MAXIMATOR GPLV 2, SPLV 2, GPLV 5, MPLV 2, MPLV 4 Instructions Manual
...
Air Amplifiers Revision 11.2011
Assembly Instructions
for Air Amplifiers
MAXIMATOR GmbH
Lange Straße 6 • D-99734 Nordhausen
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.
Table of Contents
Air Amplifiers Revision 11.2011
Table of Contents
1
Basic Information...........................................................................................................1
1.1
Notes on the Assembly Instructions..................................................................1
1.2
Intended Use....................................................................................................2
1.3
Warranty and Liability.......................................................................................2
2
Safety Instructions.........................................................................................................3
2.1
General Safety Directives.................................................................................3
2.2
Symbols and Signal Terms...............................................................................4
2.3
Basic Safety Measures.....................................................................................4
2.3.1
Technical condition...........................................................................................4
2.3.2
Safety instructions for operation .......................................................................5
2.3.3
Safety instructions for maintenance and repair work.........................................5
2.3.4
Requirements 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 ............................................................................14
4.1
General Assembly Instructions on site............................................................14
4.2
Compressed Air System.................................................................................14
4.2.1
Compressed air lubricator...............................................................................15
4.2.2
Pipe cross-sections ........................................................................................15
4.3
High-Pressure System....................................................................................16
4.3.1
Pressure pipe .................................................................................................16
4.3.2
Amplifier medium............................................................................................16
4.4
Putting into Service.........................................................................................16
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
Basic Information
Air Amplifiers Revision 11.2011
1
1 Basic Information
Air amplifiers from MAXIMATOR are used for compressing pre-amplified
compressed air from the compressed air network to a desired higher final pressure.
This process provides the following advantages:
Selective pressure increase upstream of individual consumers
No energy consumption once the final pressure has been reached
No electrical installation necessary
Simple, safe and cost-efficient operation
Requires no investment in an in-house high-pressure network or a
decentralized separate compressor system
1.1 Notes on the Assembly Instructions
These assembly instructions describe how to set up the air amplifiers and provide
information about how to operate and maintain them correctly. Read the assembly
instructions carefully before actually using this equipment. The assembly
instructions facilitate rapid understanding of the technical details and contain all the
necessary information on how to use 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 objective information and thereby losing validity.
Differences in textual and pictorial statements depend on equipment and
accessories, which means that no claims arising from this can be asserted. All
maintenance, assembly and operating information prescribed in these assembly
instructions must be complied with to ensure full functionality and safety. The air
amplifiers are intended only for the purposes mentioned in the assembly
instructions. The manufacturer cannot recognize claims caused by incorrect
operation and inadequate maintenance. The attached documents relating to
components and all other documents that are part of the scope of delivery must be
observed. The relevant accident prevention regulations and other generally
recognized safety requirements must be complied with.
Basic Information
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Air Amplifiers
1.2 Intended Use
Air amplifiers are used exclusively in compressed air networks to compress preamplified air to a desired final pressure.
The drive of the air amplifiers is designed for primary pressure of up to 10 bars.
Air amplifier changes and conversions are not permitted, for reasons of safety. All
maintenance, assembly and operating information prescribed in these assembly
instructions must be complied with to ensure full functionality and safety. If you are
using other gases, you must consult MAXIMATOR GmbH.
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 amplifiers.
Changes to the air amplifiers.
Operating the air amplifiers with defective safety devices or incorrectly
installed safety and protective devices.
Failure to comply with the information in these assembly instructions in
respect of putting into service, operation and maintenance.
Inadequate surveillance of parts that are subject to abrasion.
Incorrect repair work.
Safety Instructions
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2 Safety Instructions
2.1 General Safety Directives
The following EC Directives apply to the safety of the machinery:
Machinery Directive 2006/42/EC, Annex II No.1 B
and applied harmonized standards
EN ISO 12100-1 and 12100-2
The air amplifiers may be the source of hazards if they are used by untrained staff,
or are used incorrectly or abnormally. Each person that is instructed to operate or
maintain the air amplifiers must have read and understood the complete assembly
instructions before carrying out the corresponding activities. This also applies if the
person in question has already operated, or received training for, the air amplifiers.
We recommend that the operating company should obtain written confirmation from
staff that they are familiar with the assembly instructions. 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 the scope of their duties, is responsible for ensuring
accident-free operation.
Work safety-related data is based on currently valid directives issued by the
European Community. In other countries, the relevant laws and regulations must be
complied with. The operating company must determine the current status of all
regulations both for the European Community and for other countries. Apart from the
work safety information in these assembly instructions, generally accepted safety
and accident prevention regulations must be observed and complied with.
All information given in the assembly instructions must be observed unconditionally!
Safety Instructions
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Air Amplifiers
2.2 Symbols and Signal Terms
2.3 Basic Safety Measures
2.3.1 Technical condition
The following must be observed:
To avoid hazards and to ensure optimal performance, no modifications or
conversions must be made to the air amplifiers.
The user is obliged to ensure that the air amplifiers are operated when in
perfect working condition and safe to operate. The technical condition of
the 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 injuries or even death.
Hazard avoidance measures.
CAUTION
Type and source of hazard
Hazards that may result in bodily injuries or property damage.
Hazard avoidance measures.
NOTE
User tips and useful information.
NOTE
Environmental impact
Safety Instructions
Air Amplifiers Revision 11.2011
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2.3.2 Safety instructions for operation
Each time before the air amplifiers are put into service, checks must be performed to
ensure that they are operationally safe.
The following safety instructions must be observed when operating the air
amplifiers:
Generally accepted safety and accident prevention regulations must be
observed!
Staff must be familiar with all devices and actuators and how they function
before putting the air amplifiers into service!
During system operation, always ensure that operating conditions are
suitable for deployment of the air amplifiers.
Shut down the air amplifiers immediately if you observe 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 maintenance schedule.
The following must be observed:
The air amplifiers may only be maintained and repaired by the
manufacturer's service team or by specially trained and instructed
specialized personnel.
All maintenance and repair work must be performed when the air amplifiers
are switched off and depressurized.
CAUTION
Before working on the air amplifiers, make sure that they are depressurized.
CAUTION
Adjustment and repair work may only be undertaken by specialist workshops!
Safety Instructions
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Air Amplifiers
2.3.4 Requirements on staff
Prior to commencing work, staff must be instructed in the hazards
connected with handling the air amplifiers.
The air amplifiers may pose injury hazards if operated by untrained
personnel.
Any person instructed to put into service, maintain or repair the air
amplifiers must have read and understood the assembly instructions in their
entirety.
The assembly instructions must be available to staff at all times. We
recommend that you obtain written confirmation from staff that they are
familiar with the contents of the assembly instructions
Staff must wear protective clothing as directed by the operating company.
All safety information 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, safeguards and signs in the danger zone.
− Behaviour and measures to be taken in the event of hazards.
2.4 Special Safety Instructions
2.4.1 Safety in the event of emissions
Depending on use, some noise build-up can be expected, due to the expanding
compressed air. Air escaping from the silencer may be soiled. Small ice crystals,
which may come loose and fly away, may also form on the silencer. Staff located in
the environment of operating air amplifiers must wear protective goggles and, where
applicable, hearing protection.
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