MAXIMATOR DLE Installation And Operating Manual

Compressed air driven gas booster

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Compressed air driven gas booster

DLE, 8DLE, 14DLE, MDLE, SDLE

Installation and operating manual

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Page 1 Compressed air driven gas booster DLE, 8DLE, 14DLE, MDLE, SDLE Installation and operating manual...
Page 2 Internet: www.maximator.de Warranty and liability: As a general rule, the “General Terms and Conditions” of Maximator GmbH shall apply. These terms and conditions are available at http://www.maximator.de. Warranty and liability claims shall not be accepted if they can be attributed to one or more of the causes mentioned in this manual or explicitly stipulated below: –...
Page 3: Table Of Contents
Contents Contents ..........General information .
Page 4 Contents ........Prerequisites for installation .
Page 5 Contents ........... . . Removal .
Page 6: General Information
General information Information regarding this manual Maximator gas boosters can be used for a variety of applications. They are used to deliver gases and compress them to high pressures. This manual applies to all gas boosters with the following options in the order code: DLE, 8DLE, 14DLE, MDLE, SDLE and a serial number above 20000001.
Page 7: Rating Plate
General information Rating plate The rating plate is located on the drive cylinder of the gas booster and contains the following information: Fig. 1-1 Gas booster rating plate Maximum permitted operating Serial number pressure Pressure ratio Compressed air driven gas boost- 10 EAC label 11 Manufacturer contact informa- Type (specifications from the or-...
Page 8: List Of Abbreviations And Formula Signs Used
General information WARNING This combination of symbol and signal word indicates a potentially hazardous sit- uation which - if not avoided - may lead to severe injuries or death. CAUTION This combination of symbol and signal word indicates a potentially hazardous sit- uation which - if not avoided - may lead to light or minor injuries.
Page 9: Qualification Of The Personnel
Tab. 1-2 Formula symbol Qualification of the personnel Qualified personnel is required to work on and with the Maximator gas booster safely and properly. Allowing unqualified personnel to work on the gas booster or enter the danger zone creates hazards which could lead to death, severe inju- ries and significant property damage.
Page 10 General information Qualifications Understands the general mode of operation Understands the detailed mode of operation Able to read and comprehend work-related documents Able to read and comprehend work-related drawings/plans/ documents Possesses comprehensive tech- nical expertise Familiar with the technical safety labels utilised Able to identify and adjust safe- ty features Able to identify the risks specif-...
Page 11: Safety And Protection Measures
Safety and protection measures Safety and protection measures The following sections stipulate the residual risks associated with the product, even when used as intended. In order to reduce the risk of personal injuries and material damage, and to prevent hazardous situations, you must observe the safety information listed in this section and the warnings in all other sections of this manual.
Page 12: Non Obvious Hazards
Safety and protection measures Leak point Leak type Leak source Bleed port HP side Minor leakage High pressure seal Bleed port drive Minor leakage Rod seal drive side Booster head / cylinder Unexpected Sealing on booster head and cylinder Connection screw fitting Unexpected Loose screw connection Connecting line drive / HP...
Page 13: Product Description
Product description Active leaks can lead to serious accidents resulting in death. Assess the risk for the equipment in the risk assessment. Product description Design and function Structure Fig. 3-1 Schematic circuit diagram of the double-acting gas booster Pilot valve lower cap Exhaust port Gas inlet (A) Drive air inlet (pL)
Page 14 Product description valves, the pilot valves (1; 10), which are operated mechanically by the air piston at its end positions. The pilot valves vent the operating area of the control slide valve. An equilibrium of forces on the drive and high pressure side is generated as soon as the stall pressure is reached.
Page 15 Product description The individual gas booster types are shown below: • Single-stage, single-acting with one drive part • Single-stage, single-acting with two drive parts • Single-stage, double-acting with one drive part • Single-stage, double-acting with two drive parts 0000000141 - 002 - EN...
Page 16 Product description • Single-stage, quadruple-acting with one drive part • Single-stage, quadruple-acting with two drive parts • Two-stage, double-acting with one drive part • Two-stage, double-acting with two drive parts • Two-stage, double-acting with three drive parts 0000000141 - 002 - EN...
Page 17: Intended Use
Product description Intended use Within their technical limits, gas boosters are used to deliver and compress suit- able types of gases. If the gas booster bears an ATEX label and comes with a declaration of conformi- ty, it is designated for use in corresponding potentially explosive areas. Foreseeable misuse The product may only be used in accordance with the indications in this manual.
Page 18: Technical Specifications
Product description Spool valve “V” ventilation port Ventilation and bleeding of the spool valve. The port must not be obstructed. Pilot valve “Y” exhaust port Bleeding of the spool valve actuator chamber. An air pulse escapes here after each stroke. The port must not be obstructed. This port can be used to connect a stroke counter.
Page 19 The materials used can be found on the enclosed general drawing. Certain gas booster designs can be suitable for other operating fluids. If you are unsure regarding the use of a special fluid, please don't hesitate to contact Maximator. 0000000141 - 002 - EN...
Page 20 Compressed flu- Formula Gas booster Special notes symbol types (gases) Compressed air all models max. 100 bar Compressed air DLE xxx-S max. 350 bar Compressed air upon request Sour/acid gas DLE xxx-HMR Argon all models Ethylene all models Ethane all models...
Page 21: Dimensions And Weight
Tab. 3-4 Drive fluid requirements Drive with compressed air Maximator gas boosters generally do not need a compressed air oiler as they are treated with special grease during installation. However, after the first time an oiler is used, the drive fluid should always be oiled. In case a compressed air oiler is used, the oil must comply with DIN 51524 - ISO VG 32 specifications.
Page 22: Performance Values
For more detailed information on the respective gas booster, including charac- teristic curve and connection diagram, please refer to the respective data sheet on the Maximator website at http://www.maximator.de. Permissible leakage rate The following leakage rate thresholds apply to the gas boosters in as-delivered condition.
Page 23: Service Life
Transport, packaging and storage Gas booster max. P Gas booster max. P DLE 2-5 0,8 x pL DLE 2-5-2 1,6 x pL DLE 5-15 1,6 x pL DLE 5-15-2 3,2 x pL DLE 5-30 0,5 x pL DLE 5-30-2 1 x pL...
Page 24: Storage
Installation Storage Note the following with regard to package storage: – Do not store the packages out of doors. – Keep the packages dry and dust-free. – Do not expose the packages to corrosive media. – Keep the packages protected from sunlight. –...
Page 25: Gas Booster Installation
Installation Gas booster installation WARNING Risk of injury posed by improper installation of the gas booster! Improper installation of the gas booster can lead to accidents resulting in severe injuries or death. ► Permissible pressures at the inlet and outlet of the gas booster must not ex- ceed the maximum permitted operating pressure of the gas booster.
Page 26: Connecting The Drive Air
Installation The gas booster is delivered without any connection screw fittings or connecting lines. For this purpose, observe the specifications in section “Connections” and on the general drawing. To prevent malfunctions, the cross-sections of the con- necting lines must be designed for the corresponding volume flows. A failure of the check valves may lead to accidents resulting in severe or fatal in- juries.
Page 27: Commissioning
Installation Commissioning 5.4.1 Prerequisites for commissioning WARNING Risk of injury posed by improper installation of the gas booster! Improper installation of the gas booster can lead to accidents resulting in severe injuries or death. ► Permissible pressures at the inlet and outlet of the gas booster must not ex- ceed the maximum permitted operating pressure of the gas booster.
Page 28: Commissioning
Installation Gas booster design Standstill pressure Single-stage, single-acting Single-stage, double-acting / quadru- = i * p ple-acting Two-stage Single-stage, single-acting with two drive parts Single-stage, double-acting / quadru- = i * p ple-acting with two drive units Two-stage with two / three drive units p Tab.
Page 29: Operation
Operation We recommend slowly increasing the pressure of the drive air to keep the stress on the gas booster components low during commissioning. The stroke frequency of the booster is kept low this way. Otherwise, during the ramp-up phase, until the required operating pressure is reached, operating phases with very high cycle frequencies can occur.
Page 30: Signs Indicating The Product Is No Longer Safe To Use
Operation Signs indicating the product is no longer safe to use The following signs indicate that the gas booster is no longer safe to use. In such cases, the gas booster must be put into a safe state immediately. – Leaking high pressure seal –...
Page 31: Maintenance
The individual maintenance ac- tivities are described in the following section. Maximator recommends the intervals listed below. These intervals are calculat- ed based on 1,300,000 strokes / year. The required maintenance intervals depend on the system and application. The intervals must be adjusted based on the given conditions of use.
Page 32: Maintenance Work
Risk of injury due to inappropriate spare parts! Making repairs using inappropriate spare parts can lead to accidents resulting in severe injuries or death. ► Only use spare parts that comply with Maximator specifications. WARNING Risk of sustaining injury posed while handling lubricants! Handling lubricants may lead to accidents resulting in severe or fatal injuries.
Page 33: System Inspection
Maintenance 7.2.1 System inspection The following section explains how to check the gas booster for proper function: Description Qualifications Operating the system Type of mainte- Check nance Interval weekly Shut off the gas outlet and adjust p to a value that is standard for the sys- tem.
Page 34: Check Screw Fittings And Connecting Lines For Damages
Maintenance 7.2.3 Check screw fittings and connecting lines for damages The following section explains how to inspect the screw fittings and connecting lines: Description Qualifications Operating the system Type of mainte- Check nance Interval weekly Prerequisites The gas booster is easy to access. Tools –...
Page 35: Check Fastening Elements And Connecting Elements
Maintenance Description Interval quarterly Prerequisites – The gas booster is easy to access. – The gas booster is depressurised. Tools – Cotton cleaning cloth – Solvent-free cleaning product WARNING Risk of injury due to static electricity Cleaning the gas booster may cause a charge to accumulate in non-conduc- tive layers.
Page 36: Leak Detection
Maintenance 7.2.6 Leak detection The following section explains how to inspect for leaks: Description Qualifications Repair and service gas booster Type of mainte- Check nance Interval semi-annually Prerequisites The gas booster is easy to access. Tools – Torch – Leak detection system –...
Page 37: Repair Gas Booster
7.2.6 - Leak test If the gas booster has passed all tests, the repair is complete. Maximator devices can be sent in for repairs to your local Maximator represen- tative. All the necessary details are available on the Maximator website http:// www.maximator.de...
Page 38: Spare Parts And Consumables
Making repairs using inappropriate spare parts can lead to accidents resulting in severe injuries or death. ► Only use spare parts that comply with Maximator specifications. A list of the available spare parts, spare part kits and consumables can be found on the general drawing.
Page 39: Troubleshooting
Troubleshooting Troubleshooting The following is a list of typical gas booster faults, their causes and the corre- sponding solutions. If you experience any other specific or unexpected faults, please notify us at ser- vice@maximator.de 0000000141 - 002 - EN...
Page 40: Drive Side
Troubleshooting Drive side Fault Cause of fault Solution – The gas booster does not Friction of the O-rings on Relubrication operate at low air pres- the spool valve is too – Replace the O-rings sure. high. on the spool valve. The gas booster does not O-rings will swell if the –...
Page 41: High Pressure Side
Troubleshooting High pressure side Fault Cause of fault Solution The gas booster operates The check valves fail. Check, clean the check without delivering the valves, and replace them gas, or it operates errati- if necessary. cally. It does not reach the calculated discharge pressure.
Page 42: Removal And Disposal
Removal and disposal Removal and disposal Prerequisites for removal and disposal Follow the manual and general drawing for the product. In addition, the following conditions must be met: The product must be in a safe state. Never use in a potentially explosive atmosphere. The product must be at ambient temperature.
Page 43: Disposal
► Dispose of operating fluid residues in an appropriate manner. ► Notify other people (for example: repair department) of hazardous operat- ing fluids. If the service life has expired: Send the product back to Maximator, postage paid, for proper disposal. 0000000141 - 002 - EN...
Page 44: Use In Explosion-Prone Zones
Use in explosion-prone zones Use in explosion-prone zones 10.1 General information Gas boosters bearing an ATEX label and delivered with a declaration of conformi- ty with 2014/34/EU are suitable for use in potentially explosive atmospheres. They conform with equipment group II, equipment category 2G, explosion group IIB or IIC, structural safety.
Page 45: Operation And Maintenance
Use in explosion-prone zones Max. temperature of operating flu- Temperature class 130°C 195°C 225°C Tab. 10-1 Temperature classes For the compression of ideal gases, the maximum expected temperature can be calculated using the formula for adiabatic status change: The isentropic exponent κ can be found in the corresponding tables for common gases.
Page 46: Operation With Combustible Operating Fluids
Use in explosion-prone zones 10.4 Operation with combustible operating fluids WARNING Risk of sustaining injury due to explosion! An ignitable gas mixture in the gas booster may cause explosions. This can lead to accidents resulting in severe injuries or death. ►...
Page 47 DLE 5-15 DLE 15-30-2 DLE 5-30 DLE 15-75-2 DLE 15-30 DLE 30-75-2 DLE 15-75 DLE 30-75-3 DLE 30-75 8 DLE 1,65 DLE 2-1-2 8 DLE 3 DLE 5-1-2 8 DLE 6 Tab. 10-2 Volume flows 0000000141 - 002 - EN...
Page 48: Alternative Purging Options For The Compression Of Combustible Gases
Z3 is subject to a change in volume per stroke during operation. The stroke volume of the leakage chamber is specified in the table below: Type* Leakage chamber stroke volume DLE 2-1 910 cm³ DLE 5-1 360 cm³ DLE 15-1 105 cm³...
Page 49: Summary Of Ignition Hazards
Summary of ignition hazards Summary of ignition hazards Ignition hazard Cause Protective measure implemented Source of ignition Hot surface Heating by the operating fluid Calculation formula and compression Temperature class definition Insulation prohibited Friction Friction in the drive unit Selection of materials and operating pa- rameters Definition of maintenance intervals Definition of the compressed air quality...
Page 50 Summary of ignition hazards Ignition hazard Cause Protective measure implemented Source of ignition Static Charging of non-conductive Design in accordance with layer thickness electricity layers specifications Static Charging due to powerful Exclusion of powerful charge generating electricity charge generating mecha- mechanisms nisms Adiabatic...
Page 51: Applications With Oxidising Operating Fluids
Applications with oxidising operating fluids Applications with oxidising operating fluids WARNING Risk of sustaining injuries due to fire or explosion! Self-ignition caused by oxygen may lead to accidents with serious or fatal injuries. ► Always observe all regulations and best practices regarding the handling of oxidising operating fluids, as well as the specifications and instructions in the manual.
Page 52 Applications with oxidising operating fluids Drive fluids for oxygen applications If oxygen or oxygen-containing gas mixtures are used as compressed fluid, the following specifications and instructions also apply to the drive fluid: – The drive air must be free of oil and grease. –...
Page 53: Appendix
Appendix Appendix The appendix comprises the following documents: – Gas booster EU Declaration of Conformity – Gas booster Declaration of Incorporation 0000000141 - 002 - EN...
Page 54 Appendix 0000000141 - 002 - EN...
Page 55 Appendix 0000000141 - 002 - EN...
Page 56 Appendix Appendix for the Declaration of Incorporation according to 2006/42/EC Appen- dix II, No. 1 B Description of the basic safety and occupational health and safety requirements according to 2006/42/EC Appendix I to be applied and observed. Basic requirement Applicable Met Comment General information 1.1.1...
Page 57 Appendix Basic requirement Applicable Met Comment 1.3.4 Risks posed by surfaces, edges and corners 1.3.5 Risks posed by multiple ma- chines combined 1.3.6 Risks posed by changed usage conditions 1.3.7 Risks posed by movable parts 1.3.8 Selection of protective equip- ment against risks posed by movable parts Protective equipment requirements...
Page 58 Appendix Basic requirement Applicable Met Comment 01/05/ Risk of being locked into the ma- 2014 chine 01/05/ Risk of slipping, tripping or fall- 2015 01/05/ Lightning strike 2016 Maintenance 1.6.1 Machine maintenance In context of the overall system 1.6.2 Access to the operator stations and access points for mainte- nance 1.6.3...
Page 60 Visit our website at: www.maximator.de 3999.4891 EN 0000000141 - 002 - EN...

This manual is also suitable for:

8dle 14dle Mdle Sdle