CVS VacuStar W900 User manual

Contents
Operating instructions
VacuStar W900 / W1300 / W1600
Doc-ID: 5002 / BA / EN
Release: Rev. 06 / 16/08/2017
The operating instructions must be read by the VacuStar W operator 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

VacuStar W900 / W1300 / W1600
Contents
3
1General....................................................................................4
1.1 Information regarding the operating instructions ...........4
1.2 Pictogram explanation ...................................................5
1.3 Limitation of Liability ......................................................6
1.4 Copyright protection.......................................................7
1.5 Spare parts ....................................................................7
1.6 Warranty conditions.......................................................7
1.7 Customer Service ..........................................................7
2Safety ......................................................................................8
2.1 Intended use..................................................................8
2.2 Proper operation............................................................8
2.3 Acceptance and monitoring...........................................9
2.4 Operator's responsibility ................................................9
2.5 Operating personnel ....................................................10
2.5.1 Requirements...............................................................10
2.6 Personal protective equipment....................................11
2.7 Occupational safety and special risks .........................11
3Technical data ......................................................................17
4Design and function.............................................................18
4.1 Design..........................................................................18
4.2 Function.......................................................................19
4.3 Control and display elements ......................................19
5Transport and storage.........................................................20
5.1 Safety notes for transport ............................................20
5.2 Transport......................................................................20
5.3 Storage ........................................................................20
6Start-up and operation ........................................................21
6.1 Safety during start-up ..................................................21
6.2 Start-up........................................................................21
6.3 Switching off.................................................................23
6.4 Inspections to be performed ........................................23
7Maintenance .........................................................................25
7.1 Safety during maintenance work .................................25
7.2 Maintenance schedule.................................................25
7.3 Performance of maintenance work..............................27
8Malfunctions.........................................................................31
8.1 Safety...........................................................................31
8.2 Recommissioning after corrective action.....................32
8.3 Malfunction table..........................................................33
9Spare parts ...........................................................................35
10 Decommissioning and disposal.........................................36
Index..............................................................................................37

VacuStar W900 / W1300 / W1600
General
4
1 General
1.1 Information regarding the operating instructions
These operating instructions provide important information on how
to deal with the VacuStar W. 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 W
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
VacuStar W, well accessible to the personnel at all times.
When passing the VacuStar W on to third parties, the operating
instructions must also be handed over.

VacuStar W900 / W1300 / W1600
General
5
1.2 Pictogram explanation
Warning notes
Warning notes are characterised by pictograms in these operating
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.
Safety note ATEX!
Only for machines with Ex-approval.
This pictogram denotes the special conditions that
must be observed according to the approvals when
operating the machines in potentially explosive
areas.
Hints and recommendations
NOTE!
… highlights useful hints and recommendations as
well as information for an efficient and trouble-free
operation.

VacuStar W900 / W1300 / W1600
General
6
1.3 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:
Non-observance of 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
contract, the general terms and conditions as well as the
manufacturer'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 applied
process technology and the performance parameters identified.
The warranty period commences on the date the VacuStar W is
delivered to the customer.
Wear parts
Wear parts are all components coming into immediate contact with
the material to be processed (e.g. bearings, shaft sealing rings, oil
pumps, rotor vanes, etc.).
These components are excluded from the warranty and any claims
for defects as far as wear and tear damage is concerned.

VacuStar W900 / W1300 / W1600
General
7
1.4 Copyright protection
Surrendering the operating instructions to third parties without
written permission of the manufacturer is not permitted.
NOTE!
Content details, texts, drawings, pictures and other
illustrations are protected by copyright and are
subject 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
exploitation and/or communication of the contents are not
permitted without the manufacturer’s written declaration of consent.
1.5 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
impair safety.
Therefore:
–Use only the manufacturer's original spare
parts.
Procure spare parts from authorised dealers or directly from the
manufacturer. Refer to page 2 for address.
A list of spare and wear parts can be found in the enclosure.
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.

VacuStar W900 / W1300 / W1600
Safety
8
2 Safety
2.1 Intended use
The compressor vacuum pumps of the VacuStar W series are
exclusively intended for the compression or extraction of filtered
air.
The VacuStar W in the explosion proof design complies with
Directive 2014/34/EC (ATEX) and is suitable for conveying
potentially explosive gases and gas mixtures of explosion group
IIB, temperature class T2/T3 from potentially explosive zone 1 and
zone 2 areas. The VacuStar W may not be operated in a
potentially explosive area.
Marking of the VacuStar W:
Marking of II 2G c IIB T2 (i) (for VacuStar W without cell
ventilation)
II 2G c IIB T3 (i) (for VacuStar W with cell ventilation and
no potentially explosive external atmosphere).
The gas temperature in temperature class T2 is restricted to
220 °C and in temperature class T3 to 195 °C.
2.2 Proper operation
The following criteria in essence define the proper
operation:
–Speed range of the VacuStar W:
1000…1500 min1
–Ambient temperature: 20...+40 °C
–No coast down of the cooling system after
switching off the VacuStar W
–Permissible continuous duty vacuum with cell
ventilation: 100 mbar
–Permissible continuous duty vacuum without
cell ventilation: 200 mbar
–No back pressure on the pressure side during
vacuum operation
–Liquids and solids may not get into the VacuStar
W or be sucked into the VacuStar W.

VacuStar W900 / W1300 / W1600
Safety
9
If explosive gases and gas mixtures are conveyed, the
following guidelines must be observed:
–2014/34/EC
Devices and protection systems for the proper
use in explosive environments
–99/92/EC
Health protection and safety of the employees in
potentially explosive areas
Only use VacuStar W for the intended use.
All specifications in these operating instructions have to be strictly
complied with (technical data, ATEX regulations, etc.)
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.
2.3 Acceptance and monitoring
The VacuStar W itself is not subject to any acceptance and
monitoring obligation.
2.4 Operator's responsibility
The VacuStar W is used for industrial purposes. The operator of
the VacuStar W is therefore subject to the legal obligations
concerning occupational safety.
The provisions valid at the place of installation as well as the safety
and accident prevention regulations of the Institution for statutory
accident insurance and prevention must be observed. The operator
must in particular:
inform himself on the valid industrial safety regulations.
determine the additional hazards that arise from the special
working conditions at the machine's place of installation by
means of a hazard assessment.
implement the necessary rules of conduct for operation of the
machine at the place of installation by means of user
instructions.
check at regular intervals during the machine's entire period of
use whether the user instructions correspond to the current
state of the body of rules and regulations.
adapt the operation instructions, if necessary to the new
regulations, standards, and operating conditions .
clearly regulate the responsibilities for installing, operating,
maintaining and cleaning the device.

VacuStar W900 / W1300 / W1600
Safety
10
ensure that all employees working on or with the machine have
read and understood the operating instructions. In addition he
must at regular intervals train the employees in how to deal with
the machine and inform them about potential hazards.
In addition, it is the operator's responsibility to ensure that:
the machine is always in a technically perfect condition.
the machine is maintained in accordance with specified
maintenance intervals.
all safety equipment is regularly checked for completeness and
correct functioning.
2.5 Operating personnel
2.5.1 Requirements
WARNING!
Risk of injury in case of inadequate
qualification!
Improper handling can lead to considerable bodily
injuries and property damage.
Therefore:
–Have any activities only carried out by the
individuals designated for that purpose.
The operating instructions specify the following qualification
requirements for the different fields of activity:
Instructed persons
have been instructed during instructions provided by the
operator with regard to the work assigned to them and possible
hazards arising from improper conduct.
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.

VacuStar W900 / W1300 / W1600
Safety
11
2.6 Personal protective equipment
When handling the VacuStar W, it is necessary to wear personal
protective equipment, in order to minimise health hazards.
Before carrying out any work, properly don the necessary
protective equipment such as gloves, safety goggles, etc. and
wear during work.
2.7 Occupational safety and special risks
The remaining risks that result from the hazard analysis are
specified in the following section.
Observe the safety notes listed here and the warning notes in the
other chapters of these instructions to reduce health hazards and
to avoid dangerous situations.
Danger pictograms on the device
The relevant dangerous spots on the machine are identified by
these pictograms:
DANGER!
General danger pictogram!
… denotes general dangerous situations for
individuals. Non-observance of the safety
instructions can result in severe injuries or
death.
DANGER!
Explosion protection pictogram!
… denotes regulations and information that need to
be observed in potentially explosive areas.
Explosion protection class, temperature ranges
, etc. must be observed!
DANGER!
Danger of burns!
… denotes the presence of a hot surface.

VacuStar W900 / W1300 / W1600
Safety
12
Hazard notes and occupational safety
For your own safety and that of the machine, the following
information must be observed and complied with:
Improper operation
DANGER!
Danger due to improper operation!
–Only use VacuStar W in a perfect technical
condition. Malfunctions that are relevant for
safety have to be promptly eliminated.
–Conversions of the VacuStar W are not
permissible and can impair safety.
–Never bridge any safety equipment or put it out
of operation.
–Any work on the VacuStar W and/or on
electrical equipment must be carried out by
specialised staff.
–Repair and maintenance work may only be
carried out when the VacuStar W is stationary.
For this, the VacuStar W must be secured
against restarting!
–The VacuStar W may not be under pressure or
in a state of vacuum while work is being carried
out on it.
Close shut-off valve on the vehicle side and
vent the pipe between VacuStar W and shut-off
valve or manually relieve excess pressure at
safety valve. Observe pressure gauge!
–The drive's protective equipment may only be
removed when the VacuStar W is stationary
and has to be correctly refitted after completion
of work.
–Only dismantle accidental contact protection
after VacuStar W and pressure pipe have
cooled down.
–It is an environmental protection requirement
that any liquids arising during maintenance work
(e.g. cooling oil, cooling water, etc.) are
collected and disposed of in an environmentally
compatible manner.
–The machine may only be opened for
maintenance and repair work by specialised
staff if the VacuStar W is stationary and no
potentially explosive atmosphere is present.

VacuStar W900 / W1300 / W1600
Safety
13
Moving components
WARNING!
Risk of injury by moving components!
Powered rotating components can cause the most
serious injuries!
Therefore during operation:
–It is absolutely forbidden for persons to stay in
the hazard area or in the immediate vicinity!
–Do not put safety devices and/or functions out
of operation and do not render them inoperative
or bypass them.
–Never reach into open outlets and inlets or into
running equipment.
Before entering the hazard area:
–Switch off power supply and secure against
restarting.
–Wait for standstill of lagging components.
–Wait for automatic dissipation and/or discharge
of residual energies (compressed air).
Compressed air
WARNING!
Risk of injury due to compressed air!
Pneumatic energies can cause the most serious
injuries.
In the case of damage to individual components,
air can be discharged under high pressure and
injure e.g. the eyes.
Therefore:
–Before starting any work, first depressurise
pressurised components. Pay attention to
accumulators. Accumulator pressure must also
be completely relieved.
–Do not change pressure settings beyond the
maximum values.

VacuStar W900 / W1300 / W1600
Safety
14
Signposting
WARNING!
Risk of injury by illegible pictograms!
Labels and signs can become dirty or
unrecognisable in the course of time.
Therefore:
–Always keep safety, warning and operating
instructions in a well legible condition.
–Immediately replace damaged or obliterated
signs or labels.
Improper transport
Danger!
Danger by falling down or tilting of the
VacuStar W!
The weight of the VacuStar W may injure a person
and cause serious bruising!
Therefore:
–Depending on the dead weight and size of the
VacuStar W, use a pallet on which the VacuStar
W can be moved by means of a fork lift.
–For lifting the VacuStar W, use suitable lifting
gear (slings, etc.) that is designed for the weight
of the VacuStar W.
–When putting the slings in position, take care to
avoid putting stress on individual components.
–Only use the provided attachment points with
eye bolts.

VacuStar W900 / W1300 / W1600
Safety
15
Start-up, operation
WARNING!
Risk of injury due to improper start-up and
operation
Improper start-up and operation can lead to serious
bodily injuries or property damage.
Therefore:
–Have all work during initial operation exclusively
performed by the manufacturer's employees or
by his authorised representatives or by trained
personnel.
–Start-up and operation may only be performed
by adequately qualified personnel that has been
authorised and instructed by the operator.
–Before the start of any work, ensure that all
covers and protective devices are correctly
installed and function correctly.
–Never override any protective equipment during
operation.
–Pay attention to tidiness and cleanliness in the
working area! Loosely stacked or scattered
components and tools are accident sources.
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.
–Work on the electrical system, on individual
electrical components and on the connections
may only be carried out by electrical specialists.

VacuStar W900 / W1300 / W1600
Safety
16
Maintenance and troubleshooting
WARNING!
Risk of injury due to improper maintenance and
troubleshooting!
Improper maintenance and troubleshooting can
lead to serious bodily injuries or property damage.
Therefore:
–Maintenance work and troubleshooting work
may only be carried out by sufficiently qualified
and instructed personnel.
–Protect VacuStar W from being restarted, switch
off drives!
–Before starting any work, provide for sufficient
space and freedom of movement during
assembly.
–Pay attention to tidiness and cleanliness in the
assembly area! Loosely stacked or scattered
components and tools are accident sources.
–If components must be replaced:
–Pay attention to correct installation of spare
parts.
–Properly reassemble all fastening elements.
–Observe screw tightening torques.
–Before restarting, ensure that all covers and
protective devices are correctly installed and
function correctly.
–After completion of maintenance work and
troubleshooting, check correct functioning of
safety equipment.

VacuStar W900 / W1300 / W1600
Technical data
17
3 Technical data
VacuStar W operating data
Unit
Model
W900
Model
W1300
Model
W1600
Speed range
[min–1]
1000…1500
Nominal operating vacuum
[mbar]
400
400
400
Permissible continuous duty vacuum 1
[mbar]
100
100
100
Maximum final overpressure during compressor
operation in case of direct drive 2
[bar]
2
2
2
Maximum final overpressure during compressor
operation in case of V-belt drive 2
[bar]
2
1.5
0.5
Oil reservoir
[l]
7.5
7.5
7.5
Lubricating oil consumption
[l/h]
0.2
0.3
0.4
Weight (without accessories)
[kg]
220
279
339
Tab. 1: Operating data
Lubricating oils
The use of multigrade oils will damage the VacuStar W. In that case, the
warranty on the part of CVS Engineering GmbH shall cease.
Only single grade oils with the following specification are permitted for
operating the VacuStar W:
Specification
Value
API:
CF/CF4 or higher
ACEA:
E2 or higher
Tab. 2: Lubricating oils
Lubricating oil types
Recommendations
Brand
Suction temp. > 10 °C
Suction temp. < 10 °C
ARAL
Basic Turboral SAE 40
Basic Turboral SAE 30
BP
Vanellus C3-40
Vanellus C3-30
FUCHS
Titan Universal HD 40
Titan Universal HD 30
MOBIL
Delvac 1340
Delvac 1330
Delvac 1640
Delvac 1630
SHELL
Rimula X Monograde 40
Rimula X Monograde 30
Tab. 3: Lubricating oil types
ATTENTION!
Do not use any synthetic lubricants!
1
Only in conjunction with cell ventilation, without cell ventilation 200mbar (protection via ventilation valve)
2
Protection via a safety valve

VacuStar W900 / W1300 / W1600
Design and function
18
4 Design and function
4.1 Design
Fig. 1: View VacuStar W and details
1 Centring device and fastening
of hydraulic motor mounting
flange
2 Drive shaft
3 Cooling water inflow (1“)
4 Pressure connection
(flange DIN 28459-125)
5 Temperature measuring point
(R ½“)
6 Connection cell ventilation (R 2“)
7 Oil level indicator (bilateral)
8 Crank for manual lubrication
9 Rating plate
10 Oil filler neck cap
11 Rotation arrow
12 Transport and fixing holes
(M16)
13 Negative pressure connection
(R 3/8“)
14 Suction connection
(flange DIN 28459-125)
15 Cooling water outflow (R 1“)
16 Lubricating oil reservoir

VacuStar W900 / W1300 / W1600
Design and function
19
4.2 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 (item 14) and
reaches the pressure line after being compressed via the pressure
connection (item 4).
Lubrication of the VacuStar W
The VacuStar W is lubricated by means of an oil pump. Oil is
pumped from the oil reservoir via the oil lines to the VacuStar W's
lubricating points.
Cooling
The VacuStar W is water-cooled. The VacuStar W is equipped with
a cooling jacket inside the casing. The cooling water circulates by
means of a circulating pump.
Drives
The VacuStar W can be powered via:
Articulated shaft
V-belt
Hydraulic motor
Details about the drives and their design can be found in the
separate mounting instructions for the VacuStar W.
4.3 Control and display elements
Depending on the installation situation, different display elements
such as pressure gauge, temperature gauge and vacuum gauge
are available.

VacuStar W900 / W1300 / W1600
Transport and storage
20
5 Transport and storage
5.1 Safety notes for transport
See chapter 2.7 Safety!
5.2 Transport
The VacuStar W fastened on a baseplate 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 W.
For future transports:
Seal all open connections with protective caps
(prevents penetration of dirt and water)
Secure loose cables
Secure against vibrations
Drain all process and operating media
Securely fasten the VacuStar W prior to transport (e.g. screw it
onto a pallet)
Transport and put down the VacuStar W with a fork lift or
secure with straps and lift with suitable lifting gear.
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 to +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.
To keep moisture away from the machine's workspace, bags
with desiccant must be placed into the inlets and outlets. These
must be removed before start-up.