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Operating instructions

1. u eens 48 Load intermittent duty ssrernnnrrnnnrovnnnvnvnnnernnre 48 L UDFICATAG ONS wi iscdascenpondunconesianaranndsidvesicedsddaweceunta 21 M Me 17 49 Maintenance parts rrronnrrnnrrranrrrarevanrnnnnennnnennn 73 Maintenance schedule rrrrnrrrnnnrnvvnnrrnnnnrnnnnr 50 Malfunctions rarornnrernnnrrnnrrranrnnnnrrnnennnnennnnennn 69 Minimum pressure and non return valve 27 Minimum pressure non return valve 67 Mortal danger electrical current 13 O Occupational Safety rrrnrnnrornnnnrrerrnnrrenrnnnnnn 13 COMP CIA GS ae ee en 52 Oil drain screw rrrrrranrrrnnnnrrnnrrnvnnnrnrnnnennanennnn 52 TENNE een 54 Ol COGS i ee ee 2 38 60 OE EE 26 59 Oil level CHECK op cscs seien een 51 Oil level monitor 2202222444 4 29 41 63 Oil SUCTION nozZIe rrrrnrrrrnnrrrrnnnrnrannnrnnnennnnne 66 Operating instructions rrrnrrrrrrnrrrrrnnrrrnvnnrrennnnn 6 Operating personnel cccccseeeeeeseeseeeeeseeees 12 Operation NE 16 Operation modes rrnnnnnnnnnnnnnnnrnvnnnrnvanennnnnrnnnnne 47 OD CN ALON nennen 11 81 CVS Compressor RPO 200 300 400 600 800 Index P gg 1 200 95 Do EEE 15 Pressure EEE 39 Pressure MORIOT ui 41 Protective equipment 12 31 33 43 69 79 Maintenance arrnnanennnnnvnnnnnanennnnennnnnnnnennnnnn 49 R Rang PIATE EE inae 22 Relief va
2. Typ RPO A B C k 200 160 63 304 468 incl 7 12 5 300 160 140 63 304 468 incl 7 12 5 815 196 135 135 100 400 190 140 70 311 468incl 7 12 5 839 226 148 148 112 600 216 140 89 319 457 12 5 829 256 167 167 132 Fig 1 Dimensions RPO 200 300 400 600 AT Illustration of the possible blowout directions of the oil cooler Line to the oil cooler with blow out direction right Compressed air either to the side or to the rear With the blow out direction to the right only to the side is possible 3 Attachment borings M12 x 26 Required min screw in depth 24 mm Space for maintenance 5 Interior diameter for vent channel at the transition point Expand the vent channel to keep the accumu lated pressure as low as possible 6 Sense of rotation viewing the maintenance side of the compressor or the motor drive shaft left With RPO 300 and RPO 400 Reduction flange for electric motor 8 Terminal box for the motor is on top standard As agreed right and left are also possible gt N N 18 CVS CVS Compressor RPO 200 300 400 600 800 OOOO 3 ENGINEERING Technical data 3 2 Dimensions RPO 800 r a A hd i P A y im p ST Fig 2 Dimensions RPO 800 At Illustration of the possible blowout directions of the oil cooler Line to the oil cooler with blow out direction right 2 Compressed air either to the side or to the rear
3. 175 180177 247 0 0 0 0 0 N t N X Q O st N Tt Or 3 m o gt 8 D 5 X OG 8 Status 04 2007 71 CVS Compressor RPO 200 300 400 600 800 Spare and maintenance parts 10 2 Maintenance parts Item no 126 50 100 32 65 55 56 58 85 88 92A 92E 30 65 30 66 30 68 CVS part no RPO 200 RPO 800 RPO 600 432 055 00 463 269 00 463 274 00 432 500 00 432 700 00 432 701 00 463 135 00 463 178 00 465 059 00 940 038 00 432 929 00 440 402 00 463 060 00 463 081 00 463 110 00 463 116 00 463 010 00 Table 10 Maintenance parts Qty com Designation pressor Air suction filter Round sealing ring Oil filter Deoiling ele ment Round sealing ring Round sealing ring Flat seal Non return valve with nozzle sieve Locking screw Round sealing ring Dimensions RPO 200 RPO 800 RPO 600 12 175 x 65 179 x3 120 x 75 72 xX 151 72 x 99 80 x 4 118 x 4 90 60 x 2 1 4 x 27 R 1 2 26 x 3 45x 3 5x 1 5 190 x 3 35x 3 51x3 Cvs OOOO ENGINEERING Use Air suction filter Seal of air filter lid Oil filter Deoiling ele ment Inner seal of deoiler element Exterior seal of deoiler element
4. 53 CVS Compressor RPO 200 300 400 600 800 Maintenance Oil change on model with oil drain 1 Ventilate the safety valve See Page 55 Chapter 8 5 valve 2 Perform a pressure check on vehicle side gauge 3 Unfasten cover from the oil drain valve CVS00539 4 Remove plastic caps from the two ends of the drain hose CV500540 5 Screw drain hose onto the oil drain valve CVS00541 6 Drain oil into suitable container Empty compressor com pletely 7 Remove drain hose from the oil drain valve 8 Push plastic caps into the two ends of the drain hose 9 Screw cover onto the oil drain valve 10 Dispose of waste oil in an environmentally safe manner 11 Fill in oil See Page 53 points 7 to 9 54 CVS OOOO ENGINEERING 8 5 Safety valve on the compressor Risk of explosions A Ventilating the system ventilating the safety valve 1 CVS Compressor RPO 200 300 400 600 800 Maintenance DANGER Risk of injury by explosions Explosions can cause severe injuries Therefore Install the safety valve as instructed Observe the manufacturer s instructions Only use the safety valve for its intended pur pose Never block the safety valve Ifthe pressure exceeds the permissible value immediately shut off the compressor WARNING Danger of burns The compressed air exiting from the safety valve contains oil and measures 80 C It can cause mo
5. 58 8 9 Oil filter 100 32 CVS Compressor RPO 200 300 400 600 800 Maintenance 5 Reinstall the cleaned or new filter Here ensure the correct seat of the seal ring 121 on the lid 121 NOTE Perform the filter change together with the oil change Replace the oil filter as follows 1 Ventilate the safety valve See page 55 Chapter 8 5 2 Drain the oil See page 52 Chapter 8 4 2 3 Loosen and unscrew the oil filter cartridge 100 72 with a strap wrench A by turning it to the left Dispose of the oil filter cartridge in an environmentally friendly manner X art le En wt nn Arge N yt Et s ie Tin hy gt ay Lee Fa p 1 rr N k Nee A 100 32 59 CVS Compressor RPO 200 300 400 600 800 Maintenance 4 Moisten the seal ring of the new oil filter cartridge with oil B v ae io se eS ee Pe Er Ciera DeU E UP FE ee ie Em 5 Turn the oil filter cartridge in to the right and tighten hand tight approx 10 Nm 6 Fill the compressor with oil See page 52 Chapter 8 4 2 8 10 Oil cooler 190 The oil cooler is installed in the intermediate flange on the com pressor unit Clean the oil cooler as follows 1 Remove the plastic cap 172 182 60 CVS Compressor RPO 200 300 400 600 800 Maintenance 2 Carefully clean the cooling fins For this blow the cooler with compressed air from the outside or suction it off from the in si
6. Specialist authorised workshop 70 CVS OOOO ENGINEERING Malfunction Uneven run of compressor Compressor is switched off or cannot be turned back on Oil leaking from the drive shaft of the compressor Oil escaping from the air suction regulator Possible cause Oil very aged Bearing defective rotor vane or casing defective The pressure monitor on site has switched off the compressor Final temperature too high tem perature safety switch con nected on site switched off the compressor when 105 C was reached The overcurrent relais or the cold conductor sensor of the drive motor have been triggered Radial shaft seal leaks Slide ring seal of the drive shaft defective Non return valve is stuck O ring 30 65 of the suction non return valve damaged CVS Compressor RPO 200 300 400 600 800 Malfunctions Corrective action Execution Change oil remove compres Specialist sor test and clean all parts that have been in contact with oil Replace oil filter and air deoiler element Chapter 8 4 2 Clarify the reason for the mal function and alleviate it Have the compressor refitted by an authorised workshop Check the pressure monitor settings and correct if neces sary Ensure better room ventilation Clean oil cooler Chapter 8 10 Change oil as per specifica tions Chapter 8 4 2 Replace oil filter Chapter 8 9 Check the thermost
7. Z ZEZ 50 121 Me RR ER RJ ET DE UIII TT DE IN Status 04 2007 74 CVS Compressor RPO 200 300 400 600 800 Spare and maintenance parts 10 1 2 Compressor step RPO 200 800 drawing no 940 071 00 70 Mi L 51 i N LU G ner NN I SSS Z77 Y RS N 6 Status 04 2007 19 CVS Compressor RPO 200 300 400 600 800 Spare and maintenance parts 10 1 3 Oil temperature regulator RPO 200 800 drawing no 940 040 00 mit Ol benetzt 32 Dichtflache von Pos 5 32 10 27 Gleitfl che von Pos 15 mit Ol benetzt Ss N Ke ne ie tL TT Hest er I N 20 22 Status 04 2007 76 CWS CVS Compressor RPO 200 300 400 600 800 mjmjm m gt ENGINEERING Spare and maintenance parts 10 1 4 Assembly drawing of unit and accessories RPO 200 800 drawing no 250 176 00 HIN QT ES gt VS KL OHM ERS N Tk R GN SS DP DO X i i TE VAN SAN AER p
8. 38 CVS OOOO ENGINEERING 6 5 1 Cooling oil hoses Leaks Cooling oil hoses CVS Compressor RPO 200 300 400 600 800 Installation and assembly CAUTION When screwing the oil output and input lines into the cooler support the torque on the edge of the bushing If this is not observed there can be leaks on the bushing soldering spot The cooling oil hoses must meet the following requirements E Core made of Teflon or Viton u DIN 20024 E Interior pipe diameter as per the following table Compressor Interior pipe diameter mm RPO 200 300 400 600 9 RPO 800 12 Table 6 Interior pipe diameter of the cooling oil hoses You can also purchase the cooling oil hoses from CVS engineering 6 6 Line connection pressure line Condensate Pressure line CAUTION In order to prevent condensate from entering the compressor route the pressure line from the com pressor in a declining fashion Condensate that leaks into the compressor can cause damage to it The pressure line must fulfill the following requirements M corrosion proof E Interior pipe diameter as per the following table compressor Interior pipe diameter mm RPO 200 300 400 600 12 RPO 800 15 Table 7 Interior pipe diameter of the pressure line 39 CVS Compressor RPO 200 300 400 600 800 CVS Installation and assembly Assembly 6 7 Air suction cyclone Notes for offset air suction cyclone 6 8 Relief valve OOOO ENGINEE
9. Start up and operation 7 9 1 Load intermittent duty OOOO ENGINEERING During load intermittent duty the compressor is automatically switched off by a pressure monitor after the desired mains pres sure has been reached At the same time the non return valve in the suction regulator 30 57 closes The line network is relieved by a site supplied relief valve see Chapter 6 8 As soon as the network pressure falls below the minimum pressure set up in the pressure monitor the compressor is switched on once again In this operating mode you must ensure that the permissible switch on frequency of the drive motor is not exceeded m Switch on frequency for RPO 200 300 400 lt 50 minute m Switch on frequency for RPO 600 800 lt 40 minute CAUTION The operating temperature of the compressor should be between 75 and 90 C During load in termittent duty you must ensure that the switch on intervals are long enougn If the operating temperature is not reached there is a risk of condensate interruption in the compressor which will then lead to a failure of the compressor 7 9 2 Load idle intermittent duty Compressors with load idle intermittent duty have an additional regulator valve 220 which distinguishes them from compressors with load intermittent duty With this operating mode the suction regulator 30 57 is closed once the desired network pressure is reached The compressor runs in idle m
10. high room max 100 C Wrong oil usedl Add oil as per specifications Specialist Chapter 8 4 2 Oil level too low Check oil level and fill oil if Operator necessary Chapter 8 4 1 Oil filter 100 32 soiled Replace oil filter Specialist Chapter 8 9 Oil very aged Oil change Clean all parts that Specialist came into contact with the oil Replace oil filter and air deoiler element Oil cooler on the oil and cooling Clean oil cooler Chapter 8 10 Specialist air side soiled Thermostat valve in oil circuit Check thermostat valve and Expert defective replace if necessary electrical spe cialist 69 CVS Compressor RPO 200 300 400 600 800 Malfunctions Malfunction Volume flow too low High oil waste at the compressed air consumption location Suction regulator with non return valve does not close or open Possible cause Air suction regulator with non return valve 30 55 30 57 will not open 2 2 way solenoid valve will not close Wrong oil used Air suction filter 126 plugged Air suction cyclone Relief valve supplied on site will not close Sieve 88 in the suction line soiled Nozzle with non return valve 85 in the oil suction line obstructed or non return valve Air deoiler element 65 contami nated defective or incorrectly installed O ring seal Wrong oil used Strong pulsation in the com pressed line e g by air dryer 2 2 way solenoid valve 220 defe
11. If storage lasts longer than 3 months regularly check the gen eral condition of all parts and of the packaging Do not remove the protective film until shortly prior to installa tion E Do not remove the covers on the suction and outlet until directly before the final installation E Ifthe compressor is to be stored for more than 6 months please consult CVS Engineering 32 CVS CVS Compressor RPO 200 300 400 600 800 OOOO ENGINEERING Installation and assembly 6 Installation and assembly 6 1 Safety during start up Refer to chapter 2 5 Safety Personal protective equipment See Chapter 2 4 6 2 Installation diagram 1 190 2 3 iN AN MD 14 13 12 Fig 16 Installation diagram 1 Compressor 2 9 Fine filter 150 minimum pressure non 2 Compensator and hose line only required with com return valve 3 Compressed air after cooler pressed air quality cooling coil gt lt 5 mg m residual oil con 15 Muffler 4 safety valve tent 16 relief valve 9 Pulsation damping valve en Pos 15 and Pos 16 only required 6 Compressed air dryer 11 Compressed air reservoir jf Pos 6 is not available with Pos 7 non return valve 12 Manual emptying 14 8 safety valve 13 Muffler 14 Drainage valve of dryer T1 Output temperature compressed air T2 Input temperature compressed air dryer 1 The compressed air line between the compressor and the input of the compressed air dryer must be connected downhill to
12. RPO 200 300 400 600 800 D0080 ENGINEERING Design and function of compressed air system 4 Design and function of compressed air system 4 1 Design 30 36 171 126 204 SS N 120 161 30 57 30 55 30 45 4100 32 g6 85 Fig 5 Design of RPO compressor 5 Casing compressor 126 air filter 30 00 step complete 65 oil separator 120 air filter cover 30 36 rotor 85 nozzle with RV oil suction 145 safety valve 30 38 rotor vane 86 sieve of suction 161 temperature safety switch 30 45 needle bearing 90 oil sight glass 171 intermediate flange 30 48 slide ring seal 92A oil drain screw 186 fan with coupling 30 50 radial shaft seal 92E oil fill screw 190 oil cooler 30 55 piston for suction regulator 100 thermostat complete 204 air suction cyclone 30 57 non return valve with suction regulator 100 32 oil filter 23 CVS Compressor RPO 200 300 400 600 800 Design and function of compressed air system 145 220 221 222 204 50 92E 90 182 161 227 92A Fig 6 Maintenance and safety equipment of the RPO compressor 8 oil separator cover 90 oil sight glass 92A oil drain screw 92E oil fill screw 145 safety valve 161 temperature safety switch 105 C 182 cleaning opening with cover 220 221 222 load idle valve with coil and plug 227 oil level monitor 5 150 100 32 B Fig 7 Cooling air 5 compressor casing 150 minimum pressure non return valve 100 32 oil filter 239 electric motor A
13. RPO 200 300 400 600 800 CVS OOOO General ENGINEERING 1 General 1 1 Information regarding the operating instructions These operating instructions provide important information on how to deal with the RPO compressor A precondition for safe operation is the observance of all safety and handling instructions specified in these operating 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 They are 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 CWS CVS Compressor RPO 200 300 400 600 800 oooso ENGINEERING General 1 2 Pictogram explanation Warning notes Warning notes are characterised by pictograms in these operating instructions The warning notes are preluded by signal words ex pressing the scale 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 will lead to death or serious injuries if it is not avoided WARNING points to a potentially dangerous situation which may lead t
14. Seal under deoiler element Oil suction line Oil suction line Oil drain and oil fill screw Non return valve for suc tion regulator Lid of suction regulator Suction boring 78 CNS CVS Compressor RPO 200 300 400 600 800 mjmjmj m ENGINEERING Decommissioning and disposal 11 Decommissioning and disposal Safety Refer to chapter 2 5 Safety Personal protective equipment See Chapter 2 4 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 E The machine must only be disassembled and disposed of by specialised staff m The machine has to be disposed of in accordance with the re spective country specific regulations 79 EC Conformity Declaration for Machines GE pursuant to EC Machinery Directive 2006 42 EC Annex II A OOOgO ENGINEERING Manufacturer CVS engineering GmbH Documentation representative Hans Lutte GrossmattstraBe 14 GrossmattstraBe 14 79618 Rheinfelden Germany 79618 Rheinfelden Germany Herewith the manufacturer declares that the machine type Sliding vane compressor RPO 200 300 400 600 800 LA LLA complies with the basic safety and health requirements of the
15. With the blow out direction to the right only to the side is possible 3 Attachment borings M12 x 26 Required min screw in depth 24 mm Space for maintenance 5 Interior diameter for vent channel at the transition point Expand the vent channel to keep the accumulated pressure as low as possible Sense of rotation viewing the maintenance side of the compressor or the motor drive shaft left gt N O 8 Terminal box for the motor is on top standard As agreed right and left are also possible 19 CVS Compressor RPO 200 300 400 600 800 CVS mjmjm fa Technical data ENGINEERING 3 3 Technical data Description Unit RPO 200 RPO 300 RPO 400 RPO 600 RPO 800 eder volume flow min 180 175 260 256 380 375 550 540 770 758 Final overpressure 3 bar 10 12 Suction pressure mbar 1000 Motor rated speed min 1420 1420 1440 1455 1455 Power requirement at 2 123 2 7 3 0 3 8 4 2 5 2 5 7 7 2 7 9 2 kW the shaft Final overpressure bar 3 10 12 range Speed range min 1000 2200 1000 2200 1000 2200 1000 2200 1000 2200 Sound pressure level dB A 63 63 64 64 65 Oil content gt I 1 8 2 4 1 8 2 4 1 8 2 4 2 2 6 2 3 Remaining oil content Img m lt 5 of the compressed air 2 J Voltage of electric mo V AC 3 x 400 tor Frequency of electric Hz 50 motor Protection class of IP 55 shakeproof electric motor Design of electric mo E B35 tor Weight without drive k 49 49 49 48 5
16. and disposed of in an environmentally compatible manner 14 CVS OOOO ENGINEERING Moving components Compressed air Signposting A A CVS Compressor RPO 200 300 400 600 800 Safety WARNING Risk of injury by moving components Powered rotating components can cause the most serious injuries Therefore during operation It is 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 injuries 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 any work first depressurise pressurised components Pay attention to ac cumulators Accumulator pressure must also be completely relieved WARNING Risk of injury due to illegible pictograms Labels and signs can become dirty or unrecognis able in the course of time Therefore Always keep safet
17. 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 11 CVS Compressor RPO 200 300 400 600 800 CVS fee fa Safety ENGINEERING In addition it is the operator s responsibility to ensure that u the machine is always in a technically perfect condition E the machine is maintained in accordance with specified mainte nance intervals E all safety devices are regularly examined for completeness and operability 2 3 Operating personnel 2 3 1 Requirements WARNING Risk of injury in case of inadequate qualifica tion Improper handling can lead to considerable bodily injuries and property damage Therefore 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 4 Personal protective equipment When handling the machine it is
18. cooling air suction B cooling air exit C hose not part of the delivery scope of CVS engineering 24 Cys OOOO ENGINEERING 4 2 Function General Air passage Oil circuit CVS Compressor RPO 200 300 400 600 800 Design and function of compressed air system CVS rotational compressors with oil injection cooling of the model series RPO are compact one step compressors ready to install and constructed as per the European standard EN 1012 1 for the compression of atmospheric air designed for positive overpres sures of 10 12 barg The back cooling of the injected oil is performed by an air cooled heat exchanger The compressor delivers low pulsation compressed air with an exit temperature of approx 70 C The compressors are available in two operation modes Load intermittent duty LA m Load idle intermittent duty LLA Positive working pressure gt 10 bar only in connection with idle control The air is suctioned via the air suction cyclone 204 and reaches the suction regulator 30 55 30 57 via the air filter 126 from there it travels axially into the compressor step 30 00 In the compressor step the air is compressed At the same time oil is injected to cool and lubricate The compressed air leaves the compressor step and enters the preseparation chamber where the majority of the oil is separated from it After that it is transported on to the oil separator 65 This reduces the resi
19. directive 2006 42 EC up to the interfaces described in the enclosed operating instructions data sheets and technical documentation When installing the machine into another machine such as a streetcar vehicle all instructions and safety regulations listed in the operating and installation instructions must be observed The technical documentation according to Annex VII A of the Directive is available for a possible inspection by the responsible supervisory body The technical documentation belonging to the machine according to Annex VII A of the Machinery Directive has been compiled Machine description RPO 200 300 400 600 800 LA LLA gt Sliding vane compressor one step with oil injector cooling air cooled for the compression of cleaned atmospheric air for direct drive via coupling driven by AC motor or DC motor or hydraulic motor gt Operation modes LA Load intermittent duty LLA Load idle intermittent duty Applied harmonized standards gt DIN EN 1012 1 Compressors and vacuum pumps safety requirements Part 1 Compressors gt DIN EN ISO 12100 1 2 Safety of basic machine terminology general design guidelines Part 1 Basic terminology methodology Part 2 Technical guidelines gt DIN EN ISO 14121 1 Safety of machinery Risk Assessment Part 1 Principles gt DIN EN 15085 Parts 1 2 3 4 5 Railway applications Welding of railway vehicles and components Apart from the directive mentioned the product co
20. exposure to direct drive wind E protect the drive motor of the compressor from direct sunlight e g by attaching sheet metal paneling m offer sufficient space for accidental contact protection m offer sufficient space for the connections of the suction and pressure lines u ensure good legibility of the instruments M be accessible for maintenance and repair work e g for air and oil filter changes or the control of the safety and non return valve on the service side of the compressor Also see page 18 ff Fig 1 and Fig 2 34 CVS Compressor RPO 200 300 400 600 800 Installation and assembly Installation position The installation position of the compressor can be selected freely in reference to the driving direction if the machine axle is horizon tal Fig 17 freely selectable installation position with horizontal machine axle 1 Horizontal machine axle 35 CVS Compressor RPO 200 300 400 600 800 CWS mujm E Installation and assembly ENGINEERING In the longitudinal and the cross axle the deviation from the hori zontal machine axis may not exceed 12 or 21 ii max 12 21 max 12 21 Fig 18 top max deviation of longitudinal axle bottom max deviation of cross axle 1 Longitudinal axle 2 Cross axle 1 Use the suitable transport means to place the compressor into the intended installation position on the vehicle Observe transport instructions in Chapter 5 2 Attach th
21. monitor see operating instructions pressure monitor Briefly switch the drive motor of the compressor step on and off again Check the sense of rotation on the coupling Sense of rotation viewed on the drive shaft of the electric mo tor left Repeated consecutive switching will lead to a thermal over load of the electric motor If available check the blower motor of the external oil cooler for the correct sense of rotation The ventilator is switched on when the oil temperature reaches 75 C The sense of rotation is correct if the ventilator presses air through the oil cooler Fig 20 Sense of rotation arrows Switch the compressor on as follows 1 2 3 Open the shutoff devices if available Start the compressor drive Check operating data 45 CVS Compressor RPO 200 300 400 600 800 CVS Start up and operation 7 4 Functional testing 7 5 Switching off OOOO ENGINEERING Perform the following functional testing while the compressor is switched on m All connections are tight E Compression pressure has been reached m Ventilator motor of the external cooling package switches at an oil temperature of approx 75 C Switch the compressor off as follows 1 Switch off the compressor drive 2 Close shut off valves if available 7 6 Operation after long standstill or after extended storage 7 7 Longer standstill NOTE After a long standstill or extended storage CVS engineering reco
22. storage 5 1 Safety notes for transport Refer to chapter 2 5 Safety Personal protective equipment See Chapter 2 4 5 2 Transport The compressor which is fastened on a base plate must be trans ported either by crane or a fork lift The lifting gear must be de signed for the weight of the compressor Weight see page 20 Chapter 3 3 For future transports E Seal all open connections with protective caps prevents penetration of dirt and water m Drain the compressor oil m Securely fasten the compressor prior to transport e g screw it onto a pallet E Transport and put down the compressor with a fork lift or secure with straps and lift with suitable lifting gear Transport by crane Attach the compressor to the appropriate transport borings Fig 15 Transport by crane 31 CVS Compressor RPO 200 300 400 600 800 CVS mjmjmj jm Transport and storage ENGINEERING 5 3 Storage Storage of packages In order to protect the compressor from damages during sea trans port or in case of extended storage it is sealed in protective film Compressor parts that are not painted or galvanised are treated with preserving oils at CVS 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 Relative humidity max 95 non condensing
23. valid at the time of contract conclusion shall apply 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 Also see page 78 Chapter 10 2 Surrendering the operating instructions to third parties without writ ten permission of the manufacturer is not permitted 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 permit ted without the manufacturer s written declaration of consent CVS OOOO ENGINEERING CVS Compressor RPO 200 300 400 600 800 General 1 5 Scope of delivery and goods receiving 1 6 Spare parts 1 7 Warranty conditions Immediately check the delivery after receipt for completeness and transport damages The scope of delivery is indicated on the deliv ery note Proceed as follows in the case of outwardly recognisable transport damage m Do not accept the delivery or only under reserve m Note the extent of damage on the transport documents or
24. work shop Preventive repair of compressor step CVS engineering or an authorised work shop Replace the compressed air dryer and bearing on com pressor 2 can be omitted if an oil level monitor is used 3 if used in heavily soiled conditions this interval can be shorter You may take suction air via a vacuum tight hose line from the vehicle box 4 After consulting CVS engineering and the oil manufacturer the oil change intervals can be extended However you must have the oil inspected for this 5 Interval can be doubled if using synthetic oil Table 8 Maintenance schedule 50 CVS Compressor RPO 200 300 400 600 800 Maintenance 8 4 Oil level check and oil change CAUTION For a trouble free operation keep the oil change intervals and check the oil quality and the oil level Here observe the max fill height bottom edge of the oil fill neck thread Overfilling will lead to damages to the compressor 8 4 1 Oil level check Visual check on oil level glass 90 The oil level must be above the top edge of the oil level glass The area between the top and bottom edges see through on the oil sight glass is the reserve area If the oil level is at the upper edge of the oil sight glass the com pressor can be run for another approx 1 000 hours 92E CVS00538 CVS00537 92A Fig 21 Oil level check oil drain screw Fig 22 Oil level check oil drain valve 1 max fill height 166 o
25. 2 motor ko Weight with drive motor 70 13 80 89 101 7 kg Cooling Sell tem PC 40 40 perature 1 Suctioned volume flow referenced to 20 acceptance as per DIN ISO 1945 ISO 1217 2 with final overpressure 10 bar 12 barg 3 positive working pressure gt 10 barg only in connection with idle control to avoid the generation of condensate 4 sound pressure level as per DIN 45635 with a compressor speed of 1500 min open air measurement 7 m driven via AC motor and a positive working pressure of 10 barg When driven by a DC motor or converter driven AC motor the sound pressure level can be above the indicated values 5 higher value oil volume during first fill lower value oil volume that can be drained and refilled during an oil filter change The difference is the remaining residual oil in the compressor 6 with static operation With pulsations such as caused by the compressed air dryer a pulsation damping valve must be installed see page 42 7 compressor without fill 8 for higher temperatures please consult with CVS engineering GmbH Table 1 Technical data 20 CWS CVS Compressor RPO 200 300 400 600 800 mjmjmj Im 3 ENGINEERING Technical data Type key RPO 400 LA LLA Rotation compressor with oil cooling Suction power of the compres e g 400 400 I min sor approx Load intermittent duty 0 Load idle intermittent duty Lubricating oils Only mineral oils or synthetic oils with th
26. 2 Chapter 8 4 2 If the screw in height of the level monitor cannot be reached the connected test lamp must trigger If the level monitor does not switch it must be removed tested and replaced if needed 63 CVS Compressor RPO 200 300 400 600 800 Maintenance 5 Refill the oil See dk 52 Chapter 8 4 2 u i 227 Fig 25 Testing the oil level monitor A Terminals and to connect the test lamp 8 13 Air suction regulator with non return valve 30 55 57 When checking the air suction regulator with non return valve the round seal ring 65 may have to be replaced An oily suction open ing is an indicator for a leaking air suction regulator 1 Ventilate the safety valve See page 55 Chapter 8 5 2 Unscrew the cylinder head screw 35 Remove the air filter lid 120 ut i Pis g F r ii 2 eo f k e w N pas sn ME nen j I der ty ack 35 120 64 CVS Compressor RPO 200 300 400 600 800 Maintenance 3 Remove the regulator lid 30 34 3 cylinder screws 30 71 A air Suction opening ss Ren iu 2 A FE d 4 Ae RR a 30 34 aK se rn 30 71 4 Remove the non return valve 30 57 and the piston for the air suction regulator 30 55 Watch for the spring in the lid 30 59 30 55 30 57 5 Test the round seal ring 30 65 30 66 and replace if neces sary 6 The assembly is performed in reverse sequ
27. 57 8 8 Air suction filter 126 rrrnrnnnrnnnnrrrrnnrrenrnnnnenvnnnrnnnnnnr 58 8 9 METT Nr 59 8 10 Ol cooler 190 nee 60 8 11 Air deoiler element 65 rrrnnnnnrnnnrnnnrnnnnnnrnvnnnnnrnnnnnre 61 8 12 Oil level monitor 227 rrannnrnrnnnnnnnnnnnennnnnrennnnnnnnnnnnne 63 8 13 Air suction regulator with non return valve 30 55 57 64 8 14 Oil suction nozzle with non return valve 85 66 8 15 Minimum pressure non return valve 150 67 8 16 Compressor step 30 rrannnrnnnnnrnnnnnnnvnrnnnnrnvnnnrnnnnnner 67 SIT Electio MOD nee 68 8 18 Hose lines and compensators cccceeccseeeeeeeeeaees 68 MANE 69 9 1 Safety during maintenance work cccccseeeeeeeeeees 69 10 Spare and maintenance partS rrrrnnnnnnnnnnvnnnnnnnnnnnnevevnnnnnnnr 73 10 1 1 Assembly drawing of compressor RPO 200 800 drawing no 940 086 00 74 10 1 2 Compressor step RPO 200 800 drawing no 940 071 00 rerrrernnnrrrrnnnnnnn 75 10 1 3 Oil temperature regulator RPO 200 800 drawing no 940 040 00 rerrrernnnrrrrnnnnnnn 76 10 1 4 Assembly drawing of unit and accessories RPO 200 800 drawing no 250 176 00 77 10 2 Maintenance parts rararranornnnrrnnrrrnnrrranrrnnnrnnnnrnanennnen 78 11 Decommissioning and disposal rrrrrrnnnnvnvvnnnnnnnnvnnnnnnnnnrr 79 12 Declaration of conformity nnxrrvnnnnvvnnnnnvvnnnnvevnnnnvernnnnnvennnnnr 80 NAG 81 CVS Compressor
28. CVS OOOO ENGINEERING Operating instructions CVS Compressor RPO 200 300 400 600 800 Doc ID 5001 06 27 07 2010 BA EN Release 07 2010 The operating instructions must be read by the machine operator and before start up CVS Compressor RPO 200 300 400 600 800 CVS OOOO ENGINEERING Translation of the original operating instructions CVS engineering GmbH Grossmattstra e 14 D 79618 Rheinfelden Germany Phone 49 0 7623 71741 0 Customer service 49 0 7623 71741 30 31 32 E mail info cvs engineering de Internet www cvs eng de CVS CVS Compressor RPO 200 300 400 600 800 D0080 ENGINEERING Contents 1 OPNE EE een 6 1 1 Information regarding the operating instructions 6 1 2 Pictogram explanation rrrrnnrrnnnnrrnnnnrrvnnnrnrnnrernnrrnnnnr T 1 3 Limitation of liability roorrrrrrnnrrerrnnnrrrrrnnrrerrnnnenrnnnnnnn 8 1 4 Copyright protection rrrnrrnrnnnnrvrnnnnrvrnnnrrnvrnnrrerrnnnennnnn 8 1 5 Scope of delivery and goods receiving 9 1 6 Spare TE 9 lak Waranty conditions sus 9 1 8 Customer service eassenssenssnnnenennnennennnnnnnnnnnennnnnnn nenn 10 1 9 Declaration of conformity u0004444ne nennen nennen 10 2 UN en 11 2 1 Mee EE eee 11 2 2 Operator s responsibility rrrnrrrrrrnnrrerrnnrrerrnnnnrrnnnnnre 11 2 3 Operating personnel cccccccssseccesseeeceesseeeseeeeeess 12 2 3 1 Requirement
29. OOO ENGINEERING 8 3 Maintenance schedule Operating hour in terval years 1100 0 5 2200 1 0 8800 4 0 13000 6 0 18000 8 2 40000 18 3 1 whichever occurs first These maintenance procedures are required for an optimised and 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 of wear Changes compared to normal operation increased power con sumption 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 Maintenance work To be carried out by Visually check the oil level a l 2 Operator Visually inspect the unit for leakage Check the air suction cyclone and clean if necessary Replace the air filter insert gt Oil change when using motor oil ee Replace the oil filter Replace air deoiler element Specialist Clean oil cooler air side Check air suction regulator for leakage Replace O rings if necessary Replace suction nozzle with non return valve Replace hoses CVS engineering or an authorised
30. RING Install the line as follows m Route the pressure lines declining from the compressor E Install a compensator such as a pressure hose between the compressor and the site s compressed air supply Recommended pressure hose PTFE corrugated hose with stainless steel fixtures By standard the air suction cyclone is screwed directly to the suc tion opening of the compressor If the cyclone separator is installed offset and is connected to the compressor via a vacuum hose i e if there is a risk of suctioning water the following guidelines must be observed during installa tion Horizontal placement of the cyclone separator m Dirt disposal slot must always point down m Min interior diameter of the vacuum hose 30 mm If the devices that are installed downstream from the compressor are not equipped with relief possibility a relief valve must be in stalled on the vehicle between the compressor and the non return valve on the compressed air reservoir input When the compressor is shut off the relief valve opens and the pressure volume between the compressor and the compressed air reservoir is relieved slowly approx 5 10 seconds If there is a compressed air dryer installed downstream from the compressor which relieves pressure after a shutoff no external relief equipment is necessary A pulsation valve is to be installed upstream of the compressed air dryer which slowly relieves com pressed air from the system Al
31. Step ccccccseseeceeeeeceeeeseeeeeseeeeees 67 Contact person rrrnnnrnrannonnannnnnanennnnsnnnanennnnnene 10 Control elements rrrrrnrnrrnnrrrrnnrenrnnnnrnnnennnnnen 41 Copyright protection rrrnnrrrnrnnnnenrnnnnrrnnnnrenrnnnre 8 Customer ServiCe rrarrrrarnrrnnrarrnnnenrnnnenrnnnennnnen 10 D Danger OF DUNS 2 3 en i 13 55 Danger pictograms zuus424sennenne nenne nenne nennen 13 PAUS Jan 13 Declaration of conformity rrrrrnnrrrrrnnnnrrrnnnnnn 10 Declaration of conformity rrrrrnnrrrrrnnnnerrnnnnen 80 PE Tre 23 Diagram installation reroronrrrnnrrrnrrrrarnranennnrr 33 Dimensions RPO erennnrnnrnnvvnnnnvnrvnnnrsnenennenne 18 19 PEN 19 DIVE ee 37 E Electric OL OM EE EE 27 68 Electrical connection u222002240 nennen 42 F Fl 43 FUNCOM see een 25 Functional testing u404444sRnene nennen nennen 46 G Goods receiving u222200002nnenennnnnne nennen nennen 9 CVS Compressor RPO 200 300 400 600 800 Index H Hose lines An 68 Improper operation arrrnnrnnanennnnevnnnnnnnnnnnnennnnnn 14 Inspection prior to initial start Up rorrrarernnrrrnnrrranrnnnnn 45 gs AON see ea 33 Installation position rrarrrnnrernnrrrnnnrvnnrrrannnnnnn 35 Instructions u22uue2nuenennenenenenennnnenenne nenne nnnenennn 12 Intended WSC i unse ee 11 L LOB Vase ee 8 Load idle intermittent duty
32. at in the oil circuit and replace if necessary Room temperature or cooling air temperature on the motor too high Ensure better ventila tion Check motor and compressor and send them to the plant if necessary Have the compressor refitted by an authorised workshop Have the compressor refitted by an authorised workshop Remove and test air suction regulator with non return valve Replace if necessary Chap ter 0 Replace the entire air suction regulator with non return valve Chapter 0 authorised workshop Expert electrical spe cialist Operator Specialist Specialist Specialist Expert electrical spe cialist Operator Specialised staff or author ized workshop authorised workshop authorised workshop Specialist Specialist 71 Cvs CVS Compressor RPO 200 300 400 600 800 OOOO Malfunctions ENGINEERING Malfunction Possible cause Corrective action Execution Motor shows See Motor operating instructions changes compared Contact motor manufacturer if necessary to normal opera tion Such as noises 12 CVS OOOO ENGINEERING CVS Compressor RPO 200 300 400 600 800 Spare and maintenance parts 10 Spare and maintenance parts Data for ordering spare parts and maintenance parts Customer service In case of queries regarding the product spare part orders repairs replacement machines and dispatch of fitters please contact our custome
33. ck by the compressor step 4 5 Thermostat Fig 5 100 In order to avoid condensate failure during operation in the com pressor casing the compressor s final temperature is regulated by a thermostat that is built into the oil circuit When the oil temperature reaches 75 C or more it is routed through the oil cooler 4 6 Safety and shutoff functions The compressor is equipped with the following safety and shutoff functions u Safety valve blows off when the set overpressure is exceeded and thus protects the components from overpressure u Temperature safety switch switches the compressor off if the temperature exceeds 105 C E Cold conductor sensor on electric motor switches off the elec tric motor when the coil is overheated 27 CVS Compressor RPO 200 300 400 600 800 Design and function of compressed air system 4 6 1 Safety valve Item 145 To safeguard against exceeding the max permissible operation overpressure a safety valve has been installed as per EN 1012 1 Fig 9 safety valve 4 6 2 Temperature safety switch Item 161 As per EN 1012 part 1 5 5 3 2 the final compression temperature in the outlet must not exceed 110 C under normal circumstances The compressors are equipped with a temperature safety switch that will switch off the compressor if the temperature exceeds 105 C Fig 10 Temperature safety switch 28 4 7 Options 4 7 1 Sound proof hood 4 7 2 Oil level
34. ctive Pressure monitor on site defec tive Regulating piston 30 55 with non return valve 30 57 is stuck Corrective action Remove air suction regulator with non return valve and test Chapter 0 Check the 2 2 way solenoid valve and replace if necessary Change oil as per specifica tions Chapter 8 4 2 Clean filter and replace car tridge Chapter 8 8 Check the air suction cyclone and clean if necessary Chap ter 8 6 Check the pressure monitor supplied on site and the relief valve Clean sieve Chapter 8 7 Remove the nozzle with non return valve and check Clean or replace the entire set if nec essary Check air deoiler element and replace if necessary Ensure the correct seating of the air deoiler element Chapter 0 Change oil as per specifica tions Chapter 8 4 2 Refit the pulsation damper and or fine separator Chapter 6 12 Check the 2 2 way solenoid valve and replace if necessary Check pressure monitor and replace if necessary Remove the regulator piston and ensure smooth uncon stricted movement Have the compressor refitted by an authorised workshop Cvs OOOO ENGINEERING Execution Specialist Expert electrical spe Cialist Specialist Specialist Specialist Expert electrical spe Cialist Specialist Specialist Specialist Specialist Specialist Expert electrical spe Cialist Expert electrical spe Cialist
35. de with a vacuum cleaner A 3 Reinstall the plastic cap 8 11 Air deoiler element 65 DANGER Danger due to improper operation Only replace the air deoiler element while the system is switched off and free of pressure Protect system from being restarted switch off drives Replace the air deoiler element as follows 1 Ventilate the safety valve See page 55 Chapter 8 5 2 Remove the acorn nuts 70 2 Bl viy rf 70 61 CVS Compressor RPO 200 300 400 600 800 Maintenance 3 Remove the separator lid 8 with the air deoiler element 65 i ar 4 Unscrew the air deoiler element 65 from the lid by turning it to the left 5 Also replace the O rings 55 56 and the flange seal 58 5655 58 69 70 62 6 T 8 9 8 12 Oil level monitor 227 Bu i CVS Compressor RPO 200 300 400 600 800 Maintenance Oil the O rings and flat seals Install the air deoiler element manually onto the the locking lid 59 by turning it to the right Torque approx 5 Nm Place the separator lid with the air deoiler element into the stud bolts 68 Ay ea gt _ gt 68 Screw in the separator lid with deoiler element Torque of acorn nuts 70 23 Nm Check the oil level monitor as follows 1 2 3 4 Ventilate the safety valve See Page 55 Chapter 8 5 Connect a suitable test lamp to the oil level monitor Drain the oil See page 5
36. dual oil content of the compressed air to less than 5 mg m The compressed air leaves the compressor via the combined minimum pressure non return valve 150 The safety valve 145 protects from overpressure A thermostat 100 is installed in the oil circuit to regulate the tem perature With an oil temperature of gt 75 C the oil is routed via an oil cooler and returned to the compressor step via the oil filter In the compressor step the oil is mixed with the air to be com pressed while it picks up the compression and the friction heat and prevents backflow losses The oil is separated from the compressed air in the preseparator chamber and in the oil separator and returned to the process once again 25 CVS Compressor RPO 200 300 400 600 800 Design and function of compressed air system Functional principle of the com pressor step 4 3 Components 4 3 1 Air filter Fig 5 126 4 3 2 Oil filter Fig 5 100 32 2 TDC BDC Fig 8 Principle diagram of compressor step 1 inlet channel 2 oil injection TDC top dead centre BDC bottom dead centre The air reaches the compressor step via the inlet channel 1 The suctioning cell is closed by the subsequent vane approx at top dead centre TDC once it has reached its maximum volume When you continue to rotate the rotor the cell s volume will be decreased and this will make the air denser Shortly before reach ing the bottom dead centre BDC t
37. during operation Pay attention to tidiness and cleanliness in the working area Loosely stacked or scattered components and tools are accident sources 16 CWS CVS Compressor RPO 200 300 400 600 800 oooso ENGINEERING Safety Maintenance and trouble shooting 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 adequately 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 lf components must be replaced Pay attention to correct installation of spare parts Properly reassemble all fastening elements 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 17 CVS Compressor RPO 200 300 400 600 800 CVS 5 OOOO Technical data ENGINEERING 3 Technical data 3 1 Dimensions RPO 200 300 400 600
38. e following specifications or proven same grade oils are permitted for operating the RPO compressor Specification Value API CD SF or higher MIL L2104 C or higher Mineral oils Brand Designation up until Designation as of 2002 2002 ARAL Multi Turboral SAE 15W 40 Vanellus C6 Global Plus 10W 40 DEA Cronos Super DX SAE 15W 40 Ecomax FE PLUS ELF 10W 40 Ecomax FE 10W 40 ESSO Essolube XT 201 SAE 15W 40 Delvac 1400 Super 15W 40 SHELL Myrina TX 10W 30 Rimula Ultra 10W 40 Tab 2 Mineral oils BP Vanellus FE 10W 40 MOBIL Delvac MX 15W 40 Synthetic oils Brand Designation ALUCHEM Alusynt RRC SAE 5W 40 MOBIL Delvac 1 SAE 5W 40 ANDEROL 3057 M Tab 3 Synthetic oils Synthetic oil at deep temperatures CAUTION Use synthetic oil if the ambient temperature is 40 to 25 C 21 CVS Compressor RPO 200 300 400 600 800 Technical data 3 4 Rating plate 1 2 3 4 Typ Medi N edium ye Medium No nn D 79618 Rheinfelden O Made in Germany O End berdruck bar Wellenleistung kW Discharge Pressure barg Shaft Power kW Saugdruck mbar Drehzahl 1 min Suction Pressure mbar Speed rpm N 2 8 7 6 5 Fig 4 Rating plate Model Serial number Medium Year built Shaft power in kW Speed in 1 min Final overpressure in bar Suction pressure in mbar oNOOOIPODND 22 CVS CVS Compressor
39. e machine with screws as per Table 4 without ten sion Assembly Use the following screws to attach the compressor Screw Solidity Torque Screw in depth in the compressor casing M12 8 8 80 Nm 24 mm Table 4 Fastening screws The fastening screws for the electric motor must match the attach ment borings 36 CVS seis ENGINEERING 6 4 Drive CVS Compressor RPO 200 300 400 600 800 Installation and assembly CAUTION Ifthe drive motor is installed at a later time the selection and layout lie in the responsibility of the system designer Do not route axial forces into the compressor shaft when installing drive components Do not tap couplings or other connection com ponents onto the shaft but slide them on Check the torque and the sense of rotation ZZ Fig 19 Coupling play 6 4 1 V belt drive Motor side Compressor side 20 mm CAUTION Only install the V belt drive with additional exte rior bearing of the drive shaft The drive shaft is not designed for cross force by the belt preten sion Observe the design installation and inspection instructions of the manufacturer 3 CVS Compressor RPO 200 300 400 600 800 CVS OOOO Installation and assembly SIE Assembly E Carefully and correctly align the axles of the driving and driven shaft on all levels E Align the V belt pulleys accurately Select the V belt by l
40. ence The torque for item 30 71 is 25 Nm Oil the thread and the head rest 30 71 30 57 30 66 30 34 30 55 30 59 65 CVS Compressor RPO 200 300 400 600 800 Maintenance 8 14 Oil suction nozzle with non return valve 85 Replace the oil suction nozzle with non return valve as follows 1 Ventilate the safety valve See page 55 Chapter 8 5 aT 2 Remove the locking screw 92 EEA E 92 3 Remove the sieve insert 4 Use a wide tipped screwdriver to unscrew the oil suction noz zle with non return valve 5 Insert the suction nozzle with non return valve 6 Assembly in reverse order 66 CVS Compressor RPO 200 300 400 600 800 Maintenance 8 15 Minimum pressure non return valve 150 Test the minimum pressure non return valve 1 Switch the compressor on and let it run for about 5 minutes 2 Relieve the pressure via the pressure side line segment line to the minimum pressure non return valve 3 Ventilate the safety valve on the compressor after approx 2 hours Here there should be enough of a pressure volume in the compressor so that it can be heard exiting the safety valve If there is no pressure volume when the safety valve is venti lated the minimum pressure non return valve is leaking Re place the minimum pressure non return valve A defective minimum pressure non return valve will cause an increased residual oil content in the compressed air The set minimum p
41. ength for an even belt tension E Smallest permissible effective diameter of the pulleys 140 mm 6 5 Oil cooler The oil routed to the compressor is back cooled via a heat ex changer The following table lists the volume flow of the cooling air for the compressor Description Unit RPO 200 RPO300 RPO400 RPO600 RPO 800 Positive working pressure N barg 10 12 10 12 10 12 10 12 10 12 Oil cooler Cooling air vol m gt h 400 500 600 800 1100 Pos 190 ume flow max cooling air C 40 suction tempera ture External oil Cooling air vol m gt h 700 700 700 700 950 cooler ume flow max cooling air C 55 55 52 50 50 suction tempera ture 1 with a compressor speed of 1 500 min 2 Temperature of the air suctioned by the cooling fan for higher temperatures please consult CVS engineering Table 5 Oil cooler specifications Installing the external oil cooler Please observe the following when installing an external oil cooler m Max line length between the cooler and the compressor approx 1 m for longer line lengths please consult CVS engineering E Do not exceed the max cooling air suction temperature tem perature in the installation room of the external oil cooler indi cated in Table 5 m The oil must flow through the cooler from the bottom up m If the oil cooler is installed below the compressor an oil drain stopcock must be installed on the oil cooler or the connection line at the lowest point
42. he densified air will be ex pelled During the densifiying process oil is sprayed into decreasing cells via nozzles 2 which pick up compression and friction heat and prevents return flow losses The air filter cleans the air suctioned by the compressor The oil filter cleans the circulating oil 26 CNS CVS Compressor RPO 200 300 400 600 800 mjmjmj m 2 ENGINEERING Design and function of compressed air system 4 3 3 Minimum pressure and non return valve Fig 7 150 The combined minimum pressure and non return valve at the compressed air output is designed or adjusted so that air only can flow into the connected pressure line if there is an operation over pressure of approx 2 bar This will ensure the oil circulation in the machine even if the pressure in the consumer line is only built up very slowly or if it falls below approx 2 bar in case of large vol umes used 4 3 4 Electric motor Fig 7 239 The electric motor must be connected to the compressor step 30 00 via a form locking rotational elastic coupling The drive can also be driven by a V belt and the belt pulley Depending on the model the electric motor is switched either di rectly or via the star triangle switch The shut off or switch on of the motor depends on the respective use consumption of the com pressed air 4 4 Oil cooler Fig 5 190 The oil cooler is an air cooled heat exchanger in which the circu lating oil is cooled ba
43. il drain valve 2 reserve area 92A oil drain screw 92E oil fill screw 51 CVS Compressor RPO 200 300 400 600 800 Maintenance 8 4 2 Oil change CAUTION Perform the oil change with warm switched off and pressure free unit The oil temperature should be 30 40 C Oil level times m The oil level time depends on the operating conditions and the compression final temperature The oil level time is reduced af ter the compressor is not run within the limits indicated in the Chapter Specifications E The oil level times can be significantly increased by contamina tion E CVS engineering recommends including the oil manufacturer in the oil test and to perhaps schedule new oil change intervals Oil change on model with oil drain screw Ventilate the safety valve See Page 55 Chapter 8 5 Perform a pressure check on vehicle side gauge Unscrew the oil drain screw 92A ol gt Drain oil into suitable container Empty compressor com pletely 92A 52 CVS Compressor RPO 200 300 400 600 800 Maintenance 5 Close the oil drain screw 92A 6 Dispose of waste oil in an environmentally safe manner 7 Unscrew the oil fill screw 92E and add new oil Oil amount and specifications on page 20 Tab 2 and Tab 3 as well as Chapter 7 2 1 Adding oil page 43 ff 92E 8 Tightly close the oil fill screw 92E 9 Check the oil level during operation and add oil as needed
44. lumes also from the additional units must be ensured m The separation of input and output air must be effective E Install an additional oil cooler if needed The compressor is prepared to be connected to the vehicle control at the factory When making the electric connection observe the following m Check the supply voltage and the frequency m Route the cable without tension and friction points m Attach the cables every 300 mm After the installation perform the sense of rotation check as per Chapter 7 5 The electric motor must be connected by the operator and regu lated so that the permissible switch on frequency is not exceeded See operating instructions for max switch on frequency 42 CVS Compressor RPO 200 300 400 600 800 Start up and operation 7 Start up and operation 7 1 Safety during start up Refer to chapter 2 5 Safety Personal protective equipment See Chapter 2 4 7 2 Start up CAUTION The compressor is delivered without oil Prior to startup the compressor must be filled with oil 7 2 1 Fill oil DANGER Danger due to improper operation Only fill oil through the fill screw while the sys tem is switched off and free of pressure Protect the system from being restarted Fill oil Fill in the oil as follows Oil volume and specification on page 20 Chapter Specifications 1 Ventilate the compressor casing via a safety valve 145 Completely relieve the ove
45. lve rrrrannrnnnnnrnnannrrnannrnnnnnnnnnnnnnnnennnnne 40 S 5 I SEE ME 11 Safety equipment rarrrranrrnrnnnrrnnrrnvnnnennnnen 27 41 safety valve rrrrrrrnrrrrrnnnnvrrnnnnvrnnnnrvnvnnner 28 55 Safety VAN een 41 Scope of delivery rrrrrnrrrrrnnnrvrrnnnnvrrnnnnrnnnnnnnnnnnn 9 Sense Of rotation enneneeennennnennennnennennnennennnnen 45 Shutoff functions rrrronrrrrnnrrrrnrrnvnnnernnnennnnnen 27 SIINPOSUNG scene nennen sen 15 Sound proof hood u2222s0222sseneneenenneo 29 42 Spare parts u einsehen 9 73 GE OOOO ENGINEERING PEC EEE 12 STUP eie 16 43 Longer standstill or extended storage 46 SOAGE ee ee ee nee 32 SWIICH ee 45 Switching Off rrrnnrrnrnnrnrrnnnorrnnnennnnnnrnnnnnnnnnennnn 46 Symbols in the instructions 7 T Technical data rrrnnnnnnnnnnnnnnnvnnnnnavnnnnnnnener 18 20 Temperature safety Switch rrnrrnnnnnnrennnnnnnn 28 Thermostat c ccccsscecsseecseeeeseecseeeeeeesaneesaees 27 He eo EE 16 31 Trouble shooting rrnnrernnnrvnnnnrnvnnnrnnnnrnnnnnennnnr 17 V V belt Arive u uane en 37 Ventilating the safety valve rrrrrrnnrnnrnrnrnnnnnn 55 W VTM Gia tndan accu migusaenn sia ia EE ETEEN 8 9 Wear hearing protection ccccceceeeeeeeeeeseeees 55 82 CVS OOOO ENGINEERING CVS Compressor RPO 200 300 400 600 800 Index 83
46. mmends an inspection of the compressor by an authorised workshop In case of a longer standstill or during extended storage longer than 6 months u Perform an oil change prior to startup The quality of the oil will decrease due to condensate buildup E Perform inspections as per Chapter E Perform functional testing as per Chapter NOTE Following a longer standstill of a compressor al ready built into the vehicle CVS engineering recommends running the com pressor every 6 weeks for about 30 minutes 46 CVS OOOO ENGINEERING 7 8 Operation Positive working pressure gt 10 bar Q 7 9 Operation modes CVS Compressor RPO 200 300 400 600 800 Start up and operation CAUTION With positive working pressures of more than 10 bar the compressor should be operated in the load idle intermittent duty CAUTION The setting of the opening pressure on the mini mum pressure and non return valve must not be altered NOTE The optional oil cooler is equipped with a tempera ture dependent cooling fan which is switched on when the oil temperature reaches 75 and switched off when it reaches approx 70 As the cooling fan switches dependent on the tem perature it can suddenly start while there is current applied even if the compressor is not running NOTE The mains pressure is the pressure after the com pressed air dryer 47 CVS Compressor RPO 200 300 400 600 800 CVS
47. monitor 227 CVS Compressor RPO 200 300 400 600 800 Design and function of compressed air system To further lower the sound pressure level the compressor can be equipped with a sound proof hood You can also use a customer supplied sound proof hood Fig 11 Example CVS compressed air system with sound proof hood closed and open The optional oil level monitor can be connected either to the closer or opener By connecting suitable warning devices alarm signal warning lamp the oil level monitoring becomes more comfortable with compressor units installed inside vehicles enn I r pa if tents ge 1 b on j p Y Fig 12 Oil level monitor 29 CVS Compressor RPO 200 300 400 600 800 Design and function of compressed air system 4 7 3 Air suction cyclone 204 4 7 4 Compressed air dryer The optional air suction cyclone is used to prefilter the suctioned air Fig 13 Air suction cyclone To dry the fed compressed air you can connect a compressed air dryer The downstream compressed air dryer can cause system related pulsations in the pressure line In this case a pulsation damping valve must be installed downstream from the compressor u LS Fig 14 Example compressed air dryer and pulsation damping valve 1 Adsorption dryer 2 Pulsation damping valve 30 CVS Compressor RPO 200 300 400 600 800 Transport and storage 5 Transport and
48. mplies with the following European directives gt Low voltage guideline 2006 95 EC of the European Parliament and Council dated 12 12 2006 gt Directive electromagnetic compatibility 2004 108 EC of the European Parliament and Council dated 12 15 2004 gt Directive electric and electronic old devices 2002 96 EC of the European Parliament and Council dated 01 27 2003 gt Directive 2002 95 EC of the European Parliament and Council dated 01 27 2003 to limit the use of certain hazardous substances in electric and electronic devices ROHS Refitting or modifying the machine as a whole or on individual components will void the validity of this declaration F ee Rheinfelden December 02 2009 p p Hans Lutte Design amp Marketing EG Konformitatserlarung_Kompressor_RPO200_800_ 2009 12 02 EN Cys OOOO ENGINEERING Index A Air deoiler element rrararnnrnnanennanernnnevnnrnnnnennn 61 AARG EEE o e S 26 Air suction Cyclone rarannnrnnnnennnnnnnnnrn 30 40 56 Air suction filter re 58 Air suction regulator rrnrrrrnnrrnvnnrrvvnnrrnnnnennnnr 64 0 erect arcs Acheter nine ea re aerate 33 C Compensators rrrnnnnnnnnnnnvrnnnnnnnnnrnnnnnennnnennnnnene 68 Components MOVING ccccseeeeeeeceeseeeeeeeeeees 15 Compressed aif cccseccccseeeeceeeeeceeseeeeeeeseneeees 15 Compressed air dryer rrrrnnrnrnrnnnnvvvrnnrrvvrnnnennnnn 30 COMPpreSSof igs estan een dieu 34 Compressor
49. 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 12 CWS CVS Compressor RPO 200 300 400 600 800 oooso ENGINEERING Safety 2 5 Occupational safety and special dangers The remaining risks that result from the hazard analysis are speci fied 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 pictograms DANGER Mortal danger due to electric current identifies life threatening situations caused by electric current Non observance of the safety instructions can result in severe injuries or death Necessary work may only be carried out by an electrical specialist 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 13 CVS Compressor RPO 200 300 400 600 800 Safety CVS OOOO ENGINEERING Hazard notes and occupational safety For your own safety and that of the machine the followi
50. ng in formation must be observed and complied with Improper operation A A 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 Before carrying out regular maintenance clean ing and repair work switch off power supply and secure machine against restarting switch off drives 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 For this the machine must be secured against restarting The machine may not be under pressure or negative pressure while work is being carried out on it Close the shut off valve on the vehicle side and vent the line between the machine and the shut off valve Manually relieve the compressor overpressure at the safety valve Observe pres sure gauge The drive s protective equipment may only be removed when the machine is stationary and has to be correctly refitted after completion of work Only dismantle accidental contact protection after machine and pressure pipe have cooled down It is an environmental protection requirement that any liquids arising during maintenance work e g oil must be collected
51. nts GE OOOO ENGINEERING Transport and storage rrrrrnnnnnnnnnnnvnnnnnnnnnnnnvevnnnnnnnnnnnneennnnn 31 5 1 Safety notes for transport rrrrrnnnrrrnnnrrrrnnnrrrnrnnrrennnn 31 9 2 PPA SD OM aries seeccises davaceusecedceceGecscuesswenddee een nenn 31 39 SAGE dan 32 Installation and assembly errnnnnnnvernnnnnnnvennnnnnnnvnnnnnnnnnennnn 33 6 1 Safety during start Up rrrnrrrrrrnnrrernnrrerrnnnrrrrrnnrrennnnn 33 6 2 Installation diagram rrrrnnnnnrnnnnrnvnnnrnnnnrennnnrrnnnrrnnnnnen 33 6 3 Installing the compressor rrrnrrrrnnrrrrnrrvrnnnrnvnnrrnnnnnen 34 04 DNO Aes 37 6 4 1 V belt drive usseneeesnssnneenennnnennennnn nennen 37 MON 38 6 5 1 Cooling oil NOSES rrrrnrnnnnrnrnnnnnnrnnnnrennnnnre 39 6 6 Line connection pressure line rrrrrrnrrrrrrnnrrrnrnnrr 39 6 7 Air SUCTION cyclone rrnrrnnnnnnnnnnrennnnnennnnrnnnnnrnnnnrennnsne 40 99 FAN Ne 40 6 9 Safety equipment and control elements 41 6 9 1 Safety valve on site rrrrrrrrnrrrrrnnnrrnrnnnnre 41 6 9 2 Pressure monitor on Site 4e 41 6 10 Oil level monitor optional uus02444ee nennen 41 6 11 Cyclone separator or fine filter 41 6 12 Pulsations pulsation damping valve 42 8 13 Sound PO ho9d 2 r een 42 6 14 Electrical connection us44440nenne nenne nenne nennen 42 Start up and o
52. o death or serious injuries if it is not avoided ATTENTION points to a potentially dangerous situation which may 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 Hints and recommendations NOTE highlights useful hints and recommendations as well as information for an efficient and trouble free operation CVS Compressor RPO 200 300 400 600 800 CVS General 1 3 Limitation of liability Warranty 1 4 Copyright protection OOOO ENGINEERING 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 il lustrations described in this manual in case of special designs if additional order options are made use of or due to latest technical changes Incidentally the responsibilities agreed upon in the delivery con tract the general terms and conditions as well as the manufac turer s conditions of delivery and the statutory provisions
53. ode which will reduce the power consumption of the electric motor accordingly If the pressure monitor does not signal another pressure loss after the time that was set on the time relay the compressor is turned off completely electrically But if the demand is signalled by another pressure loss the suction regulator will open and the compressor will enter the conveyor mode once again The pressure monitor and the time relay must be supplied by the customer 48 CNS CVS Compressor RPO 200 300 400 600 800 OOOO B ETERN Maintenance 8 Maintenance 8 1 Safety during maintenance work Refer to chapter 2 5 Safety Personal protective equipment See Chapter 2 4 Environmental protection Observe the following information with regard to environmental protection during maintenance m Remove emerging used or excessive grease at all lubricating points that are manually supplied with lubricant and dispose of in accordance with valid local regulations E Collect exchanged oil in suitable containers and dispose of in accordance with valid local regulations 8 2 Cleaning CAUTION Machine damage possible Aggressive cleaning agents and substances can damage or destroy electrical cables and adjacent components Therefore Do not use cleaning agents with aggressive ingredients Remove the cleaning agent residue specifically in the oil circuit 49 CVS Compressor RPO 200 300 400 600 800 Maintenance CVS O
54. on the delivery note of the forwarder m Lodge complaint NOTE Lodge a complaint for each defect as soon as It IS recognised Compensation claims can only be submitted within the valid complaint periods WARNING Risk of injury by incorrect spare parts Incorrect or defective spare parts can result in damage malfunctions or total failure and also im pair 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 For warranty conditions refer to the General Terms and Condi tions GE CVS Compressor RPO 200 300 400 600 800 alala ja ENGINEERING General 1 8 Customer service Our customer service can be contacted for any technical advice Information about the responsible contact person can be retrieved by telephone fax E mail or via the Internet at any time refer to manufacturer s address on page 2 1 9 Declaration of conformity Declaration of conformity pursuant to EC Machinery Directive 2006 42 EC Annex II A refer to page 80 10 CNS CVS Compressor RPO 200 300 400 600 800 OOOO ENGINEERING Safety 2 Safety 2 1 Intended use The RPO compressor is intended exclusively for the compres sion of cleaned atmospheric air Only use machine for the intended use All specifications in the operating instructions must be strictly ad hered to technical data
55. operating data permissible working range refer to chapter in this regard Any 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 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 E determine the additional hazards that arise from the special working conditions at the 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 u 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 E 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
56. peratiOn snannnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnevnnnnnnn 43 7 1 Safety during start Up rrrnnrrerrnnnrevnnnrrrrnnnrrevrnnrnennnnn 43 12 SAN 43 7 2 1 FO ee en 43 1 2 2 Perform inspections rrrrnrrrrnnrrrrnnrennnnnrr 45 7 3 SMN Mee 45 7 4 Functional testing rrnnrrnnnnnrrvnnrennnnrernnrrrvnnrrrnnnrennnnr 46 15 SWIICHING Offenes aspirant 46 7 6 Operation after long standstill or after extended SON AGG REE 46 7 7 Longer standstill rrrnnnnnnnnnnnnnrrnnnnevnnrrennnrrnnnnnennnnen 46 1 3 NNN 47 13 Operaion Modes varar 47 7 9 1 Load intermittent duty rrnrrrnnnrrrnnrrnnnnnrr 48 7 9 2 Load idle intermittent duty 48 Maintenance sniecintancacesdcicesasicndecenuiaaswcsnssdevcrabeneutenniecucinueneaeds 49 8 1 Safety during maintenance WOFK cccccceeeeeeeeeees 49 92 BEIN PE EE 49 8 3 Maintenance schedule c cccececececececcueececececenees 50 CVS OOOO ENGINEERING CVS Compressor RPO 200 300 400 600 800 Contents 8 4 Oil level check and oil change ene een 51 8 4 1 Oil level check rrrrnnnrrnnnrnrnnnrnrnnnrnvanennnnne 51 8 4 2 Oil change rrnnnnrnnnnnnrnrnnnnvnvnnnnrnnnnnnnvnnnnnnnn 52 8 5 Safety valve on the compressor rrrrnrrrnnrrnrnnnrnnnnnen 55 8 6 Air suction Cyclone 204 rrrrrnrrrvrnnrrenrnnnnenvnnnnrnnnnnre 56 8 7 Cleaning the sieve insert 88 in the oil suction line
57. prior to restarting the system after lengthy storage check the system for exterior damage cracks and leaks and re place if necessary Furthermore we recommend the preventive replacement of all hose lines and compensators every 13 000 operating hours or every 6 years plus a storage period of one year even if no safety relevant damage is visible 68 CWS CVS Compressor RPO 200 300 400 600 800 mjmjmj Im ENGINEERING Malfu nctions 9 Malfunctions 9 1 Safety during maintenance work Refer to chapter 2 5 Safety Personal protective equipment See Chapter 2 4 Environmental protection Observe the following information with regard to environmental protection during maintenance m Remove emerging used or excessive grease at all lubricating points that are manually supplied with lubricant and dispose of in accordance with valid local regulations E Collect exchanged oil in suitable containers and dispose of in accordance with valid local regulations Never restart the compressor after it has been shut off due toa malfunction without checking the cause and remediating the error With malfunctions that cannot be alleviated by means of the follow ing instructions please contact the supplier Addresses gt page 2 Malfunction Possible cause Corrective action Execution Compressor final Cooling air or suction air tem Ensure a better aeration and Specialist temperature too perature too high ventilation of the installation
58. r service Phone 49 0 7623 71741 31 Always mention the following information when ordering spare parts Data Example Order no 100208 Year built 2008 Machine type RPO 600 LA Machine no L10007 00 Spare parts list no Item no Part no 432700 00 Quantity 1 Designation Air deoiler element Order no 100208 Table 9 Data for spare parts ordering 1 Data see rating plate of compressor The following drawings show all individual parts needed for the as sembly By indicating the item no and the size of the compressor these parts can be allocated Model Drawing no Designation Drawing no RPO 200 RPO 800 940086 00 940071 00 940040 00 250176 00 item no used Assembly drawing com 940086 00 1 170 pressor Step 940086 00 30 940071 00 31 80 Oil temperature regulator 940086 00 100 940040 00 5 30 Assembly drawing unit 250176 00 171 260 and accessories Example Item no 30 48 30 Main parts list compressor 48 Sub parts list Slide ring seal 13 CVS Compressor RPO 200 300 400 600 800 CVS I OODEO Spare and maintenance parts ENGINEERING 10 1 1 Assembly drawing of compressor RPO 200 800 drawing no 940 086 00 chlagen Art Nr Fortlaufende Masch Nr i Beispiel 940 086 00 20 Schrifth he 10 mm eins 6 11 52 104 94 161 162 G MI m I L r CT n m FT DE F N Sc all Lo N Wi LL
59. ressure ex factory is approx 2 barg 150 Fig 26 Minimum pressure non return valve 8 16 Compressor step 30 Usually maintenance of the compressor step is not required CVS engineering recommends having the compressor maintained over all by specialised staff as a preventive measure after approx 18 000 operating hours or after 8 2 years CVS If there are ab normal sounds coming from the compressor have it tested by CVS engineering or one of their authorised workshops 67 CVS Compressor RPO 200 300 400 600 800 CVS OOOO Maintenance ENGINEERING 8 17 Electric motor CAUTION Observe the manufacturer s operating and mainte nance instructions The maintenance of the drive motor is usually limited to the follow ing m Checking the air passages E Opening existing closed condensate water openings m Testing the condition of the respective switches and connec tions E replacing the roller bearings after 40 000 operating hours 8 18 Hose lines and compensators The function and standstill times of hose lines oil line e g when using exernal oil coolers and compensators flexible connection between the compressed air outlet on the compressor and the compressed air after cooler can be impaired by vibration exterior affects and aging Therefore we recommend the following actions pertaining to all hose lines and compensators E atleast once a year E inthe course of maintenance procedures
60. rk pressure after dryer is probed and compared to the minimum and maximum pressures set on the pressure monitor The pressure monitor emits an electrical signal to the control which shuts the compressor off or switches it on Further information is contained in the operating instructions of the pressure monitor 6 10 Oil level monitor optional The oil level monitor can be connected either to the closer or opener Further information is contained in the operating instructions of the level monitor 6 11 Cyclone separator or fine filter To further improve the quality of the compressed air an additional cyclone separator or a fine filter can be installed downstream 41 CVS Compressor RPO 200 300 400 600 800 CVS Installation and assembly OOOO ENGINEERING 6 12 Pulsations pulsation damping valve Pulsations of downstream devices 6 13 Sound proof hood Notes 6 14 Electrical connection Electrical mains connection Electric motor If there are devices installed downstream of the compressor which cause sudden pulsations pressure break ins such as adsorption dryers a pulsation damping valve must be installed downstream of the compressor CAUTION Pulsations cause malfunctions in the compressor NOTE Please consult CVS engineering if you decide to install a sound proof hood afterwards Observe the following during installation A sufficient cooling air volume to reroute the heat vo
61. rpressure See Page 55 Chapter 8 5 2 Open the oil fill screw 92E and add oil e g through a funnel 92E 43 CVS Compressor RPO 200 300 400 600 800 Start up and operation The required oil amount can only be filled by performing the procedure twice During the first filling procedure only fill the oil to the bottom edge of the fill opening approx 1 9 I Close the fill screw Close the safety valve Run the compressor for about 5 minutes to warm it up The oil cooler and the oil filter is filled Switch off the compressor Ventilate the compressor casing via the safety valve Open the oil fill screw and fill in the required remaining volume RPO 600 and RPO 800 10 Close the safety valve and the oil fill screw 44 7 2 2 Perform inspections Inspections prior to initial startup Sense of rotation 7 3 Switch on CVS Compressor RPO 200 300 400 600 800 Start up and operation The following points must be checked prior to initial start up Correctness of data on the rating plate Oil level as per page 51 Chapter 8 4 Sense of rotation of the compressor see sense of rotation ar rows see Fig 20 Correct connections of the compressed air lines see Page 39 Chapter 6 6 Correct connections of the cooling oil lines see Page 39 Chapter 6 5 1 Electrical connection see Page 42 Chapter 6 14 Screw connections for tightness Correct adjustment of the vehicle side pressure
62. s rrrnnrnnnrnnnnrvnnnvrnnnnnnnnnnnnnnnnnnn 12 2 4 Personal protective equipment rrrnnrrnrnnnrrvnnrrnvnnrennn 12 2 5 Occupational safety and special dangers 13 3 Teenager 18 3 1 Dimensions RPO 200 300 400 600 rrrrnnnrrevvnnrnennnnn 18 3 2 Dimensions RPO 800 nuuuussnsssnennennnennennnn nennen nen 19 3 3 Technical aldi 20 3 4 Rating plate rernnnrornnnnornnnnvrnnnvrnnnvvvnnnvnvnnnennnnnennnner 22 4 Design and function of compressed air system 23 A PEN eten 23 4 2 Fidje 25 43 ComponentS uagmeuaruendseur eies 26 4 3 1 Air fiter FIG 5 120 nee 26 4 3 2 Oil filter Fig 5 100 32 rrrrrnnrrorrnrnevrnnnnnnn 26 4 3 3 Minimum pressure and non return valve ge 0 T AE E A 27 4 3 4 Electric motor Fig 7 239 27 4 4 Oil cooler Fig 5 190 rrrrnrnnnnnnnrnnnnnrnnnnnnnnnvnnnnrnnnnnnnn 27 4 5 Thermostat Fig 5 100 rurnronnrrnnnnnrnnrnnrrenrnnnrennnnnnnn 27 4 6 Safety and shutoff functions uu020400 nennen 27 4 6 1 Safety valve Item 145 rrrrrrnrrrnnnnnrernnnnnnn 28 4 6 2 Temperature safety switch Item 161 28 ar NG 29 4 7 1 Sound proof hood ccccceeececeeeeeeeeeeeeees 29 4 7 2 Oil level monitor 227 rrrrrnnnnnnrnnnnrnnnnnnnnn 29 4 7 3 Air suction cyclone 204 rrrrrnnrrrnnnrrrnrnnnr 30 4 7 4 Compressed air Cryer ccccceseeeeeeeeeeeeens 30 CVS Compressor RPO 200 300 400 600 800 Conte
63. so see Page 33 Fig 16 When restarting the compressor against the relieved pressure line the required startup power of the electric motor is lower which avoids an excessive heatup of the electric motor winding with fre quent start and stopp cycles The pressure in the compressor in front of the minimum pressure valve is still at approx 2 bar after the line network has been re leased 40 CVS OOOO ENGINEERING CVS Compressor RPO 200 300 400 600 800 Installation and assembly 6 9 Safety equipment and control elements 6 9 1 Safety valve on site Risk of explosions To protect from unauthorised excession of the permitted positive working pressure safety valves must be installed at the site Install the safety valves in the locations where the line networks are separated e g back flap The site must provide suitable control elements such as pressure monitors to switch the compressor on and off according to the pressure The safety valves prevent the excession of the permissible max pressure DANGER Risk of injury by explosions Explosions can cause severe injuries Therefore Install the safety valve as instructed Observe the manufacturer s instructions Only use the safety valve for its intended pur pose Never block the safety valve 6 9 2 Pressure monitor on site The pressure monitor is used to control the compressor For this the pressure provided by the netwo
64. st severe injuries Therefore Only check the safety valve while wearing pro tective gloves and safety goggles Wear hearing protection Wear hearing protection when venting the system and when performing a functional test of the lifting device Ventilate the system as follows Turn the cap on the safety valve all the way to the left 2 Donotclose the safety valve until no more compressed air is escaping 3 Close the safety valve For this turn the cap on the safety valve all the way to the right Eu a pas h gt gt A E h ee i r Ti F Ailai KN i Fig 23 Ventilating the safety valve 55 CVS Compressor RPO 200 300 400 600 800 Maintenance Functional testing Perform a functional test in the following circumstances OF Mes Ung EENIGE during initial operation m after interruption of the operation pursuant to the operating conditions and maintenance intervals to be specified by the operator refer to TRB 600 and AD data sheet A 2 E during the external or internal test of the respective pressure vessel The manufacturer of the safety valve recommends to perform an additional functional test once per month Perform the functional test pursuant to AD data sheet A 2 para 4 7 and according to the following description 1 Turn the lift button anti clockwise until you distinctly hear that the operating medium is blown off NOTE Do not unscrew
65. the compressed air dryer 2 The temperature in the installation room must not exceed 40 3 The length of the cooling coil is to be selected so that the input temperature into the compressed air dryer does not exceed 60T CVS Compressor RPO 200 300 400 600 800 CVS OOOO Installation and assembly SIEHE 6 3 Installing the compressor CAUTION CVS engineering recommends having the installa tion performed and checked by CVS engineering Positive working pressure gt 10 bar CAUTION With positive working pressures of more than 10 bar the compressor should be operated in the load idle intermittent duty Avoiding storage damage CAUTION The compressor must be attached to the vehicle frame using rubber elastic bearings A non observance can lead to storage damage on the compressor and the electric motor NOTE CVS engineering would gladly assist you with the selection of a suitable installation location in the vehicle The machine is attached to the compressor and the electric motor via 2 attachment locations each Attachment requirements E The attachment points on the vehicle must feature a sufficient load capacity and rigidness m The attachment points must be on the same level m The fastening screws must feature a sufficient clamping length Installation location requirements The installation location must fulfill the followoing requirements E protect from dirt falling rocks and spray water M no
66. the lift button too far out of the spring center bolt 2 Turn the lift button clockwise as far as it will go 3 Now the safety valve is operative once more 8 6 Air suction cyclone 204 If the compressor is equipped with an air suction cyclone this must be tested and cleaned as per the maintenance table 204 Fig 24 Air suction cyclone 56 CVS Compressor RPO 200 300 400 600 800 Maintenance 8 7 Cleaning the sieve insert 88 in the oil suction line Clean the sieve insert in the oil suction line as follows 1 Ventilate the safety valve See Page 55 Chapter 8 5 2 Unscrew the locking screw 92 be 92 3 Take the sieve 88 out of the boring and clean with e g com pressed air Here make sure that the nozzle boring of the non return valve is not obstructed The non return valve re mains in the compressor casing 88 4 Insert the sieve 5 Tighten the locking screw 57 CVS Compressor RPO 200 300 400 600 800 Maintenance 8 8 Air suction filter 126 Clean or replace the air filter as follow 1 Ventilate the safety valve See Page 55 Chapter 8 5 2 Unscrew the cylinder head screw 35 rer er 35 120 Q 3 Remove the lid 120 and take out the air filter 126 126 4 The air filter can be cleaned once if it is not too contaminated For this tap the air filter Blow compressed air through the fil ter from the inside out
67. y warning and operating in structions in a well legible condition Immediately replace damaged or obliterated signs or labels 15 CVS Compressor RPO 200 300 400 600 800 CVS OOOO 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 the intended transport borings Start up 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 his authorised representatives or by trained personnel Start up and operation may only be performed by adequately qualified personnel that has been authorised and instructed by the operator Before the start of any work ensure that all covers and protective devices are correctly in stalled and function correctly Never override any protective equipment

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