Installation

Selecting the Installation Site: The chosen location for the air compressor must facilitate future maintenance and prevent abnormal operation due to unsuitable environmental conditions. An appropriate installation site is a prerequisite for the correct operation of the air compressor system.

1. The installation site requires good natural light and adequate artificial lighting to facilitate operation and maintenance.
2. Maintain low relative humidity, minimal dust, clean air, and adequate ventilation.
3. Where ambient temperatures exceed 45°C, implement cooling measures (e.g., avoiding direct sunlight, opening windows/doors) to prevent unnecessary shutdowns due to overheating. Where temperatures fall below 0°C, ensure the lubricant’s pour point remains above ambient temperature.
4. In dusty or poor factory environments, install a ventilation duct to direct the intake air to a cleaner location. The duct must be easily removable for maintenance, with dimensions referencing the compressor’s external measurements.
5. Maintain sufficient clearance around the compressor for component access, with a minimum distance of 1500mm between the unit and walls. Hoisting equipment is preferable.
6. Maintain a clearance of at least 1500mm between the air compressor and the ceiling.

Piping, Foundation and Cooling System Considerations

1. Piping (1) When installing the main pipeline, ensure a downward gradient of 1º to 2º to facilitate drainage of condensate. (2) Pressure drop in piping must not exceed 5% of the air compressor’s rated pressure. For longer runs, select pipe diameters larger than the design value. (3) Branch lines must be connected to the top of the main line to prevent condensate from the main line flowing back into the machine. (4) Pneumatic tools requiring lubrication should be fitted with a triple combination unit, comprising a water separator, pressure regulator, and lubricator (supplying lubricating oil) installed in series to maintain tool longevity. (5) The main line should not be arbitrarily reduced or enlarged. If reduction or enlargement is necessary, use tapered reducers. Failure to do so may cause turbulence at the joint, resulting in significant pressure loss. Additionally, gas impact pressure will substantially shorten the pipeline’s service life. (6) Where purification and buffering equipment such as air receivers and dryers follow the compressor, the ideal piping sequence is compressor + air receiver + dryer. The air receiver filters out most moisture and reduces the temperature of discharged air. Lower-temperature, drier air entering the dryer reduces its operational load. (7) For intermittent high-volume air consumption systems, installing a buffer air receiver on branch lines is advisable. This reduces the frequency of empty runs and extends the electrical and mechanical lifespan of the air compressor. (8) For compressed air below 1.5 MPa, flow velocity must not exceed 15 m/s to prevent excessive pressure drop within the piping. (9) Minimise the use of elbows and valves within the piping to reduce pressure losses. (10) The ideal piping configuration involves a main ring line encircling the entire premises, equipped with appropriately positioned valves. This ensures that any branch line within the premises can receive compressed air from two directions. Should demand at a particular branch suddenly increase, significant pressure drops are avoided. Additionally, these valves facilitate isolation during maintenance.
2. Foundations (1) Foundations must be constructed on solid soil or concrete surfaces, ensuring a level plane to prevent additional vibration caused by inclination. (2) Where compressors are installed on upper floors, anti-vibration measures (e.g., a 10mm-thick rubber layer) must be implemented to prevent vibration transmission and resonance.
3. Cooling System

General Electrical and Safety Specifications

1. Select power cable cross-section appropriately according to the air compressor’s power rating. Undersized cables must not be used, as they may burn out due to high temperatures, creating hazards.
2. The air compressor should ideally utilise a dedicated electrical system, particularly avoiding parallel connection with other electrical loads of differing power consumption. Parallel operation may cause excessive voltage drops or three-phase current imbalance, leading to compressor overload and tripping of protective devices. This requires particular attention for high-power air compressors.
3. Configure an appropriate non-fuse breaker (NFB) according to the air compressor’s power rating to protect electrical switches within the system and ensure safety.
4. When distributing power to the air compressor, verify that the supply voltage matches the motor’s rated voltage.
5. A grounding conductor must be installed for the motor or system to prevent hazards from leakage currents. The grounding conductor must not be connected directly to the air delivery piping.
6. During motor operation:
   • Power supply voltage deviation from rated value must not exceed ±5%;
   • Frequency deviation from rated value must not exceed ±1%;
   • Deviation of any single-phase current from the three-phase average must not exceed ±10% of the three-phase average.