Contents
Operating instructions
VacuStar L400
Doc-ID: 5028 / BA / EN
Release: Rev. 03 / 05.10.2018
The operating instructions must be read by the VacuStar L400 operator before start-up!
2
Translation of the original operating manual
© CVS engineering GmbH
Großmattstraße 14
79618 Rheinfelden / Germany
Phone: +49 (0)7623 71741-0
Customer service: +49 (0)7623 71741-0
E-Mail: info@cvs-eng.de
Internet: www.cvs-eng.de
Operating instructions VacuStar L400
Contents
3
1 General .................................................................................... 4
1.1 Information regarding the operating instructions ........... 4
1.2 Pictogram explanation ................................................... 5
1.3 Limitation of Liability ...................................................... 6
1.4 Copyright protection ....................................................... 6
1.5 Spare parts .................................................................... 7
1.6 Warranty conditions ....................................................... 7
1.7 Customer Service .......................................................... 7
2 Safety ...................................................................................... 8
2.1 Intended use .................................................................. 8
2.2 Acceptance and monitoring ........................................... 8
2.3 Operator's responsibility ................................................ 8
2.4 Operating personnel ...................................................... 9
2.4.1 Requirements ................................................. 9
2.5 Personal protective equipment ...................................... 9
2.6 Occupational safety and special risks ......................... 10
3 Technical data ...................................................................... 15
4 Design and function............................................................. 17
4.1 Design .......................................................................... 17
4.2 Function ....................................................................... 18
4.3 Control and display elements ...................................... 18
5 Transport and storage ......................................................... 19
5.1 Safety notes for transport ............................................ 19
5.2 Transport ...................................................................... 19
5.3 Storage ........................................................................ 19
6 Start-up and operation ........................................................ 20
6.1 Safety notes ................................................................. 20
6.2 Start-up ........................................................................ 20
6.3 Switching off ................................................................. 21
6.4 Inspections to be performed ........................................ 21
7 Maintenance ......................................................................... 23
7.1 Safety during maintenance work ................................. 23
7.2 Maintenance schedule ................................................. 23
7.3 Performance of maintenance work .............................. 25
8 Malfunctions ......................................................................... 27
8.1 Safety ........................................................................... 27
8.2 Recommissioning after corrective action ..................... 27
8.3 Malfunction table .......................................................... 28
9 Spare parts ........................................................................... 30
10 Decommissioning and disposal ......................................... 30
Index .............................................................................................. 31
Operating instructions VacuStar L400
General
4
1 General
1.1 Information regarding the operating instructions
These operating instructions provide important information on how
to deal with the VacuStar L400. A precondition for safe operation is
the observance of all specified safety and handling instructions.
Furthermore, all local accident prevention regulations and general
safety regulations valid for the application area of the
VacuStar L400 must be observed.
Carefully read the operating instructions before starting any work! It
is a product component and must be kept in direct proximity of the
VacuStar L400, well accessible to the personnel at all times.
When passing the VacuStar L400 on to third parties, the operating
instructions must also be handed over.
Operating instructions VacuStar L400
General
5
1.2 Pictogram explanation
Warning notes
Warning notes are characterised by pictograms in these operating
instructions. The warning notes are marked by signal words
expressing the extent of the hazard.
It is absolutely essential to observe the notes and to proceed with
caution in order to prevent accidents as well as bodily injuries and
property damage.
DANGER!
points to an immediately dangerous situation, which
can lead to death or serious injuries if it is not
avoided.
WARNING!
... points to an immediately dangerous situation,
which can lead to death or serious injuries if it is not
avoided.
CAUTION!
... points to a potentially dangerous situation, which
can lead to minor or light injuries if it is not avoided.
ATTENTION!
... points to a potentially dangerous situation, which
may lead to property damage if it is not avoided.
Hints and recommendations
NOTE!
… highlights useful hints and recommendations as
well as information for an efficient and trouble-free
operation.
Operating instructions VacuStar L400
General
6
1.3 Limitation of Liability
All specifications and notes in these operating instructions were
compiled with consideration to the valid standards and regulations,
the state of the art as well as to our long-standing knowledge and
experience.
The manufacturer is not liable for damages caused by:
Non-observance of the operating instructions
Improper use
Deployment of non-trained personnel
Arbitrary modifications
Technical changes
Use of non-approved spare and wear parts.
The actual scope of supply may differ from the explanations and
illustrations 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
contract, the general terms and conditions as well as the
manufacturer's conditions of delivery and the statutory provisions
valid at the time of contract conclusion shall apply.
Warranty
The manufacturer guarantees the correct functioning of the applied
process technology and the performance parameters identified.
The warranty period commences on the date the VacuStar L400 is
delivered to the customer.
Components are exempted from the warranty and from claims for
defects as far as wear and tear damage is concerned.
1.4 Copyright protection
NOTE!
Content details, texts, drawings, pictures and other
illustrations are protected by copyright and are
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.
Operating instructions VacuStar L400
General
7
1.5 Spare parts
WARNING!
Risk of injury by incorrect spare parts!
Incorrect or defective spare parts can result in
damage, malfunctions or total failure and also
impair safety.
Therefore:
– Use only the manufacturer's original spare
parts.
Procure spare parts from authorised dealers or directly from the
manufacturer. Refer to page 2 for address.
1.6 Warranty conditions
Warranty terms see "General Terms of Sale".
1.7 Customer Service
Our customer service can be contacted for any technical advice.
Information about the responsible contact person can be retrieved
by telephone, fax, E-mail or via the Internet at any time, refer to
manufacturer's address on page 2.
Operating instructions VacuStar L400
Safety
8
2 Safety
2.1 Intended use
The compressor vacuum pump VacuStar L400 is intended
exclusively for the compression or suctioning of filtered air.
Only use VacuStar L400 for the intended use.
All specifications in the operating instructions must be strictly
adhered to (technical data, operating data, permissible working
range), refer to Page 15, chapter 3 in this regard.
All types of claims due to damage arising from improper use are
excluded. The operator alone shall be responsible for any damage
arising from improper use.
2.2 Acceptance and monitoring
The VacuStar L400 is not subject to any acceptance and
monitoring obligation.
2.3 Operator's responsibility
The VacuStar L400 is used for industrial purposes.
The operator of the VacuStar L400 is therefore subject to the legal
obligations concerning occupational safety.
The provisions valid at the place of installation as well as the safety
and accident prevention regulations of the Institution for statutory
accident insurance and prevention must be observed. The operator
must in particular:
inform himself on the valid industrial safety regulations.
determine the additional hazards that arise from the special
working conditions at the VacuStar L400's place of installation
by means of a hazard assessment.
implement the necessary rules of conduct for operation of the
VacuStar L400 at the place of installation by means of user
instructions.
check at regular intervals during the VacuStar L400's entire
period of use whether the user instructions correspond to the
current state of the body of rules and regulations.
adapt the operation instructions, if necessary to the new
regulations, standards, and operating conditions .
clearly regulate the responsibilities for installing, operating,
maintaining and cleaning the VacuStar L400.
ensure that all employees working on or with the VacuStar L400
have read and understood the operating instructions. In addition
he must at regular intervals train the employees in how to deal
with the VacuStar L400 and inform them about potential
hazards.
Operating instructions VacuStar L400
Safety
9
In addition, it is the operator's responsibility to ensure that:
the machine is always in a technically perfect condition.
the machine is maintained in accordance with specified
maintenance intervals.
all safety equipment is regularly checked for completeness and
correct functioning.
2.4 Operating personnel
2.4.1 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.
Specialists
are due to their technical training, knowledge and experience
and their knowledge of the pertinent regulations able to carry
out the work assigned to them and to independently recognize
potential hazards.
2.5 Personal protective equipment
When handling the VacuStar L400, it is necessary to wear
personal protective equipment, in order to minimise health
hazards.
Before carrying out any work, properly don the necessary
protective equipment such as gloves, safety goggles, etc. and
wear during work.
Operating instructions VacuStar L400
Safety
10
2.6 Occupational safety and special risks
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.
Assembly of the VacuStar L400
The relevant dangerous spots on the VacuStar L400 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!
Danger of burns!
… denotes the presence of a hot surface.
Operating instructions VacuStar L400
Safety
11
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 VacuStar L400 in a perfect technical
condition. Malfunctions that are relevant for
safety have to be promptly eliminated.
– Conversions of the VacuStar L400 are not
permissible and can impair safety.
– Never bridge any safety equipment or put it out
of operation.
– Any work on the VacuStar L400 and/or on
electrical equipment must be carried out by
specialised staff.
– Repair and maintenance work may only be
carried out when the VacuStar L400 is
stationary.
For this, the VacuStar L400 must be secured
against restarting!
– The VacuStar L400 may not be under pressure
or in a state of vacuum while work is being
carried out on it.
Close shut-off valve on the vehicle side and
vent the pipe between VacuStar L400 and shutoff valve or manually relieve excess pressure at
safety valve. Observe pressure gauge!
– The drive's protective equipment may only be
removed when the VacuStar L400 is stationary
and has to be correctly refitted after completion
of work.
– Only dismantle accidental contact protection
after VacuStar L400 and pipes have cooled
down.
– It is an environmental protection requirement
that any liquids arising during maintenance work
(e.g. oil) must be collected and disposed of in
an environmentally compatible manner.
Operating instructions VacuStar L400
Safety
12
Moving components
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
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.
Signposting
WARNING!
Risk of injury by 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.
Operating instructions VacuStar L400
Safety
13
Improper transport
Danger!
Danger by falling down or tilting of the
VacuStar L400!
The weight of the VacuStar L400 may injure a
person and cause serious bruising!
Therefore:
– Depending on the dead weight and size of the
VacuStar L400, use a pallet on which the
VacuStar L400 can be moved by means of a
fork lift.
– For lifting the VacuStar L400, use suitable lifting
gear (slings, etc.) that is designed for the weight
of the VacuStar L400.
– When putting the slings in position, take care to
avoid putting stress on individual components.
– Only use the provided attachment points with
eye bolts.
Start-up and 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.
Operating instructions VacuStar L400
Safety
14
Electrical system
DANGER!
Mortal danger due to electric current!
There is mortal danger in case of contact with live
components.
Activated electrically driven components can start
to move uncontrolled and cause severest 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 troubleshooting
WARNING!
Risk of injury due to improper maintenance and
troubleshooting!
Improper maintenance and troubleshooting can
lead to serious bodily injuries or property damage.
Therefore:
– Maintenance work and troubleshooting work
may only be carried out by sufficiently qualified
and instructed personnel.
– Protect VacuStar L400 from being restarted,
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.
If 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
troubleshooting, check correct functioning of
safety equipment.
Operating instructions VacuStar L400
Technical data
15
3 Technical data
General data
Unit
VacuStar L400
Rated speed / Speed range
[1/min]
1500 / 1000 to 1500
Suction temperature
[°C]
-20…+40
Geodetic height
[m]
0…1000
Content of oil container
[Litres]
4.6
Lubricating oil consumption
[ml/h]
85
Weight VacuStar L400 without accessories
[kg]
76
Tab. 1: General data
Operating data during compressor vacuum pump operation at
rated speed
Unit
VacuStar L400
Vacuum without cell venting / with cell venting 1)
[mbar]
200 / 100
Final overpressure at the pressure flange 2)
[bar]
0 to 0.5
Intake volume flow at 400 / 1000 mbar
[m3/h]
320 / 345
Power requirement at 400 mbar / 0.5 bar excess pressure
[kW]
7.4 / 10
Sound pressure level (at 7 m distance) at 200 mbar / 0.5 bar
excess pressure
[dB]
70 / 78
Weight VacuStar L400 with a four-way switching valve
[kg]
85
1) Final excess pressure at the pressure flange = 0 bar, suction and ambient temperature = 20 °C
2) Intake pressure at the suction flange = 1 bar, suction and ambient temperature = 20 °C
Tab. 2: Operating data VacuStar L400 during compressor vacuum pump operation at rated speed
Operating data during compressor operation at rated speed
Unit
VacuStar L400
Intake pressure
[mbar]
1000
Final overpressure at the pressure flange
1) 3)
[bar]
0 to 2.0
Intake pressure at 0 / 2.0 bar excess pressure 2)
[m3/h]
345 / 305
Power requirement at 0 / 2.0 bar excess pressure 2)
[kW]
8 / 19.0
Sound pressure level (at 7 m distance) at 2.0 bar excess pressure
2)
[dB]
77
Weight VacuStar L400 with mounting flange for suction and
pressure line
[kg]
79
1) Suction and ambient temperature = 20 °C
2) at rated speed
3) Protection via a safety valve
Tab. 3: Operating data VacuStar L400 during compressor operation at rated speed
Operating instructions VacuStar L400
Technical data
16
Lubricating oil
The use of multigrade oils will damage the VacuStar L400. In that
case, the warranty on the part of CVS Engineering GmbH shall
cease.
Only single grade oils with the following specification are permitted
for operation:
Specification
Value
API
CF/CF4 or higher
ACEA
E2 or higher
Viscosity:
Suction temperature > 10 °C: SAE 40
Suction temperature < 10 °C: SAE 30
Tab. 4: Lubricating oils
Lubricating oil types
Recommended oil types
Brand
Suction temp. > 10 °C
Suction temp. < 10 °C
CVS
CVS Lube 4000
CVS Lube 3000
Other oil types on request.
Tab. 5: Lubricating oil types
ATTENTION!
Do not use any synthetic lubricants!
Operating instructions VacuStar L400
Design and function
17
4 Design and function
4.1 Design
Fig. 1: Design VacuStar L400 with and without a four-way switching valve
A: Compressor vacuum pump operation with four-way switching valve
The air feed direction (suction or pressure) is selected by the position of the switching lever.
B: Compressor or vacuum pump operation with mounting flange for suction and pressure line
1 Drive shaft
2 Cell ventilation connection
3 Thread for eye bolt
4 Temperature and pressure measuring point
5 Oil filling
6 Rating plate of VacuStar L400
7 Rotation arrow
8 Rating plate oil
9 Oil reservoir
10 Switching lever
11 Pressure connection
(for illustrated lever setting)
12 Four-way switching valve
13 Suction connection
(for illustrated lever setting)
14 Mounting flange for lines
15 Suction opening for cooling air
16 Connection for measuring control line
Operating instructions VacuStar L400
Design and function
18
4.2 Function
Functional principle
Sliding vane compressor vacuum pumps work according to the
displacement principle.
Due to the rotor'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 (pos. 13) and
reaches the pressure line after being compressed via the pressure
connection (pos. 11).
Lubrication
The VacuStar L400 is lubricated by means of an oil pump. Oil is
pumped from the oil reservoir via the oil lines to the
VacuStar L400's lubricating points.
Cooling
The VacuStar L400 is air-cooled. Heat removal is performed by
casing ribs on the lid and casing surface with targeted cooling air
guidance, via a ventilation wheel on the drive shaft.
Drive
The VacuStar L400 can be powered via:
Articulated shaft
V-belt
Flexible coupling
Details about the drives and their design can be found in the
separate mounting instructions for the VacuStar L400.
4.3 Control and display elements
Depending on the installation situation, different display elements
such as pressure gauge, temperature gauge and negative
pressure display are mounted.
Operating instructions VacuStar L400
Transport and storage
19
5 Transport and storage
5.1 Safety notes for transport
See chapter 2.6.
5.2 Transport
The VacuStar L400 fastened on a pallet must be transported by
means of a fork lift or suitable lifting gear. The lifting gear must be
designed for the weight of the VacuStar L400.
For future transports:
Seal all open connections with protective caps
(prevents penetration of dirt and water)
Secure against vibrations
Securely fasten the VacuStar L400 prior to transport (e.g. screw
it onto a pallet)
Transport and put down the VacuStar L400 with a fork lift or
secure with straps and lift with suitable lifting gear.
5.3 Storage
Storage of packages
Store packages under the following conditions:
Do not store outdoors.
Store dry and dust free.
Do not expose to aggressive media.
Protect against solar irradiation.
Avoid mechanical vibrations.
Storage temperature: -10 to +60 °C
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.
To keep moisture away from the VacuStar L400's workspace,
bags with desiccant must be placed into the inlets and outlets.
These must be removed before start-up.
Operating instructions VacuStar L400
Start-up and operation
20
6 Start-up and operation
6.1 Safety notes
See chapter 2.6.
6.2 Start-up
Inspection prior to initial start-up
Top up lubricating oil according to lubricating oil schedule. Oil
level in the oil supply tank at least to the middle of the oil sight
glass.
Start-up
Open present shut-off devices
Select with VacuStar L400 during compressor vacuum pump
operation at suction or pressure operation with four-way
switching valve.
Attention: Switching valve must only be operated in the two end
positions. Intermediate positions are not permitted.
Start the VacuStar L400 drive.
Adjust speed.
Check operating data
Inspections during operation
The following inspections have to be carried out during operation:
Prior to every start-up and during operation, the oil level must
be checked and topped up if necessary.
Open shut-off devices. Always turn the four-way cock until it hits
the stop, intermediate positions are not permitted.
Switch on drive and check whether pressure or vacuum are
created.
Pay attention to abnormal noises and leaks during operation. If
necessary, switch off VacuStar L400.
Drain condensate at the condensate and safety traps. Vessel
may not be in a state of vacuum when condensate is drained.
Checking the operating data:
The speed must range between 1000…1500 min-1.
Check positive working pressure at the pressure gauge
(permissible pressure refer to rating plate).
Check the operating vacuum at the vacuum meter (permissible
vacuum refer to rating plate).
The compression end temperature at 20 °C suction temperature
may not exceed the following values:
150 °C at 400 mbar operating vacuum
120 °C at 0.5 mbar excess pressure
Operating instructions VacuStar L400
Start-up and operation
21
6.3 Switching off
Switch off the VacuStar L400 as follows:
Switch off drive for the VacuStar L400.
Close the shut-off valves (if installed)
Drain the safety tank. Tank may not be under pressure then.
6.4 Inspections to be performed
Lubricating oil inspection
Only lubricating oils pursuant to the lubricants specifications
lubricating oil schedule (Tab. 4, Other oil types on request.
Tab. 5
Check oil level at the inspection glass. Oil level in the oil supply
tank at least to the middle of the oil sight glass. The oil level may
not drop below the bottom mark on the oil inspection glass.
Non-return valve inspection
The non-return valve is maintenance-free, but is subject to wear
like all other moving parts. We recommend a visual inspection
every 3 months. In this connection, the non-return valve must be
dismantled, cleaned, freed of deposits and checked for freedom of
motion.
Safety valve inspection
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.
The nominal opening pressure may not exceed the maximum
permissible final overpressure (refer to rating plate) or the
permissible system pressure, provided the latter is lower.
Functional testing is carried out by actuating the manual ventilation
with the VacuStar L400 running.
Inspection of the ventilating valve
As a matter of principle, a ventilating valve must be installed as
safety element on the VacuStar L400'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 L400'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.
Operating instructions VacuStar L400
Start-up and operation
22
Inspection of cell ventilation
The VacuStar L400 has been prepared for operation with cell
ventilation. The connection is located opposite of the pressure and
suction connection. If your system's cell ventilation is connected,
you may operate the VacuStar L400 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.
Height wear rotor vanes
Based on a daily runtime of 3 to 4 hours, the initial inspection
should be performed after approx. 6 months. For further
inspections, see page 24, Tab. 6 "Maintenance schedule".
Measuring height wear
1. Disassemble four-way switching valve or mounting flange.
2. Check vane recess with sliding calliper. The rotor vanes must
be replaced if the sliders show a recess of more than 5 mm as
compared to the rotor jacket.
Fig. 2: Measuring the height wear rotor vanes
Operating instructions VacuStar L400
Maintenance
23
7 Maintenance
7.1 Safety during maintenance work
See chapter 2.6 "Occupational safety and special risks".
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:
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.
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. 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 page 2).
For maintenance schedule refer to next page.
Operating instructions VacuStar L400
Maintenance
24
Maintenance schedule
Interval
Maintenance work
To be carried out by
Every 15 minutes
Check operating speed
Operator
Check operating pressure / vacuum
Check air outlet temperature
Daily
Check condensate
Operator
Check safety trap
Check silencer
Check oil level and top up with fresh oil if necessary
Weekly
Check safety valve
Operator
Check ventilating valve
Clean VacuStar L400
Clean vacuum filter
Check V-belt, V-belt tension and re-tension if necessary
Clean cell ventilation filter, replace if damaged
Monthly
Clean oil tank
Operator
Check fastening screws and tighten if necessary
Check shaft sealing rings for tightness
(no oil may leak from them)
quarterly
Check rotor vane wear
(replace vane at more than 5 mm)
Specialised staff
Check cell ventilation valve
Specialised staff
Half-yearly
Check non-return valve of VacuStar L400
Specialised staff
5,000 oh / 3 years
Replace shaft sealing rings
Specialised staff
10,000 oh / 5 years
Replace bearings
Specialised staff
Tab. 6: Maintenance schedule
Operating instructions VacuStar L400
Maintenance
25
7.3 Performance of maintenance work
Cleaning the VacuStar L400
Carrying out cleaning work:
1. Switch off system and secure against restarting.
2. Remove soiling appropriately. Observe the following:
Do not use aggressive cleaning agents.
Pay attention during cleaning that no water gets into the
compression chamber.
Exercise special caution when cleaning with high-pressure
cleaning systems.
Absorb oil deposits with oil-absorbing materials (e.g. sawdust).
After cleaning work, check that all previously opened covers
and safety equipment are correctly installed and function
correctly.
After wet cleaning, warm up the VacuStar W for a few minutes.
Cooling of the VacuStar L400
To warrant best cooling, the protective grid apertures must be free
of deposits.
Suction air filter
The contamination state is usually indicated by a maintenance
display. If maintenance is required, open filter casing and replace
filter cartridge.
Action after lengthy standstill
If the standstill of the VacuStar L400 installed inside the vehicle
lasts for more than a month, we recommend putting the
VacuStar L400 into operation once a month for 15 minutes.
Operating instructions VacuStar L400
Maintenance
26
Action after sucking over of foreign
matter
If foreign matter has been sucked over into the VacuStar L400,
proceed as follows:
Allow VacuStar L400 to cool down.
Unscrew the locking screw in the inlet (fig. 1, pos. 16)
Open vehicle box to allow the VacuStar L400 to be run without
vacuum or pressure build-up.
Switch on VacuStar L400 and allow approx. 0.5…1 l of a diesel-
oil-mixture (1:1 mixing ratio) to be sucked into the
VacuStar L400 through the hole in the inlet at approx. 1000 min
-
1
.
Afterwards, allow another 0.2 - 0.5 l clean oil to be sucked in via
the inlet.
Completely remove this diesel-oil-mixture from the VacuStar
L400 and do not allow to collect in the downstream silencer fire hazard!
Switch off VacuStar L400 and re-attach locking screw. Perform
a lubricating oil inspection pursuant to chapter 6.4 before the
VacuStar L400 is restarted.
Operating instructions VacuStar L400
Malfunctions
27
8 Malfunctions
This chapter describes possible causes of malfunctions and
troubleshooting 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 ( p. 2)!
8.1 Safety
See chapter 2.6 "Occupational safety and special risks".
Personnel
The trouble shooting work described at this point can be carried
out by the operator, unless otherwise indicated.
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.
Only electrical specialists may carry out work on the electrical
system.
Components and parts may only be replaced by specialised
staff.
Personal protective equipment
See chapter 2.5.
Environmental protection
See chapter 7.1.
Conduct in the case of
malfunctions
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 message or malfunction at the control
system.
3. Ensure that nobody is staying in the hazard area.
4. Start in accordance with the instructions in chapter „start-up“.
Operating instructions VacuStar L400
Malfunctions
28
8.3 Malfunction table
Malfunction:
Possible cause
Corrective action
Execution
VacuStar L400's
delivery rate
decreases
Vacuum filter soiled
Clean vacuum filter
Operator
Leaky suction line / fittings
Look for leaky spots and
eliminate leak
Specialised staff
Speed too low
Adjust speed
Operator
Wear of rotor vanes,
possibly caused by dirt or liquids
that have gotten into the
VacuStar L400 (sucking over of
foreign matter)
Replace rotor vane, remove
dirt and have VacuStar L400
overhauled at an authorised
workshop
Specialised staff
Abnormal noise
emission
VacuStar L400 is badly aligned.
Align the VacuStar L400
precisely.
Specialised staff
Bearing defective
Replace bearing (or have it
replaced)
Lack of lubricating oil
Top up oil, clean oil reservoir
and suction filter
Operator
Unsuitable lubricating oil
Fill in oil according to
lubrication schedule
Operator
Rotor vanes are jammed
Check rotor vanes
Specialised staff
Casing bore shows grooves or
corrugations due to the
aspiration of dirt
Have casing bore re-turned
and honed at an authorised
workshop. In case of heavily
soiled intake air, install fine
filter
Specialised staff
Wrong speed
Maintain speed range
Operator
Changed pressure
Maintain nominal pressure
Operator
Changed vacuum
Maintain nominal vacuum,
check exhaust system and
clean if necessary
Operator
Non-return valve rattles
Check non-return valve
Specialised staff
Foreign bodies in the
VacuStar L400
Remove foreign matter. Flush
out the VacuStar L400.
Specialised staff
Slide breakage
Switch off the VacuStar L400
at once and repair it.
Specialised staff
Compressed air
temperature too
high
End pressure too high
Maintain nominal pressure
Operator
Exhaust silencer clogged
Replace exhaust silencer
Specialised staff
Four way cock in wrong position
Correctly adjust four way cock
Operator
Non-return valve is stuck
Check non-return valve and
clean if necessary
Specialised staff
Vacuum filter clogged
Clean vacuum filter
Operator
Vacuum too high
Maintain nominal vacuum
Operator
Operating instructions VacuStar L400
Malfunctions
29
Malfunction:
Possible cause
Corrective action
Execution
Operating
pressure or
operating vacuum
is not obtained
Pressure gauge or vacuum
meter do not indicate correctly
Replace pressure gauge or
vacuum meter
Specialised staff
V-belts are slipping
Check V-belt tension and retension if necessary
Operator
Four way cock in wrong position
Correctly adjust four way cock
Operator
Condensate drain cock open
Close condensate drain cock
Operator
Silt or liquid has
gotten into the
VacuStar L400
Foreign matter has been sucked
over into the VacuStar L400
Rinse thoroughly with dieseloil-mixture at lowest
permissible speed and without
pressure or vacuum,
afterwards add lubricating oil
according to chapter
Lubricating oil inspection
page 21.
Operator
Power requirement
too high
Speed too high
Maintain speed limit
Operator
End pressure too high
Maintain nominal pressure,
actuate / check safety valve
Operator
Pressure gauge indicates
incorrectly
Replace pressure gauge
Operator
Exhaust silencer clogged
Replace exhaust silencer
Specialised staff
Lack of lubricating
oil despite full oil
tank
Oil intake strainer in oil tank
clogged
Clean oil tank and intake
strainer, check oil lines
Operator
Safety valve blows
off
Closed valves in the pressure
line
Open valves
Operator
Clogging in pressure system
Eliminate clogging
Operator
Exhaust silencer clogged
Replace exhaust silencer
Specialised staff
Ventilating valve
responds
Closed valves in the suction line
Open valves
Operator
Suction filter clogged
Clean suction filter, if
necessary replace filter
cartridge
Operator
Compressed air
blows off at shaft
end and oil is
leaking
Seal damaged
Replace radial shaft sealing
rings in sealing cover
Specialised staff
Rubber smell (at
V-belt drive)
V-belts slip due too insufficient
belt tension
Check belt tension, re-tension
if necessary
Operator
End pressure too high
Maintain nominal pressure
Operator
Reversing of Vbelts
Insufficient belt tension
Check belt tension, re-tension
if necessary
Operator
Worn V-belts
Put on new V-belts
Operator
Pulleys are not aligned
Align pulleys
Specialised staff
Worn V-belt pulleys
Replace pulleys
Specialised staff
Tab. 7: Malfunction table
Operating instructions VacuStar L400
Spare parts
30
9 Spare parts
We recommend stocking a service package as well as a suction
filter cartridge.
The service package comprises all wear parts that are required for
a normal repair.
Customer Service
In case of queries regarding the product, spare part orders, repairs,
replacement machines and dispatch of fitters, please contact our
customer service: Phone: +49 (0)7623 71741-0
Spare and wear parts
Service package
990 008-SP
Filter cartridge to cell venting
432 151-00
Filter cartridge to suction air filter
432 161-00
10 Decommissioning and disposal
A VacuStar L400 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.
Prior to decommissioning and disposal of the VacuStar L400, it
must be completely separated from the surrounding units.
The disassembly and disposal of the VacuStar L400 may only
be carried out by specialised staff.
If hazardous or poisonous material were conveyed, the
VacuStar L400 must be decontaminated prior to disposal.
The VacuStar L400 has to be disposed of in accordance with
the respective country-specific regulations.
Operating instructions VacuStar L400
Index
31
Index
A
Acceptance ........................................................... 8
Action sucking over ............................................ 26
C
Cleaning
VacuStar L400 ................................................ 25
Components, moving .......................................... 12
Compressed air .................................................. 12
Contact person ..................................................... 7
Cooling.......................................................... 18, 25
Copyright protection ............................................. 6
Customer Service ................................................. 7
D
Danger of burns .................................................. 10
Danger pictogram ............................................... 10
Danger pictograms ............................................. 10
Dangers .............................................................. 10
Design ................................................................. 17
Display elements ................................................ 18
Disposal .............................................................. 30
Drive ................................................................... 18
E
Environmental protection .............................. 23, 27
F
Function .............................................................. 18
I
Improper operation ............................................. 11
Inspection
30/38 rotor vane .............................................. 22
during operation .............................................. 20
Lubricating oil .................................................. 21
Non-return valve ............................................. 21
prior to initial start-up ...................................... 20
Safety valve .................................................... 21
Ventilating valve ........................................ 21, 22
Instructions ........................................................... 9
Intended use ......................................................... 8
L
Lengthy standstill ................................................25
Liability .................................................................. 6
Lubricating oil ......................................................16
Lubricating oil types ............................................16
Lubrication ..........................................................18
M
Maintenance .......................................................23
Maintenance .......................................................14
Maintenance schedule ........................................23
Maintenance work ...............................................25
Malfunction table .................................................28
Malfunctions ........................................................27
O
Occupational safety ............................................10
Operating elements ............................................18
Operating instructions ........................................... 4
Operating personnel ............................................. 9
Operation ..................................................... 13, 20
Operator ................................................................ 8
P
Personnel
Trouble shooting .............................................27
Protective equipment ............................... 9, 23, 27
R
Recommissioning ...............................................27
S
Safety ..............................................................8, 27
Safety notes ........................................... 19, 20, 23
Signposting .........................................................12
Spare parts .....................................................7, 30
Specialists ............................................................. 9
Start-up ........................................................ 13, 20
Storage ...............................................................19
Suction air filter ...................................................25
Switching off........................................................21
Symbols in the instructions ................................... 5
Operating instructions VacuStar L400
Decommissioning and disposal
32
T
Technical data.................................................... 15
Transport ...................................................... 13, 19
Trouble shooting ................................................ 14
W
Warranty ........................................................... 6, 7
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