LAEPPLE FIBRO 2480.00.32.71 User manual

WE LOVE TECHNOLOGY
MEMBER OF THE LAEPPLE GROUP
INSTRUCTIONS MANUAL
NITROGEN COMPACT BOOSTER
2480.00.32.71
Instructions manual Nitrogen Compact Booster

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: [phone]
Fax: [phone]
E-mail: [email protected]
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.

Instructions manual Nitrogen Compact Booster 3/38
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

4/38 Instructions manual Nitrogen Compact Booster
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

Instructions manual Nitrogen Compact Booster 5/38
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 ma-
chine" 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.

6/38 Instructions manual Nitrogen Compact Booster
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)
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 ma-
chine.
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 doc-
uments are necessary.
The information in these documents have to be adhered to.
• EU declaration of conformity as per directive 2006/42/EG
• Pneumatic plan
Manufacturer FIBRO GMBH
August-Läpple-Weg
DE 74855 Hassmersheim

Instructions manual Nitrogen Compact Booster 7/38
Introduction
1.6 Set-up
The illustration shows a schematic diagram of the principal set-up of the machine
The machine consists of:
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.
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)
a Filling and control fitting Order number 2480.00.32.21
bFilling adapter M6 Order number 2480.00.32.10
Filling adapter G1/8" Order number 2480.00.32.11
c Filling hose Order number 2480.00.31.02
3
1
2
4
5
6
A
B

8/38 Instructions manual Nitrogen Compact Booster
Introduction
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.
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.
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
c
a
b
e d
f

Instructions manual Nitrogen Compact Booster 9/38
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 re-
maining 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 avail-
able at the outlet of the gas spring.
If using a bottle pressure regulator between nitrogen outlet and filling hose a maximum permis-
sible 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)

10/38 Instructions manual Nitrogen Compact Booster
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, under-
stand 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 instruc-
tions 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 appli-
cation tip.
1.9.2 Figures
The figures in these instructions are examples. Deviations between a figure and the actual con-
ditions on the machine are possible.
The drawings of FIBRO GMBH and the information on third-party products are decisive.