COMPRESSED AIR SYSTEM

INSTALLATION GUIDE
 COMPRESSED AIR SYSTEM
INSTALLATION GUIDE
Your CAS system is designed and built to give many years of efficient service. To ensure
the system performs at its best, it is essential to install it properly in line with industry best
practices.

Whether you are updating an old compressed air system or installing a new one, we here
at Compressed Air Systems want to help you make it a success. We have compiled this
installation guide to provide you with important information regarding location, ventilation
and other essential factors of the compressor installation process that will help you get the
most out of your compressed air system.

This guide provides step-by-step instructions for installation. It will help you avoid problems
caused by improper installation that could lead to unscheduled downtime or equipment
failure.

Correct installation provides a number

of important benefits:

Reduces unscheduled downtime

Ensures energy-efficient operation
Optimizes performance
Reduces maintenance requirements
Lowers Total Cost of Operations (TCO)
Extends service life

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Carry out preparation and delivery inspection

Careful preparation is essential for a successful installation.

1. Choose a suitable location for the unit following the recommendations of this guide.
2. Ensure that all essential services and ancillary equipment are in place
and operational.
3. When the equipment is delivered, check the packaging for signs of damage
or interference.
4. If the packaging incorporates a Tip’n’Tell indicator, check its status.
5. Inspect the unit carefully for damage in transit. If damage is serious, the unit may
have to be repaired or returned.
6. Check the inventory to ensure that nothing is missing.
7. If there is no damage to the package, accept the product’s delivery
with a simple signature.

Choose a suitable location

Choosing a suitable location is important for the efficient operation, quality and life
expectancy of the equipment. While installation indoors is generally recommended,
a number of factors may make this difficult or adversely affect the equipment:

High noise levels from the unit High ambient temperatures in the area
Dirty or dusty conditions in the facility High levels of chemical concentration
in the air

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Outdoor installation may make the equipment vulnerable to extreme temperatures and
weather conditions, as well as dirt, dust and moisture from the surrounding area. Outdoor
installation may also incur additional costs, including a concrete pad, additional ducting
and power supply and security measures such as fencing and shelter against weather
conditions.

Check the suitability of the floor

Compressed air units installed indoors can be located on a standard concrete factory floor.
They do not require special foundations or surface finish.

1. Check that the floor is level, clean and capable of taking the weight of the unit,
any ancillary equipment and the equipment used to move it into position.
2. If noise is a problem, ensure the floor has the space and strength for a suitable
enclosure.

Consider all access requirements

In selecting a suitable location for the equipment, make sure that the area has sufficient
clearance for access at various stages of installation, operation and maintenance.

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The area around the unit should allow:

Access by fork lift, truck or crane for Access by maintenance teams to

installation operating panels or service points with
a minimum of 40” clearance around
Installation of power supply, ducting
the unit
and other services
Access for repair or replacement
Ventilation in line with equipment
of components.
specification

Consider environmental factors

The quality of the environment can affect operational efficiency. Check that environmental
conditions meet the following requirements:

1. Maintain ambient temperatures within the recommended range for the model.
2. Avoid low temperatures - they impede lubricant flow and create condensation.
If necessary, install a suitable cabinet heater.
3. Avoid high temperatures - they can reduce lubricant life and affect cooling and
condensate management.
4. Avoid high levels of dust or other particulates that can affect operation. Plan to
change filters more frequently to protect equipment.
5. Avoid excess moisture which can cause electrical problems or corrosion and affect
lubrication efficiency.
6. Avoid corrosive chemicals that can attack or contaminate internal components,
filters and lubricants.

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 Provide correct ventilation

Correct ventilation is essential to the efficient operation of the equipment. It can also
promote energy efficiency through heat recovery.

Poor ventilation will not remove the heat, raising temperatures and reducing operational
efficiency.

1. For small units, up to 15hp, install louvered inlets and outlets.

2. For larger units, over 20hp, it is recommended to supply forced ventilation.
3. Isolate exhaust air from air inlets of other units.
4. In extremely cold conditions, install thermostatically controlled louvers at air inlet
and exhaust discharge points.

Install optional water cooling

Water cooling is an alternative to air cooling. To implement water cooling, ensure you have
the following:

Source of suitable water

(filtered water yields better)
Pumps, plumbing, piping and filtration
equipment
Heat exchangers
Water treatment plant
Chilling equipment

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The additional equipment required can add to the cost. However, part of the cost can be
offset by implementing a heat recovery program.

1. Install connections from discharged cooling water to a heating application or

an industrial process that requires hot water.
2. Use the heat recovery program to reduce overall energy costs.

Provide a safe, compliant power supply

To protect the equipment and the safety of the operators, follow recommendations for the
correct electricity supply and comply with electrical safety regulations.

1. Ensure that operating voltage meets the equipment specification.

2. Provide a separate supply for each unit, unless it is a du-, tri- or quad-plex with a
single master controller provided from the factory.
3. Ensure correct grounding using a fuse or circuit breaker.
a) Proper wire size is critical for optimal grounding.
b) A
 lways use the same size ground wire as the incoming wire size on a variable
speed drive.
4. Work should only be carried out by qualified electrical contractors.
5. Electrical work must comply with local and national codes and regulations.

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Enhance efficiency with master controllers

To enhance efficiency when using multiple air compression units, install a master controller.
Some available models can control up to 16 units.

These controllers provide a number of important benefits:

Maintain lower operating pressures to reduce energy consumption

Control maintenance costs by balancing operating hours and reducing cold starts
Reduce downtime and improve equipment performance
Manage oily condensate
Web-based, remote monitoring of compressor systems, including alarms,
maintenance and daily performance, with real-time data, energy usage, flow, pressure,
temperature, etc

Ensure air purity

The Clean Water Act of 1970 was created by the Environmental Protection Agency (EPA), a
federal entity that strictly enforces the disposal regulations of oily compressor condensate.
In fact, most condensate contains more than 300 ppm of oil, which is illegal to dispose of
directly into drains. Due to this fact, the EPA requires a condensation management system
that minimizes the amount of oil in the water (most municipalities accept < 100 ppm).
For example, a 100 HP compressor can pass up to 10 gallons of oil per year in one-shift
environment.

The system collects the contaminated water at each filter, dryer and water separator in a
drain trap and channels it to the condensate cleaner, which separates the oil from the water.
To reduce the risk of contamination by oil, moisture or particulates, it is essential to set up
the correct combination and sequence of filters, receivers and dryers.

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 1. Select the combination of filters, receivers and dryers to suit the application and
airflow rating.
2. Select dryers based on the dew point for the application and apply correction factors
for ambient conditions—this is especially important in tropical climates.
3. As a guideline, treat smaller amounts of compressed air for specific applications,
rather than treating the entire supply to achieve the highest purity level.

All compressors form condensate that is mostly made up of water. Condensate becomes
contaminated with oil from within the compressor and particles that have been drawn into
and passed through the compressor.

To avoid problems caused by condensation, it is highly recommended that you install a

condensation system composed of drain taps, oil/water separators and the necessary
manifold and piping to connect them.

The first step is to remove the moisture from the air, and it starts with air coolers
(or aftercoolers), moisture separators, air dryers and moisture drain valves. The air coolers
lower the compressed air temperature and moisture separators collect and dispose of the
moisture from this process. Air dryers remove the remaining moisture, and moisture drain
valves channel the contaminated water and allow disposal.

After this process, filters remove the remaining oil particles, oil, vapors, etc. Air filters clean
the air, and coalescing filters remove the oil mist. Other types of filters can also be installed
for odors and bacteria. Filters are installed upstream of regulators and lubricators
to protect them.

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Drain traps can be manually operated, float-operated, timer-controlled (automated),
or feature an electronic sensor. This choice is driven by cost and drain location. Less
automated drains can waste compressed air and output a mist, which is complicated
to manage. These drains also get stuck if they are not handled often. However, they are
cheaper than a fully automated system and require less complicated installation.

A zero loss drain is often the preferred and most efficient choice.

Condensate oil water separators use a combination of technologies to separate water

from oil, including gravity, oil-absorbing prefilters and activated filter bags. The oil is usually
collected in a separate container, allowing the disposal of water with contamination within
the legal limit. Some separators have a tap to be able to sample the output without taking
if offline.

Plan and install efficient piping

In order to provide ample airflow and steady pressure to all system points, it is important
to correctly size the pipework of your system. The diameter of the pipe determines the
pressure drop across the pipework.

The Compressed Air and Gas Institute (CAGI) has published tables to estimate the pressure
drop from friction loss at specific pressures.

The type of piping material you choose will have a large impact on your system’s airflow,
pressure and air quality. Poor choices of material, diameter and layout will cause restrictions
that result in significant pressure drops across the system. PVC and ABS material are not
recommended. Certain synthetic lubricants can degrade these plastics and lead to ruptures,
which is a health hazard.

Additionally, air traveling through plastic pipes can accumulate a static electric charge that
can discharge when an employee touches it. For this reason, PVC and ABS piping are not
recommended by the Occupational Safety and Health Administration (OSHA).

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Here are some general installation tips for piping:

Follow CAGI recommendations for Pressure Loss

Use rounded elbows whenever possible. Avoid the use of “T”s and right angles that
increase friction loss
Pipe in the bottoms and tops of air receiver tanks to promote moisture separation
Use braces to secure pipes to walls, floors or ceilings to prevent movement and stress
on pipe joints
Use Flexible pipe/hose connections between rigid air piping and compressor
discharge outlets
Aluminium and copper are preferred materials for pipes. Galvanized steel piping can still
be utilized but will tend to leak after time at threaded connections

To optimize and maintain pressure in the system, select the correct piping size and material.

Follow the recommendations of the Compressed Air and Gas Institute to calculate
potential pressure loss in a system
Plan pipe flows to minimize bends that create friction and reduce pressure. Round
elbows help reduce friction, compared to right angles
Select materials that have a smooth interior and low pressure drop
Brace pipes to minimize the risk of movement
Connecting all the piping together in a “loop” offers the air a path of least resistance

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 OVER 55 YEARS OF
OUTSTANDING SERVICE
Compressed Air Systems, Inc. began doing business in 1963 with only five
employees. Over the years, we have steadily grown and now employ over 50 people.
Our thriving business operates out of our 30,000 square foot facility in Tampa, FL,
with a 4,000 square foot facility in Orlando, FL.

We carry a wide range of products and specialize in air compressors, blower, and
vacuum systems. Our sales department is backed by our own in-house service,
installation, and rental departments to make an unbeatable team. We sell, service,
and rent all types of pneumatic tools and equipment. Whether working with pumps
or tools, our complete repair facility ensures quick turn-around for your convenience.

If you’re considering the purchase of a complete air system or need diagnosis and
repair of an old system, we’re ready to put over fifty-five years of experience to work
for you.

If you’d like more information on how to select the best compressed air
solution for your company, contact us at Compressed Air Systems, Inc.

CONTACT US RESOURCE LIBRARY

9303 Stannum Street Tampa, FL 33619-2658 USA

Phone: 855.464.8525
Email: info@compressedairsystems.com
compressedairsystems.com