MAXIMATOR MPLV2 User manual

Air Amplifier
MPLV2, SPLV2, GPLV2
Installation and operating manual

1 0000000432 - 002 - EN
Key information!
Follow the manual for safe and proper use.
Keep the manual near the machine for later reference.
MAXIMATOR GmbH
Lange Straße 6
99734 Nordhausen
Germany
Phone: [phone]
e-mail: [e-mail]
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:
–Any use other than the intended use indicated in this manual
–Improper commissioning, operation or maintenance
–Operation with faulty safety equipment or incorrectly installed safety equipment and safe-
guards
–Failure to observe the commissioning, operation and maintenance instructions in this man-
ual
–Insufficient monitoring of wear parts
–Wear on seals, guiding elements, etc. due to ageing and operation
25/05/2023 Translation
© Copyright 2023 Maximator GmbH - All rights reserved

Contents
0000000432 - 002 - EN 2
Contents
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Information regarding this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Order code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Rating plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 List of abbreviations and formula signs used . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6 Qualification of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Safety and protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Work and danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Non obvious hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.1 Start-up and shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.2 Unexpected restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.3 Risk of injury posed by noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.4 Risk of injury posed by raised particles or ice crystals. . . . . . . . . . . . . . . . . . . . . 11
2.5.5 Hazardous operating fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Design and function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.4 Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.5 Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.6 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.1 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.6.2 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6.3 Performance values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6.4 Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Transport, packaging and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.1 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.2 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Contents
3 0000000432 - 002 - EN
5 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Prerequisites for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Air amplifier installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.3 Installation of connecting lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.1 Connecting the drive air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.2 Control air connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.3 Connecting the inlet line and outlet line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3.4 Exhaust silencer installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4.1 Prerequisites for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.4.2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.1 Prerequisites for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2 Normal, safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.3 Abnormal situations during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.4 Signs indicating the product is no longer safe to use . . . . . . . . . . . . . . . . . . . . . 22
6.5 Put the air amplifier in a safe state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1 Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.2.1 System inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2.2 Leak-testing the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2.3 Inspect screws and connecting lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2.4 Clean air amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.5 Check fastening elements and connecting elements . . . . . . . . . . . . . . . . . . . . . 27
7.2.6 Leak detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2.7 Repair air amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.3 Spare parts and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.4 Accessories and special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.5 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.1 Drive side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8.2 High pressure side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9 Removal and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.1 Prerequisites for removal and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Contents
0000000432 - 002 - EN 4
9.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10 Use in explosion-prone zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10.2 Temperature class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.3 Operation and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
11 Summary of ignition hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

General information
5 0000000432 - 002 - EN
1 General information
1.1 Information regarding this manual
The pneumatically driven air amplifier from MAXIMATOR is a self-reversing, oscil-
lating pressure intensifier and is used to deliver and compress air and nitrogen
without the use of oil. The drive fluid and compressed fluid are fed from the same
supply line and are therefore identical in terms of pressure and fluid.
These instructions apply to air amplifier models MPLV2/SPLV2/GPLV2 (in the sec-
tions below referred to as “compressor“) and with a serial number of above
23000001.
The provided general drawing is an integral part of these instructions and thus
must be stored together.
1.2 Order code
The order code for the compressor is structured as follows:
a Model
for example: MPLV 2
b additional codes for device options and/or variants
for example: -NPT, -FEC

General information
0000000432 - 002 - EN 6
1.3 Rating plate
The rating plate is located on the pneumatic cylinder of the compressor and con-
tains the following information:1:
1Individual compressors may have different rating plates, e.g. metal ones
1 Max. permitted operating pres-
sure
2 Air amplifier
3 Type (specifications from the or-
der code)
4 Maximum drive pressure
5 Minimum inlet pressure
6 Calendar week/year of manufac-
ture
7 Article number
8 Serial number
9 Gear ratio
10 Manufacturer contact informa-
tion
11 Label according to applied guide-
lines
12 Operating temperature range

General information
7 0000000432 - 002 - EN
1.4 Explanation of symbols
DANGER
This combination of symbol and signal word indicates a hazardous situation
which - if not avoided - may lead to severe injuries or death.
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.
NOTICE
This combination of symbol and signal word indicates a potentially hazardous sit-
uation which - if not avoided - may lead to property damage or damage to the en-
vironment.
WARNING
This combination of symbol and signal word characterises contents and instruc-
tions for the intended use in potentially explosive areas. If failing to comply with
instructions marked as such, an increased risk of explosion will be posed and may
result in severe or fatal injuries.

General information
0000000432 - 002 - EN 8
1.5 List of abbreviations and formula signs used
Tab. 1-1 List of abbreviations
Tab. 1-2 Formula symbol
1.6 Qualification of the personnel
Only qualified personnel who are specialised and have been trained to do so must
work on the air amplifier. Allowing unqualified personnel to work on the com-
pressor or enter the danger zone creates hazards which could lead to death, se-
vere injuries and significant property damage.
Abbreviation Description
A Gas inlet
Fig. Figure
ATEX EU explosion prevention directive
B Gas outlet
E Exhaust port
CET Central European Time
PLDrive air inlet
PPE Personal protective equipment
Tab. Table
V1 Spool valve air supply
X Control air port
Y Pilot valve air supply
Formula sym-
bol
Description
pBOperating pressure
pLDrive pressure
i Gear ratio
nsp Strokes under standstill pressure
Vleak Leakage volume
Vstroke Stroke volume

Safety and protection measures
9 0000000432 - 002 - EN
2 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.
2.1 Personal protective equipment
Personal protective equipment (in other sections also referred to as PPE) protects
personnel from occupational safety and health hazards while at work.
Wearing personal protective equipment may be required during work on the
product. Wherever possible, this personal protective equipment is listed in these
instructions for the individual work steps.
However, detailed specifications of the required protective equipment can only
be determined with full knowledge of the system. The required personal protec-
tive equipment should therefore be determined by the user.
2.2 Signs and labels
The following signs are found on the product.
Over time, labels can become unrecognisable due to dirt or other causes. As a re-
sult, hazards cannot be identified, or necessary operating indications cannot be
followed. Resulting errors can lead to severe injuries or death.
Keep the labels in good, legible condition and replace any damaged labels.
Tab. 2-1 Overview of labels
2.3 Work and danger zone
The danger zone comprises the entire area surrounding the product. The hazards
associated with the product and the danger zone depend on the application and
the installation location. The danger zone should therefore be determined by the
user.
Signs and labels Graphic display
Rating plate:
The rating plate is affixed to
the pneumatic cylinder of
the air amplifier. The rating
plate indicates the operat-
ing characteristics of the air
amplifier.