Festo DPA-***-A Series User manual

(en) Operating
instructions
Pressure booster
DPA
8080164
2017-07e
[8080166]

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Translation of the original instructions
Symbols: Installation and commissioning may only be per
formed in accordance with these instructions by
technicians with appropriate qualifications.
Warning
Caution
Note
Environment
Accessories
English 3.........................................................................

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Pressure booster DPAEnglish
Documentation on the product
For all available product documentation èwww.festo.com/pk
1 Operating elements and ports
DPA-40 DPA-63/100
1
2
3
4
5
6
7
4
1
3
2
6
5
7
8
8
1Pneumatic connection 1 for input pressure
2Pneumatic connection 2 for output pressure
3Pneumatic connection 3 for exhaust air
4Rotary knob for output pressure (not DPA-…-D)
5Manual override
6Exhaust hole; sealed with sintered filter
7Valve exhaust port (on the right and left of
the valve sub-base); DPA-40 with silencers in
scope of delivery
8Threaded holes for fastening
Fig. 1

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2 Function and application
The type DPA pressure booster has been designed for increasing the pressure in
air supply lines. Due to its two coupled pressure chambers, the DPA functions as
a double piston compressor. No external energy other than compressed air is re
quired to operate the DPA. Once the input pressure has been applied, the DPA
starts up automatically. An integrated way valve conducts the pressure, which is
applied constantly at pneumatic connection 1, alternately into one compression
chamber then into the other. These generate an output pressure of up to double
the value of the input pressure. On pressure boosters with a controller, the pres
sure increase can be reduced by setting the rotary knob. When the set output pres
sure is reached, the DPA stops operating to save energy but restarts automatically
if the pressure drops due to application operation.
With the DPA-…-A it is possible to record the individual strokes of the drive piston
using an external sensor and an adding counter.
Note
Pressure boosters are intended to occasionally relieve compressed air. Pressure
boosters are not suitable for use as compressor replacements, as wear on seals
and drive pistons increases significantly during continuous operation without
breaks.
3 Conditions of use
Note
Incorrect handling can result in malfunctioning.
SMake sure that the following specifications are always observed:
SCompare the maximum values specified in these operating instructions with
your actual application (e.g. operating media, pressures, forces, temperatures,
masses, flow rates).
SEnsure that there is a supply of correctly prepared compressed air.
STake into consideration the ambient conditions at the location of use.
SPlease comply with national and local safety laws and regulations (e.g. Safety
regulations as per EN 1012, part 1).

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SUse a three-way on-off valve on the input side of the DPA.
SUse a three-way on-off valve on the output side of the DPA.
In this way, the downstream switched system can be exhausted quickly.
SRemove the packing with the exception of the self-adhesive labels on the
compressed air connections (to prevent dirt from entering).
It is intended that the packaging be recycled on the basis of its constituent
materials (exception: oiled paper = other waste).
SPlease observe the warnings and instructions
– on the product and
– in these operating instructions.
SUse the product in its original state. Unauthorised modification is not
permitted.
4 Transport and storage
Warning
Falling loads may cause personal injuries.
STake the weight of the DPA into consideration. Depending on the version,
the DPA can weigh up to 13 kg.
The rotary knob must not be used as a support for transporting the DPA
because the large load may dislodge the rotary knob.

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5 Installation
Mechanical
Note
The DPA must not be installed on the controller thread because the controller
thread may be destroyed under the load of the DPA.
Fasten the DPA in one of the following ways only:
Type Fastening method1) Fastening
DPA-40 Direct fastening – with 4 screws (M4) in
the threaded holes of the
DPA. Tightening torque
2 Nm.
With FDPA-40
flange mounting
accessory
– Flange with 4 screws
(M4) in the threaded
holes of the DPA.
Tightening torque 2 Nm.
– Fit the flange to the wall
with 2 screws (M5).
DPA-63/100 Direct fastening – With 4 screws (M10) in
the threaded holes of
the DPA. Tightening
torque 30 Nm.
With HUA foot
mounting acces
sory (2x)
– Foot mounting, with two
screws each in the
threaded holes of the
DPA on the right and left.
Tightening torque 30 Nm.
1)The exhaust hole and both valve exhaust ports (6/7èFig. 1) must not be sealed.

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Fitting the proximity sensors for sensing option (DPA-…-A only) èFig. 2
SFasten the proximity sensor1in one
of the 6 available sensor grooves on
the right-hand side of the DPA (rotary
knob top, pneumatic ports front). The
proximity sensor must be positioned
in the middle of the cylinder barrel.
SConnect the proximity sensors to the
adding counter.
Note
The proximity sensor records each individual stroke of the drive piston. In order
to arrive at the usual count of double strokes, the number of individual strokes
has to be halved.
Information of the proximity sensor and the adding counter can be found in the
operating instructions for these products.
Pneumatic connection for input pressure, output pressure, exhaust air
Note
Incorrectly dimensioned cable cross-sections can impair the timing behaviour of
downstream switched components.
SUse hoses with a minimum inner diameter or the hose types recommended in
Fig. 3 for the input and output pressure.
SUse a silencer for the exhaust air. If the exhaust air is to be ducted, it must be
vented relative to atmosphere.
The exhaust air from both valve exhaust ports (7èFig. 1) must not be
ducted.
SCheck whether an air reservoir is required. In this way you will avoid pressure
fluctuations.
Fig. 2
1

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SConnect the tubing to the supply ports as per Fig. 3.
With an output pressure greater than 10 bar, make sure that the permitted
limits for the connecting elements used at output 2are observed (if
necessary connect the tubing to the DPA).
DPA-40 DPA-63/100
1
2
1
2
3
3
Fig. 3
Type DPA-40 DPA-63 DPA-100
Connection number 1Pneumatic connection 1 for input pressure
2Pneumatic connection 2 for output pressure
3Pneumatic connection 3 for exhaust air
Pneumatic connection 1/2G¼GyG½
3M7 GyG½
Tightening torque 1/215 Nm 25 Nm 40 Nm
32 Nm 25 Nm 40 Nm
Inner hose diameter/
recommended hose
type
17 mm/
PAN-10x1.5
12 mm/
PAN-16x2
12 mm/
PAN-16x2
25 mm/
PAN-R-8x1.25
10 mm/
PAN-R-16x3
10 mm/
PAN-R-16x3

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Pneumatic connection for pressure gauges èFig. 4
1. Remove the screws plugs from the pressure gauge ports 4.
2. DPA-40 only:
Seal off the pressure gauges with PTFE tape.
The pressure gauges for the DPA-63/100 have a PTFE coating. It is not necessary
to seal them with PTFE tape.
3. Firmly screw the pressure gauges into the ports 4clockwise by hand. Pressure
gauge (A) shows the input pressure, pressure gauge (B) shows the output pres
sure.
Use pressure gauges with a sufficient dial to show the input and output pressure
(è10 Technical data). To show the output pressure, a pressure gauge with a
larger final value on the dial is required.
Exception: The DPA-…-10-MA-SET pressure gauge set (è8 Accessories) contains
two identical pressure gauges with a sufficient dial for the DPA-…-10.
DPA-40-10/16/D DPA-63/100-10/16
44
DPA-63-D DPA-100-D
44
(A)
(A)
(A)
(A)
(B)
(B)
(B)
(B)
Fig. 4
4. Align the pressure gauge with the spanner by screwing it in further by a maximum
of 1.5 turns.

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6 Commissioning
Warning
Sudden expulsion of compressed air can cause injuries.
SMake sure that the compressed air outputs of the DPA for output air 2and
exhaust air 3are connected (èFig. 3).
Note
High compressed air forces can damage equipment further along the com
pressed air path.
SMake sure that equipment connected downstream of the DPA is designed
to withstand the maximum output pressure which can be achieved.
Note
The three-way on-off valve on the input side of the DPA must not be opened
until the pressure in the system has been built up.
First open the three-way valve on the input side, then the three-way on-off valve
on the output side.
Note
The output pressure on pressure boosters without a controller is twice the
input pressure.

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Consider the following correlations:
Setting Reaction
The set output pressure is lower than the
input pressure
The pressure controller on the DPA
vents until the pressures are equal
The input pressure is always 2 bar lower than
the set output pressure
The DPA reaches the set output
pressure
Increase the output pressure Increase of air consumption
Air volume/current on the input side is too low Output pressure fluctuates
Maximum controller setting
DPA-…-10: typ. 10 bar, max. 14 bar
DPA-…-16: typ. 16 bar, max. 22 bar
The max. output pressure can be
exceeded by up to 40 %
(product-dependent scatter of the
regulator springs)
Setting the output pressure:
Note
Pressure gauges are strongly recommended for checking pressure levels.
1. DPA-63/100-10 only:
Pull the rotary knob away from the housing.
2. Turn the adjusting knob (4èFig. 1) clockwise as far as it will go (status as at
delivery).
3. Apply the input pressure to pneumatic port 1 on the DPA.
4. Turn the rotary knob (4èFig. 1) clockwise until the desired output pressure
is shown on the pressure gauge.
The pressure statuses are monitored by pressure gauges (èFig. 4):
– Pressure gauge (A): input pressure
– Pressure gauge (B): output pressure
5. DPA-63/100-10 only:
Press the rotary knob towards the housing to lock it.

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7 Removal
1. Switch off the compressed air. The system must be fully depressurised.
2. First close the on-off valve on the output side of the DPA, then the on-off
valve on the input side of the DPA.
3. Then turn the rotary knob anti-clockwise as far as it will go.
4. Disconnect the pneumatic ports of the DPA.
8 Accessories
Designation for Type
Flange mounting DPA-40 FDPA-40
Foot mounting DPA-63 HUA-63
DPA-100 HUA-100
Pressure gauge set DPA-40-10 DPA-40-10-MA-SET
DPA-40-16/DPA-40-D DPA-40-16-MA-SET
DPA-63-10 DPA-63-10-MA-SET
DPA-63-16 DPA-63-16-MA-SET
DPA-100-10 DPA-100-10-MA-SET
DPA-100-16 DPA-100-16-MA-SET
Pressure gauges DPA-63-D/DPA-100-D MA-40-16-x-EN for input pressure,
MA-40-25-x-EN for output pressure

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9 Troubleshooting
Malfunction Possible cause Remedial action
Output pressure
fluctuates too
much
Air consumption of downstream
equipment too high
Use air reservoir
The desired
output pressure
is not reached
– Input pressure too low
– Too many consuming devices
at the Output
Increase the input pressure
Flow too low Silencer, tubing or screw
connectors with insufficient
flow used
Use only components of suffi
cient sizes
Insufficient air volume at
compressed air input
Increase volume at compressed
air input (e. g. with large com
pressed air reservoir)
Pressure booster
does not start
Fault in commissioning/unfa
vourable Operating conditions
(valve in mid-position)
Briefly exhaust the switching
valve by pressing the manual
override 5(èFig. 1)

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10 Technical data
Type DPA-40 DPA-63 DPA-100
-10 -16 -D -10 -16 -D -10 -16 -D
Input pressure [bar] 2.5 …
8
2.5 …
10
2.5 …
8
2 …
8
2 …
10
2 …
8
2 …
8
2 …
10
2 …
8
Output
pressure1)
[bar] 4.5 …
10
4.5 …
16
5 …
16
4 …
10
4 …
16
4 …
16
4 …
10
4 …
16
4 …
16
Operating medium Filtered compressed air, non-lubricated, grade of filtration
40 μm
Installation position as desired
Ambient
temperature
[°C] +5 … +60
Weight [kg] 1.5 6.0 13.0
1) If the regulator spring is at maximum tension (rotary knob turned all the way clock
wise), the maximum output pressure can be exceeded by 40 %:
– Max. 14 bar on DPA-…-10
– Max. 22 bar on DPA-…-16

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tion of its contents to others without express authorization is
prohibited. Offenders will be liable for damages. All rights re
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Copyright:
Festo AG & Co. KG
Ruiter Straße 82
73734 Esslingen
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Internet:
www.festo.com