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Mounting instructions
VacuStar L400
Doc-ID: 5027 / MA / EN
Release: Rev. 05 / 28.03.2023
Prior to installing the VacuStar L400 and putting it into operation you must have read and understood
these instructions. These instructions are only valid together with the operating instructions, they do
not replace them!
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Summary of Contents for CVS VacuStar L400
- Page 1 Doc-ID: 5027 / MA / EN Release: Rev. 05 / 28.03.2023 Prior to installing the VacuStar L400 and putting it into operation you must have read and understood these instructions. These instructions are only valid together with the operating instructions, they do...
- Page 2 Translation of the Original Assembly Instructions © 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...
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Page 3: Table Of Contents
Transport ..............14 Storage ................ 15 Installation and assembly ........... 16 Safety ................16 Setup example for VacuStar L400 in compressor operation ..............17 Setup example for VacuStar L400 in compressor vacuum pump operation ..........18 Necessary work ............18 Sound insulation ............ - Page 4 Mounting instructions VacuStar L400 Contents 6.8.6 Cell ventilation valve ........24 6.8.7 Safety tank ............25 6.8.8 Display and monitoring equipment ....26 Drive ................27 6.9.1 V belt drive ............28 6.9.2 Articulated shaft drive ........29 6.9.3 Drive via flexible coupling and hydraulic motor .............29 Start-up ..................30...
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Page 5: General
It is a product component and must be kept in direct proximity of the VacuStar L400, well accessible to the personnel at all times. All safety instructions of the operating instructions must additionally be... -
Page 6: Pictogram Explanation
Mounting instructions VacuStar L400 General 1.2 Pictogram explanation Warning notes Warning notes are characterised by pictograms in these mounting 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. -
Page 7: Limitation Of Liability
Mounting instructions VacuStar L400 General 1.3 Limitation of Liability Information regarding the limitation of liability can be found in the operating instructions "VacuStar L400"". 1.4 Copyright protection Information regarding the copyright protection can be found in the operating instructions "VacuStar L400"". -
Page 8: Safety
The VacuStar L400 is intended exclusively for the compression or suctioning of filtered air. 2.2 Acceptance and monitoring The VacuStar L400 itself is not subject to any acceptance and monitoring obligation. 2.3 Operator's responsibility See operating instructions "VacuStar L400" for information about the responsibility of the operating company. -
Page 9: Technical Data
Mounting instructions VacuStar L400 Technical data 3 Technical data 3.1 Dimensions Fig. 1: Dimensions of VacuStar L400 A: Pressure vacuum design with four-way switching valve (can be switched between suction and pressure operation) B: Pressure or vacuum design Feather key DIN 6885 A10x8x40... -
Page 10: Technical Data
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... - Page 11 Mounting instructions VacuStar L400 Technical data Lubricating oil Only single grade oils with the following specification are permitted for operation: Specification Value CF/CF4 or higher ACEA E2 or higher Viscosity: Suction temperature > 10 °C: SAE 40 Suction temperature < 10 °C: SAE 30 Tab.
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Page 12: Design
Design 4 Design Fig. 2: 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. -
Page 13: Function
(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. -
Page 14: Transport And Storage
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. -
Page 15: Storage
If necessary, brush up or recondition the preservation. In case of extended storage or extended downtimes, one desiccant bag each should be inserted in the inlets and outlets. The bags must be removed again before the VacuStar L400 is started. -
Page 16: Installation And Assembly
Therefore: – Always keep the working area clean. – Remove objects that are not required. – Mark tripping points with yellow-and-black tape. Please observe all safety instructions as per the operating instructions "VacuStar L400", chapter Occupational safety... -
Page 17: Setup Example For Vacustar L400 In Compressor Operation
Mounting instructions VacuStar L400 Installation and assembly 6.2 Setup example for VacuStar L400 in compressor operation Fig. 3: Setup example for VacuStar L400 in compressor operation VacuStar L400 (compressor Pressure gauge Vacuum display operation) Safety valve Suction air filter Thermometer... -
Page 18: Setup Example For Vacustar L400 In Compressor Vacuum Pump Operation
The illustration shows an example of a system with an installed VacuStar L400 in compressor vacuum pump operation. Fig. 4: Setup example for VacuStar L400 in compressor vacuum pump operation Cell ventilation unit Safety valve 11 Four-way switching valve with... -
Page 19: Sound Insulation
Be accessible for maintenance and repair work e.g. for replacing the air filter cartridge, or for checking the safety and non-return valve. The VacuStar L400 must not be installed on a closed ground plate. There must be sufficient free space for discharge of cooling air. Assembly Attach the VacuStar L400 with screws as per Tab. -
Page 20: Suction And Pressure Lines
Connect suction and pressure pipe at the 2“ thread Assembly Observe that pipes connected to the connection flange do not protrude over the sealing face to the VacuStar L400. Max. screw-in depth: 19 mm. Requirements Corrosion-proof ... -
Page 21: Safety Valve
– Never block the safety valve. The German accident prevention regulations require a non- lockable safety valve to be installed after the VacuStar L400 at the pressure side. This valve must be selected such that it prevents the pressure to exceed the highest permissible operating pressure by more than 10 %. -
Page 22: Non-Return Valve
The ventilation valve can be procured from CVS! 6.8.3 Non-return valve The non-return valve prevents a backflow of air from the pressure line into the VacuStar L400 when the VacuStar L400 is stopped. Assembly Install the non-return valve (min. DN 50) after the safety valve. -
Page 23: Protection Against Contact
Mounting instructions VacuStar L400 Installation and assembly Requirements for VacuStar L400 in The filter casing must be pressure and vacuum-resistant. compressor vacuum pump A filter mesh of less than 0.1 mm must be provided for the operation setup with suction vehicles. -
Page 24: Cell Ventilation Valve
Mounting instructions VacuStar L400 Installation and assembly 6.8.6 Cell ventilation valve Assembly The VacuStar L400 has been prepared for operation with cell ventilation. The cell ventilation connection is located opposite of the pressure and suction connection. Observe the following points during installation: Install fresh air line (6) between the cell ventilation connection at the compressor (Fig. -
Page 25: Safety Tank
11 Bore M12 for additional attachment 6.8.7 Safety tank Requirements The safety tank (min. 2.5 litre) protects the VacuStar L400 from sucking in liquids. It must comply with the following requirements: Incoming air must not contact the liquid directly ... -
Page 26: Display And Monitoring Equipment
With atmospheric suction (pressure operation) no more than 1 l of liquid must be suctioned into the VacuStar L400 per hour. When the liquid volume in the container is reached, the line to the VacuStar L400 must close. -
Page 27: Drive
– Selection and design are within the responsibility of the system builder. – Do not route axial forces into the VacuStar L400 shaft when installing drive components. – Do not tap couplings or other connection components onto the shaft, but slide them on. -
Page 28: Belt Drive
Mounting instructions VacuStar L400 Installation and assembly 6.9.1 V belt drive ATTENTION! The maximum permissible belt tensile force must not exceed 2,500 N. Observe the design, installation and inspection instructions of the manufacturer. Assembly Select V-belt drive according to Tab. 7. -
Page 29: Articulated Shaft Drive
ATTENTION! Observe the ratings, installation instructions and inspection intervals from the manufacturer. The hydraulic motor is installed to the VacuStar L400 via an intermediate flange. The power is transmitted via a flexible coupling. Components that match the VacuStar L400 can be ordered from CVS. -
Page 30: Start-Up
– Pay attention to tidiness and cleanliness in the working area! Loosely stacked or scattered components and tools are accident sources. Please observe all safety instructions as per the operating instructions "VacuStar L400", chapter "Occupational safety and special danger". -
Page 31: Start-Up
Check the attachment screws. (see page 19, chapter 6.6.) Start-up Proceed as follows during start-up: Pay attention to permissible inclination of the VacuStar L400 Open shut-off devices (if available) Start the VacuStar L400 drive (engage gently). ... -
Page 32: Switching Off
120 °C at 0.5 mbar excess pressure 7.3 Switching off Switching of the VacuStar L400: 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. -
Page 33: Declaration Of Incorporation
Mounting instructions VacuStar L400 Declaration of Incorporation 8 Declaration of Incorporation Einbauerklärung im Sinne der Maschinenrichtlinie 2006/42/EG Anhang II 1B - Orginaleinbauerklärung Declaration of Incorporation according to the EC Machinery Directive 2006/42/EC Annex II 1B – Original Declaration of Incorporation... - Page 34 Mounting instructions VacuStar L400 Declaration of Incorporation Declaration of Incorporation according to The Supply of Machinery (Safety) Regulations 2008 Annex II 1B - Original Declaration of Incorporation Manufacturer: CVS engineering GmbH Großmattstraße 14 D-79618 Rheinfelden Importer: CompVac Ltd. Mr. Lee Benton...
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Page 35: Index
Mounting instructions VacuStar L400 Index Index Installation ............16 Installation location Acceptance ............8 Requirement ............19 Articulated shaft Installation position ..........19 Requirement ........... 29 Intended use ............8 Articulated shaft drive ......... 29 Articulated shaft flange Liability ..............7 Assembly............29 Lubricating oil ............11... - Page 36 Mounting instructions VacuStar L400 Index Switching off ............32 Symbols in the instructions ........6 V belt drive ............28 Vacuum suction filter .......... 22 Technical data..........9, 10 Ventilating valve ..........21 Transport ............14 Warranty ............... 7...
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