Festo DPA-***-10-***-CRVZS Series User manual

en Operating
instructions
8074546
2017-07a
[8074548]
Pressure booster combination
DPA-CRVZS

DPA-CRVZS
2Festo – DPA-CRVZS – 2017-07a
Original instructions
DPA-CRVZS-EN
Identification of hazards and instructions on how to prevent them:
Danger
Immediate dangers which can lead to death or serious injuries
Warning
Hazards that can cause death or serious injuries
Caution
Hazards that can cause minor injuries
Other symbols:
Note
Material damage or loss of function
Recommendations, tips, references to other documentation
Essential or useful accessories
Information on environmentally sound usage
Text designations:
 Activities that may be carried out in any order
1. Activities that should be carried out in the order stated
– General lists
èResult of an action/References to more detailed information

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English – Pressure booster combination DPA-CRVZS
Table of contents
1 About this document 5......................................................
2 Safety 5..................................................................
2.1 Safety instructions 5........................................................
2.2 Use for intended purpose 5...................................................
2.2.1 Areas of application 5...............................................
2.3 Foreseeable misuse 6.......................................................
2.4 Training of specialized personnel 6.............................................
3 Further information 6.......................................................
4 Service 6.................................................................
5 Product overview 6.........................................................
5.1 Function 6.................................................................
5.1.1 Operational principle 6..............................................
5.1.2 Switching function 6................................................
5.2 Design 7..................................................................
5.2.1 Product design 7...................................................
6 Transport 8...............................................................
7 Storage 8.................................................................
8 Mounting 9...............................................................
8.1 Preparation 9..............................................................
8.2 Mechanical installation 9.....................................................
8.2.1 Alignment 9.......................................................
8.2.2 Mounting 9.......................................................
8.3 Pneumatic installation 10.....................................................

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9 Commissioning 11...........................................................
9.1 Switching on 11.............................................................
9.2 Setting the outlet pressure 12..................................................
9.3 Switching off 13.............................................................
10 Maintenance and care 14.....................................................
10.1 Visual and audible check 14...................................................
10.2 Functional test 14...........................................................
10.3 Draining condensate 14.......................................................
11 Disassembly 15.............................................................
12 Fault clearance 15...........................................................
13 Technical data 16............................................................

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1 About this document
For all available product documentation èwww.festo.com/pk
The combination of DPA pressure booster and CRVZS air reservoir is designated as a product in these
operating instructions.
 Read the operating instructions carefully before starting all work on the product.
2 Safety
2.1 Safety instructions
 Take into consideration the legal regulations for the respective destination.
 Observe product labelling.
 Before working on the product, switch off the power supply and secure it against being switched on
again.
 Use the product only within the defined values (è 13 Technical data).
 Protect the product during operation from damaging influences.
Damaging influences include grinding dust, glowing chips or sparks.
2.2 Use for intended purpose
The DPA pressure booster has been designed for increasing the pressure in compressed air lines up to a
maximum outlet pressure of 16 bar.
The air reservoir CRVZS has been designed for saving air (fluid of group 2 as per EU Pressure Equipment
Directive).
2.2.1 Areas of application
– For increasing the pressure up to double the inlet pressure of 8 bar
– For the occasional extraction of compressed air
– Compensation of pressure fluctuations
– For the supply of quick-pulsing drives
– For the compensation of sudden air consumption

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2.3 Foreseeable misuse
– For the continuous extraction of compressed air
Note
Severe wear to seals and the drive piston.
 Avoid operation without pauses between cycles.
 Pressure booster combinations are no replacement for compressors.
2.4 Training of specialized personnel
Only qualified personnel may perform installation, commissioning, maintenance and disassembly of the
product. The specialized personnel must be familiar with the installation and operation of electrical and
pneumatic control systems.
3 Further information
Accessories èwww.festo.com/catalogue.
4 Service
Contact your regional Festo contact person if you have technical questions èwww.festo.com.
5 Product overview
The product is a combination of a DPA pressure booster and a CRVZS air reservoir. The air reservoir is
filled to network pressure continuously via a bypass with check valve. Two pressure gauges are there to
monitor supply and outlet pressure.
5.1 Function
A pneumatic valve conducts the inlet pressure, alternately into two compression chambers. The com
pression chambers generate an outlet pressure up to max. double the value of the inlet pressure. This
increased outlet pressure is stored in the CRVZS and is available for compressed air applications.
5.1.1 Operational principle
The air pressure is increased by a pressure ratio via a double piston.
5.1.2 Switching function
As soon as the inlet pressure is switched on at pneumatic connection P1, the DPA starts automatically.
When the set outlet pressure is reached, the pressure booster stops operating, but restarts automatic
ally as soon as the outlet pressure drops due to application operation.

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5.2 Design
5.2.1 Product design
1
2
3
6
7
8
9
4
5
aJ
aA
1CRVZS air reservoir
2CRVZS connecting tubing to DPA pres
sure booster (connection 2)
3DPA pressure booster
4Adapter plate with silencers
5Profile plate
6Pneumatic valve with manual override
7Pressure displays for ports P1 and P2
8Rotary knob on the pressure regulator for
port P2
9Pneumatic port P1 (inlet)
aJ Bypass
aA Pneumatic connection P2 (outlet) with coup
ling socket KD4
Fig. 1

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6 Transport
Warning
Loads which suddenly fall down may cause injury to people.
 Take the product's weight into account. Depending on the design, the DPA-CRVZS
weighs up to 30 kg.
 Do not use the rotary knob on the pressure regulator 8as a transport support.
The weight of the product may cause the rotary knob to detach from its support.
7 Storage
 Remove the packing with the exception of the adhesive labels on the supply ports (to prevent dirt
from entering).
The packaging is intended for recycling (exception: oil paper = residual waste).

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8 Mounting
8.1 Preparation
Before fitting:
 Remove the rubber buffers from the bottom of the profile plate.
 Switch off the complete system to depressurise it.
8.2 Mechanical installation
Note
The manufacturing process leaves a layer of oxide on the inside of the reservoir caps of
the air reservoir CRVZS.
 For sensitive applications, use suitable filters between the air reservoir CRVZS and
other downstream-switched pneumatic devices.
8.2.1 Alignment
 Ensure that the screwing points for the profile plate are on the same level.
With pressure booster combinations DPA-CRVZS5/10/20:
 Align the product so that the condensate drain faces downwards.
8.2.2 Mounting
 Secure product by the grooves in the profile plate on the system or on the machine frame.
Mounting attachments from the profile kit system 5 for machine stands
– Slot nuts IPM-VN-05-15/M5-ST
– Cover caps for profile plate IPM-AN-05-20X40-PA
This accessory can be obtained from Festo Sales, quoting Mechanical Components.
Additional accessories:
–M5 machine screws
– Strength: min. 8.8
–Screw length: Frame thickness + 6 mm screw-in depth
–Tightening torque: 5 Nm±10%

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8.3 Pneumatic installation
Note
High pressure differential between ports P1 and P2 causes high air consumption by the
product.
 Limit network pressure at port P1 to 8 bar without additional pressure regulators.
 Use short lines at port P1.
 Connect hoses and plug connections to pneumatic
ports P1 and P2.
 For port P2 use a KS4 coupling connector.
Exhausting is performed by the pressure regulator.
Fig. 2
P2
P1
– Controller failsafe LRVS-D-MINI, LRVS-D-MIDI
– Padlock LRVS-D
Accessories (èwww.festo.com/catalogue)
When using a pressure-buildup valve in the system
1. Connect a 3-way on/off valve HE-…-D or HEE-…-D at
the inlet side before portP1 between pressure
buildup valve and pressure booster.
2. Connect a 3-way on/off valve HE-…-D or HEE-…-D at
the outlet side after portP2.
Exhausting is performed by the pressure regulator.
Fig. 3
P2
P1
With pressure booster combinations
DPA-…-CRVZS10/20:
1. Connect a 3-way HE-…-D or HEE-…-D on/off valve at
the inlet side before port P1.
2. Connect a 3-way on/off valve HE-…-D or HEE-…-D at
the outlet side after portP2.
3. Connect a third 3-way HE-…-D or HEE-…-D on/off
valve between the DPA pressure booster and the
CRVZS air reservoir.
This enables larger reservoir volumes to be ex
hausted more rapidly.
Fig. 4
P2
P1

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9 Commissioning
Warning
The sudden escape of compressed air can cause injury to human beings.
 Make sure that the connections P1 and P2 are connected.
Note
High pressure forces can damage equipment switched downstream.
 Only use fittings designed for the maximum achievable outlet pressure of 16 bar.
Vibrations can cause signs of fatigue in materials and can reduce the endurance
strength of DPA-CRVZS pressure booster combinations and mounting components.
 Protect the device against mechanical vibrations.
Coupling and uncoupling of compressed air outlet
 Connect hose KS4 to port P2. (accessoriesèwww.festo.com/catalogue)
 Set outlet pressure to max. 10 bar to reduce the amount of force required.
Warning
Pressurized compressed air lines can cause whipping effects. Metal screw connectors
at the ends of tubing can therefore cause serious injury.
 Grip the hose when unfastening the hose sleeve.
9.1 Switching on
When using the product without 3-way on/off valves (èFig. 2):
 Apply compressed air to port P1.
When using the product with 3-way on/off valves (èFig. 3, Fig. 4):
1. To fill the CRVZS air reservoir, open the 3-way on/off valve between the DPA pressure booster and
the CRVZS air reservoir (èFig. 4) and leave open at all times during operation.
2. Open the 3-way on/off valve at port P1 (inlet).
3. Open the 3-way on/off valve at port P2 (outlet).

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9.2 Setting the outlet pressure
The rotary knob on the pressure regulator is used for setting (è Fig. 18).
Regulator lock (only DPA-63-10-… and DPA-100-10-…)
– Pushing: Rotary knob locked
– Pulling: Rotary knob unlocked
1. Unlock the rotary knob (only DPA-63-10-… and DPA-100-10-…).
2. Turn the rotary knob clockwise as far as stop (delivery condition).
3. Apply inlet pressure to port P1.
Note
Do not exceed the maximum permitted pressure.
 Use to check the pressure gauges:
– inlet pressure at port P1: max. 8 bar
– differential pressure between ports P1 and P2: min. 2 bar
4. Turn the rotary knob clockwise until the desired outlet pressure is reached.
– Pressure display for port P1: inlet pressure
– Pressure display for port P2: outlet pressure
5. Lock the rotary knob (only DPA-63-10-… and DPA-100-10-…).
Settings on the pressure regulator 8DPA-…-10-…-CRVZS-… DPA-…-16-…-CRVZS-…
The outlet pressure setting is less than
the inlet pressure.
The pressure regulator on the DPA relieves pressure until
pressure levels are in balance. The CRVZS is emptied.
The outlet pressure setting is at least
2 bar greater than the inlet pressure.
Normal operating status. The outlet pressure is reached.
The DPA also switches at low air consumption.
Increasing the outlet pressure. Increasing the air consumption
outlet pressure P2 Max. 10 bar1) max. 16 bar
1) The max. outlet pressure can be exceeded by up to 40 % (14 bar).
Tab. 1 Setting on the pressure regulator

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9.3 Switching off
When using the product without 3-way on/off valves (èFig. 2):
1. Switch off pressure to the pneumatic system.
2. Turn the rotary knob clockwise as far as stop.
Exhausting is performed by the pressure regulator.
When using the product with 3-way on/off valves before port P1 and after port P2 (èFig. 3, Fig. 4):
1. Close the 3-way on/off valve at port P1 (inlet).
2. Close the 3-way on/off valve at port P2 (outlet).
The pressure booster is exhausted by port 3 on the two 3-way on/off valves.
The air reservoir must be exhausted separately by the pressure regulator (èrotary knob 8).
Exhausting the air reservoir faster
 Close the on/off valve between the DPA pressure booster and the CRVZS air reservoir (èFig. 4).
This contains the air in the high-pressure chamber of the pressure booster. The rotary knob remains in
the set position.
Reducing outflow noise
 Use a silencer on port 3 of the 3-way on/off valves.

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10 Maintenance and care
10.1 Visual and audible check
 Once a year, conduct a visual and audio inspection.
In the event of damage or leakage:
 Replace the product.
10.2 Functional test
1. Fill the air reservoir up to maximum pressure (10 or 16 bar).
The pressure booster must switch off automatically.
2. Exhaust the air reservoir.
The pressure booster must start again automatically until the set outlet pressure is reached.
If the pressure booster runs continuously with outlet P2 closed:
1. Carry out a leakage check.
2. Tighten loose screw connectors.
If there is internal leakage:
 Replace the device.
10.3 Draining condensate
 Drain the condensate from the air reservoir.
For DPA-CRVZS2:
1. Switch off the product.
2. Disconnect the hose from port P2.
3. Attach a KS4 coupling connector to the coupling socket at port P2.
4. Set the product at an oblique angle.
For DPA-CRVZS5/10/20:
1. Switch off the pressure booster combination.
2. Open the condensate drain (waf 8) on the air reservoir (è9.3).

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11 Disassembly
For DPA-CRVZS10/20:
1. Close the 3-way on/off valve at port P2 (outlet).
2. Close the 3-way on/off valve at port P1 (inlet).
3. Close the 3-way on/off valve between the DPA pressure booster and the CRVZS air reservoir
(èFig. 4).
4. Turn the rotary knob clockwise as far as stop.
5. Depressurise the system. Pay attention to the pressure gauges on ports P1 and P2.
6. Disconnect all pneumatic ports.
12 Fault clearance
Malfunction Possible cause Remedy
The desired outlet pressure is
not reached.
Inlet pressure too low.  Increase inlet pressure to
max. 8 bar.
Too many consumers at the
outlet.
 Reduce the number of con
sumers.
Flow rate too low. Volumetric flow rate at com
pressed air inlet too low.
 Use larger compressor.
 Use short tubing
Pressure booster does not start. Fault during start-up or valve in
centre position.
 Press manual override on
pneumatic valve.
Exhaust bores or sinter filter
blocked.
 Keep exhaust bores or sinter
filter unblocked.
External damage after visual
inspection.
Improper mounting or handling.  Replace the product.
Audible leakage Gaskets, hoses, valves or coup
ling socket defective.
 Replace defective connector.
 Replace the product.
Corrosion Aggressive ambient conditions  Replace the product.
Tab. 2

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13 Technical data
Size DPA-40 DPA-63 DPA-100
P2 max. [bar] -10 -16 -10 -16 -10 -16 -10 -16 -10 -16
Volume [l] 225510 10 20 20 20 20
Inlet pressure at port P1
Min. [bar] 2.5 2
Max. [bar] 8
Jutlet pressure at port P2
Min. [bar] 4.5 4
Max. [bar] 101) 162) 101) 162) 101) 162) 101) 162) 101) 162)
Operating medium Compressed air acc. to ISO 8573-1:2010 [7:3:4]
Notice: Oiled operation not permitted
Assembly position Any Condensate drain below air reservoir
Condensate drain
Max. tighten
ing torque
[Nm] – 27 (Qy)
Ambient
temperature
[°C] +5 … +60
Pneumatic port
P1 QS-10 QS-12 QS-16
P2 KD4
P3 Pneumatic silencers
CE mark èConformity
declaration
èwww.festo.com/sp
–In accordance with EU Pressure Equipment Directive
Classification into
categories
Good
engineering
practice
III
Air reservoir material: High-alloy stainless steel
Weight [kg] 4.4 7.3 16.0 21.5 30.0
1) Due to production-related variation in regulator springs, up to 14 bar can be reached.
2) Max. 15.5 bar can be reached through air consumption.
Tab. 3

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tion of its contents to others without express authorization is
prohibited. Offenders will be liable for damages. All rights re
served in the event that a patent, utility model or design patent is
registered.
Copyright:
Festo AG & Co. KG
Ruiter Straße 82
73734 Esslingen
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Internet:
www.festo.com