air which is much contaminated, make

sure that the air circulation and the gas ballast valve are not adversely
affected.
Pls. take the spare parts numbers from the enclosed spare parts list.
In case of special designs and variants please always indicate the special, variant and serial number.
22
GA01203_1102 - 07/2005
Maintenance
Key to Fig. 9
1 Oil-fill plug
2 Oil-level mark maximum
3 Oil-level mark minimum
4 Oil-drain plug
Fig. 9 Oil change
5.1
Checking the Oil Level
During operation of the TRIVAC B the oil level must always remain between
marks (9/2) and (9/3) on the oil-level glass. The amount of oil must be
checked and topped up as required.
Fill in oil only after the pump has been switched off.
5.1.1
Caution
Checking the Condition of N 62 or

HE 200 Oil
The ageing process for the standard operating fluid N 62 respectively

HE 200 (see Section 1.2) will depend very much on the area of application
for the pump.
a) Visual check
Normally the oil is clear and transparent. If the oil darkens, it should be
changed.
b) Chemical check
The neutralisation number of N 62 oil is determined according to DIN
51558. If it exceeds 2, the oil should be changed.
c) Viscosity check
If the viscosity of N 62 at 25 C exceeds a level of 240 mPas (20 % higher
than the viscosity of fresh oil) an oil change is recommended.
If gases or liquids dissolved in the oil result in a deterioration of the ultimate pressure, the oil can be degassed by allowing the pump to run for
approx. 30 min. with the intake port closed and the gas ballast valve open.
When wanting to check the oil, switch off the pump first and drain out from
the warm pump the required amount of oil through the oil drain (9/4) into a
beaker or similar.
Please note the safety information given in Section 5.
Caution
GA01203_1102 - 07/2005
23
Maintenance
5.2
Warning
Oil Change
Before pumping oxygen (or other highly reactive gases) at concentrations

exceeding the concentration in the atmosphere (> 21 % for oxygen) it will
be necessary to use a special pump. Such a pump will have to be modified and degreased, and an inert special lubricant (like PFPE) must be
used.
Hazardous substances may escape from the pump and the oil. Take adequate safety precautions. For example wear gloves, face protection or
breathing protection.
For proper operation of the pump, it is essential that the pump has an adequate supply of the correct and clean oil at all times.
The oil must be changed when it looks dirty or if it appears chemically or
mechanically worn out (see Section 5.1.1).
The oil should be changed after the first 100 operating hours and then at
least every 2.000 to 3.000 operating hours or after one year. At high intake
pressures and intake temperatures and/or when pumping contaminated
gases, the oil will have to be changed much more frequently.
Further oil changes should be made before and after long-term storage of
the pump.
If the oil becomes contaminated too quickly, install a dust filter and/or oil filter (see Section 1.3).
Contact us for more information in this matter.
Caution
Only change the oil after the pump has been switched off and while the
pump is still warm.
Required tool: Allen key 8 mm.
Remove the oil-drain plug (9/4) and let the used oil drain into a suitable container. When the flow of oil slows down, screw the oil-drain plug back in,
briefly switch on the pump (max. 10 s) and then switch it off again. Remove
the oil-drain plug once more and drain out the remaining oil.
Screw the oil-drain plug back in (check the gasket and reinstall a new one
if necessary).
Remove the oil-fill plug (9/1) and fill in with fresh oil.
Screw the oil-fill plug (9/1) back in.
Warning
Torques
Caution
24
GA01203_1102 - 07/2005
If there is the danger that the operating agent may present a hazard in
any way due to decomposition of the oil, or because of the media which
have been pumped, you must determine the kind of hazard and ensure
that all necessary safety precautions are taken.
Torque for the oil-fill plug (9/1):

Gasket: P/N: 239 55 165
10 Nm
Torque for the oil-drain plug (9/4):

Gasket: P/N.: 239 55 165
10 Nm
We can only guarantee that the pump operates as specified by the technical data if the lubricants recommended by us are used.
Maintenance
5.3
Cleaning the Inlet Screen
A wire-mesh sieve is located in the intake port of the pump to act as a dirt
trap for coarse particles. It should be kept clean to avoid a reduction of the
pumping speed.
For this purpose, remove the inlet screen (2/2) from the intake port and
rinse it in a suitable vessel with solvent. Then thoroughly dry it with compressed air. If the inlet screen is defective, replace it with a new one.
The cleaning intervals depend on the application. If the pump is exposed
to large amounts of abrasive materials, a dust filter should be fitted into
the intake line.
5.4
Caution
Removing and Fitting the

Internal Demister
Required tools: Allen keys 6 mm and 8 mm.

Required spare parts:
Gasket for oil case
200 09 148
Internal demister
390 26 014
The internal demister is spring-mounted in a frame. When it is clogged, it

rises periodically to reduce the pressure difference created.
The resultant noise at high intake pressures indicates that the internal
demister is dirty.
Periodically clean the internal demister; the maintenance interval depends
on the application.
Shutdown the pump and drain the oil (see Section 5.2).
Remove the six recessed screws (10/6) on the oil case (10/4). Dont
remove the non-recessed screws; they hold the motor flange in place.
Pull the oil case forward off the pump.
Remove the gasket (10/5).
Unscrew screw (10/1).
Remove small washer (10/1), spring (10/1), large washer (10/1) and O-ring
(10/1).
Lift off the frame (10/2) and remove the internal demister (10/3).
Clean all parts and check that they are in perfect condition; if not, replace
them with new parts.
Reassemble in the reverse order.
Torque for the screws (10/6) is 12 Nm.
Caution
GA01203_1102 - 07/2005
25
Maintenance
Key to Fig. 10
1 Screw with small washer, spring, large washer and O-ring
2 Frame for demister
3 Demister
4 Oil case
5 Gasket
6 Fixing screws
Fig. 10 Removal and fitting of the internal demister
Key to Fig. 11
1 Gasket
2 Coupling with fan blades
3 Hex. socket screws
4 Intermediate flange
5 Hex. socket screws
6 Electric motor
6
5
4
3
2
1
Fig. 11 Disassembly and reassembly of the electric motor
26
GA01203_1102 - 07/2005
Maintenance
5.5
Disassembly and Reassembly

of the Electric Motor
Before starting any disassembly work, always disconnect the motor from
the mains.
Reliably prevent the pump from running up.
Warning
Required tools:
Screwdriver 1.0 x 5.5 mm (for junction box), open-jaw wrenches size 7 and
size 19 (for junction box), Allan keys size 3 and size 6.
Possibly a puller for the coupling.
Disconnect the mains connection.
Support the motor.
Unscrew the four non-recessed hex. socket screws (11/5).
Remove the intermediate flange (11/4) together with the electric motor.
Loosen the threaded pin and pull the coupling with the blade wheel (11/2)
off the motor shaft.
Unscrew the hex. socket screws (11/3).
Remove the electric motor (11/6).
Clean all parts and check that they are in perfect condition; if not, replace
them with new parts.
Reassemble in the reverse order.
In the case of 60 Hz motors (USA versions) the coupling must not be pushed on to the shaft right up to the stop. On the other hand if it is not pushed on far enough the pump module may be damaged during operation.
Push the coupling on in such a way that the distance between the front
end of the coupling and the gasket (11/1) on the intermediate flange
amounts to 43.7 mm.
Caution
GA01203_1102 - 07/2005
27
Maintenance
Key to Fig. 12
1 Coupling element
2 Cylinder head screw
3 Spring washer
4 Coupling (one half)
5 Key
6 Compression ring
7 O-ring
8 Shaft seal
9 Screws
10 Centering disk
11 O-ring
12 Bushing
12
11
10
9
8
7
6
5
4
3
2
1
Fig. 12 Exchanging the shaft seal
5.6
Replacing the Shaft Seal
Required tools:
Allen keys size 3, 5 and 8, flat-nose pliers, plastic hammer, shaft seal
driver, possibly a puller for the coupling.
Required Spare Parts:
Shaft Seal
239 53 007
Bushing
231 92 034
Oil marks under the coupling housing are signs of a damaged shaft seal.
The shaft seal can be replaced without removing or disassembling the
pump module.
Shutdown the pump.
Drain the oil (see Section 5.2).
Support the motor.
Unscrew the four non-recessed hex. socket screws (11/5) and remove
the motor (11/6).
Remove gasket (11/1).
Remove coupling element (12/1).
Unscrew screw (12/2) and pull off the spring washer (12/3).
Pull off the coupling half (12/4).
Remove key (12/5).
28
GA01203_1102 - 07/2005
Maintenance
Pull off the compression ring (12/6) and O-ring (12/7).
Unscrew the hex. socket screws (12/9) and pull out the centering disc
(12/10).
If the centering disc does not come loose, use the forcing thread into which
screws (12/9) can be screwed in.
Remove the O-ring (12/11).
Force the shaft seal (12/8) out of the centering disk.
Pull off the bushing (12/12) from the shaft.
We recommend the use of a new shaft seal and bushing for reassembly.
Before fitting the new shaft seal, moisten it slightly with a little vacuum
pump oil.
Using a suitable plastic or aluminium cylinder (shaft seal driver) and a plastic hammer, force the shaft seal (12/8) carefully and without bending it into
the centering disk (for position of shaft seal, see Fig. 12).
If you do not have a shaft seal driver, place the shaft seal on the centering
disk and carefully force it in with light blows of the plastic hammer.
The shaft seal must not be bent.
Push the bushing (12/12) on to the shaft.
Insert the O-ring (12/11) into its groove.
Carefully push the centering disk (12/10) with the shaft seal onto the shaft
and up against the end plate; fasten it with the screws (12/9).
Push the O-ring (12/7) and the compression disk (12/6) on to the shaft.
Insert the key (12/5).
Mount the pump-half of the coupling (12/4) on the shaft.
Install the spring washer (12/3) and tighten the screw (12/2).
Insert the coupling element (12/1) into the coupling and mount the motor
(see Section 5.5).
GA01203_1102 - 07/2005
29
Maintenance
Key to Fig. 13
1 Hex. nuts
2 Pump module
3 Gasket
4 Coupling element
5 Tie rods
Fig. 13 Removing and Remounting the Pump Module
5.7
Removing and Remounting the

Pump Module
Required tools:
Allen keys size 3, 5, and 8 mm, box wrench size 13, possibly pliers, torque
wrench.
Required spare parts:
Gaskets
5.7.1
239 73 039
200 09 148
Removing the Pump Module
Drain the oil and remove the oil case (see Section 5.4).
Unscrew the hex. nuts (13/1).
Pull the entire pump module (13/2) forward off the tie rods (13/5).
Caution
When doing so, ensure that the individual pin-fitted parts are not loosened. Further disassembly of the pump module should only be carried out
by a trained service engineer.
Remove the coupling element (13/4).
Caution
After removing the protective shipping materials, handle the new pump
module with care.
Before installing a new pump module, remove the four tie rods from the
new module and insert them in the old one for protection during shipment.
30
GA01203_1102 - 07/2005
Maintenance
5.7.2
Remounting the Pump Module
When installing a new pump module, it is also advisable to use a new gasket (13/3).
Check the coupling element (13/4) for damage; if necessary, install a new
one.
Use the tie rods supplied with the new pump module only if the old ones
are damaged. To do so, unscrew the old tie rods with lock nuts, and screw
in the new ones. With the aid of the lock nuts, tighten the tie rods. Then
remove the lock nuts.
Push the gasket (13/3) onto the tie rods (13/5), push the coupling element
(13/4) onto one coupling half.
Push the entire pump module (new or repaired) onto the tie rods.
Screw on the hex. nuts (13/1) and carefully cross-tighten them (torque
17 Nm).
Caution
Mount the oil case together with the gasket (see Section 5.4).
Fill in oil.
5.8
Service by Leybold
Whenever you send a pump to Leybold, indicate whether the pump is contaminated or is free of substances which could pose a health hazard. If it is
contaminated, specify exactly which substances are involved. You must
use the form we have prepared for this purpose; we will forward the form
on request.
Contamination
A copy of the form is printed at the end of these operating instructions:

Declaration of contamination of vacuum equipment and components.
Another suitable form is available from the Leybold homepage:
http://www.leybold.com under the headline Support & Download.
Form
Attach the form to the pump or enclose it with the pump.

This statement detailing the contamination is required to satisfy legal requirements and for the protection of our employees.
Pumps which are not accompanied by a contamination statement will be
returned to the sender.
The pump must be packed in such a way, that it will not be damaged
during shipping and so that any contaminants are not released from the
package.
Warning
GA01203_1102 - 07/2005
31
Maintenance
5.8.1
Waste Disposal of Used Pump

Materials
The corresponding environmental and safety regulations apply. This applies

equally to used filters and filter elements (oil filter, exhaust filter and dust
filter).
Warning
In the case of hazardous substances determine the kind of hazard first

and observe the applicable safety regulations. If the potential hazard still
persists, the pump must be decontaminated before starting with any
maintenance work. For professional decontamination we recommend our
Leybold service.
Never exchange the oil or the filters while the pump is still warm. Let the
pump cool down to uncritical temperatures first. You must wear suitable
protective clothing.
5.9
Caution
Storing the Pump
Before putting a pump into operation once more it should be stored in a

dry place preferably at room temperature (20 C). Before the pump is
shelved it must be properly disconnected from the vacuum system, purged with dry nitrogen and the oil should be changed too.
The inlets and outlets of the pump must be sealed with the shipping seals
which are provided upon delivery.
The gas ballast switch must be set to the 0 position and if the pump is
to be shelved for a longer period of time it should be sealed in a PE bag
containing some desiccant (silica gel).
When a pump is put into operation after it has been shelved for over one
year, standard maintenance should be run on the pump and the oil should
also be exchanged (see Section 5.2). We recommend that you contact the
Leybold Service.
32
GA01203_1102 - 07/2005
Maintenance
5.10 Maintenance Plan

No. Rotary vane pump
TRIVAC D 40 B
TRIVAC D 65 B
Measurement/test quantity
Interval
Operating/auxiliary materials VE VP t 6m a n-a
Operate the pump for at least 0.8 h

with gas ballast.
Check the oil level,

if required change the oil.
Oil: N 62 or specialand alternative oils
Check the quality of the oil,

change the oil if required.
visually
Clean the inlet screen in the intake

port, change it as required.
(Recommendation)
Remarks
Refer also to the Operating Instructions
Section: individual components.
Condensed water is thus removed from the oil.
Refill: Only after the pump has been switched

off.
Visually: normally light and transparent, oil

change is required when discolorations increase.
chemically
Chemically: to DIN 51558, when the

neutralisation number exceeds 2; then an oil
change will be required.
mechanically
Mechanically: when dynamic viscosity at 25 C

exceeds 240 mPas; then an oil change will be
required.
Disposal of waste oil: see Section: 5.8.1
Suitable cleaning agent and

compressed air.
Clean inlet screen with a cleaning agent and

blow it out with compressed air under a suction
hood.
Replace the defective inlet screen.
Use a cleaning agent which complies with the
national/international specifications.
Observe the safety regulations when using
cleaning agents.
Clean the internal demister,

change it as required.
Suitable cleaning agent.
Already clean before the maintenance

interval has elapsed when the noise level
increases.
Clean internal demister with cleaning agent
Replace the defective internal demister
Dispose of the defective internal demister as
special waste.
Cleaning agent according to
national/international specifications.
Observe the safety regulations when using
cleaning agents.
Check the edges of the teeth on

the coupling element for any
damages, change the coupling
element as required.
Change the oil -
Oil: N 62 or specialand alternative oils
and
clean the oil level glass.
Suitable cleaning agent

and compressed air.
Check the fan of the pump and

motor as well as the cooling fins
Brush and industrial vacuum

cleaner.
Key to maintenance plan

VE = Maintenance before switching on
the system
VP = Maintenance before starting
production
t = Daily maintenance
6m = Six monthly maintenance
a = Annual maintenance
n-a = Maintenance every n years
Oil change:
First oil change after 100 operating hours.
Pump switched off and cold.
Exchange the oil while the pump is cold
so as to avoid releasing adsorbed gases.
Clean the oil level glass with a cleaning agent
and blow it out with compressed air under a
suction hood.
Use cleaning agents only corresponding to
the national/international specifications.
Quantity of oil: see Section 1.4
Oil disposal: see Section 5.8.1.
Already clean before the maintenance interval

has elapsed when the pump or the motor gets
too warm.
Caution: switch off the pump and ensure that
it cannot run inadvertently (disconnect from the
mains).
We recommend that you service the pump

every two years covering the following:
Cleaning
Checking the individual components
Exchange of all seals
Functional check
This check should be run by the Leybold
Service.
GA01203_1102 - 07/2005
33
Troubleshooting
Troubleshooting
Fault
Pump does not
start.
Pump does not

reach ultimate
pressure.
Pumping speed is
too low.
After switching off

the pump under
vacuum, pressure
in the system
rises too fast.
Pump gets hotter
than usually
observed.
Oil in the intake line

or in the vacuum
vessel.
Oil is turbid.
Pump is excessively
noisy.
Pump shuts down

after a few minutes
with very high motor
temperature or with
a very high current
uptake (> 15 A).
Possible cause
Wiring is malfunctioning.
Motor protection switch incorrectly set
(three-phase motors only).
Operating voltage does not match motor.
Motor is malfunctioning.
Oil temperature is below 12 C.
Oil is too thick.
Exhaust filter/exhaust line is clogged.
Pump is seized up (sign: pump is jammed).
Measuring technique or gauge is unsuitable.
External leak1).
Anti-suckback valve is malfunctioning.
Exhaust valve is malfunctioning.
Oil is unsuitable.
Vacuum lines are dirty.
Pump is too small.
Inlet screen in the intake port is clogged.
Exhaust filter is clogged.
Connecting lines are too narrow or too long.
System has a leak.
Anti-suckback valve is malfunctioning.
Cooling air supply is obstructed.

Ambient temperature is too high.
Process gas is too hot.
Oil level is too low.
Oil is unsuitable.
Oil cycle is obstructed.
Exhaust filter/exhaust line is obstructed.
Exhaust valve is malfunctioning.
Pump module is worn out.
Deviating mains voltage.
Oil comes from the vacuum system.
Anti-suckback valve is blocked.
Sealing surfaces of the anti-suckback valve are
damaged or dirty.
Oil level is too high.
Condensation.
Oil level is much too low (oil level is no longer visible).
Silencing nozzle is clogged.
Intake pressure is too high.
Internal demister is clogged.
Coupling element is worn.
Vanes or bearings are damaged.
Relay does not switch off the start-up capacitor
(voltage too low).
Remedy
Check and repair wiring.
Set motor protection switch properly.
Repair
3.3
Replace the motor.

Replace the motor.
Heat the pump and pump oil or use a different oil.
Change the oil.
Replace the filter or clean the exhaust line.
Repair the pump.
Use correct measuring technique and gauge.
Measure the pressure directly at the pumps intake port.
Repair the pump.
Repair the valve.
Repair the valve.
Change the oil (degas it, if necessary).
Clean the vacuum lines.
Check the process data, replace the pump, if necessary.
Clean the inlet screen.
Precaution: install a dust filter in the intake line.
Install new filter element.
Use adequately wide and short connecting lines.
Check the system.
Repair the valve.
4.2
4.2
4.2.3/5.2
5.2
Service
-
Set pump up correctly.

Set pump up correctly.
Change the process.
Add oil.
Change the oil.
Clean or repair the oil lines and channels.
Replace the exhaust filter, clean the exhaust line.
Repair the valve.
Replace the pump module.
Check the motor voltage and check available mains voltage.
Check the vacuum system.
Clean or repair the anti-suckback valve.
Clean or repair intake and anti-suckback valve
3.1
3.1/4.2.3
5.1
5.2
Service
Service
5.7
Drain out excess oil.

Degas the oil or change the oil and clean the pump.
Precaution: open the gas ballast valve or fit separator.
Add oil.
Clean the silencing nozzle or replace it.
Lower the intake pressure.
Clean or replace demister.
Install new coupling element.
Repair pump.
Let the motor cool down (for at least 10 minutes).
Ensure correct power supply voltage (218-242 V).
5.1
4.2.2/5.2
Service
Service
Service
5.2
5.3
3.2
Service
Service
Service
5.1/5.2
Fig. 10
5.4
5.5/5.6
Service
* Repair information: Refer to the stated section in these Operating Instructions.

1) Bubble test: The warm pump with degassed oil is running without gas ballast and the intake is blanked off. The exhaust line is led into a vessel with water.
If an evenly spaced line of bubbles appears then the pump has an external leak.
34
GA01203_1102 - 07/2005
Spare Parts
Spare Parts
The spare parts for your vacuum pump are listed in the spare parts list
enclosed with the product.
GA01203_1102 - 07/2005
35
EEC-Declaration of
Conformity
We - LEYBOLD Vacuum GmbH - here with declare that the products defined below meet the basic requirements
regarding safety and health of the relevant EC directives by design, type and versions which are brought into circulation by us.
In case of any product changes made without our approval, this declaration will be void.
Designation of the products: Rotary vane vacuum pump
Types:
TRIVAC D 40 B / D 65 B
Cat. No.:
113 47; 113 57
The products conform to the following directives:

EC Directive on Machinery (98/37/EG)
EC Directive on Low-Voltages (73/23)+(93/68/EG)
EC EMC Directive (89/336/EG)/(91/263/EG)/(92/31/EWG)/(93/68/EG)
Applied harmonised standards:

EN 1012 - 2
1996
EN 60204 - 1
1997
EN 60034 - 1/A1/A2/A11
2002
Cologne, 01.07.2005
Cologne, 01.07.2005
Marcus Eisenhuth
Member of the Management Board
Head of Product Development
Wolfgang Giebmanns
Head of Design
Forevacuum Pump Design
vacuum
Leybold Vacuum GmbH
Bonner Strae 498
D-50968 Cologne
Tel.:
++49 (0)221 347-0
Fax:
++49 (0)221 347-1250
documentation@leybold.com
36
GA01203_1102 - 07/2005
www.leybold.com
EEC Manufacturers Declaration

in the sense of the Directive on Machinery 89/392/EWG, Annex IIb
We Leybold Vacuum GmbH herewith declare that operation of the incomplete machine defined below, is not
permissible until it has been determined that the machine into which this incomplete machine is to be installed,
meets the regulations of the EEC Directive on Machinery.
Designation of the Products: Rotary vane pump - dual stage
Types:
TRIVAC D 40 B without Motor / D 65 B without Motor
Cat. - Nos.:
113 46; 113 56
Applied harmonized Standards:

EN 1012 - 2
1996
Cologne, 01.07.2005
Cologne, 01.07.2005
Marcus Eisenhuth
Member of the Management Board
Head of Product Development
Wolfgang Giebmanns
Head of Design
Forevacuum Pump Design
vacuum
Leybold Vacuum GmbH
Bonner Strae 498
D-50968 Cologne
Tel.:
++49 (0)221 347-0
Fax:
++49 (0)221 347-1250
documentation@leybold.com
www.leybold.com
GA01203_1102 - 07/2005
37
vacuum
Declaration of Contamination of Compressors, Vacuum Pumps and Components

The repair and / or servicing of compressors, vacuum pumps and components will be carried out only if a correctly completed declaration has been submitted. Non-completion will result in delay. The manufacturer can refuse to accept any equipment without a declaration.
A separate declaration has to be completed for every single component.
This declaration may be completed and signed only by authorised and qualified staff.
Customer/Dep./Institute: ________________________________
Reason for returning
___________________________________________________
repair
Address
___________________________________________
replacement
___________________________________________
DKD-calibration
Person to contact:
Phone:
___________________________________
__________________ Fax: __________________
Order number of customer:
______________________________
A. Description of the equipment (machine or component)
applicable please mark
chargeable
warranty
chargeable
warranty
Factory calibration
Returning of goods because of following reason:

rent/loan
for credit
against exchange
exchange already received/arranged

Ancillary equipment
Type:
_______________________________________
__________________________________________________
Part number:
_______________________________________
__________________________________________________
Serial number:
_______________________________________
__________________________________________________
Type of oil used:
_______________________________________
__________________________________________________
B. Condition of the equipment

No
1.
2.
3.
4.
Has the equipment been used

Drained (Product/service fluid)
All openings sealed airtight
Purged
If yes which cleaning agent:
and which method of cleaning:
Yes
No
_______________________________________
_______________________________________
Contamination:
toxic
corrosive
microbiological
explosive
radioactive
other harmful substances
No
Yes
C. Description of processed substances (Please fill in absolutely)

1. What substances have come into contact with the equipment:
Trade name and / or chemical term of service fluids and substances processed, properties of the substances; According to safety data sheet
(e.g. toxic, inflammable, corrosive, radioactive)
Trade name:
Chemical name:
Residues:
a) ____________________________________________________________________________________
Yes
No
b) ____________________________________________________________________________________
Yes
No
c) ____________________________________________________________________________________
Yes
No
d) ____________________________________________________________________________________
Yes
No
2. Are these substances harmful?
3. Dangerous decomposition products when thermally loaded
Which:
Yes
No
Components contaminated by microbiological, explosive or radioactive products will not be accepted

without written evidence of decontamination.
D. Legally binding declaration
I / we hereby declare that the information supplied on this form is accurate and sufficient to judge any contamination level.
Name of authorised person (block letters):
____________________________
Date _____________ Signature of authorised person

Leybold Vacuum Kln
38
GA01203_1102 - 07/2005
___________________________
Company stamp
Notes
GA01203_1102 - 07/2005
39
Sales and Service Net Worldwide

Germany
Leybold Vacuum GmbH
Bonner Strasse 498
D-50968 Cologne
Phone: +49-221-347 1234
Fax:
+49-221-347 1245
sales@leybold.com
Leybold Vacuum GmbH
Sales Area North/East
Branch office Berlin
Buschkrugallee 33
1. Obergeschoss
D-12359 Berlin
Phone: +49-30-435 609 0
Fax:
+49-30-435 609 10
sales.berlin@leybold.com
Leybold Vacuum GmbH
Sales Area South/Southwest
Branch office Munic
Karl-Hammerschmidt-Strasse 38
D-85609 Aschheim/Dornach
Phone: +49-89-357 33 90
Fax:
+49-89-357 33 933
sales.muenchen@leybold.com
service.muenchen@leybold.com
Leybold Vacuum GmbH
Sales Area West
Branch office Cologne
Emil-Hoffmann-Strae 43
D-50996 Cologne-Suerth
Phone: +49-221-347 1270
Fax:
+49-221-347 1291
sales.koeln@leybold.com
Leybold Vacuum GmbH
Service Center
Phone: +49-221-347 1439
Fax:
+49-221-347 1945
service@leybold.com
Leybold Vacuum GmbH
Mobile after sales service
Phone: +49-221-347 1765
Fax:
+49-221-347 1944
kundendienst@leybold.com
Leybold Vacuum
Dresden GmbH
Zur Wetterwarte 50, Haus 304
D-01109 Dresden
Service:
Phone: +49-351-88 55 00
Fax:
+49-351-88 55 041
info@leybold-dresden.de
www.leybold-dresden.de
Europe
Belgium
Leybold Vacuum Nederland B.V.
Belgisch bijkantoor
Leuvensesteenweg 542-9A
B-1930 Zaventem
Sales:
Phone: +32-2-711 00 83
Fax:
+32-2-720 83 38
sales.belgium@leybold.com
Service:
Phone: +32-2-711 00 82
Fax:
+32-2-720 83 38
service.belgium@leybold.com
France
Leybold Vacuum France S.A.
7, Avenue du Qubec
Z.A. de Courtaboeuf, B.P. 42
F-91942 Courtaboeuf Cedex
Sales and Service:
Phone: +33-1-69 82 48 00
Fax:
+33-1-69 07 57 38
sales.france@leybold.com
Leybold Vacuum France S.A.
Valence Factory
640, Rue A. Bergs - B.P. 107
F-26501 Bourg-ls-Valence Cedex
Phone: +33-4-75 82 33 00
Fax:
+33-4-75 82 92 69
marketing.valence@leybold.fr
Great Britain
Leybold Vacuum UK Ltd.
Waterside Way, Plough Lane
GB-London SW17 0HB
Sales:
Phone: +44-20-8971 7000
Fax:
+44-20-8971 7001
sales@leybold.com
Service:
Phone: +44-20-8971 7030
Fax:
+44-20-8971 7003
service@leybold.com
Italy
Leybold Vacuum Italia S.p.A.
8, Via Trasimeno
I-20128 Milano
Sales:
Phone: +39-02-27 22 31
Fax:
+39-02-27 20 96 41
sales@leybold.it
Service:
Phone: +39-02-27 22 31
Fax:
+39-02-27 20 96 41
service@leybold.it
Field Service Base
Z.I.Le Capanne
I-05021 Acquasparta (TR)
Phone: +39-0744-93 03 93
Fax:
+39-0744-94 42 87
service@leybold.it
Hotline
Sales: +49-221-347 1234
Service: +49-221-347 1765
Asia
Netherlands
P.R. China
Japan
Leybold Vacuum Nederland B.V.

Computerweg 7
NL-3542 DP Utrecht
Sales and Service:
Phone: +31-346-58 39 99
Fax:
+31-346-58 39 90
sales.netherlands@leybold.com
service.netherlands@leybold.com
Spain
Leybold Vacuum (Tianjin)

International Trade Co., Ltd.
Beichen Economic
Development Area (BEDA),
No. 8 Western Shuangchen Road
Tianjin 300400, China
Sales and Service:
Phone: +86-22-2697 0808
Fax:
+86-22-2697 4061
Fax:
+86-22-2697 2017
leybold@leybold.com.cn
Leybold Vacuum
Japan Co., Ltd.
Head Office
Tobu A.K. Bldg. 4th Floor
23-3, Shin-Yokohama
3-chome
Kohoku-ku, Yokohama-shi
Kanagawa-ken 222-0033
Sales:
Phone: +81-45-4713330
Fax:
+81-45-4713323
Leybold Vacuum Espaa S.A.

C/. Huelva, 7
E-08940 Cornella de Llobregat
(Barcelona)
Sales:
Phone: +34-93-666 46 16
Fax:
+34-93-666 43 70
sales.spain@leybold.com
Service:
Phone: +34-93-666 49 51
Fax:
+34-93-685 40 10

Equipment Manufacturing Co., Ltd.
Beichen Economic
Development Area (BEDA),
No. 8 Western Shuangchen Road
Tianjin 300400, China
Phone: +86-22-2697 0808
Fax:
+86-22-2697 4061
Fax:
+86-22-2697 2017
leybold@leybold.com.cn
Leybold Vacuum
Japan Co., Ltd.
Osaka Branch Office
MURATA Bldg. 7F
2-7-53, Nihi-Miyahara
Yodogawa-ku
Osaka-shi 532-0004
Sales:
Phone: +81-6-6393-5211
Fax:
+81-6-6393-5215

Beijing Branch:
1-908, Beijing Landmark Towers
8 North Dongsanhuan Road
Chaoyang District
Beijing 100004, China
Sales and Service:
Phone: +86-10-6590-7607
Fax:
+86-10-6590-7622
Leybold Vacuum
Japan Co., Ltd.
Tsukuba Technical S.C.
Tsukuba Minami Daiichi
Kogyo Danchi
21, Kasumi-no-Sato,
Ami-machi, Inashiki-gun
Ibaraki-ken, 300-0315
Service:
Phone: +81-298-89-2841
Fax:
+81-298-89-2838
Sweden
Leybold Vacuum Scandinavia AB
Box 9084
SE-40092 Gteborg
Sales and Service:
Phone: +46-31-68 84 70
Fax:
+46-31-68 39 39
info@leybold.se
Visiting/delivery address:
Datavgen 57B
SE-43632 Askim
Switzerland
Leybold Vacuum Schweiz AG
Leutschenbachstrasse 55
CH-8050 Zrich
Sales:
Phone: +41-1-308 40 50
Fax:
+41-1-302 43 73
sales@leybold.ch
Service:
Phone: +41-1-308 40 62
Fax:
+41-1-308 40 60
America
USA
Leybold Vacuum USA Inc.
5700 Mellon Road
Export, PA 15632
info@leyboldvacuum.com
Sales:
Eastern & Central time zones
Phone: +1-724-327-5700
Fax:
+1-724-733-1217
Pacific, Mountain,
Alaskan & Hawaiian time zones
Phone: +1-480-752-9191
Fax:
+1-480-752-9494
Service:
Phone: +1-724-327-5700
Fax:
+1-724-733-3799

Shanghai Branch:
Add: No. 33, 76 Futedong San
Rd., Waigaoqiao FTZ ,
Shanghai 200131, China
Sales and Service:
Phone: +86-21-5064-4666
Fax:
+86-21-5064-4668
leybold_sh@leybold.com.cn
Guangzhou Branch:
Add: G/F,#301 Building,
110 Dongguangzhuang Rd.
Tianhe District,
Guangzhou 510610, China
Sales:
Phone: +86-20-8723-7873
Phone: +86-20-8723-7597
Fax:
+86-20-8723-7875
leybold_gz@leybold.com.cn
India
Leybold Vacuum India Pvt Ltd.
A-215 Road No. 30
MIDC Wagle Industrial Estate
Thane(W) - 400 604 Maharashtra
India
Sales and Service:
Phone: +91-22-2581 2929
Fax:
+91-22-2581 2626
ivt2004@yahoo.com
Korea
Leybold Vacuum Korea Ltd.
#761-4, Yulkeum-ri,
SungHwan-eup, Cheonan-City
Choongchung-Namdo,
330-807, Korea
Sales:
Phone: +82-41-580-4420
Fax:
+82-41-588-3737
Service:
Phone: +82-41-580-4415
Fax:
+82-41-588-3737
Singapore
Leybold Vacuum
Singapore Pte Ltd.
No.1, International
Business Park,
B1-20B, The Synergy
Singapore 609917
Sales and Service:
Phone: +65-66652910
Fax:
+65-65668202
vacuum@leyboldvac.com.sg
Taiwan
Leybold Vacuum Taiwan Ltd.
No 416-1, Sec. 3
Chung-Hsin Rd., Chu-Tung
Hsin-Chu, Taiwan, R.O.C.
Sales and Service:
Phone: +886-3-5833988
Fax:
+886-3-5833999
LV_07885_2005
07.05
sales@leybold.com
service@leybold.com
Leybold Vacuum Products Inc.

5700 Mellon Road
Export, PA. 15632-8900
Phone: 724-327-5700
Fax:
724-325-3577
info@leyboldvacuum.com
Leybold Vacuum GmbH

Bonner Strasse 498
D-50968 Cologne
Phone: +49-221 347- 0
Fax:
+49-221 347-1250
info@leybold.com
vacuum
www.leybold.com
@rlikon
leyboldvacuum
TRIVAC@B
D40BundD6SB
Ersatzteilliste
/ SparePartsListET01203_14
Drehschieber-Vakuumpumpe
RotaryVaneVacuumPump
Pompe rotative vide palettes
Gltigab: 1. Oktober2005 - ersetztallebisherigenVersionen

Validfrom:October1, 2005 - replacesall previousversions
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OPERATING INSTRUCTIONS
GAO1299_0802
AF 1,6.14-8.116.25140-65
AK 1,614-an6.2514o-65
Exhaust Filters
Condensate Trap
Cat.-No.
18902/06/11/16
18802106/11/16
r-Leybold
VACUUTN
Contsnts
Scon
1
t.l
::
"""";;;..............................................:.
Designand Function. , , . ,
, . , , . , . , . , . , , , . . . . .3
T c h n i s cDhaatl a . , , . , , . ,
, , , , . , , , , . , . , . . , . , .4
l t l l . o n. , . . . . . , . . .
,. ,.. .. .. .. .. .. .,. .8
Mounting
AK 1,6undAF1,6 . . .. . . . .. .. . . . . . . . . . . .. . . . . . . . . . . . . . . .6
2.2
MourtingAVAF4-8,1&25 und50-65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
l r a i n tn r n c o... . , . . , . .
3.1
Exhaust-Fihs6
3.2
condensatTreps,. , , . . .
. , , , , . , . , . , . , . . . . . .9
3.3
Swicat Leyboldb. . . . .
. . . . . . . . . . . . . . . . . . 10
f.eybold
... ... .. ,. ,. ,,. . ,. .a

...........................8
SMce
f a pump is returnd to Leybold indicate whethe. the pump is fre of sub-
stancsdamaging
to halthor whtherit is contaminated.
f it is contaminated
alsoindicateth naturol the hazard.Leyboldmust
retumarrypumpsMhout a 'Dedaration
of Contamination'
to thesnderb
aooress.
Dlaposal of lr'l,este Oll
O^,nersof wasteoil areentirelysef-responsible
for properdisposalof this
waste.
Wastoilfromvacuumpumpsmustnotbe mixedwithothrsubstancs
or
matrials.
Wasteoil fromvacuumpumps(Leyboldoilswhicharc basedon mineral
o s)whicharsubiectto nomalwsarandlvhicharecontaminated
dueto
the infuenceof orygnin the air,hightemperaturcs
or mechanical
wear
mustbedisposd
ofthroughthelocallyavailable
wasteoildisposaisystem.
Wasteoil tom wcuum pumpswhichis contaminated
with othersubstancesmustbe ma*dandstoredin sucha waythatthetypeol contaminationis apparit.Thiswastmustb disposedof asspecialwaste.
European,nationaland regionalregulations
concrningwastedisposal
needto be ohserved.
Wastemustonlybtransported
anddisposedof by
anapproved
wastedis@salvendor
Figu.ss
The referencsto diagrams,.9. (1/2)consistof the Fig. No. and the ltem
No. in that order.
We reservethe right to modifythe design and the specifieddata. The
illustrationsare not binding.
- oerzoou
looorzee-oeoz
Descrlpon
The icon indicatesprocedurasthat must be strictly observedto prevent Waming
This specialjcon wams about dangerscausd by high electdcvoftages. Wamlng

Touchingpartsat a highvoftagecan rcsultin immediatedeath.
Coverswhich are markedwith this icon must only be removedby trained
electdciansafter havingreliablydisconnectedthe electdcpowersource.
Indicatespoceduresthat muststrictlybe observedto preventdamageto,
or destruqtionof th ouioment.
A
Caution
Emphasisesadditionalapplicationinformationand other usetulinformation Not

povided withintheseOperatingInstructions.
Description
1.1
Design and Function
Exhauat-Flltr
In the exhaustfiltersoil mistand arosolsaretrapped,whereaseasilyvolatile substancesand aromaticspassthroughthe filtr
The gas dischargedby the vacuumpumpiows though the flter element
wheresmallestoil dropsand dirt particelscontainedin the gasarekapped.
Thesoaratedoil droosare collectedin the exhaustftter.
In the exhaustflter AF 40-65two filterlementsare aranged in parallel.
Filterelernentsmay get cloggedin the long run due to crack productsin
the oil, and this may causeoverpressure
to build up in the pump. In order
to makesurethat the pressurewill not exceedan admissiblevalue(approx.
1.5 ba4 a pressurereliefvaNis providedon the exhaustflter.
lf the ffterelementshouldhavebecomeclogged,thebuiltinpressurerelief
vave opensso that the oil mistexpelledby the pumpis conductedinto the
open air In this way any damagewhich might be causedby overpressure
is salelyexcluded.
*or""" o"o"- o"r.ooul3
Dsscription
Waming
An exhaust line fulfillingthe safety requirementsconcmed is

imprativeff poisonousgassor vapoursare flterd.
A,
Obsrvethe applicablesafetyregulationsfor the mediawhichare

Dumod.
Condenagtg
TFapa
condensatetraps rnountdinto the intake line protct the pump from

condensateswhichmightresultfrom the pumpedvaporsand gases.
Condensatetraps mountedinto the exhaustlineprotect againstbackllow
of liquidswhichmightcondensin the outltline.
Condensatetrapscan be frttedoptionallyon the intakeanc/or exhaustside
of a TRIVAC
oumo.
1.2
Technlnl
Data
AF iO-65
AF I,5
AF 4.4
aF 16-25
Usdon pump
s/D 1,6B
SD4B
9D8B
s,D40&cs
9D 65StsCS
Connctingianges
DN 16 KF
DN 16 KF
s/D 16B/BCS
s/D 25 B/BCS
DN25KF
0.1|
0.37|
0.48t
1 . 0|
Wsight
0.9 kg
2.4 kS
2.4 kg
6.5 kg
E{|aust flti cal, no,
149M
18906
1 8 91 1
18916
Sparefller lment,cal, no.
18970
18971
149 72
18973 (2x)
Erhauat-Fillor
Sepratot
aK lr5
AK 4
aK tE-25
DN40 KF
AK,l{F05
lJsdon pump
S/D1,6B
S'/D4B
M)88
S,D 16 B/BCS
S/D 25 B/BCS
s/D 40 B/EICS
S/D 65 B/BGS
Connctingflanges
DN 16 KF
DN 16 KF
DN25 KF
DN40 KF
0.16|
0.66|
1 . 2|
3.0 |
Wight
0.7 kg
1.7kg
2.4 kg
5.5 kg
Spar6,cat, rr,
18402
18806
1 8 81 1
18416
Draintap
18890
18890
18890
18490
Drajnlap, vcuum-tighl
18891
18891
18891
18891
Centringdng
18326
18326
18327
18328
Clampingnng
18341
18341
14342
18343
AccBaoriea
o lo*rr""-0"0,- o"r.oo"
E escrlpon
Fig. 1 UffiddEl
dEwirs of th xha!$ ntrs, saparator sihilar, dirE '!io.'s in mm (jnch)
K.y to Fl!. 2
2 E husttnrAF1,6
Frg.2 CoilctDn or ih spratorAK 1.6 snd 1orhaJsi fr[r AF 1.6 to TFTVAC
$D 1 6 B
- os/2oosl5
GAol2ee-oso2
lnstallaon
lnstallation
2.1
Mounting AK 1.6 and AF 1,6
Removeinlet andlor outlet port connection,as requid, on top of pump

body,undoingtwo each hexsocket headscrews{Allenscrws},
The sameconnectionare thenfitted on top of connectedintake-sidecondensattrap or exhaust-sideflter Mounttrap and/orffter on the pump by
the counterffangat the undersideof the connectingyoke.
The ncessaryO-ringand two addtionalAllenscrewsaresuppliedwith the
trap and filter.
lf the TRIVACs'/D '1.6 B pumpis usedwith condensatetrap only,the lower
part of the M 1.6 may be tumed round to facilitate condensatelevel-checking,
un-screwingthe two Allenscrewsthroughthe uppryoke.
The coolingribs of the AK '1.6 arc theby placeddirectlyoppositeto those
of the pump, \,vhilethe inspectionwindow together with the oil level
indictorof the pump,can be checkedat a glance.
2.2
Caution
Mouriling AKIAF 4-8, 1fi-25

and uK)-65
The directionof flow is markedby an anow and must be observed when connctingthe filter
As shown in Flg. 3, fit the exhaustflter or the separatordireqtlyon the

horizontallymountediange of the TRIVAC.Forconnctionfttings referto
'1
Sction .2.
Whenaromaticvaporsare pumped,ws recommendfittingan exhaustline
evenin caseof optionallymountedexhaustflters.
Waming
Whentoxic gasesor vaporsare pumped,an exhaustlinemust be

fitted in accor-dancewiththe safetyregulationsrelatingto protection againstpoisonousvapors.
After mountingto the pump, adiust the supportingscrew of AF 40-65

exhaustilter and AK 40-65 condensatetrap so that it is fimty positioned
on the pumphousing,
thussupporting
the connected
component.
Caution
Iooorrnn-*o,o"rroo"
Theconnectingiange facesmust be in parallelto eachother- no

tilting!
lnstallaon
K.y iD Flg. 3
1 Aofison filtrnang
3 Ofainplug
Fig.3
x.t
1
2
3
Fig.4
TFMACEtary vanvacuumpumpwlih xhalst filt.fttd on
to Flg.4
Bolb on fne| iang
Levlgiass
ain plug
IFIVAC toiary!m vacuumpumpwith condensaiolrap fn6d on
- os/2oosl
7
GAo129e-oso2
Malntenance
Fig,5
IBIVACElary !?r| lacuum pumpwith oxhausinltrand condensatotrap nttdd
Maintenance
Caution
@A
@@
Hazardoussubstancesmayescapelrom the filter,condensateor

the oil.
Take suitableprcautions(e. L gloves,goggles or gas mask).
Observeall safetyrgulations.
3.1
E)aust Filters/Draining
the Oil
Theihered-outquantityof oil mustbe drainedfromthe ilter at regrlaf intervalsdepending

on the operating
conditions
of the pump.Forthispurpose
unscrewoil drainplug (3/3).
The oil must not riseabovethe cntreof the oil levelglass(3/2).At higher
oil levelthe filterelementsmaybe iooded causingoil dropsto be entrained
by the gas stream.
ADartftom this reductionof the effectiveiltr area will increasethe differentialprcssurewhich mightcausthe pressurereliefvalveto open.
- o",roou
a j ooorrnn-o"o"
Malntenanc
Re9lacamnt of fltor elelnnt3
Th fltr elmntsmust be replacedfrom time to time. The time interval
dependson th applicationand the operatingconditionsof the vacuum
pump.The higherthe degc of contamination
dudngoperation
and the
hotter th pump, the shorterthe time intorvalfor replacingthe fltr elements.
Theyshouldb replacedin anycasif the pressurereliefvalveopenswhile
the oil has beenduly drajnedfom the flter
For replacingthe flter elementsshut dovvnthe pump.
Drainthe oil (3i/3)and reinsertthe oil drainplug.
Supportthe filter housingby placing,say,woodenstdpsunderneath.
Remove4 screws(3/1)and put downthe flter housing.
Loosn th small-iange @nnectionsto the pump's exhaust port and
exhaustlinand rmovethe lid.
Replacthe usdfilterelementswith new ones.Makesurethat the vulcanisedon seal of the filterelementsis seatedin the conteringgroovein the
nougng@ver.
Vvhendisposingof used oil and spent filter elements,please
protectionregulations.
obseryethe relevantnvironmental
Caulion
Mountthe housinglid btwenthe pump's exhaustport and line.

Rscrewthe flter lid with a gasketthat is in perfectcondition.
The startingtorqueof the scws is 5 Nm.
3.2 Condensate Thaps

The accumulatingcondensatemustbe draindat regularintervals(depenpumps).
of theTRIVAC
dingon the application
unscrewthe drainplug (4/3)and drainthe condensate.
lf the condensatelevelin the trap is too high- liquidlevelvisiblein the inspectionwindow(4/2)- it mayiow back into the pump afiectingits operation severely.
- os/2oo5l
9
GAot299-oso2
Malntenance
3.3
Letold
Srv|ce
lf quipmbnt
is returnd
to Let/bold,
indicatewhethertheequipment
fieof
substances
damaging
to healthor whetherit is contaminatd,
tf it is contaminatd
alsoindicate
thenatureof thehazard.Forthisyoumust
usea formwhichhasbeenplsparedby us whichwe will provideupon
request.
A copy of this form is rproducedat the end of thes Operating
Instuctions:'Declaration
of Contamination
ol Vacuumlnsfumntsand
Components'.
Ploaseattachthisformto theequipment
or encloseit withthequipmert.
Thisdeclaration
of contamination
is rquiredto meetGermanLawandto
protectourprsonnei.
Lyboldmust return any equipmentwithout a 'Declarationof
Contamination'
to thesendrbaddrcss.
Wlmlng
lO
- or2oo5
lcaol2ss_oso2
Thequipment
mustbe packedin sucha way,thatit willnot b
damagddudngshippingandso thatanycontaminants
arenot
releasd
froanthepackage.
r\
r-Leybold
vacuut-t't
Declarali0n
ol Contaminalion
0f C0mpress0rs,
Vacuum
Pumps
andComp0nenls
pumps
wllbecafiled
hasbeen
subThepairand/or
serycing
olcompressors,
vacuum
andcomponenls
outonlyil acorreclly
compleled
declaElion
manulmlurercan
reluse
wilhout
adecLaElion.
milled.
l{on-complatlon
slllrlsllInd6layThe
loaccepl
anyequipmenl
lor.v6rysingle
comporcnl.
A s$araladadahllon
[aalota camplaLd
Tlris
may
andsigned
only
byaulhorised
andqualilied
stafi.
declaralion
becomphted
pl8emr*
Ra,aor
forrrluml|lo E epplicable
Cuslome/Dep.,4n$ilule
O warranly
O repairO charoe3ble
Address
O chargeable
O \|larranly
A repacemenl
O DKD-ca
iblal
0n O Faclofy
cllibralion
Person
lo conlacl
Ralm100
ol00oda
bacraa
ollollorln!ruaaon:
Phone:
O rcnvloan
O lorcredil
O aoainslerchanoe
order
number
olcustomer:
O exchangs
already
received/afianoed
A.Dascrlpllon
olItr aqullma(machlnr
orcompona
l
Type:
Parl
nurnber:
Seria
number
Type
oloi used:
Ancillary
equipmenl
Condilion
ol tio eqipment
L Haslheequpmenl
been
used
(Producvseft
iceiluid)
2. Drained
ainlohl
3. AILopenings
seahd
4. Purged
ll yeswiichcleanin0
aoenl:
melhod
andwhich
ofcleanino:
NO
Yes
o
o
o
o
NO
Conlamlnrllon:
loxrc
No
o
o
o
microbiological
o
radioaclive
o
olher
harmiul
subslances o
o
o
Yes
o
o
o
o
o
o
(Plirie lill ir ehsollely)

C. Dascrlptlo0
ol proclssldaubalrncls
1.Whalsubslances
have
come
rntocontacl
wilhlheeouioment:
processed,
propenles
lludsandsubslances
losahly
data
sheet
Trade
name
and/ 0rchemica
lermolservice
olthesubshncesiAccording
(e.q.
loxic,
inilamrnable
cofiosive,
dioaclive)
ladename:
Chemicalname:
Besidues:
O YesONo
a)
b)
O YesONo
c)
O YesONo
BYes ONo
d)
harmiul?
2. Are
lhese
sub$ances
prcducts
decomposilion
lvhen
lherma
lyloaded
3. Dangefous
Yes
No
o
o
o
o
Which:
prcdcls
erplosive
radioaclive
vill nolboaccaplrd
componrnL
conlamlnrlad
!y micrchiologic.l,
*llhodsrlllln rvidenca
0l dsconlemiralion,
I
I
I
D. $sany
u.
klilly srNrnu
hi|ldir0oEcrdrdtrutr
declaElion
|/ve hereht
l/ve
herehtdeclaru
declarc
lhatlhe
lhrl
theInlor
lilomatlonsrDpllod
onlhli lo|mla acrural!andiulficianllo id!6ery co emimlionlevel.
peon
(block
leller$
Name
oiaulhorised
Dale
peon
Sgnalure
olaulhorised
Companyslamp
Kln
O Leybo
d Vacuurn
*0,a"" ouo,- o"r"ooulrt
Sales and Service Net Worldwide

Ggrmany
Pho6: +49-22i-347
1234
+49 221 U7 1245
Fu
Pho: +.4S'30.4355090
Fa:
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Europg
Asla
LrboldV&uum N.d.dard B,V frbold \r.@um N.d.n nd B.V. Lrbold V&uud fri&ji.)
f m.riond ldd. Co., Lld.
LMnsslMwS 5.42'94
Ele!opme A@ (BEETA)
No I WanernShu&g.hs F@d
Pho: +31 346 5a 39 99
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Kdroku-ku.Yokoham shi
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eles bererum@blt4ld.com
Phore +46-22-26s7moa
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6m
F:
+6-22.26914c61
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bybold Vacuuh E p.n. S-A

E.08940Cornrad LJob6gai
t ybold Vadum F|!,E S-4"

Sal6 A South/SouthGt
Kad'Hanmhm dl'$re
3a
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Ptb: +.49-49-357
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$6-22-2697 2017
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F.265O1
Bdreb'\k r C6dx
Phore: +33 4-75 32 33 m
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Add: No. 33, 76 Fdedog So
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24641
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America
foybold lbduh
t SA Inc,
Pho: +46-m-4723'7473
ftFm: +46 20 4723 7597
F4
+A6-20-a723-7a75
hybold E@16)bold.om.cn
f.rbold \tlcuuh India Pvl Lld.
PtFft
Fd
+39.0744-9303 93
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Hotline -- -- -- - - --- -- - -- - -- l
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+8r.2949.2434
L.yb.ld va.uum 01.4h)

|mmalirEl TEd. Co,, l-td,
L.rtold \hdun
Pnde +49.351-4455@
Fd:
+4S'351'445504i
Fi
Pndq +3s10-659G7m7
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Moblb afid ..16 3atc.
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+3r'6-6393-5215
1-S08 8iins Ladmar* T<i@

3 Nslh Ddrgsh@ F@d
Phom: +44.20'497i 7000

+44 20-49717m3
Fa:
Phoe, +a9.22r.3a71766
Fd:
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klndodiol@ eybold.cm
Fd:
Lyboldlh@um tnanlln)
aB Int malimd TEd. Co,, Lld,
ubr6d r4/ar4
P@qh Lrne
Pt[m: +,49'22r'3.47
1439
Fd:
r{9-221-3/71945
Llybold \bcuum (lisjin)

Eq&ri M.rturirt co" tld
L.ybold Vlcuum USAInc.

Expon PA.156328900
Tel.:
724-327-57A0
Fax:
724-325-3577
+mail inlo@leyboldvacuum
com
L.ybold vlcuun GmbH

BonnerSlae498(Bayenlhal)
50968K n
Tel:
++49\0)2213a7-A
Fat:
++49(0)221347-1250
e-mai. documental
on@leybo
d com
MIDCWagbIndlstrialEsraro
]harelw - 4m 604 Mahaashl
Pnm: +Sr'22.254r2929
F^:
+91 22 25412626
vrcuum@bltrohkc coh.sg
Loyboldlbcuun TaiwnLtd,
Bd., Chu.Tng
Chung-Hsin
Ileybold
VACUUTN
ww$.leybold.com
Vakuumpumpen
Instrumente
Bauteile und Ventile
LEYBOLD VAKUUM
ET 01.299/10
AF 1,6 / 4-8 / 16-25

AF 40-65
AK 1,6 / 4-8 / 16-25
AK 40-65
Auspuff-Filter (AF)
Exhaust-Filter (AF)
Filtre dchappement (AF)
Kondensatabscheider (AK)
Condensate Traps (AK)
Sparateurs (AK)
Gltig ab Kat.-Nr. / Fabrikations-Nr.
Valid from Cat.-No. / Serial-No.
Valable partir du No. de Cat. /
No. de Fabrication
188 02/06/11/16 A96 12 00001
189 02/06/11/16 A96 12 00001
Ersatzteilliste
Spare Parts List
Liste des pices de rechange
2
ET 01.299/10 - 09/96
Auspuff-Filter AF 1,6
Exhaust-Filter AF 1,6
Filtres dchappement AF 1,6
-Kondensatabscheider AK hnlich
-Condensate traps AK similar
-Sparateurs AK similaires
AF 4-8, AF 16-25, AF 40-65
ET 01.299/10 - 09/96
Pos.
Stckzahl / Quantity
Nombre de pices
1,6
1
2
3x)
3y)
5x)
6x)
7x)
7y)
8x)
8y)
9
10
11
11
11
12
12
12
13x)
13x)
13x)
14x)
14x)
14x)
15x)
15x)
15x)
16x)
16x)
17
17
17
18x)
18y)
18x)
18y)
18x)
18y)
19
20
21
22
2
4
1
1
1
1
1
1
1
1
1
1
4-8 16-25 40-65
1
1
4
1
1
1
1
4
4
1
1
1
2
2
2
1
1
2
1
1
1
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
zu/to/pour AF / AK
Benennung
O-Ring
Zylinderschraube
Oberteil
Oberteil
Filter
Druckfeder
Dichtung
Dichtung
Unterteil
Unterteil
Flach-Dichtring
Ablaschraube
Zylinderschraube
Zylinderschraube
Zylinderschraube
Oberteil
Oberteil
Oberteil
Gewindestange
Gewindestange
Gewindestange
Filter
Filter
Filter
Filterpratze
Filterpratze
Filterpratze
Sechskantmutter
Sechskantmutter
Dichtung
Dichtung
Dichtung
Unterteil
Unterteil
Unterteil
Unterteil
Unterteil
Unterteil
Flach-Dichtring
Schauglas
Scheibe
Schraubring
Specification
O-ring
Cylinder screw
Upper part
Upper part
Filter
Split spring
Gasket
Gasket
Lower part
Lower part
Flat gasket
Drain plug
Cylinder screw
Cylinder screw
Cylinder screw
Upper part
Upper part
Upper part
Threaded pin
Threaded pin
Threaded pin
Filter
Filter
Filter
Pressing plate
Pressing plate
Pressing plate
Hexagon nut
Hexagon nut
Gasket
Gasket
Gasket
Lower part
Lower part
Lower part
Lower part
Lower part
Lower part
Flat gasket
Sight glass
Washer
Lock ring
Dsignation
Joint torique
Vis tte cylindrique
Partie suprieure
Partie suprieure
Filtre
Ressort de pression
Joint
Joint
Partie infrieure
Partie infrieure
Joint plat
Vis de vidange
Vis tte cylindrique
Vis tte cylindrique
Vis tte cylindrique
Partie suprieure
Partie suprieure
Partie suprieure
Vis sans tte
Vis sans tte
Vis sans tte
Filtre
Filtre
Filtre
Plaque-presseur
Plaque-presseur
Plaque-presseur
Ecrou hexagonal
Ecrou hexagonal
Joint
Joint
Joint
Partie infrieure
Partie infrieure
Partie infrieure
Partie infrieure
Partie infrieure
Partie infrieure
Joint plat
Hublot
Rondelle
Anneau filet
Abmessungen / Dimensions
(mm)
Werkstoff/Material/Matriel
Bestell-Nr.
Ref. No.
Rf.
27 x 2,5
FPM
M 5 x 12
DIN 912
118,5 x 72 x 40 Al
118,5 x 42,5 x 35 Al
55 x 74
2,5 x 32 x 71,5
Edelstahl
72 x 72 x 0,5
AFM
72 x 42,5 x 0,5
AFM
incl. Pos. 9, 10
incl. Pos. 9, 10
15,1 x 22 x 2
FPM
M 16 x 1,5
St
M 6 x 20
DIN 912
M 6 x 30
DIN 912
M 8 x 25
DIN 912
120 x 90 x 40
Al
142 x 125 x 50
Al
170 x 156 x 58
Al
M 4 x 105
1.4305
M 4 x 125
1.4305
M 6 x 210
1.4305
55 x 114
82 x 125
55 x 211
67 x 50 x 3
St
96 x 60 x 3
Al
108 x 54 x 4
St
M4
DIN 934
M6
DIN 934
90 x 90 x 0,5
AFM
125 x 110 x 0,5 AFM
156 x 140 x 0,5 AFM
incl. Pos. 9,10,19,20,21,22
incl. Pos. 9,10,19,20,21,22
incl. Pos. 9,10,19,20,21,22
incl. Pos. 9,10,19,20,21,22
incl. Pos. 9,10,19,20,21,22
incl. Pos. 9,10,19,20,21,22
24 x 30 x 2
FPM
30 x 4
Glas
30 x 23 x 2
Al
M 32 x 1,5
Al
239 70 436
201 03 216
200 09 368x)
200 09 425y)
390 26 145x)
200 09 419x)
200 10 756x)
200 10 754y)
200 09 364x)
200 09 423y)
239 55 165
201 27 105
201 03 103
201 03 259
201 03 121
200 09 075
200 09 084
200 09 114
200 39 141x)
200 39 140x)
200 39 139x)
200 09 063x)
200 09 092x)
200 09 144x)
371 82 125x)
200 09 091x)
200 09 119x)
211 28 112x)
211 28 114x)
200 10 753
200 10 752
200 10 751
200 09 008x)
200 09 074y)
200 09 083x)
200 09 079y)
200 09 115x)
200 09 143y)
239 55 141
226 80 139
233 75 135
231 54 207
Bemerkungen
Notes
Remarques
x)
nur fr AF /
only for AF /
uniquement
pour AF
y)
nur fr AK /
only for AK /
uniquement
pour AK
Technical alterations reserved

1.81.6.637.06 RSP 09.96
Printed in Germany on chlorine-free bleached paper
LEYBOLD VAKUUM GmbH

Bonner Strae 498 (Bayenthal)
D-50968 Kln
Telefon:(0221) 347-0
Telefax:(0221) 347-1250
ltev bold
VACUUITT
RoLry VanoPumDa
RotaryPislonPumps
VacuumFittinqs
Produkt
Memo
Cologne,
Juni28m,2OOs
Additional Assembly Information

Filter Elements in AF / AK / AR
Payattention
thattheseardisc(1)(vurcenised
onthetirtereremenr)
overries
compretery
onthe
sealfaceofthecasingcover(2).
Youhaveto avoidabsolutelvleakysituations
(arow).
Abb.I (incorrectassembly)
Abb.2 (corroctassombty)
1t1
@by L.ybold V.ct um
BA 087R/09/a6/09.00
SAP 510 00471
RIA 251
Betriebsanleitung
Mise en service
Inbedrijfstellingsvoorschriften
Manuale operativo
Instrucciones de operacin
Process display
Prozeanzeiger
Betriebsanleitung
(Bitte lesen, bevor Sie das Gert in Betrieb nehmen)
Gertenummer:...........................
Deutsch
1 ... 14
Process indicator
(Please read before installing the unit)
Unit number:................................
English
15 ... 28
Indicateur de process
Mise en service
(A lire avant de mettre lappareil en service)
N dappareil:....................................
Franais
29 ... 42
Procesaanwijsinstrument
Bediningsinstructies
(Lezen voor ingebruikname, a.u.b.)
Serienummer:................................
Nederlands
43 ... 56
Display di processo
Manuale operativo
(Leggere prima di installare lunita)
Numero di serie:................................
Italiano
57 ... 70
Indicador de proceso
Instrucciones de operacin
(Por favor, leer antes de instalar la unidad)
Nmero de unidad:...........................
Espaol
71 ... 84
15
Process display
Contents
Safety hints
Installation, setting up and operating personnel
English
17
18
1. System description
19
2. Mechanical installation
19
3.1 Terminal layout and power supply
3.2 Electrical connection
4. Operating overview
4.1 Display and operating elements
4.2 Setting up using the operating menu
4.3 Operating menu overview
5. Operating parameter description
16
Page
20
20
20
22
22
23
24
24
6. Fault finding and repair
25
7. Technical data
27
Process display
Safety hints
Correct use
English
- The manufacturer cannot be held responsible for damage

caused by incorrect use of the instrument. Changes must not
be made to the unit.
- The unit has been designed for use in industrial areas and
must only be used in an installed condition.
- The process display is manufactured using state of the art
technology and complies to the EN 61010-1 directives. On
the version for use in explosion hazardous areas the norms
EN 50014, EN 50020, FM 3600, FM 3610 C22.2 No 157 are
also complied with.
The unit could become dangerous if it is incorrectly installed or
used.
Therefore please take note of all the safety hints and
pictograms shown in these installation and operating
instructions. The meaning of the pictograms is as follows:
Note means activities or sequences that, if not

done correctly could have an indirect influence on
the units operation or could release an unforeseen
unit reaction.
Caution means activities or sequences that, if not

done correctly could lead to personal injury or faulty
unit operation.
Warning means activities or sequences that, if not

done correctly could lead to serious personal injury,
to a safety risk or total damage to the unit.
17
Process display
Installation, initial setting up and operating

personnel
- Mechanical and electrical installation, setting up and
maintenance of the unit must only be carried out by skilled
and qualified personnel who have been authorised to do so
by the plant operator. The skilled personnel must have read
and understood these installation and operating instructions.
They must follow them carefully.
- The unit must only be operated by trained personnel who
have been authorised by the plant operator. They must
follow all instructions contained in this manual.
- Always make sure that the unit is correctly connected
following the electrical connection diagrams. When removing
the unit cover electrical contact protection is lost (danger of
electrical shock). The housing must only be opened by
qualified skilled personnel.
- The unit must only be used in an installed condition.
Repairs
Repairs must only be carried out by trained customer service
personnel. If the unit is to be returned for repair please include
a description of the fault.
Technical advancement
The manufacturer reserves the right to improve and update the
technical details.
18
Process display
1. System description
The process display is connected directly to a 4...20 mA current
circuit. The energy required to power the unit is derived from
the current loop. The unit registers an analogue measured
value and shows this on an easily readable LC display.
2. Mechanical installation
Installation hints:
- The unit must only be operated in an installed condition.
- The installation area must be vibration free.
- The permissible operating ambient temperature
is -10...+60C.
- Protect the unit from heat sources.
Normally the installation requirements for both Ex and non-Ex
units are the same.
Any national standards for the installation must be adhered to.
Panel installation:
Prepare a panel cut out of 45+/-0.6 x 92+/-0.6 mm (to DIN 43700).
Installation depth of the unit is 90 mm.
Push the unit through the gasket and the front of the
panel cutout.
Hold the unit horizontally and fix the jackscrews to their

respective slots (top and bottom).
Tighten the jackscrews evenly using a screwdriver.
19
Process display
3.1 Terminal layout and power supply
1 23 4
Terminal layout
1 Measured signal (+) 4...20 mA
for further instrumentation (link
2 Terminal
with 4)
3 Measured signal (-) 4...20 mA
4 Terminal for further instrumentation (link
with 2)
In and outputs
Signal input
Terminal
Signal input
Terminal
3.2 Electrical connection

Both the terminal layout as well as the connection values of the
process display relate to the Ex version.
The unit is only meant for use in a 4...20 mA current loop circuit.
Potential equilibrium must be gauanteed on the current loop
(inside and outside the Ex hazardous area). In order to achieve
this use the earthing (ground) lug on the housing.
20
Process display
3.2.1 Connecting an active current source

E.g. a sensor with its own power supply and active current
output.
If a respective barrier is used the display can be installed
directly in the explosion hazardous area.
Terminals 2 and 4
internally linked
Y
I
3.2.2 Connecting a passive current source

E.g. Transmitter with additional loop power supply.
(The unit as front end display):
An Ex-certified process display can be applied as a front end

display in the non-explosion hazardous area.
21
Process display
4. Operating overview
Operation as well as the parameter settings and their function
are exactly the same as the Ex version. Please note the
following paragraphs for operation and the notes for setting up.
4.1 Display and operating elements
Measured value:
5 digit, LC display. Displayed are:

- Instantaneous numeric measured value (in operation).
- Dialogue text for setting up.
Enter push button:

Entry to the setting up menu.
- Selection of operation functions within a function group.
- Saving set up data.
+/- push button:

- Selection of function groups within the menu.
- Setting up parameters and numbers (If the push button is
continuously held down then the number change on this
display increases in speed).
- The actual loop circuit current is displayed when operating the
+/- push buttons in operation mode.
Identification field:
Additional information can be written onto the information field.
In order to write on this field follow these simple instructions:
- Degrease and clean the front panel.
- Write on the field using a light and water resistant felt tip pen.
22
Process display
4.2 Setting up using the operating menu
2134,5
-
4
6
_ Editing
E Accept value
E >3s
_
+
1
2
SAVE?
5
E>3s
Enter the operating menu.

Selecting operation function
Parameter entry in editor mode
(enter/select data using + or - and acknowledge using E).
Return from editor mode or operation function to a function

group. A return to the home position (display mode) can be
made by simultaneous operation of the + / - push buttons a
number of times. Before returning, a question is asked if the
set up data is to be saved.
Direct return to the home position (display mode). Before

returning, a question is asked if the set up data is to be saved
Question whether data is to be saved (Selection YES/NO

with + or - push button and acknowledge with E).
23
Process display
4.3 Operating menu overview
DI DP
DI LO
DI HI
OFFST
Decimal point
Display value 0%
Display value 100%
Offset
5. Operating parameter description

Parameter
Setting up selections
Decimal point
DI DP
Selecting the decimal

point of the numeric
display
Selection range:
0 to 4 decimal points
Display value 0%
DI LO
Display value of the 4 mA Values:

current signal
-19999 to 99999
Display value 100%
DI HI
Display value of the

20 mA current signal
Values:
-19999 to 99999
Offset
OFFST
Signal offset for matching

to the measured value
display
24
Values:
-19999 to 32767
Default
settings
9999,9
0,0
100,0
0,0
DISPL
Actual
settings
Process display
6. Fault finding and repair

During production all units go through a number of quality
control stages. In order to assist you in fault finding we have
listed a number of possible faults, causes and cures.
Process display system fault messages
Faults that could occur during the self test or during operation
are immediately indicated on the display. Fault messages that
can be acknowledged are deleted after operating a push.
Fault code
Cause
Cure
E 090
Loop current to low. To store operating data a

minimum of 3.6 mA has to be on the input provided.
Please check the

loop current.
E 101
The EEPROM for storing operating parameters is

defective.
Please return the

unit for repair.
E 102
Checksum of operating parameters is invalid or the

software version in the EPROM does not correspond
with the operating data in the EEPROM. Possible
cause is a power failure during parameter save
procedure or a software update.
A PRESET is automatically initiated by

operating the E
push button. This
means all parameters are returned
to default.
E 103
Checksum for the calibration value of the analogue

input in the EEPROM is faulty. Possible cause is a
power failure during calibration, an uncalibrated unit
or a defective EEPROM.
Please return the

unit for repair.
E 106
Warning: Due to a setting up fault an incorrect setting

up of the display range/scale or bargraph was
initiated (lower and upper values identical).
Please correct the

value.
E 111
Checksum for the operating value of the analogue

input in the EEPROM is faulty. Possible cause is a
power failure during parameter save procedure or a
software update.
Please return the

unit for repair.
25
Process display
Process display system fault messages

Effect
Cause
Cure
Display indicates:
NNNNN
Low range: An input signal of

< 3.8 mA is connected to the
terminals.
Check the input signal.
Display indicates:
UUUUU
Over-range: An input signal of

> 20.5 mA is connected to the
terminals.
Check the input signal.
Display indicates:
SAVE?
Operating parameters have been

changed. The unit requests a save
command.
Release save/do not save

using push buttons + / -
and acknowledge with the
E push button.
Display flashes:
SAVE
The unit is saving changes to the

operating parameters into the
EEPROM.
The unit displays a measured

value once the save has
been completed.
26
Process display
7. Technical data
General details
Unit function
Application
Process display The display receives an analogue signal and shows the
corresponding value on the display. The unit is
connected in a 4...20 mA current loop and pulls the
required energy from that loop.
Operating and
system
construction
Measurement
principle
The analogue signal connect is digitalised, analysed and

indicated in the display.
Measurement
system
Microcontroller controlled display with an LC display.
Input type
Current
Measurement
range
4...20 mA (pole protected)
Max. input
current
150 mA (short circuit current)
Voltage drop
< 2 Volt
Input
Process display without loop power supply for panel

mounting
HART protocol The display is suitable for transmission of the HART

protocol
Accuracy
Current
Application
conditions
Installation conditions
Installation
angle
Accuracy < 0.1 % FSD

Temperature drift: 0.01 % / K ambient temperature
No limit
Ambient conditions
Ambient
temperature
- 10 C..+ 60 C
Storage
temperature
- 25 C..+ 70 C
Climate
classification
To EN 60654-1 Class B2
Ingress
protection
Between bazel and panel: IP 65,

Terminals: IP 20
27
Process display
Application
conditions
(continued)
EMC immunity
RF protection
To EN 55011 Group 1, Class A
Interferance safety
ESD
To EN 61000-4-2, 6 kV/8 kV
Electromagnetic To EN 61000-4-3, 10 V/m

fields
Burst (supply)
Mechanical
construction
Display and
operating level
Power supply
Certification
To EN 61000-4-4, 2 kV
Surge
To EN 61000-4-5, 1 kV
Cable high
frequency
To EN 61000-4-6, 10 V
Dimensions
H: 48 mm, W: 96 mm, D: 90 mm
Weight
300 g
Materials
Housing front: Die cast aluminium

Housing casing: Galvanised sheet steel
Housing rear panel: Plastic ABS
Electrical
connection
Plug on screw terminals (fixable), Terminal size

1.5 mm solid core, 1.0 mm stringed with ferrules
Display
5 digit LC display, 17 mm character size
Display range
- 19999 to + 99999
Offset
- 19999 to + 32767
Operation
3 push button operation (-/+/E)
Power supply
Via 4...20 mA current loop
Volt drop
< 2 Volt
CE
Directives 89/336/EWG
Ex certification ATEX II 1 G EEx ia IIC T6

FM
IS, Class I, Div. 1+2, Group A,B,C,D
CSA IS, Class I, Div. 1+2, Group A,B,C,D
Technical alterations reserved
28
K091R07/R17 Electronic bottle scale

Page 1 of 3
The following versions are available:

K091R07:
K091R17:
Electronic bottle scale 0-150 kg, not calibrated version

Electronic bottle scale 0-150 kg, calibrated version
Safety instructions
Before putting the bottle scale into operation, carefully read the information given in the
operating instruction as it contains important instructions regarding the installation, proper use
and maintenance of the device. The manufacturer cannot be held liable for any failure arising
from the nonobservance of the following instructions:
When using electrical components under increased safety requirements, always observe the
corresponding regulations. Never work on the device while voltage is applied.
The electrical conditions for the power supply must be in conformity with the values printed on
the power supply unit which must never become humid despite the system of protection IP65.
The device is dust-proof and hose-proof. Make sure that all sealings are in perfect condition.
During battery operation the socket of the bottle scale must be sealed with the supplied rubber
cap.
The admissible ambient temperatures must be strictly adhered to (see technical data).
The device meets the requirements for electromagnetic compatibility EMV.
Do not exceed the maximum values specified in the applicable standards.
Application
The bottle scale has been designed for the use involving compulsory (Class III) and
non-compulsory calibration within the EU. The Soehnle display unit 2790 corresponds to the
design described in the qualification approval certificate and the statutory requirements of EU
directives 90/384/EWG, 89/336/EWG, 73/23/EWG and the European standard EN 45501.
C 2280-04

Page 2 of 3
Data sheet / Technical data

Weighing range:
Increments:
Accuracy:
Power supply:
System of protection:
Operating temperature:
Steel parts:
Weight:
Dimensions (installed):
0-150 kg
0,05 kg
50 g
batteries/accumulators
(4 x 1,5 V AA)
IP65
-10 ... +40C
hot-galvenized
20 kg
(L) 390 x (W) 450 x (H) 790mm

Take the bottle scale from the storage compartment (loosen safety lever).
Put the metal frame of the bottle scale to vertical position (re-place star-shaped screw).
Put the bottle scale to horizontal position. Uneven ground can be compensated by the placing
screws.
After the operation fold the bottle scale and put it in the K091R31 storage compartment.
Initial operation
Battery compartment
Power supply unit
Open the battery compartment and

insert the supplied batteries.
Connect the battery/accumulator
(4x1,5V AA) or power supply unit (option).
C 2280-04
Page 3 of 3
Operating keys:
1
0
T
F
ON-OFF
Zero position
Tare
Print
Function key
(not reserved)
(not reserved)
Switching on (without bottle):

Press the 1 key.
After the test routine the display is set to 0. The bottle scale is ready for use.
If the display does not indicate 0 the function setting to zero must be carried out.
Place the bottle onto the scale. The display indicates the gross weight.
Switching on (with bottle):
When switching on the scale with the bottle in place, the display indicates __0__
Press the 0 key and the gross weight is indicated. The zero position which was
saved last is retrieved.
Switching off:
Press the 1 key
Immediately possible if the display indicates 0. If not, keep the key pressed for 3
seconds.
Setting to zero:
Press the 0 key.
If the display does not indicate 0 when the scale is empty.
Possible range of zero position 1% ...+3% of the weighing range.
Tare weighing:
Place the empty bottle onto the scale.
Press the T key. The display indicates 0.
Bottle scale is ready for net weighing.
Background illumination:
If there are no changes in weight during the battery operation the background illumination
switches off after 30 seconds.
Maintenance
The bottle scale does not require any routine maintenance. However, it would be advisable to
check the accuracy of the bottle scale at regular intervals.
(Only for K91R17: regular verification by an authorized calibration office).
C 2280-04

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Mega

DILO Armaturen und

General safety notes

Transport and installation

Setting into operation

Functional diagram with parts list

Removal and storage of SF6

Flooding of the gas compartment with

Maintenance and functional test

Circuit diagram and parts list

Operating- and maintenance instructions for

DILO D-87727 Babenhausen

General safety notes

Obligation to exercise due care

complete and legible operating instructions are available on site.

only qualified personnel operates or repairs the device.

DILO D-87727 Babenhausen

General safety notes

Specific safety notes and standard symbols

This symbol refers to risks for persons (danger to life, danger of

This symbol refers to risks for machines, material and the

This symbol refers to electric shock

If the warning sign Warning, appears, there is no danger for persons.

DILO D-87727 Babenhausen

General safety notes

Basic safety measures during normal operation

Basic safety measures during maintenance

DILO D-87727 Babenhausen

General safety notes

Work on electrical equipment

Work on pneumatic equipment

Observe environmental standards

DILO D-87727 Babenhausen

Construction and operation of the service cart

Sheet metal frame:

DILO D-87727 Babenhausen

DILO D-87727 Babenhausen

Particle filter/ Dry filter:

DILO D-87727 Babenhausen

Functional description of the Mega service cart:

DILO D-87727 Babenhausen

DILO D-87727 Babenhausen

DILO D-87727 Babenhausen

Dimension sheet / Technical data

Max. admissible pressure

Theoretical delivery rate:

DILO D-87727 Babenhausen

Transport and installation

Transport regulations for DILO service carts

DILO D-87727 Babenhausen

Transport and installation

DILO D-87727 Babenhausen

Setting into operation

Prior to setting the device into operation check the following:

Oil level of the vacuum pump (if installed)

Put the weighing device (if exists) in the working position

Checking of safety equipment

DILO D-87727 Babenhausen

Setting into operation

Filling for transport

DILO D-87727 Babenhausen

Setting into operation

Pull out the pin.