How to install the compressor correctly
Correct installation is very important. Improper installation may cause the air compressor to not operate normally, seriously affect the service life of the air compressor, and also bring additional maintenance and repair costs to the enterprise.
Site selection of air compressor
◆ avoid outdoor installation: to avoid sun exposure or rain soaking and dust entering the unit, damaging machine parts.
◆ avoid installation in places with corrosive gas: corrosive gas (acid or alkaline substance) is contained in the air. Like HCl, HF, SO2, etc.). It will cause serious damage to the air compressor. Including: corrosion, rust, premature failure of coolant.
◆ the air compressor should be avoided to be installed in a narrow space without ventilation: to prevent the unit from exhaust high temperature and other adverse conditions.
◆ requirements for ambient temperature: the installation ambient temperature shall be kept between 1.7 ° C and 40 ℃; if the ambient temperature is too low, it may cause freezing of condensate, startup failure, high exhaust pressure alarm and other faults.
◆ avoid installation in places with more dust: the use environment with high dust will shorten the service life of air filter, oil filter, oil separation and oil. The replacement cycle shall be shortened, and the cooler shall be purged regularly to remove dust.
Air filter surface blocked by dust
Cooler surface blocked by dust
Layout of air compressor room and placement of air compressor
◆ installation ground: the ground is flat and can bear the self weight of air compressor.
◆ noise reduction and vibration reduction: if necessary, the air compressor base can be padded with a piece of rubber to reduce vibration and noise.
◆ installation distance: the distance between the air compressor and the surrounding objects shall not be less than 1 m, and the lighting and lighting conditions shall be good for operation and maintenance.
◆ traveling crane equipment: for air compressor above 75kW, it is recommended to install traveling crane in air compressor station to facilitate maintenance. If there is no standard lifting equipment such as traveling crane, at least temporary lifting equipment such as forklift and gantry, and the installation location or access of these equipment are required.
◆ placement of air tank: air tank shall be installed behind the air compressor, and the volume of the air tank shall be more than 20% of the air compressor's exhaust volume per minute, and personnel shall be arranged for regular drainage.
Pipeline connection of air compressor
◆ installation of hot gas discharge pipe (only applicable to air cooling unit)
① Independent installation: each air compressor shall be installed with independent exhaust pipe
② Pipe diameter: the diameter of the exhaust pipe shall not be less than the size of the exhaust port of the air compressor. The pipe diameter can be appropriately increased according to the distance of compressed air transmission to reduce the pressure loss.
③ Pipeline trend: try to adopt straight pipeline trend, and adopt 90 ° arc transition when turning to reduce pressure loss.
④ Do not face the wind at the air outlet: avoid the exhaust hot air being inhaled by the air compressor again.
⑤ Install isolation ball valve: install isolation ball valve between exhaust pipe and air compressor, but generally do not need to install check valve to avoid frequent loading and unloading.
(installation example of correct hot air discharge pipe of air compressor)
◆ precautions for installation of cooling water pipe
① Sufficient flow and head shall be considered when selecting water pump.
② Deep well water and chilled water shall not be used for cooling water. Because the water quality of deep well water is very hard, if the cooler is scaling in the future use, the scale cannot be removed by pickling. Professional water treatment method shall be used to clean the cooler with chemicals that do not produce corrosion to metal.
③ The cooling water supply pressure shall be 3.0-5.0bar, and the inlet and return water pressure difference shall be more than 1.5bar.
④ Filter screen shall be installed for cooling water inlet pipe
⑤ The maximum temperature of cooling water inlet is 35 ℃. Generally, cooling tower is required for cooling water system.
⑥ Drain valve shall be installed at the end of cooling water supply pipe.
⑦ The water quality of customers shall be tested regularly. If the water quality fails to meet the requirements, the cooling water must be treated with professional water treatment methods until the water quality reaches the standard.
(water quality requirements of water cooling unit)
|Substance||Test interval||Acceptable content|
|Corrosivity (hardness, pH value, total amount of solid solution, temperature of inlet alkalinity)||Test once a month or 3-4 months. Quarterly analysis||Langelier index（0-1）|
|sulfate||Monthly||< 50 ppm|
|chloride||Monthly||< 50 ppm|
|nitrate||Monthly||< 2 ppm|
|silica||Monthly||< 100 ppm|
|undissolved oxygen||once a day or once a week||0ppm(The lower the better)|
|oil and grease||Monthly||< 5 ppm|
|ammonia||Monthly||< 1 ppm|
Installation of main circuit cable of air compressor
◆ ensure the correctness of power supply voltage of air compressor.
◆ select appropriate black air switch according to the power of air compressor, and use independent power control.
◆ Standard Fuse and air isolating switch must be installed on the incoming line of low-voltage power supply. The fuse and air isolating switch shall be installed near the air compressor and easily accessible and controlled.
◆ cables shall not be installed with too much stress to avoid short circuit caused by cable loosening in the future.
◆ the cable shall not contact with the metal block mouth, so as to avoid the short circuit caused by the cable being cut in the future.
The installation of air compressor is very important, your air compressor energy-saving journey, to start from the first step.