Operating instructions
Contents
1. Have any activities only carried out by the indi viduals designated for that purpose The operating instructions specify the following qualification re quirements for the different fields of activity Instructed persons have been instructed during instructions provided by the opera tor with regard to the work assigned to them and possible haz ards arising from improper conduct u Specialised staff is due to its technical training knowledge and experience as well as due to its knowledge of the pertinent regulations able to carry out the work assigned to it and to independently recognise potential hazards 2 5 Personal protective equipment When handling the machine it is necessary to wear personal pro tective equipment in order to minimise health hazards m Before carrying out any work properly don the necessary pro tective equipment such as gloves safety goggles etc and wear during work CNS Operating instructions VacuStar L400 Multi cell compressor vacuum pump oooso ENGINEERING Safety 2 6 Occupational safety and special risks The remaining risks which result from the hazard analysis are specified in the following section Observe the safety notes listed here and the warning notes in the other chapters of these instructions to reduce health hazards and to avoid dangerous situations Danger pictograms on the device The relevant dangerous spots on the machine are identified by these pictograms2. 1 mixing ratio to be sucked into the machine through the hole in the inlet at approx 1000 rpm e Afterwards allow another 0 2 0 5 I clean oil to be sucked in via the inlet e Completely remove the diesel oil mixture from the machine and the downstream silencer again fire hazard Switch off machine and re attach locking screw VacuStar pursuant to chapter Lubricating oil inspection 26 CNS Operating instructions VacuStar L400 Multi cell compressor vacuum pump jalal fm Eee Malfunctions 8 Malfunctions This chapter describes possible causes of malfunctions and trouble shooting tasks Reduce the maintenance intervals if similar malfunctions occur re peatedly due to above average intensive use so intervals correspond to the actual load Contact the manufacturer in case of malfunctions that cannot be re paired with the aid of the following information gt p 2 8 1 Safety See Chapter 2 6 Occupational safety and special risks Personnel e The trouble shooting work described at this point can be carried out by the operator unless otherwise indicated e Some work may only be carried out by specially trained special ised staff or exclusively by the manufacturer himself This is specifically pointed out in the description of the individual mal functions e Only electrical specialists may carry out work on the electrical sysiem e Components and parts may only be replaced by specialised staff Personal protecti
3. Observe screw tightening torques Before restarting ensure that all covers and protective devices are correctly installed and function correctly After completion of maintenance work and trou ble shooting check correct functioning of safety equipment 15 Operating instructions VacuStar L400 Multi cell compressor vacuum pump GEASS DOOSO Technical data EES 3 Technical data General data Unit VacuStar L400 Rated speed Speed range 1 min 1500 1000 to 1500 Suction temperature C 20 40 Geodetic height m 0 1000 Oil container contents Litres 4 6 Oil consumption ml h 85 Weight compressor without accessories kg 76 Table 1 General Data NOTE We recommend stocking a service package as well as a suction filter cartridge The service package comprises all wear parts that are required for a normal repair Operating data compressor vacuum pump at rated speed Unit VacuStar L400 Vacuum without cell venting with cell venting 1 mbar 200 100 Final overpressure at the pressure flange z bar Oto 0 5 Intake volume flow at 400 1000 mbar m3 h 320 345 Power requirement at 400 mbar 0 5 bar excess pressure kW 7 4 10 Sound pressure level at 7m distance with 200 mbar 0 5 bar dB 70 78 overpressure Weight compressor with four way switching valve kg 85 1 Final excess pressure at the pressure flange 0 bar suction and ambient temperature 20 C 2 Intake pressure at the s
4. and has to be correctly refitted after completion of work Only dismantle accidental contact protection af ter machine and pipes have cooled down Itis an environmental protection requirement that any liquids arising during maintenance work e g oil must be collected and disposed of in an environmentally compatible manner 12 CVS OOOO ENGINEERING Moving components Pneumatics Signposting Operating instructions VacuStar L400 Multi cell compressor vacuum pump A Safety WARNING Risk of injury by moving components Powered rotating components can cause the most serious injuries Therefore during operation Itis absolutely forbidden for persons to stay in the hazard area or in the immediate vicinity Do not put safety devices and or functions out of operation and do not render them inoperative or bypass them Never reach into open outlets and inlets or into running equipment Before entering the hazard area Switch off power supply and secure against re starting Wait for standstill of lagging components Wait for automatic dissipation and or discharge of residual energies compressed air WARNING Risk of injury due to compressed air Pneumatic energies can cause the most serious in juries In the case of damage to individual components air can be discharged under high pressure and in jure e g the eyes Therefore Before starting a
5. cell ventilation line The filter must be cleaned weekly and re placed in case of visible damage 22 CVS Operating instructions VacuStar L400 Multi cell compressor vacuum pump ODOOSO E ENGINEERING Start up and operation Height wear rotor vanes Based on a daily runtime of 3 to 4 hours the initial inspection should be performed after approx 6 months For further inspec tions see page 25 Table 6 Maintenance schedule Measuring height wear 1 Disassemble four way switching valve or mounting flange 2 Check vane recess with sliding calliper The rotor vanes must be replaced at a recess of more than 5 mm Fig 2 Measuring of rotor vane height wear 23 Operating instructions VacuStar L400 Multi cell compressor vacuum pump EENS Maintenance 7 Maintenance OOOO ENGINEERING 7 1 Safety during maintenance work Personal protective equipment Environmental protection 7 2 Maintenance schedule See Chapter 2 6 Occupational safety and special risks See Chapter 2 5 Observe the following information with regard to environmental protection during maintenance e Collect exchanged oil in suitable containers and dispose of in accordance with valid local regulations The following describes the maintenance work that is necessary for an optimum trouble free operation Maintenance intervals must be observed If increased wear of individual components or functional groups is de termined during regu
6. his authorized representatives or by trained personnel Start up and operation may only be performed by adequately qualified personnel who have been authorized and instructed by the operator Before the start of any work ensure that all co vers and protective devices are correctly in Stalled and function correctly Never override any protective equipment during operation Pay attention to tidiness and cleanliness in the working area Loosely stacked or scattered components and tools are accident sources 14 CVS OOOO ENGINEERING Maintenance and troubleshooting Operating instructions VacuStar L400 Multi cell compressor vacuum pump A Safety WARNING Risk of injury due to improper maintenance and trouble shooting Improper maintenance and trouble shooting can lead to serious bodily injuries or property damage Therefore Maintenance work and trouble shooting work may only be carried out by sufficiently qualified and instructed personnel Secure machine against restarting switch off drives Before starting any work provide for sufficient space and freedom of movement during as sembly Pay attention to tidiness and cleanliness in the assembly area Loosely stacked or scattered components and tools are accident sources If components must be replaced Pay attention to correct installation of spare parts Properly reassemble all fastening elements
7. replace filter cartridge Compressed air blows off at shaft En Replace radial shaft sealing Specialised end and oil is leak g P g rings in sealing cover Staff Ing Rubber smell at hin slip due too insufficient Check belt tension re tension if Operator V belt drive belt tension necessary End pressure too high Maintain nominal pressure Operator Table 7 Malfunction table 29 Operating instructions VacuStar L400 Multi cell compressor vacuum pump CVs OOOO Spare parts ENGINEERING 9 Spare parts We recommend stocking a service package as well as a suction fil ter cartridge The service package comprises all wear parts that are required for a normal repair Customer Service In case of queries regarding the product spare part orders repairs replacement machines and dispatch of fitters please contact our customer service Phone 49 0 7623 71741 31 10 Decommissioning and disposal A compressor that is no longer usable should not be recycled as complete unit but disassembled into individual components and recycled according to material types Non recyclable materials have to be disposed of in an environmentally compatible manner m Prior to decommissioning and disposal of the machine it must be completely separated from the surrounding units m The disassembly and disposal of the machine may only be car ried out by specialised staff m The machine has to be disposed of in accordance with the re spective country
8. specific regulations 30 Cys OOOO ENGINEERING Index A Acceptance unu ansenanenvenanren ee nennen 8 C Cleaning COMPFESSOT sia cscictantccicieteetcnnctedctnetendctesancatensetan 24 Components MOVING aaneen eenen 12 Compressed air nanne nennen rennen vens 12 Contact person eeen edentate nde 7 COON EET 18 Copyright protection cccccccceeesssesseeeeeeeeeaeeeeees 6 Customer Service rrrrrrrnrrrrnnnnnrnovvnnrrnnnnnnsvennnn 7 D Danger of OUTS EEE 10 Danger pictogram rrnnnnnnrnnnnnrvnvnnnnvnvnnnnennnnnnnn 10 Danger pictograms aanne ennen 10 BE 10 nein een eaten nde teken 10 DesigN annen enn ennn enn ennen eennnensennnens eneen 17 Display elements aanne eneen 18 PISO Al nes ee aan nenn 29 DL 18 E Environmental protection 23 26 F FUNCTION nennen 18 Improper operation aanne ennn 11 Inspection during operation anssen ennn eennnnenn eenn 20 non return Valve nun nnnn eneen eneen erven 21 KOE E e E E T E E A E 22 safety valve cccccssccccessseeccesseeeceesseessenseeseees 21 ventilating valve rrnrrnnnnnnnnnnnnnvvnnnnnrvnnnnenennnnn 21 Inspection prior to initial start up aaneen 20 INSITUCHONS cisnienie iente 9 Intended VG 8 Operating instructions VacuStar L400 Multi cell compressor vacuum pump Index L Lengthy standstill ee 24 25 Fable einen 6 Melder NG Ole een 16 Lubricating oil types rrrrrrrnnnrrrrrrrnnnnrvrnnnnnnnenn 16
9. ventilation valve Specialised staff Half yearly Check non return valve of VacuStar Specialised staff 5 000 oh 3 years Replace shaft sealing rings Specialised staff 10 000 oh 5 years Replace bearings Specialised staff Table 6 Maintenance schedule 7 3 Performance of maintenance work Cleaning the VacuStar Observe the following when cleaning the compressor 1 Switch off compressor and secure against restarting 2 Remove soiling Do not use aggressive cleaning agents No water may penetrate the compressor Caution when using a high pressure cleaner 3 After wet cleaning warm up the compressor for a few min utes Compressor cooling To warrant best cooling the protective grid apertures must be free of deposits 25 Operating instructions VacuStar L400 Multi cell compressor vacuum pump CVs Maintenance Suction air filter Action after lengthy standstill Action after sucking over of for eign matter OOOO ENGINEERING The contamination state is usually indicated by a maintenance dis play If maintenance is required open filter casing and replace filter cartridge During a lengthier standstill we recommend to put the compressor into operation every 4 weeks for approx 15 minutes Proceed as follows if dirt or liquid is sucked on e Unscrew the locking screw in the inlet e Operate VacuStar without vacuum and counter pressure e Switch on machine and allow approx 0 5 1 of a diesel oil mixture 1
10. DANGER General danger pictogram denotes general dangerous situations for indi viduals Non observance of the safety instruc tions can result in severe injuries or death DANGER Danger of burns denotes the presence of a hot surface 11 Operating instructions VacuStar L400 Multi cell compressor vacuum pump CVS OOOO Safety ENGINEERING Hazard notes and occupational safety For your own safety and that of the machine the following in formation must be observed and complied with Improper operation DANGER Danger due to improper operation Only use machine in a perfect technical condi tion Malfunctions that are relevant for safety have to be promptly eliminated Conversions of the machine are not permissible and can impair safety Never bridge any safety equipment or put it out of operation Any work on the machine and or on electrical equipment must be carried out by specialised staff Repair and maintenance work may only be car ried out when the machine is stationary Secure the machine against restarting The machine may not be under pressure or negative pressure while work is being carried out on it Close shut off vane on vehicle side and venti late line between machine and shut off vane or drain excess pressure manually from safety valve Observe pressure gauge The drive s protective equipment may only be removed when the machine is stationary
11. E r staff Bearing defective eplace bearing or have it re placed Lack of lubricating oil Top up oil clean all ESET Operator and suction filter Unsuitable lubricating oil FU Met gosgelng korea Operator tion schedule Rotor vanes are jammed Check rotor vanes re Have casing bore re turned Casing bore shows grooves or and honed at an authorised er Specialised corrugations due to the aspira workshop In case of heavily i E ae a staff tion of dirt soiled intake air install fine fil ter Wrong speed Maintain speed range Operator Changed pressure Maintain nominal pressure Operator Maintain nominal vacuum Changed vacuum check exhaust system and Operator clean if necessary Non return valve rattles Check non return valve m Foreign matter in the machine Remove foreign matter Rinse Specialised out machine Staff Slide breakage Switch off machine immediately Specialised and repair staff Compressed air End pressure too high Maintain nominal pressure Operator temperature too Savalas high Exhaust silencer clogged Replace exhaust silencer ee Four way Bn vawe U Correctly adjust four way cock Operator wrong position Check non return valve and Specialised Non return valve is stuck clean if necessary staff Vacuum filter clogged Clean vacuum filter Operator Vacuum too high Maintain nominal vacuum Operator 28 CVS Operating instructions VacuStar L400 Multi cell compressor vacuum pump jalal fm ens Malfunctions Malfunction Possible caus
12. Lubrication au 18 M Maintenance En 23 Maintenance asrrnnnnnnnvnnnnnnvnnnnnnsvnvnnnnennnnnsnnnnnnee 14 Maintenance schedule nnen een 23 Maintenance work aaan een nennen rennen 24 Malfunction table nnen eneen 27 MAME ONS ee eneseqces ee 26 O Occupational safety rrrrrrnnnnnnrnrvrrrrrnnnnnnnvnnnn 10 Operating elements rrrrnnrrnnnnnnnnvvnnnrrnnnnnnevnnnn 18 Operating instructions nnnnnnnnn eeen evenn 4 Operating personnel saunas eenen eenen 9 OPS MOM ee ee ee 13 20 01 16 lo EE 8 P Personnel Trouble shooting nnen eennnn 26 PASUMAUCS zepen desinteresse 12 Protective equipment 9 19 20 23 26 R Recommissioning nanne nn ennen eennnene ennen 26 S S ll OLY essen A naats snee 8 26 Safety NOLES annae ennen eneen 19 20 23 Je 9 0 0 1 11 0 EE 12 Spare paris EE 7 29 Specialised staff annae ee nennnnnneenen 9 En 13 20 16 0 EEE 19 SUCTION air filter nennen enneenen enne nennn 25 SWIICHNG Ol tende eneen 21 Symbols in the instructions nnen 5 31 Operating instructions VacuStar L400 Multi cell compressor vacuum pump CVs OOOO Index ENGINEERING T Trouble shooting ae 14 Technical data nnee 15 W FANS DON EEE 13 19 WAI EE E T 6 7 32
13. VS OOOO Operating instructions ENGINEERING VacuStar L400 Multi cell compressor vacuum pump Go Doc ID 5028 00 23 11 2010 BA EN Release 11 2010 Prior to installing the machine and putting it into operation you must have read and understood these operating instructions Translation of the Original Operating Instructions CVS engineering GmbH GrossmattstraBe 14 79618 Rheinfelden Germany Phone 49 0 7623 71741 0 Customer service 49 0 7623 71741 31 E mail info cvs engineering de Internet www cvs eng de Created by alphatec Technische Dokumentationen Basler Str 79639 Grenzach Wyhlen Deutschland www alphatec dokumentation de CVS Operating instructions VacuStar L400 Multi cell compressor vacuum pump OOOO RNS Contents GEN 5 1 1 Information regarding the operating instructions 5 1 2 Pictogram explanation rrnrnnnnrvnnnnnrvrnnnnrenvnnnrnvnnnnennnnn 6 1 3 Limitation of Liability aaneen 7 1 4 Copyright protection ssis crnini 7 Lo PAR 8 1 6 Warranty conditions rerrnnrvnrnnnnrvrnnnnrvrnnnnrennnrrenrnnerennnnn 8 1 7 Customer Service uueesssnsssnnnnnneennnnnnnnnnnennnnnnnnnnnnnenn nennen 8 2 SUN een 9 2 1 neo 9 2 2 Acceptance and monitoring nanne eneen een 9 2 3 Operator s responsibility nanannn eenen nen 9 2 4 Operating personnel cccccccssseseeeeeeeeeeeeeeseeeeeeeeeees 10 2 4 1 Requirements nnuu
14. Warranty The manufacturer guarantees the correct functioning of the applied process technology and the performance parameters identified The warranty period commences on the date the machine is deliv ered to the customer Components are exempted from the warranty and from claims for defects as far as wear and tear damage is concerned 1 4 Copyright protection NOTE Content details texts drawings pictures and other illustrations are protected by copyright and are sub ject to industrial property rights Any improper use shall be liable to prosecution Any type and form of duplication also of extracts as well as the exploitation and or communication of the contents are not permitted without the manufacturer s written declaration of consent Operating instructions VacuStar L400 Multi cell compressor vacuum pump GAS OOOO General ENGINEERING 1 5 Spare parts WARNING Risk of injury by incorrect spare parts Incorrect or defective spare parts can result in da mages malfunctions or total failure and also impair safety Therefore Use only the manufacturer s original spare parts Procure spare parts from authorised dealers or directly from the manufacturer Refer to page 2 for address 1 6 Warranty conditions Warranty terms see General Terms of Sale 1 7 Customer Service Our customer service can be contacted for any technical advice Information about the responsible contact person ca
15. e Corrective action Execution Operating pres Pressure gauge or vacuum me Replace pressure gauge or Specialised sure or operating ter do not indicate correctly vacuum meter staff vacuum Is not ob V ane Check V belt tension and re tained belts are slipping Operator tension if necessary Four way switching valve in oe Correctly adjust four way cock Operator wrong position Condensate drain cock open Close condensate drain cock Operator Silt or liquid has Rinse thoroughly with diesel gotten into the oil mixture at lowest permissi ble speed and without pressure or vacuum afterwards add lu Operator bricating oil according to chap ter Lubricating oil inspection machine Foreign matter has been sucked over into the machine page 30 Power requirement Speed too high Maintain speed limit Operator too high Maintain nominal pressure ac End pressure too high tuate check safety valve Operator hen whahaha Replace pressure gauge Operator Exhaust silencer clogged Replace exhaust silencer ais a nn 9 Oil intake strainer in oil tank Clean oil tank and intake Oper tank clogged strainer check oil lines p gee valves in the pressure Open valves Operator Safety valve blows oe off Clogging in pressure system Eliminate clogging Operator Exhaust silender clogged Replace exhaust silencer DS Ventilating valve Closed valves in the suction line Open valves Operator responds ion fi i 5 Suction filter clogged Clean SHEEN dar U Operator sary
16. e machine s place of installation by means of a hazard assessment E implement the necessary rules of conduct for operation of the machine at the place of installation by means of user instruc tions m check at regular intervals during the machine s entire period of use whether the user instructions correspond to the current state of the body of rules and regulations E adapt the operating instructions if necessary to the new regulations standards and operating conditions m clearly regulate the responsibilities for installing operating maintaining and cleaning the device E ensure that all employees working on or with the machine have read and understood the operating instructions In addition he must at regular intervals train the employees in how to deal with the machine and inform them about potential hazards Operating instructions VacuStar L400 Multi cell compressor vacuum pump CVs alala jm Safety ENGINEERING In addition it is the operator s responsibility to ensure that m the machine is always in a technically perfect condition E the machine is maintained in accordance with specified mainte nance intervals m all safety devices are regularly examined for completeness and operability 2 4 Operating personnel 2 4 1 Requirements WARNING Risk of injury in case of inadequate qualifica tion Improper handling can lead to considerable bodily injuries and property damage Therefore
17. injuries if it is not avoi ded ATTENTION points to a potentially dangerous situation which can lead to minor or light injuries if it is not avoided CAUTION points to a potentially dangerous situation which may lead to property damage if it is not avoided NOTE highlights useful hints and recommendations as well as information for an efficient and trouble free operation CNS Operating instructions VacuStar L400 Multi cell compressor vacuum pump ooogo INEC GNG General 1 3 Limitation of Liability All specifications and notes in these operating instructions were compiled with consideration to the valid standards and regulations the state of the art as well as to our long standing knowledge and experience The manufacturer is not liable for damages caused by Non observance of the operating instructions Improper use Deployment of non trained personnel Arbitrary modifications Technical changes Use of non approved spare and wear parts The actual scope of supply may differ from the explanations and illus trations described in this manual in case of special designs if addi tional order options are made use of or due to latest technical changes Incidentally the responsibilities agreed upon in the delivery contract the general terms and conditions as well as the manufacturer s con ditions of delivery and the statutory provisions valid at the time of contract conclusion shall apply
18. king or shrink compressing with each revolution Lubrication is performed by economic lubrication at four points via an oil pump from an oil supply container The machine is air cooled Heat removal is performed by casing ribs on the lid and casing surface with targeted cooling air guid ance via a ventilation wheel on the drive shaft The machine is driven by an articulated shaft hydro motor V belt or directly by an elastic coupling 4 3 Control and display elements Depending on the installation situation different display elements such as pressure gauge temperature gauge and negative pressure display are mounted 19 Operating instructions VacuStar L400 Multi cell compressor vacuum pump EENS mjin fm Transport and storage ENGINEERING 5 Transport and storage 5 1 Safety notes for transport See Chapter 2 6 Occupational safety and special risks Personal protective equipment See Chapter 2 5 5 2 Transport For future transports E Seal all open connections with protective caps prevents penetration of dirt and water e Secure against vibrations e Securely fasten the machine prior to transport 5 3 Storage Storage of packages Store packages under the following conditions e Do not store outdoors e Store dry and dust free e Do not expose to aggressive media e Protect against solar irradiation e Avoid mechanical vibrations e Storage temperature 10 to 60 C e Relative humidity max 95 no
19. lar inspections the operator has to reduce the required maintenance intervals on the basis of the actual signs of wear Changes compared to normal operation increased power consump tion temperatures vibrations noises etc or response of monitoring systems lead to the assumption that the functions are impaired These then have to be subjected to an inspection by specialised staff In case of queries regarding the maintenance work and intervals contact the manufacturer service address gt page 2 For maintenance schedule refer to next page 24 CVS Operating instructions VacuStar L400 Multi cell compressor vacuum pump jalal fm d ens Maintenance Maintenance schedule Interval Maintenance work To be carried out by Check operating speed Every 15 minutes Check operating pressure vacuum Operator Check air outlet temperature Check condensate Check safety trap Daily Operator Check silencer Check oil level and top up with fresh oil if necessary Check safety valve Check ventilating valve Clean compressor vacuum pump Weekly Operator Clean vacuum filter Check V belt V belt tension and re tension if necessary Clean cell ventilation filter replace if damaged Monthly Clean oil tank Check fastening screws and tighten if necessary Operator Check shaft sealing rings for tightness no oil may leak from them quarterly Check rotor vane wear Be Specialised staff replace vane at more than 5 cm Check cell
20. led cleaned freed of deposits and checked for freedom of motion Safety valve The safety valve is no regulating device The operational capability must be checked on start up and later at weekly intervals The safety valve must be secured against maladjustment Blocking or manipulating the safety valve can have penal consequences if it gives rise to an accident Any warranty claims shall also be for feited in such a case The nominal opening pressure may not exceed the maximum per missible final overpressure refer to rating plate or the permissible system pressure provided the latter is lower Functional testing is carried out by actuating the manual ventilation with the machine running Inspection of the ventilating valve As a matter of principle a ventilating valve must be installed as safety element on the vacuum pump s suction side When the set vacuum Is reached the ventilating valve opens and admits atmos pheric auxiliary air into the system The operational capability must be checked weekly with the aid of a vacuum meter at the VacuStar s inlet In case of systems without cell ventilation the vacuum may not drop below the permissible value of 200 mbar In case of systems with cell ventilation the vacuum may not drop below the permissible value of 100 mbar Inspection of cell ventilation When the cell ventilation is connected the VacuStar can be oper ated at a vacuum of up to 100 mbar A suction filter is located in the
21. n be retrieved by telephone fax E mail or via the Internet at any time refer to manufacturer s address on page 2 CNS Operating instructions VacuStar L400 Multi cell compressor vacuum pump mj im ENGINEERING Safety 2 Safety 2 1 Intended use The compressor vacuum pump VacuStar L400 is intended exclu sively for the compression or suctioning of filtered air Only use machine for the intended use All specifications in the operating instructions must be strictly ad hered to technical data operating data permissible working range refer to Page 16 chapter 3 in this regard All types of claims due to damage arising from improper use are excluded The operator alone shall be responsible for any damage arising from improper use 2 2 Acceptance and monitoring The compressor vacuum pump VacuStar L400 itself is not subject to any acceptance and monitoring obligation 2 3 Operator s responsibility The machine is used for industrial purposes The operator of the machine is therefore subject to the legal obliga tions concerning operational safety The provisions valid at the place of installation as well as the safety and accident prevention regulations of the Institution for statutory accident insurance and prevention must be observed The operator must in particular E inform himself on the valid industrial safety regulations determine the additional hazards that arise from the special working conditions at th
22. n condensing e f storage lasts longer than 3 months regularly check the gen eral condition of all parts and of the packaging e To keep moisture away from the machine s workspace bags with desiccant must be placed into the inlets and outlets These must be removed before start up 20 Cys OOOO ENGINEERING Operating instructions VacuStar L400 Multi cell compressor vacuum pump Start up and operation 6 Start up and operation 6 1 Safetynotes Personal protective equipment 6 2 Start up Inspection prior to initial start up Start up Inspections during operation See Chapter 2 6 Occupational safety and special risks Refer to chapter 2 5 Top up lubricating oil according to lubricating oil schedule Fill oil reservoir with oil up to max 3 cm below filler neck thread Open present shut off devices Select suction or pressure operation with four way switching valve in compressor vacuum pump Attention Switching valve must only be operated in the two end positions Intermediate positions are not permitted Start the VacuStar drive Adjust speed Check operating data The following inspections have to be carried out during operation Prior to every start up and during operation the oil level must be checked and topped up if necessary Open shut off devices Check that the four way switching valve is in the end position Switch on drive and check whether pressure or vacuum are created Pay a
23. ny work first depressurise pressurised components Pay attention to ac cumulators Accumulator pressure must also be completely relieved WARNING Risk of injury by illegible pictograms Labels and signs can become dirty or unrecognis able in the course of time Therefore Always keep safety warning and operating in structions in a well legible condition Immediately replace damaged or obliterated signs or labels 13 Operating instructions VacuStar L400 Multi cell compressor vacuum pump CVS mjmjmj jm Safety ENGINEERING Improper transport Danger Danger by falling down or tilting of the ma chine The weight of the machine may injure a person and cause serious bruising Therefore Depending on the dead weight and size of the machine use a pallet on which the machine can be moved by means of a fork lift For lifting the machine use suitable lifting gear slings etc that is designed for the weight of the machine When putting the slings in position take care to avoid putting stress on individual components Only use attachment points with eye bolts pro vided for that purpose Start up and operation WARNING Risk of injury due to improper start up and op eration Improper start up and operation can lead to serious bodily injuries or property damage Therefore Have all work during initial operation exclusively performed by the manufacturer s employees or by
24. pump oooso ee General 1 General 1 1 Information regarding the operating instructions These operating instructions provide important information on how to deal with the machine A precondition for safe operation is the observance of all specified safety and handling instructions Furthermore all local accident prevention regulations and general safety regulations valid for the application area of the machine must be observed Carefully read the operating instructions before starting any work It is a product component and must be kept in direct proximity of the machine well accessible to the personnel at all times When passing the machine on to third parties the operating in structions must also be handed over Operating instructions VacuStar L400 Multi cell compressor vacuum pump CWS General 1 2 Pictogram explanation Warning notes Hints and recommendations OOOO ENGINEERING Warning notes are identified by icons in these operating instruc tions The warning notes are marked by signal words expressing the extend of the hazard It is absolutely essential to observe the notes and to proceed with caution in order to prevent accidents as well as bodily injuries and property damage DANGER points to an immediately dangerous situation which can lead to death or serious injuries if it is not avoided WARNING points to a potentially dangerous situation which can lead to death or serious
25. tor Oil 30 FUCHS Titan Universal HD 40 Titan Universal HD 30 MOBIL Delvac 1340 Delvac 1330 SHELL Rimula X Monograde 40 Rimula X Monograde 30 Table 5 Lubricating oil types 17 Operating instructions VacuStar L400 Multi cell compressor vacuum pump Design and function 4 Design and function 4 1 Design A CVS00522a Fig 1 Setup compressor or vacuum pump A Compressor vacuum pump with four way switching valve The position of the switching lever selects the air feed direction suction or pressure B Compressor or vacuum pump with mounting flange for suction and pressure line 1 Drive shaft 10 Switching lever 2 Cell ventilation connection 11 Pressure connection 3 Thread for eye bolt for illustrated lever setting 4 Temperature and pressure measuring point 12 Four way switching valve 5 Oil filling 13 Suction connection 6 Rating plate machine for illustrated lever setting 7 Rotation arrow 14 Mounting flange for lines 8 Rating plate oil 15 Suction opening for cooling air 9 Oil reservoir 16 Connection for measuring control line 18 Cys OOOO ENGINEERING 4 2 Function Functional principle Lubrication Cooling Drive Operating instructions VacuStar L400 Multi cell compressor vacuum pump Design and function In the working area of the compressor vacuum pump rotor vanes in conjunction with the impeller and the casing form cells that are separated from each other and steadily grow suc
26. ttention to abnormal noises and leaks during operation If necessary switch off machine Drain condensate at the condensate and safety traps Vessel may not be in a state of vacuum when condensate is drained Checking the operating data The speed must range between 1000 1500 min 1 Check positive working pressure at the pressure gauge per missible pressure refer to rating plate Check the operating vacuum at the vacuum meter permissible vacuum refer to rating plate The compression end temperature at 20 C suction temperature may not exceed the following values m 150 C at 400 mbar operating vacuum m 120 C at 0 5 mbar excess pressure 21 Operating instructions VacuStar L400 Multi cell compressor vacuum pump CVs eee jn Start up and operation NOINESEING 6 3 Switching off Switch the compressors off as follows m Switch off drive m Close shut off valves 6 4 Inspections to be performed Lubricating oil inspection Only lubricating oils pursuant to the lubricating oil tab 5 are permit ted Check oil level at the inspection glass and if necessary fill with oil to approx 3 cm below the filler neck thread The oil level may not drop below the bottom mark on the oil inspection glass Non return valve The non return valve is maintenance free but is subject to wear like any other moving part We recommend a visual inspection every 3 months In this connection the non return valve must be dismant
27. uction flange 1 bar suction and ambient temperature 20 C Table 2 Operating data compressor vacuum pump at rated speed Operating data compressor at rated speed Unit VacuStar L400 Intake pressure mbar 1000 Final overpressure at the pressure flange gt bar Oto 2 0 Intake pressure at 0 2 0 bar excess pressure gt m3 h 345 305 Power requirement at 0 2 0 bar excess pressure a kW 8 19 0 Sound pressure level at 7 m distance with 2 0 bar overpressure a dB 77 Weight compressor with mounting flange for suction and pressure line 1 Suction and ambient temperature 20 C 2 at rated speed kg 19 Table 3 Operating data compressor at rated soeed CVS Operating instructions VacuStar L400 Multi cell compressor vacuum pump OOOO ENGINEERING Technical data Lubricating oils The use of multigrade oils will damage the VacuStar In that case the warranty on the part of CVS Engineering GmbH shall cease Only single grade oils with the following specification are permitted for operation Specification Value API CD SF or higher MIL L2104 C or higher Table 4 Lubricating oil Lubricating oil types Brand Suction temp gt 10 C Suction temp lt 10 C ARAL Basic Turboral SAE 40 Basic Turboral SAE 30 AVIA Cronos Super SAE 40 Special HDC 30 BP Vanellus C3 40 Vanellus C3 30 Energol C DG 40 Energol C DG 30 Essolube XD 3 Essolube XD 3 ESSO Motor Oil 40 Motor Oil 30 Essolube X 301 Essolube X 301 Motor Oil 40 Mo
28. uennsnneennennnennennnnennenen nen 10 2 5 Personal protective equipment annen 10 2 6 Occupational safety and special risks 11 Technical dala nn 16 Design and function aanuvvnnnnnvevnnnnvnnnnnnnevnnnnvevnnnnnvennnnnueennn 18 4 1 ee B lt 0 enn ennnenn ennen vennen eennnensennnensennneenenn 18 4 2 FUNCION eerereneerentansdeenennene seen 19 4 3 Control and display elements aaneen 19 5 Transport and storage uuuauuu0nnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnn 20 5 1 Safety notes for transport una sennnnn enen 20 92 PASO i EE 20 3 DOS tenet nee eee eee 20 6 Start Up and operation anna n nnn enanennnennnnennnenenn 21 6 1 Safetynotes sssnseseneeneeeennnennnnnnnennnnnnnnnnnnnnennnnnnnnnnnnnn 21 Ne 21 C OWING ON EEE EE 22 6 4 Inspections to be performed annae 22 7 Maintenance en 24 7 1 Safety during maintenance work nnn 24 7 2 Maintenance SCNedUIE cccccceeccecssseceeeeeeeeeseeeees 24 7 3 Performance of maintenance work ee 25 Operating instructions VacuStar L400 Multi cell compressor vacuum pump CVs Contents OOOO ENGINEERING 8 Malfunctions nennen 27 ol SUN 27 8 2 Recommissioning after corrective action 27 8 3 Malfunction table annae ennen eneen 28 ISEN 30 10 Decommissioning and disposal rnrrrnnnnvnnnnnvvvnnnnnvennnnnuernnn 30 CNS Operating instructions VacuStar L400 Multi cell compressor vacuum
29. ve equipment See Chapter 2 5 Environmental protection See Chapter 7 1 Conduct in the case of malfunc The following basically applies tions 1 Immediately switch off the compressor in case of malfunctions representing an immediate danger for individuals or material assets 2 Switch of all power supplies and secure against restarting 3 Inform person in charge at the place of installation 4 Depending on the type of interference have the cause deter mined and removed by the relevant authorised specialists 8 2 Recommissioning after corrective action After corrective action or trouble shooting 1 Ensure that nobody is staying in the hazard area 2 Start in accordance with the instructions in chapter Start up 27 GE Operating instructions VacuStar L400 Multi cell compressor vacuum pump OOoOgoO ENGINEERING Malfunctions 8 3 Malfunction table Malfunction Possible cause Corrective action Execution VacuStar s deliv Vacuum filter soiled Clean vacuum filter Operator ery rate decreases imi ali y Leaky suction line fittings Look for leaky spots and elimi Specialised nate leak staff Speed too low Adjust speed Operator Wear of rotor vanes possibly oe Replace rotor vane remove dirt eee and have machine overhauled Spele g at an authorised workshop sucking over of foreign matter Unnormal nouse eA l AT A n nmen nm n r ir development achine IS OUT OT allgnme IQ achine accurately Specialised B
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