MPS RL03S-D User manual

Model Number RL03S-D
Bootstrap Compressor • 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
Mount the Model RL03S-D Bootstrap Compressor on a
horizontal surface. Other mounting orientations are not
recommended. The booster system vibrates while operating, so
use the four 1/2” mounting holes, shown in the diagram to the
right, to bolt it to a solid surface.
1
Connect your shop air line to the 1/4” FNPT air inlet filter on the
front of the booster. A shutoff valve can be installed upstream of
the filter for convenient removal of the system for maintenance.
The booster has a built-in discharge pressure regulator. Do not
install a supply pressure regulator. Lowering the supply pressure
reduces the efficiency of the system. The unit is permanently
lubricated. Use of an inlet lubricator will void the
warranty. The maximum inlet pressure is 150 psig.
2
Attach discharge line to the 1/2” FNPT ball valve located in
front of the receiver tank. If the application requires a
lubricator, make sure the lubricator is installed
downstream of the booster.
3
The discharge pressure regulator is set by the black, snap- !
lock knob mounted on the top of the unit. Pull up on the !
knob to unlock it. Adjust the knob by turning it clockwise for !
a higher discharge pressure (up to a maximum of 240 psig), !
or counterclockwise for a lower discharge pressure. Inlet !
pressure is read on the gauge to the left hand side. The !
second gauge indicates discharge pressure. Supply shop air !
to the booster and it will start to operate. Set the regulator to !
attain the desired discharge pressure, and push down on the !
regulator knob until it “clicks” to lock the regulator on that !
setting. The regulator is self-relieving. When the discharge !
pressure setting on the regulator is reduced, the higher !
pressure stored in the system will vent through the regulator !
until pressure equilibrium is reached. If the inlet pressure !
is higher than 120 psig, it is possible to set the !
regulator so the booster exceeds the maximum !
discharge pressure of 240 psig. Do not operate the
booster under these conditions. It is designed to
operate continuously at a maximum discharge
pressure of 240 psig. !
!
5
The Bootstrap Compressor will operate as long as there is
demand for high pressure air. When there is no demand, the
booster will “stall” at the pressure set by the booster’s discharge
regulator. The stalled condition consumes no energy and does
not damage the booster. The booster will start up automatically
when the pressure falls slightly as a result of demand for high
7
Mounting Bolt Pattern:
7.5”
6.5”
Inlet port
1/4” FNPT
Discharge port
1/2” FNPT
The accumulator tank has a 1/4” ball valve to drain condensate. A
drain line or automatic drain valve can be attached to this valve
when needed. Close the valve before starting booster.
4
The accumulator is rated for 350 psig and includes a relief valve
set for 250 psig. This relief valve was selected to prevent
operation of the booster above its maximum
allowable discharge pressure of 240 psig.
8
For maximum high pressure air storage,Bootstrap Compressor’s
regulator to charge the accumulator to 240 psig. Set the
secondary regulator on the discharge line to the desired
discharge pressure. This allows for greater accumulator storage
capacity, and minimizes pressure fluctuations in the system.
Make sure that any downstream components are rated for the
accumulator pressure, or are protected by a relief valve in case
the secondary regulator fails.
6
250 psig
Pressure
Relief Valve
Secondary
Regulator
Midwest Pressure Systems, Inc.
850 Transport Drive, Valparaiso, IN 46383
Phone [phone] Fax [phone]
www.midwestpressuresystems.com

Model Number RL03S
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 Model RL03S-D Bootstrap
Compressor. The moving parts of the 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 unit and foul the seals, or cause premature wear
of the highly-polished seal surfaces. The wear parts in the booster
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 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 Model RL03S-D Bootstrap Compressor 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 Model
RL03S-D is designed to operate at a maximum discharge pressure
of 240 psig. Higher discharge pressures, though possible, can result
in catastrophic failure of the booster.
Operating Description
General Concerns
Midwest Pressure Systems, Inc. warrants the Model RL03S-D Bootstrap Compressor 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] Fax [phone]
www.midwestpressuresystems.com