How to Set Up an Air Compressor A Step-by-Step Guide
Need help setting up your air compressor? Look no further than this detailed diagram, complete with step-by-step instructions and helpful tips.
Install air compressor
● When setting up an air compressor air dryer, it is important to choose a spacious and well-lit location for ease of operation and maintenance.
● The environment should have low relative humidity, minimal dust, and good ventilation to ensure clean and dry air output.
● The temperature of the environment should be kept below 40℃, as higher temperatures can reduce the amount of air output.
● If the factory environment is poor with high levels of dust, it is recommended to install a pre-filtering device.
● It is also advisable to reserve space for maintenance and provide access for maintenance equipment such as a crane.
● The air compressor should be at least 70cm away from the wall, and the distance between the compressor and the ceiling should be at least 1 meter.
Matters needing attention in air compressor piping, foundation and cooling system
● Piping Precautions for Air Lines
- First, the piping should be sloped at a 1°-2° angle to allow for proper drainage of condensation.
- Second, the pressure drop in the piping should not exceed 5% of the set pressure of the compressor, so it is best to use larger diameter pipes.
- Third, branch lines should be taken from the top of the main line to prevent condensation from flowing into the equipment.
- Fourth, if multiple compressors are installed in series, a ball valve or automatic drain valve should be added at the end of the main line to facilitate drainage of condensation.
- Fifth, the main line should not be arbitrarily reduced in size, and if necessary, a tapered reducer should be used to avoid mixing and pressure loss at the joints.
- Sixth, if the compressor has a storage tank and dryer, the ideal piping configuration is screw compressor + storage tank + pre-filter + dryer + post-filter + precision filter. This setup can filter out some of the condensation in the storage tank and reduce the load on the dryer or filter.
- Seventh, if the air usage is large and instantaneous, a storage tank should be added as a buffer (with a capacity greater than or equal to 20% of the maximum instantaneous air volume) to reduce the frequency of compressor loading and unloading and control component actions.
- Eighth, for compressed air with a system pressure below 1.5 MPa, the flow velocity in the delivery pipe should be below 15 m/sec to avoid excessive pressure drop.
- Ninth, the use of elbows and valves should be minimized in the piping to reduce pressure loss.
- Tenth, the ideal piping configuration is to have the main line surround the entire plant so that compressed air can be obtained from any location. Appropriate valves should be installed on the circular main line for maintenance and shutdown purposes.
● Basic
- The foundation should be built on a hard floor, and the foundation plane must be leveled before installation to avoid noise caused by vibration of the air compressor.
- If the air compressor is installed upstairs, anti-vibration treatment must be done to prevent the vibration from being transmitted to the downstairs or causing resonance, which will pose a safety hazard to the air compressor and the building itself.
- The vibration generated by the screw air compressor is very small, so there is no need for a fixed foundation. But the ground where it is placed must be flat, and the ground cannot be soft soil. The bottom of the air compressor is best covered with cushions or anti-vibration pads to prevent vibration and noise.
● Cooling system
- When selecting an air-cooled air compressor, the ventilation environment should be considered. Do not place the air compressor near high-temperature equipment to prevent the air compressor from sucking in high-temperature atmosphere and causing the exhaust temperature to be too high and affecting the normal operation of the unit.
- When the use conditions limit the air compressor to be installed in a small confined space, it must be equipped with suction and exhaust equipment to facilitate air circulation, and the capacity of the suction and exhaust equipment must be greater than that of the cooling fan of the air compressor The exhaust air volume, and the position of the exhaust air inlet should be suitable for the position of the hot exhaust air outlet of the air compressor.
Debugging and running
● When commissionging a new air compressor air dryer,it is important from the company perform the setup.
● Before starting the machine, ensure that there are no personnel inside and check for any leftover items or tools, then close the unit door.
● When conducting a trial run, carefully inspect the direction of the air compressor’s rotation. If it is found to be rotating in the wrong direction, immediately shut down the machine, cut off the power, switch any two of the three-phase lines, and restart.
● Failure to do so may damage the air compressor (be sure to pay attention to this during factory power inspections!).
● The air compressor should not operate at pressures higher than those specified on the nameplate, as this can cause the motor to overload and burn out.
● When the air compressor is in remote control mode, it may start at any time, so be sure to post a warning sign.
Maintenance and repair
The maintenance and repair of the air compressor must be carried out under the guidance of qualified personnel.
● Compressed air and electrical appliances are dangerous. During inspection or maintenance, it is necessary to confirm that the power supply has been cut off, and hang warning signs such as “inspection” or “no opening” at the power supply to prevent injuries caused by others switching on and transmitting electricity;
● When shutting down for maintenance, it is necessary to wait for the entire air compressor to cool down and the system compressed air to be released safely, and the maintenance personnel should try to avoid any exhaust port in the air compressor system and close the corresponding isolation valve;
● When cleaning the parts of the unit, non-corrosive and safe solvents should be used, and the use of flammable, explosive and volatile cleaning agents is strictly prohibited;
● After the air compressor has been running for a period of time, the safety valve and other protection systems must be inspected regularly to ensure its sensitivity and reliability, usually once a year;
● The spare parts of the air compressor must be provided by the original factory, and the screw oil must be the special oil designated by the company for the screw air compressor, and it is strictly forbidden to mix the two brands of oil, otherwise it will cause coking in the system and cause major accidents.
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