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Part 4 - Two-Stage Piston Compressor
Part 4 - Two-Stage Piston Compressor
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ET 500 Two-Stage Piston
Compressor Unit
Instruction Manual
Table of Contents
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1 Introduction
1.1 Compressor
power.
- Mining: driving the machines.
- Chemical industry: process control enginee-
ring.
- Workshops, petrol stations: tools, paint spray
guns, tyre inflators.
- Assembly shops: automatic, pneumatic con-
trols.
A compressed-air generation system consists es-
sentially of:
- Compressor (1)
- Drive motor (2)
5 4 2 7 - Compressed-air tank (3)
1 - Safety valve (4)
1 Introduction 1
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
1.2 Function
1 Introduction 2
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
1
cylinder. The pressure increases with de-
creasing volume.
p1 p2 - Discharge
At point 2, the pressure in the cylinder has
2
reached the pressure p2 in the pressure line. The
discharge valve opens and the compressed air
v
1 flows into the pressure line.
- Re-expansion
At point 3, the piston has reached top dead
p1 p2
centre (TDC) and then reversed its direction.
3
The discharge valve closes and the air left in
2
the cylinder expands again. The pressure
v drops.
1
- Intake
At point 4, the pressure has dropped to the
p1 p2
ambient pressure p1 with the result that the
3 intake valve opens and fresh air flows into the
4 2 cylinder. This process continues until the pi-
v ston has reached bottom dead centre (BDC),
1 where (at point 1) the entire procedure starts
again.
1 Introduction 3
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
- Two-stage compression
If the pressure of the single-stage compression is
increased, both the counter-pressure and tem-
perature of the medium increase as well. The
compression ratio is limited by the tempera-
ture at which the oil-gas mixture explodes. In
the multi-stage compression, the medium is
cooled down between the single stages. This
decreases the volume losses, the powers on
the rods and the required power. The cooling
process allows a decrease of both the intake
temperature and the intake volume of the se-
All rights reserved G.U.N.T. Gerätebau GmbH, Barsbüttel 11/96
cond stage.
In an ideal p-v diagram, the process of the
second stage begins directly after the isentro-
pic cooling of 1II and continues until the end
pressure 2II. If this is a single-stage compres-
sion, the process would hold isentropically wit-
hout stop until reaching the final pressure 2’.
The difference between these two process-
runs is the work saving.
3II 2II 2’
p3
Stage II
4II 1II 2
p2
3
Stage I
p1
4 1
v
1 Introduction 4
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
2 System description
0 16 0 1,6
bar bar
Kl .1 ,6 Kl .1 ,6
bar
16
Kl. 1,6
are according to the latest industrial stand-
ards.
- Large intake damper smoothens the volume
flow and holds the measuring sensors.
2 System description 5
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
5 6 7 8 9 10 11 12
4
All rights reserved G.U.N.T. Gerätebau GmbH, Barsbüttel 11/96
3 13
1 17 16 15 14
2 System description 6
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
a cooling pipe.
For the purpose of a stationary operating condition,
the compressed air can be blown through an
outlet valve equipped with an acoustic silencer.
Safety valve and pressure switch complete the
system.
3 Safety
M EI
PI
PI 04
TI TI
04 03
Tank 2
TI PI
PI 01 01
PI PD
Tank 1
TI
02
PI
02
3 Safety 7
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
3 Safety 8
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
4 Operation
4 Operation 9
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
4 Operation 10
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
4.4 Maintenance
Oil level:
Before start-up, check the compressor for oilavailability.
- Check the oil level at the oil mark in the viewing
window. Oil level must be at least up to the
Viewing window max
lower mark, otherwise add more oil up to the
upper mark.
4 Operation 11
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
Pressure:
The digital displays show the absolute pressure of
the measurement positions in bar. The manome-
ters mounted on the tanks show the overpressure
of the measurement position in bar.
and Ad=1,131∗10−4 m2
The density ρ of air depends on temperature and
ambient pressure
100 ⋅ p0
∆p ρ = 287 ⋅ (T + 273)
Temperature:
The temperatures are measured by means of four
resistance thermometers. The values are display-
ed digitally. Transmitters converted the measured
values to analog signals.
Power:
The power of the compressor motor is measured
by means of a power transmitter. The measured
value is also displayed digitally.
All rights reserved G.U.N.T. Gerätebau GmbH, Barsbüttel 11/96
.
p1 t1 p2 t2 t3 p4 t4 ∆p V Pel. time 1)
in in in in in in in in in in Watt in
bar °C bar °C °C bar °C mbar l/min min
0,99 23,0 3,4 127,1 58,8 11,7 151,6 7,4 239,51 2550 3
0,99 22,9 3.4 126,1 58,4 11,0 146,5 7,4 239,51 2510 3
0,99 22.8 3.3 125,1 58.0 10.0 141,5 7,5 241,12 2460 5
0,99 22,6 3.3 123,4 57,2 9,0 133,4 7,5 241,12 2400 5
0,99 22,3 3.2 121,0 56,1 8.2 124,2 7.6 242,73 2350 5
0,99 21,9 3.1 118,1 54,7 6,7 108,7 7,6 242,73 2240 5
.
where p in Pa and V in m3/s
The efficiency is the ratio of hydraulic power to
electric power input.
All rights reserved G.U.N.T. Gerätebau GmbH, Barsbüttel 11/96
P
η = Phydr.
el.
6 Appendix
Main dimensions
length 1520 mm
width 750 mm
height 1500 mm
weight approx. 260 kg
Compressor
All rights reserved G.U.N.T. Gerätebau GmbH, Barsbüttel 11/96
cylinders 2, V-shape
number of stages 2
max. pressure: 35 bar
(used pressure 12 bar)
Intake flow : 250 l/min.
speed 710 rpm
maintenance intervals first oil service after 50
operation hours, further services
after 500 hours or after
1 year
oil specification compressor oil conforming with
DIN 51 506, group VG 30
(SAE 30)
oil volume approx. 1.5 litre
Drive motor:
power 2,2 kW
speed 3000 rpm
power supply 230 V, 50 Hz
Intake vessel:
capacity 20 l
max. pressure 16 bar
Intercooler vessel:
capacity 5 l
max. pressure 16 bar
Pressure vessel:
capacity 20 l
max. pressure 16 bar
6 Appendix 16
ET 500 Piston Compressor Test Rig
with PC-Data Acquisition
Pressure transmitter:
measuring range 1x 0 - 1.6 bar abs.
and 2x 0 - 16 bar abs.
output signal 0 - 10 V DC
auxiliary power 24 V DC
Power transmitter:
measuring range 0 - 2500 W
output signal 0 - 10 V DC
auxiliary power 230 V, 50 Hz
Multifunction card
Analog inputs: 16, 0 - 10 VDC
Analog outputs: 2, 0 - 10 VDC
Digital inputs: 8, TTL
Digital outputs: 8, buffered TTL
Counter: 1, 16 bit
Software
Runtime version of visual designer 4.0 completely configured.
The software enables for online representation
of measured values, graphically & numerically.
6 Appendix 17
All rights reserved G.U.N.T. Gerätebau GmbH, Barsbüttel 11/96
p1 t1 p2 t2 t3 p4 t4 ∆p Pel. Time
6.2
V.
in in in in in in in in in in Watt in
bar °C bar °C °C bar °C mbar l/min min
ET 500
6 Appendix
Work sheet
Measurements table
with PC-Data Acquisition
Piston Compressor Test Rig
18