Frequently Asked Questions For Air Compressors:

We've found the most frequently asked questions we get about air compressors, system design and maintenance.

Your question isn't answered here? Get in touch for any other issues you have in mind. One of our compressed air system experts will be happy to help you!

1- How do I dispose of used air compressor oil?

One of the most frequently asked questions is this. Air compressor oil is toxic to humans and animals and can cause problems in the environment if not disposed of properly. For the prevention and management of waste, it regulates the elimination of used oil from air compressors and other industrial equipment.

Both oil and oil filters must be disposed of properly to maintain compliance and avoid costly fines. Used air compressor oil (including synthetic and petroleum-based oils) can be recycled or refined into a lower grade of oil or fuel.

• Look for a registered used oil collection center in your area.

• Make sure the used oil is well sealed.

• Many service stations and stores are also registered oil collection centers.

• If you only collect a small amount of oil for recycling, you may be able to partner with one of your local companies.

• Larger stores should consult the state hazardous waste program for instructions on recycling oil.

• Oil filters should be punctured and hot drained or crushed before disposal. Alternatively, you can drop off used oil filters at the same facility that collects used oil.

The oil collected by your oil/water separator must also be disposed of properly. Add this oil to the oil you collect during oil changes for recycling.

2- How often should I take an oil sample from my air compressor?

Oil sampling is performed to monitor the condition of the oil and keep your air compressor in optimal operating condition. It is a relatively inexpensive preventive maintenance tool.

Oil sampling is normally performed every 2000 hours. With new equipment, you may want to take samples more frequently, up to every 500-1,000 hours, to determine the best oil change intervals for your operating patterns. Your warranty may specify oil sampling intervals, so check your owner's manual and warranty documentation. The oil sample is sent to a laboratory for analysis. An oil analysis provides data on:

• The viscosity of the oil.

• The concentration and composition of particles.

• pH levels.

• The presence of wear metals.

This information is used to optimize oil change intervals for your usage patterns and environment. For example, if you are working in a very dirty environment, the oil sample may show that you need to change the oil more frequently than the standard PM intervals in your normal use.

Sampling can also help diagnose emerging problems with the compressor, such as varnish buildup or excessive wear on metal components.

Regular oil sampling will minimize unexpected downtime and keep your air compressor running at peak performance.

3- How can I make my air compressor quieter?

Air compressors can be quite noisy. A reciprocating air compressor typically operates at noise levels of up to 85 decibels (dB), while rotary screw air compressors range between 70 and 75 dB. There are a series of steps you can follow to lower the volume:

Choose a quieter compressor. If the compressor operates near areas where people are working, it may be worth considering the decibel levels in your purchasing decision. As noted above, rotary screw air compressors tend to be quieter than reciprocating compressors, but even within the same type there are differences in dB levels.

When comparing units, remember that the decibel scale is logarithmic.

A 3 dB increase means approximately double the noise, and a 10 dB difference increases perceived noise levels by a factor of 10. At 85 dB, you must raise your voice to be heard.

Place the compressor in a soundproof enclosure or in a separate area with sound-deadening materials, such as foam panels or acoustic panels.

You can also hang sound blankets in the compressor room or place them over the compressor housing to muffle the noise.

Wrap the compressor. Sound blankets can be wrapped directly around the compressor to absorb noise from the pistons or rotors.

Make sure the material does not block: the intake, exhaust, cables or hoses.

Install an intake silencer. Much of the noise from an air compressor resonates in the air intake, which can create high-frequency pulsating noises.

These damping devices use tubes or sound-deadening materials to muffle the sound of incoming air. They can also act as input filters.

Place a rubber mat under the compressor.

This will dampen vibrations between the compressor and the ground. You can also use rubber washers on the air compressor bracket.

Make sure your unit is in good working condition. Inspect your unit regularly and perform all recommended preventive maintenance tasks.

Tighten any loose bolts or screws that cause the unit to vibrate, check lubrication levels, check bearings and belts, and change air filters regularly. An air compressor in good condition will run quieter (and last longer).

4- Does my backup air compressor need to be the same size as my main air compressor?

Another of the most frequently asked questions is the doubt regarding backup compressors.

Not necessarily. It depends on what you need your backup air compressor to do and how dependent your jobs are. There are several ways to think about sizing your primary and backup air compressors.

Emergency Backup: In this scenario, the secondary compressor is only used if the primary compressor fails. It may be a smaller size than your main compressor. This works well if you can easily scale production or if you have a small number of “essential” processes that use air and other less essential applications.

For example, you may have a 50 HP main air compressor that can handle all your air needs at maximum production capacity. Your backup can be a 25 HP compressor, not enough to rev everyone up to full speed, but enough to avoid shutting down the entire operation while the main compressor is repaired.

Auxiliary Power: In this scenario, the secondary compressor is used as an emergency backup and as an auxiliary compressor during periods of high demand.

This allows you to have a smaller main compressor. The backup can be the same size or even smaller.

The two compressors operate in parallel when demand is maximum. This works well for stores with highly variable demand patterns.

Complete redundancy: In some cases, having a continuous air supply is absolutely essential.

When demand is continuous and constant, it may be worth investing in a fully redundant compressed air system.

Both compressors in this scenario are sized to handle the maximum compressed air demand for the facility. When the primary unit is offline for maintenance or repair, the secondary unit takes over. You can also periodically switch between machines to balance wear.

5- Why does my compressor shut down at high temperatures?

Industrial air compressors include a temperature sensor and a switch that will shut off the compressor motor if it begins to overheat. This is very important to avoid costly damage to your compressor.

When ambient temperatures are high, the engine is more prone to overheating and you are more likely to see your engine shut down unexpectedly.

You can reduce unplanned shutdowns due to air compressor overheating by keeping the compressor cooler and ensuring there is adequate ventilation around the compressor.

If the compressor is located outside, shading the area may help. If the air compressor is inside, make sure the compressor room has adequate ventilation.

Overheating can also be caused by other problems, such as clogged oil filters, clogged air filters, low oil levels, or the wrong type of lubricant.

Sometimes a faulty temperature switch can also cause excessive shutdowns.

If your air compressor shuts down frequently and you have already addressed ventilation, cooling, filters and lubrication, contact a qualified repair technician to fix the problem.

6- Why do my air compressor fuses keep blowing?

If the air compressor keeps tripping its circuit breaker, this is a clear indication that something is wrong, either with the wiring or with the compressor itself.

First, make sure you are using an electrical source with the proper voltage for the air compressor.

A large air compressor should be plugged directly into an outlet with the appropriate voltage for the machine, using a properly rated heavy-duty power cord.

Please refer to the user manual for more details.

If the wiring and electrical system are fine, blown fuses may indicate a problem with the compressor that is causing it to overheat or consume too much power.

The most common culprits are usually:

• Dirty air filter

• Faulty motor (for example, sparking or arcing within the motor)

• Defective circuit breaker

• Clogged pistons or problems with bearings or rotors

• Excessive usage/excessive duty cycles

• Stuck centrifugal switch

• Pressure switch shorted

• Wastegate failure

If you are not sure what is causing the fuses to blow, you should have it checked by a qualified service technician as soon as possible.

7- Is it normal to have some residual oil in my compressed air tank?

Another of the most frequently asked questions about compressors is this. It is not uncommon for an oil-lubricated air compressor to leave a trace.

This is known as "oil carryover." Small amounts of oil may appear in the air receiver tank or compressed air supply.

You can reduce oil carryover with an inline filter. A coalescing filter will remove both oil mists and dry particles from the compressed air.

However, if you notice oil building up in the air tank or in or around the outside of your compressor, it's a problem.

Oil pooling around the compressor indicates a leak somewhere in the compressor. Oil pooling in the tank may mean that the air/oil separator has failed.

These are urgent issues that must be addressed before continuing to work with the machine.

8- How do I drain water from the compressed air tank?

Draining condensate that builds up inside the compressed air system is very important.

Moisture buildup inside the tank, pipes or compressor will cause corrosion over time.

In the air tank, condensation will collect at the bottom of the tank, where it can be drained with a drain valve.

For manual drain valves, simply open the valve and let the water drain into a container or floor drain until it stops working, usually just a few seconds.

This should be done at least once a day and you may need to do it several times a day.

You can reduce maintenance with an automatic drain valve.

Electric drain valves open on a timer to drain water. They can be set to open for a few seconds at a time on a regular schedule, such as once a minute or once an hour.

A zero-loss drain valve uses a float mechanism to trigger the valve to open. This reduces air loss because the drain valve only opens when necessary.

Drain valves can also be found on compressors, air dryers, in-line filters, and at low points in compressed air piping. They should be used anywhere moisture can accumulate in the compressed air system.

That's all the most frequently asked questions about compressors we've found for now!

You can call us at 772-271-0263 or send us an email: jpindustrial772@gmail.com to help you diagnose, troubleshoot and repair your unit.

Frequently Asked Questions