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Operating instructions Boosters

1. nnennnnneea 28 vi P a a Connecting inlet and outlet connections 56 i A A MISUSG 11245125 ab tikk ale 11 Connecting the drive air 55 Mode of ti 39 CONNECHONS AST 44 ce pi KARA EE pe Te m Contact information mnennnei 9 N nn ens CONLAGES 45 14 van veena akkas een 9 Na AA 33 Control valve 00eeeeeeeeneneeeeneeee 38 a teas te eee eec ic earnest Cooling Cylinder ccceeceeeeeeeceeeeeeeeeeeeeeeeeeeees 39 i al A Operating conditions ma 32 Copyrighti suagsi ist a teemast k ed etapa 9 6 t kallal 33 rating materials Customer service nnenennnennennnennnenn nenn 9 J an D OVENI CW aien a a a ai 37 EEN EEOSE OT EA TEES E E TE 18 Daily inspections wrwrrra 61 v id Dangers AAA AAS 14 Packaai 49 ING isn Danger ZONES enea a aa 46 ackag ng gt A A Performance characteristics 31 Dismantlind nsesensne nat 106 WR i i Permissible displacement media 12 Disp sal naana 106 Personnel herioari neh 21 Drive component 1 6nnnnnnnnnnnnenaneeneeat 38 i E Pilot valve icccccsscsesees oniani iaia 38 P isites for installation 51 Emergency situation vmnrneaeni 68 kaka talendi lil Pressurised componentS een 15 Emergency Stop 68 Blast
2. eneenenn 18 2 5 Personnel requirement c cseceeeeeeeeeeeeeeeeeees 21 2 5 1 Qualifications mocinno aa aa 21 2 3 2 NSTUC OM sninen ni a iari 22 2 6 Personal protective eguipment 0 22 2 7 Safety devices seeesenssnnnnnennnnnnnnnnnnnnnnnennnnnnnn nn 23 2 8 gage EEEE 23 2 9 Behaviour in case of fire or accidents 24 2 10 Spare pats i aa 25 2 11 Environmental protection mannanenai 25 Technical data 27 3 1 Dimensions and weights ma 27 3 2 Connected loads mnrnnnnnannnnnannnena 28 3 3 Performance characteristics 2222444444444 444 gt 31 3 4 Operating conditions ra 32 3 5 Operating materials mra 33 3 6 EMISSIONS aninha tajate alkeen l 33 3 7 EXMA ci 34 3 8 Type plate iersinii iaia ia aia 35 3 9 TYPE K A 35 Structure and function 37 C E OV T E AE 37 4 2 Briefdescription nennnnnnnnt 37 4 3 Assembly description merme 38 4 3 1 Booster head with inlet and outlet valve 38 4 3 2 High pressure component t 38 4 3 3 Pilot valve 2 un nenn al 38 43 4 Control VANE icccsanriaccecssnssiiductnanesnndd cdedeasaacdeceeaestanlae 38 26 01 2012 Boosters DLE 2 1 2 DLE 75 1
3. 42 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Boosters with two drive pistons Version Single stage single acting with two air pistons Types DLE 2 1 2 DLE 5 1 2 DLE 15 1 2 DLE 30 1 2 DLE 75 1 2 Single stage dual acting with two air pistons Types DLE 2 2 DLE 5 2 DLE 15 2 DLE 30 2 DLE 75 2 Dual stage dual acting with two air pistons Types DLE 2 5 2 DLE 5 15 2 DLE 5 30 2 DLE 15 30 2 DLE 15 75 2 DLE 30 75 2 Structure and function Versions Graphic representation Py 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 43 Structure and function Connections 4 6 Connections MAXIMATOR O The boosters are delivered without any piping or i threaded unions The connected load information Connected loads mechanical on page 28 must be observed for all interface connections A connection drawing of all connections to be installed can be found in amp Appendix B Connection drawing on page 123 The boosters have the following interfaces Fig 9 Interfaces side view Item no Designation Connection 1 Control air connection X G 1 8 2 Ventilation connection for Bore control valve Y 3 Air connection for pilot valve M5 xX 4 Exhaust air silencer connec G1 2 tion Function Connection for direct pilot valve air uncontrolled and filtered control air gt drive air Ventilation and bleeding of the contr
4. 99 8 3 9 Checking high pressure seals and high pressure cylinder for signs of damage 100 8 4 Start up after a corrected fault 102 Maintenance 103 Dismantling and disposal nn 105 10 1 Safety instructions for dismantling and disposal 105 10 2 Dismal esca 106 10 3 Disposals riesis 106 10 4 Tightening torques sseeessreessererrrrnnnrssnnnnenseeees 106 IndeX 2 A E ne eee et 109 APBENdIK aan heine 111 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 5 MAXIMATOR WOCNORUCKTECHNIK HYDRAULK PNEUMATIK PR FTECIKNIN Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 1 General General Explanation of symbols 1 1 Information about this manual This manual enables safe and efficient handling of the booster The operating manual is a component ofthe booster and must be kept in the immediate vicinity of the booster where it is available to personnel at all times Personnel must have carefully read and understood this manual before performing any tasks The basic prereguisite for safe work is compliance with all safety instructions and handling instructions specified in this manual In addition the applicable local occupational health and safety reg ulations and general safety regulations for the booster s area of implementation must be complied with The illustrations in this manual are
5. 4 and 14 15 if a com 1 pressed air control unit is present If no com pressed air control unit is installed the drive air line must be removed from the control valve housing instead of the elbow union 74 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Faults Fault correction tasks gt Replacing the O rings on the control valve 2 Purge booster with nitrogen Proceed as described in amp Appendix A Hydrogen compression with Maximator boos ters on page 113 to do this 3 Undo threaded union Fig 30 1 of compressed air control unit on control valve housing Fig 30 2 4 Undo and remove elbow union Fig 31 1 of compressed air control unit or on drive air connection of control valve housing Fig 31 2 5 Position circlip pliers Fig 32 1 on circlip of control valve housing Fig 32 2 and carefully remove circlip and secure to prevent it from getting lost Fig 32 Removing the circlip 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 75 Faults MAXIMATOR Fault correction tasks gt Replacing the O rings on the control valve 6 Insert screwdriver into drive air connection Fig 33 arrow of control valve housing Fig 33 1 and carefully press out cap Fig 33 2 and control valve Fig 33 3 7 Remove all O rings from control valve and caps Fig 33 Removing control valve and cap 8 Grease new O rings Fig 34 Fig 34 Gr
6. Boosters DLE 2 1 2 DLE 75 1 2 15 Safety Basic dangers gt Dangers due to low temperatures 2 3 3 Dangers due to low temperatures Cold surfaces CAUTION Risk of injury due to cold and iced up surfaces Components such asthe exhaust air silencer can cool down severely and ice up due to expanding air or gas Skin contact with cold surfaces can cause skin irrita tions Always wear protective clothing and protective gloves during all work in the vicinity of cold or iced up Surfaces Ensure that all surfaces have warmed up to ambient temperature before all work Flying ice crystals and accumu lated liguids WARNING A Risk of injury caused by flying ice crystals and accumulated liquids Icing can develop on the exhaust air silencer of the booster during operation that is freed up by expanding exhaust air and tossed around The pushed off ice crystals can result in eye injuries and accumulated liq uids on the floor Always wear protective goggles during all work Immediately pick up any accumulated liquid using appropriate means Always wear non slip safety footwear Place warnings and mandatory action signs on or near the area where liquids can collect on the floor or where there can be flying ice crystals 16 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 2 3 4 Dangers due to fire Fire prevention and protection A 2 3 5 Dangers due to explos
7. MAXIMATOR hydrogen boosters are marked with the suffix H2 ExIIC and are generally suited for applications in explosion class IIC Materials Hydrogen places significant demand on material choice In this area the phenomenon of hydrogen embrittlement must be especially mentioned Hydrogen embrittlement describes the change in the ductility of metals Atomic hydrogen penetrates the microstructure of metallic material At voids or grain boundaries the atomic hydrogen recombines to form molecular hydrogen thus in creasing the pressure inside the structure This process causes internal stresses and leads to material embrittlement Material failure becomes apparent in cracks that spread outside hydrogen induced crack formation In practical tests austenitic steel has proven to be especially successful After high performance tests the MAXIMATOR hydrogen booster showed no sign of hydrogen embrittlement Piston compressors with dynamically loaded seals are not absolutely gas tight To increase the performance of the piston seal for hydrogen compression purposes both sealing geo metry and material were adapted to the special requirements Flushing Connection From a technical point of view the most important part in the compression of hydrogen is to avoid the formation of explosive atmospheres As gas leakages cannot be ruled out MAXI MATOR hydrogen boosters have to be flushed with inert gas preferably nitrogen prior during
8. A 53 EMISSIONS meie tia kavand v es k re katva ran ea teren 33 R PN eu Environmental protection RE if paiva 74 Cleaning liquids 00ssn nennen 25 au ee aia a 68 Lubricants mmmerrenenenennnnnae aenea 25 js ne TAA Residual risks rmnnni 14 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 109 Index S OEMIGE iaaii a e alata Ea 9 SIGNS A E E E T 23 SOA Jeo AES 50 SWITCHING Off eier eek 67 SWITCHING ON A NA 63 Symbols in the instructions uuuseseeenenenenesneneeneeennnnn 7 T Type Kay inserieren 35 Type plate een 35 MAXIMATOR U Use en 11 V VETON Saiano and nenne anne ae k na talad 41 W Working ares eesin inira aaa 46 110 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Appendix Appendix 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 111 112 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Hydrogen compression with Maximator boosters A Hydrogen compression with Maximator boosters 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 113 114 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 HOCHDRUCKTECHNIK HYDRAULIK PNEUMATIK PR FTECHNIK Achtung Wichtige Informationen f r die MAXIMATOR Kompressoren der DLE Baureihe Werden die Kompressoren zur Verdichtung von aggressiven brennbaren gef hrlichen oder g
9. Protective eguipment Protective work clothing Safety footwear Safety goggles Switching the booster on In a booster without compressed air control unit the booster starts delivering as soon as the displacement medium is present and the drive air of the in house compressed air network is applied 1 Calculate the required operating pressure Chapter 7 3 Calculating the operating pressure on page 62 2 Adjust drive pressure on pressure regulator of in house com pressed air network and check pressure on manometer 3 Open displacement medium gas on transport gas container The displacement medium flows in 4 Open compressed air line of compressed air network to booster The booster starts delivering as soon as the drive air pressure is applied 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 63 Operation MAXIMATOR Switching on Switching the booster on with a compressed air control unit pre sent 1 Calculate the required operating pressure Chapter 7 3 Calculating the operating pressure on page 62 2 gt Make sure that the ball valve Fig 23 1 of the compressed air control unit is closed Fig 23 Ball valve of the compressed air control unit 3 gt Make sure that the vent valve Fig 24 1 of the compressed air control unit is closed 4 Open valve of displacement medium gas on transport gas container The displacement medium flows in
10. ceutical or sanitary purposes involving food Always comply with all instructions concerning installation maintenance and fault correction specified in this manual Compression of hydrogen To prevent potentially explosive atmospheres in areas around hydrogen systems from developing always observe the following Always set up hydrogen systems in a well ventilated room Always keep hydrogen systems leak tight Blow out lines of safety valves and leakage lines must always be routed outside into the open Blow out lines must not be installed under eaves openings in buildings or in the vicinity of air intake openings For hydrogen systems in rooms or buildings it must be pos sible to safely and quickly shut off the gas supply coming from the outside at a safe point Pipe connections on hydrogen systems must always be cre ated so that these ensure the connection will be leak tight for a long time 2 2 Permissible displacement media gases Displacement media gases Displacement media that are permitted for compression with the boosters are listed in the following 12 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 TE Safety Permissible displacement media gases WARNING Risk of accident if the permissible displacement media are not observed If the permissible displacement media and the special instructions are not observed this can result in severe accidents Only compress displacement media
11. 5 Open compressed air line of compressed air network to booster Drive air is applied to the compressed air control unit Fig 24 Vent valve 64 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Operation Switching on 6 Pullthe pressure regulator Fig 25 1 upward The pressure regulator will audibly detach from the locking mechanism Fig 25 Releasing pressure regulator from locking mechanism 7 Slowly adjust the previously calculated drive pressure by turning the pressure regulator Fig 26 1 and check required drive pressure on manometer Fig 26 2 Turning it to the right will increase the drive pressure turning it to the left reduces the driver pressure 8 Once the drive pressure has been adjusted press the pres sure regulator downward The pressure regulator audibly clicks into place Fig 26 Adjusting the operating pres sure 9 Open the ball valve Fig 27 1 of the compressed air control unit Fig 27 arrow The booster starts delivering as soon as the operating pressure is released via the ball valve Fig 27 Opening the ball valve 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 65 Operation Draining the condensate at the water separator MAXIMATOR 7 5 Draining the condensate at the water separator Fig 28 Checking the water separator A description of how the condensation is drained at the vent valve
12. 5 Remove sleeve Fig 43 1 out on other side of control valve housing 6 Check inside of sleeve for score marks and other signs of damage O If the sleeve is damaged it must be replaced O Make sure not to slide any O ring onto the 1 groove Fig 44 3 of the control sleeve as there is a cross bore in this groove Remove O rings Fig 44 1 from the sleeve Fig 44 2 Clean inside and outside of sleeve with a paper towel Grease new O rings and carefully slide onto sleeve Clean inside and outside of sleeve with a finger Grease the inside of the control valve housing Carefully insert sleeve into control valve housing and push in up to the stop Insert control valve To do this proceed as described in Chapter 8 3 2 Replacing the O rings on the control valve on page 74 steps 11 14 Fig 45 Inserting the sleeve 8 3 4 Cleaning the exhaust air silencer and replacing it if necessary A description of how the exhaust air silencer is cleaned and replaced if necessary is provided below 80 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Faults Fault correction tasks gt Cleaning the exhaust air silencer and replacin Cold components CAUTION Danger of injury due to cold components The exhaust air silencer cools down severely during operation and ices up Prior to starting the tasks let the exhaust air silencer thaw adequately Wipe off any dew that might
13. 5 After completion of hydrogen compression the booster chamber shall again be flushed as described under item 2 Volume flow for gas flushing Depending on the type of booster different volume flows must be ensured to provide for sufficient flushing performance The table below shows the minimum required volume flow Boosters marked in red only require volume flow during start up and decommissioning whereas no volume flow is required during operation Apart from flushing gas volume flow the cross sections of flushing lines are also significant We recommend not to fall below an inner diameter of 4 mm If the diameter is smal ler this involves the hazard of gas pressure accumulating inside the flushing line Under certain circumstances the high pressure component of the booster might be damaged Also make sure the flushing line exit remains unobstructed Type Volumenstrom IN min DLE 2 1 190 DLE 5 1 90 DLE 15 1 40 DLE 30 1 20 DLE 75 1 10 DLE 2 170 DLE 5 90 DLE 15 30 DLE 30 20 DLE 75 10 DLE 2 5 110 DLE 5 15 60 DLE 5 30 70 DLE 15 30 20 DLE 15 75 30 DLE 30 75 10 DLE 2 1 2 190 DLE 5 1 2 90 DLE 15 1 2 30 DLE 30 1 2 20 DLE 75 1 2 10 DLE 2 2 170 DLE 5 2 80 DLE 15 2 30 DLE 30 2 20 DLE 75 2 10 DLE 2 5 2 100 DLE 5 15 2 60 DLE 5 30 2 70 DLE 15 30 2 20 DLE 15 75 2 20 DLE 30 75 2 10 Temperature Booster temperature is dependent of the medium temperature the degree of compression and other operating conditions A pr
14. are used during all fault correction work See Appendix D Cross sectional drawings and bills of materials on page 127 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 47 MAXIMATOR WOCHDRUCKTECHNIK HYDRAULK PNEUMATIK PR FTECIKNIN Accessories 48 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Transport packaging and storage Packaging 5 Transport packaging and storage 5 1 Safety instructions for transport Improper transport 5 2 Transport inspection 5 3 Packaging About packaging Handling packaging materials NOTICE Material damage due to improper transport Transport items can fall or tip over if transported improperly This can cause considerable material damage When unloading transport items at delivery as well as for internal transport proceed carefully and pay attention to the symbols and instructions on the packaging Only remove the packaging just before installation On receipt immediately inspect the delivery for completeness and transport damage Proceed as follows in the event of externally apparent transport damage Do not accept the delivery or only accept it subject to reserva tion m Note the extent of the damage on the transport documentation or the shipper s delivery note Initiate complaint procedures O Issue a complaint in respect of each defect immedi 1 ately following detection Damage compensation claims can o
15. faces Protective work clothing Protective work clothing is tight fitting work clothing with low resist ance to tearing with tight sleeves and without projecting parts Safety footwear Safety footwear protects the feet from crushing injuries falling parts and slipping on a slippery substrate Safety goggles The protective goggles protect the eyes from flying parts and liquid splashes 22 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Safety Signage 2 7 Safety devices Integration into an emergency stop The boosters are incomplete machines and do not have their own concept is reguired controller and do not have an autonomous emergency stop func tion Before the boosters are put into operation emergency stop eguip ment for the machine must be installed and integrated into the plant control safety chain Connect the emergency stop eguipment so that dangerous situa tions for persons and property are ruled out when the power supply is interrupted or restored after an interruption The emergency stop eguipment must always be freely accessible 2 8 Signage The following symbols and information signs can be found in the work area They refer to the immediate surroundings in which they are applied WARNING Danger in the case of illegible signage Stickers and signs can become dirty or otherwise obscured over time so that dangers cannot be recog nised and necessary operating instructions cannot be followe
16. of the water separator is provided below O The booster must be checked daily during operation 1 for the presence of condensation If condensate is pre sent in the water separator it must be drained Personnel Operator Protective eguipment Protective work clothing Safety footwear Safety goggles Special tool Collection container 1 Check water separator of compressed air control unit Fig 28 2 for the presence of condensate If condensate is present it must be drained 2 Position collecting container under vent screw CAUTION Danger from condensate splashing out Slowly open vent screw Fig 28 1 and let condensate drain 3 p 4 Close the vent screw Fig 28 1 66 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Operation Switching off 7 6 Switching off A description of how the booster is switched off is provided below O The boosters have no main switch The booster stops JI operating as soon as the drive air is shut off The switch off process using the compressed air control unit is different from the switch off process without compressed air control unit The two processes are described below Personnel Operator Protective equipment Protective work clothing Safety footwear Safety goggles Switching the booster off In a booster without compressed air control unit the booster stops as soon as the drive air from the in house compressed air netw
17. operating compres sion ratio ating tem mentin pressure sion ratio i1 i2 peraturein Min Pa max Pa cm pB KG static bar DLE 15 30 2 122 600 1 40 1 30 1 60 100 7 30 PL DLE 15 75 2 122 1500 1 100 1 30 1 150 100 7 7 PL DLE 30 75 2 60 1500 1 50 1 60 1 150 100 15 40 PL O Maximum permissible pressure load that may be l used for the high pressure component of the booster Compression ratio operating pressure admission pressure 3 4 Operating conditions Environment Data Value Unit Temperature range 20 60 C Relative humidity maximum 60 Ambient pressure range min 1 bar less than drive pres sure max 10 bar Altitude max unlimited m above sea level Duration Data Value Switch on time Switch on time 50 with stroke frequency gt 60 strokes per minute Switch on time Switch on time 100 with stroke frequency lt 30 strokes per minute 32 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 3 5 Operating materials Lubricant rial Lubricating grease 3 6 Emissions Il Data Noise emission Operating mate Technical data Emissions Manufacturer Designation Kl ber Lubrica ISOFLEX TOPAS NB 52 tion The noise emission measurement was made at a height of 1 5 metres and at a distance of 1 metre to the tester The determined noise emission was measured during full load operation with a counterpressure of 10 bar Value Unit 81 dB A 26 01 2012 Boosters DLE 2 1
18. specialists for potentially explosive areas can independently recog nize potential hazards and prevent dangers Only persons who can be expected to perform their work reliably are authorised as personnel Persons whose capacity to react is impaired e g due to drugs alcohol or medication are not approved as personnel When selecting personnel observe the age and job specific regu lations that apply to the operating site 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 21 Safety Personal protective eguipment 2 5 2 Instruction MAXIMATOR The owner must train personnel on a regular basis Execution of the training must be logged for better traceability Date of training Name of the trained person Content of the training Name of the instructor Signatures of the trained person and of the instructor 2 6 Personal protective equipment Description of the personal protec tive equipment O Q Personal protective equipment is used to protect personnel from impairments to occupational health and safety During the various tasks performed on and with the boosters per sonnel must wear personal protective equipment to which special reference is made in the individual sections of this manual The personal protective equipment is explained below Protective gloves Protective gloves protect hands from friction abrasion puncture wounds or deeper injuries as well as from contact with hot sur
19. 104 sanb10 JONYLS4QYd HINHIILAINIOHIOH HLLVANIN HUINVUGAH UOLJDUJOJU DITUUII o HAO LVWNIXVWN ZNVHL MAXIMATOR Tightening torgues 108 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Index 11 Index A Exhaust air silencer ueseneeenenenennnnnn 39 ACeldent een 24 EX marking urssmeie kn 34 B F Behaviour in the event of faults 71 Fault table rrnnenennrnnennennnna 71 Booster head 22222220200neneeeensnnnnnnnnnnnennnnnn 38 Fire innen 24 Brief description 31 FISst aldi 24 C G Calculating the operating pressure 62 General information mme 27 Checking the manometer for function 58 H Checks before initial commissioning 58 High pressure component 38 Cleaning and greasing the pilot valve 82 Cleaning and greasing the sleeve of the con Initial commissioning nnnennennn 58 trol NON eae TT thawed 78 Inspection at delivery RS AT AD 49 Cleaning the exhaust air silencer and Installing a separate leakage line 56 replacing it if necessary nennen 80 nsa o 57 Cold SUrfa CE Sneins ai 16 on a ahs on a eae 53 nnecting lines m Compressed air control unit 39 m Ker a SS ii Connected loads
20. 2 DLE 75 1 2 33 Technical data Ex marking 3 7 Ex marking Fig 3 Ex marking explosion group IIC Marki ng Ce 2GD IIB IIC Designa tion CE marking Device group Device cat egory Explosion group Explosion group Ignition pro tection type Additional marking MAXIMATOR The Ex marking is located on the drive component of the booster in the immediate vicinity of the type plate Meaning Conformity marking in accordance with Appendix X of Directive 94 9 EC The manufacturer attaches it before the device is put into circulation The booster can be used in potentially explosive areas with the exception of mining For device category 2GD a potentially explosive atmosphere may develop occa sionally involving gases G and dusts D The device ensures a high level of safety and can be used in zone 1 and zone 2 Can be used for substances with a Max imum Experimental Safe Gap of 0 5 mm lt MESG lt 0 9 mm IEC 60079 1 Can be used for substances with a Max imum Experimental Safe Gap lt 0 5 mm IEC 60079 1 Design safety for non electronic devices in potentially explosive areas as per DIN EN 13463 5 Indicates the necessity for compliance with special operating conditions here ambient temperatures Chapter 3 4 Operating conditions on page 32 34 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR 3 8 Type plate
21. 2 1 2 DLE 75 1 2 93 Faults MAXIMATOR Fault correction tasks gt Replacing O ring on air piston 19 Insert socket pin Fig 77 1 into piston mount Fig 77 2 and secure with cotter pin 1 Fig 77 Inserting the socket pin 20 Detach O rings Fig 78 1 from air pipes 21 Grease new O rings and slide onto air pipes Fig 78 Air pipe 22 Remove O rings Fig 79 1 from control bore Fig 79 2 of upper and lower cap with a pointed object scriber Fig 79 O rings of control tube 94 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Faults Fault correction tasks gt Replacing O ring on air piston 23 Place new greased O rings onto ends of control tube Fig 80 1 and insert control tube into control bore Fig 80 2 of upper cap gt Because of the grease on the O ring the seal adheres to the control tube Fig 80 24 Insert stay bolt through upper cap 25 Insert two air pipes Fig 81 1 with new and greased O rings into air pipe bores of upper cap 26 Position lower cap Fig 81 2 on air cylinder and thread in air pipes Fig 81 1 and control tube O The upper stay bolts must be mounted with a il nut a spring washer and a sguare taper washer for U sections The lower stay bolts must only be mounted with a nut a spring washer and the assembly brackets Position stay bolts with nuts spring washers and sguare Fig 81 Installing
22. 70 Pulling out the socket pin 2 10 Push air piston Fig 71 1 in direction of upper cap Fig 71 2 of drive component Fig 71 Air piston 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 91 Faults MAXIMATOR Fault correction tasks gt Replacing O ring on air piston 11 Carefully detach air cylinder Fig 72 1 from air piston Fig 72 2 12 Check seal of upper cap Fig 72 3 and replace if necessary Fig 72 Detaching the air cylinder 13 Detach seal from air piston Fig 73 14 Grease new seal and slide onto air piston O The seal on the air piston is a floating seal and l appears to be too big for the air piston However that is done on purpose 15 Push back air piston in direction of lower cap Fig 73 arrow Fig 73 Detaching the seal NOTICE Risk of damaging the piston seal Position air cylinder Fig 74 1 at an incline to the air piston Fig 74 2 and carefully slide over air piston Fig 74 Putting on the air cylinder 92 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Fig 75 Seal of lower cap Fig 76 Position piston rod Faults Fault correction tasks gt Replacing O ring on air piston 17 Check seals of lower cap Fig 75 1 and replace if neces sary 18 Position lower cap with piston rod Fig 76 1 on piston mount Fig 76 2 and make sure that holes are aligned 26 01 2012 Boosters DLE
23. Improper operation can cause severe injuries and sig nificant material damage Execute all operating steps in accordance with the information and instructions in this manual Comply with the following before starting the work Ensure that all piping threaded unions dis placement media and safety devices are installed correctly and that they function prop erly Ensure that no persons are in the danger zone Never render safety devices inoperable during operation or bypass them 7 2 Daily inspections The inspections listed below must be performed daily before and during operation Personnel Operator Protective equipment Protective work clothing Safety footwear Safety goggles Perform the following inspections before operation Check all threaded unions and piping for damage m f no compressed air control unit is used check the quality of the compressed air Pneumatic on page 28 m Ifa compressed air control unit is used check the function of the manometer Checking the manometer for function on page 58 Perform the following inspection before operation Drain condensation via the vent screw of the compressed air control unit Chapter 7 5 Draining the condensate at the water separator on page 66 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 61 Operation Calculating the operating pressure 7 3 Calculating the operating pressure Before the boo
24. in air will wash out the pneumatic grease Type Inlet connec Outlet con Recommended internal tube diameter in mm tion nection Drive air Admission Operating pres pressure sure DLE 2 1 G 1 2 G 1 2 19 13 13 DLE 5 1 G 1 2 G 1 2 19 13 13 DLE 15 1 G 1 4 G 1 4 19 6 4 DLE 30 1 G 1 4 G 1 4 19 6 4 DLE 75 1 G 1 4 G 1 4 19 6 4 28 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Technical data Connected loads Type Inlet connec Outlet con Recommended internal tube diameter in mm gen nn Drive air Admission Operating pres pressure sure DLE 2 G 1 2 G 1 2 19 13 13 DLE 5 G 1 2 G 1 2 19 13 13 DLE 15 G 1 4 G 1 4 19 6 4 DLE 30 G 1 4 G 1 4 19 6 4 DLE 75 G 1 4 G 1 4 19 6 4 DLE 2 5 G 1 2 G 1 2 19 13 13 DLE 5 15 G 1 2 G 1 4 19 13 4 DLE 5 30 G 1 2 G 1 4 19 13 4 DLE 15 30 G 1 4 G 1 4 19 6 4 DLE 15 75 G 1 4 G 1 4 19 6 4 DLE 30 75 G 1 4 G 1 4 19 6 4 DLE 2 1 2 G 1 2 G 1 2 19 13 13 DLE 5 1 2 G 1 2 G 1 2 19 13 13 DLE 15 1 2 G 1 4 G 1 4 19 6 4 DLE 30 1 2 G 1 4 G 1 4 19 6 4 DLE 75 1 2 G 1 4 G 1 4 19 6 4 DLE 2 2 G 1 2 G 1 2 19 13 13 DLE 5 2 G 1 2 G 1 2 19 13 13 DLE 15 2 G 1 4 G 1 4 19 6 4 DLE 30 2 G 1 4 G 1 4 19 6 4 DLE 75 2 G 1 4 G 1 4 19 6 4 DLE 2 5 2 G 1 2 G 1 2 19 13 13 DLE 5 15 2 G 1 2 G 1 4 19 13 4 DLE 5 30 2 G 1 2 G 1 4 19 13 4 DLE 15 30 2 G 1 4 G 1 4 19 6 4 DLE 15 75 2 G 1 4 G 1 4 19 6 4 DLE 30 75 2 G 1 4 G 1 4 19 6 4 8 DLE 3 G1 2 G 1 2 19 13 13 8 DLE 6 G1 2 G1 2 19 13 13 8 DLE 1 65 G1 2 G1 2 19 13 13 26 01 2012 B
25. max 60 When storing for longer than three months check the general condition of all parts and the packaging on a regular basis Touch up or reapply anti corrosion agents as needed O It may be the case that storage instructions are affixed l to the packages that extend beyond the requirements cited here Comply with these instructions accordingly 50 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 SS AE MAGMATOR 6 Installation and initial commissioning Prerequisites for installation Installation and initial commissioning 6 1 Safety instructions for installation and initial commissioning Improper installation and initial commissioning A Explosion protection A 6 2 Prerequisites for installation WARNING There is an injury hazard if the device is not installed and commissioned properly Improper installation and commissioning can cause severe injuries and significant material damage Only allow mechanical engineers and plant engi neers to perform installation and initial commis sioning Ensure order and cleanliness at the installation location Parts and tools that are Iying loose or on top of each other are accident hazards Properly mount lines and hoses Maintain the pre scribed bolt tightening torque Only remove sealing plugs immediately before mounting the connecting lines Comply with the following before initial commis sioning Ensure that all installation tas
26. replaced is provided below Personnel m Specialist for potentially explosive areas Protective eguip Safety goggles ment m Safety footwear Protective work clothing Special tool m Spanner width across flats 13 mm 0 51 inch Long nose pliers Lubricating grease O It is always necessary to clean grease or if neces l sary replace both pilot valves 1 gt Bring the booster to a standstill depressurise and let the stored pressure completely dissipate 2 Purge booster with nitrogen Proceed as described in amp Appendix A Hydrogen compression with Maximator boos ters on page 113 to do this 3 gt Position spanner Fig 48 1 at threaded union of pilot valve Fig 48 2 Fig 48 Pilot valve 82 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR WOCNORUCKTECHNIK HYDRAULK PNEUMATIK PR FTECINN Fig 50 Pilot valve tappet Faults Fault correction tasks gt Cleaning and greasing the pilot valve 4 Remove threaded union with sealing ring Fig 49 1 and pilot valve spring Fig 49 2 and secure to prevent it from getting lost The pilot valve tappet Fig 50 1 is located in the pilot valve opening 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 83 Faults MAXIMATOR Fault correction tasks gt Cleaning and greasing the pilot valve 5 Carefully insert long nose pliers Fig 51 1 into pilot valve opening and pull out pilot valve tapp
27. severe or fatal injuries for persons in the danger zone Before starting work shut off all media depressu rise the booster and safeguard it from being switched on again 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 69 Faults Safety instructions for fault correction Improperly executed fault correc tion tasks WARNING Danger of injury due to improper fault correction Improperly executed fault correction tasks can cause severe injuries and significant material damage Compressed air and gases Before starting work purge the booster with nitrogen Ensure order and cleanliness at the installation location Parts and tools that are lying loose or on top of each other are accident hazards If components have been removed ensure that they are properly reinstalled that all fastening ele ments are reinstalled and that all threaded connec tions are tightened with the specified bolt tight ening torgue Comply with the following before restarting Ensure that all fault correction tasks have been properly executed and concluded in accord ance with the instructions in this manual Ensure that no persons are in the danger zone WARNING Danger of injury due to compressed air and gases In the event of a fault or a defect compressed air or gas can escape from compressed air lines hoses or pressurised components of the booster This com pressed air or gases can whirl up dust cause u
28. unchanged Special features in project planning of hydrogen stations Generally the compression of hydrogen does not place spe cial demands on safety installations For example the ins tallation of additional temperature and pressure monitoring devices is normally not necessary In the selection of the various components regulators valves filters etc special emphasis must be placed on their suitability for hydrogen In general it must be ensured that only such components are used which do not have a potential source of ignition The material also has to be resistant against hydrogen embrittle ment Therefore medium carrying lines should be of stainless steel grade 1 4404 1 4571 or similar Hose lines are unsuitable for hydrogen stations according to ATEX IIC because of their lack of conductivity SB MAXIMATOR B Connection drawing Connection drawing 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 123 124 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR C Installation plan Installation plan 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 125 126 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Cross sectional drawings and bills of materials D Cross sectional drawings and bills of materials 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 127 128 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAX
29. which are per missible for the particular booster models For this purpose compare the type information on the type plate with that in the following table Always observe the special instructions for the par ticular displacement media Displacement Symbol Booster types Special instructions for the com medium gases pression of the displacement media Argon Ar All models N butane CH All models Lay pipes and rinse SFP special flushing port and leak bores high pressure seal not 100 gas tight Compressed air All models Carbon monoxide co DLE xxx C Lay pipes and rinse SFP special flushing port and leak bores high pressure seal not 100 gas tight Carbon dioxide CO DLE xxx C Ethane CH All models Lay pipes and rinse SFP special flushing port and leak bores high pressure seal not 100 gas tight Ethylene C2H4 All models Lay pipes and rinse SFP special flushing port and leak bores high pressure seal not 100 gas tight Freon F 12 CCL F2 DLE xx CR Lay pipes and rinse SFP special flushing port and leak bores high pressure seal not 100 gas tight Helium He All models Hydrogen H2 DLExxx H2 Lay pipes and rinse SFP special flushing port and leak bores high pressure seal not 100 gas tight Methane CH All models Lay pipes and rinse SFP special flushing port and leak bores high pressure seal not 100 gas tight Acid gas natural gas DLE xxx NACE Lay pipes and rinse SFP special with portions of flu
30. 1 9 Carefully attach booster head Fig 88 1 on the stay bolts 10 Fasten booster head with nuts and square taper washer for U sections and tighten with a torque of 40 Nm 11 Install booster at installation location and tighten foundation bolts with a torque of 85 Nm 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 97 Faults MAXIMATOR Fault correction tasks gt Cleaning the inlet and outlet valve of the boo 8 3 7 Cleaningthe inlet and outlet valve of the booster head Fig 89 Releasing the valves A description of how the inlet and outlet valve of the booster head is checked for soiling and cleaned is provided below Personnel m Specialist for potentially explosive areas Protective equipment M Protective work clothing m Safety footwear m Safety goggles E Spanner Torque wrench Special tool O In single stage dual acting and two stage boosters Jl inlet and outlet valves must be removed and cleaned on both booster heads O The inlet and outlet valves of booster models DLE 2 1 and DLE 5 differ in design from those described below However the fault correction procedure is identical 1 gt Bring the booster to a standstill depressurise it and let the stored pressure completely dissipate 2 gt Purge booster with nitrogen Proceed as described in Appendix A Hydrogen compression with Maximator boos ters on page 113 to do this 3 Remove inlet and outl
31. 2 3 Table of contents 4 3 5 Drive component imannnnnnnneeannannenenae 38 4 3 6 Exhaust air silencer mteenrn 39 4 3 7 Cooling cylinder aaaananmnt sanataaanenaneni 39 4 3 8 Compressed air control unit 39 4 4 Mode of operation of the boosters 39 4 9 Version S sauce hunn mare wenden 41 4 6 Connections 44 4 7 Working areas and danger zones 46 4 8 Scope of delivery wrmnnnnn 46 4 9 ACcessofi8S 12sssvviviitaddmimava aa ktaavi 46 5 Transport packaging and storage 49 5 1 Safety instructions for transponrt 49 5 2 Transport inspection rew 49 5 3 Packaging trnamrramr 49 9 4 Storage iiber 50 6 Installation and initial commissioning 51 6 1 Safety instructions for installation and initial commis SIONINg nes een aa A 51 6 2 Prerequisites for installation nn 51 6 3 Mounting the booster as 53 6 4 Installing the connecting lines 53 6 4 1 Connecting the drive air ma 55 6 4 2 Connecting the inlet line for admission pressure and outlet line for operating pressure 56 6 4 3 Installing a sep
32. 5 Cleaning and greasing the pilot valve on page 82 Check high pressure seal or high pressure cyl Personnel Specialist for potentially explosive areas Operator Operator Specialist for potentially explosive areas Specialist for potentially explosive areas Specialist for potentially explosive areas Specialist for potentially explosive areas Specialist for potentially explosive areas Specialist for potentially explosive areas Specialist for potentially explosive areas Specialist for of bores Z1 and Z3 seal or high pres inder for wear and replace if necessary potentially sure cylinder is Chapter 8 3 9 Checking high pressure seals explosive worn and high pressure cylinder for signs of damage areas on page 100 72 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Fault description Leaks on silencers of bores Z1 and Z3 only for DLE 15 30 and 75 Booster does not work but exhaust air silencer blows out air Leaks on inlet and or outlet valve of booster head booster does not reach operating pressure Cause High pressure piston with pres sure cylinder is worn O ring on the air piston is worn Inlet and or outlet valve soiled or defective 8 3 Fault correction tasks 8 3 1 Purging the high pressure component with nitrogen Boosters that are used to compress combustible or toxic gases must be purged with nitrogen prior to starting t
33. IMATOR Safety data sheet for lubricating grease E Safety data sheet for lubricating grease 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 129 130 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 ISOFLEX TOPAS NB 52 LUBER LUBRICATION MATERIAL SAFETY DATA SHEET Printdate 14 Dec 2010 Revision Number 2 Revision date 14 Dec 2010 1 IDENTIFICATION OF THE SUBSTANCE PREPARATION AND THE COMPANY UNDERTAKING Product Name ISOFLEX TOPAS NB 52 Article Code 004131 Synonyms No information available Chemical characterisation Not applicable Supplier Kl ber Lubrication North America L P 32 Industrial Drive Londonderry NH 03053 603 647 4104 Fax 603 647 4106 Emergency telephone number CHEMTREC 1 800 424 9300 International 703 527 3887 2 COMPOSITION INFORMATION ON INGREDIENTS Components CAS No ACGIH TWA mg m3 OSHA TWA mg m3 Synthetic hydrocarbon oil None None Barium complex soa None None 3 HAZARDS IDENTIFICATION Properties affecting health Harmful if swallowed Principle routes of exposure Skin Skin contact Substance may cause slight skin irritation Eye contact Contact with eyes may cause irritation Inhalation Vapors and or aerosols which may be formed at elevated temperatures may be irritating to eyes and respiratory tract Ingestion Harmful if swallowed Ingestion may cause gastrointestinal irritation nausea vomiting and diarrhoea 4 FIRST AID MEASURES General
34. MAXIMATOR DRUCKLUFTBETRIEBENER KOMPRESSOR Typ Baujahr Serien ir Gasdruck min Einlad max Auslad ax Luftantrieb Obersetzungsverhaltnis max eupfohlenes Koapressionsverhaltinis Fig 4 Type plate 3 9 Type key DLE XX XX X XX X 1 ue K 3 4 Fig 5 Type key Technical data Type key The type place is centrally located on the drive component of the booster and contains the following information Manufacturer Type information from type key Year of manufacture Gas pressure min inlet Gas pressure max outlet Maximum air drive Transmission ratio Max compression ratio The type key for the corresponding booster models is structured as follows 1 Version for C CO S oxygen 2 Thread of gas inlet and outlet G pipe thread standard U high pressure connection N NPT 3 1 1 high pressure piston 2 2 drive pistons 4 Design e g DEL 15 75 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 35 MAXIMATOR WOCHDRUCKTECHNIK HYDRAULK PNEUMATIK PR FTECIKNIN Type key 36 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Structure and function MAXIMATOR Brief description 4 Structure and function 4 1 Overview Fig 6 Overview 1 Pilot valve 1 5 Exhaust air silencer 2 Control valve 4 2 directional control valve 6 Booster head with suction and pressure valve 3 Air cyli
35. Operating instructions Boosters DLE 2 1 2 DLE 75 1 2 Read the instructions prior to performing any task Maximator GmbH Lange Stra e 6 D 99734 Nordhausen Telephone 49 0 3631 9533 0 Fax 49 0 3631 9533 5065 email info maximator de Internet www maximator de Translation of the original operating instructions Maxi 14315 DE 1 en_GB This operating manual was created by Kothes Technische Kommunikation GmbH 8 Co KG Internet www kothes de Maximator GmbH 2010 2 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Table of contents Table of contents General inienn a data taga dla 7 1 1 Information about this manual een 7 1 2 Explanation of symbols useennennnnnnnneeennnnnenn 7 1 3 Copyrigh ecic E a 9 1 4 Customer service 2 emnenrennnnat 9 Safely E A 11 2 1 Intended use ennnnnentennennnnnenane 11 2 2 Permissible displacement media gases 12 2 3 Basic dangers aissi 14 2 3 1 General dangers at the workplace 15 2 3 2 Dangers due to gases under pressure 15 2 3 3 Dangers due to low temperatures 16 2 3 4 Dangers due to fire nenn 17 2 3 5 Dangers due to explosion 00mu 17 2 3 6 Dangers due to chemical substances 18 2 4 Responsibility of the owner
36. Personnel Mechanical and plant engineers Protective work clothing Safety goggles Safety footwear Protective equipment Power drill m Vacuum cleaner Special tool 1 Set up booster with pre assembled angle brackets at installa tion site O To do this observe the installation plan 1 Appendix C Installation plan on page 125 Place booster mark bore holes and remove booster again Drill installation holes Remove drilling dust using vacuum cleaner gt jo ID Set up booster and use fixing bolts and spring washers with a torque of 85 Nm to fasten to foundation 6 4 Installing the connecting lines A description of how the booster is connected to the compressed air network and to a transport gas container is provided below O The booster is delivered without any threaded unions 1 or piping Observe the information in Connected loads mechanical on page 28 and Appendix B Connection drawing on page 123 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 53 Installation and initial commissioning Installing the connecting lines Personnel Protective eguipment Special tool Unforeseeable movements A Use of incorrect connecting lines A Mechanical and plant engineers Protective work clothing Safety footwear Safety goggles Spanner WARNING Danger of injury due to unforeseeable movements of compressed air lines Lines of the in house compressed air net
37. RT INFORMATION IMO IMDG ICAO IATA 15 REGULATORY INFORMATION TSCA TSCA Listed in TSCA U S Regulations Barium complex soap SARA 313 Threshold Barium compound 25 35 Sara 311 312 hazard class Canada WHMIS hazard class Non controlled 16 OTHER INFORMATION NFPA Health 1 Flammability 1 Instability 0 HMIS Health 1 Flammability 1 Physical Hazard 0 Reason for revision Not applicable Prepared by Health amp Safety The information and recommendations contained herein are based upon tests believed to be reliable However Kl ber does not guarantee their accuracy or completeness NOR SHALL ANY OF THIS INFORMATION CONSTITUTE A WARRANTY WHETHER EXPRESSED OR IMPLIED AS TO THE SAFETY OF THE GOODS THE MERCHANTABILITY OF THE GOODS OR THE FITNESS OF THE GOODS FOR A PARTICULAR PURPOSE Adjustment to conform to actual conditions of usage maybe required Kl ber assumes no responsibility for results obtained or for incidental or consequential damages including lost profits arising from the use of these data No warranty against infringement of any patent copyright or trademark is made or implied 4 of 4
38. advice If symptoms persist call a physician Skin contact Rinse with plenty of water If skin irritation persists call a physician Inhalation Move to fresh air in case of accidental inhalation of fumes from overheating or combustion If symptoms persist call a physician Product name ISOFLEX TOPAS NB 52 10f4 Eye contact Flush eye with water for 15 minutes If symptoms persist call a physician Ingestion Do not induce vomiting Consult a physician Notes to physician Treat symptomatically 9 FIRE FIGHTIN G MEASURES Suitable extinguishing media Carbon dioxide CO2 Dry chemical Dry sand Water spray mist or foam Extinguishing media which must not be used for safety reasons Do not use a solid water stream as it may scatter and spread fire Special protective eguipment for firefighters In the event of fire and or explosion do not breathe fumes In the event of fire wear self contained breathing apparatus Standard procedure for chemical fires Specific hazards Burning produces irritant fumes In the event of fire and or explosion do not breathe fumes Unusual hazards No hazards resulting from the material as supplied Specific methods Water mist may be used to cool closed containers Standard procedure for chemical fires Flash point Not applicable Autoignition temperature Not determined Flammability Limits in Air Lower No information available Upper No information available 6 ACCIDENTAL RELEASE MEASURES Perso
39. ain through these inlet and outlet valves 4 3 2 High pressure component The high pressure component is used to compress the particular displacement medium The high pressure component consists of the pressure cylinder booster head with inlet and outlet valves and the high pressure piston with the sealing and guide elements 4 3 3 Pilot valve The pilot valves are used by the air piston as a limit switch The pilot valves are actuated by the air piston in the end positions they forward air pulses to the control valve As a result the pilot valves ventilate the actuation chamber of the control valve This moves the control valve from one end position to the other 4 3 4 Control valve The control valve is used to alternately apply compressed air to the upper and lower side of the air piston The control valve is actuated via the pilot valves it ensures that the drive air is directed to the left and or right side ofthe air piston 4 3 5 Drive component The drive component is used to accommodate the drive air com pressed air it actuates the high pressure component of the booster via a piston rod thus compressing the particular displace ment medium to a higher pressure 38 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Structure and function Mode of operation of the boosters 4 3 6 Exhaust air silencer The exhaust air silencer is used to discharge expanding air from the booster with reduced noise The drive ai
40. air pipes and lower taper washers for U sections and tighten with a torque of 55 8 3 6 3 Installing the high pressure component 1 Position high pressure cylinder with high pressure piston Fig 82 1 on piston rod Fig 82 2 and make sure that holes are aligned Fig 82 Installing the high pressure cylinder 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 95 Faults MAXIMATOR Fault correction tasks gt Replacing O ring on air piston 2 Insert dowel pin Fig 83 2 into bore and slide safety sleeve Fig 83 1 over dowel pin connection Fig 83 Securing the dowel pin 3 p Slide O ring Fig 84 1 on piston rod into groove in front of safety sleeve The safety sleeve is fixed in place by the O ring 4 Slide high pressure cylinder in direction of lower cap Fig 84 O ring 5 Carefully slide cooling pipe and high pressure pipe Fig 85 1 over high pressure cylinder Fig 85 2 Fig 85 Cooling pipe and high pres sure pipe 96 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Faults Fault correction tasks gt Replacing O ring on air piston 6 Fasten cooling pipe Fig 86 1 to threaded piece of control valve housing Fig 86 Fastening the cooling pipe 7 _ Detach seal from booster head Fig 87 1 8 Grease new seal and carefully slide onto booster head Fig 87 Booster head seal Fig 88 Attaching booster head
41. al Prior to dismantling purge the booster with nitrogen to flush any remaining toxic and combus tible gases out of the booster Only perform dismantling work when a potentially explosive atmosphere can be ruled out Only use those tools that are authorised for use in the Ex zone Non compliance with these instructions will result in loss of explosion protection Improper dismantling WARNING Danger of injury due to improper dismantling Stored residual energy sharp edged components points and corners on or in the booster or on the required tools can cause injuries Prior to starting the tasks ensure that there is ade quate free space Shut off all operating media to the booster Ensure order and cleanliness at the workplace Parts and tools that are lying loose or on top of each other are accident hazards Consult with the manufacturer if there are ques tions 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 105 Dismantling and disposal Tightening torgues 10 2 Dismantling Personnel m Specialist for potentially explosive areas Protective equipment M Protective work clothing Safety footwear E Safety goggles 1 Bring the booster to a standstill depressurise and let the stored pressure completely dissipate 2 Purge booster with nitrogen Proceed as described in amp Appendix A Hydrogen compression with Maximator boos ters on page 113 to do this R
42. and after use An explosive mixture can form inside the compressor cham ber but also in the rear piston chamber due to a little leakage at the high pressure seals aoe PAN FO GI GLOBAL PRESSURE SOLUTIONS To also provide for safe flushing of these areas the MAXI MATOR hydrogen boosters are also fitted with an additional flushing connection In accordance with the boosters opera ting principle different flushing processes shall be carried out to ensure safe operation If no flushing is carried out these areas are characterised by zone zero In this case MAXIMATOR boosters would belong in category 1 which requires type approval test In the cur rent version the boosters do not meet the requirements of category 1 Therefore operation without flushing is expressly prohibited Flushing plans for MAXIMATOR hydrogen boosters To be able to effectively flush the rear piston chamber of the booster please observe the following installation scheme when fitting the flushing line It is important that there is a continuous flow of flushing gas through the flushing lines during the complete duty cycle Make sure in particular that flushing lines are not pressurised Otherwise this might result in damage of the high pressure section Prior and after operation of the booster or equipment the booster chamber and associated lines shall be flushed with copious amounts of nitrogen or another inert gas Through the flushing process
43. arate leakage line 56 6 5 Installing exhaust air SINCE eee een 57 6 6 Initial commissioning mrrmrrs 58 7 Operation 61 7 1 Safety instructions for operation 61 7 2 Daily insPEGti ONS seatakse kakaga aaalasi en 61 7 3 Calculating the operating pressure 62 1 4 SWitching On nel 63 7 5 Draining the condensate at the water separator 66 1 6 Switching Off ee 67 7 7 Shutdown in an emergency situation 68 8 Fa lts ecoscore einen 69 8 1 Safety instructions for fault correction 69 8 2 Faulttable nn ensiiensnkiine dead 71 8 3 Fault correction tasks 00 mra 73 8 3 1 Purging the high pressure component with NOGO Sa 73 8 3 2 Replacing the O rings on the control valve 74 8 3 3 Cleaning and greasing the sleeve ofthe control VAIVE ie enpu E lead 78 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 1 Table of contents 8 3 4 Cleaning the exhaust air silencer and replacing it if NECESSAry sera naar rare 80 8 3 5 Cleaning and greasing the pilot valve 82 8 3 6 Replacing O ring on air piston 85 8 3 7 Cleaning the inlet and outlet valve of the booster GAG AAA 98 8 3 8 Replacing the high pressure cylinder with high pressure piston as a complete component
44. be present Personnel Operator Safety goggles Protective work clothing Safety footwear Protective gloves Protective equipment O Depending on the version the exhaust air silencers of 1 the individual booster models can be different How ever the tasks described below are always identical 1 Bring the booster to a standstill depressurise and let the stored pressure completely dissipate 2 Letthe iced up exhaust air silencer thaw adequately wipe off any water that might have thawed 3 gt Unscrew silencer Fig 46 1 from exhaust air connection Fig 46 2 4 gt Adequately purge exhaust air residues in the exhaust air silencer with water and detergent Fig 46 Exhaust air silencer 5 Blow out exhaust air silencer with a compressed air gun in pt the opposite direction of the exhaust air Fig 47 arrow i _ Ifthe deposits cannot be removed or if the Fig 47 Blowing out the exhaust air 1 booster does not reach the required stroke fre silencer guency or power after it has been cleaned the exhaust air silencer must be replaced 6 Screw exhaust air silencer into exhaust air connection and tighten hand tight 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 81 Faults MAXIMATOR Fault correction tasks gt Cleaning and greasing the pilot valve 8 3 5 Cleaning and greasing the pilot valve A description of how the pilot valves are cleaned and greased or if necessary
45. ch high pressure cylinder Fig 64 1 from piston rod Fig 64 2 Fig 64 Detaching the high pressure cylinder 8 3 6 2 Removing drive component and replacing O ring of air piston 1 Undo threaded union of 4 stay bolts Fig 65 marked in red and secure to prevent from getting lost O The upper stay bolts are mounted with a nut a Jl spring washer and a square taper washer for U sections The lower stay bolts are only mounted with a nut and a spring washer 2 gt Pull out stay bolt 3 Remove mounting bracket Fig 65 1 Fig 65 Stay bolt 4 Push lower cap Fig 66 1 of drive component from air cyl inder Fig 66 2 gt The 2 air pipes are now hanging free Fig 66 Lower cap 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 89 Faults MAXIMATOR Fault correction tasks gt Replacing O ring on air piston 5 Detach air pipes Fig 67 1 X Fig 67 Air pipes 6 Remove control tube Fig 68 1 Fig 68 Control tube 7 Remove cotter pin Fig 69 1 of socket pin from piston mount Fig 69 2 Fig 69 Cotter pin 90 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Faults HOCHDRUCKTECHNIK MYDRALLIK PNEUMATIK PROFTE Fault correction tasks gt Replacing O ring on air piston 8 Pull out socket pin Fig 70 1 with pliers from the piston mount 9 Detach lower cap of drive component and piston rod 12 Fig
46. ction Skin and body protection Usual safety precautions while handling the product will provide adequate protection against this potential effect Eye protection Avoid contact with eyes Hygiene measures Avoid contact with skin eyes and clothing 9 PHYSICAL AND CHEMICAL PROPERTIES Physical State Grease Appearance Paste Color Beige Odor Not significant Specific gravity 0 96 Boiling point range No information available Evaporation rate Not determined Vapor density Not determined Vapor pressure Not determined Solubility Insoluble 10 STABILITY AND REACTIVITY Stability No hazards to be especially mentioned Polymerization Hazardous polymerisation does not occur Hazardous decomposition products None under normal use Materials to avoid Strong oxidising agents Conditions to avoid Heat flames and sparks 11 TOXICOLOGICAL INFORMATION Acute toxicity No data available 12 ECOLOGICAL INFORMATION Mobility No information available Bioaccumulative potential No information available Ecotoxicity effects No data available Aquatic toxicity No information available 13 DISPOSAL CONSIDERATIONS Waste from residues unused In accordance with local and national regulations products Contaminated packaging Empty containers should be taken for local recycling recovery or waste disposal 14 TRANSPORT INFORMATION oO OT Proper shipping name Not regulated by DOT TDG Canada 30f4 14 TRANSPO
47. ction marked in this manner is not observed there is an increased danger of explosion and severe or fatal injuries can be the conseguence Safety instructions in operating Safety instructions can refer to specific individual instructions instructions Such safety instructions are incorporated into the instructions so that they do not interrupt the flow of reading when carrying out the action The signal words described above are used Example 1 Loosen screw 2 CAUTION Risk of pinching at the lid Carefully close the lid 3 Tighten screw Tips and recommendations O This symbol highlights useful tips and recommenda 1 tions as well as information designed to ensure effi cient and smooth operation Additional designations The following designations are used in this manual to indicate instructions results listings references and other elements 8 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Designation Explanation General Customer service Step by step handling instructions gt Results of handling instructions D References to sections of this manual and to other applicable documents m Listings without specified sequence 1 3 Copyright The contents of this manual are protected by copyright They are permitted to be used in the context of utilisation of the booster Any use beyond this without the written permission of the manufacturer is not authorised 1 4 Customer service Our cus
48. d This causes a risk of injury Always keep all safety notices warnings and oper ating instructions in a clearly legible condition Replace damaged signs or stickers immediately Signage at the booster The signs attached on the booster are presented and explained in the following illustration O Depending on the version of the booster the informa 1 tion on the signs can vary 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 23 Safety MAXIMATOR KTECHNIK M Behaviour in case of fire or accidents Illustration Description Attention Not suitable for ACHTUNG oxygen F r Sauerstoff nicht geeignet WARNING Do not use for oxygen gases Attention Keep grease free suitable for OPERATION WITH M Fettfrei halten gereinigt f r Fig 1 Signage SAUERSTOFFBETRIEB OXYGEN WARNING Usenolubricants cleanedtor EN SERVICE 2 9 Behaviour in case of fire or accidents Preventive measures E Be prepared for fire and accidents at all times Keep first aid equipment first aid kit blankets etc and fire extinguishing devices operational and readily available E Make your personnel familiar with accident reporting equip ment as well as first aid and rescue equipment E Keep access paths clear for rescue vehicles Steps in case of fire and accidents Immediately trigger an Emergency Stop using EMERGENCY STOP devices E Provided your own health is not in danger rescue al
49. easing O rings 9 Slide new O rings Fig 35 1 onto control valve and cap 10 Lightly lubricate control valve and cap with grease 4 Fig 35 Sliding on new O rings 76 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Faults MAXIMATOR Fault correction tasks gt Replacing the O rings on the control valve 11 Insert control valve Fig 36 1 into control valve housing and push in up to the stop Fig 36 arrow Fig 36 Inserting control valve 1 12 Insert cap Fig 37 1 into control valve housing Fig 37 2 a 2 Fig 37 Inserting the cap 13 Secure cap in control valve housing using circlip Fig 38 1 Fig 38 Securing the cap 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 77 Faults MAXIMATOR Fault correction tasks gt Cleaning and greasing the sleeve of the contro 14 Position and fasten elbow union Fig 39 1 of compressed air control unit to drive air connection of control valve housing Fig 39 Removing the elbow union 15 Fasten piping Fig 40 1 of compressed air control unit to elbow union Fig 40 2 Fig 40 Installing compressed air con trol unit 8 3 3 Cleaning and greasing the sleeve of the control valve A description of how the sleeve of the control valve is cleaned and greased is provided below Personnel Specialist for potentially explosive areas Protective equip ment Safety goggles Safety footwea
50. emove all piping and threaded unions Undo foundation bolts Then properly clean assemblies and components and take them apart in compliance with the applicable occupational health and safety and environmental protection regulations 10 3 Disposal If no return or disposal agreement has been made send the dis mantled components for recycling m Scrap metals m Send plastic elements for recycling Sort and dispose of other components in accordance with their material composition NOTICE Danger to the environment due to incorrect dis posal Incorrect disposal may pose risks to the environment Electrical scrap electronic components lubricants and other auxiliary materials must be disposed of by authorised specialist companies Ifin doubt obtain information about disposal in accordance with the environmental regulations from the local municipal authorities or specialised waste disposal companies 10 4 Tightening torques 106 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 kad x H q Guruado UIUSIM MS yaus m xoq dsai pua u d 0 1 sz oe s 310 1 s 370 1 z 370 TN M s 10 Oo PM OM u01498S dH pod 21 uo 9 uuo0 snoyx JUUUIDJID U0 SId puoj6 2 3ng pud 6 jaju MALIS AJDA JO Id GUISNOU JAJDA oodG jpas dH nu voluyn u0l 99S ALJP JID pOJ OI 4915008 41d ad4 Hgug 0 X ZUDIY IPIUYUIS Jap Yo aieqs soyosag su0o1 99UU0OI M J S
51. erating instructions The owner must clearly regulate and specify responsibilities for installation operation fault correction maintenance and cleaning The owner must ensure that all personnel who handle the boosters have read and understood this operating manual In addition the owner must train personnel and inform them about the hazards at regular intervals The owner must provide the reguired protective eguipment for personnel and instruct personnel that the wearing of the required protective equipment is a binding obligation The owner is also responsible for keeping the boosters in faultless technical condition at all times The following therefore applies The owner must ensure that the boosters are integrated in the emergency stop devices or in the safety chain of the system in which the boosters are installed When aggressive displacement media and or toxic gases are used the owner must ensure that lines will be installed that will capture the leaking aggressive media and or toxic gases in cor responding containers and that the aggressive and toxic media will be disposed of properly When aggressive combustible dangerous or toxic gases are compressed the owner must ensure that the boosters are flushed with nitrogen before any fault elimination work is per formed The owner must ensure that only permissible displacement media Chapter 2 2 Permissible displacement media gases on page 12 will be compressed with
52. erequisite for safe operation is that the booster is correctly connected to earth potential For ideal gases the temperature to be expected can be cal culated by the following formula 4 PAN FO GI GLOBAL PRESSURE SOLUTIONS X Pars E with T Temperature after compression in K T Temperature prior to compression in K P Pressure after compression in bar P Pressure prior to compression in bar X Isentropic exponent The isentropic exponent for hydrogen is 1 41 Due tothe fact that compression cannot take place without a heat exchange with the environment the actual temperature will always remain below the calculated temperature If the temperature of the compressed gas exceeds the maximum admissible temperature compression has to be performed in several steps with a cooling phase in between the individual compression steps Ifthe temperature of the compressed gas lies below the ma ximum admissible temperature you have to ensure that in dependence with the respective explosion zone that ope rating conditions do not change A slightly less inlet pressure would result in a higher temperature High pressure screw connections and hydrogen As arule high pressure screw connections cone and thread are suitable for hydrogen operation The operator of hydrogen equipment with high pressure screw connections has to be advised that there might be possib le leakage from leakage bores in fitti
53. et Fig 51 2 6 Check pilot valve tappet and O ring for signs of damage O A damaged pilot valve tappet must be replaced 7 gt Clean and grease pilot valve tappet with a paper towel Fig 52 Pilot valve tappet 8 Carefully insert pilot valve tappet Fig 53 2 with the long nose pliers Fig 53 1 Fig 53 Inserting the pilot valve tappet 84 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Faults Fault correction tasks gt Replacing O ring on air piston 9 Position and tighten pilot valve spring Fig 54 2 and threaded union with sealing ring Fig 54 1 O To clean and grease the second pilot valve proceed 1 as described in steps 1 9 Fig 54 Fastening the pilot valve 8 3 6 Replacing O ring on air piston A description of how the O ring on the air piston is replaced is pro vided below O Many of the steps described below must be carried out 1 inthe exact same manner for other fault correction tasks In the corresponding chapters references are made to the respective steps in this chapter Personnel m Specialist for potentially explosive areas Protective equipment M Safety goggles m Safety footwear Protective work clothing a Special tool Spanner 8 3 6 1 Removing the high pressure component 1 Bring the booster to a standstill depressurise and let the stored pressure completely dissipate 2 gt Purge booster with nitrogen Proceed as desc
54. et valves on the booster head and pro tect the open lines from soiling 4 Undo inlet and outlet connections Fig 89 1 on booster head with a spanner Fig 89 2 98 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Faults Fault correction tasks gt Replacing the high pressure cylinder with high 5 Remove inlet and outlet valve from booster head Fig 90 Removing the valve 2 3 4 5 1 6 gt Carefully dismantle valve on a clean working surface ios a O The valves consist of two O rings Fig 91 1 oO SS wy u O 1 valve seat Fig 91 2 ball Fig 91 3 compres Fig 91 Dismantled valve sion spring Fig 91 4 and valve body Fig 91 5 N Y Clean all components of the valve check for signs of damage and replace if necessary 8 gt NOTICE Danger of material damage due to incorrect installation Install valve in identical seguence 9 Make sure when installing the valves that the conical valve seat Fig 92 1 of the valve is always inserted in the flow direction Fig 92 arrows into the booster head Fig 92 2 10 Fasten inlet and outlet connections and tighten with a torque of 120 Nm 11 Install piping of inlet and outlet lines according to amp Appendix B Connection drawing on page 123 Fig 92 Installation direction 8 3 8 Replacing the high pressure cylinder with high pressure piston as a complete component A description
55. etach booster head Fig 58 1 from stay bolts Fig 58 Detaching the booster head 10 Undo threaded union of cooling pipe from control valve housing Fig 59 1 Fig 59 Removing the cooling pipe 11 Carefully pull off cooling pipe and cooling cylinder Fig 60 1 from pressure cylinder Fig 60 2 Fig 60 Removing the cooling pipe 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 87 Faults MAXIMATOR Fault correction tasks gt Replacing O ring on air piston 12 NOTICE Danger of material damage Carefully pry off high pressure cylinder Fig 61 1 with a screwdriver Fig 61 2 from lower cap of drive component Fig 61 3 13 Slowly pull back high pressure cylinder on piston rod Fig 61 Prying off the high pressure cylinder 14 Release O ring Fig 62 1 from groove of piston rod and slide in direction of drive component Fig 62 arrow Fig 62 O ring 15 Slide safety sleeve Fig 63 1 of piston rod in direction of drive component Fig 63 arrow A dowel pin Fig 63 2 is located below the safety sleeve which connects the piston rod to the high pressure piston 16 Push out dowel pin Fig 63 2 with a screwdriver and secure to prevent it from getting lost 2 Fig 63 Safety sleeve 88 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Faults Fault correction tasks gt Replacing O ring on air piston 17 Deta
56. f the boosters dangers arise that can cause severe injuries and considerable prop erty damage Always have all work performed only by personnel gualified for the particular work Keep unqualified personnel away from the danger Zones In this operating manual the gualifications of the personnel for the various areas of activity are listed below Mechanical and plant engineers Mechanical and plant engineers are personnel who due to their specialised training skills and experience as well as knowledge of the applicable regulations are capable of performing the tasks assigned to them In addition mechanical and plant engineers are familiar with the installation assembly and the bringing together of machines and are capable of recognising and avoiding possible hazards on their own Operator Operator has received instructions by the owner about his or her responsibilities as well as any possible danger arising from improper behaviour The operator may not perform any tasks that exceed the scope of normal operation unless specified in this manual and unless the owner has expressly entrusted the operator with these tasks Specialist for potentially explosive areas The specialists for potentially explosive areas due to their special ized training skills and experience as well as knowledge of the applicable standards and regulations are able to perform tasks on systems or sub components in potentially explosive areas The
57. ff the booster and safeguard it from being switched on again 68 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 8 Faults Faults Safety instructions for fault correction Possible causes for faults and fault correction tasks are described in the following chapter In the events of faults that cannot be corrected with the help ofthe notes below contact the manufacturer see contact information in Chapter 1 4 of this operating manual 8 1 Safety instructions for fault correction Nitrogen A Safeguarding against restart A WARNING Danger of suffocation due to improper handling of nitrogen Improper handling of nitrogen while purging the booster can result in poisoning or even death by suffo cation Always observe the manufacturer s safety data sheet Always ensure adeguate ventilation Keep a self contained breathing apparatus ready for emergencies If there are signs of suffocation immediately pro vide the affected person with the breathing appa ratus that does not depend on circulating air move to fresh air into recovery position and keep warm If no longer breathing provide first aid measures and start artificial respiration Seek medical attention immediately WARNING Life threatening danger due to unauthorised restart Due to unauthorised restart or opening of the com pressed air supply or the displacement media during troubleshooting and fault correction there is danger of
58. for inlet and outlet lines according to De Appendix B Connection drawing on page 123 Fig 14 Connecting inlet and outlet connections 6 4 3 Installing a separate leakage line When compressing combustible or toxic gases an additional leakage line must be installed on the booster 1 Unscrew the breather silencer Fig 15 1 from the leakage connections Z1 and Z3 2 Connect leakage piping Fig 16 1 to leakage connections Z1 Fig 16 2 and Z3 Fig 16 3 3 p Install separate leakage line according to Appendix B Connection drawing on page 123 on leakage piping Fig 16 Piping for leakage line 56 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Installation and initial commissioning MAXIMATOR Installing exhaust air silencer 6 5 Installing exhaust air silencer A description of how the exhaust air silencer is installed is provided below O Depending on the booster version the exhaust air Jl silencer can be made of plastic or aluminium The installation of the exhaust air silencer is always iden tical Personnel Mechanical and plant engineers Protective equipment Protective work clothing Safety footwear Safety goggles 1 Have exhaust air silencer ready Fig 17 Exhaust air silencer 2 Unscrew sealing plug from exhaust air connection 3 Position exhaust air silencer Fig 19 1 at exhaust air con nection Fig 19 2 and tighten hand ti
59. ght Fig 19 Installing exhaust air silencer 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 57 Installation and initial commissioning Initial commissioning 6 6 Initial commissioning A description of how the booster is commissioned is provided below Personnel Mechanical and plant engineers Protective eguipment Protective work clothing Safety goggles Safety footwear Special tool Leak detector spray Checks before initial commis sioning 1 Check all media connections for correct installation 2 Check all piping and threaded unions for mechanical damage 3 Open displacement medium gases on transport gas con tainer The displacement medium flows in 4 Open compressed air line of compressed air network to booster The booster starts delivering O When a compressed air control unit is used 1 the drive air is connected to the manometer of the compressed air control unit when the compressed air network is opened In this case the manometer must also be checked for function Checking the manometer for function on page 58 5 Perform a leak test with leak detector spray on all connec tions Checking the manometer for func During the initial commissioning the manometer of the com tion pressed air control unit must be checked for function Proceed as follows to do this 58 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Instal
60. he tasks for fault cor rection purposes in order to purge any remaining combustible or toxic gases and to thus prevent the development of oxyhydrogen gas and toxic gas mixtures In the following chapters for fault cor rection references are made to Supplement Hydrogen compres sion with Maximator boosters in the Appendix To purge the Faults Fault correction tasks gt Purging the high pressure component with nitro Remedy Replace high pressure piston with pressure cyl inder as a complete component Chapter 8 3 8 Replacing the high pressure cylinder with high pressure piston as a complete component on page 99 Check O ring on air piston for wear and replace if necessary Chapter 8 3 6 Replacing O ring on air piston on page 85 Check inlet and or outlet valve of booster head clean or replace if necessary Chapter 8 3 7 Cleaning the inlet and outlet valve of the booster head on page 98 booster proceed as described in the supplement DANGER A Personnel Specialist for potentially explosive areas Specialist for potentially explosive areas Specialist for potentially explosive areas Danger of explosion caused by toxic and combus tible gas residues on the inside of the booster Failing to purge the booster with nitrogen following pre viously compressed toxic or combustible gases prior to starting fault correction tasks can result in an explosion caused by the development
61. iftigen Gasen eingesetzt sind die Hinweise wie im Fallbeispiel Wasserstoff unbedingt zu beachten Weiterhin m ssen nat rlich die dem entsprechenden Gas geltenden Vorschriften und Richtlinien eingehallten werden F r den sicheren Betrieb der Kompressoren ist der Betreiber verantwortlich Caution Important information for MAXIMATOR DLE Series Booster If the boosters are used to compress aggressive flammable hazardous or toxic gases the instructions as mentioned in the document Best Practice Hydrogen Compression need to be observed Furthermore the current regulations and directives for the specific gas need to be complied The operator is responsible for the safe operation of the booster MAXIMATOR GmbH Walkenrieder Stra e 15 37449 Zorge Harz Fon 49 0 5586 8 03 0 Fax 49 0 55 86 80 3 3040 eMail info maximator de www maximator de JALAK KOO EI Best Practice Hydrogen compression safety explosion protection systems engineering What you need to know Safety during compression of hydrogen Hydrogen is a colourless odourless and flavourless gas and therefore cannot be detected with our human sensory organs Hydrogen burns with invisible flame and radiates only little heat in this process When mixing with air in a ratio of 4 to 76 percent by volume vol of hydrogen a detonating gas develops that already can be brought to explosion by a low energy spark Oxygen hydrogen
62. ig 8 9 has moved to the right end position of the drive component it opens the pilot valve Fig 8 13 The control air flows from the connection through the open pilot valve Fig 8 13 to the large control valve side of the booster The control valve Fig 8 8 switches to the other switch position and the drive air flows to the right side of the air piston Fig 8 9 The air piston moves to the left side of the drive component As a result a pressure stroke is generated on the left side of the high pressure component and a suction stroke on the right side The now expanding drive air escapes from the working chamber via the exhaust air silencer Fig 8 6 O In the booster variants with a transmission ratio gt 5 Jl the air is directed through the cooling cylinder and therefore used to cool down the high pressure compo nents The individual booster type versions are listed below 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 41 Structure and function MAXIMATOR Versions Boosters with one drive piston Legend II P Air drive II P Gas admission pressure BEP Operating pressure Exhaust air Version Graphic representation Single stage single acting P Types E DLE 2 1 DLE 5 1 DLE 15 1 DLE 30 1 DLE 75 1 Single stage dual acting Types DLE 2 DLE 5 DLE15 DLE 30 DLE 75 Dual stage dual acting Types DLE 2 5 HM DLE 5 15 DLE 5 30 DLE 15 30 DLE 15 75 DLE 30 75
63. ion Explosion protection A Safety Basic dangers gt Dangers due to explosion WARNING Danger of injury due to limited or improper fire fighting In the event of fire if the fire extinguisher is not opera tional or is unsuited to the specific fire class serious injuries or death together with significant damage to property may result Ensure that the only fire extinguishers available are those suited to the fire class in question Check functionality of fire extinguishers every two years Refill fire extinguishers after each activation Only use extinguisher propellants and spare parts which conform to the recognised models specified on the fire extinguisher In the event of use observe the safety and opera tion instructions on the fire extinguisher In the event of use observe the function tempera ture range WARNING Risk of explosion Bringing in ignition sources such as sparks open flames and hot surfaces can result in explosion in the Ex zone Obtain written work approval before starting work in the Ex zone Only perform tasks when a potentially explosive atmosphere can be ruled out Before all fault elimination work flush booster with nitrogen to prevent oxyhydrogen gas from devel oping from previously compressed toxic or com bustible gases Only use those tools that are authorised for use in the Ex zone Never smoke in the potentially explosive area Non compliance with these instructi
64. ission pressure place operating compres sion ratio ating tem z mentin pressure sion ratio i1 i2 perature in Min Pa max Pa cm pB XE static bar DLE 2 1 922 20 1 10 1 2 60 0 20 DLE 5 1 373 50 1 15 1 5 60 2 50 DLE 15 1 122 150 1 20 1 15 100 7 150 DLE 30 1 60 300 1 20 1 30 100 15 300 DLE 75 1 25 750 1 20 1 75 100 35 750 DLE 2 1844 40 1 10 1 2 60 0 40 DLE 5 746 100 1 15 1 5 60 2 100 DLE 15 244 300 1 20 1 15 100 7 300 DLE 30 120 600 1 20 1 30 100 15 600 DLE 75 50 1500 1 20 1 75 100 35 1500 DLE 2 5 922 100 1 25 1 2 1 5 60 0 0 8 PL DLE 5 15 373 300 1 45 1 5 1 15 100 2 6 PL DLE 5 30 373 600 1 90 1 5 1 30 100 2 2 PL DLE 15 30 122 600 1 40 1 15 1 30 100 7 15 PL DLE 15 75 122 1500 1 100 1 15 1 75 100 7 3 5 PL DLE 30 75 60 1050 1 50 1 30 1 75 100 15 20 PL DLE 2 1 2 922 40 1 10 1 4 60 0 40 DLE 5 1 2 373 100 1 15 1 10 60 4 100 DLE 15 1 2 122 300 1 20 1 30 100 10 300 DLE 30 1 2 60 600 1 20 1 60 100 20 600 DLE 75 1 2 25 1500 1 20 1 150 100 45 1500 DLE 2 2 1844 40 1 10 1 4 60 0 40 DLE 5 2 746 100 1 15 1 10 60 4 100 DLE 15 2 244 300 1 20 1 30 100 10 300 DLE 30 2 120 600 1 20 1 60 100 20 600 DLE 75 2 50 1500 1 20 1 150 100 45 1500 DLE 2 5 2 922 100 1 25 1 4 1 10 60 0 1 6 PL DLE 5 15 2 373 300 1 45 1 10 1 30 100 2 12 PL DLE 5 30 2 373 600 1 90 1 10 1 60 100 2 4 PL 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 31 Technical data Operating conditions Type Dis Max Max Transmis Max oper Admission pressure place
65. it must be ensured that the oxygen con tent inside the booster or equipment falls below 1 percent by volume Flushing plan for single stage single acting booster With SFP flushing connection and Z1 leakage connection on the high pressure side pro Flushing 71 Inlet Flushing Outlet Flushing procedure 1 Prior to booster start up connect the nitrogen supply to the inlet pressure connection PA and to the flushing connection SFP 2 Switch on the booster for approx 1 min depending on the volume to be flushed 3 Switch off the booster after completion of the flushing process 4 Afterwards the inlet pressure line PA can be connected to the hydrogen supply During hydrogen compression the flushing connection shall be continuously flushed with nitrogen 5 After completion of hydrogen compression the booster chamber shall again be flushed as described under item 2 Flushing plan for single stage double acting boosters With SFP flushing connection and Z1 and Z3 leakage con nection on the high pressure side Flushing ___________________ Inlet i p wo SFP SFP l j 1 23 Pa j l ne EEE Flushing eee Outlet Flushing procedure 1 Prior to booster start up connect the nitrogen supply to the inlet pressure po
66. ks have been properly executed and concluded in accord ance with the instructions in this manual Ensure that a leak test of all line connections has been performed Ensure that no persons are in the danger zone WARNING Danger of explosion during installation Bringing in ignition sources such as sparks open flames and hot surfaces can result in explosions in the Ex zone Obtain written work approval before starting instal lation Only perform installation when a potentially explo sive atmosphere can be ruled out Only use those tools that are authorised for use in the Ex zone Non compliance with these instructions will result in loss of explosion protection The prerequisites that must be in place for installation of the booster are described below 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 51 Installation and initial commissioning Prerequisites for installation O The booster is an incomplete machine and is designed Il to be installed in a plant or system Set up the booster in such a manner that the following conditions are satisfied The installation site must be level The booster must be stable and secure or firmly and securely seated m The booster must not be exposed to any vibration or oscilla tion m The booster must be easily accessible from all sides The booster must be installed in such a manner that it is not exposed to any external heat sources m The boos
67. l personnel from the danger area E If necessary initiate first aid measures m Alert the fire department and or emergency medical services Incase of fire provided your own health is not in danger extin guish the fire using fire extinguishing equipment and continue to do so until the fire department arrives Notify the person in charge at the machine s place of installa tion E Clear access paths for rescue vehicles E Wave rescue vehicles into position 24 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 2 10 Spare parts Explosion protection A 2 11 Environmental protection Safety Environmental protection WARNING Explosion hazard due to the use of incorrect spare parts The use of incorrect or defective spare parts may result in explosions in the ex zone This in turn may result in serious injuries or death as well as significant damage to property Only use original spare parts produced by the manufacturer or spare parts explicitly authorised by the manufacturer Always contact the manufacturer if in doubt Non observance of these instructions results in the loss of explosion protection NOTICE Danger to the environment due to incorrect han dling of materials which can harm the environ ment In case of incorrect handling of materials which can harm the environment especially improper disposal there can be significant damage to the environment Always heed the
68. lation and initial commissioning Initial commissioning Keep the ball valve of the compressed air control unit Fig 20 1 closed O The ball valve is closed if its position is perpen 1 dicular Fig 20 1 to the centre axis Pull the pressure regulator Fig 20 2 of the manometer upward The pressure regulator will audibly detach from the locking mechanism Open the pressure regulator Fig 21 1 by turning it to the right The drive air is applied On the manometer Fig 21 2 check whether the applied pressure is displayed Fig 21 Opening pressure regulator 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 59 Installation and initial commissioning MAXIMATOR Initial commissioning 5 Open the vent screw Fig 22 1 of the water separator Fig 22 2 and dissipate the pressure Pressure escapes from the vent valve and the pressure drop is displayed on the manometer 6 Close the vent screw Fig 22 1 7 gt Close the pressure regulator by turning anticlockwise 8 Press the pressure regulator downward The pressure regulator audibly clicks into place 9 Perform a leak test with leak detector spray on all connec tions Fig 22 Bleeding 60 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Operation Daily inspections 7 Operation 7 1 Safety instructions for operation Improper operation WARNING Danger of injury due to improper operation
69. ling the high pressure com ponent O To reinstall the high pressure components proceed as 1 described in Chapter 8 3 6 3 Installing the high pressure component on page 95 8 4 Start up after a corrected fault After correcting the fault execute the following steps to start up again 1 Properly reconnect all high pressure lines 2 Check connections for signs of leaks with a leak detection spray 3 Ensure that no persons are in the danger zone 4 Start in accordance with the notes in Chapter Operation 102 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Maintenance MAXIMATOR 9 Maintenance O No maintenance work is planned for the boosters 1 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 103 MAXIMATOR WOCNORUCKTECHNIK HYDRAULK PNEUMATIK PR FTECIKNIN 104 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Dismantling and disposal Safety instructions for dismantling and disposal 10 Dismantling and disposal After the end ofthe useful life has been reached the booster must be dismantled and disposed of in an environmentally responsible manner 10 1 Safety instructions for dismantling and disposal Explosion protection WARNING Danger of explosion during dismantling Bringing in ignition sources such as sparks open flames and hot surfaces can result in explosions in the Ex zone Prior to dismantling obtain a written work approv
70. mixtures with a fraction of below 10 5 per cent by volume are heavier than air and sink to the floor Physical and chemical properties Appearance colourless gas Odour odourless Molar mass 2 g mol Melting point 259 C Boiling point 253 C Critical temperature 240 C Ignition temperature 560 C Explosion limits vol in air 4 V 75 V Relative density gaseous 0 07 air 1 Solubility in water mg 1 1 6 mg l Avoiding explosive atmospheres in confined spaces and outdoors The formation of an explosive atmosphere in adjacent areas near the hydrogen equipment is prevented by observing the following requirements Hydrogen equipment shall be installed in well ventilated areas if possible outdoors Hydrogen equipment has to be leak proof and remain so Venting lines from safety valves leakage lines and similar lines shall be directed into the open Discharge units must not terminate below eaves openings in buildings or placed near air intake ports In case hydrogen equipment is installed in confined spaces the gas supply coming from the outside must be provided with a reliable shut off device placed at a safe point Pipe connections on hydrogen equipment shall be fitted such that they ensure a long term tightness of the joint PYAR A GLOBAL PRESSURE SOLUTIONS Explosive mixture Avoiding explosive mixtures in hydrogen eguipment Explosive mixtures cannot be tolerated i
71. n PL of the control valve housing or if a compressed air control unit is available at the air drive connection of the compressed air control unit Observe the information in Connected loads mechanical on page 28 and Appendix B Connec tion drawing on page 123 for how to use drive air lines hose connections or threaded unions A description of how the drive air is installed on the compressed air control unit is provided below 1 Unscrew sealing plug from drive air connection Fig 12 1 of the control valve housing or from compressed air control unit Fig 12 2 2 gt Insert connecting piece or pipe G 3 4 Fig 13 1 into drive air connection PL of compressed air control unit Fig 13 2 together with seal and tighten using a torque of 50 Nm Fig 13 Drive air connection com pressed air control unit 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 55 Installation and initial commissioning MAXIMATOR Installing the connecting lines gt Installing a separate leakage line 6 4 2 Connecting the inlet line for admission pressure and outlet line for operating pressure O Observe the information in Connected loads 1 mechanical on page 28 and Appendix B Connec tion drawing on page 123 for how to use drive air lines hose connections or threaded unions 2 1 Detach sealing plugs from inlet and outlet connections Fig 14 1 and 2 a 2 gt Install piping
72. n hydrogen eguipment with regard to safety aspects Such mixtures are easily ignited by e g the friction heat generated in activating a valve or by the friction generated by rust particles dragged through Even the heating of the gas caused by a pressure surge during rapid inflow of hydrogen into a equipment component filled with air can induce ignition Prior to commissioning the air has to be removed from the hy drogen equipment e g by evacuation or flushing The safest method is by flushing with hydrogen when an oxygen content of below 1 percent by volume is achieved inside the plant When decommissioning hydrogen equipment it is necessary to render the eguipment free of gas by evacuation or flushing To achieve this the hydrogen content must be below 1 percent by volume before the eguipment can be opened Please observe in all flushing procedures that flush gas always takes the path of lowest resistance Therefore the flush gas flow must be directed such that dead pockets are avoided Hydrogen compression with MAXIMATOR booster MAXIMATOR hydrogen booster design MAXIMATOR booster are especially modified for the com pression of hydrogen in the following areas Material suited for pressurised components Sealing geometry Flushing Connection Air drive section suitable for Atex These modifications are available for the following high pressure sections DLE 2 DLE5 DLE 15 DLE 30 DLE 75
73. nal precautions Contaminated surfaces will be extremely slippery Avoid contact with skin eyes and clothing Wear personal protective eguipment Environmental precautions Prevent further leakage or spillage if safe to do so Do not allow material to contaminate ground water system Prevent product from entering drains Methods for cleaning up Scrape up Pick up and transfer to properly labelled containers Clean contaminated surface thoroughly 7 HANDLING AND STORAGE Handling Technical measures precautions No special technical protective measures reguired Safe handling advice Spilling onto the container s outside will make container slippery Avoid contact with skin eyes and clothing Handle in accordance with good industrial hygiene and safety practice Storage Technical measures storage conditions Keep containers tightly closed in a dry cool and well ventilated place Keep away from open flames hot surfaces and sources of ignition Keep in properly labelled containers Keep out of reach of children Incompatible products Oxidising and spontaneously flammable products 6 EXPOSURE CONTROLS PERSONAL PROTECTION 2014 6 EXPOSURE CONTROLS PERSONAL PROTECTION Engineering measures to reduce exposure Ensure adeguate ventilation especially in confined areas Personal Protective Eguipment Respiratory protection No personal respiratory protective eguipment normally reguired Hand protection Preventive skin prote
74. ncon trolled movements of the lines and result in severe injuries Always establish depressurised status before mounting or removing hoses lines threaded unions or quick release couplings Completely depressurise the pressure accumulator Always wear personal protective equipment Have defective components that are pressurised in operation replaced immediately by qualified per sonnel mechanical and plant engineer 70 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Cold surfaces Behaviour in the event of faults 8 2 Faulttable Fault description Booster does not work at low air pressure Cause Excessive friction on the control valve Faults Fault table CAUTION Risk of injury due to cold and iced up surfaces Components such asthe exhaust air silencer can cool down severely and ice up due to expanding air or gas Skin contact with cold surfaces can cause skin irrita tions Always wear protective clothing and protective gloves during all work in the vicinity of cold or iced up surfaces Ensure that all surfaces have warmed up to ambient temperature before all work The following always applies 1 For faults that pose an imminent danger to personnel or material assets immediately trigger the emergency stop function shut off all lines and depressurise the booster Determine the cause of the fault If correction of the fault requires work in the danger zone switch off
75. nder 7 Pressure cylinder 4 Pilot valve 2 8 Cooling cylinder 4 2 Brief description The boosters work on the principle of a pressure intensifier They are used to compress gas and compressed air to a higher pres sure they are operated with a pneumatic admission pressure of a maximum of 10 bar compressed air This admission pressure is required to compress the particular delivery medium to a higher operating pressure In the process large areas are driven by means of low pressure by the air piston thus generating a high pressure level on small areas of the booster via the high pressure piston The following are fields of application for the boosters E Pressure test with gas Transferring gases from transport containers with a low pres sure level to a high pressure level Filling hydraulic accumulators with nitrogen Gas recovery Nitrogen reservoir filling Supply of seal gas plants Gas assisted injection moulding 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 37 Structure and function Assembly description gt Drive component m CO foaming E Filling clean air cylinders m Leakage tests 4 3 Assembly description 4 3 1 Booster head with inlet and outlet valve The booster head closes the compression chamber and separates it spatially from the surrounding pressure The booster head con tains the inlet and outlet valves The displacement medium to be compressed flows into the compression chamber and back out ag
76. nding the entire booster If the booster has an optional com pressed air control unit Fig 11 1 the working area is located within the danger zone Fig 11 Working areas and danger zones 4 8 Scope of delivery O The booster is delivered without piping or threaded 1 UNIONS The following components are part ofthe scope of delivery Designation Auantity Booster 1 Retaining bracket for mounting 2 Operating instructions for boosters DLE 2 1 2 1 DLE 75 1 2 Installation explanation 1 Conformity declaration according to ATEX Cate 1 gory IIB and or IIC 4 9 Accessories The following accessories are available for the boosters Compressed air control unit The compressed air control unit is used to manually adjust the drive air directly at the booster The compressed air control unit consists of a pressure filter a water separator a shut off valve a pressure regulator a hose line and a manometer A safety valve for the compressed air control unit is also available 46 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Air lubricator Gasket sets Structure and function Accessories The air lubricator is used to increase the oil content in the drive air The manufacturer recommends the use of an air lubricator if the drive air is extremely dry The individual gasket sets of the booster components are available from the manufacturer as complete sealing kits These sealing kits
77. ngs t pieces elbows crosspieces etc If required suitable monitoring measures shall ensure that equipment using this type of screw connection is only used when tightness of the connection is assured The require ments are stipulated by the classification into explosion zones MAXIMATOR hydrogen stations ATEX for housing and electrical cabinets Suitability of the housing or electrical cabinets for ATEX IIC shall be separately examined for the relevant application As a rule the following criteria should be met e Stainless steel no potential source of ignition e Ventilation ports on top and at the bottom All accessory parts have to be electrically conductive Var nished surfaces or sight glasses normally do not meet these requirements In case this is required the availability of such components with the corresponding manufacturer s confirmation must be checked Due to the material s non conductive properties noise insu lation of the housing is also inadmissible ATEX for power packs The standard MAXIMATOR power packs are not admissible for ATEX IIC The reason here is the labelling foil The foil with a printed flow diagram on instrumentation is approximately 1 mm thick However the ATEX 94 9 EC Directive limits ma ximum thickness of foil suitable for category IIC to 0 2 mm In case ATEX IIC is reguired the stations are also available with plates as an alternative to foil The frame itself remains
78. nly be asserted within the applicable com plaint deadlines The individual packages are packaged in accordance with antici pated transport conditions Only environmentally friendly materials have been used in the packaging The packaging is intended to protect the individual components from transport damage corrosion and other damage prior to assembly Therefore do not destroy the packaging and only remove it shortly before assembly Dispose of packaging material in accordance with the relevant applicable legal requirements and local regulations 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 49 Transport packaging and storage Storage NOTICE Danger to the environment due to incorrect dis posal Packaging materials are valuable raw materials and in many cases can continue to be used or can be prop erly processed and recycled Incorrect disposal of packaging materials may pose risks to the environ ment Dispose of packaging materials in accordance with the environmental regulations Observe locally applicable waste disposal regula tions If necessary outsource the disposal to a specialist company 5 4 Storage Storage of packages Only store packages under the following conditions Do not store outdoors Store in a dry and dust free environment Do not expose to any aggressive media Protect from direct sunlight Avoid mechanical vibration Storage temperature 20 to 60 C Relative humidity
79. notes below about the handling of materials which can harm the environment and their disposal If materials which can harm the environment acci dentally escape into the environment take suitable measures immediately In case of doubt inform the responsible local authority about the damage and ask what suitable measures to take might be The following materials which might harm the environment are used Cleaning liquids Cleaning liquids incorporating solvents contain toxic substances They must not be allowed to escape into the environment Disposal must be carried out by a specialist disposal company Lubricants Lubricants such as greases and oils contain toxic substances They must not be allowed to escape into the environment Disposal must be carried out by a specialised disposal company 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 25 Safety MAXIMATOR Environmental protection Displacement media Displacement media such as gases can contain toxic substances They must not be released into the environment Potentially leaking displacement media must be disposed of by a specialist company 26 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 3 Technical data 3 1 Dimensions and weights Technical data Dimensions and weights The dimensions and weights of all booster types are listed below O The values listed below are approximate values and 1 can vary slightly Type Width Heigh
80. of how the high pressure cylinder with the high pres sure piston is replaced as a complete component is provided below The high pressure piston is located on the inside of the high pressure cylinder O These fault correction tasks only apply to booster 1 models DLE 15 30 and 75 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 99 Faults Fault correction tasks gt Checking high pressure seals and high pressure Personnel m Specialist for potentially explosive areas Protective equipment M Protective work clothing m Safety footwear m Safety goggles Special tool E Spanner 8 3 8 1 Removing the high pressure cylinder with high pressure piston O To remove the high pressure cylinder with high pres 1 sure piston proceed as described in amp Chapter 8 3 6 1 Removing the high pressure com ponent on page 85 8 3 8 2 Installing a new high pressure cylinder with high pressure piston O To install a new high pressure cylinder with high pres i sure piston proceed as described in amp Chapter 8 3 6 3 Installing the high pressure compo nent on page 95 8 3 9 Checking high pressure seals and high pressure cylinder for signs of damage An explanation of how the high pressure seal and the high pres sure cylinder are checked for signs of damage and replaced if necessary is provided below Personnel m Specialist for potentially explosive areas Protective equipment M Protective work clothing m Safety fo
81. of oxyhydrogen gas and to severe injuries or even death Purge the high pressure component of the booster with nitrogen before any fault correction task 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 73 Faults Fault correction tasks gt Replacing the O rings on the control valve Personnel Protective eguipment Specialist for potentially explosive areas Safety footwear Safety goggles 1 Bringthe booster to a standstill depressurise and let the stored pressure completely dissipate 2 Purge the booster Proceed as described in Appendix A Hydrogen compression with Maximator boosters to do this 8 3 2 Replacing the O rings on the control valve A description of how the O rings on the control valve are replaced is provided below Personnel Protective eguipment Special tool Specialist for potentially explosive areas Safety goggles Protective work clothing Safety footwear Circlip pliers Spanner Lubricating grease Screwdriver O The fault correction tasks below are described on a Jl booster with an optionally installed compressed air control unit The fault correction tasks for boosters without compressed air control unit are identical In this case only the steps 3 4 are eliminated This is pointed out at the appropriate place 1 Bring the booster to a standstill depressurise it and let the stored pressure completely dissipate O Only carry out steps 3
82. ol valve pulse type air discharge Bleeding of the pilot valve This connection can be used to connect a stroke counter The air escapes in pulses here The connection must therefore not be closed Outlet of the expanding drive air 44 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Structure and function Connections Fig 10 Interfaces top view Item no Designation Connection Function 5 Outlet connection B Depends on Outlet for operating pressure model 6 Leakage connection for high G 1 8 Ventilation of the high pressure cylinder behind the pressure sides Z and Z3 piston Alternate admission and expulsion alter nately fitted with silencer 7 Operation connection PL G 1 8 Inlet for the compressed drive air 8 Leakage connection for high G 1 8 Ventilation of the high pressure cylinder behind the pressure sides Z and Z3 piston Alternate admission and expulsion alter nately fitted with silencer 9 Inlet connection A Depends on Inlet for the admission pressure model 10 Leakage connection for air G 1 8 Discharge of the leakage at the drive component sides Z and Z 11 Leakage connection for air G 1 8 Discharge of the leakage at the drive component sides Z and Z 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 45 Structure and function Accessories 4 7 Working areas and danger zones The danger zone Fig 11 marked in red is the entire zone sur rou
83. ons will result in loss of explosion protection 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 17 Safety Responsibility of the owner 2 3 6 Dangers due to chemical substances Displacement media WARNING Risk of injury due to improper handling of dis placement media Improper handling of displacement media can result in severe poisoning or even death by suffocation Always observe the manufacturer s safety data sheet When working with gases always ensure ade guate ventilation Do not smoke within the danger zone and in the immediate vicinity Do not use open flames fire and ignition sources of any kind Keepaself contained breathing apparatus ready for emergencies If there are signs of suffocation immediately pro vide the affected person with the breathing appa ratus that does not depend on circulating air move to fresh air into recovery position and keep warm If no longer breathing provide first aid measures and start artificial respiration Seek medical attention immediately Occurring vapours WARNING Risk of injury due to occurring vapours During the work process exhaust gas of the drive air can develop on the drive component of the booster that can result in poisoning when inhaled or on contact with skin Donot stay in the immediate vicinity while the boosters are operated Donot eat or drink in the vicinity of the boosters Incase of do
84. oosters DLE 2 1 2 DLE 75 1 2 29 Technical data Connected loads O When the recommended internal tube diameters are Il observed the boosters reach the maximum delivery output Additional connections O The above inlet and outlet connections are standard l connections Additional connection options for inlet and outlet are provided below These additional con nection options must correspond to the type key infor mation on the type plate See Chapter 3 9 Type key on page 35 in this operating manual for this Inlet connection Table Connected loads mechanical Connection Dimension Booster types designation of inlet connec tion N NPT G1 2 DLE 2 DLE 5 NPT G1 4 DLE 15 75 U 9 16 18 UNF for DLE 15 75 G1 4 high pressure pipe connection H4 downstream of Maxi mator Outlet connection Table Connected loads mechanical Connection desig Dimension Booster types nation of outlet connection N NPT G1 2 DLE 2 DLE 5 NPT G1 4 DLE 15 75 U 9 16 18 UNF for DLE 15 75 G1 4 high pressure pipe connection H4 downstream of Max imator O The following combinations of threaded inlet and outlet Jl unions are possible GG GU UU NU and NN 30 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 HH aay S MAXIMATOR M YI x V ww 3 3 Performance characteristics Technical data Performance characteristics Type Dis Max Max Transmis Max oper Adm
85. ork is shut off 1 gt Shut off compressed air line of in house compressed air net work 2 gt Shut off displacement medium at valve of gas transport con tainer The booster stops delivering O For this see the operating instructions for the in house 1 compressed air network Switching the booster off with a compressed air control unit pre sent 1 gt Close the ball valve Fig 29 1 of the compressed air control unit Fig 29 arrow 2 gt Shut off displacement medium at valve of gas transport con tainer 3 Shut off compressed air line of in house compressed air net work The booster stops delivering Fig 29 Close ball valve 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 67 Operation Shutdown in an emergency situation 7 7 Shutdown in an emergency situation In dangerous situations movements of components must be stopped as guickly as possible and the energy supply must be switched off Shutdown in an emergency situa Proceed as follows in an emergency to 1 Immediately trigger an emergency stop with the emergency stop device 2 gt Immediately shut off the displacement medium and com pressed air lines 3 If there is no danger for your own health get people out of the danger zone If required initiate first aid measures Alert the fire brigade and or rescue service Inform the responsible persons at the operating site N 2 9 gt Switch o
86. otwear m Safety goggles Special tool E Spanner Checking the high pressure seals and replacing them if necessary To check the high pressure seals for signs of damage 1 the high pressure component must be removed Pro ceed as described in Chapter 8 3 6 1 Removing the high pressure component on page 85 to do this 100 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Faults Fault correction tasks gt Checking high pressure seals and high pressure 1 Check high pressure seal Fig 93 1 on booster head Fig 93 2 for signs of wear and replace if necessary 2 Fig 93 High pressure seal on high pressure side 2 Check high pressure seal Fig 94 1 on lower cap of drive component Fig 94 2 for signs of wear and replace if neces sary Fig 94 High pressure seal on air side 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 101 Faults MAXIMATOR Start up after a corrected fault 3 Check inside of removed high pressure cylinder Fig 95 for score marks and other signs of damage Ifthe high pressure cylinder is damaged it must 1 be replaced as a complete component O In booster model DLE 15 30 75 the high pres 1 sure piston is located in the high pressure cyl inder In the event of damage the high pressure r A i cylinder with the integrated high pressure piston Fig 95 High pressure cylinder must be replaced as a complete component Reinstal
87. provided for purposes of basic understanding and can be different from the actual version In addition to this manual the manuals for the installed compo nents provided in the Appendix also apply 1 2 Explanation of symbols Safety instructions Safety instructions are marked with symbols in these instructions The safety instructions are always introduced by signal words which express the extent of the danger DANGER This combination of symbol and signal word indicates an immediately dangerous situation which will cause death or severe injuries if not avoided WARNING This combination of symbol and signal word indicates a possibly dangerous situation which could cause death or severe injuries if it is not avoided CAUTION This combination of symbol and signal word indicates a possibly dangerous situation which could cause slight injuries if it is not avoided 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 7 General Explanation of symbols NOTICE This combination of symbol and signal word indicates a possibly dangerous situation which could cause property and environmental damage ifit is not avoided Special safety instructions The following symbols are used in the safety instructions to draw attention to specific dangers WARNING This combination of symbol and signal word indicates content and instructions for the intended use ofthe booster in potentially explosive areas If an instru
88. r 4 4 Mode of operation of the boosters The piping and instrumentation P I flow chart of the boosters is illustrated in the graphic below 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 39 Structure and function MAXIMATOR Mode of operation of the boosters Fig 8 P 1 flow chart ofthe boosters Pilot valve lower cap Inlet valve High pressure piston Outlet valve Pilot valve air connection X Exhaust air silencer Air connection P Control valve Air piston Outlet valve B High pressure piston Inlet valve A Pilot valve upper cap OO NODURON gt ee Wn O Explanation of the mode of opera The drive air flows from the air connection Fig 8 7 through the tion control valve Fig 8 8 to the underside of the air piston Fig 8 9 The air piston moves to the right in the drive component thus per forming a suction stroke on the left side of the high pressure com ponent The inlet valve Fig 8 2 opens and the gas to be com pressed flows through the connection Fig 8 A into the compression chamber of the high pressure component A pressure stroke is performed on the right side of the high pressure compo nent 40 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 4 5 Versions Structure and function Versions The inlet valve Fig 8 12 closes the outlet valve Fig 8 10 opens and the compressed gas flows out of the connection Fig 8 B When the air piston F
89. r Only displacement media that are permitted for use in boosters may be compressed Chapter 2 2 Permissible displacement media gases on page 12 The boosters are driven by compressed air with a maximum drive pressure of 10 bar The boosters can be used if they are marked accordingly in explosion protected areas Intended use also includes compliance with all the instructions in this manual Any use that extends beyond the intended use or any other use of the system is considered to be misuse 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 11 Safety Permissible displacement media gases Foreseeable misuse WARNING Danger in the event of misuse Misuse of the boosters of the model series DLE 2 1 2 DLE 75 1 2 can result in dangerous situa tions Never use any displacement media other than those listed in Chapter 2 2 Permissible dis placement media gases on page 12 Never operate the boosters in closed containers Never make unauthorised conversions or modifica tions to the booster Compressed air must never be used for respiration purposes Never use the boosters in any manner other than that described in this operating manual Never exceed the technical limits or pressures specified in this operating manual Only operate the booster if it is in faultless tech nical condition The boosters must not be used directly for pharma
90. r Protective work clothing Special tool Circlip pliers Spanner Screwdriver Lubricating grease Drift punch Hammer Removing the sleeve of control To clean the sleeve of the control valve it must be removed valve 78 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Faults MAXIMATOR Fault correction tasks gt Cleaning and greasing the sleeve of the contro 1 gt Bring the booster to a standstill depressurise it and let the stored pressure completely dissipate O The sleeve of the control valve is located in the 1 control valve housing To remove the sleeve of the control valve the control valve must first be removed To dothis proceed as described in amp Chapter 8 3 2 Replacing the O rings on the control valve on page 74 steps 3 6 2 Purge booster with nitrogen Proceed as described in amp Appendix A Hydrogen compression with Maximator boos ters on page 113 to do this 3 Carefully position drift punch at edge of sleeve Fig 41 1 in control valve housing Fig 41 2 Fig 41 Positioning the drift NOTICE Risk of damaging the female thread Carefully punch out sleeve Fig 42 making sure that the female thread in the control valve housing is not damaged Fig 42 Punching out the sleeve 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 79 Faults MAXIMATOR Fault correction tasks gt Cleaning the exhaust air silencer and replacin
91. r lower cap is blocked Pilot valve in the upper cap or lower cap is defective High pressure Remedy Replace O rings and use acid free and silicone free lubricant Chapter 8 3 2 Replacing the O rings on the control valve on page 74 Dewater compressed air using water separator Chapter 7 5 Draining the condensate at the water separator on page 66 Clean silencer replace if necessary Chapter 8 3 4 Cleaning the exhaust air silencer and replacing it if necessary on page 80 Replace and regrease O rings on control valve Chapter 8 3 2 Replacing the O rings on the control valve on page 74 Replace and regrease O ring on air piston Chapter 8 3 6 Replacing O ring on air piston on page 85 Clean sleeve of control valve Chapter 8 3 3 Cleaning and greasing the sleeve of the control valve on page 78 Check O rings on control valve and sleeve and replace and grease if necessary Chapter 8 3 3 Cleaning and greasing the sleeve of the control valve on page 78 and amp Chapter 8 3 2 Replacing the O rings on the control valve on page 74 Clean and grease the pilot valve Chapter 8 3 5 Cleaning and greasing the pilot valve on page 82 Check pilot valve for wear and replace if neces sary Chapter 8 3 5 Cleaning and greasing the pilot valve on page 82 Clean and grease the pilot valve or replace if necessary Chapter 8 3
92. r escapes from the booster after the operation has been performed via the exhaust air silencer The exhaust air silencer is made of plastic or aluminium depending on the booster model 4 3 7 Cooling cylinder The cooling cylinder is used for insulating and cooling the high pressure component of the booster The cooling cylinder encloses the high pressure cylinder The expanding very cold drive air is directed into the space between the two cylinders in order to cool the high pressure cylinder during operation 4 3 8 Compressed air control unit 2 3 4 5 The compressed air control unit Fig 7 is a freguently installed sub assembly however it is not part of the standard equipment The manufacturer recommends the use of a compressed air con trol unit The compressed air control unit is used to manually adjust and control the operating pressure directly at the booster It is pre assembled at the drive air connection of the control valve Fig 7 1 Using the pressure regulator Fig 7 4 the particular NY operating pressure can be adjusted and controlled on the pressure gauge Fig 7 5 Furthermore the drive air can be dehydrated via the water trap Fig 7 6 and the bleeder valve Fig 7 7 The ball valve Fig 7 3 manually shuts off the drive air from the com 1 pressed air network to the booster The control line Fig 7 2 sup Fig 7 Compressed air control unit plies the pilot valve air connection with direct pilot valve ai
93. r into a plant or system The mechanical engineer and system engineer must ensure that when installing the boosters in a plant or in a system that an overall risk assessment is produced and that reguired steps to minimise hazards are initiated The mechanical engineer and plant engineer must ensure that the boosters are integrated in the emergency stop concept of the plant system The mechanical engineer and plant engineer must ensure that all pressure hoses pressure lines couplings and threaded unions are configured and dimensioned for the pressure ranges of the boosters Additional responsibilities of the Additional obligations arise for the owner from the EC directive for owner regarding explosion preven improving the safety and health protection of workers potentially at tion risk from explosive atmospheres These include the following organisational measures Identification of areas with potentially explosive atmosphere Clear prohibition signs Creating explosion prevention documents for each zone Preventing unauthorised personnel from accessing areas with potentially explosive atmosphere 20 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Safety Personnel requirements gt Qualifications 2 5 Personnel requirements 2 5 1 Qualifications WARNING Risk of injury in the event of inadequate qualifica tion of the personnel If unqualified personnel perform work on the booster or stay in the danger zone o
94. ribed in amp Appendix A Hydrogen compression with Maximator boos ters on page 113 to do this 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 85 Faults MAXIMATOR Fault correction tasks gt Replacing O ring on air piston 3 gt Unscrew inlet and outlet line Fig 55 1 from inlet and outlet connection of booster head 4 Close openings of removed inlet and outlet line with sealing plug to protect these against soiling 5 Undo fixing bolts of booster from foundation and secure to prevent them from getting lost 6 Remove line from drive air connection O Depending on the version drive air connection 1 PL is connected to the compressed air control unit or to the control valve housing Fig 55 Inlet and outlet line O In a dual acting booster the cooling pipe must be 1 removed from the high pressure components and the inlet connections 7 Undo threaded union of cooling pipe from both high pressure components Fig 56 2 and from inlet connections Fig 56 1 and remove cooling pipe 2 7 8 Undo the four nuts of the stay bolts on the booster head Fig 57 marked in red with a spanner Secure nuts and square taper washer for U sections to prevent them from get ting lost Fig 57 Undoing the booster head 86 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Faults Fault correction tasks gt Replacing O ring on air piston 9 Carefully d
95. rt PA and to the flushing connections SFP 2 Switch on the booster for approx 1 min depending on the volume to be flushed 3 Switch off the booster after completion of the flushing process 4 Afterwards the inlet pressure line PA can be connected to the hydrogen supply During hydrogen compression the flushing connection do not neet to be continuously flushed with nitrogen because in single stage double acting compressors no ambient air is sucked in via the leakage ports 5 After completion of hydrogen compression the booster chamber shall again be flushed as described under item 2 SBa PLATOO EA GLOBAL PRESSURE SOLUTIONS Flushing plan for two stage booster With SFP flushing connections and Z1 and Z3 leakage con nections on the high pressure side Flushing Be ee 5 Inlet gt SEP SFP yal 23 m L o A 9 Flushing Lu ee ei Outlet Flushing procedure 1 Prior to booster start up connect the nitrogen supply to the inlet pressure port PA and to the flushing connection SFP 2 Switch on the booster for approx 1 min depending on the volume to be flushed 3 Switch off the booster after completion of the flushing process 4 Afterwards the inlet pressure line PA can be connected to the hydrogen supply During hydrogen compression the flushing connection shall be continuously flushed with nitrogen
96. ructions in the other sections of this operating manual 14 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 2 3 1 General dangers at the workplace Noise A Safety Basic dangers gt Dangers due to gases under pressure WARNING Risk of injury caused by noise The noise level that occurs in the work area can cause severe hearing loss depending on the type of installa tion and expanding air Always wear personal protective equipment when working on running boosters Only stay in the danger zone to the extent required 2 3 2 Dangers due to gases under pressure Pressurised components A WARNING Danger of injury due to pressurised components Compressed air or gas can escape from compressed air lines threaded unions or pressurised components if these components are not handled properly This compressed air or gases can harm the eyes whirl up dust cause uncontrolled movements of the lines and result in severe injuries Defective pressurised components can also cause uncontrolled movements that can result in severe inju ries Always establish depressurised status before mounting or removing hoses lines threaded unions or quick release couplings Completely depressurise the pressure accumulator Always wear personal protective equipment Have defective components that are pressurised in operation replaced immediately by qualified per sonnel mechanical and plant engineer 26 01 2012
97. shing port and leak bores high hydrogen sulphide pressure seal not 100 gas tight 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 13 Safety Basic dangers Displacement medium gases Propane Nitrogen Laughing gas Oxygen Sulphur hexafluoride Xenon Symbol CaHg N2 N20 O2 SFe XE 2 3 Basic dangers Booster types Special instructions for the com pression of the displacement media All models Lay pipes and rinse SFP special flushing port and leak bores high pressure seal not 100 gas tight All models All models DLE xxx S Lay pipes for leak bores lubrication with halocarbon grease oxygen cleaning max compression ratio 1 6 Max pressure 350 bar DLExxx CR Lay pipes and rinse SFP special flushing port and leak bores high pressure seal not 100 gas tight All models O Contact the manufacturer for special instructions for 1 the use ofother media See the contact information on Page 2 ofthis operating manual O Remove plug on SFP special flushing port for haz 1 ardous gases and lay pipes See Appendix A Hydrogen compression with Maximator boosters on page 113 in this operating manual for this The following section lists residual risks from boosters that exist even if they are used as intended To reduce the risk of personal injury and property damage and to avoid dangerous situations observe the safety instructions listed here as well as the safety inst
98. ster is put into operation the operating pressure must be calculated The static end pressure of the booster is calcu lated for the particular booster type using the following formulas O A list of booster types can be found in Chapter 4 5 1 Versions on page 41 A legend for the calculation of the operating pressure Jl can be found below the table Booster type Single stage single acting Single stage dual acting Dual stage Single stage single acting with two drive components Single stage dual acting with two drive components Dual stage with two drive com ponents Legend PL Drive pressure PB Operating pressure PA Gas admission pressure i Transmission ratio i1 Transmission ratio stage 1 i2 Transmission ratio stage 2 Calculation of the static oper ating pressure PB PL i PB i PL PA PB i2 PL i2 i1 PA PB PL i PB i PL PA PB i2 PL i2 i1 PA Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Operation Switching on 7 4 Switching on A description of how the booster is switched on is provided below O The boosters have no main switch The booster starts JI to operate as soon as the displacement medium is pre sent and the drive air is applied at the booster The switch on process using a compressed air control unit is different from the switch on process without com pressed air control unit The two processes are described below Personnel Operator
99. t Depth Weight mm mm mm kg DLE 2 1 440 275 180 15 DLE 5 1 440 275 180 15 DLE 15 1 450 275 180 13 DLE 30 1 450 275 180 13 DLE 75 1 450 275 180 13 DLE2 600 275 180 20 DLE5 600 235 180 20 DLE 15 620 235 180 18 DLE 30 620 235 180 18 DLE 75 620 235 180 18 DLE 2 5 600 235 180 20 DLE 5 15 610 235 180 19 DLE 5 30 610 235 180 19 DLE 15 30 620 235 180 19 DLE 15 75 620 235 180 19 DLE 30 75 620 235 180 19 DLE 2 1 2 610 275 180 22 DLE 5 1 2 610 235 180 22 DLE 15 1 2 615 235 180 20 DLE 30 1 2 615 235 180 20 DLE 75 1 2 615 235 180 20 DLE 2 2 780 275 180 25 DLE 5 2 780 235 180 25 DLE 15 2 800 235 180 23 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 27 Technical data Connected loads Type DLE 30 2 DLE 75 2 DLE 2 5 2 DLE 5 15 2 DLE 5 30 2 DLE 15 30 2 DLE 15 75 2 DLE 30 75 2 8 DLE 3 8 DLE 6 8 DLE 1 65 3 2 Connected Pneumatic Width 800 800 780 790 790 800 800 800 990 990 810 loads Connected loads mechanical Data Height 235 235 235 235 235 235 235 235 350 350 350 Compressed air guality Solids max particle size Solids max particle concentration Dew pointup to 10 C water content Dew pointup to 2 C water content Depth Weight mm kg 180 23 180 23 180 25 180 24 180 24 180 24 180 24 180 24 220 55 220 55 220 40 Value Unit Oil free pos sible 5 um 5 mg m 9 4 g m 5 6 g m if an oiler has been used the air must always be oiled as oil
100. ter must be installed in a dust free environment Installation instructions WARNING Danger of explosion if the installation instructions are not observed If the installation instructions for boosters designed for the compression of toxic and combustible gases are not observed this can result in the development of a potentially explosive atmosphere Always set up boosters in a well ventilated room Always keep hydrogen systems leak tight Blow out lines of safety valves and leakage lines must always be routed outside into the open Blow out lines must not be installed under eaves openings in buildings or in the vicinity of air intake openings For hydrogen systems in rooms or buildings it must be possible to safely and guickly shut off the gas supply coming from the outside at a safe point Pipe connections on hydrogen systems must always be created so that these ensure the con nection will be leak tight for a long time 52 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Installation and initial commissioning Installing the connecting lines 6 3 Mounting the booster CAUTION Danger of material damage Dirt or drilling dust that gets into the connections of the booster during installation can result in booster damage Keep all connections sealed with sealing plugs during installation Only remove the sealing plugs directly prior to mounting the connection piping
101. the booster The owner must ensure that the operating media compressed air gases are pre installed and stored as prescribed The owner must ensure that all pressure hoses pressure lines couplings and threaded unions are configured and dimen sioned for the pressure ranges of the boosters The owner must ensure that suitable media connections are present and that these connections can be safeguarded via a separate shut off valve The owner must ensure that the connections of the operating media compressed air gases function properly 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 19 Safety Responsibility of the owner The owner must ensure that the boosters are kept and oper ated exclusively in technically faultless condition The owner must ensure adeguate lighting is always provided in the work area ofthe boosters The owner must ensure that all fault correction and repair tasks are executed exclusively by specialised personnel who have the gualifications cited in the fault table The owner must ensure that all warnings instruction and safety signs attached on the boosters are always complete and main tained in legible condition The owner must ensure that the boosters are checked for damage and proper condition before each start up Obligations of the mechanical engi The mechanical engineer and plant engineer have additional obli neer and plant engineer gations resulting from the installation of the booste
102. the booster and safeguard it against being restarted Immediately inform the responsible persons at the operating site about the fault Depending on the type of fault have it corrected by the required personnel specified below O The fault table provided below lists personnel who are 1 authorised to correct the fault Remedy Personnel Replace and relubricate the O rings on the con Specialist for trol valve Chapter 8 3 2 Replacing the O potentially rings on the control valve on page 74 explosive areas 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 71 Faults Fault table Fault description Booster does not work or it works too slowly Booster does not work Air escapes via the exhaust air silencer Booster does not work Air escapes via a small bore on the control valve housing Booster does not work Air escapes via small bore in the lower cap Booster operates at high freguency and with short strokes Leaks on silencers Cause O rings of the control valve swell when the wrong oil or lubri cating grease is used Exhaust or control valve iced up Formation of a residue in the exhaust air silencer O ring on control valve is defective O ring on the air piston is defective or worn Control valve is blocked Control valve is blocked Pilot valve in the upper cap or lower cap is blocked Pilot valve in the upper cap o
103. tomer service organisation is available for technical infor mation and repairs Address Telephone customer service Mon Fri 07 00 17 00 CET Telephone customer hotline Mon Fri 08 00 22 00 CET Sat Sun and public holidays 08 00 20 00 CET Fax email website Maximator GmbH Ullrichstra e 3 99734 Nordhausen 49 0 3631 9533 5026 Service Manager 49 0 1805 629 462 867 49 03631 9533 5065 service maximator de www maximator de In addition we are always interested in new information and expe riences associated with the application which could prove valuable in improving our products 26 01 2012 Boosters DLE 2 1 2 DLE 75 1 2 MAXIMATOR Customer service 10 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 2 Safety 2 1 Intended use Safety Intended use This section provides an overview of all safety aspects that are essential to the best possible protection of the personnel and the safe and trouble free operation of the machine Additional safety instructions for specific work tasks are contained in the sections regarding the individual life stages of the machine The compressed air driven boosters of the model series DLE 2 1 2 DLE 75 1 2 are incomplete machines and designed to be installed in plants or systems The boosters are used exclu sively for the oil free compression of combustible toxic and non toxic gases and compressed ai
104. ubt wear light respiratory protection 2 4 Responsibility of the owner Owner The owner is the person who is operating the boosters for indus trial or commercial purposes or who entrusts the use application to a third party and who has the legal product responsibility during the operation for the protection of the user the personnel or third par ties Owner s obligations The boosters are used commercially The owner of the boosters is therefore subject to legal occupational health and safety obliga tions 18 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 Safety Responsibility of the owner In addition to the safety instructions in this operating manual appli cable occupational health and safety accident prevention and environmental protection regulations must be complied with for the area of implementation of the boosters In this regard the following particularly applies The owner must inform himself about applicable occupational health and safety regulations and in a hazard analysis identify additional hazards that may exist at the operating site of the boosters due to special work conditions The owner must con vert this information into operating instructions for operation of the boosters The owner must ensure during the entire operating time ofthe boosters that the operating instructions drawn up by the owner correspond to the current state of legislation and if necessary the owner must adapt these op
105. work can move in an unforeseeable manner and can cause inju ries ifthere is a load change Depressurise the connecting line before all mounting tasks All piping must be securely anchored to the floor or to walls All piping must be routed in such a manner that it will not cause any tripping hazard Always wear personal protective equipment CAUTION Danger of material damage if the wrong con necting lines are used The use of incorrectly dimensioned piping or threaded unions can cause malfunctions and material damage to the booster The piping and lines must be matched to the max imum output pressure of the booster The tightening torque of the respective threaded unions must be complied with The cross section of the high pressure pipes and lines must not be smaller than the cross section of the connections The prerequisites that must be in place for proper installation are the presence of a professionally planned installed and maintained compressed air net work and a shut off valve additionally installed at the inlet of the compressed air network 54 Boosters DLE 2 1 2 DLE 75 1 2 26 01 2012 MAXIMATOR Installation and initial commissioning Installing the connecting lines gt Connecting the drive air 6 4 1 Connecting the drive air O Depending on the version the connection of the drive 1 air on the booster must be either installed on the air drive connectio

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