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: +49 3631 9533-0
e-mail: info@maximator.de
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
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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.
This manual suits for next models
4
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