CVS SKL 1200 C User manual

Contents
Assembly instructions
Screw compressor
SKL 1200 C
Doc-ID: 5113 / MA / EN
Release: Rev. 01 / 29/03/2019
Prior to installing the SKL 1200 C 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

Assembly instructions Screw compressor SKL 1200 C
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......................................9
2.6 Occupational safety and special risks ...........................9
2.7 Hazard symbols on the compressor..............................9
3Technical data ......................................................................10
3.1 Compressor dimensions..............................................10
3.2 Technical data..............................................................11
4Design and Function............................................................13
4.1 Design..........................................................................13
4.2 Function.......................................................................14
5Transport and storage.........................................................15
5.1 Safety notes for transport ............................................15
5.2 Transport......................................................................16
5.3 Storage ........................................................................17
6Installation and assembly ...................................................18
6.1 Safety...........................................................................18
6.2 Installation....................................................................19
6.3 Necessary work ...........................................................19
6.4 Installation requirements..............................................20
6.5 Drive.............................................................................21
6.5.1 Articulated shaft drive...................................21
6.6 Pressure flange............................................................22
6.7 Suction and pressure line ............................................22
6.8 Muffler (silencer)..........................................................23
6.9 Safety equipment.........................................................23
6.9.1 Safety valve..................................................23
6.9.2 Non-return valve...........................................24
6.9.3 Suction filter..................................................24
6.9.4 Protection against contact............................24

Assembly instructions Screw compressor SKL 1200 C
Contents
4
6.10 Display and monitoring equipment...............................25
6.11 Oil cooler26
6.11.1 Oil cooler circuit............................................26
6.11.2 Connection of the oil cooler..........................27
6.12 Compressed air after-cooler ........................................27
7Start-up..................................................................................28
7.1 Safety during start-up...................................................28
7.2 Start-up ........................................................................28
7.3 Switching off.................................................................29
8EC Declaration of Incorporation.........................................30
Index..............................................................................................31

Assembly instructions Screw compressor SKL 1200 C
General
5
1 General
1.1 Information on the assembly instructions
These assembly instructions provide important information about
installation and start-up of the screw compressor SKL 1200 C,
hereinafter referred to as "compressor". 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 compressor
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
compressor, well accessible to the personnel at all times. All safety
instructions of the operating instructions must additionally be
observed.
These assembly instructions do not apply to the installation of a
compressor unit completed by a third party.

Assembly instructions Screw compressor SKL 1200 C
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.

Assembly instructions Screw compressor SKL 1200 C
General
7
1.3 Limitation of Liability
See operating instructions "SKL 1200 C" for information about
limitation of liability.
1.4 Copyright protection
See operating instructions "SKL 1200 C" for information about
limitation of liability.
1.5 Spare parts
Information regarding the spare parts can be found in the operating
instructions "SKL 1200 C".
1.6 Warranty conditions
For warranty conditions refer to the "General Terms and
Conditions".
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, Part 1, Section B, Annex II) see page 30.

Assembly instructions Screw compressor SKL 1200 C
Safety
8
2 Safety
2.1 Intended use
The screw compressor SKL 1200 C is intended for the
installation in a superordinate system. 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 compressor is intended exclusively for the compression of
filtered air.
Use the compressor only as intended.
All information in the installation and operating instructions must be
strictly observed (technical data, operating data, permissible
working range, see page 11).
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 compressor itself is not subject to any acceptance and
monitoring obligation.
2.3 Operator's responsibility
See operating instructions "SKL 1200 C" 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.

Assembly instructions Screw compressor SKL 1200 C
Safety
9
2.5 Personal protective equipment
Information regarding the personal protective equipment can be
found in the operating instructions "SKL 1200 C".
2.6 Occupational safety and special risks
Please observe all safety instructions as per the operating
instructions "SKL 1200 C", Chapter "Occupational safety".
2.7 Hazard symbols on the compressor
Depending on the installation situation of the compressor, it may
be necessary to mark the compressor and/or the components with
additional danger pictograms. The necessity results from the
danger analysis of the unit and/or vehicle manufacturer. These
pictograms can be for example:
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.
DANGER!
Rotating parts!
… marks that potentially hazardous rotating parts
are present.

Assembly instructions Screw compressor SKL 1200 C
Technical data
10
3 Technical data
3.1 Compressor dimensions
* Distances for the contacting surfaces of the fastening threads
Fig. 1: Compressor dimensions

Assembly instructions Screw compressor SKL 1200 C
Technical data
11
3.2 Technical data
General data
Unit
Mass moment of inertia compressor
[kgm2]
1.52 (CR) / 1.44 (CL)
Compressor weight
[kg]
123
Permissible inclination from the horizontal during
operation
[°]
all sides ±7
Tab. 1: General data
Permissible working range
Unit
Input speed
[min–1]
1000…1800
Suction temperature 1)
[°C]
- 10…+ 40
Geodetic height 1)
[m]
0…1000
Negative pressure suction side
(e.g. due to soiling)
[mbar]
0…65
Maximum final overpressure at the pressure flange
2)
[bar]
2.5
Running time in continuous operation 3)
[h]
max. 3.0
1) For suction temperatures or heights outside the permissible working range, consult with CVS.
2) In case of increased suction temperatures or heights, the maximum permissible final pressure is reduced. Consult with CVS.
3) For continuous operation in excess of 3 hours, an oil cooler must be installed. Installation instructions on request.
Tab. 2: Permissible working range
Compressor performance data 1)
Unit
Input speed
[min–1]
1000
1400
1800
Intake volume flow
at a final overpressure
at the pressure flange
0.0 bar
[m3/h]
620
920
1170
2.5 bar
480
800
1045
Coupling power
at a final overpressure
at the pressure flange:
0.0 bar
[kW]
10,0
16,0
22,5
2.5 bar
35,0
49,5
64,5
Final temperature at final overpressure = 2.0 bar
[°C]
177
177
166
max. perm. final temperature
at final overpressure = 2.5bar
[°C]
250
1) Suction pressure at suction flange = 1.0 bar, suction and ambient temperature = 20 °C,
geodetic altitude max. 1000 m
Tab. 3: Performance characteristics

Assembly instructions Screw compressor SKL 1200 C
Technical data
12
Gear oil specification
Value
Specification
API CD/SF or higher
SAE viscosity class
10W40 or 15W40
Oil pressure of compressor
min. 0.5 bar (excess pressure)
Gear oil quantity compressor
4.8 litres
1) When connecting a gear oil cooler, the oil quantity must be increased commensurate with the additional volume.
Tab. 4: Gear oil specification
Recommended gear oils
Brand
Type of oil
MOBIL
Delvac MX Extra 10W40
ARAL
Multi Turboral SAE 15W40
DEA
Cronos Super DX SAE 15W40
ESSO
Essolube XT 201 SAE 15W40
SHELL
Universal Engine Oil SAE 15W40
FUCHS
Titan Universal HD SAE 15W40
BP
Vanellus C5 Global SAE 15W40
Other gear oil grades on request.
Tab. 5: Types of gear oil

Assembly instructions Screw compressor SKL 1200 C
Design and Function
13
4 Design and Function
4.1 Design
Fig. 2: Compressor view
1 Fastening threads vertical (3
pieces on each side of the
compressor)
2 Air outlet flange
3 Attachment point for transport
4 Rating plate gear oil
5 Oil filler neck cap / gearbox
ventilation
6 Drive shaft with feather key
7 Oil drain screw
8 Rating plate data compressor
9 Flange A air inlet
10 Flange B air inlet (closed)
11 Gear oil filter
12 Connection oil pressure gauge
13 Connection pressure gauge or
temperature sensor for
compressed air
14 Connection of external oil
cooler
15 Lock pin for external oil cooler
16 Control bore for oil filling
17 Rotation direction arrow

Assembly instructions Screw compressor SKL 1200 C
Design and Function
14
4.2 Function
Functional principle
Cleaned air is taken in via the air inlet flange A or B. Two screw rotors
compress the air completely dry. The rotors are running contact-free
both in relation to each other and to the casing. They are kept apart by
a synchronising gearbox. The compressed air reaches the consumer
via the air outlet flange.
Lubrication
Bearing and gearbox are supplied with gear oil via an oil filter by
means of an integrated oil pump.
Cooling
The heat is dissipated to the ambient air via the casing surface.
Drives
The drive is via an articulated shaft.
Sense of
rotation
SKL 1200 CR
The drive shaft's sense of rotation is clockwise when looking onto the
drive shaft.
SKL 1200 CL
The drive shaft's sense of rotation is counter-clockwise when looking
onto the drive shaft.
Fig. 3: Sense of rotation
Direction of rotation clockwise
Direction of rotation counter-clockwise

Assembly instructions Screw compressor SKL 1200 C
Transport and storage
15
5 Transport and storage
5.1 Safety notes for transport
Improper transport
Danger!
Danger by falling down or tilting of the
compressor!
The weight of the compressor may injure a person
and cause serious bruising!
Therefore:
–Depending on the dead weight and size of the
compressor, use a pallet on which the
compressor can be moved by means of a fork
lift.
–For lifting the compressor, use suitable lifting
gear (slings etc.) that is designed for the weight
of the compressor.
–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
"SKL 1200 C"!

Assembly instructions Screw compressor SKL 1200 C
Transport and storage
16
5.2 Transport
The compressor must be transported with suitable lifting gear.
Ropes or belts should preferably be attached to the two eye bolts
(M10).
Fig. 4: Crane transport
For future transports
Seal all open connections with protective caps
(prevents penetration of dirt and water)
Secure against vibrations
Drain gear oil
Securely fasten the compressor prior to transport (e.g. screw
it onto a pallet)
Transport and put down the compressor with a fork lift or
secure with straps and lift with suitable lifting gear.

Assembly instructions Screw compressor SKL 1200 C
Transport and storage
17
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.
On compressors intended for export (overseas), bags with
desiccant are placed into the inlets and outlets. These bags
keep moisture away from the compressor's working
chambers. Remove bags before suction and pressure line
are connected.

Assembly instructions Screw compressor SKL 1200 C
Installation and assembly
18
6 Installation and assembly
6.1 Safety
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 all safety instructions as per the operating
instructions "SKL 1200 C", Chapter "Occupational safety".

Assembly instructions Screw compressor SKL 1200 C
Installation and assembly
19
6.2 Installation
The figure gives a schematic illustration of the compressor with accessories.
Fig. 5: Compressor with accessories
1 Compressor
2 Suction filter
3 Maintenance display
4 Suction flange
5 Connection sleeve
6 Pipe socket
7 Suction hose
8 Flat seal
9 Pressure flange
10 Pressure silencer (muffler)
11 Safety valve
12 Non-return valve
13 Shaft flange
14 Safety clutch
15 Articulated shaft
16 Spacer
6.3 Necessary work
The following preparatory work is necessary to install the
compressor:
Installing the compressor with suction and pressure lines.
Connecting the drive components with the compressor.
Installing safety and monitoring equipment.
Installing accessories.

Assembly instructions Screw compressor SKL 1200 C
Installation and assembly
20
6.4 Installation requirements
Attaching the compressor
The compressor is mounted on 3 attachment points M16 (see
Fig. 2, pos. 1) either right or left on each side of the
compressor, inside the vehicle frame.
Requirements
on the installation panel and
the fixture
The installation panel and attachment points on the vehicle
must be of adequate load-carrying capacity and stiffness.
The two attachment points lying vertically on top of each
other are in one plane.
The third attachment point is set back by 15 mm or 45 mm
(see Fig. 1 footnote). Suitable spacer elements (see Fig. 5,
pos. 16) must be used for screwing.
The fastening screws must feature a sufficient clamping
length.
Requirements
upon 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.
be accessible for maintenance and repair work e.g. for
replacing the oil filter, or for checking the safety and non-
return valve.
Installation position
The pressure flange must point upwards.
Mount the compressor horizontally or with an inclination (see
table 1) according to the inclination of the auxiliary drive.
Assembly
Install the compressor with screws according to the following
table free from distortion.
Use the following screws to attach the compressor:
Screw
Model
Solidity
Torque
Screw-in depth in the housing
of the compressor
M16
Verbus Ripp
8.8
190 Nm
22…24 mm
Tab. 6: Fastening screws