CVS VacuStar W1300 Operating Instructions Manual Download Page 1

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Contents

Operating instructions

VacuStar W900 / W1300 / W1600

Doc-ID: 5002 / BA / EN

Release: Rev. 06 / 16/08/2017

The operating instructions must be read by the VacuStar W operator before start-up!

Summary of Contents for VacuStar W1300

Page 1: ...Contents Operating instructions VacuStar W900 W1300 W1600 Doc ID 5002 BA EN Release Rev 06 16 08 2017 The operating instructions must be read by the VacuStar W operator before start up ...

Page 2: ...ation of the original operating manual CVS engineering GmbH Großmattstraße 14 79618 Rheinfelden Germany Phone 49 0 7623 71741 0 Customer service 49 0 7623 71741 0 E Mail info cvs eng de Internet www cvs eng de ...

Page 3: ...7 Occupational safety and special risks 11 3 Technical data 17 4 Design and function 18 4 1 Design 18 4 2 Function 19 4 3 Control and display elements 19 5 Transport and storage 20 5 1 Safety notes for transport 20 5 2 Transport 20 5 3 Storage 20 6 Start up and operation 21 6 1 Safety during start up 21 6 2 Start up 21 6 3 Switching off 23 6 4 Inspections to be performed 23 7 Maintenance 25 7 1 Sa...

Page 4: ...and handling instructions Furthermore all local accident prevention regulations and general safety regulations valid for the application area of the VacuStar W 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 VacuStar W well accessible to the personnel at all times When passing the VacuStar W o...

Page 5: ... avoided WARNING points to an immediately dangerous situation which can lead to death or serious injuries if it is not avoided CAUTION points to a potentially dangerous situation which can lead to minor or light injuries if it is not avoided ATTENTION points to a potentially dangerous situation which may lead to property damage if it is not avoided Safety note ATEX Only for machines with Ex approv...

Page 6: ...esigns if additional 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 conditions of delivery and the statutory provisions valid at the time of contract conclusion shall apply Warranty The manufacturer guarantees the correct functioning of the applied...

Page 7: ...ent 1 5 Spare parts WARNING Risk of injury by incorrect spare parts Incorrect or defective spare parts can result in damage 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 A list of spare and wear parts can be found in the enclosu...

Page 8: ...B T2 i for VacuStar W without cell ventilation II 2G c IIB T3 i for VacuStar W with cell ventilation and no potentially explosive external atmosphere The gas temperature in temperature class T2 is restricted to 220 C and in temperature class T3 to 195 C 2 2 Proper operation The following criteria in essence define the proper operation Speed range of the VacuStar W 1000 1500 min 1 Ambient temperatu...

Page 9: ...e VacuStar W is therefore subject to the legal obligations concerning occupational 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 inform himself on the valid industrial safety regulations determine the additional haz...

Page 10: ...ing personnel 2 5 1 Requirements WARNING Risk of injury in case of inadequate qualification Improper handling can lead to considerable bodily injuries and property damage Therefore Have any activities only carried out by the individuals designated for that purpose The operating instructions specify the following qualification requirements for the different fields of activity Instructed persons hav...

Page 11: ... 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 pictograms DANGER General danger pictogram denotes general dangerous situations for individuals Non observance of the safety instructions can result in seve...

Page 12: ...be secured against restarting The VacuStar W may not be under pressure or in a state of vacuum while work is being carried out on it Close shut off valve on the vehicle side and vent the pipe between VacuStar W and shut off valve or manually relieve excess pressure at safety valve Observe pressure gauge The drive s protective equipment may only be removed when the VacuStar W is stationary and has ...

Page 13: ...t Before entering the hazard area Switch off power supply and secure against restarting Wait for standstill of lagging components Wait for automatic dissipation and or discharge of residual energies compressed air Compressed air WARNING Risk of injury due to compressed air Pneumatic energies can cause the most serious injuries In the case of damage to individual components air can be discharged un...

Page 14: ... Danger Danger by falling down or tilting of the VacuStar W The weight of the VacuStar W may injure a person and cause serious bruising Therefore Depending on the dead weight and size of the VacuStar W use a pallet on which the VacuStar W can be moved by means of a fork lift For lifting the VacuStar W use suitable lifting gear slings etc that is designed for the weight of the VacuStar W When putti...

Page 15: ...at all covers and protective devices are correctly installed 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 Electrical system DANGER Mortal danger due to electric current There is mortal danger in case of contact with live components ...

Page 16: ...ff drives Before starting any work provide for sufficient space and freedom of movement during assembly 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 Observe screw tightening torques Be...

Page 17: ...s will damage the VacuStar W 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 operating the VacuStar W Specification Value API CF CF4 or higher ACEA E2 or higher Tab 2 Lubricating oils Lubricating oil types Recommendations Brand Suction temp 10 C Suction temp 10 C ARAL Basic Turboral SAE 40 Basic Tur...

Page 18: ...er inflow 1 4 Pressure connection flange DIN 28459 125 5 Temperature measuring point R 6 Connection cell ventilation R 2 7 Oil level indicator bilateral 8 Crank for manual lubrication 9 Rating plate 10 Oil filler neck cap 11 Rotation arrow 12 Transport and fixing holes M16 13 Negative pressure connection R 3 8 14 Suction connection flange DIN 28459 125 15 Cooling water outflow R 1 16 Lubricating o...

Page 19: ...4 Lubrication of the VacuStar W The VacuStar W is lubricated by means of an oil pump Oil is pumped from the oil reservoir via the oil lines to the VacuStar W s lubricating points Cooling The VacuStar W is water cooled The VacuStar W is equipped with a cooling jacket inside the casing The cooling water circulates by means of a circulating pump Drives The VacuStar W can be powered via Articulated sh...

Page 20: ...ansport e g screw it onto a pallet Transport and put down the VacuStar W with a fork lift or secure with straps and lift with suitable lifting gear 5 3 Storage Storage of packages Store packages under the following conditions Do not store outdoors Store dry and dust free Do not expose to aggressive media Protect against solar irradiation Avoid mechanical vibrations Storage temperature 10 to 60 C R...

Page 21: ...up to the maximum mark on the compensation reservoir Add antifreeze according to manufacturer s specifications Top up lubricating oil according to lubricating oil schedule Fill oil reservoir with oil up to max 3 cm below filler neck thread Manually prelubricate the VacuStar W by means of the crank handle refer to lubricating oil inspection Chapter 6 4 Start up Proceed as follows during start up Op...

Page 22: ...uge permissible 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 140 C at 400 mbar operating vacuum 120 C at 0 5 mbar excess pressure If potentially explosive gases and gas mixtures are conveyed the following points must be observed P...

Page 23: ...l prelubrication of the VacuStar W is always necessary in case of initial operation in case of recommissioning after a standstill of more than 4 weeks after sucking over of foreign matter after repair work on the VacuStar W Procedure to be followed for manual prelubrication Remove the crank handle from the retaining bracket and push it through the oil filler neck onto the oil pump shaft Push the c...

Page 24: ... permissible Depending on the type of drive this may according to the table Technical data on page 17 lower Inspection of the ventilating valve As a matter of principle a ventilating valve must be installed as safety element on the VacuStar W s suction side When the set vacuum is reached the ventilating valve opens and admits atmospheric auxiliary air into the system The operational capability mus...

Page 25: ...dance with valid local regulations 7 2 Maintenance schedule 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 determined during regular inspections the operator has to reduce the required maintenance intervals on the basis of the actual signs ...

Page 26: ...valve Clean cooling unit water cooler Clean VacuStar W 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 Operator Check fastening screws and tighten if necessary Check shaft sealing rings for tightness no oil may leak from them quarterly Check rotor vanes wear Specialised staff Check cell ventilation ...

Page 27: ...cleaning work check that all previously opened covers and safety equipment are correctly installed and function correctly After wet cleaning warm up the VacuStar W for a few minutes Water cooling system cleaning the radiator Check cooling water level in compensation reservoir and top up if necessary Clean radiator in case of soiling as the cooling air must have free passage Action after lengthy st...

Page 28: ...r W and re attach locking screw Prelubricate VacuStar W pursuant to chapter Lubricating oil inspection chapter 6 4 before the VacuStar W is restarted Cleaning suction filter Clean the suction filter depending on accumulated dirt or specification in the maintenance schedule Disassembly Release the cross handle 1 to open the suction filter 5 cross handles 1 must be released in the pressure right des...

Page 29: ...and tighten the hexagon nut 5 manually Turn the nut 5 by about 0 5 to 1 turn onwards with a wrench Installing the round seal 6 at the lid 2 Insert the lid 2 into the housing 3 Tighten the cross handle 1 or cross handles 1 well manually Fig 3 Suction filter 1 Star handle 2 Lid 3 Casing 4 Filter element 5 Hexagon nut 6 Round seal ring 7 Air inlet dirt side 8 Air exit clean side ...

Page 30: ...tention during the inspection that no liquid dirt or other objects get into the VacuStar W Procedure Dismantle vacuum filter and if necessary suction line Press rotor vanes into the rotor slit in horizontal position and measure the distance to the rotor surface with the depth gauge The wear measurement of 6 mm may not be exceeded Replace rotor vane if necessary Fig 4 Cross section through the Vacu...

Page 31: ...rained specialised staff or exclusively by the manufacturer himself This is specifically pointed out in the description of the individual malfunctions Only electrical specialists may carry out work on the electrical system Components and parts may only be replaced by specialised staff Personal protective equipment Refer to chapter 7 1 Environmental protection Refer to chapter 7 1 Conduct in the ca...

Page 32: ...r corrective action After corrective action or trouble shooting 1 Reset emergency stops 2 Acknowledge error message or malfunction at the control system 3 Ensure that nobody is staying in the hazard area 4 Start in accordance with the instructions in chapter start up ...

Page 33: ... Unsuitable lubricating oil Fill in oil according to lubrication schedule Operator Rotor vanes are jammed Check rotor vanes Specialised staff Casing bore shows grooves or corrugations due to the aspiration of dirt Have casing bore re turned and honed at an authorised workshop In case of heavily soiled intake air install fine filter Specialised staff Wrong speed Maintain speed range Operator Change...

Page 34: ...ensate drain cock open Close condensate drain cock Operator Silt or liquid has gotten into the VacuStar W Foreign matter has been sucked over into the VacuStar W Rinse thoroughly with diesel oil mixture at lowest permissible speed and without pressure or vacuum afterwards add lubricating oil according to chapter Lubricating oil inspection page 30 Operator Power requirement too high Speed too high ...

Page 35: ...r Worn V belts Put on new V belts Operator Pulleys are not aligned Align pulleys Specialised staff Worn V belt pulleys Replace pulleys Specialised staff 9 Spare parts 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 Customer Service In case of queries regarding the product spare part ord...

Page 36: ...ls have to be disposed of in an environmentally compatible manner Prior to decommissioning and disposal of the VacuStar W it must be completely separated from the surrounding units The disassembly and disposal of the VacuStar W may only be carried out by specialised staff If hazardous or poisonous material were conveyed the VacuStar W must be decontaminated prior to disposal The VacuStar W has to ...

Page 37: ...l 23 Non return valve 24 prior to initial start up 21 Safety valve 24 Ventilating valve 24 Instructions 10 Intended use 8 L Lengthy standstill 27 Liability 6 Lubricating oil types 17 Lubricating oils 17 M Maintenance 25 Maintenance schedule 25 Maintenance work 27 Malfunction table 33 Malfunctions 31 O Occupational safety 11 Operating instructions 4 Operating personnel 10 Operator 9 P Packaging 20 ...

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