CVS VacuStar L400 User manual

Contents
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!

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 VacuStar L400
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 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 ...................................................................................12
4.1 Function.......................................................................13
4.2 Sense of rotation..........................................................13
5Transport and storage.........................................................14
5.1 Safety notes for transport ............................................14
5.2 Transport......................................................................14
5.3 Storage ........................................................................15
6Installation and assembly ...................................................16
6.1 Safety...........................................................................16
6.2 Setup example for VacuStar L400 in compressor
operation......................................................................17
6.3 Setup example for VacuStar L400 in compressor
vacuum pump operation ..............................................18
6.4 Necessary work ...........................................................18
6.5 Sound insulation ..........................................................19
6.6 Attachment and installation space...............................19
6.7 Suction and pressure lines ..........................................20
6.8 Safety equipment.........................................................20
6.8.1 Safety valve..................................................21
6.8.2 Ventilation valve ...........................................21
6.8.3 Non-return valve...........................................22
6.8.4 Vacuum suction filter....................................22
6.8.5 Protection against contact............................23

Mounting instructions VacuStar L400
Contents
4
6.8.6 Cell ventilation valve.....................................24
6.8.7 Safety tank....................................................25
6.8.8 Display and monitoring equipment...............26
6.9 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
7Start-up..................................................................................30
7.1 Safety notes for start-up...............................................30
7.2 Start-up ........................................................................31
7.3 Switching off.................................................................32
8Declaration of Incorporation...............................................33
Index..............................................................................................35

Mounting instructions VacuStar L400
General
5
1 General
1.1 Information on the assembly instructions
These assembly instructions provide important information about
installation and start-up of 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.
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
VacuStar L400, well accessible to the personnel at all times. All
safety instructions of the operating instructions must additionally be
observed.

Mounting instructions VacuStar L400
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 VacuStar L400
General
7
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"".
1.5 Spare parts
Information regarding the copyright protection can be found in the
operating instructions "VacuStar L400".
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 Declaration of Incorporation
Declaration of incorporation (pursuant to EC Machinery Directive
2006/42/EC and “The supply of Machinery (Safety) Regulations
2008”) see page 33.

Mounting instructions VacuStar L400
Safety
8
2 Safety
2.1 Intended use
The compressor vacuum pump series VacuStar L400 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 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.
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 "VacuStar L400"".
2.6 Occupational safety and special risks
Please observe all safety instructions as per the operating
instructions "VacuStar L400", chapter "Occupational safety and
special danger".

Mounting instructions VacuStar L400
Technical data
9
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
1 Feather key DIN 6885 A10x8x40
2 Oil level switch, option

Mounting instructions VacuStar L400
Technical data
10
3.2 Technical data
General data
Unit
VacuStar L400
Angular momentum on the drive shaft
[kgm2]
0.074
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

Mounting instructions VacuStar L400
Technical data
11
Lubricating oil
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!

Mounting instructions VacuStar L400
Design
12
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.
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

Mounting instructions VacuStar L400
Design
13
4.1 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.
Drives
The VacuStar L400 can be powered via:
Articulated shaft
V-belt
Flexible coupling
See chapter 6.9, page 27.
4.2 Sense of rotation
The VacuStar L400 must only be operated in the indicated
rotational direction. The rotational direction is determined by the
customer in the order.

Mounting instructions VacuStar L400
Transport and storage
14
5 Transport and storage
5.1 Safety notes for transport
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:
–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.
Please also observe the safety notes in the operating instructions
"VacuStar L400"!
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.

Mounting instructions VacuStar L400
Transport and storage
15
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.
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.

Mounting instructions VacuStar L400
Installation and assembly
16
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 observe all safety instructions as per the operating
instructions "VacuStar L400", chapter Occupational safety

Mounting instructions VacuStar L400
Installation and assembly
17
6.2 Setup example for VacuStar L400 in compressor operation
Fig. 3: Setup example for VacuStar L400 in compressor operation
1 VacuStar L400 (compressor
operation)
2 Thermometer
3 Pressure gauge
4 Safety valve
5 Non-return valve
6 Vacuum display
7 Suction air filter

Mounting instructions VacuStar L400
Installation and assembly
18
6.3 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
1 Cell ventilation unit
2 Vehicle tank
3 Thermometer
4 Pressure gauge
5 Ventilating valve
6 Safety valve
7 Safety tank
8 Drain tap
9 Vacuum suction filter
10 Oil level switch
11 Four-way switching valve with
hand lever
12 VacuStar L400 (compressor
vacuum pump operation)
13 Muffler
6.4 Necessary work
The following work is necessary to install the VacuStar L400:
Connecting the VacuStar L400 with suction and pressure lines.
Installing safety and monitoring equipment.
Installing accessories.
Connecting the drive with VacuStar L400. Here, observe the
correct sense of rotation (rotation direction arrow) and the
speed range.

Mounting instructions VacuStar L400
Installation and assembly
19
6.5 Sound insulation
Measures for sound insulation
You can avoid or reduce the triggering of adjacent vehicle
components by body sound or media sound as follows:
Downstream installation of a muffler
Compensators in the suction and pressure lines
6.6 Attachment and installation space
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.
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.
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. 6 without
tension.
Use the following screws for securing the VacuStar L400:
Screw
Solidity
Torque
M12
8.8
80 Nm
Tab. 6: Fastening screws

Mounting instructions VacuStar L400
Installation and assembly
20
6.7 Suction and pressure lines
Assembly
Connect suction and pressure pipe at the 2“ thread
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
Pressure and temperature resistance (up to 240 °C)
Rated diameter DN 50 (2“)
Installation
Install the lines as follows:
The connected lines must not have any reaction force on the
VacuStar L400. Support the lines, if necessary.
Place suction lines rising towards the VacuStar L400; place
pressure line falling away from the VacuStar L400. The
condensate must be able to be drained.
Remove dirt, welding residues and rust, if necessary, before
commissioning.
If intake-side initial contamination is expected from the intake
line, install a corresponding filter.
Check the lines for leaks.
6.8 Safety equipment
The following safety equipment must be installed:
Safety valve
Non-return valve
Monitoring the compression end temperature
Protection against contact
Ventilation valve 1)
Vacuum suction filter 1)
Cell ventilation valve if needed 1)
Shut-off valve in the control line 1)
Safety tank 1)
Air filter 2)
1) Operation as compressor vacuum pump
2) Operation as compressor