MPS R60T User manual

Model Number R60T
Air Pressure Booster System • Installation and Operating Instructions
Midwest Pressure Systems, Inc.
RAV Rev. 0
MPS
M I DW E ST
PRESSURE
SY S T E M S
MPS
M I D W E S T
PRESSURE
S YS T E M S
MPS
M I D W E ST
PRESSURE
SYS T E M S
MPS
M I D W E S T
PRESSURE
SY S T E M S
MPS
M ID W E S T
PR ESSURE
S YS T E MS
MPS
M I D W E S T
PRESSURE
SYS T E M S
MPS Logos
12/5/91
1/2" Square
3/4" Square
1" Square
1-1/4" Square
1-1/2" Square
2" Square
MPS
M ID W E S T
PR ESSURE
S YS T E MS
Installation
1 Bolt the tank to the floor using the four 1/2
inch diameter mounting holes (A).
2Connect your drive air supply to the 1
inch NPT inlet filter shown above (B). The air
supply piping should be 1 inch pipe diameter
or larger.
3Connect your discharge line to the 2 inch
NPT pipe port shown above (C). There are
several other plugged ports on the tank that
can be used for the discharge line.
4Attach your condensate drain line to the
1/4 NPT port on the valve shown above (D).
Make sure that your discharge piping
components are rated for 200 psi.
Startup
1This system can be operated with one, two, or all three boosters. To operate with all
three boosters, open the inlet (E) and discharge valves (F). To operate with one booster,
close the inlet and discharge valves of the idle boosters.
2There is a discharge pressure regulator for each booster. Pull up on the black
knob on the top of the booster to unlock it. Turn the knob clockwise for a higher
discharge pressure and counterclockwise for a lower pressure. If all of the boosters
are operating, set the regulators for the same discharge pressure. The regulators are
self relieving so if one is set for a higher pressure, the other regulators will try to vent
the pressure. The pressure gauges marked (G) indicate inlet pressure and the gauges
marked (H) indicate discharge pressure. When the boosters have pressurized the tank
to the maximum desired pressure, they will stall. If one of the regulators vents at the
stall condition, turn the knob clockwise until the venting stops. The maximum
recommended discharge pressure is 190 psi. The relief valve is set for 200 psi. If the
supply pressure is higher than 95 psi, it is possible to set the regulators so the system
exceeds the maximum discharge pressure of 190 psi. During startup, do not turn the
regulators to their highest setting, but slowly increase the regulator settings until the
desired pressure is reached.
Operation
The system is fully automatic. When the desired discharge pressure has been
reached, and no flow is required, the boosters will stop automatically. They will
restart when the pressure drops about 5 psi.
Maintenance
The air supply filters and condensate drain should be checked periodically. If a
booster needs to be removed for service, close the air supply valve and the discharge
valve. The discharge valve will vent the pressure between the two valves and the
booster pressure gauges should both read zero. The booster can safely be removed
and repaired while the system continues to operate.
A
A
B
C
D
E
E
F
H
G
F
G
H
F
E
H
G
Midwest Pressure Systems, Inc.
850 Transport Drive, Valparaiso, IN 46383
Phone [phone]
www.midwestpressuresystems.com

Model Number R60T
Bootstrap Compressor • Operation and Warranty
Midwest Pressure Systems, Inc.
RAV Rev. 0
MPS
M I DW E ST
PRESSURE
SY S T E M S
MPS
M I D W E S T
PRESSURE
S YS T E M S
MPS
M I D W E ST
PRESSURE
SYS T E M S
MPS
M I D W E S T
PRESSURE
SY S T E M S
MPS
M ID W E S T
PR ESSURE
S YS T E MS
MPS
M I D W E S T
PRESSURE
SYS T E M S
MPS Logos
12/5/91
1/2" Square
3/4" Square
1" Square
1-1/4" Square
1-1/2" Square
2" Square
MPS
M ID W E S T
PR ESSURE
S YS T E MS
Compression
Chamber A1
Compression
Chamber A2 Drive
Chamber
B2
Drive
Chamber
B1
Piston 1 Piston 2
4-way
Valve
Switch
4-way
Valve
Switch
Pilot Signal to regulator
Built-in discharge regulator
Regulated drive air
Plant air
Exhaust air
Pilot signal to regulator
High pressure air Exhaust air
Regulated drive air
Please refer to the operating description on the right, and the
schematic above to gain an understanding of the design principles
and mechanical function of the R60T Model Booster System. The
moving parts of each Bootstrap Compressor are permanently
lubricated with a multipurpose grease (except for the check valves).
Operation with a lubricator upstream voids the warranty. If a
lubricator is required, it should be installed on the downstream
(discharge) side. A well-maintained 5 micron inlet air filter is
required to maintain the warranty by ensuring that no dust particles
enter the units and foul the seals, or cause premature wear of the
highly-polished seal surfaces. The wear parts in the boosters consist
of check valves, springs and dynamic seals. These parts are
designed for 1800 miles of piston travel. The four-way valve, which
controls movement of the pistons, is a lapped, stainless steel valve
with no elastomeric seals subject to wear. Under normal conditions,
this valve will provide many years of operation. The discharge
regulator built into the center of the unit sees very little wear, and is
designed to provide many years of service under normal conditions.
The wear parts are typically replaced 2 to 3 times before a valve or
regulator kit is required.
#KRW • Wear parts kit
#KRV • Valve kit
#KRR • Regulator kit
The plant air stream always fills Compression Chambers A1 and A2
directly, through a set of check valves. These two chambers are
always pressurized to the maximum initial air pressure available
(the R60T Model Booster System is not designed for inlet air
pressures higher than 150 psig). A branch of the plant air stream
flows through a pilot-activated regulator, which reduces the pressure
to the level required to attain the desired Bootstrap Compressor
discharge pressure (the discharge pressure is set manually by
adjusting the regulator handle). This regulated air stream flows
through a four-way valve which directs it to Drive Chamber B2. At
the same time, the four-way valve opens Drive Chamber B1 to
exhaust. The pressure force exerted on the interconnected pistons by
the pressures in Drive Chamber B2 and Compression Chamber A1,
is sufficient to compress the air in Chamber A2 to a higher pressure
(the maximum discharge pressure attainable is two times the plant
air pressure). At the end of its travel, Piston 2 switches the four way
valve, which opens Drive Chamber B2 to exhaust, and pressurizes
Drive Chamber B1 with regulated drive air, thus reversing the
direction of the interconnected pistons, until Piston 1 switches the
valve back to its original position. The interconnected pistons
shuttle back and forth continuously, producing a high pressure air
stream, determined by the discharge pressure set on the built-in
regulator. The R60T Model is designed to operate at a maximum
discharge pressure of 190 psig. Higher discharge pressures, though
possible, can result in catastrophic failure of the booster.
Operating Description
General Concerns
Midwest Pressure Systems, Inc. warrants the R60T Model Booster System to be free of defects in material and workmanship for a
period of one year after purchase, except piston seals, rod seals, and check valves which are warranted for six months after purchase. We
will either repair or replace a failed unit returned by the customer. No other warranty is expressed or implied. Proof of the purchase
date is required. This warranty does not apply to equipment which has been abused, and is voided by use of a lubricator, or failure to
use a well-maintained inlet filter. Customer must obtain a return authorization number before shipping the unit to the factory.
WARRANTY
Midwest Pressure Systems, Inc.
850 Transport Drive, Valparaiso, IN 46383
Phone [phone]
www.midwestpressuresystems.com