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To make sure your air tools work properly, set your air compressor’s output pressure to the required PSI range of air tool is important, the air compressor pressure can be adjusted up or down very easily by the pressure regulator!
If you’re not sure how to do this, the following will help solve all your questions including what a pressure regulator is, how to read a pressure gauge, and how to adjust the pressure regulator.
What is an air compressor pressure regulator?
As the name implies, an air compressor pressure regulator is an air compressor accessory that adjusts the pressure per square inch (PSI) to meet your compressed air needs. It controls the compressed air flow from the compressor and ensures that they are delivered at the required pressure, and you can manually adjust the pressure within specific parameters.
A pressure regulator allows you to precisely regulate the air pressure going into specific tools and applications. It maintains a constant output pressure regardless of changes in input air pressure or downstream flow requirements. A pressure regul ator helps avoid over-pressurize issues, which wastes energy and increases the CFM requirements of the air compressor.
Without air compressor pressure regulator, you will not be able to regulate the pressure or strength of the compressed air coming from the compressor output. The regulator prevents each tool from being starved or overloaded, helping to ensure the quality of your pneumatic applications.
Improper pressure levels can cause inefficiencies in your tools or even damage or destroy your tools.
Regulating the pressure of your air compressor also helps save energy for your tools and production. Without a pressure regulator, you may be consuming a lot of energy to meet peak demands every workday, even if only a small portion of your applications require such high compressed air pressure.
Using an air compressor regulator can save your business energy and money. Learn more about improve air compressor energy efficiency?
How does a pressure regulator work?
A pressure regulator is essentially a control valve that allows you to increase or decrease airflow based on the needs of a specific application. Pressure regulators are designed to dampen the PSI fluctuations that occur when an air compressor is turned on and off.
An air compressor regulator consists of a gauge that displays the PSI, an adjustable valve that controls the airflow, and a dial or knob that allows for manual adjustment. The regulator typically has an internal spring that tightens or loosens the seal, allowing more or less air to pass through the regulator. When airflow is reduced, the pressure downstream of the regulator also decreases.
Pressure regulators can be either direct-operated or pilot-operated. Pilot-operated regulators (both internal and external) have no spring to overcome. Additionally, pilot-operated regulators are more precise and keep pressure within a tighter range.
It is important to note that pressure regulators can only reduce the pressure of an air compressor, they cannot increase the pressure beyond the PSI that the air compressor can produce. Therefore, pressure regulators can be either a pressure-relieving or non-pressure-relieving type.
Pressure-relieving regulators: Pressure-relieving regulators release excess air to the atmosphere to relieve downstream pressure, so you may notice a loud hissing sound as the excess air is released.
Non-Relieving Pressure Regulators: Non-relieving pressure regulators do not vent excess air and require the use of a downstream valve to relieve excess pressure.
How to read pressure gauge?
Gauge Units: Determine the units the gauge uses and the difference between each numbered unit. For example, a gauge might display measurements of 0, 100, and 200 PSI, meaning there is a 100 PSI difference between each major unit.
Marked Units: Count the number of spaces between the marked units to determine how many PSI units each space represents. If the example gauge has 10 spaces, each space represents 10 units.
Find the tank gauge on the compressor’s air tank. Look at the air compressor and find a gauge connected to the nozzle of the air tank. This is the tank gauge. This is usually the larger of the two gauges on the air compressor.
Find the outlet gauge connected to the compressor’s air hose. Find the air hose (the hose that connects to the air tool) and find the gauge near where the hose connects to the tank. This is the compressor’s outlet gauge. This is usually the smaller of the two gauges.
The pressure regulator knob is usually located just below or next to the gauge connected to the air tank, but sometimes it is located between the two gauges.
Look at the tank gauge to see the compressed air pressure. Check the number that the needle on the tank gauge is pointing to. This is the air pressure in the tank that available for you to use, measured in pounds per square inch (PSI).
The needle will move down when you use the air tool and will move up again when you stop using the compressed air in the tank.
The reserve pressure is automatically adjusted by a pre-programmed pressure switch. This keeps it within the manufacturer’s acceptable air pressure range (PSI).
Your air compressor cannot provide a pressure greater than the compressed air pressure in its air tank. Read the outlet pressure gauge to see the output pressure of the compressed air.
Look at the needle and read the PSI it is pointing to. This is the air pressure that the compressor is currently supplying from the air tank to the tool connected to the air line. The number the needle is pointing to will change as you adjust the pressure.
The outlet pressure cannot be higher than the reserve pressure of the air tank. This is also the only pressure you need to adjust on the air compressor’s pressure regulator each time you use a different tool.
How to adjust air compressor pressure regulator?
Use the following steps to learn more about adjusting your air compressor regulator. However, remember that air compressor models can vary โ some may adjust pressure through a simple knob or dial, while others may use a digital human-machine interface (HMI). It’s always best to review your owner’s manual for model-specific instructions before trying to adjust your air compressor regulator.
Turn on the air compressor: To accurately adjust the pressure gauge, you will first need to turn on the machine and allow it to warm up for proper operation. Wait a few minutes for the air tank to refill with pressurized air. It is important to get a full air tank for this adjustment procedure.
Check the PSI compatibility of the tool: Once you have enough air in the air tank, check the PSI of the air tool reserved for this test. The tool you are using must be compatible with the compressor. If the PSI requirement of the tool exceeds the capabilities of the air compressor, replace the appropriate tool to continue this test. You will know you got the right tool when the compressor pressure exceeds the requirements of the tool at hand. Once you have determined the compatible tool, you can continue with the test.
Connect the tool and air hose. Connect the air tool to the air hose, and then connect that air hose to the air compressor. If you are connecting this tool for the first time, look for the port on the instrument. If you are unsure of this feature, consult the owner’s manual to locate the port.
Adjust the pressure regulator: Once you have secured the tool and hose connections, adjust the setting on the pressure regulator to match the PSI requirement specified on the tool. On most compressors, there is a knob on the right side of the pressure regulator. However, on some compressors, the knob may be located in a different area of the machine. In the latter case, consult your owner’s manual to locate the knob for the pressure regulator.
Unlocking the Regulator Knob: Most regulator knobs have a lock feature on them that you need to loosen in order to turn the knob. In most cases, the lock is a push-pull type. To release the knob from the locked position, pull it outward. To re-lock the knob, push it back inward. If this doesn’t work, consult your owner’s manual for information about the regulator lock on your compressor.
Adjusting the pressure up or down: To increase or decrease the air pressure on your compressor, turn the regulator knob clockwise. You can quickly notice an increase in pressure. The gauge reading will indicate the pressure change, and you may hear a sound from the machine. Once the regulator is adjusted to the required pressure, push the knob back in to lock that setting.
If you need to decrease the pressure, turn the adjustment knob counterclockwise until the pressure is reduced to the required level. Then make sure to return the knob to the locked position.
When increasing or decreasing the pressure, always do it slowly and keep a close eye on the gauge. Also, remember that you cannot adjust the pressure above the maximum PSI of the air compressor. Also, make sure not to adjust the PSI below the minimum rating of your tools and equipment to prevent expensive damage or operational failure.
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How to change a pressure switch?
Check the manufacturer’s instructions for the new pressure switch to see the cut-in and cut-out pressures that its manufacturer initially set. Set them to the same as your air compressor, if it is initially set to the same range as the air compressor, then no adjustment is necessary.
The cut-in pressure is the pressure at which the air compressor engine starts, and the cut-out pressure is the pressure at which the engine shuts down. The cut-in and cut-out pressures protect the air compressor tank wonโt get over-pressurized and explode.
For safety reasons, these pressures are automatically adjusted by the factory-installed pressure switch, so only set them when itโs necessary to install a new pressure switch on the compressor.
Locate the remove the adjustment screws on the pressure switch housing. Remove the cover of the pressure switch and locate the two adjustable screw. Look at the label on the switch or refer to the owner’s manual to determine which screw is for making pressure and which is for breaking pressure.
Some pressure switches may only have 1 adjustable screw that changes the pressure differential or range between the cut-in pressure and the cut-out pressure. If you are not sure which is which, never adjust these screws.
Use a screwdriver to turn the start adjustment screw to set the start pressure. Turning the screw counterclockwise will cause the compressor motor to start at a lower pressure. Turning the screw clockwise will cause the motor to start at a higher pressure. Always refer to your compressor’s owner’s manual for the manufacturer’s recommended cut-in pressure.
Generally, the cut-in pressure should be around the lowest PSI at which you operate the tool.
If your pressure switch only has one differential screw, turning it will automatically lower or raise the cut-in and cut-out pressures.
Use a screwdriver to turn the cutout adjustment screw to set the cutout pressure. Turning the screw clockwise increases the pressure at which the compressor motor shuts off. Turning the screw counterclockwise allows the motor to shut off at a lower pressure. Always set the cutout pressure to the manufacturer’s recommended PSI so the compressor does not stay on if the tank pressure builds up.
In general, the cut-off pressure should be about 20-40 PSI higher than the cut-in pressure.If your compressor only has 1 adjustment screw, there is no need to set the cut-off pressure. It changes automatically when you move the single differential pressure screw.
FAQ
How much PSI should I adjust my air compressor?
If you are unsure of the optimal PSI value, consult your operation manual. Different tools have different PSI requirements for optimal operation. The operator’s manual will tell you the minimum PSI rating for the tool. Most air tools are designed to operate at 90 PSI. Your operation manual may have three ratings: recommended operating pressure, minimum operating pressure, and maximum operating pressure. If the pressure drops below the minimum, the tool will not function properly or stop working, while operating above the maximum pressure will cause excessive wear on the equipment or may even result in costly damage.
What tools are needed when adjusting pressure regulator?
Generally speaking, the adjustment process needs very little in terms of tools and materials. Youโll need a screwdriver or wrench, depending on the type of air pressure switch that you have on your compressor. If the compressor and lighting in the area are hardwired into a breaker, youโll need to throw the breaker, so make sure you tape it off and have alternative lighting available to be able to see what youโre doing. Depending on how long it has been since youโve adjusted the pressure switch, you may need to use dielectric grease or an electrical solvent to get the set screw to move. Do not spray flammable liquids on the pressure switch while it is hooked up to an electrical current.
What should I pay attention to when adjusting pressure regulator?
Air compressors often work on an electrical circuit, which makes it important to take appropriate safety precautions. Because the pressure switch will control the electrical current to the compressor motor, itโs vital that you follow safety measures, including wearing personal protective equipment. Turn off the air compressor and if possible, pull the plug to avoid accidental shocks to yourself or any bystanders in the area.
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