MPS R12S - User Manual

Drain Valve
1/4” FNPT
Model Number R12S
Bootstrap Compressor • Installation and Operating Instructions
Midwest Pressure Systems, Inc.
RAV Rev. 0
MPS
MI DW E ST
PRESSURE
SY S TE M S
MPS
M ID W E S T
PRESSURE
S YS TE M S
MPS
M I D W EST
PRESSURE
SY S TE M S
MPS
M I DW E ST
PRESSURE
SY ST E M S
MPS
M ID W E ST
PRESSURE
SYS T E MS
MPS
M I DW E ST
PRESSURE
SYS T E M S
MPS Logos
12/5/91
1/2" Square
3/4" Square
1" Square
1-1/4" Square
1-1/2" Square
2" Square
MPS
M ID W E ST
PRESSURE
SYS T E MS
Mount the Model R12S Bootstrap Compressor on a horizontal
surface. Other mounting orientations are not recommended.
The booster system vibrates while operating, so use the four 1/2”
mounting holes, shown in the diagram to the right, to bolt it to a
solid surface.
1
Connect your shop air line to the 1/2” FNPT air inlet filter on the
front of the booster. A shutoff valve can be installed upstream of
the filter for convenient removal of the system for maintenance.
The booster has a built-in discharge pressure regulator. Do not
install a supply pressure regulator. Lowering the supply pressure
reduces the efficiency of the system. The unit is permanently
lubricated. Use of an inlet lubricator will void the
warranty. The maximum inlet pressure is 150 psig.
2
Attach the discharge line to the 1/2” FNPT port on the left side
of the receiver tank. If the application requires a
lubricator, make sure the lubricator is installed
downstream of the booster. A filter should be installed to
protect downstream components from seal/booster wear
particles.
3
The discharge pressure regulator is set by the black, snap-
lock knob mounted on the top of the unit. Pull up on the knob
to unlock it. Adjust the knob by turning it clockwise for a
higher discharge pressure (up to a maximum of 230 psig), or
counterclockwise for a lower discharge pressure. Inlet
pressure is read on the gauge closest to the inlet connection.
The second gauge indicates discharge pressure. Supply shop
air to the booster and it will start to operate. Set the regulator
to attain the desired discharge pressure, and push down on
the regulator knob until it “clicks” to lock the regulator on
that setting. The regulator is self-relieving. When the
discharge pressure setting on the regulator is reduced, the
higher pressure stored in the system will vent through the
regulator until pressure equilibrium is reached. If the inlet
pressure is higher than 115 psig, it is possible to
set the regulator so the booster exceeds the
maximum discharge pressure of 230 psig. Do not
operate the booster under these conditions. It is
designed to operate continuously at a maximum
discharge pressure of 230 psig.
5
The Bootstrap Compressor will operate as long as there is
demand for high pressure air. When there is no demand, the
booster will “stall” at the pressure set by the discharge regulator.
The stalled condition consumes no energy and does not damage
the booster. The booster will start up automatically when the
pressure falls slightly as a result of demand for high pressure air.
7
Mounting Bolt Pattern:
16.5”
10”
Inlet port
1/2” FNPT
Discharge
port
1/2” FNPT
The accumulator tank has a 1/4” ball valve to drain condensate. A
drain line or automatic drain valve can be attached to this valve
when needed. Close the valve before starting booster.
4
The accumulator is rated for 235 psig and includes a relief valve
set for 235 psig. This relief valve was selected to prevent
operation of the booster above its maximum
allowable discharge pressure of 230 psig.
8
For more precise booster control, set the discharge regulator for
a higher pressure than required, and install a filter and secondary
regulator on the discharge line of the accumulator. This allows
for greater accumulator storage capacity, and minimizes pressure
fluctuations in the system. For maximum high pressure air
storage, Bootstrap Compressors are set to charge the
accumulator to 230 psig, and the secondary regulator in the
discharge line of the accumulator is set at the desired, lower
pressure. Make sure that any downstream components are rated
for the accumulator pressure, or are protected by a relief valve in
case the secondary regulator fails.
6
235 psig
Pressure
Relief Valve
Midwest Pressure Systems, Inc.
850 Transport Drive, Valparaiso, IN 46383
Phone 219-462-0070 Fax 219-318-2277
www.midwestpressuresystems.com

Summary

Installation and Operating Instructions

Mount the R12 S Compressor

Mount the compressor on a horizontal surface using the four 1/2" mounting holes.

Connect Shop Air Line

Connect shop air to the 1/2" FNPT inlet filter; max inlet pressure is 150 psig. Use shutoff valve upstream.

Attach Discharge Line

Connect discharge line to the 1/2" FNPT port on the receiver tank. Install filter downstream if lubricator used.

Drain Accumulator Tank

Use the 1/4” ball valve to drain condensate. Close valve before starting the booster.

Set Discharge Pressure Regulator

Adjust snap-lock knob clockwise for higher, counterclockwise for lower pressure. Lock setting by pushing knob down.

Optimize Booster Control

For precise control, set regulator higher and use secondary regulator downstream.

Booster Operation While Stalled

Booster operates as long as there is demand; stalls at set pressure without energy consumption.

Accumulator and Relief Valve Rating

Accumulator rated for 235 psig; relief valve set for 235 psig to prevent operation above 230 psig.

Operation and Warranty

General Concerns

Unit is permanently lubricated. Use of inlet lubricator voids warranty. Maintain 5-micron inlet filter.

Operating Description

Plant air fills chambers; pilot regulator reduces pressure for drive air, actuating pistons to compress air.

Warranty Information

Warrants against defects for one year (six months for seals/check valves). Excludes abuse, lubricator, or filter failure.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The Midwest Pressure Systems Model R12S Bootstrap Compressor is a device designed to increase the pressure of shop air for various applications. It operates by utilizing a unique compression mechanism to boost the incoming air pressure to a higher discharge pressure.

Function Description

The R12S Bootstrap Compressor operates by continuously shuttling interconnected pistons to produce a high-pressure air stream. Plant air directly fills Compression Chambers A1 and A2 through a set of check valves, pressurizing them to the maximum initial air pressure available (up to 150 psig). A branch of the plant air stream flows through a pilot-activated regulator, which reduces the pressure to the level required to attain the desired discharge pressure. This regulated air then flows through a four-way valve, directing it to Drive Chamber B2 while opening Drive Chamber B1 to exhaust. The pressure force on the interconnected pistons compresses the air in Chamber A2 to a higher pressure. At the end of its travel, Piston 2 switches the four-way valve, opening Drive Chamber B2 to exhaust and pressurizing Drive Chamber B1 with regulated drive air, reversing the piston direction. This continuous back-and-forth motion generates the high-pressure air. The unit is designed to operate as long as there is demand for high-pressure air. When demand ceases, the booster will "stall" at the pressure set by the discharge regulator, consuming no energy and without damage. It automatically restarts when pressure drops due to demand.

Important Technical Specifications

• Maximum Inlet Pressure: 150 psig. Operating with higher inlet pressure is not recommended and can reduce efficiency.
• Maximum Discharge Pressure: 230 psig. While higher pressures might be attainable, operating above 230 psig can lead to catastrophic failure.
• Accumulator Rating: The accumulator tank is rated for 235 psig.
• Pressure Relief Valve: Includes a relief valve set for 235 psig to prevent operation above the maximum allowable discharge pressure.
• Inlet Port: 1/2" FNPT (Female National Pipe Taper) for connecting the shop air line.
• Discharge Port: 1/2" FNPT for connecting the discharge line.
• Drain Valve: 1/4" ball valve for draining condensate from the accumulator tank.
• Mounting: Designed for horizontal surface mounting using four 1/2" mounting holes. Other orientations are not recommended due to vibration during operation.
• Dimensions (Mounting Bolt Pattern): 16.5" x 10".

Usage Features

• Built-in Discharge Pressure Regulator: The unit features an integrated regulator for setting the desired discharge pressure. It is adjusted by pulling up on a black, snap-lock knob, turning it clockwise for higher pressure or counterclockwise for lower pressure, and then pushing down to lock the setting. The regulator is self-relieving, meaning excess pressure vents through it when the setting is reduced.
• Pressure Gauges: Two gauges are present: one closest to the inlet connection for reading inlet pressure, and a second for indicating discharge pressure.
• Lubrication: The moving parts are permanently lubricated with a multipurpose grease (except for check valves).
• Condensate Drain: A 1/4" ball valve on the accumulator tank allows for manual or automatic draining of condensate.
• Secondary Regulation (Optional): For more precise control and minimized pressure fluctuations, a filter and secondary regulator can be installed on the discharge line downstream of the accumulator. This setup allows the booster to charge the accumulator to its maximum (230 psig) while the secondary regulator provides the desired lower pressure to the application.
• Continuous Operation: The compressor is designed for continuous operation at its maximum discharge pressure of 230 psig.

Maintenance Features

• Permanent Lubrication: The unit is permanently lubricated, eliminating the need for an inlet lubricator. Using an inlet lubricator will void the warranty.
• Inlet Filter Requirement: A well-maintained 5-micron inlet air filter is required to prevent dust particles from entering the unit, which could foul seals or cause premature wear. Failure to use such a filter will void the warranty.
• Wear Parts: The booster's wear parts include check valves, springs, and dynamic seals, designed for 1800 miles of piston travel.
• Four-Way Valve: This valve, controlling piston movement, is a lapped, stainless steel valve without elastomeric seals, designed for many years of operation under normal conditions.
• Discharge Regulator: The built-in discharge regulator is designed for many years of service with minimal wear.
• Maintenance Kits: Midwest Pressure Systems offers specific kits for maintenance:
  • #KRW: Wear parts kit
  • #KRV: Valve kit
  • #KRR: Regulator kit
• Warranty: The R12S Model Bootstrap Compressor is warranted against defects in material and workmanship for one year from purchase, with piston seals, rod seals, and check valves specifically warranted for six months. Repair or replacement of failed units is offered, provided proof of purchase date. The warranty is voided by abuse, use of a lubricator, or failure to use a well-maintained inlet filter. A return authorization number is required for factory returns.

MPS R12S Specifications

General

Brand	MPS
Model	R12S
Category	Compressor
Language	English