Compressors FAQ

Compressed air is the main workhorse of manufacturing plants. An air compressor converts power into energy. This energy is stored in compressed air which provides reliable and steady air flow. This power and pressure supply is used for running air tools and equipment.

When picking an air compressor, here are the main factors to consider:

• number of tools that the compressor operates
• how the tools are used
• where the tools are used

The number of tools determines compressor size. Compressor size is measured in cubic foot per minute (CFM). Rotary screw and oil-free compressors have some benefits over piston compressors, their main advantages including higher air quality and energy efficiency and lower noise level. Oil can also damage equipment in certain uses, therefore, oil-free air compressors provide safe oil-free air supply and 100% air purity.

1. Make sure the power switch is turned off before plugging in the air compressor.
2. Before turning on the compressor, check its oil level (if applicable).
3. Turn on the compressor and allow it to run for a few minutes to fill the air tank. Check the air gauge and make sure the compressor shuts off when the pressure reaches 100-115 psi.
4. Ensure that the air control valve is set to match the maximum air pressure allowed on the air tool that you will be using.
5. Attach an air hose to the compressor and ensure the length is sufficient for the air hose to reach the work area.
6. Attach your air tool to the other end of the air hose.
7. You should periodically drain the moisture from the air tank by loosening the drain valve at the bottom using an adjustable wrench. You can check your owner’s manual for recommendations.

• Using microscopy to collect filters: Using an optical microscope, this technique analyzes particles in compressed air using a grid membrane that can capture small particles.
• Laser Particle Counter: A laser particle counter can be used to sample compressed air in accordance with ISO 8573 compressed air quality standards, which can be effective for testing air samples for particles of all sizes.
• Water Vapour Testing: Water vapour impurities are detected using this water vapour testing. The following methods measure water saturation by either using the water’s physical properties, or using chemical reactions:
  • Hygrometers
  • Detector tubes
  • Spectroscopy
  • Hygrometers
  • Industrial compressed air testing procedure
• Oil Testing: Oil testing is performed for a wide range of hydrocarbon compounds including the below:
  • Oil
  • Condensed hydrocarbons
  • Oil vapour
  • Total gaseous hydrocarbons
• Oil Aerosol Testing: Using high-efficiency membranes, oil from compressed air samples is dissolved on the membranes and then analyzed by an infrared spectrometry.
• Oil Vapour and Solvent Testing: This method is performed on hydrocarbon compounds whose chemical structure contains six atoms of carbon or more. Using gas chromatography, this method detects oil vapour contamination in compressed air within the range of 0.001mg/m3 – 10mg/3.

The decision of an air compressor’s size depends on the number of tools that it will operate at the same time. Compressor size is measured by cubic foot per minute (CFM). For single tools, the compressor has to meet the highest CFM requirement of the tool and for multiple tools, we have to sum the CFM requirements of the tools. We also recommend choosing a compressor size with spare capacity to allow for future extensions and tool add-ons.

Piston compressors use pistons in a cylinder. Rotary compressors use rotating screws to compress air, providing higher air quality and efficiency and quieter operation. Duty cycle of piston compressors is 60-70%. Rotary screw compressors operate at a 100% duty cycle and supply constant air flow. Belt-drive system of screw compressors reduces vibration and noise level since they use filters and separators for cleaner air and whilst they require more maintenance, they improve air quality and lifespan.

Oil free compressors generate compressed air through oilless operation. Air compression is a two-stage process; First, air passes through the air filters, Then it is compressed as it enters the chamber. After compression, an intercooler cools down the air and removes further moisture, providing a more compressed and oxygen-rich air.

Oil free compressors guarantee 100% clean air supply. They comply with the ISO 8573-1 Class 0 air quality standards. These compressors do not need oil for their operation because they are already pre-lubricated. Filtration and separator are removed as no oil-separation is necessary, allowing for a compact and lightweight design. The condensate is 100% oil free, therefore reducing operational costs and ecological footprints for businesses. Our oil free compressors are also available with acoustic boxes for extremely low noise levels.

Oil free compressors require reduced maintenance because filtration and separator are removed. They do not require oil change or routine filter replacements, the reduced maintenance allowing for significant cost savings. They supply 100% clean air with no risk of contamination.

In certain sectors even a little oil can cause serious damage or product spoilage, including in the food, beverage and pharmaceutical industries. Only the oil free air compressors can provide 100% pure air supply. These compressors also comply with the ISO Class 0 air quality standards. Low noise level is important in dental applications. We can install oil-free compressors with acoustic boxes that reduce noise level significantly.

An air receiver tank is an integrated part of an air compression system that acts as a reservoir for and temporary storage of the compressed air to better manage demand peaks and pressure drops.

Refrigerated air dryers are commonly used together with air compressors since air compressors cannot eliminate water from the air entirely. The refrigerated air dryer cools down the air to 2 degrees Celsius as it passes through, thereby condensing all air vapour into water. Once the liquid water is removed, it supplies completely dry air.

The refrigerated air dryer removes water as it cools down the air to 2 degrees Celsius. Desiccant dryer uses a drying and a regenerating tower. It has a desiccant material that absorbs the water vapour. Desiccant dryer delivers compressed air to -100 degree dew points; as a result, they suit freezing conditions better.

1. Step #1. Always wear closed-toe shoes and safety glasses when using air compressors or power tools.
2. Step #2. Check the oil level in the compressor and add oil if necessary.
3. Step #3. Make sure the compressor’s power switch is “off.” Turn the pressure regulator knob clockwise until the outlet pressure reaches zero.
4. Step #4. Connect your air hose to the compressor’s regulator valve and your tool to the other.
5. Step #5. Connect the compressor to the wall outlet and set the power switch to “Auto.”
6. Step #6. Wait until the machine reaches the maximum pressure. Tanks fill up with air and gain pressure when the compressor charges. Use the tank pressure gauge to check the pressure.
7. Step #7. Make sure you set the pressure according to the manufacturer’s recommendation. Each tool has a different pressure requirement, so be sure to check.
8. Step #8. Once you’ve finished working, turn off the air compressor, unplug it and disconnect the air hose. Using the pressure relief valve, drain the pressure from the tank.

1. Step #1. Read the Manual
   You should always read the user’s manual that comes with the air compressor before installing it. Follow the instructions explaining how to secure it and where to place it.
   When you’re ready to connect it to power, be sure to check the manual for the minimum wire size since it differs depending on the manufacturer and model. In most cases, the minimum size required is a 10 gauge wire.
2. Step #2. Wire the Switch to the Motor
   There is a pressure switch on every air compressor that monitors the tank pressure. The motor will turn on when the pressure drops below a preset level and will turn off when the pressure reaches the preset cutoff level.
   When you connect the air compressor to power, power leads should be connected to the switch, not the motor. Most of the time, the switch is pre-wired to the motor.
   If the switch is not yet connected to the motor, refer to the user’s manual for the wiring diagram of the air compressor motor. A typical installation requires three short strands of the recommended wire gauge. One black, one white and one green or bare for the ground.
   The black wire should be connected to one of the brass motor terminals on the switch to the corresponding brass switch terminal on the motor. Then, connect the other pair of brass terminals to the white wire, followed by the ground terminals.
   For secure connections, a forked-style brass connector should be crimped on both ends of each wire.You will need to loosen each terminal screw enough for the fork to slide underneath it, then tighten the screw down securely.
3. Step #3. Connect a 240V Air Compressor to Power
   Compressors must be on a dedicated circuit controlled by a double-pole breaker with the amperage specified on the compressor’s label. If you are not confident with installing a breaker, don’t hesitate to hire an expert (electrician) to do the installation.
   From the panel, run a 3-conductor cable of the correct gauge to an outlet box located as close as possible to the compressor. After that, you can either hardwire the compressor directly to the panel or install a 240V receptacle to plug it in.
   In a three-conductor cable, there are two hot wires, a neutral and a ground. However, you might end up not needing the neutral. There may be instances in which a compressor may only have two line terminals and a ground. This will result in an extra wire. You can deal with it by leaving the white wire disconnected from the neutral bus and capping both ends. Keep one end in the panel and the other in the electrical box that feeds the compressor. Alternatively, you can simply use a two-conductor cable.
   Make a final connection by crimping a fork connector on the end of each wire that connects to a terminal in the compressor. If you install a receptacle and buy a power cord to plug into it, you may find that the wires will already have these connections. In the switch housing, feed the cable through the clamp connector. Connect the red and black wire to the tow line terminals on the switch housing, and connect the ground wire to the ground screw. If ever the compressor has a neutral terminal, connect the white wire to it. Make sure the cable is secure by tightening down the screws. Complete the installation by tightening the cable clamp on the switch housing to secure the cable and replace the housing cover.