Basic compressor knowledge
Portable Air After Sales Market Department
Effective Absolute pressure
total pressure
effective
pressure
absolute
atmospheric pressure
pressure
pressure = 0
Portable Air After Sales Market Department
Effective pressure
• The effective pressure is the difference
between absolute pressure and atmospheric
pressure
• It is the pressure available to deliver work
Atmospheric pressure
1 bar
Absolute pressure Effective pressure
8 bar 7 bar
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Effective pressure
• XRVS 455 Md : receiver pressure during
unload is 27 bar
• Forces on the air receiver cover
(0.08 m²) is more then 22.000 kgf!
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Free Air Delivery
• Free Air Delivery :
is the measured “real”
delivered volume of air
(in l/s or m³/min or cfm)
at the same conditions of
pressure and temperature
at the air inlet
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Free Air Delivery
• FAD is not equal to the displacement
volume of the compressor element, because
internal losses in the element (leaks to air
inlet)
• FAD is independent from the ambient
conditions (temperature & pressure)
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Compression principle
Pressure
Volume
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Compression principle
Pressure
2
Compression
Volume
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Compression principle
Pressure
3 Discharge 2
Compression
Volume
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Compression principle
Pressure
3 Discharge 2
Pressure Compression
reduction
1
4
Volume
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Compression principle
Pressure
3 Discharge 2
Pressure Compression
reduction
1
4 Suction
Volume
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Compression principle
Pressure
3 Discharge 2
Pressure Compression
reduction
1
4 Suction
Suction Volume Volume
Stroke Volume
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Screw Compressor
• Introduced in 1958 by Atlas Copco
• Male and female rotors move towards each
other, while the volume between them and
the housing decreases.
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Screw Compressor
• Screw profile improved in 1966
• Symmetrical screw was changed in an
asymetrical helical profile
• 10% more efficiency
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Compression principle
Compression start
Suction
Compression
Delivery
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Pressure Ratio
• Each screw element has a fixed, integrated
pressure ratio
• This depends on :
– length of the rotors
– Pitch of the screw
– form of the discharge port
• Best efficiency is reached when the pressure
ratio is adapted to the required working pressure
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Piston Screw compressors
advantages screw compressor
• High shaft speeds and large flow rate :
– gives small exterior dimensions
• Simple and strong design :
– no valves and seals reliable and maintenance
friendly
– small dirt particles improve the sealing and the
efficiency
– almost pulsation free air
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Piston Screw compressors
advantages screw compressor
• Low wear :
– guaranteed long life time and constant capacity
– life time is determined by the bearing wear
• Absolute oil free design possible
• No inertia forces
– vibration free operation
– high speeds possible
– big power possible
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Piston Screw compressors
disadvantages screw compressor
• Lower efficiency because of internal leaks
• High quality bearing of the rotors required
– rotor clearances are small
– axial bearings needed
• Higher noise level (high frequency)
• High quality finishing of the rotors required
– expansion of rotors through heat results in blocked
elements
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Oil injected screw compressors
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Oil injected screw compressors
• Oil is used for :
– Cooling : compression heat is absorbed by the oil
– Lubrication of rotors, bearings, gears
– Sealing between rotors and rotor and housing
– Corrosion protection of the internal metal parts
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Oil injected screw compressors
Oil is injected in the bottom of the rotor housing,
on the bearings and gears
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Oil injected screw compressors
• Only one rotor is driven, this rotor then drives
the other one :
– old XAS 90 : female driven rotor
– all other compressors : male driven rotor
• When required a gear box or drive belt brings
the compressor element to the correct speed
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Oil Free screw compressor
• No oil is injected in the air
• Complete separation of oil used for lubrication of
bearings and gears
• An external synchronizing gear is used to
synchronize the rotors
no contact between rotors and housing
• Pressure ratio is limited by the temperature
difference between the intake and the discharge
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Oil Free screw compressor
Seal rings
Synchronizing Gear
Water jacket cooling
Oil gallery
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Comparison
Oil Free Oil Injected
• Separate oil system with • Integrated oil system
oil pump without oil pump
• No oil separators • Oil separators needed
required
• Compression of gasses is • Not suitable for oil
possible aggressive gasses
• Special coating on the • No coating on the rotors
rotors
• Water jacket cooling • Oil cooling
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Comparison
Oil Free Oil Injected
• Seal rings on the shafts • No internal sealing
• Synchronization gears • One rotor drives the other
• High speed, high noise • Lower noise due to lower
speed and oil
• High temperature • Low temperature due to
oil cooling
• Max. pressure ratio is • High pressure ratio
low (1:4) possible (1:13)
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Compressor regulating system
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Compressor running condition
• Four major running conditions :
– NO-LOAD
Machine started, minimal pressure build-up
– UNLOAD
Receiver tank pressurized, no air consumption
– LOAD
Receiver tank pressurized and air consumption
– BLOW-DOWN
Machine stopped, blow-off of air pressure
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Compressor systems
• Four major components :
– Air system
– Oil system
– Regulating system
– Electrical system
Portable Air After Sales Market Department
Air system
• Air filter Compressor Element (AFCE) (with
vacuator valve VV, Safety Cartridge SC and
vacuum indicator VI)
• Unloading Valve (UV)
• Compressor Element (CE)
• Temperature Switch (TS)
• Check Valve (CV)
• Air Receiver (AR)
• Non Return Valve
• Minimum Pressure Valve (MPV)
• Air Outlet Valve (AOV)
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Air filter
• Filtration of the inlet air in 3 stages :
– centrifugal dust separation
– paper filter element
– safety cartridge (optional)
• Vacuum indicator gives an indication when
the pressure drop over the filter element is too
high filter element needs to be replaced
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Air filter
Air inlet Centrifugal separation
Vacuum indicator Filter element
Dust
to compressor element
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Unloading valve
• Opens and closes the air inlet to the
compressor element.
– Open position at load condition
=> Air consumption
– Closed position at no load condition
=> No air consumption.
• Control of the valve by regulating pressure.
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Unloading valve
Regulating pressure Air inlet
Spring loaded
Vent Hole
Integrated
blow-down valve Valve
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Unloading valve
LOAD UNLOAD
Regulating pressure
Air inlet
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Compressor element
• Oil is injected in the air and compressed to the
pressure as set by the regulating valve.
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Compressor element
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Compressor element
Air inlet
Oil Air/Oil
Oil
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Check valve
• Check valve is integrated in the unloader for
Series 6 compressors.
• Closes when the compressor is stopped.
• The air receiver is pressurized, which would
result in a reverse air flow.
the check valve prevents this.
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Check valve
LOAD SHUT-DOWN
Check valve
Receiver pressure return
after shut-down
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Air receiver / Separator
Separator element
Centrifugal separation
Air outlet
Air/Oil
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Minimum pressure valve / nozzle
• Guarantees a minimum pressure in the oil
separator (approx. 3.5 bar)
• Minimum pressure is required to guarantee an
continuous oil supply to the element.
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Nozzle / Minimum pressure valve
MINIMUM PRESSURE VALVE
NOZZLE
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Oil system
• Air receiver
• Oil cooler
• Oil filter
• Oil stop valve (only on Size II)
• Compressor element
• Oil separator
• Scavenge line
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Oil system (Series 6)
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Air receiver
Pressure
Oil flow
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Oil cooler
Cool Oil
Cooling air
Warm Oil
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Oil filter
By-pass valve
Dirty Oil Filtered Oil
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Compressor element
Greasing to the bearings
Air inlet
Oil Air/Oil
Oil
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Oil separator
Scavenge line
Separator element
Centrifugal separation
Air/Oil
Oil
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Regulating system
• Regulating valve
• Unloading valve
• Speed regulator
• Blow-down valve
• Safety valve
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Regulating system (Series 6)
Regulating Valve
Safety Valve
Speed Regulator
Unloading Valve
Portable Air After Sales Market Department
Regulating valve
• Regulates the effective pressure in the air
receiver
• Provides regulating pressure to :
– unloading valve
=> regulates the air inlet according the air
requirements
– speed regulator
=> regulates the engine speed to reduce fuel
consumption
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Regulating valve
Adjusting receiver pressure
by changing spring tension
Spring loaded
Pressure gauge
Regulating pressure
to speed regulator
to unloading valve
to blow-down valve
Receiver pressure
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Regulating valve
LOAD UNLOAD
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Unloading valve
• Opens and closes the air inlet to the
compressor element.
– Open position at load condition
=> Air requirements
– Closed position at no load condition
=> No air requirements
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Unloading valve
Regulating pressure Air inlet
Vent Hole
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Unloading valve
LOAD UNLOAD
Regulating pressure
Air inlet
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Speed regulator
• Regulates the engine speed in relation to the
required air flow
• Load condition : maximum engine speed
• Unload condition : minimum engine speed
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Speed regulator
Spring loaded
Regulating pressure Vent Hole
- Min
Engine speed
- Max
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Speed regulator
LOAD UNLOAD
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Blow-down valve
• Blows off the air receiver pressure once the
compressor has shut-down
=> this to depressurize the receiver tank
• Integrated in the unloading valve
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Blow-down valve
blow-down valve
Receiver pressure
Air inlet
blow-off hole
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Blow-down valve
LOAD / UNLOAD BLOW-DOWN
Receiver pressure
Blow-off
receiver pressure
Receiver pressure return
after shut-down
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Safety valve
• Blows off the air receiver pressure once this
pressure raises above the design pressure.
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Electrical system
• Battery voltage : 12 or 24 V
• Starting system
– cuts-out starter motor when engine is running
– avoids cranking when receiver tank is pressurized
• Safety shut-downs
• Instrument indications
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Safety shut-downs
• Compressor :
– Compressor element outlet temperature
• Engine :
– Coolant temperature
– Coolant level
– Oil pressure
– Fuel level (XAHS 186 / Size II)
• Emergency stop
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Safety shut-downs
• All safety shut-downs are Normal Closed
switches
– Fail safe as a loose wire will result in a shut-down
Good electrical contacts are important
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Air treatment options
• Lubricator
• Aftercooler
• Water separator
• Fine filters PD / QD
• Re-heater
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Lubricator
• Injects tool oil in the compressor outlet air
• Used to lubricate the tools connected to the
compressor (breaker, drill, …)
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Air treatment options
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Aftercooler - Water separator
• The aftercooler is a heat exchanger, which cools
the hot compressed air to precipitate the water that
otherwise would condensate in the air hose.
• The outlet temperature is ambient + 7°C.
• It is followed by a water separator that separate the
condensate and drains it
• Used for : sandblasting, fibre optic cable steering,
pipe cleaning
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Aftercooler - Water separator
Water separator
Aftercooler
Portable Air After Sales Market Department
Fine filters PD / QD
• PD filter will separate oil and solid particles.
• QD filter or carbon filter will separate oil and
water vapour.
• Air becomes technically “oil free”.
Only 0.003 ppm oil is available in the air
outlet
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Fine filters PD / QD
QD filter
PD filter
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Re-heater
• The re-heater is a heat exchanger, which warms up
the compressor outlet air to ambient + 60°C.
• The water and oil will be vaporized resulting in hot
and dry air, this avoids condensate problems.
• XAS 46-96 : engine oil warms up the compressed
air.
• XAS 146-186 : compressor oil warms up the
compressed air
Portable Air After Sales Market Department
Product nomination
oil injected compressors
Engine supplier
Working principle C : Caterpillar
Product range A : Single stage D : Deutz
X : Oil injected compressor Silencing G : Detroit Diesel Prime mover
portable R : Two stage : Un-silenced M : Mercedes d : diesel engine
compressor compressor S : Silenced Y : Yanmar E : electric motor
X A M S 445 Md
Working pressure Capacity (FAD)
Single stage Two stage Liter/sec
: standard pressure 7 bar 17 bar CFM (US-version)
M : medium pressure 8.6 bar -
T : “ten” pressure 10.3 bar -
H : high pressure 12 bar 20 bar
V : very high pressure 14 bar 25 bar
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Product grouping (GAC 40)
7 bar 8.6 bar 10.3 bar 12 bar 14 bar
100 psig 125 psig 150 psig 175 psig 204 psig
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Applications
Road maintenance Sandblasting
Civil works
Electrical tools
Portable Air After Sales Market Department
