ACACA PROTOCOL™ 2000 - amei.com.au

1 ACACA PROTOCOL 2000(AS AT 31st MARCH, 2002) ACACA PROTOCOL 2000 INCLUDES (A) CODE OF PRACTICE FORMANUFACTURERS AND/OR SUPPLIERS OF COMMERCIAL AIRCOMPRESSORS AND METHOD FOR DETERMINING (B) RECIPROCATINGAIR COMPRESSOR PUMP DISPLACEMENT (C) FREE AIR DELIVERY OFAN AIR COMPRESSOR PACKAGE WITH A PUMP DISPLACEMENT OF UPTO 600 LITRE/MINUTE AND (D) TEST of ContentsA. Code of PracticePage 2B. Pump DisplacementPage Air Delivery (FAD) of Air CompressorPage 3 (i) Pump Up Test (Simplified Method)Page 3 (ii) General Pump Up FormulaPage 4 (iii) Specific ACACA Pump Up Test MethodPage 4 (iv) Calculation of FADPage 4 (v) Protocol 2000 FAD Standard Testing ProcedurePage 5D. Test Report RecordPage OF PRACTICEM embers of the Australian Commercial Air Compressor Association agree to.

2 I) Actively promote the aims and objectives of ACACA in the market, andto other suppliers in the ) To manufacture and/or supply air compressors which are safe to useand which comply with both Federal and State Government regulationsin respect of workplace, electrical and pressure vessel safety and theElectromagnetic Compatibility (EMC) ) Where regulations so require, to apply the relevant Australian Standardor equivalent International Standard to components used in the aircompressor package such as motor, pump, air receiver tank ) Act in accordance with ACACA Protocol 2000 when calculating thepump displacement and free air delivery ratings of each air ) To affix the approved ACACA Protocol 2000 label on each and everyair compressor package sold by )Each ACACA label shall show both Pump Displacement (PD)and Free Air Delivery (FAD)b) each member may choose to show PD and FAD in litres/min orCFM but not both.

3 That is, if PD is shown in litres/min then FADalso shall be shown in )To encourage other manufacturers, assemblers, and importers to joinACACA and to adopt ACACA Protocol DISPLACEMENTD isplacement is the theoretical volume of air that can be pumped by areciprocating air compressor, if it was 100% four critical parameters that must be known for calculating displacementare:1. Cylinder Bore Diameter measured in Bore Area [= (Bore diameter)_ ] of piston movement (Stroke) measured in of pistons or speed of pump shaft which shall be determined by the speedof rotation (rpm) of the pump shaft under load when the air receiver isshowing a pressure of 700 kPA (7 Bar). The shaft speed shall bemeasured by means of a standard tachometer with an accuracy of or for calculating Pump Displacement (PD):The calculation requires the area of the cylinder bore to be multiplied by thepiston stroke, this give cylinder volume or capacity.

4 This is then multiplied bythe number of cylinders and then multiplied by the rotational speed of the (litres/min) = Bore Area (mm_) x Stroke (mm) x No. of cylinders x pump speed (rpm) 1,000, Factorsa) = )To convert litres/min to litres/sec divide by )To convert litres/min to cubic feet/min (cfm) divide by calculate the displacement of a pump of the following dimensions:Bore diameter (d)=60mm (Bore Area = )Stroke length=40mmSpeed of pump shaft=933rpm as measured by a tachometerNumber of cylinders=2 Then PD (litres/min) = Bore Area (mm_) x Stroke (mm) x No. of cylinders x pump speed (rpm) 1,000,000= 000,000,1]933240) [(46060 xxxxx= 211 litres/min (rounded to nearest litre)PD (cfm) = 211 = cfm (rounded to nearest ) AIR DELIVERY (FAD) OF AIR COMPRESSOR PACKAGEa)FAD is the volume flow rate of air (measured at ambient pressure andtemperature and humidity) which has been compressed and deliveredto the terminal discharge point of the air compressor package.

5 It is ameasure of the volume of air available for use at the exit point of the aircompressor ) Pump Up Test (Simplified Method)i)The pump up test consists of operating a compressor at a constant speed and observing the time required to increase the pressure in the air receiver (tank of measured volume) from 600 kPa(g) to 800 kPa(g) ie when the compressor is operating under load. The approximate air output of the compressor or FAD can then be pump-up test is a simplified method of estimating Free Air Delivery. Normal Variations in ambient temperature, atmospheric pressure and relative humidity are ignored so the results are indicative only and cannot be taken as the pump up test is a useful comparative measure andhas been selected as being suitable to rate commercial aircompressors for Pump Displacements up to 600 compressors will continue to be rated in accordance withISO ) General Pump Up FormulaTo estimate the average free air delivered by the compressorduring the pump up pressure change the following formula maybe used.

6 The result disregards temperature differences andchanges throughout the systemTPPPVFAD.)(012 =WhereFAD is the average volume of air delivered by the compressor during the pump up pressure air receiver volumeP0is atmospheric pressureP1 is air receiver pressure at commencement of testP2 is air receiver pressure at end of testTis the pump up time taken to increase the pressure in theair receiver from P1 to P2 And where P0 P1 and P2 are expressed in absolute ) Specific ACACA Pump Up Test MethodFAD shall be based on the average pump up time for the gaugepressure in the air receiver to increase from 600 kPa to 800 kPa(or 6 Bar to 8 Bar). This recognises that as the pressure buildsfrom zero the pump efficiency test to determine Pump Up Time shall be carried outindoors under normal operating conditions which have beendefined as ambient conditions where.

7 Room temperature is in the range 15 C 30 C. Atmospheric Pressure is that between sea level and 300 metres. Relative humidity is between 50% and 85%.These conditions have been taken to approximate thecompressor package performance when in normal use. ActualFAD may vary from the stated FAD by up to an estimated 5%when the air compressor is operated at the extremes of theabove ambient shall be carried out strictly in accordance with Protocol2000 FAD Standard Test Procedure refer (v) below.(iv)Calculation of FADU sing the general formula (refer (ii) above)TPPPVFAD.)(012 =5P2 P1 = 800 kPa 600 kPa= 200 kPa (2 Bar)P0= 1 Bar (100 kPa)Then FAD= TV2V The air receiver capacity in litres.

8 This must be verified by filling theair receiver with water and measuring the volume of water in litres, tothe nearest The average time in minutes and decimals of a minute, for thepressure of air in the receiver to increase from 600 kPa to 800 kPa. Theaverage time shall be taken as the mean of three time rest The Free Air Delivery is then calculated by dividing twice thecapacity of the air receiver by the pump up time (measured in minutesand decimals of a minute) taken for the pressure in the air receiver toncrease from 600 kPa to 800 kPa (6 Bar to 8 Bar).FAD (litres/minute) = 2V (twice the volume of receiver - litres)T (time in minutes to pump up from 600kPa to 800kPa)ExampleV = 54 litresT = 25 sec = minutesThen FAD = 2 x 54 = 259 litres/min ( CFM)To convert from litres/min to CFM divide by (v)Protocol 2000 - FAD Standard Testing ProcedureTesting Free Air Delivery of an Air Compressor Package using ACACAP ressure Timing Instrument (Test Box)Step 1 - Preliminary Requirementsa) Measure the volume of the air receiver tank by filling the air receiverwith water and measuring the volume in litres or cubic feet to anaccuracy of For example, for a nominal 50 litre air receivertank measure its volume to the nearest )

9 Ensure stable 240 volt supply to compressor package under test. Ifvoltage varies it may affect RPM of compressor pump and thereforeaffect accuracy of the 2 Connect Test BoxConnect Test Box to(a) outlet valve of compressor package using no more than 1 metre of6 mm nylon tube.(b) Plug in Test Box to 240 volt 3 Warm up to operating temperature Operate compressor for between 5-10 minutes under a load of 700kPa to ensure that the compressor has reached normal operatingtemperature before starting the test. Turn compressor off, drain air and condensate completely from AirReceiver, Close air bleed valve and press re-set button on 4 Time Tests (must be carried out whilst air compressor unit is atoperating temperaturea)With compressor at operating temperature and air receiver empty start compressor pumpingb)Timer will activate when pressure reaches 600 kPa and stopwhen compressor reaches 800 )Read off time and record it.

10 Record time to nearest )Press reset button to zero timer for next )IMPORTANT: bleed all pressure in unit back to zero kPa. Ifpressure is not bled back to zero the timer WILL NOTACTIVATE on your next test. Red OUT1 LED must be off forthe next test to )Do not remove connection tube between compressor and testbox until all testing for unit is completed. Drain residual air viaanother port (bleed valve).g)Repeat procedure 3 times and record the test results on ACACAP rotocol 2000 Test )Testing must be completed within twenty minutes after theCompressor has reached normal operating )After the results of 3 tests have been recorded, take the averageand calculate FAD of compressor package in accordance withthe ACACA Protocol 2000 )Round the results as follows:-i)CFM should be rounded to the nearest CFM eg.