Proper air compressor installation and design of your compressed air system will result in superior operation and performance, making your air compressor work more efficiently and providing flexibility for future expansions. This article will provide a complete guide and diagrams for your compressor installation and layout.
Top 6 Air Compressor Installation Considerations
Location
Install your air compressor indoors if possible, because it’s less affected by the uncontrollable humidity and weather problems of outdoor environment. A stable and controllable surroundings and air intake source are very important for the air compressor. And try to place the air compressor in a clean and dry room close to the compressed air use terminal, which can reduce the distance of the pipeline that the compressed air needs to pass through and minimize the pressure loss.
When you have multiple air compressors, spacing the compressors a certain distance can help control air quality, reduce productivity losses caused by noise, and reduce problems such as overheating caused by rapid temperature rise of the air compressor.
If you choose to install the air compressor outdoors, place the compressor away from direct sunlight, especially in the morning or afternoon sun, to avoid damage to the compressor’s HMI and additional heating of the machine by the sun. Make sure it is protected from the bad weather and temperature extremes. Don’t sure how to design air compressor system?<、u>
Floor
The floor should be flat and level concrete that can handle the static weight of the unit. Most rotary screw compressors do not require special foundations, nor will you need to anchor it down. However, piston, centrifugal and some rotary screw air compressors do require special foundations.
The compressor’s base should rest on a level surface that can support the gross dead weight of the machine. If the floor surface is uneven or irregular, install it on a 5- to 15-mm pad made of rubber or other pliable material.
Temperature and air quality
The ambient temperature should be 5-35℃. The higher the ambient temperature, the smaller the compressor output air volume. When it is below 5℃, the air compressor must take measures to prevent icing. The air humidity should be low, with less dust and clean air. If the factory environment is poor and there is a lot of dust, pre-filtration equipment must be installed.
Maintenance space
Plus, you’ll want to allow enough space around the compressor to enable your maintenance teams to access it. The distance between the compressor and the wall should be at least one meter; the distance between the air compressor and the top space should be at least one meter; it is best to keep more than one meter between multiple compressors; the width of the main passage of the compressor room should be at least 1.5 meters.
Ventilation
The compressor room needs good ventilation. Make sure the roof is not too low to trap hot exhaust gases, and that the hot exhaust gases must be exhausted from the building, away from hazardous areas such as gasoline or paint spray filter outlets, so that the exhaust gases continue to circulate into the atmosphere after being discharged from the compressor, and ensure that the exhaust gases do not re-enter the compressor cycle.
The ventilation system should be able to convert the CFM of the entire unit (including the compressor and dryer. This information can be found in the compressor and dryer engineering data sheets.
Compressed air piping installation
The main pipeline must have a slope of 1°~2° to facilitate the discharge of condensed water in the pipeline.
Minimize the use of unnecessary elbows and various valves in the pipeline to reduce pressure loss.
The pressure drop of the pipeline must not exceed 5% of the air compressor pressure, so it is best to use a larger pipe diameter when piping.
The branch pipe must be connected from the top of the main pipeline to prevent condensed water from flowing into the working machine. A check valve should be installed on the air compressor outlet pipeline.
When installing compressors in series, a ball valve (or automatic drain valve) should be added at the end of the main pipeline to discharge condensed water.
If there are air tank and dryer behind the compressor, the ideal piping should be compressor + air tank + front filter + dryer + other filters. In this way, the air tank can filter out part of the condensed water, and it also has the function of reducing the temperature of the compressed air. The lower temperature and less water content can reduce the load on the dryer or filter.
If the system uses a large amount of gas in a short period of time, an air tank should be installed as a buffer to reduce the number of frequent loading and unloading, reduce the number of control element actions, and maintain the reliability of compressor operation. Generally, we can select an air tank with a capacity of 20% to 30% of the air compressor CFM. Know more about CFM of air compressor
Air compressor installation procedure
Here are the steps to install an air compressor:
- Unpack the air compressor. Check and make sure it is not damaged and got all the necessary parts.
- Assemble the components in the correct order according to the manufacturer’s instructions.
- Fix the air compressor securely, paying attention to the mattersbefore compressor installation mentioned above (foundation, ventilation and clearance requirements).
- Connect the pipe system and valves, etc., making sure they are all installed on the correct interfaces.
- Install the regulator, filter and lubricator. These are usually included with the air compressor you purchased. If not, you may need to contact your air compressor supplier or order the parts.
- After installation, don’t forget to check for any possible leaks and perform a pressure test according to the operator’s manual.
Air Compressor Installation FAQ
How to install air filter on air compressor?
Check out the filters and distinguish where they are supposed to be according to their interfaces. Pay attention to distinguishing the inlet and outlet directions of the filters. There are usually arrows on the filter to indicate the direction of air flow.
Install the filter correctly according to the arrow direction. When installing the air filters, be sure to fit the upper and lower interfaces tightly to prevent any air leaks in the air compressor. Pay attention to regular cleaning and replacement of the filters.
Also, The filters should be installed vertically to the ground, and leave a certain height from the ground to facilitate the replacement of the filter element when necessary.
Where to install water separator on air compressor
The water separator should be installed downstream from the compressor on its discharge line, as near as possible to the compressor itself, so as to maximize the separation of moisture in the cooled air. When installing, ensure that the oil-water separator is in a horizontal position, and the top of the water level regulating pipe and the upper edge of the oil overflow tank must be kept at the same level.
The oil-water separator should be installed directly above the horizontal pipeline, and ensure that the valve on the pipeline is closed before the equipment is operated to avoid affecting the normal operation of the equipment. When connecting the pipeline, good sealing must be ensured to prevent air leaks and affect the separation effect.
How to install air compressor dryer
Choose a location: Choose a suitable location to place the dryer according to the same considerations for the air compressor location above.
Installation and mounting: Install the bracket on the wall or ground of the installation location to ensure that the bracket is stable and firm.
Connect the pipelines: First, distinguish the air inlet and outlet of the dryer. The air inlet is generally at the bottom and the air outlet is at the top; connect the dryer to the air compressor through the air inlet pipeline, and connect the air outlet pipeline to the post-processing equipment. Both pipelines should be sealed to avoid air leakage.
Connect the power supply: Connect the power cord to the dryer, note if the standard voltage is suitable to ensure sufficient power supply.
Start the trial run: After confirmed the installation is completed correctly, start the trial run of the dryer. This process requires inspection and debugging to ensure the smooth operation of the subsequent work of the dryer.
Complete the debugging: Finally, debug according to the actual situation and adjust the parameters and operation mode of the dryer as needed.
Note: The dryer is usually equipped with a drain valve, which can be found at the bottom of the air dryer. The drain valve can be manual or automatic, so it is necessary to leave enough space for your daily inspection and drainage of the air dryer.
How to install auto drain valve for air compressor
The installation position of the automatic drain valve should be selected as close as possible to the drain outlet of the air compressor, and also needs to be easy to observe and replace, to ensure its drainage efficiency and reduce the difficulty of maintenance.
Mount the drain valve: Fix the auto drain valve and the mounting bracket at the selected position.
Connect the exhaust pipe: Connect the drain valve to the pipe or interface, and pay attention to using a suitable gasket to avoid air or water leakage. Make sure there is a drainage device with sufficient depth downstream of the drain valve to avoid water back-flow affecting the operation of the system.
Debugging: After the installation is completed, check whether the drainage system is operating normally. If there is any abnormality, check and deal with it in time.
It is necessary to pay attention to regularly clean and replace the gasket for the automatic drain valve to ensure its sealing effect and safety.
How to install a pressure switch on an air compressor?
- Cut offelectrical power of air compressor. Locate the pressure switch on the air compressor’s storage tank. A short pipe nipple is used to conduct the air from the tank into the pressure switch. Typically a ¼- inch diameter pipe is prepared on the storage tank for the pressure switch.
- Use the Teflon tape and install two or three rounds of the sealant tape over the male pipe threads. Screw the female fitting of the pressure switch onto the pipe nipple. Tighten with the crescent wrench. Remove the top cover of the pressure switch.
- Observe the set of four contacts, small copper discs, on the interior of the pressure switch. The contacts are electrically connected together on the topside of the copper discs. Each set of discs has a corresponding screw connector. Think of each set of contacts like a light switch. One set of contacts will be used for each wire to be switched. Strip back the four wires, two wires coming from the power source and two wires going to the compressor motor, with the wire strippers. Remove 1 inch of the plastic insulation to reveal the bare copper wire underneath.
- Use the screwdriver to connect the two wires coming from the power source (power cord or wires coming from the AC source) to the two outermost screws of the contacts. (in most cases) These screw terminals may also be marked as “line.” Connect the other two wires, going to the compressor motor, to the two inside screw terminals (in most cases) on the pressure switch. These terminals maybe identified as “load”. In a 240 VAC feeder circuit the wires do not have to be mated to the switch. In a 120 VAC circuit the white neutral wires must be connected to the same set of contact screw terminals. Connect the bare copper wire or green insulated wire to the green screw on the metal frame of the pressure switch.
- Replace the cover over the pressure switch. Apply power to the air compressor circuit. Switch the pressure switch to the on position.
Use only pressure switches rated for your air system and the electric motor. Follow all local electrical codes when performing any electrical wiring.
Do not adjust the factory settings on the pressure switch. Tampering with the factory presets could cause damage to the air compressor by over pressurization.
How to install air compressor lines in garage?
If you’ve selected and purchased the suitable air compressor and relative parts, you can set the unit up in your garage according to the following steps: (how to select the right air compressor please refer to What Size Air Compressor Do I Need?
- Select a suitable areato place the air
- Determine how much room will be needed for work and tool applications.
- Select sufficient hose lengths and fittings for the attachments.
- Set the compressor on vibration isolation pads to stabilize and lower noise from vibrations. Read the owners manual to follow proper start-up and commissioning procedure.
- Power the compressor for commissioning
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