MAXIMATOR DLE User manual

Compressed air driven gas booster
DLE, 8DLE, 14DLE, MDLE, SDLE
Installation and operating manual

1 0000000141 - 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:
–Use other than the intended use stated in this document
–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
26.04.2021 Translation of the Original
© Copyright 2021 Maximator GmbH - All rights reserved

Contents
0000000141 - 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 List of abbreviations and formula signs used . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.6 Qualification of the personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Safety and protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Personal protective equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3 Work and danger zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Non obvious hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.1 Start-up and shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.2 Risk of injury posed by noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5.3 Hazardous operating fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Product description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Design and function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 Misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5 Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.6.1 Operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.6.2 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6.3 Performance values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.6.4 Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4 Transport, packaging and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1 Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2 Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Contents
3 0000000141 - 002 - EN
5.1 Prerequisites for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Gas booster installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3 Installation of connecting lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3.1 Connecting the drive air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.2 Control air connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.3 Connecting the inlet line and outlet line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.4 Connecting a separate bleed pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.5 Purge line connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3.6 Exhaust silencer installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.1 Prerequisites for commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.4.2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.1 Prerequisites for operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.2 Normal, safe operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3 Abnormal situations during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.4 Signs indicating the product is no longer safe to use . . . . . . . . . . . . . . . . . . . . . 29
6.5 Putting the gas booster in a safe state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.1 Maintenance intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2.1 System inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2.2 Leak-testing the connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.2.3 Check screw fittings and connecting lines for damages . . . . . . . . . . . . . . . . . . . 33
7.2.4 Clean gas booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.2.5 Check fastening elements and connecting elements . . . . . . . . . . . . . . . . . . . . . 34
7.2.6 Leak detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.2.7 Repair gas booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.3 Spare parts and consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4 Accessories and special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.5 Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
8 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.1 Drive side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.2 High pressure side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9 Removal and disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.1 Prerequisites for removal and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Contents
0000000141 - 002 - EN 4
9.2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10 Use in explosion-prone zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.2 Temperature class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
10.3 Operation and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.4 Operation with combustible operating fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . 45
10.4.1 Purging plans for the compression of combustible gases . . . . . . . . . . . . . . . . . . 45
10.4.2 Alternative purging options for the compression of combustible gases . . . . . . . . 47
11 Summary of ignition hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
12 Applications with oxidising operating fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

General information
5 0000000141 - 002 - EN
1 General information
1.1 Information regarding this manual
Maximator gas boosters can be used for a variety of applications. They are used
to deliver gases and compress them to high pressures. This manual applies to all
gas boosters with the following options in the order code: DLE, 8DLE, 14DLE,
MDLE, SDLE and a serial number above 20000001.
The general drawing included is an integral part of this manual, and must be
stored with it.
1.2 Order code
The order code for gas boosters is structured as follows:
a Model
b Number of drive pistons
without = 1 drive piston
2= 2 drive pistons
3= 3 drive pistons
c Thread (gas inlet and outlet)
G = pipe thread (standard)
U = high-pressure connection (UNF)
N = NPT
d Option code
Additional codes for device options and/or variants may be en-
tered here.

General information
0000000141 - 002 - EN 6
1.3 Rating plate
The rating plate is located on the drive cylinder of the gas booster and contains
the following information:1:
Fig. 1-1 Gas booster rating plate
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.
1Individual gas boosters may have different rating plates, e.g. made of metal
1 Maximum permitted operating
pressure
2 Compressed air driven gas boost-
er
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 Pressure ratio
10 EAC label
11 Manufacturer contact informa-
tion
12 Operating temperature range
13 ATEX label
14 Maximum standstill pressure

General information
7 0000000141 - 002 - EN
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
environment.
This symbol characterises contents and instructions for the intended use in po-
tentially explosive areas.
This symbol highlights useful tips and recommendations as well as information
for efficient and flawless operation.
1.5 List of abbreviations and formula signs used
Tab. 1-1 List of abbreviations
Abbreviation Description
Tab. Table
Fig. Figure
EAC Eurasian economic union mark of conformity
CE EU mark of conformity
DGRL EU pressure equipment directive
ATEX EU explosion prevention directive
max. maximum
min. minimum
H2 Symbol for hydrogen
No. Number
CET Central European Time
EPL Equipment Protection Level

General information
0000000141 - 002 - EN 8
Tab. 1-2 Formula symbol
1.6 Qualification of the personnel
Qualified personnel is required to work on and with the Maximator gas booster
safely and properly. Allowing unqualified personnel to work on the gas booster
or enter the danger zone creates hazards which could lead to death, severe inju-
ries and significant property damage.
Formula
symbol
Description
i, i1, i2Gear ratio
Leq Noise emission
pAInlet gas pressure
pBOperating pressure
pB max. maximum permitted operating pressure
pLDrive pressure
TA, TBTemperature
κ Isentropic exponent

General information
9 0000000141 - 002 - EN
Tab. 1-3 Qualification of the personnel
Qualifications
System design Transport and storage Installation Commissioning Operation Tooling and set-up Cleaning Repair and maintenance De-installation Operator
Understands the general mode
of operation
x x x x
Understands the detailed
mode of operation
x x x
Able to read and comprehend
work-related documents
x x x x
Able to read and comprehend
work-related drawings/plans/
documents
x x x x x
Possesses comprehensive tech-
nical expertise
x x x x x x x x x
Familiar with the technical
safety labels utilised
x x x x x x x x
Able to identify and adjust safe-
ty features
xxx
Able to identify the risks specif-
ic to the work and comply with
appropriate protective mea-
sures
x
Able to identify the risks specif-
ic to the work and derive ap-
propriate protective measures
x x x x x x x
Able to identify and interpret
the risks specific to the work
and derive appropriate protec-
tive measures
x
Knows and understands the rel-
evant standards, directives and
regulations and is able to apply
them
x x x