MAXIMATOR GPLV 2 Assembly Instructions Manual Download Page 1 | Manualshive

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Air Amplifiers

Revision 11.2011

Assembly Instructions

for Air Amplifiers

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Summary of Contents for GPLV 2

Page 1: ...Air Amplifiers Revision 11 2011 Assembly Instructions for Air Amplifiers ...

Page 2: ...Tel 0 36 31 9553 0 Fax 0 36 31 9553 5010 e mail info maximator de Internet http www maximator de Copyright of the issuer These assembly instructions may only be reproduced translated or made available to third parties with the issuer s express consent ...

Page 3: ...on staff 6 2 4 Special Safety Instructions 6 2 4 1 Safety in the event of emissions 6 2 4 2 Safety in the event of defective devices 7 2 4 3 Safety at the installation location 7 3 Technical Description 8 3 1 Operation of Air Amplifiers 9 3 1 1 MPLV 4 and MPLV 4L air amplifiers 9 3 1 2 MPLV 2 SPLV 2 and GPLV 2 air amplifiers 10 3 2 Overview of Air Amplifiers 12 4 Assembly and Putting into Service ...

Page 4: ...Table of Contents Revision 11 2011 Air Amplifiers 5 Servicing and Maintenance 18 5 1 Maintenance Information 18 5 2 Maintenance 18 5 3 Repair 19 5 3 1 Warranty 20 6 Technical Data 21 ...

Page 5: ...e the air amplifiers The assembly instructions contain technical data a technical description and information on how to put into service operate and maintain the air amplifiers Technical data and measurement and weight information apply to the day on which these assembly instructions were printed They may differ in detail from a particular implementation without fundamentally changing the objectiv...

Page 6: ...bH 1 3 Warranty and Liability In principle the General Conditions of Sale and Delivery supplied by the manufacturer of the air amplifiers shall apply Warranty and liability claims in case of personal or property damage shall be precluded if they are due to one or more of the following causes Abnormal use of the air amplifiers Incorrect putting into service operation or maintenance of the air ampli...

Page 7: ...tions Familiarity with the content of the assembly instructions is one of the prerequisites for protecting people against hazards and for avoiding errors and hence for operating the air amplifiers safely and without malfunction The assembly instructions must be available to operators and maintenance staff at all times The operating company or staff authorized by it to use the air amplifiers within...

Page 8: ...e air amplifiers must comply with statutory requirements and regulations Each time before the air amplifiers are put into service checks must be performed to ensure that they are not damaged and are in proper condition Staff must immediately report to the operating company any changes to the air amplifier that affect safety HAZARD Type and source of hazard Hazards that may result in serious bodily...

Page 9: ...erve changes during operation 2 3 3 Safety instructions for maintenance and repair work Operating malfunctions brought about by inadequate or incorrect maintenance may also cause substantial repair costs and long downtimes in relation to the air amplifiers The manufacturer accepts no liability for damage resulting from incorrect maintenance and care The maintenance intervals are laid down in a mai...

Page 10: ...ormation contained in these assembly instructions and in all other documents must always be fully observed and complied with If hazards that might result in personal injury are identified the air amplifier must be shut down immediately Staff must have sound knowledge of the following operating processes regulations and procedures Operating procedures for air amplifiers Protective fencing safeguard...

Page 11: ...y Air amplifiers are designed exclusively for compressing air If you are using other gases you must consult MAXIMATOR GmbH Pipes and accessories must be matched to system pressure and be of the corresponding size You must take appropriate measures to ensure that the drive and charge pressure pL and pa does not exceed the permissible value of 10 bars Before repair work is undertaken the entire syst...

Page 12: ...5 SPLV 10 They can be fitted to air amplifier stations which are equipped with a compressed air tank The compressed air tank is designed to offset fluctuations in pressure and accumulate a greater air quantity which needs to be available quickly The amplifier code indicates the pressure ratio A floating gate valve alternately applies working pressure to the pistons The flow redirection process is ...

Page 13: ...ressure outlet port B When the piston actuates the pilot valve in the bottom cap the inflow of air into the drive compartment is interrupted and the process begins again The pressure increase is due to the surface of the piston in the drive compartment being four times larger than that of the piston in the compression compartment Example Drive pressure 6 bars Pressure ratio 1 4 Operating pressure ...

Page 14: ...rt A This enables you to use lower primary pressures 3 1 2 MPLV 2 SPLV 2 and GPLV 2 air amplifiers The charge air flows from port A through the non return valves 2 and enters compression compartments I and II The drive pressure port PL fills drive compartment II via the control slide valve while drive compartment I is depressurized Due to its movement the piston reduces the volume in compression c...

Page 15: ... off Example Drive compartment II 4 bars compression compartment I 4 bars Compression compartment II 8 bars Fig 4 How MPLV 2 SPLV 2 and GPLV 2 work 1 Compression compartment II 2 Non return valves inlet 3 Drive compartment II 4 Non return valves outlet 5 Pilot valve 6 Pilot valve 7 Drive compartment I 8 Compression compartment I 9 Control slide valve 10 Exhaust PL Drive pressure B Pressure outlet ...

Page 16: ...al pressure has been reached no energy consumption SPLV 2 Output capacity 960 IN min at 6 bars primary pressure and 8 bars operating pressure Operating time 50 Selective pressure increase upstream of an individual consumer Once final pressure has been reached no energy consumption MPLV 2 Output capacity 580 IN min at 6 bars primary pressure and 8 bars operating pressure Operating time 50 Selective...

Page 17: ...been reached no energy consumption MPLV 4 Output capacity 50 IN min at 6 bars primary pressure and 16 bars operating pressure Operating time 50 Selective pressure increase upstream of an individual consumer Once final pressure has been reached no energy consumption GPLV 5 Output capacity 360 IN min at 8 bars primary pressure and 30 bars operating pressure Operating time 50 Selective pressure incre...

Page 18: ...rresponding ports 4 2 Compressed Air System The compressed air port requires a Maximator compressed air control unit to be fitted downstream of the air amplifier This air control unit consists of a pressure filter water separator shut off valve pressure controller manometer and where applicable a safety valve Fig 5 Compressed air control unit If no compressed air control unit is fitted when operat...

Page 19: ...ommend use of a compressed air lubricator in such cases 4 2 2 Pipe cross sections The compressed air port must not have a smaller specification than the port thread Reduction to smaller port threads may cause performance losses and air amplifier malfunctions Excessively long supply pipes may give rise to problems due to pressure drop in small pipes CAUTION Once a compressed air lubricator has been...

Page 20: ...r medium Air amplifiers are designed exclusively for use with compressed air Other media must be tested by MAXIMATOR GmbH in respect of their compatibility with the air amplifier materials before being used 4 4 Putting into Service As with a standard piston compressor the stroke frequency also causes pressure pulsations in the air amplifier You can reduce these pressure pulsations by providing an ...

Page 21: ...PLV 2 Drive air flows through the bypass pipe to the pressure outlet until the same pressure is achieved It is possible to fill a larger volume quickly on the pressure outlet side The air amplifier operates until the operating pressure set at pressure switch NO is achieved This connection option is only appropriate if there is no continuous compressed air consumption 4 Use of a pressure switch NC ...

Page 22: ...f fault Fault removal Air amplifier fails to operate at low air pressure Friction of o rings on control slide valve is too high Re lubricate Replace o rings on control slide valve Exhaust or control slide valve covered with ice Use water separator to de water compressed air Air amplifier does not operate or operates only slowly Formation of residue in the silencer Clean the silencer Replace where ...

Page 23: ...bottom cap is defective Clean and grease pilot valve If necessary replace pilot valve Seals on air pistons are worn out Change and grease seals Air amplifier does not achieve the calculated final pressure Non return valves fail Check and clean non return valves If necessary replace non return valves Only for MPLV 4 Air amplifier does not achieve the final pressure Leakage in HP seal Replace HP sea...

Page 24: ...the housing of the air amplifier 5 3 1 Warranty The manufacturer provides a warranty of 12 months on material quality and workmanship for air amplifiers The warranty shall commence on the date on which the air amplifier is shipped The warranty shall not cover defects that arise due to incorrect handling or malfunctions caused by the use of impermissible liquids and foreign matter in the drive or a...

Page 25: ...bar 1 10 1 10 1 10 1 10 2 10 1 10 max operating pressure in bar 20 20 20 32 40 60 max noise level in dB 79 79 79 79 79 79 max operating temperature in C 60 60 60 60 60 60 Port for air drive pressure G 3 4 G 1 2 G 3 8 G 1 2 G 3 8 G 1 2 Port for pressure inlet G 1 2 G 1 2 G 3 8 G 1 2 G 3 8 G 3 8 Port for pressure outlet G 1 2 G 1 2 G 3 8 G 1 2 G 1 2 G 3 8 Weight 20 5 16 0 3 3 8 5 2 2 16 0 ...

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