MAXIMATOR HIGH PRESSURE TECHNOLOGY HYDRAULICS PNEUMATICS TESTING EQUIPMENT Opeating Instuctions Compessos issue 08.2007
MAXIMATOR GmbH Walkeniede Staße 15 D-37449 Zoge Gemany Telefon 0 55 86 / 803-0 Telefax 0 55 86 / 8033040 e-mail: info@maximato.de Intenet: http://www.maximato.de Copyight of the edito: These Opeating Instuctions may only be duplicated, tanslated o made available to thid paties with expess consent by the edito. Compessos issue 08.2007
Index 1 Basic infomation...1 1.1 Notes on the Opeating Instuctions... 1 1.2 Use to the intended pupose... 2 1.3 Waanty and liability... 2 2 Safety notes...3 2.1 Geneal safety diectives... 3 2.2 Symbols and signal wods... 4 2.3 Fundamental Safety measues... 4 2.3.1 Technical condition... 4 2.3.2 Safety notes elating to compesso opeation... 5 2.3.3 Safety notes elating to maintenance and epai... 5 2.3.4 Requiements to owne s pesonnel... 6 2.4 Specific safety notes... 6 2.4.1 Safety in case of emissions... 6 2.4.2 Safety in case of defective compessos... 7 2.4.3 Safety at the place of installation... 7 3 Technical Desciption...9 3.1 Functioning of a high-pessue compesso... 9 3.2 Oveview of compessos...12 3.3 Compesso designs...18 3.4 Type odeing code...19 3.5 Calculation of final pessues...20 4 Eection and stat-up...21 4.1 Geneal notes on eection at place of application...21 4.2 Compessed ai system...21 4.2.1 Compessed ai lubificato...22 4.2.2 Pipe coss sections...22 4.2.3 Diect pilot-valve ai...22 Compessos issue 08.2007
4.3 High-pessue system...23 4.3.1 Inlet...23 4.3.2 Pessue pipe...23 4.3.3 Compesso medium...23 4.4 Stat-up...23 5 Maintenance and sevicing...24 5.1 Maintenance notes...24 5.2 Sevicing...24 5.3 Repai...25 5.3.1 Liability fo mateial defects...25 6 Technical data...26 Compessos issue 08.2007
1 Basic infomation High-pessue compessos made by MAXIMATOR ae suitable fo oil-fee compession of gases and compessed ai. The compessos ae mainly employed in: Pessue tests with gases Tansfe of gases Gas ecupeation Chaging of nitogen accumulatos Feeding of seal gas system Gas-assisted pocesses CO 2 foaming Filling of aqualung cylindes Leakage testing Commecially available gases, such as agon, helium and nitogen, can be compessed to pessues up to 1500 bas. 1.1 Notes on the Opeating Instuctions These pesent Opeating Instuctions descibe the configuation of compessos and povides infomation elating to thei appopiate opeation and maintenance. Please, thooughly study the Opeating Instuctions pio to the fist use of a MAXIMATOR compesso. The Opeating Instuctions facilitate a swift undestanding of all technical details and contain all necessay infomation fo pope utilisation of ou compessos. The Opeating Instuctions include technical data, a technical desciption, and infomation egading stat-up, opeation and maintenance. Each and any povided technical data as well as dimensions and weights ae valid as at the pinting date of these Opeating Instuctions. Such data may deviate fo the actual compesso model without fundamentally changing the mateial infomation and lose validity. Deviations fom naative and pictoial infomation depend on the espective specific technical featues and accessoies, which means that the custome may not deive any claims whatsoeve fom such. Please, make sue to comply with all maintenance, eection and opeating notes povided in these pesent Opeating Instuctions to ensue full function and safety. MAXIMATOR compessos may only be used fo applications and puposes listed in these Opeating Instuctions. The manufactue will not ecognise any claims due to inappopiate opeation and insufficient maintenance. Please, make sue to note and obseve all documentation egading compesso components and all othe documents and ecods attached in the annex theeto. All elevant accident pevention egulations and othe geneally accepted safety equiements must be obseved and complied with. Compessos issue 08.2007 1
1.2 Use to the intended pupose MAXIMATOR compessos may only be opeated with media fo which they ae suitable accoding to the media enduance schedule. Any othe media have to be tested by us fo compatibility with compesso mateials pio to thei use. Compesso dives ae ated fo compessed ai up to 10 bas, othe gases than those indicated have to be tested by us fo compatibility with compesso mateials pio to thei use. Changes at, and modifications of, compessos ae not pemitted fo safety easons. All maintenance, eection and opeating notes povided in these Opeating Instuctions have to be complied with in ode to ensue full functioning and safety. 1.3 Waanty and liability As a ule, the Geneal Conditions of Sale and Delivey povided by the compessos manufactue ae valid. Waanty and liability claims in case of pesonnel injuy and/o popety damage shall be excluded when such ae attibutable to one o moe of the below causes: Use of a compesso to othe than the intended pupose. Inappopiate stat-up, opeation and/o maintenance of a compesso. Changes at a compesso. Opeation of a compesso with defective safety installations impopely mounted safety and potection installations. Non-obsevance of notes and advices given in these Opeating Instuctions egading compesso stat-up, opeation and maintenance. Insufficient monitoing of compesso components that ae subject to wea and tea. Inappopiate epai wok. 2 Compessos issue 08.2007
2 Safety notes 2.1 Geneal safety diectives Safety of the machines is govened by the below EC Diectives: Diective 89/655/EEC Accident pevention egulations VSG 1.1, VSG 3.1 Machine Diective 98/37/EC, Annex II A as well as the applied hamonised standads EN ISO 12100-1 and 12100-2, EN 294, EN 349, EN 418 Accident pevention egulations of Geman Employes Liability Insuance Association [Beufsgenossenschaft] Compessos may emanate hazads when used by non-skilled pesonnel, inappopiately o fo any othe than the intended pupose. Evey peson that is odeed to opeate o maintain the compessos must have ead and undestood the complete Opeating Instuctions pio to caying out any of such opeations. This applies also when the peson aleady with the compessos o eceived taining on compessos. The owne is advised to equest its pesonnel to veify peusal of the contents of these Opeating Instuctions in witing. Knowledge of the contents of the Opeating Instuctions is one peequisite to potect opeatives fom hazads as well as avoid faults and thus opeate the compessos safe and without distubances o malfunctions. The Opeating Instuctions shall be accessible to opeating and maintenance pesonnel at any time! Responsibility fo accident-fee opeation of compessos is the owne o its authoised pesonnel that is employed in opeating o maintaining the compessos. All notes egading labou safety efe to the cuently valid egulations in the Euopean Community. The applicable laws and national egulations have to be kept in othe counties. Both in the Euopean Community and in non-eu counties, the owne is obliged to detemine the pesent status of codes and egulations. Beside the labou safety notes in these Opeating Instuctions, the geneally valid safety and accident pevention egulations must be obseved and complied with. All infomation povided in these Opeating Instuctions has to be obseved without any estictions! Compessos issue 08.2007 3
2.2 Symbols and signal wods HAZARD Types and souces of hazads that may esult in seious pesonal injuies o death. Measues to avet such hazads. CAUTION Types and souces of hazads that may esult in pesonal injuies o popety damage. Measues to avet such hazads. NOTE Advice fo uses and useful infomation. NOTE Envionmental impacts 2.3 Fundamental Safety measues 2.3.1 Technical condition Please, obseve the following: In ode to avoid hazads and ensue optimal pefomance, do not cay out any changes o modifications at the compessos. The use is obliged to opeate the compessos in an appopiate and safe opeating condition. The technical condition must confom to all statutoy equiements and egulations. Inspect the compessos pio to each stat-up fo damage and appopiate condition. Any changes at the compessos that have an impact on thei safety have to be epoted by pesonnel at once to the owne. 4 Compessos issue 08.2007
2.3.2 Safety notes elating to compesso opeation Check the compessos fo opeating safety pio to each stat-up! Obseve the following safety notes duing compesso opeation: All geneally valid safety and accident pevention egulations have to be obseved! Make sue to know all installations, actuatos and contols as well as thei functions pio to stating the compessos! Caution at all pneumatically actuated pats! Make sue duing the entie opeation that on-site conditions ae conducive to the application of the compessos. Stop the compessos at once when any changes ae noticed duing thei opeation. CAUTION Make sue to obseve all applicable safety egulations when compessing hazadous gases. CAUTION Make sue to depessuise the compessos pio to stating any wok on the units. CAUTION Setting and epai wok may only be caied out by cetified wokshops! 2.3.3 Safety notes elating to maintenance and epai Opeating distubances that ae caused by insufficient o inappopiate maintenance may esult in vey high epai costs and long downtimes of the compessos. The manufactue will not assume any liability fo damage that is due to inappopiate maintenance and cae! Requied maintenance intevals ae specified in a maintenance schedule. Please, obseve the following: The compessos may only be seviced, maintained and epaied by sevice pesonnel of the manufactue o specifically tained and instucted skilled pesonnel. Each and any maintenance and epai wok at the compessos may only be caied out when the compessos have been switched off and depessuised. Compessos issue 08.2007 5
2.3.4 Requiements to owne s pesonnel The hazads that may emanate fom the compessos have to be pointed out to pesonnel befoe stating any wok. Hazads of injuy may emanate fom the compessos when not opeated by popely skilled pesons. Each peson that is instucted to stat up, maintain o epai the compessos must have completely ead and undestood these Opeating Instuctions. The Opeating Instuctions must be accessible to the pesonnel at any time. It is ecommended that taking note of the contents of the Opeating Instuctions be documented in witing. Upon instuction of the owne pesonnel has to wea potective clothing. All Safety notes in these Opeating Instuctions and in all petaining documents must be obseved and complied with at any time and without any estictions. A compesso has to be immediately switched off when hazads ae detected that may esult in pesonal injuy. Pesonnel must have well-founded knowledge of the following opeational sequences, in-house egulations and behavious: Opeating sequences of the compessos Limitation, safeguading and making of hazad zones Behaviou and measues in cases of hazads o emegency 2.4 Specific safety notes 2.4.1 Safety in case of emissions Depending on the specific type of application, expanding compessed ai will geneate a cetain noise level. Ai leaving the silence may be soiled with wate, oil o gease. It is also possible that small ice cystals fom at the silence that may come loose and hul away. Pesons nea unning compessos may have to wea potective goggles and, as the case may be, ea potection. 6 Compessos issue 08.2007
2.4.2 Safety in case of defective compessos Duing opeation of the compessos, both the dive pat and the high-pessue pat ae unde pessue. Exiting gases ae unde high pessue afte a defective but also duing nomal opeation and must not be caught o deflected by objects o body pats. It must be ensued that upon a defect, the compesso concened is immediately depessuised and epaied. HAZARD Maintenance and epai wok may only be caied afte the compessos wee depessuised. 2.4.3 Safety at the place of installation The compessos must not be opeated in confined containes. Dive ai flowing out may bust the containe. Hydaulic bolted unions at suction and pessue nozzles must not be loosened. Bolted unions must be fimly tightened to avoid leakages and damage. Compessos must be installed so that contols and actuating elements as well as bolted unions ae feely accessible at any time. Compessos issue 08.2007 7
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3 Technical Desciption Basically, MAXIMATOR compessos opeate accoding to the pessue intensifie pinciple. Lage aeas ae chaged with a low pessue (ai piston) and geneate via the small suface aeas a high pessue (HP piston). Pulsation is geneated by an impulse-contolled 4/2-way valve (sevo-valve). The sevo-valve altenately admits pessue to the top and bottom side of the ai piston. The sevo-valve is selected via two 2/2-way valves (pilot valves) which ae mechanically actuated by the ai piston in its stop positions. The pilot valves aeate and ventilate the actuation compatment of the sevo-valve. Dive ai povides the estoing foce fo the sevo-valve. In the actuation compatment, the sevo-valve has a lage effective aea than in the contol compatment to which compessed ai is continually admitted. The HP piston geneates the volume flow by means of check valves (intake valve, pessue valve). The outlet pessue depends on the pe-selected dive pessue. The fomulae in chapte 3.5 Calculation of final pessue can be used to calculate the static final pessue. The compesso comes to a stop upon eaching the final pessue and ceases to consume ai. The compesso only e-stats upon a pessue dop on the high-pessue side o a pessue incease on the dive side. 3.1 Functioning of a high-pessue compesso Dive ai-flows fom the pot (7) though the sevo-valve (8) to the bottom side of the ai piston (9). The ai piston moves to the ight. An intake stoke is caied out on the left side. The inlet valve (2) opens and the gas to be compessed flows though the pot (S) into the compession compatment of the compesso. A pessue stoke is caied out on the ight side. The inlet valve (12) shuts. The outlet valve (10) opens and the compessed gas flows out of the pot (P). When the ai piston (9) has eached its ight stop position, it actuates the pilot valve (13). Contol ai gets fom the pot (5) though the opened pilot valve (13) to the lage sevo-valve side. The sevo-valve (8) is moved into the othe switching position and dive ai is now chaged to the ight side of the ai piston (9). The piston moves to the left. Now the compesso caies out a pessue stoke on the left side and an intake stoke on the ight side. Expanding dive ai leaves the woking compatment though the silence (6). In compessos with a pessue atio > 5 ai is led though cooling cylindes and used to cool the high-pessue pats. Compessos issue 08.2007 9
Fig. 1: Functioning pinciple of a compesso 1 Pilot valve 2 Inlet valve 3 HP piston 4 Outlet valve 5 Pilot valve Ai 6 Outlet Dive ai 7 Ai pot 8 sevo-valve 9 Ai piston 10 Outlet valve 11 HP piston 12 Inlet valve 13 Pilot valve 10 Compessos issue 08.2007
Fig. 2: Compesso components (Example) 1 Pilot valve 2 sevo-valve 3 Dive pat 4 Silence 5 Compesso head with inlet/outlet valve 6 HP pat 7 Cooling cylinde Compessos issue 08.2007 11
3.2 Oveview of compessos Designation Figue Bief chaacteistic DLE 2-1 q Output capacity 150 I N at 3 bas admission pessue and 6 bas opeating pessue q Dive pessue 6 bas q small size q pice-efficient solution DLE 2 q Output capacity 190 I N at 3 bas admission pessue and 10 bas opeating pessue q Dive pessue 6 bas q lage stoke volume q low pulsation ate DLE 2-1-2 DLE 2-2 DLE 5-1 q Output capacity 160 I N at 3 bas admission pessue and 10 bas opeating pessue q Dive pessue 6 bas q small size q high opeating pessue q Output capacity 205 I N at 3 bas admission pessue and 16 bas opeating pessue q Dive pessue 6 bas q high opeating pessue q low pulsation ate q Output capacity 145 I N at 8 bas admission pessue and 15 bas opeating pessue q Dive pessue 6 bas q compact model q pice-efficient solution 12 Compessos issue 08.2007
Designation Figue Bief chaacteistic DLE 5 q Output capacity 145 I N at 8 bas admission pessue and 15 bas opeating pessue q Dive pessue 6 bas q compact model q pice-efficient solution DLE 2-5 q Output capacity 80 I N at 2 bas admission pessue and 25 bas opeating pessue q Dive pessue 6 bas q compact model q pice-efficient solution DLE 5-1-2 DLE 5-2 DLE 2-5-2 DLE 15-1 q Output capacity 145 I N at 8 bas admission pessue and 30 bas opeating pessue q Dive pessue 6 bas q High admission pessue q high opeating pessue q Output capacity 210 I N at 8 bas admission pessue and 40 bas opeating pessue q Dive pessue 6 bas q high output capacity q low pulsation ate q Output capacity 104 I N at 4 bas admission pessue and 40 bas opeating pessue q Dive pessue 6 bas q high opeating pessue q low admission pessue q Output capacity 95 I N at 15 bas admission pessue and 50 bas opeating pessue q Dive pessue 6 bas q small size q pice-efficient solution Compessos issue 08.2007 13
Designation Figue Bief chaacteistic DLE 15 DLE 5-15 DLE 15-1-2 DLE 15-2 q Output capacity 160 I N at 15 bas admission pessue and 60 bas opeating pessue q Dive pessue 6 bas q Lage stoke volume q low pulsation ate q Output capacity 75 I N at 4 bas admission pessue and 60 bas opeating pessue q Dive pessue 6 bas q high output capacity q low admission pessue q Output capacity 90 I N at 15 bas admission pessue and 80 bas opeating pessue q Dive pessue 6 bas q high pessue atio q small size q Output capacity 130 I N at 15 bas admission pessue and 100 bas opeating pessue q Dive pessue 6 bas q high pessue atio q low pulsation ate DLE 5-15-2 q Output capacity 102 I N at 10 bas admission pessue and 120 bas opeating pessue q Dive pessue 6 bas q high opeating pessue q low admission pessue DLE 30-1 q Output capacity 82 I N at 25 bas admission pessue and 83 bas opeating pessue q Dive pessue 6 bas q small size q pice-efficient solution 14 Compessos issue 08.2007
Designation Figue Bief chaacteistic DLE 30 DLE 5-30 DLE 15-30 DLE 30-1-2 q Output capacity 125 I N at 25 bas admission pessue and 120 bas opeating pessue q Dive pessue 6 bas q high output capacity q low pulsation ate q Output capacity 63 I N at 3 bas admission pessue and 100 bas opeating pessue q Dive pessue 6 bas q high output capacity q low admission pessue q Output capacity 98 I N at 15 bas admission pessue and 100 bas opeating pessue q Dive pessue 6 bas q high output capacity q high admission pessue q Output capacity 82 I N at 25 bas admission pessue and 150 bas opeating pessue q Dive pessue 6 bas q high compession ate q small size DLE 30-2 DLE 5-30-2 q Output capacity 125 I N at 25 bas admission pessue and 150 bas opeating pessue q Dive pessue 6 bas q high compession ate q high output capacity q Output capacity 52 I N at 4 bas admission pessue and 150 bas opeating pessue q Dive pessue 6 bas q high compession ate q low admission pessue Compessos issue 08.2007 15
Designation Figue Bief chaacteistic DLE 15-30-2 DLE 75-1 DLE 75 DLE 15-75 DLE 30-75 DLE 75-1-2 q Output capacity 105 I N at 30 bas admission pessue and 200 bas opeating pessue q Dive pessue 6 bas q high output capacity q low admission pessue q Output capacity 85 I N at 70 bas admission pessue and 240 bas opeating pessue q Dive pessue 6 bas q small size q pice-efficient solution q Output capacity 150 I N at 75 bas admission pessue and 300 bas opeating pessue q Dive pessue 6 bas q small stoke volume q low pulsation ate q Output capacity 75 I N at 11 bas admission pessue and 200 bas opeating pessue q Dive pessue 6 bas q low admission pessue q high opeating pessue q Output capacity 95 I N at 30 bas admission pessue and 250 bas opeating pessue q Dive pessue 6 bas q low admission pessue q high output capacity q Output capacity 90 I N at 70 bas admission pessue and 400 bas opeating pessue q Dive pessue 6 bas q high pessue atio q small size 16 Compessos issue 08.2007
Designation Figue Bief chaacteistic DLE 75-2 q Output capacity 130 I N at 70 bas admission pessue and 400 bas opeating pessue q Dive pessue 6 bas q low pulsation ate q high output capacity DLE 15-75-2 q Output capacity 50 I N at 15 bas admission pessue and 500 bas opeating pessue q Dive pessue 6 bas q high pessue atio q low admission pessue DLE 30-75-2 q Output capacity 60 I N at 40 bas admission pessue and 600 bas opeating pessue q Dive pessue 6 bas q high pessue atio q high admission pessue Compessos issue 08.2007 17
3.3 Compesso designs Technical chaacteistics Compessos with one dive piston One-stage, single-acting (e.g. DLE 15-1) Design One-stage, double-a(e.g. DLE 15) Two-stage (e.g. DLE 15-75) Compessos with two dive pistons One-stage, single-acting (e.g. DLE 15-1-2) One-stage, double-acting (e.g. DLE 15-2) 18 Compessos issue 08.2007
Technical chaacteistics Two-stage (e.g. DLE 15-75-2) Design Legend Luftantieb = Ai dive Gasvoduck = Gas admission pessue Betiebsduck = Opeating pessue Abluft = Exhaust ai 3.4 Type odeing code NOTE Type odeing codes ae equied fo odeing compessos. The type odeing code fo ou compessos is stuctued as follows: Compessos issue 08.2007 19
3.5 Calculation of final pessues The static final pessue of a compesso is calculated fo the espective compesso type with the following fomulae: Compesso type Single-acting one-stage e.g. DLE 5-1 Double-acting one-stage e.g. DLE 15 Two-stage e.g. DLE 5-30 Single-acting one-stage with 2 dive pats e.g. DLE 15-1-2 Double-acting one-stage with 2 dive pats e.g. DLE 30-2 Two-stage with 2 dive pats e.g. DLE 15-75-2 Legend: PB PL PA i i1 i2 Calculation of static final pessue PB = PL * i PB = i * PL + PA PB = i2 * PL + i2 / i1 * PA PB = PL * i PB = i * PL + PA PB = i2 * PL + i2 / i1 * PA Opeating pessue Dive pessue Gas admission pessue Pessue atio Pessue atio Stage 1 Pessue atio Stage 2 20 Compessos issue 08.2007
4 Eection and stat-up 4.1 Geneal notes on eection at place of application Ou compessos can be installed in any desied position. A vetical position entails cetain advantages fo the duability of sealings because then gavity will not have to be absobed by any of the sealings. Fixing angles ae povided fo fastening the compessos. Make sue to avoid ingess of any foeign matte into the compesso pots duing eection (e.g. dilling dust duing wall mounting). Remove the blind plugs fom compesso pots only just pio to fastening the espective pots. 4.2 Compessed ai system The compessed-ai pot equies mounting of a compessed ai contol unit made by MAXIMATOR downsteam of the compesso. The compessed ai contol unit consists of pessue filte, wate sepaato, shut-off valve, pessue contolle, pessue gauge and, if need be, safety valve. Fig. 3: Compessed ai contol unit If the owne of the compesso does not install a compessed ai contol unit, compessed ai quality has to be ensued accoding to the equiements of the manufactue. Compessos issue 08.2007 21
Requiements to compessed ai quality: q Solid matte Maximum paticle size 5 µm Maximum paticle concentation 5 mg/m 3 Dew point Up to +10 C, wate content of 9.4 g/m 3 Up to + 2 C, wate content of 5.6 g/m 3 4.2.1 Compessed ai lubificato A compessed ai lubificato is not necessaily equied. All moving compesso pats ae teated with special gease duing eection. The gease may become gummy when the compesso is opeated with extemely dy ai fo a longe peiod of time. Use of a compessed ai lubificato is ecommended in such cases. CAUTION Afte use of a compessed ai lubificato the compesso must neve be opeated without this oile. The oil of the compessed ai lubificato puges gease fom the compesso so that pemanent lubication cannot be ensued. Special gease made by the manufactuing company may be used fo e-lubication. When employing a compessed ai lubificato, the oil content of compessed ai should be 1 mg/m 3 to 5 mg/m 3. 4.2.2 Pipe coss sections The compessed ai pot must not be specified smalle than the pot thead. Reduction to smalle pot theads may esult in pefomance losses and malfunctions of the compesso. Excessively long supply pipes may give ise to poblems due to pessue dop in smalle pipes. 4.2.3 Diect pilot-valve ai The compessos ae designed fo opeation with diect pilot-valve ai. The pilot-valve ai should be connected upsteam of the pessue contolle in the dive ai pipe. The compesso can evese bette at lowe dive pessues. Howeve, the compesso does not function when the diect pilot-valve ai is not connected. 22 Compessos issue 08.2007
4.3 High-pessue system The employed HP pipes and accessoies pats must be matched to the compesso as egads pessue and coss sections. Othewise the pefomance capacity and safety of the compesso may be impaied. 4.3.1 Inlet The compessos have to e chaged with the admission pessue of the gas to be compessed in ode to achieve economically efficient output capacities and the indicated final pessues. Compessos with a pessue atio of 2 can be opeated without admission pessue. When thee is no admission pessue available, an optimal compesso pefomance can only be ealised by an unde-pessue tight intake pipe because compesso medium may be soiled by ambient ai. Cutting-ing bolted unions must not be used. A filte with a maximum mesh width of 10 µm has to be installed into the admission pessue pipe in ode to avoid damage at intake and pessue valves as well as the HP sealing. 4.3.2 Pessue pipe The pessue pipe and the petaining accessoies must withstand the maximum outlet pessue of the compesso. The pessue stength may only be fallen shot of when an adequate safety valve is installed in the pessue pipe. The coss section of the pessue pipe must not be smalle than that of the pessue pot. A smalle coss section will educe output capacity and lead to highe waming of the compesso medium. 4.3.3 Compesso medium The compessos may only be used fo media that ae listed in the media enduance schedule. Any othe media have to be tested befoe utilisation by MAXIMATOR fo compatibility with compesso mateials. Compessos issue 08.2007 23
4.4 Stat-up The compesso stats to convey medium as soon as dive ai and diect pilot-valve ai ae available. Escaping dive ai is used fo cooling HP pats in compessos with highe pessue atios. When the compesso uns in continuous opeation with a high stoke fequency, thee may be stong waming of the compesso despite cooling. This may esult in excessive wea and tea at sealings. In ode to avoid oveheating it is necessay to monito the tempeatue of the compessed gas. Tempeatues in excess of 100 C at the compesso outlet have to be avoided. 24 Compessos issue 08.2007
5 Maintenance and sevicing 5.1 Maintenance notes The ai dives of all compessos ae pe-teated with high-pefomances gease duing eection and equie no othe fom of lubication. Duing maintenance and sevicing wok of the compessos, the sevo-valves and ai pistons shall be teated with an acid- and silicon-fee high-pefomances gease povided by the manufactuing company. 5.2 Sevicing Possible fault Cause of fault Fault emoval Compesso fails to un at low ai pessue. Fiction of O-ings on sevovalve is too high. Re-lubicate. Replace O-ings on sevovalve. O-ings swell due to use of wong oil o lubicant. Change O-ings. Use acid- and silicon-fee lubicant. Compesso fails to un o opeates only slowly. Exhaust o sevo-valve coveed with ice. Dewate compessed ai with wate sepaato. Fomation of esidue in the silence. Clean the silences. Replace, if need be. Compesso fails to un. Ai escapes though the exhaust. Compesso fails to un. Ai flows though small boing at sevo-valve housing. O-ings at sevo-valve ae defective. O-ing at ai piston is defective o won out. Sevo-valve is hung up. Change and gease O-ings. Change and gease O-ing. Clean sevo-valve and sleeve. Check O-ings and sleeve and eplace, if need be. Lubicate. Compesso fails to un. Ai escapes though small boing in bottom cap. Pilot valve in top o bottom cap is hung up. Clean and gease pilot valve. Check fo wea and tea and eplace, if need be. Compesso uns with high fequency and shot stokes. Pilot valve in top o bottom cap is defective. Clean and gease pilot valve and eplace, if need be. Compessos issue 08.2007 25
5.3 Repai NOTE Repai instuctions fo the compessos can be found on the Intenet at www.maximato.de. CAUTION Repai wok has to be caied out by qualified skilled opeatives. Make sue to obseve absolute cleanliness. Mino impuities may cause seious damage at pecision-machined compesso components. NOTE You can ship defective compessos fo epai to MAXIMATOR. All epai wok is conducted by qualified pesonnel in clean ooms. Individual pats of the compessos can be odeed as spae pats fom MAXIMATOR. Sealings ae subject to high wea and tea. The ode numbes and compositions of sealing kits in indicated in the espective dawing. Said dawing is pat of each compesso documentation and is enclosed to the packaging of the compessos. Please, quote the seial numbe of the compesso when odeing spae pats. The seial numbe (a 6-digit numbe) is located on the machine plate and the compesso housing. 5.3.1 Liability fo mateial defects Fo compessos, manufactue gants a waanty of twelve (12) months on mateial quality and wokmanship. Said waanty commences on the compesso shipment date. This waanty does not cove defects caused by application of inadmissible medias and foeign matte in the dive o media. This shall also apply to excision of maximum opeating pessue. This waanty does also not apply to damage esulting fom nomal wea and tea (wea pats, such as sealings, guiding elements, etc.), impope opeation and inadequate maintenance. 26 Compessos issue 08.2007
6 Technical data Type Pessue atio Compession Admission pessue Max. opeating Piston capacity Pots Weight Max. opeating (i1 / i2) atio min. max. pessue Inlet Outlet temp. max. pa pa bas pb cm 3 kg C DLE 2-1 1:2 1:10 0 20 20 922 G 1/2 G 1/2 15 60 DLE 5-1 1:5 1:15 2 50 50 373 G 1/2 G 1/2 15 60 DLE 15-1 1:15 1:20 7 150 150 122 G 1/4 G 1/4 13 100 DLE 30-1 1:30 1:20 15 300 300 60 G 1/4 G 1/4 13 100 DLE 75-1 1:75 1:20 35 750 750 25 G 1/4 G 1/4 13 100 DLE 2 1:2 1:10 0 40 40 1844 G 1/2 G 1/2 20 60 DLE 5 1:5 1:15 2 100 100 746 G 1/2 G 1/2 20 60 DLE 15 1:15 1:20 7 300 300 244 G 1/4 G 1/4 18 100 DLE 30 1:30 1:20 15 600 600 120 G 1/4 G 1/4 18 100 DLE 75 1:75 1:20 35 1500 1500 50 G 1/4 G 1/4 18 100 DLE 2-5 1:2 / 1:5 1:25 0 0,8*PL 100 922 G 1/2 G 1/2 20 60 DLE 2-15 1:5 / 1:15 1:45 2 6*PL 300 373 G 1/2 G 1/2 19 100 DLE 5-30 1:5 / 1:30 1:90 2 2*PL 600 373 G 1/2 G 1/4 19 100 DLE 15-30 1:15 / 1:30 1:40 7 15*PL 600 122 G 1/4 G 1/4 19 100 DLE 15-75 1:15 / 1:75 1:100 7 3,5*PL 1500 122 G 1/4 G 1/4 19 100 DLE 30-75 1:30 / 1:75 1:50 15 20*PL 1500 60 G 1/4 G 1/4 19 100 DLE 2-1-2 1:4 1:10 0 40 40 922 G 1/2 G 1/2 22 60 DLE 5-1-2 1:10 1:15 4 100 100 373 G 1/2 G 1/2 22 60 DLE 15-1-2 1:30 1:20 10 300 300 122 G 1/4 G 1/4 20 100 DLE 30-1-2 1:60 1:20 20 600 600 60 G 1/4 G 1/4 20 100 DLE 75-1-2 1:150 1:20 45 1500 1500 25 G 1/4 G 1/4 20 100 DLE 2-2 1:4 1:10 0 40 40 1844 G 1/2 G 1/2 25 60 DLE 5-2 1:10 1:15 4 100 100 746 G 1/2 G 1/2 25 60 DLE 15-2 1:30 1:20 10 300 300 244 G 1/4 G 1/4 23 100 DLE 30-2 1:60 1:20 20 600 600 120 G 1/4 G 1/4 23 100 DLE 75-2 1:150 1:20 45 1500 1500 50 G 1/4 G 1/4 23 100 DLE 2-5-2 1:4 / 1:10 1:25 0 1,6*PL 100 922 G 1/2 G 1/2 25 60 DLE 5-15-2 1:10 / 1:30 1:45 2 12*PL 300 373 G 1/2 G 1/4 24 100 DLE 5-30-2 1:10 / 1:60 1:90 2 4*PL 600 373 G 1/2 G 1/4 24 100 DLE 15-30-2 1:30 / 1:60 1:40 7 30*PL 600 122 G 1/4 G 1/4 24 100 DLE 15-75-2 DLE 30-75-2 1:30 / 1:150 1:100 7 7*PL 1500 122 G 1/4 G 1/4 24 100 1:60 / 1:150 1:50 15 40*PL 1500 60 G 1/4 G 1/4 24 100 *Compession atio = Opeating pessue / admission pessue Abbeviations: pl = Ai dive, pa = Gas admission pessue, pb = Gas outlet pessue Compessos issue 08.2007 27
NOTE The admissible, maximum opeating tempeatue is 60-100 C. Wate-cooling systems can be optionally povided. Maximum stoke fequency is 90 110 stokes pe minute at 50 % ED. HAZARD Unde-uns of the minimum admission pessue (pa min ) ae not admissible and may esult in damage at the compessos. 28 Compessos issue 08.2007
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MAXIMATOR Hochduck-Pumpen fü veschiedene Flüssigkeiten (Öl, Wasse, Emulsion usw.) High-pessue pumps fo diffeent liquids (oil, wate, emulsion etc.) Pompes haute pession pou diffeents fluides Duckluft-Ehöhe Compessed Ai Amplifies Supesseus d ai compimé Gasinnenduck-Technik Gas Assist Injektion Systems Technique de gaz sous pession Püfstände fü Duckpüfungen, Bestduckpüfungen und Impulspüfungen Special Test Benches Bancs d essai spéciaux Ventile, Rohe, Amatuen fü die Hochduck-Technik High Pessue Valves, Fittings, Tubing Vannes, tubes, accods pou techniques haute pession 3999.0278 1000 DSB MAXIMATOR GmbH Walkeniede Staße 15 D-37449 Zoge Fon +49 (0) 55 86 / 80 30 Fax +49 (0) 55 86 / 8 03-30 40 email: info@maximato.de Intenet: www.maximato.de