WE LOVE TECHNOLOGY
INSTRUCTIONS MANUAL
NITROGEN COMPACT BOOSTER
2480.00.32.71
Instructions manual Nitrogen Compact Booster
MEMBER OF THE LAEPPLE GROUP
Document: Instructions manual
Document number: 2.7528.04.0718.0100000
Revision: R07-2018
Version: V04
Language:
In the German language, this document is the original version in the EU language of the manufacturer and is labelled
with the German national flag.
In the EU language of a country of use, this document is a translation of the original version and labelled with the
national flag of the country of use.
This document is referred to as "instructions" in the following text.
Number of pages in this manual including the title page: 38
These instructions are valid for the product
2480.00.32.71
Nitrogen Compact Booster
This document was created by
FIBRO GMBH
August-Läpple-Weg
DE 74855 Hassmersheim
Phone: +49 (0) 62 66 73 0
Fax: +49 (0) 62 66 73 237
E-mail: info@fibro.de
Internet: www.fibro.de
© All rights to this document are subject to copyright of the author.
Without the prior written permission of FIBRO GMBH, this document must not be copied or
reproduced, either in full or in part.
The instructions are intended only for the operator of the described machine only
and must therefore not be made available to uninvolved third parties - in particular to competitors.
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Incorrect application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 EC declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Further applicable documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.6 Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.7 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.8 Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.9 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9.1 Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9.2 Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.9.3 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.9.4 General instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.1.1 Due diligence of the operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1.2 Personnel requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Residual hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 General technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1.1 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Packaging and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.2 Transport damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3 Interim storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Return shipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.5 Disposing of the packaging material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.2 Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.3 Installing the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Workstations for operating personnel . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.3 Prior to commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.4 Operating the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4.1 Settings prior to the operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4.2 Fill gas spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7 Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Customer services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Instructions manual Nitrogen Compact Booster 3/38
8 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.3 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.3.1 Prior to each use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.4.1 If necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.5 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.2 Temporary decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
9.3 Final decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10 Disassembly and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.1 Important safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.2 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.3.1 Disposal of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11 Service and spare parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.1 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
11.3 Spare parts ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
12 Indexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
12.1 Third-party products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
13 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
13.1 Pneumatic plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
13.2 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4/38 Instructions manual Nitrogen Compact Booster
Introduction
1 INTRODUCTION
1.1 Definition
The Nitrogen Compact Booster product is a machine in terms of 2006/42/EC, section 1a and 2a.
In the following text of these instructions, the product is referred to as machine.
1.2 Intended use
This machine is intended to compress the nitrogen flowing into a nitrogen bottle in order to fill
gas springs. The machine may only be used to compress nitrogen. The machine may only be
used to fill gas springs.
The intended use also includes
• reading of these instructions and.
• the adherence of safety information.
• the adherence of all applicable documents.
• adherence to the maintenance regulation.
The machine may only be used as intended. Only processes and handling may be used as de-
scribed in these instructions.
1.3 Incorrect application
Any use which goes beyond the intended use of the machine and therefore classed as misuse
and not allowed.
The machine may not be stressed beyond its limits.
The machine is not suitable for
• the compression of other gases.
• filling of other components.
• the operation with impermissible changes or alterations (see chapter 6.4 "Operating the machine" on page 22).
For all damage to persons or property which has been caused by improper use, the liability lies
with the operator of the machine described in this document.
Instructions manual Nitrogen Compact Booster 5/38
Introduction
1.4 EC declaration of conformity
All machines have a EU declaration of conformity when supplied as per the directive 2006/42/
EG (machine directive). The excerpt of the text in this EU declaration says:
EU declaration of conformity as per directive 2006/42/EG, annex II A (machinedirective)
Manufacturer FIBRO GMBH
August-Läpple-Weg
DE 74855 Hassmersheim
declares herewith that the machine
Nitrogen Compact Booster
that the models introduced to the market correspond to all relevant regulations of directive 2006/
42/EG.
The machine also corresponds to all relevant regulations of further directives applied to the machine.
Applied harmonised standards:
DIN EN ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment
and risk reduction (ISO 12100:2010)
Authorised for the compilation of the Technical Documentation is:
FIBRO GMBH August-Läpple-Weg DE 74855 Hassmersheim
1.5 Further applicable documents
In addition to these instructions for the safe handling of the machine further, with applicable documents are necessary.
The information in these documents have to be adhered to.
• EU declaration of conformity as per directive 2006/42/EG
• Pneumatic plan
6/38 Instructions manual Nitrogen Compact Booster
Introduction
1.6 Set-up
The illustration shows a schematic diagram of the principal set-up of the machine
The machine consists of:
1 Compressor
2 Start-up valve
3 Filter- and control valve compressed air
4 Nitrogen outlet (labelled with B)
5 Pressure relief valve
6 Nitrogen inlet via bottle hose (labelled with A)
2
3
A
1
4
B
5
6
Fig. 1-1 Set-up
To fill a gas spring a filling hose, a filling adapter and a filling and control fitting is required.
The parts can be ordered from FIBRO GMBH using the indicated order number.
a Filling and control fitting Order number 2480.00.32.21
Filling adapter M6 Order number 2480.00.32.10
b
Filling adapter G1/8" Order number 2480.00.32.11
c Filling hose Order number 2480.00.31.02
Instructions manual Nitrogen Compact Booster 7/38
Introduction
c
a
b
e d
f
To fill a gas spring safely we recommend the use of optionally available optional additional
equipment.
The parts can be ordered from FIBRO GMBH using the indicated order number.
d Connection adapter Order number 2480.00.32.07.04
e Bottle pressure regulator Order number 2480.00.32.07.01
f Gas bottle connection Order number 2480.00.32.07.02
Fig. 1-2 Optional additional equipment
The filling and control fitting (a) is connected via the filling adapter (b) to the filling inlet of the gas
spring.
The filling hose (c) creates the connection between nitrogen outlet of the machine and the filling
and control fitting.
The bottle pressure regulator (e) can be connected between filling hose and nitrogen outlet.
For the assembly a connection adapter (d) for the filling hose and a gas bottle adaptor (f) to con-
nect the nitrogen outlet.
At the bottle pressure regulator a maximum permissible filling pressure gas spring can be ad-
justed. Permanent monitoring of the filling process is not required. A gas spring is protected
against overfilling.
With the retaining plate the machine can be adjusted securely to the nitrogen bottle.
8/38 Instructions manual Nitrogen Compact Booster
Introduction
1.7 Function
The filling of a gas spring directly from a nitrogen bottle only works if the pressure in the bottle
is higher than the required filling pressure of the gas spring.
The filling of a gas spring with 150 bar is not possible with a bottle pressure of 120 bar. The remaining nitrogen in the bottle remains unused or has to be used for other applications.
By using the nitrogen compact booster the entire volume of a nitrogen bottle can be used up the
residual pressure of approx. 30 bar.
The machine works according to the principle of a pressure intensifier. The low inlet pressure of
a nitrogen bottle is increased by continuous and constant piston motion. A high pressure is available at the outlet of the gas spring.
If using a bottle pressure regulator between nitrogen outlet and filling hose a maximum permissible filling pressure can be set.
The machine is powered with pressurised air. The operating pressure is adjustable.
1.8 Warranty
The guarantee is regulated contractually (see Terms and Conditions or contract)
Instructions manual Nitrogen Compact Booster 9/38
Introduction
1.9 Manual
These instructions describe the handling of the machine and contain important information
about its intended use.
A copy of these instructions must be stored and made continuously available at the operating
site of the machine, and everyone assigned to work on or with the machine must read, understand and apply them.
The safety information in the individual chapters must be observed.
These instructions and the other applicable documents are not subject to any modification ser-
vice.
We reserve the right to update data and drawings in these instructions based on continuing tech-
nical development.
The respectively current version can be requested from FIBRO GMBH.
1.9.1 Legend
Certain marks, symbols and abbreviations with the following meaning are used in these instructions for clear organisation of its contents:
1) indicates an enumeration.
a) indicates the second level of an enumeration.
• indicates a listing.
– indicates the second level of a listing.
The book icon in front of the text is a reference to an applicable document or another chapter in
these instructions. The content of this document or chapter must be observed.
The information symbol before the text indicates an additional instruction or an important application tip.
1.9.2 Figures
The figures in these instructions are examples. Deviations between a figure and the actual conditions on the machine are possible.
The drawings of FIBRO GMBH and the information on third-party products are decisive.
10/38 Instructions manual Nitrogen Compact Booster
Introduction
1.9.3 Safety instructions
This manual contains safety informations, which are intended to draw your attention to possible
hazards and which should be heeded in order to avoid injury.
The associated text describes
• the type of hazard
• the source of the hazard
• the options for avoiding injury
• the possible consequences if the warning notice is not heeded
Safety informations are highlighted using a colored signal bar with a warning triangle and signal
word.
The signal bars have the following meaning:
DANGER!
A safety notice on a red signal bar with the signal word DANGER designates a hazard
with a high risk level which, if not avoided, will result in death or severe injury.
WARNING!
A safety notice on an orange signal bar with the signal word WARNING designates a hazard with a medium risk level which, if not avoided, might result in death or severe injury.
CAUTION!
A safety notice on a yellow signal bar with the signal word CAUTION designates a hazard
with a low risk level which, if not avoided, could result in minor or moderate injury.
1.9.4 General instructions
In addition to the safety notices, these instructions contain information that must be observed to
prevent property damage.
The pertinent text describes
• the possible reason for property damage
• the possibilities for preventing property damage
Notices of possible property damage are emphasised by a blue signal bar and the signal word
ATTENTION.
NOTICE
Notices for the prevention of property damage are not related to possible injuries.
Furthermore, these instructions contain general information on use.
General information on use and tips for certain applications are emphasised with a blue infor-
mation symbol.
Instructions manual Nitrogen Compact Booster 11/38
2SAFETY
2.1 Basic safety instructions
Die meisten Unfälle beim Umgang mit technischen Einrichtungen sind auf die Missachtung der
grundlegenden Sicherheitsregeln zurückzuführen.
Erkennen einer möglichen Gefährdung kann einen Unfall vermeiden, bevor dieser eintritt. Sind
Gefährdungen vorhanden, warnen Sicherheitsinformationen an der machine und in diesem Dokument vor diesen Gefährdungen. Wenn die Warnungen nicht beachtet werden, kann es zu
Körperverletzungen oder Tod kommen.
FIBRO GMBH kann nicht alle möglichen Umstände voraussehen, die potentielle Gefährdungen
enthalten können. Die Warnungen in diesem Dokument und an der machine sind folglich nicht
alles umfassend.
Personal muss die erforderliche Schulung und Erfahrung sowie erforderliche Werkzeuge haben, um Arbeiten an der machine richtig ausführen zu können.
Unsachgemässe Bedienung, Wartung oder Instandsetzung kann gefährlich sein und schwere
oder tödliche Verletzungen verursachen.
Keine Arbeiten zu Transport, Montage, Wartung oder Instandsetzung ausführen, wenn die Informationen zu Transport, Montage, Wartung oder Instandsetzung nicht gelesen und verstanden wurden.
Die machine darf in keiner Weise abweichend von den Betrachtungen in dieser Anleitung benutzt werden. Alle für die Benutzung anwendbaren Sicherheitsregeln und Schutzmassnahmen
am Einsatzort müssen beachtet werden, einschliesslich Standort bezogene Regelungen und
Schutzmaßnahmen am Arbeitsplatz.
Wird ein Arbeitsmittel, eine Handlung, eine Arbeitsmethode oder eine Arbeitstechnik angewendet, die nicht ausdrücklich von FIBRO GMBH vorgeschlagen ist, muss der Anwender selbst die
Sicherheit für sich und andere Personen sicherstellen.
Es muss auch gewährleistet werden, dass die machine durch die beabsichtigten Arbeiten zu
Bedienung, Wartung und Instandsetzung nicht beschädigt oder unsicher wird.
Die Informationen, Beschreibungen und Abbildungen in diesem Dokument basieren auf der
Grundlage von Informationen, die zum Zeitpunkt der Erstellung dieses Dokuments verfügbar
waren.
Diese und andere Punkte können sich jederzeit ändern. Die Änderungen können die Eigenschaften der Maschine beeinträchtigen. Vor der Ausführung jeglicher Arbeiten die derzeit verfügbaren Informationen einholen.
Safety
12/38 Instructions manual Nitrogen Compact Booster
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