CVS RPO 200 User manual

Operating instructions
CVS Compressor RPO 200/300/400/600/800
Doc-ID: 5001 / BA / EN
Release: Rev. 20 / 28.03.2023
The operating instructions must be read by the operator of the compressor and before start-up!

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

CVS Compressor RPO 200/300/400/600/800
Contents
3
1General...............................................................................6
Information regarding the operating instructions ......6
Pictogram explanation ..............................................7
Limitation of Liability .................................................8
Copyright protection..................................................8
Scope of delivery and goods receiving.....................9
Spare parts ...............................................................9
Warranty conditions..................................................9
Customer Service ...................................................10
Declaration of Incorporation Declaration of
Conformity...............................................................10
2Safety ...............................................................................11
Intended use...........................................................11
Operator's responsibility .........................................11
Operating personnel ...............................................12
2.3.1 Requirements..........................................12
Personal protective equipment...............................12
Occupational safety and special risks ....................13
3Technical data .................................................................18
Dimensions RPO 200/300/400/60013).....................18
Dimensions RPO 600/80013)...................................19
Technical data.........................................................20
Rating plate.............................................................22
4Design and function of the compressed air system ...23
Design.....................................................................23
Function..................................................................25
4.2.1 Functional principle of the construction of
the compressor........................................27
Components............................................................28
4.3.1 Air filter (Fig. 5: Pos. 126)........................28
4.3.2 Oil filter (Fig. 5: Pos. 100/32)...................28
4.3.3 Minimum pressure valve (Fig. 7:
Pos. 150).................................................28
4.3.4 Electric motor (Fig. 7: Pos. 239)..............28
Oil cooler (Fig. 5: Pos. 190)....................................28
Thermostat (Fig. 5: Pos. 100).................................28
Safety and shutoff functions ...................................29
4.6.1 Safety valve 14 barg(Pos. 145)...............29
4.6.2 Safety temperature switch (Pos. 161).....30
Options....................................................................31
4.7.1 Sound proof hood....................................31
4.7.2 Oil level monitor (Pos. 227).....................31
4.7.3 Compressed air dryer..............................32
5Transport and storage....................................................33
Safety notes for transport .......................................33
Transport.................................................................33
Storage ...................................................................34
5.3.1 Storage for a period of more than 3
months.....................................................34
5.3.2 Recommissioning of stored
compressors............................................34
5.3.3 Storage or standstill of compressors
installed in the vehicle .............................34
6Installation and assembly ..............................................36

CVS Compressor RPO 200/300/400/600/800
Contents
4
Safety at installation and assembly........................ 36
Installation diagram................................................ 36
Installing the compressor....................................... 37
Drive....................................................................... 40
6.4.1 V belt drive.............................................. 40
Oil cooler................................................................ 41
6.5.1 Cooling oil lines....................................... 42
Line connection (pressure line).............................. 42
Cyclone separator.................................................. 43
Relief valve............................................................. 43
Safety equipment and control elements................. 44
6.9.1 Safety valve (on site).............................. 44
6.9.2 Pressure monitor (on site) ...................... 44
Oil level monitor (optional) ..................................... 44
Cyclone separator or micro filter............................ 45
Pulsations (pulsation damping valve) .................... 45
Sound proof hood................................................... 45
Electrical connection.............................................. 46
7Start-up and operation................................................... 47
Safety during start-up............................................. 47
Start-up .................................................................. 47
Operation after long standstill or after extended
storage ................................................................... 48
Longer standstill..................................................... 49
Operation ............................................................... 49
Operation modes.................................................... 49
7.6.1 Load intermittent duty (LA) ..................... 50
7.6.2 Load idle intermittent duty (LLA)............. 50
7.6.3 Load idle drying run intermittent duty
(LLTA)..................................................... 51
7.6.4 Load idle intermittent duty with externally
controllable drying run (LLA-T)............... 52
8Maintenance.................................................................... 53
Safety during maintenance work............................ 53
Cleaning................................................................. 53
Maintenance schedule........................................... 53
Oil level check and oil change ............................... 55
8.4.1 Oil level check......................................... 55
8.4.2 Fill oil....................................................... 56
8.4.3 Oil change............................................... 58
Safety valve at the compressor (Pos. 145)............ 60
8.5.1 Functional testing.................................... 62
8.5.2 Ventilate the compressor........................ 62
Cyclone separator (Pos. 204)................................ 63
8.6.1 Check the cyclone separator.................. 63
8.6.2 Clean the cyclone separator................... 64
Clean or blow out screen insert (Pos. 88) and oil
return nozzle (Pos. 85) of the oil return.................. 64
Air filter (Pos. 126) ................................................. 66
Oil filter (Pos. 100/32) ............................................ 68
Oil cooler (Pos. 190) .............................................. 70
Air deoiler element (Pos. 65) ................................. 71
Oil level monitor (Pos. 227).................................... 75
8.12.1 Checking the oil level monitor................. 75
8.12.2 Dismantling and cleaning of the oil level
monitor.................................................... 75

CVS Compressor RPO 200/300/400/600/800
Contents
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Air suction regulator with non-return valve
(Pos. 30/55, Pos. 30/57).........................................77
Minimum pressure valve (Pos. 150).......................79
8.14.1 Maintenance of the minimum pressure
valve........................................................79
8.14.2 Check minimum pressure valve..............81
Compressor stage (Pos. 30)...................................82
Electric motor..........................................................82
Hose lines and compensators ................................82
9Malfunctions....................................................................83
Safety during troubleshooting.................................83
10 Spare and maintenance parts........................................87
10.1.1 Assembly drawing of compressor RPO
200…800 (drawing no.: 940 086-00) ......88
10.1.2 Compressor stage RPO 200…800
(drawing no.: 940 071-00).......................89
10.1.3 Oil temperature controller RPO 200…800
(drawing no.: 940 040-00).......................90
10.1.4 Assembly drawing of unit and accessories
RPO 200…800 (drawing no.: 250 176-
00) ...........................................................91
Maintenance parts ..................................................92
11 Decommissioning and disposal....................................93
12 EU Declaration of Incorporation....................................94
13 UK Declaration of Incorporation....................................95
14 EU Declaration of Conformity........................................96
15 UK Declaration of Conformity........................................97
Index.........................................................................................98

CVS Compressor RPO 200/300/400/600/800
General
6
1 General
Information regarding the operating instructions
These operating instructions provide important information on how
to deal with the compressor type RPO.
A precondition for safe operation is the observance of all safety
and handling instructions specified in these operating instructions.
Furthermore, all local accident prevention regulations and general
safety regulations valid for the application area of the compressor
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
compressor, well accessible to the personnel at all times.
When passing the compressor on to third parties, the operating
instructions must also be handed over.

CVS Compressor RPO 200/300/400/600/800
General
7
Pictogram explanation
Warning notes
Warning notes are characterised by pictograms in these operat-
ing 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 inju-
ries 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.
ATTENTION!
... points to a potentially dangerous situation, which
can lead to minor or light injuries if it is not avoided.
CAUTION!
... points to a potentially dangerous situation, which
may lead to property damage if it is not avoided.
Hints and recommendations
NOTE!
… highlights useful hints and recommendations
as well as information for an efficient and trouble-
free operation.

CVS Compressor RPO 200/300/400/600/800
General
8
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:
Failure to follow 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 con-
tract, the general terms and conditions as well as the manufactur-
er'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 ap-
plied process technology and the performance parameters identi-
fied.
The warranty period commences on the date the compressor 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.
→Also see page 92, Chapter 10.2.
Copyright protection Surrendering the operating instructions to third parties without writ-
ten permission of the manufacturer is not permitted.
NOTE!
Content details, texts, drawings, pictures and other
illustrations are protected by copyright and are sub-
ject to industrial property rights. Any improper use
shall be liable to prosecution.
Any type and form of duplication also of extracts as well as the ex-
ploitation and/or communication of the contents are not permitted
without the manufacturer’s written declaration of consent.

CVS Compressor RPO 200/300/400/600/800
General
9
Scope of delivery and goods receiving
Immediately check the delivery after receipt for completeness and
transport damages. The scope of delivery is indicated on the deliv-
ery note.
Proceed as follows in the case of outwardly recognisable transport
damage:
Do not accept the delivery or only under reserve.
Note the extent of damage on the transport documents or on
the delivery note of the forwarder.
Lodge complaint.
NOTE!
Lodge a complaint for each defect, as soon as it is
recognised. Compensation claims can only be sub-
mitted within the valid complaint periods.
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 im-
pair safety.
Therefore:
–Use only the manufacturer's original spare
parts.
Procure spare parts directly from the manufacturer or from author-
ised dealers.
Warranty conditions
Warranty terms see "General Terms of Sale".

CVS Compressor RPO 200/300/400/600/800
General
10
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.
Declaration of Incorporation
Declaration of Conformity
Declaration of Incorporation and Declaration of Conformity, refer to
page 94ff.