How to Configure an Air Preparation Unit? A Practical Step-by-Step Guide.

A properly selected air preparation unit has a major impact on operational safety, the service life of pneumatic components, and the efficiency of the entire system.

However, choosing the right configuration does not have to be complicated. Festo has developed a practical configuration path that allows you to select a complete system tailored to a specific application step by step.

Below, we present the key elements worth considering when configuring an air preparation unit

— from control, filtration, and pressure regulation to safety and sensor integration in modern pneumatic systems.

Selection Path for a Complete Air Preparation System

Configuring the right solution requires consideration of many factors, such as the type of application, required filtration level, air drying method, and system safety level.

Follow these 7 steps to properly configure a complete air preparation unit:

Step 1. Choose the Control Method

The first step is to determine how the system will be controlled. Available options include:

• manual control,
• soft-start function,
• electric control.

The soft-start function enables gradual pressure build-up within the installation, improving machine start-up safety and reducing the risk of component damage.

Step 2. Select Material and Basic Parameters

The next stage involves selecting the material used for the components:

• high-quality polymer,
• metal.

At this stage:

• choose the pressure gauge type (integrated or separate) or a digital sensor,
• define the pressure regulation method,
• select the filter type.

Properly selected components help optimize system performance and simplify future maintenance.

Step 3. Plan Flow and System Layout

Proper selection of pipe diameters and flow direction is crucial for minimizing pressure losses.

When designing the system, it is worth considering:

• selection of pipe diameters,
• component arrangement,
• pipe length,
• required flow parameters.

A properly designed system ensures stable delivery of compressed air to all receivers.

Step 4. Consider Sensor Integration

Modern air preparation units increasingly cooperate with monitoring and automation systems.

Available options include:

• parameter displays,
• IO-Link communication,
• digital pressure sensors,
• integrated pressure and flow sensors.

It is important to ensure that the selected sensors are compatible with the machine control system and provide the required level of diagnostics.

Step 5. Select the Appropriate Filtration Level

The filtration range should be tailored to the application requirements.

In more demanding industries — such as food processing or semiconductor manufacturing — fine filtration and activated carbon filters for removing oil aerosols may be required.

In some cases, lubrication of the system should also be considered.

The most important factor is matching air quality to the process requirements and all system components.

Step 6. Remember Air Drying

Moisture in a pneumatic installation may lead to corrosion, reduced efficiency, and equipment failures.

When selecting an air drying system, it is important to:

• reduce the dew point temperature,
• choose the most suitable drying method for the application,
• analyze energy consumption,
• monitor the impact on flow and pressure,
• locate the dryer close to the application.

Compact membrane solutions effectively reduce moisture levels without requiring major system expansion.

Step 7. Review Safety Requirements

Designing an air preparation unit should take into account the safety level required by the application.

Depending on the requirements, three solutions may be used:

• Variant C: single-channel system with soft-start function,
• Variant D: dual-channel configuration with valve position feedback signal,
• Variant E: dual-channel solution with self-test function for the highest safety level.

Regular inspections, emergency procedures, and technical documentation are just as important as the component selection itself.