MAXIMATOR SPLV2 Setup guide

Operating, maintenance and repair
instructions for
MAXIMATOR®
Air Amplifier
SPLV2
MAXIMATOR GmbH
Walkenrieder Straße 15
37449 Zorge
Phone: [phone]
Fax: [phone] E-Mail: [email protected]
Homepage: www.maximator.de

Index
1. Function principle of SPLV2................................................................................ 3
2. Technical data..................................................................................................... 4
3. Performance graph.............................................................................................. 4
4. Dimension and Connection Drawing ................................................................... 5
5. Safety.................................................................................................................. 6
5.1 Pneumatic amplifier...................................................................................... 6
5.2 Pneumatic amplifier stations ........................................................................ 6
6. Installation / Operation......................................................................................... 6
6.1 Pneumatic amplifiers.................................................................................... 7
7. Maintenance........................................................................................................ 7
8. Maintenance tips ................................................................................................. 8
9. Compressed air quality........................................................................................ 8
10. Guarantee........................................................................................................ 9
11. Amplifier Disassembling................................................................................. 10
11.1 Check valve disassembling........................................................................ 19
11.2 Spool valve disassembling......................................................................... 23
12. Amplifier assembling...................................................................................... 25
12.1 Check valve assembling............................................................................. 25
12.2 Air drive section assembling....................................................................... 29
12.3 Spool valve assembling.............................................................................. 42

PL= drive pressure air
A = supply pressure
B = pressure outlet
Y1= exhaust control
valve
Y2= Exhaust pilot air
X = Control mechanism
(possible an external
connection to the
control mechanism)
1. Function principle of SPLV2
MAXIMATOR pneumatic amplifiers are driven by air pressure and increase the
pressure according to the given ratio. With a constant pressure in the oneumatic
system a brief or locally needed high pressure level can be generated. Pneumatic
amplifier stations are equipped with a receiver which reduces pressure fluctuations
and have a larger air capacity available immediately. The amplifier indicator gives the
ratio. A floating slide valve pumps the piston or pistons alternately with working
pressure. The reversal process is set in motion by the pilot valves which are activated
in the end position of the piston or pistons. Check valves protect the intake and outlet
connectors.
The supply air flows through check valve b from connector A and enters compression
chamber I and II. The drive pressure (connector PL) fills drive chamber II via the
control slide valve as the pressure is released from the drive chamber I.
By means of its motion, the piston reduces the volume of the compression chamber II
and the pressure is increased. The operating pressure reaches the outlet of the
machine (connector B) by means of the check valve a.
Upon reaching the final position, the pilot valve switches the control slide valve, the
air in drive chamber II is released and the pressure increase takes place in the
compression chamber I.
Example: drive chamber II = 4 bars
+ compression chamber I = 4 bars
compression chamber II = 8 bars
In pneumatic amplifiers with connector X, the pilot air flows in from the outside. To
that end, it is branched off from the drive air pressure and reaches connector X
through the conduits. A pressure switch in the control mechanism switches the
amplifier on and off when the pressure is set.

2. Technical data
Pressure ratio (i) 1 : 2
Air drive pressure (PL) 1-10 bar
Max. discharge pressure (PB) 16 bar
Max. noise level 79 dB (A)
Max. operating temperature (T) 60 °C
Air drive connection BSP 1/2”
Inlet connection BSP 1/2”
Outlet connection BSP 1/2”
Net weight 8.5 kg
3. Performance graph
Performance Graph SPLV 2
0
500
1000
1500
2000
2500
0 2 4 6 8
10 12
14
16 18
20
Outlet Pressure (bar)
Outlet Flow
(l
N
/min)
0
500
1000
1500
2000
2500
Air Consumption
(l
N
/min)
Outlet Flow at 2 bar Outlet Flow at 4 bar Outlet Flow at 6 bar
Outlet Flow at8 bar Outlet Flow at 10 bar Air Consumptionat 2 bar
Air Consumption at 4 bar Air Consumption at 6 bar Air Consumptionat8 bar
Air Consumption at 10 bar
6 bar
2 bar
4 bar
8 bar
10 bar
For air demand add together outlet flow and air consumption

4. Dimension and Connection Drawing

5. Safety
The MAXIMATOR pneumatic amplifier was constructed in accordance with the
established technical regulations as described in the law regulating technical working
devices
(machines protection law), the accident protection provision and the pressure tank
statute.
These provisions should also be given attention when installing or using the
pneumatic amplifier. MAXIMATOR pneumatic amplifiers are only intended for air
compression. Please consult the manufacturer in cases where other gases are being
considered for use.
The connections and attachment parts must be compatible with the system pressure.
Appropriate methods must be implemented to make certain that the drive pressure
and supply pressure (pL and pa) do not exceed the permissible limit of 10 bars. The
system should be completely depressurised before any repairs take place.
5.1 Pneumatic amplifier
Safety devices should prevent more than 10% increase in permissible operating
pressure limits. The safety devices, in accordance with the pneumatic amplifier,
cannot be blocked off, should be given regular functional checks and be easily
accessible. Measurement devices should be included to monitor the compressor
pressure.
The provisions regulating pressure tanks should be considered when using a
pressure tank that is topped up by another object or device.
5.2 Pneumatic amplifier stations
Pneumatic amplifier stations are devices which meet the safety regulations described
in the pneumatic tank provisions. Assuming that no damage has resulted from
transportation, no checks or inspection are necessary before the first use.
However, depending on the construction size, regular pressure checks of the
pneumatic tank are necessary. Stations with SPLV 2 and GPLV 2 pneumatic
amplifiers are equipped with a pneumatic tank of the group III type. These tanks and
the built-in safety features should be inspected at least every four years by a qualified
technician.
The operating conditions described on the pneumatic tank (pressure and
temperature) must be met. Condensation should be released from pneumatic tank at
regular intervals.
6. Installation / Operation
The pneumatic amplifier used with oiling device must be still operated with oiling
device in future. A filter with maximum mesh width of 5 m. should be installed into the
air conduits of the drive (see also point maintenance).

6.1 Pneumatic amplifiers
The pneumatic amplifiers can be operated in any installed position. For the
pressurized air connector we recommend our control unit ”C 2” with filter, water
separator, shutoff valve, pressure regulator, pressure control gauge.
As with usual piston seals, pressure pulsation sometimes result from stroke
frequency. The can be reduced with an additional volume (pneumatic tank) (see
illustration 1). The loading time of this additional volume, as is the case with large
volumes following the pneumatic amplifier, can be reduced by means of a bypass
conduit. To that end, to bypass the pneumatic amplifier a connection with a relief
valve is branched off from the pneumatic connection. The pneumatic amplifier begins
with a pressure increase if the operating pressure pb is equal to the intake pressure
pa (see illustration 2). Pneumatic amplifiers with external pilot air intake valves have
a connector marked with ”X” (possible with SPLV 2
and GPVL 2). The conduits which are branched off from the intake pressure can be
used for the installation of a pressure switch (illustrations 5 and 6).
7. Maintenance
The pneumatic amplifier are pre-treated with industrial strength grease and need no
additional greasing. When overhauling the pneumatic amplifier, the control slides and
the air pistons should be treated with acid-free and silicon-free grease.
On a high stroke frequency ≥150 strokes/min or > 50 % continuous duty an air
pressurized oiling device shall be installed in front of the unit.

8. Maintenance tips
Only use original MAXIMATOR replacement parts when conducting repairs. When
repairing or maintaining the pneumatic amplifier, pay special attention to cleanliness
so that you can increase the operation life and guarantee good functional operation.
During installation, pay special attention to the torque (8Nm) for the nuts of the 4 stay
rods so that you can avoid a faulty gripping and the upper or lower sections.
9. Compressed air quality
The drive air should have a quality class of 3 to 4 (solids / water / oil) according to
DIN ISO 8573-1:
Solids: maximum particle size 5 µ
maximum particle concentration 5 mg/m3
Dew point: + 10° C = water content of 9.4 g/m3 to
+ 2° C = water content of 5.6 g/m3
Oil content: 1.0 to 5 mg/m3
By observing this drive air quality, an optimum life time of the seals and packing will
be achieved.
Operating time:
All MAXIMATOR products are designed for intermittent operation. Please consult
factory for special applications.
Technical data:
All technical and dimensional information subject to change. We reserve the right to
alter our products due to technical improvement.
Copyright / Patent-right:
All MAXIMATOR products are subject to copyrights. The protective rights to DIN 34
have to be observed.
Important:
All MAXIMATOR pumps, boosters and amplifiers are treated with sislicon free grease
during the assembly.

10. Guarantee
All repair work is to be carried out be qualified skilled personnel under extremely
clean conditions. Even smallest impurification may cause serious damage at the
precision-machined pneumatic components.
All individual pump and compressor parts are available from MAXIMATOR as spare
parts. The respective purchase order numbers can be gathered from the drawings
attached to each compressor. Typically, there is more than one sealing defective or
worn out, hence, we have compiled different sealing kits. The compositions of sealing
kits can be gathered from the drawings, like the respective purchase order numbers.
Make sure to indicate the compressor serial number when ordering spare parts. The
serial number is located in the machine plate of the compressor and is also punched
into the compressor housing (as a 6-digit number).
It goes without saying that the most convenient approach for you is to ship a
defective unit to us. All repairs are carried out by qualified persons in our workshops,
where there are no metal-cutting activities and thus extreme cleanliness is ensured.
As a rule we acknowledge the receipt of the forwarded unit and send you a cost
estimate and, after your confirmation, repair your unit as quickly as possible and
return it to you.

11. Amplifier Disassembling
Loosing and disassembling the exhaust muffler (item 14)
Unscrew and disassembling of the two
screws (item 46).
Tool size 6
Disassemble the connection block (item
48) and draw the air tube (item 51) out of
the spool valve housing.

Loosen the five socket head screws (item
13+12) in the spool valve housing.
Disassemble the spool valve housing.
Loosen the two socket head screws (item 44 and 43) and disassemble the base plate
(item 42).

Loosen the four hexagon nuts (item 56) and remove the u-washer (item 54) and spring
washer (item 55) from the stud bolts.
Carefully separate the bottom cap (item
46), maybe by means of light hammer
taps with a plastic hammer, from the air
cylinder (item 26) and disassemble the air
tube (item 24).
Disassemble the bottom cap (item 46) compl. from the air cylinder (item 26).

Carefully separate the top cap (item 1) by
means of light taps with a plastic hammer
from the air cylinder (item 26).
Loosen the two hexagon screws (item 33).
Key size : 19
Disassemble the both hexagon nuts (item 33) and u-washers (item 32) from the piston
rod (item 27).

Carefully separate the first air cylinder
(item 26) from the air separation plate
(item 34), maybe by means of light taps
with a plastic hammer.
Carefully separate the second air cylinder
(item 26) in the same way.
Pull the piston rod (item 27) out of the air separation plate (item 34) and disassemble
the two o-ring (item 31) on both ends.

Remove the piston sealing ring (item 30)
from the piston (item 28).
Remove the o-ring (item 29) from the
piston (item 28).
Dismantle the o-ring (item 25) from the bottom cap (item 46).

Dismantle the o-ring (item 23) out of the
groove in the bottom cap (item 46).
Loosen completely and unscrew the pilot valve screw (item 16).
Disassemble the gasket (item 21), the spring (item 18) and pilot valve tappet (item 19).

Dismantle the o-ring (item 25) from the top
cap (item 1).
Dismantle the o-ring (item 23) out of the
groove in the top cap (item 1).
Loosen completely and unscrew the pilot valve screw (item 15).
Disassemble the gasket (item 21) and the spring (item 18).

Dismantle the pilot valve tappet (item 19) out of the top cap (item 1).
Air separation plate (item 34) with the
compl. check valves .

11.1 Check valve disassembling
Remove the locking ring (item 41).
Remove the retainer ring (item 40).
Remove the spring holder (item 39).

Remove the spring (item 38).
Remove the check plate (item 37).
Remove the check seat (item 36).
Separate the o-ring (item 9) from the
check seat (item 36).