Pressure booster combination DPA-CRVZS. Operating instructions a [ ]

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1 Pressure booster combination en Operating instructions a [ ]

2 Original instructions -EN Identification of hazards and instructions on how to prevent them: Danger Immediate dangers which can lead to death or serious injuries Warning Hazards that can cause death or serious injuries Caution Hazards that can cause minor injuries Other symbols: Note Material damage or loss of function Recommendations, tips, references to other documentation Essential or useful accessories Information on environmentally sound usage Text designations: Activities that may be carried out in any order 1. Activities that should be carried out in the order stated General lists Result of an action/references to more detailed information 2 Festo a

3 English Pressure booster combination Table of contents 1 About this document Safety Safety instructions Use for intended purpose Areas of application Foreseeable misuse Training of specialized personnel Further information Service Product overview Function Operational principle Switching function Design Product design Transport Storage Mounting Preparation Mechanical installation Alignment Mounting Pneumatic installation Festo a English 3

4 9 Commissioning Switching on Setting the outlet pressure Switching off Maintenance and care Visual and audible check Functional test Draining condensate Disassembly Fault clearance Technical data Festo a English

5 1 About this document For all available product documentation The combination of DPA pressure booster and CRVZS air reservoir is designated as a product in these operating instructions. Read the operating instructions carefully before starting all work on the product. 2 Safety 2.1 Safety instructions Take into consideration the legal regulations for the respective destination. Observe product labelling. Before working on the product, switch off the power supply and secure it against being switched on again. Use the product only within the defined values ( 13 Technical data). Protect the product during operation from damaging influences. Damaging influences include grinding dust, glowing chips or sparks. 2.2 Use for intended purpose The DPA pressure booster has been designed for increasing the pressure in compressed air lines up to a maximum outlet pressure of 16 bar. The air reservoir CRVZS has been designed for saving air (fluid of group 2 as per EU Pressure Equipment Directive) Areas of application For increasing the pressure up to double the inlet pressure of 8 bar For the occasional extraction of compressed air Compensation of pressure fluctuations For the supply of quick-pulsing drives For the compensation of sudden air consumption Festo a English 5

6 2.3 Foreseeable misuse For the continuous extraction of compressed air Note Severe wear to seals and the drive piston. Avoid operation without pauses between cycles. Pressure booster combinations are no replacement for compressors. 2.4 Training of specialized personnel Only qualified personnel may perform installation, commissioning, maintenance and disassembly of the product. The specialized personnel must be familiar with the installation and operation of electrical and pneumatic control systems. 3 Further information Accessories 4 Service Contact your regional Festo contact person if you have technical questions 5 Product overview The product is a combination of a DPA pressure booster and a CRVZS air reservoir. The air reservoir is filled to network pressure continuously via a bypass with check valve. Two pressure gauges are there to monitor supply and outlet pressure. 5.1 Function A pneumatic valve conducts the inlet pressure, alternately into two compression chambers. The compression chambers generate an outlet pressure up to max. double the value of the inlet pressure. This increased outlet pressure is stored in the CRVZS and is available for compressed air applications Operational principle The air pressure is increased by a pressure ratio via a double piston Switching function As soon as the inlet pressure is switched on at pneumatic connection P1, the DPA starts automatically. When the set outlet pressure is reached, the pressure booster stops operating, but restarts automatically as soon as the outlet pressure drops due to application operation. 6 Festo a English

7 5.2 Design Product design aa aj CRVZS air reservoir 2 CRVZS connecting tubing to DPA pressure booster (connection 2) 3 DPA pressure booster 4 Adapter plate with silencers 5 Profile plate 6 Pneumatic valve with manual override 7 Pressure displays for ports P1 and P2 8 Rotary knob on the pressure regulator for port P2 9 Pneumatic port P1 (inlet) aj Bypass aa Pneumatic connection P2 (outlet) with coupling socket KD4 Fig. 1 Festo a English 7

8 6 Transport Warning Loads which suddenly fall down may cause injury to people. Take the product's weight into account. Depending on the design, the weighs up to 30 kg. Do not use the rotary knob on the pressure regulator 8 as a transport support. The weight of the product may cause the rotary knob to detach from its support. 7 Storage Remove the packing with the exception of the adhesive labels on the supply ports (to prevent dirt from entering). The packaging is intended for recycling (exception: oil paper = residual waste). 8 Festo a English

9 8 Mounting 8.1 Preparation Before fitting: Remove the rubber buffers from the bottom of the profile plate. Switch off the complete system to depressurise it. 8.2 Mechanical installation Note The manufacturing process leaves a layer of oxide on the inside of the reservoir caps of the air reservoir CRVZS. For sensitive applications, use suitable filters between the air reservoir CRVZS and other downstream-switched pneumatic devices Alignment Ensure that the screwing points for the profile plate are on the same level. With pressure booster combinations 5/10/20: Align the product so that the condensate drain faces downwards Mounting Secure product by the grooves in the profile plate on the system or on the machine frame. Mounting attachments from the profile kit system 5 for machine stands Slot nuts IPM-VN-05-15/M5-ST Cover caps for profile plate IPM-AN-05-20X40-PA This accessory can be obtained from Festo Sales, quoting Mechanical Components. Additional accessories: M5 machine screws Strength: min. 8.8 Screw length: Frame thickness + 6 mm screw-in depth Tightening torque: 5 Nm±10% Festo a English 9

10 8.3 Pneumatic installation Note High pressure differential between ports P1 and P2 causes high air consumption by the product. Limit network pressure at port P1 to 8 bar without additional pressure regulators. Use short lines at port P1. Connect hoses and plug connections to pneumatic ports P1 and P2. For port P2 use a KS4 coupling connector. Exhausting is performed by the pressure regulator. P2 Fig. 2 P1 Controller failsafe LRVS-D-MINI, LRVS-D-MIDI Padlock LRVS-D Accessories ( When using a pressure-buildup valve in the system 1. Connect a 3-way on/off valve HE- -D or HEE- -D at the inlet side before portp1 between pressure buildup valve and pressure booster. 2. Connect a 3-way on/off valve HE- -D or HEE- -D at the outlet side after portp2. Exhausting is performed by the pressure regulator. P2 P1 Fig. 3 With pressure booster combinations DPA- -CRVZS10/20: 1. Connect a 3-way HE- -D or HEE- -D on/off valve at the inlet side before port P1. 2. Connect a 3-way on/off valve HE- -D or HEE- -D at the outlet side after portp2. 3. Connect a third 3-way HE- -D or HEE- -D on/off valve between the DPA pressure booster and the CRVZS air reservoir. This enables larger reservoir volumes to be exhausted more rapidly. Fig. 4 P2 P1 10 Festo a English

11 9 Commissioning Warning The sudden escape of compressed air can cause injury to human beings. Make sure that the connections P1 and P2 are connected. Note High pressure forces can damage equipment switched downstream. Only use fittings designed for the maximum achievable outlet pressure of 16 bar. Vibrations can cause signs of fatigue in materials and can reduce the endurance strength of pressure booster combinations and mounting components. Protect the device against mechanical vibrations. Coupling and uncoupling of compressed air outlet Connect hose KS4 to port P2. (accessories Set outlet pressure to max. 10 bar to reduce the amount of force required. Warning Pressurized compressed air lines can cause whipping effects. Metal screw connectors at the ends of tubing can therefore cause serious injury. Grip the hose when unfastening the hose sleeve. 9.1 Switching on When using the product without 3-way on/off valves (Fig. 2): Apply compressed air to port P1. When using the product with 3-way on/off valves (Fig. 3, Fig. 4): 1. To fill the CRVZS air reservoir, open the 3-way on/off valve between the DPA pressure booster and the CRVZS air reservoir (Fig. 4) and leave open at all times during operation. 2. Open the 3-way on/off valve at port P1 (inlet). 3. Open the 3-way on/off valve at port P2 (outlet). Festo a English 11

12 9.2 Setting the outlet pressure The rotary knob on the pressure regulator is used for setting ( Fig. 18). Regulator lock (only DPA and DPA ) Pushing: Rotary knob locked Pulling: Rotary knob unlocked 1. Unlock the rotary knob (only DPA and DPA ). 2. Turn the rotary knob clockwise as far as stop (delivery condition). 3. Apply inlet pressure to port P1. Note Do not exceed the maximum permitted pressure. Use to check the pressure gauges: inlet pressure at port P1: max. 8 bar differential pressure between ports P1 and P2: min. 2 bar 4. Turn the rotary knob clockwise until the desired outlet pressure is reached. Pressure display for port P1: inlet pressure Pressure display for port P2: outlet pressure 5. Lock the rotary knob (only DPA and DPA ). Settings on the pressure regulator 8 DPA CRVZS- DPA CRVZS- The outlet pressure setting is less than the inlet pressure. The outlet pressure setting is at least 2 bar greater than the inlet pressure. Increasing the outlet pressure. The pressure regulator on the DPA relieves pressure until pressure levels are in balance. The CRVZS is emptied. Normal operating status. The outlet pressure is reached. The DPA also switches at low air consumption. Increasing the air consumption outlet pressure P2 Max. 10 bar 1) max. 16 bar 1) The max. outlet pressure can be exceeded by up to 40 % (14 bar). Tab. 1 Setting on the pressure regulator 12 Festo a English

13 9.3 Switching off When using the product without 3-way on/off valves (Fig. 2): 1. Switch off pressure to the pneumatic system. 2. Turn the rotary knob clockwise as far as stop. Exhausting is performed by the pressure regulator. When using the product with 3-way on/off valves before port P1 and after port P2 (Fig. 3, Fig. 4): 1. Close the 3-way on/off valve at port P1 (inlet). 2. Close the 3-way on/off valve at port P2 (outlet). The pressure booster is exhausted by port 3 on the two 3-way on/off valves. The air reservoir must be exhausted separately by the pressure regulator (rotary knob 8). Exhausting the air reservoir faster Close the on/off valve between the DPA pressure booster and the CRVZS air reservoir (Fig. 4). This contains the air in the high-pressure chamber of the pressure booster. The rotary knob remains in the set position. Reducing outflow noise Use a silencer on port 3 of the 3-way on/off valves. Festo a English 13

14 10 Maintenance and care 10.1 Visual and audible check Once a year, conduct a visual and audio inspection. In the event of damage or leakage: Replace the product Functional test 1. Fill the air reservoir up to maximum pressure (10 or 16 bar). The pressure booster must switch off automatically. 2. Exhaust the air reservoir. The pressure booster must start again automatically until the set outlet pressure is reached. If the pressure booster runs continuously with outlet P2 closed: 1. Carry out a leakage check. 2. Tighten loose screw connectors. If there is internal leakage: Replace the device Draining condensate Drain the condensate from the air reservoir. For 2: 1. Switch off the product. 2. Disconnect the hose from port P2. 3. Attach a KS4 coupling connector to the coupling socket at port P2. 4. Set the product at an oblique angle. For 5/10/20: 1. Switch off the pressure booster combination. 2. Open the condensate drain (waf 8) on the air reservoir (9.3). 14 Festo a English

15 11 Disassembly For 10/20: 1. Close the 3-way on/off valve at port P2 (outlet). 2. Close the 3-way on/off valve at port P1 (inlet). 3. Close the 3-way on/off valve between the DPA pressure booster and the CRVZS air reservoir (Fig. 4). 4. Turn the rotary knob clockwise as far as stop. 5. Depressurise the system. Pay attention to the pressure gauges on ports P1 and P2. 6. Disconnect all pneumatic ports. 12 Fault clearance Malfunction Possible cause Remedy The desired outlet pressure is not reached. Flow rate too low. Pressure booster does not start. Inlet pressure too low. Increase inlet pressure to max. 8 bar. Too many consumers at the outlet. Volumetric flow rate at compressed air inlet too low. Fault during start-up or valve in centre position. Exhaust bores or sinter filter blocked. Reduce the number of consumers. Use larger compressor. Use short tubing Press manual override on pneumatic valve. Keep exhaust bores or sinter filter unblocked. External damage after visual Improper mounting or handling. Replace the product. inspection. Audible leakage Gaskets, hoses, valves or coupling Replace defective connector. socket defective. Replace the product. Corrosion Aggressive ambient conditions Replace the product. Tab. 2 Festo a English 15

16 13 Technical data Size DPA-40 DPA-63 DPA-100 P2 max. [bar] Volume [l] Inlet pressure at port P1 Min. [bar] Max. [bar] 8 Jutlet pressure at port P2 Min. [bar] Max. [bar] 10 1) 16 2) 10 1) 16 2) 10 1) 16 2) 10 1) 16 2) 10 1) 16 2) Operating medium Compressed air acc. to ISO :2010 [7:3:4] Notice: Oiled operation not permitted Assembly position Any Condensate drain below air reservoir Condensate drain Max. tightening [Nm] 27 (Qy) torque Ambient [ C] temperature Pneumatic port P1 QS-10 QS-12 QS-16 P2 KD4 P3 Pneumatic silencers CE mark Conformity declaration In accordance with EU Pressure Equipment Directive Classification into categories Good I engineering practice High-alloy stainless steel Air reservoir material: Weight [kg] ) Due to production-related variation in regulator springs, up to 14 bar can be reached. 2) Max bar can be reached through air consumption. Tab. 3 II 16 Festo a English

17 Festo a 17

18 Copyright: Festo AG & Co. KG Ruiter Straße Esslingen Germany Phone: Fax: Reproduction, distribution or sale of this document or communication of its contents to others without express authorization is prohibited. Offenders will be liable for damages. All rights reserved in the event that a patent, utility model or design patent is registered. service_international@festo.com Internet:

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