MAXIMATOR MPLV4 User manual

Air amplifier
MPLV4, MPLV7, SPLV3, SPLV10, GPLV5
Installation and operating manual

1 0000000455 - 001 - 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
30.08.2023 Translation
© Copyright 2023 Maximator GmbH - All rights reserved

Contents
0000000455 - 001 - 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Safety and protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Work and danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Non obvious hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5 Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.1 Start-up and shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.2 Unexpected restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.3 Risk of injury posed by noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.4 Risk of injury posed by raised particles or ice crystals. . . . . . . . . . . . . . . . . . . . . 12
2.5.5 Hazardous operating fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Design and function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.6 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6.1 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6.2 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.6.3 Performance values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.6.4 Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Transport, packaging and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Contents
3 0000000455 - 001 - EN
5 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 Prerequisites for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2 Air amplifier installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Installation of connecting lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3.1 Connecting the drive air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3.2 Control air connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3.3 Connecting the inlet line and outlet line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3.4 Connecting a separate bleed pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3.5 Exhaust silencer installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4.1 Prerequisites for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4.2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Prerequisites for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Normal, safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.3 Abnormal situations during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4 Signs indicating the product is no longer safe to use . . . . . . . . . . . . . . . . . . . . . 24
6.5 Put the air amplifier in a safe state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1 Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.2.1 System inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2.2 Leak-testing the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2.3 Inspect screws and connecting lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.2.4 Clean air amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.2.5 Check screw fittings on air amplifier and connection ports . . . . . . . . . . . . . . . . 30
7.2.6 Leak detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2.7 Repair air amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3 Spare parts and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.4 Accessories and special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.5 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.1 Drive side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.2 High pressure side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9 Removal and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Contents
0000000455 - 001 - EN 4
9.1 Prerequisites for removal and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10 Use in explosion-prone zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
10.2 Temperature class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
10.3 Operation and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
11 Summary of ignition hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

General information
5 0000000455 - 001 - EN
1 General information
1.1 Information regarding this manual
The pneumatically driven air amplifier manufactured by MAXIMATOR is a self-
controlling, oscillating pressure booster and is used for transporting and com-
pressing pressurised air and nitrogen.
These instructions are applicable for the air amplifier models MPLV4, MPLV7,
SPLV3, SPLV10 and GPLV5 (only referred to as “compressor” in other sections and
chapters) and with a serial number of greater than 23000001.
The general drawing supplied along the models is an integral component of these
instructions and must be kept in safe custody along with them.
1.2 Order code
The order code for the air amplifier is structured as follows:
a Model
for example: MPLV 4, GPLV 5...
b additional codes for device options and/or variants
for example: -NPT, -FEC

General information
0000000455 - 001 - 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 0000000455 - 001 - 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
0000000455 - 001 - EN 8
1.5 List of abbreviations and formula signs used
Tab. 1-1 List of abbreviations
Tab. 1-2 Formula symbol
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
V2 Air supply to back of piston
X Control air port
Y Pilot valve air supply
Formula sym-
bol
Description
i Gear ratio
κ Isentropic exponent
nsp Strokes under standstill pressure
pAPrimary pressure
pBOperating pressure
pLDrive pressure
TAInput temperature
TBOutput temperature
Vstroke Stroke volume
Vleak Leakage volume

General information
9 0000000455 - 001 - EN
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.

Safety and protection measures
0000000455 - 001 - EN 10
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.

Safety and protection measures
11 0000000455 - 001 - EN
During assessment, check the following leak points:
Tab. 2-2 leak point danger zone
The hazards are primarily due to the high pressure and extreme temperatures of
the conveyed fluid and/or the hazardous substances used.
The system designer must determine detailed danger zones as part of his job and
can use his special knowledge of high-pressure technology and the hazardous
substances used in each case.
leak point leak type leak source Comment
silencer normal operating
leakage
air drive compo-
nent
permanent leak of
operating fluids
bleed port minor leakage high-pressure
seal, piston seal
on drive side
only for SPLV 3/
SPLV 10 and GPLV
5
air supply port minor leakage high-pressure
seal, piston seal
on drive side
only for MPLV 4
and MPLV 7
bleed port unexpected faulty high-pres-
sure seal, piston
seal on drive side
only for SPLV 3/
SPLV 10 and GPLV
5
air supply port unexpected faulty high-pres-
sure seal, piston
seal on drive side
only for MPLV 4
and MPLV 7
High-pressure/
drive section
unexpected Defective high-
pressure / drive
section or seals on
these components
All equipment
screw fittings unexpected loose screw fit-
ting, faulty screw
fitting
All equipment
drive connection
lines
unexpected connection line,
fitting, O-ring
All equipment

Safety and protection measures
0000000455 - 001 - EN 12
2.4 Non obvious hazards
Using asphyxiant operating fluids can lead to severe injuries or death by asphyxi-
ation. Assess the risk for the equipment in the risk assessment. The following are
some potential corrective actions:
–Operate the compressor in an adequately ventilated space.
–Check the compressor for leaks on a regular basis.
–Ensure that lines are connected in such a way as to remain leak-tight for a
long time.
–If necessary, use connecting lines to remove the escaping operating fluids.
Assess the risk for the equipment in the risk assessment.
2.5 Residual risks
2.5.1 Start-up and shut down
There is no command device for safe shut-down (E-stop). This can lead to severe
injuries or death.
Assess the risk for the equipment in the risk assessment.
2.5.2 Unexpected restart
When restoring the pneumatic energy supply or in case of changes made to the
operating parameters, the compressor may start accidentally. This can lead to se-
vere injuries or death.
Assess the risk for the equipment in the risk assessment.
2.5.3 Risk of injury posed by noise
The noise level emitted in the work area depends on the mounting and applica-
tion.
Assess the risk for the equipment in the risk assessment.
2.5.4 Risk of injury posed by raised particles or ice crystals.
Escaping gas raises particles or ice crystals and can cause injuries to the eyes.
Assess the risk for the equipment in the risk assessment.
2.5.5 Hazardous operating fluids
Improper use of operating fluids can lead to serious accidents resulting in death.
Assess the risk for the equipment in the risk assessment.
Active leaks can lead to serious accidents resulting in death.
Assess the risk for the equipment in the risk assessment.

Product description
13 0000000455 - 001 - EN
3 Product description
3.1 Design and function
Structure
Tab. 3-1 Schematic diagram
Functional description
The operating principle of an air amplifier is similar to that of a pressure intensi-
fier. As shown in the schematic diagram, drive air inlet PL and gas inlet A on the
air amplifier are supplied by the same supply line. This requires that the device
have the same pressure and the same fluid on the drive side and the high pres-
sure side.
Schematic diagram without control air Schematic diagram with control air
1 Air piston
2 High-pressure piston
3 Pilot valve lower cap
4 Pilot valve top cap
5 Spool valve
A Gas inlet to the air amplifier
B Gas outlet from the air amplifier
PL Drive air inlet
E Exhaust port/silencer
V1 Spool valve air supply
V2 Back of piston air supply
Y Pilot valve air supply
X Pilot supply port

Product description
0000000455 - 001 - EN 14
Low pressure is applied to the large area of the air piston (1) which applies high-
pressure to the small area of the high-pressure piston (2). The piston of the air
amplifier performs reciprocating movements until the stall pressure is reached.
In so doing, the high pressure piston delivers and compresses the operating fluid
by means of the check valves in gas inlet A and gas outlet B. The output pressure
results from the set pressure in the supply line, which is applied to ports PL and A
and the fixed pressure ratio.
The continuous operation is achieved by means of an internally controlled direc-
tional valve, the spool valve (5). The spool valve alternately guides the operating
fluid to the two sides of the air piston. The spool valve is controlled by two direc-
tional valves, the pilot valves (3 and 4), which are operated mechanically by the
air piston in its stop positions. The pilot valves vent the operating area of the con-
trol slide valve.
An equilibrium of forces on the drive and high-pressure side is generated as soon
as the stall pressure is reached. The air amplifier stops and no longer consumes
drive fluid. If the pressure drops on the high pressure side or increases on the sup-
ply side, the air amplifier automatically restarts, while the operating fluid is com-
pressed until an equilibrium of forces is restored.
In air amplifiers equipped with a pilot air port X, the operating area of the spool
valve will only be supplied with air if air pressure is present on the pilot port. If no
pilot air pressure is present, the amplifier will not cycle.
The GPLV 5 is equipped with a double-acting high pressure unit and exerts com-
pression on both the forward and return stroke.
Air amplifiers types MPLV 2.5/MPLV 4/MPLV 7 operate without a pilot valve in the
lower cap (3). The return stroke is performed by the operating fluid entering the
high pressure unit. The pneumatic piston return chamber has a vent hole for this
purpose.
3.2 Intended use
Within their technical limits, air amplifiers are used to deliver and compress com-
pressed air and nitrogen. Other operating fluids must be released by specific
clearance issued by Maximator.
If the air amplifier bears an ATEX label and comes with a declaration of conformi-
ty, it is designated for use in corresponding potentially explosive areas.
3.3 Foreseeable misuse
The product may only be used in accordance with the indications in this manual.
The product cannot be used for:
–sealing containers

Product description
15 0000000455 - 001 - EN
3.4 Misuse
Unauthorised modifications or technical changes to the product may lead to ac-
cidents with serious or fatal injuries.
Never carry out unauthorised modifications or technical changes to the product!
3.5 Ports
Comply with the connected load specifications for all interface connections. Refer
to the enclosed general drawing for the connection ports available on the air am-
plifier.
The following interfaces are standard on the air amplifier:
Drive air inlet "PL"
Input of drive fluid.
Gas inlet "A"
Input of operating fluid.
Gas outlet "B"
Output of operating fluid.
Exhaust port "E"
Output of expanding drive fluid.
Pilot air port “X”
Port for pilot air. The air amplifier will only operate if the pilot air connection is
pressurised. The pressure of the pilot air must always be larger or equal to the
drive pressure to ensure flawless function. The pilot air is subject to the same flu-
id quality requirements as the drive fluid/operating fluid.
Spool valve air supply port "V1"
Spool valve air supply and ventilation. The port must not be obstructed.
Air supply port "V2" to back of piston
Air supply and ventilation of the piston return chamber of the pneumatic drive.
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.

Product description
0000000455 - 001 - EN 16
3.6 Technical specifications
3.6.1 Operating conditions
Ambiance
Tab. 3-2 Ambient conditions
Operating fluids
Tab. 3-3 Operating fluids
Specification Value Unit
Ambient temperature, min. - 20 °C
Ambient temperature, max. + 60 °C
Installation area protected against
climatic exposure
Specification Value Unit
Operating temperature, min.a
a. Depending on the design of the compressor. See enclosed general drawing.
-20 °C
Operating temperature, max.b
b. Depending on the design of the compressor. See enclosed general drawing.
+60 °C
Operating fluid Compressed air
or nitrogenc
c. Certain compressors may be suitable for other operating fluids. A specific clearance from
Maximator is necessary.
Max. number of particles of 0.1 - 0.5 µm size
(class 3)d
d. Specifications for purity classification in line with ISO 8573-1 “Compressed air - Part 1:
Contaminants and purity classes“
information not
available
units
Max. number of particles of 0.5 - 1.0 µm size
(class 3)e
e. Specifications for purity classification in line with ISO 8573-1 “Compressed air - Part 1:
Contaminants and purity classes“
90000 units
Max. number of particles of 1.0 - 5.0 µm size
(class 3)f
f. Specifications for purity classification in line with ISO 8573-1 “Compressed air - Part 1:
Contaminants and purity classes“
1000 units
Max. solids, particle concentration of parti-
cles (class 6)g
g. Specifications for purity classification in line with ISO 8573-1 “Compressed air - Part 1:
Contaminants and purity classes“
5 mg/m³
Particle size, max. 10 µm

Product description
17 0000000455 - 001 - EN
In case of applications with special specifications for the quality of the fluid that
go beyond what is usual in high-pressure system designs, the system manufactur-
er will have to determine whether the compressor is adequate for the applica-
tion. For example, these applications may include (but are not limited to) the
following:
–Compression of breathing air
–Handling of diving gases
–Compression of auxiliary fluids in food production
–Applications within the pharmaceutical industry without direct contact
Drive fluid (air quality according to ISO 8573-1)
Tab. 3-4 Requirements for drive fluids
Specification Value Unit
Drive pressure pL, min. 1 bar
Drive pressure pL, max. 10 bar
Drive fluida
a. Certain compressors may be suitable for other operating fluids. A specific clearance from
Maximator is necessary.
Compressed air
or nitrogen
Drive fluid temperature, min.b
b. Depending on the design of the compressor. See enclosed general drawing.
-20 °C
Operating fluid temperature, max.c
c. Depending on the design of the compressor. See enclosed general drawing.
+60 °C
Max. compressed air purity class of oil (Class
4)
5 mg/m³
Max. particle count at 0.1 - 0.5 µm size (Class
3)
information not
available
units
Max. particle count at 0.5 - 1.0 µm size (Class
3)
90000 units
Max. particle count at 1.0 - 5.0 µm size (Class
3)
1000 units
Max. solids, particle concentration (Class 6) 5 mg/m³
Max. pressure dew point for humidity (Class
4)
+3d
d. For fluid temperature of 20 °C; depending on the temperature of the operating fluid, dif-
ferent values may be required.
°C
Particle size, max. 10 µm

Product description
0000000455 - 001 - EN 18
Operation with compressed air
Maximator air amplifiers generally do not need a compressed air oiler as they are
treated with lubricant during installation. However, after the first time an oiler is
used, the drive fluid should always be oiled, since the oil washes the lubricant out.
In case a compressed air oiler is used, the oil must comply with DIN 51524 - ISO
VG 32 specifications.
If dry or very dry compressed air is used, a gas booster with FEC option is recom-
mended.
Operation with nitrogen
As standard, all Maximator air amplifiers can be operated with nitrogen. This is
equivalent to operation with dry or very dry compressed air.
Operation with different fluids and/or pressures
Consult with Maximator before operating the system with different fluids and/or
supply pressures in the drive unit and high pressure unit.
3.6.2 Dimensions and weight
The dimensions and weight of the air amplifier are indicated in the general draw-
ing.
3.6.3 Performance values
The performance values of the air amplifier can be found on the rating plate and
general drawing.
For more detailed information on the air amplifier, including characteristic curve,
please refer to the corresponding data sheet on the Maximator website at http:/
/www.maximator.de.
Permissible leakage rate
For compressors, assessing leakage through the HP seal and the check valves is a
complicated process. Refer to the "Maintenance" section for instructions on mea-
suring leakage and detecting wear.
Under the following assumptions, from the strokes at standstill pressure nsp it is
possible to roughly estimate the quantity of leakage:
–At standstill pressure and with gas outlet (B) blocked, the number of strokes
obtained nsp result solely from the leakage through the piston seal, check
valves and the rod seal.
–Leakage at standstill pressure and leakage in the operating point of the com-
pressor are comparable.
The leakage volume can be estimated as follows:
Vleak = Vstroke*pB*nsp

Product description
19 0000000455 - 001 - EN
MPLV4 / MPLV7 / SPLV3 / SPLV10 / GPLV5
Permissible number of strokes at standstill pressure at the time of delivery:
Tab. 3-5 Permissible number of strokes at standstill pressure at the time of delivery
Permissible number of strokes at standstill pressure at the time of delivery for
safe function:
Tab. 3-6 Permissible number of strokes at standstill pressure for safe function
Listing of stroke volumes of the air amplifiers:
Tab. 3-7 Listing of stroke volumes of the air amplifiers
3.6.4 Service life
The service life of the product depends on the conditions of use. The service life
should therefore be determined and defined by the user.
Criterion Limit value Unit
Strokes under standstill pressure nsp 1 -
Criterion Limit value Unit
Strokes under standstill pressure nsp 2 -
Type VStroke Unit
MPLV4 31 cm3
MPLV7 18 cm3
SPLV3 373 cm3
SPLV10 122 cm3
GPLV5 373 cm3