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I
Table of contents
Contents
1.1The history of compressed air
...............................................
1
1.1.1 The origin of compressed air................................................11.1.2 The first applications of compressed air...............................2
1.2Units and formula symbols
....................................................
6
1.2.1 Basic units............................................................................61.2.2 Compressed air units ...........................................................6
1.3What is compressed air?
.......................................................
7
1.3.1 The composition of air..........................................................71.3.2 The properties of compressed air ........................................71.3.3 How does compressed air behave? .....................................7
1.4Physical fundamentals
...........................................................
8
1.4.1 Temperature .........................................................................91.4.2 Volume .................................................................................91.4.3 Pressure.............................................................................101.4.3 Volume flow........................................................................11
1.5Compressed air in motion
....................................................
13
1.5.1 Flow behaviour...................................................................131.5.2 Types of flow ......................................................................13
2.1The advantages of compressed air
.....................................
142.2Pressure ranges
....................................................................
172.3Possible applications for compressed air
...........................
18
2.3.1 Tensioning and clamping with compressed air ...................182.3.2 Conveyance by compressed air .........................................182.3.3 Pneumatic drive systems ...................................................192.3.4 Spraying with compressed air ............................................192.3.5 Blowing and flushing with compressed air..........................192.3.6 Testing and inspection with compressed air .......................202.3.7 Using compressed air for process control ..........................20
2.4Examples of specialised applications
.................................
213.1Compressors (Compactors)
.................................................
24
3.1.1 Dynamic compressors ( Turbo-compressors ) ....................243.1.2 Displacement compressors................................................24
3.2Types of compressor
............................................................
25
3.2.1 Standard compressors .......................................................263.2.2 Piston (reciprocating) compressor......................................273.2.3 Diaphragme compressor....................................................293.2.4 Free piston compressor......................................................303.2.5 Rotary vane compressor ....................................................313.2.6 Liquid ring compressor.......................................................323.2.7 Screw compressor .............................................................333.2.8 Roots compressor ..............................................................343.2.9 Axial compressor................................................................353.2.10 Radial compressor .............................................................36
Part 1Fundamentals ofcompressed airPart 2Applications forpneumaticsPart 3Compressed airgeneratorsChapterPage
 
II
Table of contents
Part 4Control of compressorsChapterPage
3.3Piston compressors
..............................................................
37
3.3.1 General ..............................................................................373.3.2 Suction capacity - Output ...................................................383.3.3 Cooling...............................................................................393.3.4 Coolant...............................................................................403.3.5 Control of reciprocating piston compressors ......................403.3.6 Advantages of reciprocating piston compressors...............403.3.7 Components of a piston compressor..................................41
3.4Screw compressors
..............................................................
42
3.4.1 General ..............................................................................423.4.2 Compression process ........................................................423.4.2 Method of operation ...........................................................433.4.3 Oil circuit ............................................................................443.4.4 Pneumatic circuit................................................................453.4.5 Heat reclamation ................................................................463.4.6 Intake control......................................................................463.4.7 Advantages of screw compressors.....................................463.4.8 Components of a screw compressor..................................47
3.5Components
..........................................................................
48
3.5.1 Drive motor.........................................................................483.5.2 Drive belts ..........................................................................483.5.3 Belt tensioning....................................................................483.5.4 Inlet and pressure valves ...................................................493.5.5 Safety valve........................................................................493.5.6 Intake filter..........................................................................49
3.6Compressor lubricants and coolants
..................................
504.1Pressure definitions
..............................................................
514.2Operating status
....................................................................
52
4.2.1 Stopped ( L
0
) .....................................................................524.2.2 Idle ( L
1
).............................................................................524.2.3 Part-load ............................................................................534.2.4 Operating load ( L
2
) ..........................................................53
4.3Controlling individual compressors
....................................
54
4.3.1 Intermittent control .............................................................544.3.2 Idle mode control................................................................544.3.3 Delayed intermittent control................................................554.3.4 Part-load control.................................................................564.3.4.1 Infinite output control..........................................................564.3.4.2 Frequency control...............................................................56
4.4.The ARS control concept
.....................................................
57
4.4.1 Automatic ...........................................................................584.4.2 Autotronic ...........................................................................584.4.3 Ratiotronic..........................................................................594.4.4 Supertronic.........................................................................59
 
III
Table of contents
Part 5Compressed air treatmentChapterPage
4.5Control of several compressors
..........................................
60
4.5.1 MCS 1 and MCS 2 .............................................................604.5.2 MCS 3 ................................................................................614.5.3 MCS 4 ................................................................................624.5.4 MCS 5 ................................................................................634.5.5 MCS 6 ................................................................................644.5.6 MCS 7 ................................................................................65
5.1Why treatment?
....................................................................
66
5.1.2 Planning information ..........................................................675.1.3 Consequences of poor treatment .......................................685.1.3 Impurities in the air.............................................................69
5.2Water in the compressed air
................................................
70
5.2.1 Atmospheric humidity.........................................................705.2.2 Dew points .........................................................................715.2.3 Air moisture content ...........................................................715.2.4 Quantity of condensate during compression ......................725.2.5 Example for calculating quantities of condensate ..............735.2.6 Quantity of condensate on a humid summer day ...............745.2.7 Determining the pressure dew point...................................755.2.8 Pressure dew point after removal of pressure....................76
5.3Compressed air quality
.........................................................
77
5.3.1 Quality classes defined in DIN ISO 8573-1.......................77
5.4Methods of drying
.................................................................
78
5.4.1 Operating conditions ..........................................................795.4.2 Condensation by over-compression ...................................805.4.3 Condensation by refrigeration drying ................................815.4.4 Diffusion by membrane drying............................................825.4.5 Sorption by Absorption.......................................................835.4.6 Sorption by Adsorption.......................................................845.4.6.1 Cold regeneration...............................................................855.4.6.2 Internal hot regeneration ....................................................865.4.6.3 External hot regeneration...................................................875.4.6.4 Vacuum regeneration .........................................................885.4.7 Arrangement of the refrigeration compressed air dryer......895.4.7.1 Dryer before the compressed air receiver ..........................895.4.7.2 Dryer behind the compressed air receiver..........................90
5.5Compressed air filters
..........................................................
91
5.5.1 Basic terminology of filters .................................................915.5.1.1 Filter separation rate
η
[ % ] ...............................................915.5.1.2 Pressure drop
∆
p ...............................................................925.5.1.3 Operating pressure ............................................................925.5.2 Dust separators..................................................................935.5.3 Pre-filters............................................................................945.5.4 Microfilters..........................................................................955.5.5 Active carbon filters............................................................975.5.6 Active carbon adsorbers.....................................................985.5.7 Sterile filters .......................................................................99
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