CVS RKL 160 User manual

Contents
Mounting instructions
Multi-cell compressor
RKL 160
Doc-ID: 5006 / MA / EN
Release: Rev. 03 / 28/03/2023
Prior to installing the RKL 160 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!

2
Translation of the Original Assembly Instructions
© CVS engineering GmbH
Großmattstraße 14
79618 Rheinfelden / Germany
Phone: [phone]
Customer service: [phone]
E-Mail: [email protected]
Internet: www.cvs-eng.de

Mounting instructions Multi-cell compressor RKL 160
Contents
3
Contents
Contents .........................................................................................3
1General....................................................................................5
1.1 Information on the assembly instructions.....................5
1.2 Pictogram explanation..................................................6
1.3 Limitation of Liability.....................................................7
1.4 Copyright protection.....................................................7
1.5 Spare parts...................................................................7
1.6 Warranty conditions......................................................7
1.7 Customer Service.........................................................7
1.8 EC Declaration of Incorporation...................................7
2Safety ......................................................................................8
2.1 Intended use.................................................................8
2.2 Acceptance and monitoring..........................................8
2.3 Operator's responsibility...............................................8
2.4 Requirements placed upon the specialised staff .........8
2.5 Personal protective equipment.....................................8
2.6 Occupational safety and special risks..........................8
3Technical data ........................................................................9
3.1 Dimensions...................................................................9
3.2 Technical data............................................................10
4Design ...................................................................................11
4.1 Design ........................................................................11
4.2 Function......................................................................12
4.3 Sense of rotation........................................................12
5Transport and storage.........................................................13
5.1 Safety notes for transport...........................................13
5.2 Transport....................................................................13
5.3 Storage.......................................................................14
6Installation and assembly ...................................................15
6.1 Safety .........................................................................15
6.2 Setup example ...........................................................16
6.3 Necessary work..........................................................17
6.4 Changing the sense of rotation of the RKL 160.........17
6.5 Attachment and installation space .............................17
6.6 Suction and pressure flanges.....................................19
6.7 Suction and pressure lines.........................................19
6.8 Safety equipment .......................................................19
6.8.1 Safety valve................................................................20
6.8.2 Non-return valve.........................................................20
6.8.3 Suction filter................................................................21

Mounting instructions Multi-cell compressor RKL 160
Contents
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6.8.4 Protection against contact..........................................21
6.8.5 Display and monitoring equipment.............................21
6.9 Cooling .......................................................................22
6.10 Drive ...........................................................................22
6.10.1 V belt drive..................................................................23
6.10.2 Articulated shaft drive.................................................23
6.10.3 Drive via flexible coupling and hydraulic motor..........24
7Start-up..................................................................................25
7.1 Safety notes for start-up.............................................25
7.2 Start-up.......................................................................26
7.3 Switching off ...............................................................26
8Declaration of Incorporation...............................................27
Index..............................................................................................29

Mounting instructions Multi-cell compressor RKL 160
General
5
1 General
1.1 Information on the assembly instructions
These assembly instructions provide important information about
installation and start-up of the multi-cell compressor RKL 160
(hereinafter referred to as "RKL 160"). 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 RKL 160
must be observed.
You must have read and understood the mounting instructions
before you start installing the machine and put it into operation! It is
a product component and must be kept in direct proximity of the
RKL 160, well accessible to the personnel at all times. All safety
instructions of the operating instructions must additionally be
observed.

Mounting instructions Multi-cell compressor RKL 160
General
6
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.
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.

Mounting instructions Multi-cell compressor RKL 160
General
7
1.3 Limitation of Liability
See operating instructions "RKL 160" for information about
limitation of liability.
1.4 Copyright protection
See operating instructions "RKL 160" for information about
limitation of liability.
1.5 Spare parts
Information regarding the copyright protection can be found in the
operating instructions "RKL 160".
1.6 Warranty conditions
The warranty conditions are included in the sales documentation
as a 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 EC Declaration of Incorporation
Declaration of incorporation (pursuant to EC Machinery Directive
2006/42/EC and “The supply of Machinery (Safety) Regulations
2008”) see page 27.

Mounting instructions Multi-cell compressor RKL 160
Safety
8
2 Safety
2.1 Intended use
The multi-cell compressor RKL 160 is intended for the installation
in a superior machine (upstream). The manufacturer of the
overall system must assess the new risks resulting from the
installation. These risks must be included in the operating
instructions of the system.
The RKL 160 is intended exclusively for the compression of
filtered air.
2.2 Acceptance and monitoring
The RKL 160 itself is not subject to any acceptance and monitoring
obligation.
2.3 Operator's responsibility
See operating instructions "RKL 160" for information about the
responsibility of the operating company.
2.4 Requirements placed upon the specialised staff
The mounting instructions specify the following qualification
requirements for the different fields of activity:
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.
Electrical specialists
are, due to their technical training, knowledge and experiences
and their knowledge of the relevant standards and regulations,
able to work on electrical systems and to independently
recognize possible hazards.
2.5 Personal protective equipment
Information regarding the personal protection can be found in the
operating instructions "RKL 160".
2.6 Occupational safety and special risks
Please observe all safety instructions as per the operating
instructions "RKL 160", Chapter "Occupational safety and special
danger".

Mounting instructions Multi-cell compressor RKL 160
Technical data
9
3 Technical data
3.1 Dimensions
Fig. 1: Dimensions RKL 160

Mounting instructions Multi-cell compressor RKL 160
Technical data
10
3.2 Technical data
General data
Unit
RKL 160
Angular momentum on the drive shaft
[kgm2]
0.034
Weight RKL 160
[kg]
33
Rated speed
[1/min]
1500
Sound pressure level at final overpressure = 2.0 bar 1)
[dB(A)]
75
1) Distance to RKL 160 = 7 m
Tab. 1: General data
Permissible working range
Unit
RKL 160
Speed range
[1/min]
1200…1600
Suction temperature 1)
[°C]
-10…+40
Geodetic height 1)
[m]
0…1000
Vacuum suction side
[mbar]
0…65
Maximum final overpressure at the pressure flange 2)
[bar]
2.5
1) Consult CVS for suction temperature and/or altitudes outside the permissible working range.
2) Intake pressure at the suction flange = 1 bar, suction and ambient temperature = 20 °C
Tab. 2: Permissible working range
Performance characteristics at rated speed
Unit
RKL 160
Suction volume flow at final overpressure
0.0 bar
[m3/h]
145
2.0 bar
115
Coupling output at final overpressure
0.0 bar
[kW]
4.5
2.0 bar
8.1
1) Intake pressure at the suction flange = 1 bar, suction and ambient temperature = 20 °C
Tab. 3: Performance characteristics at rated speed

Mounting instructions Multi-cell compressor RKL 160
Design
11
4 Design
4.1 Design
Fig. 2: Design
1 Suction flange –air entry DN 40
2 Pressure flange –air exit DN 32
3 Attachment thread for flanges
4 Drive shaft
5 Shaft protection grid drive side
6 Shaft protection grid counter-side
7 Fixing feet
8 Rating plate
9 Rotation arrow
10 Thread for eye bolt M10
11 Connection for pressure or temperature
monitoring G ¼“

Mounting instructions Multi-cell compressor RKL 160
Design
12
4.2 Function
Functional principle
In the working area, self-lubricating sliders in conjunction with the
impeller and the casing form cells that are separated from each
other and steadily grow (sucking) or shrink (compressing) with
each revolution.
Lubrication
Lubrication of the rotor bearing is warranted by a permanent
grease fill.
Cooling
The RKL 160 is air-cooled.
Heat removal is performed by casing ribs on the entire casing
surface with targeted cooling air guidance, via a ventilation wheels.
Drives
The RKL 160 can be driven via:
Articulated shaft
V-belt
Flexible coupling
See chapter 6.10, page 22.
4.3 Sense of rotation
The RKL 160 has a continuous drive shaft. It can be driven from
either side. The sense of rotation therefore may be chosen either
clockwise or counter-clockwise (see page 17). The standard sense
of rotation at delivery is clockwise with view of the drive shaft.

Mounting instructions Multi-cell compressor RKL 160
Transport and storage
13
5 Transport and storage
5.1 Safety notes for transport
Improper transport
DANGER!
Danger by falling down or tilting of the
RKL 160!
The weight of the RKL 160 may injure a person
and cause serious bruising!
Therefore:
–Use a pallet on which the RKL 160 can be
moved by means of a fork lift.
–For lifting the RKL 160, use suitable lifting
gear (slings, etc.) that is designed for the
weight of the RKL 160.
–When putting the slings in position, take care
to avoid putting stress on individual
components.
–Only use the provided attachment points with
eye bolts.
Please also observe the safety notes in the operating instructions
"RKL 160"!
5.2 Transport
The RKL 160 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 RKL 160.
For future transports:
Seal all open connections with protective caps
(prevents penetration of dirt and water)
Secure against vibrations
Securely fasten the RKL 160 prior to transport (e.g. screw it
onto a pallet)
Transport and put down the RKL 160 with a fork lift or secure
with straps and lift with suitable lifting gear.

Mounting instructions Multi-cell compressor RKL 160
Transport and storage
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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…+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.

Mounting instructions Multi-cell compressor RKL 160
Installation and assembly
15
6 Installation and assembly
6.1 Safety
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.
–Only skilled electricians are allowed to carry out
any work on the electric systems, on electric
components and connections.
Dirt and lying about items
CAUTION!
Risk of tripping from dirt and objects lying
around!
Contamination and discarded items can lead to
slipping and tripping, resulting in substantial
injuries.
Therefore:
–Always keep the working area clean.
–Remove objects that are not required.
–Mark tripping points with yellow-and-black tape.
Please also observe the safety notes in the operating instructions
"RKL 160"!

Mounting instructions Multi-cell compressor RKL 160
Installation and assembly
16
6.2 Setup example
The figure gives a schematic illustration of the RKL 160 with
accessories and drive variants.
Fig. 3: Setup with accessories and drive variants
1 RKL 160
2 Flexible coupling
3 Articulated shaft mounting
flange
4 Intermediate flange for
hydraulic motor installation
5 Hydraulic motor
6 Suction air filter
7 Vacuum display
8 Thermometer installation point
9 Manometer installation point
10 Safety valve
11 Non-return valve

Mounting instructions Multi-cell compressor RKL 160
Installation and assembly
17
6.3 Necessary work
The following work is necessary to install the RKL 160:
Connecting the RKL 160 with suction and pressure lines.
Installing safety and monitoring equipment.
Installing accessories.
Connecting the drive with RKL 160. Here, observe the correct
sense of rotation (rotation direction arrow) and the speed range.
6.4 Changing the sense of rotation of the RKL 160
The standard rotating direction at delivery is clockwise with view of
the drive shaft.
To change the sense of rotation, swap the shaft protection grids
(see Fig. 2, pos. 5 and pos. 6). Tightening torque of the
4 attachment screws: 4.5 Nm.
6.5 Attachment and installation space
Attachment of the feet at the
RKL 160
Attachment of the RKL 160 to the vehicle takes place by two feet
connected to the RKL 160; connection takes place right to the
chassis or the traverses.
The feet can be installed at all 4 longitudinal sides (right, left,
top, bottom) of the RKL 160.
If the feet position must be changed, the attachment screws
must be coated with installation paste again and tightened with
34 Nm.
Requirements
placed upon installation point
and attachment
The attachment points on the vehicle must feature a sufficient
load capacity and rigidness.
The attachment points must be on the same level.
The fastening screws must feature a sufficient clamping length.

Mounting instructions Multi-cell compressor RKL 160
Installation and assembly
18
Requirements
on the installation location
The installation location must fulfil the following requirements:
Protect from dirt, falling rocks and spray water.
Offer sufficient space for accidental contact protection.
Offer sufficient space for the connections of the suction and
pressure lines.
Ensure good legibility of the instruments.
Accessible for maintenance and repair work (e.g. for replacing
the air filter, or for checking the safety and non-return valve).
The RKL 160 must not be installed on a closed ground plate.
There must be sufficient free space for discharge of cooling air.
Fig. 4: Installation position
Top: Impermissible installation position, cooling air exit covered.
Bottom: Intended installation position, cooling air exit open.
Installation position of the RKL 160
Pressure and suction flange may point up, right or left. Setup
with pressure and suction flange pointing down is not
recommended due to thermal reasons.
Install the RKL 160 horizontally or with tilt matching the
inclination of the auxiliary drive. But do not incline by more than
±5° degrees for a horizontal vehicle.
Installation at the vehicle
Attach the feet of the RKL 160 free from distortion with screws
according to Tab. 4.
Use the following screws for securing the RKL 160:
Screw
Solidity
Torque
M10
8.8
40 Nm
Tab. 4: Fastening screws

Mounting instructions Multi-cell compressor RKL 160
Installation and assembly
19
6.6 Suction and pressure flanges
Assembly
1. Coat all threads with anti-fretting paste.
2. Install flanges with stud bolts M10-8.8 with a tightening torque
of 40 Nm for the hexagon nut.
Fig. 5: Assembly example for suction flange
6.7 Suction and pressure lines
Requirements
Corrosion-proof
Pressure and temperature resistance (up to 240 °C)
Minimum inside diameter:
Suction side: 40 mm
Pressure side: 35 mm
Installation
Install the lines as follows:
The connected lines must not have any reaction force on the
RKL 160. Support the lines, if necessary.
Place suction lines rising towards the RKL 160; place pressure
line falling away from the RKL 160. Provide a condensate sack
with drain outlet at the lowest point.
Check for tightness when using aplastic hose on the suction
side
Install a sieve in front of the suction flange if initial
contamination is expected on the suction side (recommended
mesh width 1 mm)
6.8 Safety equipment
The following safety equipment must be installed:
Suction filter
Safety valve
Non-return valve
Protection against contact

Mounting instructions Multi-cell compressor RKL 160
Installation and assembly
20
6.8.1 Safety valve
Risk of explosions
DANGER!
Risk of injury by explosions!
Explosions can cause severe injuries!
Therefore:
–Install the safety valve as instructed. Observe
the manufacturer's instructions.
–Only use the safety valve for its intended
purpose.
–Never block the safety valve.
The German accident prevention regulations require a non-
lockable safety valve to be installed after the RKL 160 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 %. It must be identified with a TÜV component
test number and be equipped with a manual venting element.
ATTENTION!
The safety valve (overpressure protection) must be
chosen to match the maximum permitted operating
pressure, the volume flow and the temperature
range.
Assembly
Install the safety valve directly downstream of the RKL 160.
The nominal opening pressure may not exceed the maximum
permissible final overpressure (refer to Tab. 2) or the
permissible system pressure, provided the latter is lower.
Protect the settings against unauthorised or erroneous
changes.
6.8.2 Non-return valve
The non-return valve prevents the reverse operation of the
RKL 160 after it has been switched off when the pressure tank is
not relieved. The valve is not suitable for retaining material to be
conveyed.
Assembly
Install non-return valve right behind the safety valve.
Install a second non-return valve at the transfer to the
consumer to securely avoid any material to be conveyed in the
pressure line.