Operating instructions
Contents
1. points to a potentially dangerous situation which may lead to 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 Safety note ATEX Only for machines with Ex approval This pictogram denotes the special conditions that must be observed according to the approvals when operating the machines in potentially explosive areas NOTE highlights useful hints and recommendations as well as information for an efficient and trouble free operation 3 O88 B B P CVS OOOO ENGINEERING 1 3 Limitation of liability Warranty Wear parts 1 4 Copyright protection VacuStar W900 W1300 W1600 General 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 illustrations described in this manual in case of special designs2. m lf hazardous or poisonous material were conveyed the machine must be decontaminated prior to disposal H The machine has to be disposed of in accordance with the respective country specific regulations 33 VacuStar W900 W1300 W1600 Index Index A Acceptance naiiinaaaaaaaanaaaananasananaaaananannaananaa 10 Action SUCKING OV r inaaananaananaaa aaaananaaananananaa 27 ME ee ans 9 22 C Cleaning 6 2 6 EE renner T NENNE NERREENRER 27 SUCTION filter aiaaaaaaaaaiaaaan nannnnnnnnnnnnnnnnnnnn 28 VI 26 Components MOVING cseeeecceeeeeeseeeeeeeeeeeeees 14 Compressed air rrrrnnnnnnnnnvrnrnnnnnnnnvornnrnnnnnnnnnnee 14 Contact BEI SON une 8 Copyright Protection ccccccecccceeeesseseeeeeeeeeeaes 7 Customer Service aaiinaaaaaaaasaaaaaaaanananuaaannann 8 D Danger of burns rrnrrnnnnnnovvnnnnnnvennrnnnnnvennnnnnnsenn 12 Danger pictogram aaaiaaananaaasnaaas naaaanaaanana 12 Danger pictograms rrrnnnnrvnrnnnnvnnnnnnvnnnnnnrvnnnnee 12 BE ge EE a ne 12 DISPOSA ENE 33 E Explosion protection aiiinaaasaaaa nss nasananaa 12 F F NCHON ans E 18 H Height wear rotor VANGS ccccseeeeeeeeeeeeeneeees 29 Improper operation ccccesececceeseeeseeseeesseeees 13 Inspection Cell VENIAM ON aa nn 24 during operation aaaainaaaaaaiaaaaas nasasanaaaan 21 UDCA Ol unse 23 non return valve einen 24 pri
3. 11 2 5 1 Requirements naaanaaaaaaaaaaaanaaanunananunnnnnnnnnnnnnnnnni 11 2 6 Personal protective equipment aaaiaainaaasaaani 12 2 Occupational safety and special dangers 12 Technical data nn nennen 17 Design and function aaa2aaaanaaaanvnnununnnunnnnnnununnnnnnnnunnnnnnnnnn 18 Al DOSO b a a 18 B FOO Ne 18 4 3 Control and display elements aan aaina siasa aasnaani 19 Transport and storage xrrrnnnnnnnvnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnenn 20 5 1 Safety notes for transport nanaaaaannsnaasnsssnnnnanaa 20 92 TOP DO nennen 20 Er SN 20 Start up and operation aaaaaaaaaaaaaanannunnnnunaunnnnnnnnnnunnnnnnnna 21 6 1 Safety during Start Up rrrrnnnnrrnorrrrrrnnnnnrnrrrnnrrrnnnnnnnner 21 ID EEE 21 63 SWIIENING Ol nn an 22 6 4 Inspections to be performed aaiinaaaasiaaasaseaaaani 23 MAINLENAaNce nen 25 7 1 Safety during maintenance work ccccceeeeseseeeeeees 25 7 2 Maintenance SCHedUIe cccccsscecsseeeseseeteseeeteeeens 25 7 3 Performance of maintenance Work a aina inna 26 VacuStar W900 W1300 W1600 Contents Cys OOOO ENGINEERING VANTIN IONS eee 30 DIE een een 30 8 2 Recommissioning after corrective action 30 8 3 Malfunction table ainaaaaaaaaaaaaaaaaaaaanaaaaanaaaanaaaaaaaa 31 I SES 33 10 Decommissioning and
4. can cause the most serious injuries Therefore during operation Itis absolutely forbidden for individuals 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 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 under high pressure and injure e g the eyes Therefore Before starting any work first depressurise pressurised components Pay attention to accumulators Accumulator pressure must also be completely relieved Do not change pressure settings beyond the maximum values Signposting WARNING Risk of injury due to illegible pictograms Labels and signs can become dirty or unrecognisable in the course of time Therefore Always keep safety warning and operating instructions in a well legible condition Immediately replace damaged or obliterated signs or labels 14 ENGS VacuStar W900 W1300 W1600 D0080 ENGINE
5. cartridge Check for damage after cleaning A damaged cartridge must be replaced Check round sealing ring on casing lid for damage Damaged sealing rings must be replaced m After cleaning reassemble the filter in reverse order Fig 3 Suction filter 1 Star handle 4 Air inlet soiled air 2 Casing 5 Air outlet filtered air 3 Filter cartridge 28 CVS OOOO ENGINEERING Check rotor vane s height wear VacuStar W900 W1300 W1600 Maintenance Carry out the first inspection either after 6 months or after 500 operating hours depending on which occurs first The following inspection has to be scheduled according to the measuring result NOTE Pay attention during the inspection that no liquid dirt or other objects get into the vacuum pump Procedure E Dismantle vacuum filter and if necessary suction line m Press rotor vanes into the rotor slit in horizontal position and measure the distance to the rotor surface with the depth gauge E The wear measurement of 6 mm may not be exceeded Replace rotor vane if necessary Fig 4 Cross section through the VacuStar 1 Depth gauge max 6 mm 4 Casing 2 Rotor vane 6x 5 Rotor 3 Rotor slit 6x 29 VacuStar W900 W1300 W1600 Malfunctions 8 Malfunctions 8 1 Safety Personnel Personal protective equipment Environmental protection Conduct in the case of malfunctions Cys OOOO ENGINEERING This chapter describes pos
6. 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 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 delivered to the customer Wear parts are all components coming into immediate contact with the material to be processed e g bearings shaft sealing rings oil pumps rotor vanes etc These components are excluded from the warranty and any claims for defects as far as wear and tear damage is concerned Surrendering the operating instructions to third parties without written permission of the manufacturer is not permitted NOTE Content details texts drawings pictures and other illustrations are protected by copyright and are subject to industrial property rights Any improper use Shall be liable to prosecution Any type and form of duplication also of extracts as well as the exploitation and or communication of the contents are not permitted without the manufacturer s written declaration of consent VacuStar W900 W1300 W1600 CVS OOOO General ENGINEERING 1 5 Spare parts WARNING Risk of inj
7. level at the inspection glass and if necessary fill with oil to approx 3 cm below the filler neck thread The oil level may not drop below the bottom mark on the oil inspection glass Manual prelubrication of the machine is always necessary M incase of initial operation E in case of recommissioning after a standstill of more than 4 weeks H after sucking over of foreign matter E after repair work on the VacuStar Procedure to be followed for manual prelubrication H Remove the crank handle from the retaining bracket and push it through the oil filler neck onto the oil pump shaft Push the crank handle down until the drive dog engages and now prelubricate for approximately 40 full turns m Afterwards clip crank handle back into the retaining bracket and screw locking screw back on again 2 Fig 2 Oil pump 1 Crank handle 3 Lubricating oil pump 2 Oil filler neck screw 4 Lubricating oil drain screw The oil reservoir must be filled up before every suction process 23 VacuStar W900 W1300 W1600 Start up and operation Non return valve inspection Safety valve inspection Inspection of the ventilating valve Inspection of cell ventilation Cvs OOOO ENGINEERING The non return valve is maintenance free but is subject to wear like all other moving parts We recommend a visual inspection every 6 months In this connection the non return valve must be dismantled cleaned freed of dep
8. s eccentric arrangement inside the casing limited crescent shaped working chambers are created by means of the rotor vanes which are enlarged or reduced with every turn of the rotor Cleaned air is drawn in via the suction connection item 14 and reaches the pressure line after being compressed via the pressure connection item 4 The machine is lubricated by means of an oil pump Oil is pumped from the oil reservoir via the oil lines to the machine s lubricating points CVS OOOO ENGINEERING Cooling Drives VacuStar W900 W1300 W1600 Design and function The machine is water cooled The machine is equipped with a cooling jacket inside the casing The cooling water circulates by means of a circulating pump The VacuStar can be powered via H Articulated shaft m V belt H Hydraulic motor Details about the drives and their design can be found in the separate installation instructions for the VacuStar 4 3 Control and display elements Depending on the installation situation different display elements such as pressure gauge temperature gauge and vacuum gauge are available VacuStar W900 W1300 W1600 CVS OOOO Transport and storage Ne 5 Transport and storage 5 1 Safety notes for transport Refer to chapter 2 7 Safety 5 2 Transport The machine which is fastened on a base plate must be transported with a fork lift or suitable straps The lifting gear must be designed for the weight of
9. the machine For future transports E Seal all open connections with protective caps prevents penetration of dirt and water Secure loose cables Secure against vibrations Drain all process and operating media Securely fasten the VacuStar prior to transport e g screw it onto a pallet H Transport and put down machine 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 H 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 If storage lasts longer than 3 months regularly check the general condition of all parts and of the packaging If necessary brush up or recondition the preservation H To keep moisture away from the machine s workspace bags with desiccant must be placed into the inlets and outlets These must be removed before start up 20 ENS VacuStar W900 W1300 W1600 OOOO ENGINEERING Start up and operation 6 Start up and operation 6 1 Safety during start up Refer to chapter 2 7 Safety 6 2 Start up Inspection prior to initial start up The following points must be checked prior to initial start up m Fill in cooling water clean tap water up to the maximum mark on the compensation reservoir Add antifreeze accordi
10. 301 Motor Oil 40 Titan Universal HD 40 Delvac 1340 Rimula X Monograde 40 Suction temperature 10 C Basic Turboral SAE 30 Special HDC 30 Vanellus C3 30 Energol C DG 30 Essolube XD 3 Motor Oil 30 Essolube XD 301 Motor Oil 30 Titan Universal HD 30 Delvac 1330 Rimula X Monograde 30 Only in conjunction with cell ventilation without cell ventilation 200mbar protection via ventilation valve Protection via a safety valve VacuStar W900 W1300 W1600 Design and function 4 Design and function 4 1 Design Fig 1 View VacuStar and details 1 Centring device and fastening 6 of hydraulic motor mounting 1 flange 8 2 Drive shaft 9 3 Cooling water inflow 1 10 4 Pressure connection 11 flange DIN 28459 125 5 Temperature measuring point R Ye 4 2 Function Functional principle Machine lubrication CVS OOOO ENGINEERING Connection cell ventilation R 2 12 Transport and fixing holes Oil level indicator bilateral M16 Crank for manual lubrication 13 Negative pressure connection Rating plate R 3 8 Oil filler neck cap 14 Suction connection Sense of rotation arrow flange DIN 28459 125 15 Cooling water outflow R 1 16 Lubricating oil reservoir Sliding vane compressor vacuum pumps work according to the displacement principle Due to the rotor
11. CVS see LI ENGINEERING Operating instructions VacuStar W900 W1300 W1600 Doc ID BA EN 0001 V05 Release 11 2007 The operating instructions must be read by the machine operator and before start up CVS engineering GmbH GrossmattstraBe 14 D 79618 Rheinfelden Germany Phone 49 0 7623 71741 0 Customer service 49 0 7623 71741 31 E mail info cvs engineering de Internet www cvs eng de Created by alphatec Technische Dokumentationen Basler Str 1 D 79639 Grenzach Wyhlen Germany www alphatecnet de CVS OOOO ENGINEERING Contents VacuStar W900 W1300 W1600 Contents E Ale eee R 5 1 1 Information regarding the operating instructions 5 1 2 Pictogram explanation aaaaanaaananaaa nasanananananananaaa 6 1 3 Limitation of liability nnaaaaaanaaaananaaaanannanaannaaannanaaa 7 1 4 Copyright protection aaaaiiaaaaaaanaaannaaaaaananunaaaanaaanl 7 15 SIAL PMS nenn 8 1 6 Warranty conditions aanaaainaaananaan nanannannnnanananaaa 8 1 7 Customer Service iu 8 1 8 Manufacturer s declaration ccccccesccesssseceeeeeeeeeeees 8 S E O E T 9 21 Mendea Une a 9 2 2 Proper operation a naaiaaaaaaaaaaaanaaaaaaaanaaanaaannaaanaaanaa 9 2 3 Acceptance and monitoring naaiaaaaaaasaaasnaaanaaan 10 2 4 Operator s responsibility 002220000220nne nennen 10 2 5 Operating personnel u
12. ERING Safety Improper transport DANGER Danger by falling down or tilting of the machine The weight of the machine may injure a person and cause serious bruising Therefore Depending on the dead weight and size of the machine use a pallet on which the machine can be moved by means of a fork lift For lifting the machine use suitable lifting gear slings etc that is designed for the weight of the machine When putting the slings in position take care to avoid putting stress on individual components Only use attachment points with eye bolts provided for that purpose Start up operation WARNING Risk of injury due to improper start up and operation 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 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 15 VacuS
13. Operator Maintain nominal vacuum Changed vacuum check exhaust system and Operator clean if necessary Non return valve rattles Check non return valve Sa i Remove foreign matter Rinse Specialised Foreign matter in the machine Apna chine staff Immediately switch off machine Specialised alle HE and repair staff Compressed air End pressure too high Maintain nominal pressure Operator S too Exhaust silencer clogged Replace exhaust silencer a i Four way cock in wrong position Correctly adjust four way cock Operator Replenish cooling water clean Poor cooling radiator clean cooling water Operator chamber inside the machine Valve plate in non return valve is Check non return valve and Specialised jammed clean if necessary staff Vacuum filter clogged Clean vacuum filter Operator Vacuum too high Maintain nominal vacuum Operator 31 CVS VacuStar W900 W1300 W1600 njaln fm Malfunctions ENGINEERING Malfunction Possible cause Corrective action Execution Operating Pressure gauge or vacuum Replace pressure gauge or Specialised pressure or meter do not indicate correctly vacuum meter staff operating vacuum ES Check V belt tension and re Operator is not obtained ppIng tension if necessary Four way cock in wrong position Correctly adjust four way cock Operator Condensate drain cock open Close condensate drain cock Operator Cooling water Too little cooling water in cooling Top up cooling water Operator temperature system exce
14. These then have to be subjected to an inspection by specialised staff In case of queries regarding the maintenance work and intervals contact the manufacturer Service address gt page 2 For maintenance schedule refer to next page 25 VacuStar W900 W1300 W1600 CVS mmm fm Maintenance SENERE Table maintenance schedule Interval Maintenance work To be carried out by Check operating speed Check operating pressure vacuum Every 15 minutes Operator Check air outlet temperature Check cooling water return temperature Check condensate Check safety trap Daily Check silencer oil trap Operator Check oil level and top up with fresh oil if necessary Check coolant Check safety valve Check ventilating valve Clean cooling unit water cooler Weekly Clean compressor vacuum pump Operator Clean vacuum filter Check V belt V belt tension and re tension if necessary Clean cell ventilation filter replace if damaged Monthly Clean oil tank Check fastening screws and tighten if necessary Operator Check shaft sealing rings for tightness no oil may leak from them Quarterly Check rotor vanes wear Specialised staff Check cell ventilation valve Specialised staff Half yearly Check non return valve of stage Specialised staff 10 000 oh 3 years Replace shaft sealing rings Specialised staff 15 000 oh 5 years Replace bearings Specialised staff 7 3 Performance of maintenance work Cleaning the VacuStar Carrying out c
15. achine identification II 2G c IIB T2 i for machines without cell ventilation Ex II 2G c IIB T3 i for machines 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 The following criteria in essence define the proper operation Machine speed range 1000 1500 rom Ambient temperature 20 40 C No coast down of the cooling system after switching off the machine Permissible continuous duty vacuum with cell ventilation 100 mbar Permissible continuous duty vacuum without cell ventilation 200 mbar No back pressure on the pressure side during vacuum operation Liquids and solids may not get into the machine or be sucked into the machine If potentially explosive gases and gas mixtures are conveyed the following guidelines must be observed 94 9 E6 ATEX 95 Requirement on equipment 99 92 E6 ATEX 137 Assembly installation and operation of equipment VacuStar W900 W1300 W1600 CVS OOOO Safety ENGINEERING Only use machine for the intended use All specifications in these operating instructions have to be strictly complied with technical data ATEX regulations etc 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 3 Acc
16. all covers and protective devices are correctly installed and function correctly After completion of maintenance work and trouble shooting check correct functioning of safety equipment 16 CYS OOOO ENGINEERING 3 Technical data VacuStar operating data Nominal operating vacuum Permissible continuous duty vacuum Maximum final overpressure during compressor operation in case of direct drive Maximum final overpressure during compressor operation in case of V belt drive Oil reservoir Lubricating oil consumption Weight without accessories Table 1 Operating data Lubricating oils VacuStar W900 W1300 W1600 Model Unit W900 mbar 400 mbar 100 bar 2 bar 2 I 75 l h 0 2 kg 220 Technical data Model Model W1300 W1600 400 400 100 100 2 2 1 5 0 5 7 5 7 5 0 3 0 4 279 339 The use of multigrade oils 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 API MIL Table 2 Lubricating oils Lubricating oil types Brand ARAL AVIA BP ESSO FUCHS MOBIL SHELL Table 3 Lubricating oil types Value CD SF or higher L2104 C or higher Suction temperature gt 10 C Basic Turboral SAE 40 Cronos Super SAE 40 Vanellus C3 40 Energol C DG 40 Essolube XD 3 Motor Oil 40 Essolube XD
17. at 20 C suction temperature may not exceed the following values m 140 C at 400 mbar operating vacuum H 120 C at 0 5 mbar excess pressure 21 VacuStar W900 W1300 W1600 Start up and operation 6 3 Switching off Cys OOOO ENGINEERING Safety note ATEX If potentially explosive gases and gas mixtures are conveyed the following points must be observed H Prior to every machine start and during operation Check coolant Check oil level Check for leaks m During the suction process pay attention to abnormal noises and switch off machine if necessary Regularly examine the machine daily for signs of overheating and exceptional deformations If necessary switch off machine or do not put into operation E Regularly examine the machine for leaks such as leaking oil or water or escaping gas If necessary switch off machine or do not put into operation If the machine is extremely hot Switch off machine and only switch on again after approximately half an hour to prevent the rotor from starting To switch off the VacuStar proceed as follows m Switch off drive for the VacuStar H Close shut off valves if available 22 ENS VacuStar W900 W1300 W1600 ajajaj fm Start up and operation ENGINEERING 6 4 Inspections to be performed Lubricating oil inspection Only lubricating oils pursuant to the lubricating oil schedule on page 17 are approved for the VacuStar W series Check oil
18. chine and inform them about potential hazards In addition it is the operator s responsibility to ensure that H the machine is always in a technically perfect condition H the machine is maintained in accordance with specified maintenance intervals E all safety equipment is regularly checked for completeness and correct functioning 10 ENS VacuStar W900 W1300 W1600 OOOO ENGINEERING Safety 2 5 Operating 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 have been instructed during instructions provided by the operator with regard to the work assigned to them and possible hazards 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 VacuStar W900 W1300 W1600 CVS OOOS8O Safety ENGINEERING 2 6 Personal protective equipment It is necessary to wear personal protective equipment when dealing with the machine so as to minimise healt
19. disposal nnrrnnnnvernnnnnevnnnnvennnnnvennnn 33 ale gt REE EE 34 ENS VacuStar W900 W1300 W1600 OOOO ENGINEERING General 1 General 1 1 Information regarding the operating instructions These operating instructions provide important information on how to deal with the machine Prerequisite for safe working is the observance of all specified safety notes and instructions In addition the local accident prevention regulations valid at the machine s area of application and general safety regulations have to be complied with 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 instructions must also be handed over VacuStar W900 W1300 W1600 General 1 2 Pictogram explanation Warning notes Hints and recommendations Cys OOOO ENGINEERING Warning notes are characterised by pictograms in these operating instructions The warning notes are preluded by signal words expressing 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
20. eds 60 C Radiator soiled or compressor Clean radiator clean cooling Operator cooling water chambers silty water chambers on compressor Silt or liquid has Rinse thoroughly with diesel gotten into the oil mixture at lowest machine Foreign matter has been sucked permissible speed and without i pressure or vacuum afterwards Operator over into the machine cee i add lubricating oil according to chapter Lubricating oil inspection page 30 Power requirement Speed too high Maintain speed limit Operator too high l Maintain nominal pressure End pressure too high actuate check safety valve Operator Pressure gauge indicates incorrectly Replace pressure gauge Operator Exhaust silencer clogged Replace exhaust silencer un on 9 Oil intake strainer in oil tank Clean oil tank and intake Operator tank p clogged strainer check oil lines p e valves in the pressure Open valves Operator Safety valve blows off Clogging in pressure system Eliminate clogging Operator Exhaust silencer clogged Replace exhaust silencer Ba Ventilating valve Closed valves in the suction line Open valves Operator responds Clean suction filter if Suction filter clogged necessary replace filter Operator cartridge Compressed air blows off at shaft Replace radial shaft sealing Specialised end and oil is Soalliie BANE aufs GAMES rings in sealing cover staff leaking Rubber smell at V Ve slip due too insufficient Check belt tension re tension if Operator belt drive elt t
21. ension necessary End pressure too high Maintain nominal pressure Operator Reversing of V reser Check belt tension re tension if Operator belts necessary Worn V belts Put on new V belts Operator Pulleys are not aligned Align pulleys a Worn V belt pulleys Replace pulleys Fre 32 CVS OOOO ENGINEERING 9 Spare parts Spare and wear parts VacuStar W900 W1300 W1600 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 orders repairs replacement machines and dispatch of fitters please contact our customer service Phone 49 0 7623 71741 31 Model Service package Filter cartridge VacuStar W900 900 000 SP VacuStar W1300 990 001 SP VacuStar W1600 990 002 SP Suction filter 1600 F 432 020 00 Suction filter 1600 G 432 021 00 10 Decommissioning and disposal A VacuStar unit 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 H Prior to decommissioning and disposal of the machine it must be completely separated from the surrounding units H The disassembly and disposal of the machine may only be carried out by specialised staff
22. eptance and monitoring The VacuStar W itself is not subject to any acceptance and monitoring obligation 2 4 Operator s responsibility The machine is used for industrial purposes The operator of the machine 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 E inform himself on the valid industrial safety regulations H 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 instructions H check at regular intervals during the machine s entire period of use whether the user instructions correspond to the current state of the body of rules and regulations E adapt the operating instructions if necessary to the new regulations standards and operating conditions m clearly regulate the responsibilities for installing operating maintaining and cleaning the device H ensure that all employees working on or with the machine have read and understood the operating instructions In addition he must at regular intervals train the employees in how to deal with the ma
23. ge or malfunction at the control system 3 Ensure that nobody is staying in the hazard area Start in accordance with the instructions in chapter start up 30 CWS VacuStar W900 W1300 W1600 ajaja u X BA Malfunctions 8 3 Malfunction table Malfunction Possible cause Corrective action Execution Compressor s Vacuum filter soiled Clean vacuum filter Operator vacuum pump s Leaky suction line fittings Look for leaky spots and Specialised delivery rate eliminate leak staff decreases Speed too low Adjust speed Operator Wear of rotor vanes possibly caused by dirt or liquids Replace rotor vane remove dirt that have gotten into the and have machine overhauled SEn Bs staff machine sucking over of foreign at an authorised workshop matter Abnormal noise Weis al Al hi z emission acnine Is out ot alignmen Ign macnine accurately Specialised bear z staff Bearing defective eplace bearing or have it replaced Lack of lubricating oil Top up oll clean all sense Operator and suction filter a Fill in oil according to Unsuitable lubricating oil TR Operator Rotor vanes are jammed Check rotor vanes u Have casing bore re turned and Casing bore shows grooves or honed at an authorised Specialised corrugations due to the workshop In case of heavily oe SR staff aspiration of dirt soiled intake air install fine filter Wrong speed Maintain speed range Operator Changed pressure Maintain nominal pressure
24. h hazards m Before carrying out any work properly don the necessary protective equipment such as gloves safety goggles etc and wear during work 2 7 Occupational safety and special dangers The remaining risks that result from the hazard analysis are specified in the following section Observe the safety notes listed here and the warning notes in the other chapters of these instructions to reduce health hazards and to avoid dangerous situations Danger pictograms on the device The relevant dangerous spots on the machine are identified by these pictograms DANGER General danger pictogram denotes general dangerous situations for individuals Non observance of the safety instructions can result in severe injuries or death DANGER Explosion protection pictogram denotes regulations and information that need to be observed in potentially explosive areas Explosion protection class temperature ranges etc must be observed DANGER Danger of burns denotes the presence of a hot surface Cys OOOO ENGINEERING VacuStar W900 W1300 W1600 Safety Hazard notes and occupational safety For your own safety and that of the machine the following information must be observed and complied with Improper operation DANGER Danger due to improper operation Only use machine in a perfect technical condition Malfunctions that are relevant for safety have to be promptly elimi
25. hout vacuum or pressure build up m Switch on machine and allow approx 0 5 1 of a diesel oil mixture 1 1 mixing ratio to be sucked into the machine through the hole in the inlet at approx 1000 rom H Afterwards allow another 0 5 1 I clean oil to be sucked in via the inlet E Completely remove this diesel oil mixture from the machine and do not allow to collect in the downstream silencer fire hazard m Switch off machine and re attach locking screw Prelubricate VacuStar pursuant to chapter Lubricating oil inspection chapter 6 4 before the machine is restarted 27 VacuStar W900 W1300 W1600 Maintenance Cleaning the suction filter Cys OOOO ENGINEERING Clean the suction filter depending on accumulated dirt and specification in the maintenance schedule To open the suction filter 1600 F fine filter and 1600 G coarse filter it is necessary to open a star handle on the suction filter 1600 F D fine filter pressure resistant and 1600 G D coarse filter pressure resistant 5 star handles need to be opened to remove the lid The hexagon nut on the stud bolt must be unscrewed to remove the filter cartridge NOTE Pay attention during cleaning that no liquid dirt or other objects get into the vacuum pump Cleaning procedure H Rinse out filter casing with detergent H Rinse out stainless steel fabric filter cartridge with detergent H Carefully rinse out filter cartridge with fine filter
26. leaning work 1 Switch off system and secure against restarting 2 Remove soiling appropriately Observe the following H Do not use aggressive cleaning agents m Pay attention during cleaning that no water gets into the compression chamber m Exercise special caution when cleaning with high pressure cleaning systems H Absorb oil deposits with oil absorbing materials e g sawdust m After cleaning work check that all previously opened covers and safety equipment are correctly installed and function correctly m After wet cleaning warm up the machine for a few minutes 26 CVS OOOO ENGINEERING Water cooling system cleaning the radiator Action after lengthy standstill Action after sucking over of foreign matter VacuStar W900 W1300 W1600 Maintenance 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 If the standstill of the VacuStar installed inside the vehicle lasts for more than a month we recommend putting the machine into operation once a month for 15 minutes The machine must be prelubricated prior to start up refer to chapter lubricating oil inspection chapter 6 4 If foreign matter has been sucked over into the machine proceed as follows m Unscrew locking screw in inlet or dismantle fitted additional lubrication line m Open vehicle box to allow the VacuStar to be run wit
27. nated Conversions of the machine are not permissible and can impair safety Never bridge any safety equipment or put it out of operation Any work on the machine and or on electrical equipment must be carried out by specialised staff Repair and maintenance work may only be carried out when the machine is stationary For this the machine must be secured against restarting The machine 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 machine and shut off valve or manually relieve excess pressure at safety valve Observe pressure gauge indication 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 cooling oil cooling water etc are collected and disposed of in an environmentally compatible manner The machine may only be opened for maintenance and repair work by specialised Staff if the machine is stationary and no potentially explosive atmosphere is present 13 VacuStar W900 W1300 W1600 CVS ooomso Safety ENGINEERING Moving components WARNING Risk of injury by moving components Powered rotating components
28. ng to manufacturer s specifications E 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 m Open shut off devices if available m Start the VacuStar drive m Check operating data Inspections during operation The following inspections have to be carried out during operation H Prior to every start up and during operation the oil level and the coolant level must be checked and topped up if necessary E Open shut off devices Always switch four way cock up to the limit stop intermediate positions are not permitted m Switch on drive and check whether pressure or vacuum are created m Pay attention to abnormal noises and leaks during operation if necessary switch off machine m Drain condensate at the condensate and safety traps Vessel may not be in a state of vacuum when condensate is drained Checking the operating data m The speed must range between 1000 1500 rpm m The cooling water outlet temperature return flow to radiator may be max 60 C m Check positive working pressure at the pressure gauge permissible pressure refer to rating plate m Check the operating vacuum at the vacuum meter permissible vacuum refer to rating plate H The compression end temperature
29. or to initial start UP ainaanaaaaninasa sasa saiii 21 safety valve nennen ae 24 venlllaling VAIN GC cn ei 24 Cys OOOO ENGINEERING HAS TMICTIONS EE 11 Intended use ccccccssseeceeceeeeeeeeeeaeeseeeeseaeeeeeeas 9 L Lengthystandstilli isses nee 27 KADI eee 7 Lubricating oil types rrrnnrrrrrrnnnrrrrrrnnnnnrennnnnnnre 17 UDC IOG ernennen 17 M Maintenance aaaanaaanaaaanaaaaa naaannnannnnnnannnaa 25 Maintenance schedule a2aaiiaaaaasssanaa ni 25 Maintenance Work aaannaaananaaa nanananaananaananaa 26 Malfunction table aaaaiaaaaaaaaaanann nasanannaani 31 IVETE G OFS ee 30 Manufacturer s declaration 8 O Occupational safety rrrrrrnrrrrnnrnnrrrnrrrnnnnnnnnr 12 Operating instructions 2aaaaaiaaaaaaaaaaaaaaaaanaaan 5 Operating personnel rrrrrrrrrnnnnnrnnrvnnnrnnnnnnnee 11 OD Cl ALOR ARR 10 P PACKA N Gasser 20 Personnel Trouble shooting uss020240eee nennen 30 Pictograms in the operating instructions aa aa aaaaa nr 6 PNCUMAUGCS insert hands 14 Proper operation rrrrannrrnrnnnnvnvnnnnvnnnnnnvnnnnnnsennnnee 9 Protective equipment rrrrnnrnrrrnnrrvvnnnrrevnnrnennnnn 12 Maintenance ananaananaaa aaaan naannnnananananini 25 R Recommissioning nnnazasanaaainaaananaaananananaani 30 S SC EE eee 9 SIGMPOSTING i ccnicn
30. osits and checked for freedom of motion Prior to assembly the cylinder pin s slide face must be brushed with Loctite No 8065 lubricant Worn out non return valves must be replaced The safety valve is no regulating device The operational capability must be checked on start up and later at weekly intervals The safety valve must be secured against misadjustment Blocking or manipulating the safety valve can have penal consequences if it gives rise to an accident Any warranty claims shall also be forfeited in such a case A maximum pressure pursuant to rating plate is permissible Depending on the type of drive this may according to the table Technical data on page 19 be lower As a matter of principle a ventilating valve must be installed as safety element on the vacuum pump s suction side When the set vacuum is reached the ventilating valve opens and admits atmospheric auxiliary air into the system The operational capability must be checked weekly with the aid of a vacuum meter at the VacuStar s inlet In case of systems without cell ventilation the vacuum may not drop below the permissible value of 200 mbar In case of systems with cell ventilation the vacuum may not drop below the permissible value of 100 mbar The VacuStar W has been prepared for operation with cell ventilation The connection is located at the upper part of the pressure flange If your system s cell ventilation is connected you may operate the VacuSta
31. r up to a vacuum of 100 mbar A suction filter is located in the cell ventilation line The filter must be cleaned weekly and replaced in case of visible damage 24 ENS VacuStar W900 W1300 W1600 OOOO ENGINEERING Maintenance 7 Maintenance 7 1 Safety during maintenance work Refer to chapter 2 7 Safety Personal protective equipment The following must be worn during all maintenance work Safety working clothing Protective gloves Safety shoes Safety goggles 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 H Collect exchanged oil in suitable containers and dispose of in accordance 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 of wear Changes compared to normal operation increased power consumption temperatures vibrations noises etc or response of monitoring systems lead to the assumption that the functions are impaired
32. scsexsanetcnsuadescsnesecatenivexstacesendecnexs 14 Spare PartS ccccccccssssssscceceeeeseeeeeeeeesseeeeeees 8 33 Specialised staff rrrrnnnnrnnrrrnnrrnnnnnrrrrrnnrnnnnnn 11 34 CVS OOOO ENGINEERING SIT NE a E E 21 Start UfP uanuaaaiauaaaaanaaaanaanuaaan nunaaananuannunnanananuunaananl 21 OAS EEE 20 WIN 22 T FME 17 VacuStar W900 W1300 W1600 Index TE ee 20 W ND en 7 8 NE PT 7 35
33. sible causes of malfunctions and trouble shooting tasks Reduce the maintenance intervals if similar malfunctions occur repeatedly due to above average intensive use so intervals correspond to the actual load Contact the manufacturer in case of malfunctions that cannot be repaired with the aid of the following information gt page 2 Refer to chapter 2 7 Safety m The trouble shooting work described at this point can be carried out by the operator unless otherwise indicated E Some work may only be carried out by specially trained specialised staff or exclusively by the manufacturer himself This is specifically pointed out in the description of the individual malfunctions m Only electrical specialists may carry out work on the electrical system E Components and parts may only be replaced by specialised staff Refer to chapter 7 1 Refer to chapter 7 1 The following basically applies 1 Immediately trigger an emergency stop in case of malfunctions constituting an immediate danger for individuals or material assets 2 Switch of all power supplies and secure against restarting 3 Inform person in charge at the place of installation 4 Depending on the type of malfunction have the cause determined and eliminated by responsible and authorised specialised personnel 8 2 Recommissioning after corrective action After corrective action or trouble shooting 1 Reset emergency stops 2 Acknowledge error messa
34. tar W900 W1300 W1600 CVS OOOSO Safety ENGINEERING Electrical system DANGER A Mortal danger due to electric current There is mortal danger in case of contact with live components Activated electrically driven components may start to move in an uncontrolled manner thereby causing the most serious injuries Therefore Switch off the electric power supply before commencing any work and secure against restarting Work on the electrical system on individual electrical components and on the connections may only be carried out by electrical specialists 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 sufficiently qualified and instructed personnel Secure machine against restarting switch off drives Before starting any work provide for sufficient space and freedom of movement during assembly 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
35. ury 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 enclosure 1 6 Warranty conditions The warranty conditions are included in the sales documentation as separate document 1 7 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 8 Manufacturer s declaration Manufacturer s declaration pursuant to EC Machinery Directive 98 37 EC Annex II refer to enclosure CYS OOOO ENGINEERING 2 Safety 2 1 Intended use 2 2 Proper operation VacuStar W900 W1300 W1600 Safety The machines of the VacuStar series are exclusively intended for the compression or extraction of filtered air The VacuStar in the explosion proof design complies with Directive 94 9 EC ATEX and is suitable for conveying potentially explosive gases and gas mixtures of explosion group IIB temperature class T2 T3 from potentially explosive zone 1 and zone 2 areas The machine may not be operated in a potentially explosive area M
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