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Summary of Contents for MAXIMATOR MPLV4
- Page 1 Air amplifier MPLV4, MPLV7, SPLV3, SPLV10, GPLV5 Installation and operating manual...
- Page 2 Internet: www.maximator.de Warranty and liability: As a general rule, the “General Terms and Conditions” of Maximator GmbH shall apply. These terms and conditions are available at http://www.maximator.de. Warranty and liability claims shall not be accepted if they can be attributed to one or more of the causes mentioned in this manual or explicitly stipulated below: –...
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Page 3: Table Of Contents
Contents Contents ..........General information . - Page 4 Contents ........... Installation .
- Page 5 Contents ....... Prerequisites for removal and disposal ........... . . Removal .
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Page 6: General Information
These instructions are applicable for the air amplifier models MPLV4, MPLV7, SPLV3, SPLV10 and GPLV5 (only referred to as “compressor” in other sections and chapters) and with a serial number of greater than 23000001. -
Page 7: Rating Plate
General information Rating plate The rating plate is located on the pneumatic cylinder of the compressor and con- tains the following information: Max. permitted operating pres- Serial number sure Gear ratio Air amplifier 10 Manufacturer contact informa- Type (specifications from the or- tion der code) 11 Label according to applied guide-... -
Page 8: Explanation Of Symbols
General information Explanation of symbols DANGER This combination of symbol and signal word indicates a hazardous situation which - if not avoided - may lead to severe injuries or death. WARNING This combination of symbol and signal word indicates a potentially hazardous sit- uation which - if not avoided - may lead to severe injuries or death. -
Page 9: List Of Abbreviations And Formula Signs Used
General information List of abbreviations and formula signs used Abbreviation Description Gas inlet Fig. Figure ATEX EU explosion prevention directive Gas outlet Exhaust port Central European Time Drive air inlet Personal protective equipment Tab. Table Spool valve air supply Air supply to back of piston Control air port Pilot valve air supply Tab. -
Page 10: Qualification Of The Personnel
General information Qualification of the personnel Only qualified personnel who are specialised and have been trained to do so must work on the air amplifier. Allowing unqualified personnel to work on the com- pressor or enter the danger zone creates hazards which could lead to death, se- vere injuries and significant property damage. -
Page 11: Safety And Protection Measures
Safety and protection measures Safety and protection measures The following sections stipulate the residual risks associated with the product, even when used as intended. In order to reduce the risk of personal injuries and material damage, and to prevent hazardous situations, you must observe the safety information listed in this section and the warnings in all other sections of this manual. - Page 12 Safety and protection measures During assessment, check the following leak points: leak point leak type leak source Comment silencer normal operating air drive compo- permanent leak of leakage nent operating fluids bleed port minor leakage high-pressure only for SPLV 3/ seal, piston seal SPLV 10 and GPLV on drive side...
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Page 13: Non Obvious Hazards
Safety and protection measures Non obvious hazards Using asphyxiant operating fluids can lead to severe injuries or death by asphyxi- ation. Assess the risk for the equipment in the risk assessment. The following are some potential corrective actions: – Operate the compressor in an adequately ventilated space. –... -
Page 14: Product Description
Product description Product description Design and function Structure Schematic diagram without control air Schematic diagram with control air Tab. 3-1 Schematic diagram Air piston A Gas inlet to the air amplifier High-pressure piston B Gas outlet from the air amplifier Pilot valve lower cap Drive air inlet Pilot valve top cap... -
Page 15: Intended Use
Within their technical limits, air amplifiers are used to deliver and compress com- pressed air and nitrogen. Other operating fluids must be released by specific clearance issued by Maximator. If the air amplifier bears an ATEX label and comes with a declaration of conformi- ty, it is designated for use in corresponding potentially explosive areas. -
Page 16: Misuse
Product description Misuse Unauthorised modifications or technical changes to the product may lead to ac- cidents with serious or fatal injuries. Never carry out unauthorised modifications or technical changes to the product! Ports Comply with the connected load specifications for all interface connections. Refer to the enclosed general drawing for the connection ports available on the air am- plifier. -
Page 17: Technical Specifications
Depending on the design of the compressor. See enclosed general drawing. c. Certain compressors may be suitable for other operating fluids. A specific clearance from Maximator is necessary. d. Specifications for purity classification in line with ISO 8573-1 “Compressed air - Part 1: Contaminants and purity classes“... - Page 18 µm a. Certain compressors may be suitable for other operating fluids. A specific clearance from Maximator is necessary. b. Depending on the design of the compressor. See enclosed general drawing. c. Depending on the design of the compressor. See enclosed general drawing.
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Page 19: Dimensions And Weight
Product description Operation with compressed air Maximator air amplifiers generally do not need a compressed air oiler as they are treated with lubricant during installation. However, after the first time an oiler is used, the drive fluid should always be oiled, since the oil washes the lubricant out. -
Page 20: Service Life
Product description MPLV4 / MPLV7 / SPLV3 / SPLV10 / GPLV5 Permissible number of strokes at standstill pressure at the time of delivery: Criterion Limit value Unit Strokes under standstill pressure n Tab. 3-5 Permissible number of strokes at standstill pressure at the time of delivery... -
Page 21: Transport, Packaging And Storage
Transport, packaging and storage Transport, packaging and storage Dimensions and weight The dimensions and weight of the air amplifier are indicated in the general draw- ing. Delivery Scope of delivery Designation Quantity Air amplifier Installation and operating manual including Decla- ration of Incorporation and EU Declaration of Con- formity General drawing... -
Page 22: Installation
Installation Installation Prerequisites for installation Observe the manual and general drawing of the product. In addition, the following conditions must be met: – The product must be free of damage. – The product must be easily accessible from all sides. –... -
Page 23: Control Air Connection
Installation 5.3.2 Control air connection Connect the connecting line for the control air, if applicable, to the control air port (X) of the air amplifier. Observe the connection specifications on the general drawing. 5.3.3 Connecting the inlet line and outlet line Connect the inlet and outlet lines to the corresponding air amplifier ports (A and B) as appropriate. -
Page 24: Commissioning
Installation 5.4.2 Commissioning WARNING Risk of injury due to extreme temperatures! The surfaces of the product can be very hot or very cold. This can lead to acci- dents resulting in severe injuries or death. ► Before working on the product, please ensure that the product is at ambient temperature. -
Page 25: Operation
Operation Operation Prerequisites for operation Observe the manual and general drawing of the product. In addition, the following conditions must be met: – The product must be free of damage. – The product must be securely attached. – The product is not subject to any vibrations greater than those typically oc- curring in high-pressure systems. -
Page 26: Put The Air Amplifier In A Safe State
Operation Put the air amplifier in a safe state In a safe state, the air amplifier is depressurised on the drive and high pressure side. The steps necessary in order to achieve a safe state depend on the installa- tion position in the system. Refer to the general system documentation for the re- quired actions. -
Page 27: Maintenance
The individual maintenance activ- ities are described in the following section. Maximator recommends the intervals listed below. These intervals are calculated based on 1,300,000 strokes/year. The required maintenance intervals depend on the system and application. The intervals must be adjusted based on the given conditions of use. -
Page 28: Maintenance Work
Risk of injury due to inappropriate spare parts! Making repairs using inappropriate spare parts can lead to accidents resulting in severe injuries or death. ► Only use spare parts that comply with Maximator specifications. WARNING Risk of injury when handling lubricants! Handling lubricants can lead to accidents resulting in severe or fatal injuries. -
Page 29: System Inspection
Maintenance 7.2.1 System inspection The following section explains how to check the air amplifier for proper function: Description Qualifications Operating the system Type of mainte- Check nance Interval weekly – Safety goggles – Hearing protection Shut off the fluid outlet and adjust p to a value that is standard for the sys- tem. -
Page 30: Leak-Testing The Connections
Maintenance 7.2.2 Leak-testing the connections The following section explains how to check the connections for leaks: Description Qualifications Operating the system Type of mainte- Check nance Interval weekly Prerequisites – The air amplifier is easy to access. – All connections are pressurised. Tools –... -
Page 31: Clean Air Amplifier
Maintenance 7.2.4 Clean air amplifier The following section explains how to clean the air amplifier: Description Qualifications Clean air amplifier Type of mainte- Cleaning nance Interval quarterly Prerequisites – The air amplifier is easy to access. – The air amplifier is depressurised. Tools –... -
Page 32: Leak Detection
Maintenance 7.2.6 Leak detection The following section explains how to check the air amplifiers for leakage: Description Qualifications Repair and service the air amplifier Type of mainte- Check nance Interval semi-annually Prerequisites The air amplifier is easy to access. Tools –... - Page 33 Maintenance Description Vent p does not drop by more than 10% (holding time 30 s). Set p to approx. 50% of the value from the first step and slowly vent P The air amplifier will start up automatically. – Vent p –...
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Page 34: Repair Air Amplifier
7.2.6 - Leak test If the compressor has passed all tests, the repair is complete. Maximator devices can be sent in for repairs to your local Maximator representa- tive. All the necessary details are available on the Maximator website http:// www.maximator.de... -
Page 35: Spare Parts And Consumables
Making repairs using inappropriate spare parts can lead to accidents resulting in severe injuries or death. ► Only use spare parts that comply with Maximator specifications. A list of the available spare parts, spare part kits and consumables can be found on the general drawing. -
Page 36: Troubleshooting
Troubleshooting Troubleshooting The following is a list of typical product faults, their causes and the appropriate solutions. If you experience any other specific or unexpected faults, please notify us at ser- vice@maximator.de 0000000455 - 001 - EN... -
Page 37: Drive Side
Troubleshooting Drive side Fault Cause of fault Solution – The air amplifier does Friction of the O-rings on Relubricate not operate at low air the spool valve is too – Replace the O-rings pressure high on the spool valve The air amplifier does O-rings will swell if the –... -
Page 38: High Pressure Side
Troubleshooting High pressure side Fault Cause of fault Solution The air amplifier oper- Check valve failure Inspect the check valves ates without delivering and replace if necessary the gas, or it operates er- ratically. It does not reach the calculated op- erating pressure. -
Page 39: Removal And Disposal
► Use protective gloves and goggles. ► Avoid contact with the skin. ► Observe the safety data sheet of the lubricant accordingly. If the service life has expired: Send the product back to Maximator, postage paid, for proper disposal. 0000000455 - 001 - EN... -
Page 40: Use In Explosion-Prone Zones
10 Additional marking X: Further details with regard to explosion protection that go beyond the content about the ATEX label can be found in the operat- ing instructions. Fig. 10-2 Display of ATEX zones for MPLV4, MPLV7 0000000455 - 001 - EN... -
Page 41: Temperature Class
Use in explosion-prone zones Fig. 10-3 Display of ATEX zones for MPLV4L Fig. 10-4 Display of ATEX zones for SPLV3, SPLV10 Fig. 10-5 Display of ATEX zones for GPLV5 Legend: No zone: Zone 0: Zone 1: Zone 2: 10.2 Temperature class The temperature of the compressor mainly depends on the temperature of the operating fluid. - Page 42 Use in explosion-prone zones Max. temperature of operating flu- Temperature class 60°C Tab. 10-1 Temperature classes For the compression of ideal gases, the maximum expected temperature can be calculated using the formula for adiabatic status change: Legend: = input temperature = output temperature = inlet pressure = outlet pressure...
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Page 43: Operation And Maintenance
Use in explosion-prone zones 10.3 Operation and maintenance Static electricity on the product can lead to explosions. This may result in severe or fatal injuries. Never use high-power mechanisms for charge generation on or near the product. The possibility of an explosive atmosphere must be excluded before undertaking any and all work on the product –... -
Page 44: Summary Of Ignition Hazards
Summary of ignition hazards Summary of ignition hazards Ignition hazard Cause Protective measure implemented Source of ignition – Hot surfaces Heating by the operating fluid Temperature class definition and compression – Insulation prohibited – Hot surfaces Friction Operating fluid quality specification –... -
Page 45: Appendix
Appendix Appendix The appendix comprises the following documents: – EU Declaration of Conformity for air amplifier MPLV4, MPLV7, SPLV3, SPLV10 and GPLV5 – Declaration of incorporation of air amplifier MPLV4, MPLV7, SPLV3, SPLV10 and GPLV5 – Description of the basic safety and occupational health and safety require-... - Page 46 Appendix 0000000455 - 001 - EN...
- Page 47 Appendix 0000000455 - 001 - EN...
- Page 48 Appendix Description of the basic safety and occupational health and safety requirements (MRL 2006/42/EC, Appendix I) Basic requirement Applicable Met Comment BASIC SAFETY AND OCCUPA- TIONAL HEALTH AND SAFETY RE- QUIREMENTS GENERAL INFORMATION 1.1.1 Terminology 1.1.2 Safety integration principles 1.1.3 Materials and products 1.1.4 Lighting...
- Page 49 Appendix Basic requirement Applicable Met Comment 1.3.2 Risk of breakage during opera- tion 1.3.3 Risks posed by dropping or eject- ed objects 1.3.4 Risks posed by surfaces, edges Deburring generally re- and corners quired 1.3.5 Risks posed by multiple ma- chines combined 1.3.6 Risks posed by changed usage...
- Page 50 Appendix Basic requirement Applicable Met Comment 1.5.4 Assembly fault Connection labels 1.5.5 Extreme temperatures Machine may heat up or cool down 1.5.6 Fire 1.5.7 Explosion Considered separately 1.5.8 Noise Depending on installa- tion and application 1.5.9 Vibrations Vibrations within the range common for the market 01/05/...
- Page 51 Appendix Basic requirement Applicable Met Comment 1.6.5 Cleaning of machine parts in the The capacity of the in- interior ternal volume in ques- tion is not sufficient to pose a risk to the main- tenance personnel due to residues of the per- missible operating flu- ids when the compressor is at a...
- Page 52 Visit our website at: www.maximator.de 1999.0061 EN 0000000455 - 001 - EN...
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