ET500 - Two Stage Piston Compressor
ET500 - Two Stage Piston Compressor
Instruction Manual
Please read and follow the safety regulations before the first installation!
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Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
All Rights Reserved G.U.N.T. Gerätebau GmbH, Barsbüttel, Germany 06/2009
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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5 Experiments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1
– Drive motor (2)
6 – Compressed air tank (3)
8
– Safety valve (4)
1 Introduction 1
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2 Description 2
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5 6 7 8 9 10 11 12
4
All Rights Reserved G.U.N.T. Gerätebau GmbH, Barsbüttel, Germany 06/2009
3
13
1 17 16 15 14
1 Trolley 10 Nozzle for volume flow measurement
2 Drive Motor 11 Differential pressure transducer
3 Acoustic attenuator 12 Switch Cabinet with Digital Displays
4 Pressure vessel 2nd stage 13 Resistance thermometer
5 Pressure transducer 14 Pressure vessel and intermediate cooler for 1st stage
6 Manometer 15 1. Compressor Stage
7 Safety valve 16 2-Stage piston compressor
8 Regulating valve 17 2. Compressor Stage
9 Inlet pressure vessel
2 Description 3
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1 2 3 4 5 6 7 8
1 p1-Inlet pressure
2 T1-Inlet temperature
3 p2-Pressure after 1st compressor stage
4 T2-Temperature after 1st compressor stage
5 p4-Pressure vessel pressure
6 T3-Temperature before 2nd compressor stage
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12 11 10 9
Fig. 2.2 Switch cabinet with displays and
controls
2 Description 4
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EI
M
PI
PI 04
TI TI
04 03
Tank 2
TI PI
PI 01 01
PD
PI
Tank 1
TI
PI 02
02
2 Description 5
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2 Description 6
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Oil level:
Prior to commissioning, check and if necessary fill
the compressor with oil.
– Check oil level using the marking in the oil
level window, if the level is below the
minimum, top up with oil using the oil filler up
to the max. oil level.
Oil change:
Change the oil while the unit is warm.
– Drain oil by removing the oil drain plug
– Only use the stipulated engine oil for flushing
Oil level marking min. the crankcase
– Top up the oil as far as the mark using the oil
filler.
2 Description 7
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Installation Routine
Notice:
The test stand must not be connected to the PC's
USB port during the installation of the program.
Only after the software has been installed can the
trainer be connected.
• Boot the PC.
• Load the G.U.N.T. CD-ROM.
• From the "Installer" folder, launch the
"Setup.exe" installation program.
• Follow the installation procedure onscreen.
• After starting, the installation runs automati-
cally. During the course of the installation,
various program components are loaded
onto the PC:
– Program for PC-data acquisition
– Driver routines for the "LabJackâ" USB
converter
• Reboot the PC after installation is finished.
2 Description 8
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menu.
• Various pull-down menus are provided for
Fig. 2.4 Language selection additional functions.
• For detailed instrauctions on use of the pro-
gram refer to its Help functin. This Help func-
tion is accessed by opening the pull-down
menu "?" and choosing "Help".
2 Description 9
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3 Safety
DANGER!
Caution when making changes to electrical sys-
tem components. There is a risk of electric shock.
It is therefore imperative to unplug the unit from
the mains first. Only have work performed by suit-
ably qualified personnel.
DANGER!
Caution near hot surfaces and system
components. There is a risk of burns. Prior to
working on system, leave to cool down.
DANGER!
Caution on the drive. There is a risk of injury due to
rotating parts. Always operate the unit with a bas-
ket guard.
3 Safety 10
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ATTENTION!
The system must not be operated unsupervised.
CAUTION!
Do not modify or disable the safety devices fitted.
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CAUTION!
On the flow meter, exceeding the measuring
range by more than 20% can impair the function.
Pressure peaks and sudden inflow caused by
solenoid valves, ball-cocks, or similar can result
in irreparable damage to the unit.
3 Safety 11
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4 Theory
4.1 Function
1 Cylinder cover
2 Pressure valve
3 Intake valve
4 Cylinder
5 Piston
6 Piston pin
7 Connecting rod
8 Crankshaft
9 Crankcase
10 Oil sump
4 Theory 12
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– Compression
Starting from point 1, bottom dead centre
(BDC), the piston compresses the air in the
cylinder. With reducing volume, the pressure
V 1 increases.
– Expulsion
At point 2 the pressure in the cylinder has
p1 p2
reached the pressure p2 in the pressure line.
The pressure valve opens and the compres-
2 sed air flows into the pressure line.
1 – Return expansion
V
At point 3 the piston has reached top dead
centre (TDC) and reverses its direction of
movement. The pressure valve closes and
p1 p2
the air remaining in the cylinder expands
3 again. The pressure drops.
2
– Intake
1 At point 4 the pressure has dropped back to the
V
ambient pressure p1 such that the intake valve
opens and fresh air flows into the cylinder. This
process continues until the piston has reached
p1 p2
bottom dead centre (BDC). Here, at point 1 the
3 entire process starts all over again.
4
2
1
V
4 Theory 13
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– 2-Stage Compression
If the pressure ratio is increased during single
stage compression, then the back-pressure and
temperature of the medium increase. The
pressure ratio during compression is limited by
the temperature at which the lubricating oil - gas
mixture can explode. On staged compression,
the medium is cooled between the individual
All Rights Reserved G.U.N.T. Gerätebau GmbH, Barsbüttel, Germany 06/2009
Stage II
4II 1II
p2
3 2
Stage I
p1
4 1
V
Fig. 4.2 Pressure progression on a p,v diagram
4 Theory 14
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5 Experiments
Pressure:
The digital displays indicate the absolute pressure
at the measuring points in bar. The manometers
on the tanks indicate the over-pressure at the
All Rights Reserved G.U.N.T. Gerätebau GmbH, Barsbüttel, Germany 06/2009
= A × 2 ×rDp
·
V d
and Ad = 1131
. × 10 -4
m2
,p
The density r of the air depends on the
temperature and pressure
r = 287100 ×p 0
× T + 273
5 Experiments 15
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Temperature:
Four resistance thermometers (Pt100) with
transducers measure the temperature; this is
indicated on the digital displays.
Rating:
The effective power of the compressor motor is
measured using a transducer and indicated on
digital displays.
All Rights Reserved G.U.N.T. Gerätebau GmbH, Barsbüttel, Germany 06/2009
· Time 1
p1 t1 p2 t2 t3 p4 t4 ,p V Pelec. )
in in in in in in in in in in
in
bar °C bar °C °C bar °C mbar l/min Watt
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 9.0 133.5 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 21.3 3.1 118.1 54.7 6.7 108.7 7.6 242.73 2240 5
5 Experiments 16
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= p ×V × lnæçç pp ö÷
·
Phydr ÷ø
4
1 1
è 1
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·
with p in Pa andV in m3/s
The overall efficiency is the result of the
relationship between the hydraulic output and the
electrical power supplied.
h= PP hydr
elektr
5 Experiments 17
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6.1
·
p1 t1 p2 t2 t3 p4 t4 ,p V PWirk p1
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in in in in in in in in in in in
ET 500
bar °C bar °C °C bar °C mbar L/min W bar
6 Appendix
Appendix
Working Sheets
TWO-STAGE PISTON COMPRESSOR
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Overall Dimensions
Length 1520 mm
Width 800 mm
Height 1500 mm
Weight approx. 260 kg
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Compressor:
Manufacturer Kaeser
Type K 2502 H35
Cylinder 2 in V-shape
Max. pressure 35 bar
Working Pressure 12 bar
Intake Capacity 15 m 3/h = 250 l/min
Speed 710 min-1
Stage 1
Bore 78 mm
Length of driving rod 150 mm
Stage 2
Bore 45 mm
Length of driving rod 150 mm
Stroke 72 mm
6 Appendix 19
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Maintenance intervals:
First oil change after 50 operating hours.
Further changes every 500 operating hours
or annualy.
Oil specification:
HD motor oil to DIN 51 506
Viscosity class VG 30 to DIN 51 506
Oil quantity: approx. 1.5 l
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Drive Motor:
Rating 2,2 kW
Speed 3000 rpm
Inlet Tank:
Volume 20 l
Max. pressure 16 bar
6 Appendix 20
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Pressure Sensor:
Measuring range 1x 0-1.6 bar abs.
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Power transducer:
Measuring range 0 - 2500 W
Output signal 0 - 10 V DC
6 Appendix 21
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Data acquisition
Program environment:
LabVIEW Runtime
System requirements:
PC with processor Pentium IV, 1 GHz
Minimum 1024 MB RAM
Minimum 1 GB available memory
on hard disk
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1 CD-ROM drive
1 USB port
Graphics card resolution
min. 1024 x 768 pixel, True Color
Windows XP / Windows Vista /
Windows 7
1 x ET 500 unit
1 x ET 500 Instruction manual
6 Appendix 22