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Compressor World

Air Compressor Blog

  • Air Compressor Pump Safety Valves

    Today we had a client call us about his air compressor pump not working properly and only holding 60 psi to his plant.   It's easy to sell someone a new compressor but to find the right machine for their application, our staff asked for a picture of their current system.  From this picture we can evaluate and find a solution.

    When we received the picture, we found a piece of a granite countertop holding down their safety valve on the second stage.

    This is a big SAFETY NO, NO!   The safety valve is their for a reason...

    If the safety valve "pops" it is best to;

    - Replace the Safety Valve
    - Inspect/replace the Check Valve
    - Inspect/replace the Compressor 1st and 2nd Stage Valves

    It is NOT recommended to remove the safety valve or hold it down with any item!

    If the compressor pump has discoloration on the discharge pipe, this could be a result of the compressor pump reaching it's upper end of it's duty cycle and maybe it's time to replace it with a new, larger compressor pump (increase the hp size) or with a new rotary screw air compressor.  Rotary screw air compressors can operate at 100% duty vs a piston pump is rated at 60%.  Piston pumps require a "time out" to cool the oil in between cycles.

    If the compressor items are in good condition and the compressor pump is beyond repair, replace the compressor pump only and retrofit a new style on the air tank.  This is a inexpensive solution vs. buying a new air compressor system.

    Tips for Keeping a Compressor Pump Running;
    - Size the pump correctly
    - Change the compressor oil frequently.  Piston oil is inexpensive, change the oil every 4-6 weeks
    - Keep the Inlet filters clean and replace accordingly.  Pipe the intake filters outside if the compressor pump is near an outside wall.  Make sure you have outdoor filter assemblies to protect the filter element
    - Drain the tank weekly or install a tank drain
    - Keep the compressor pump clean

    Remember, your air compressor is the lifeline for your business.  Spending short money on maintenance can eliminate compressor downtime and keep your business in operation.

     

  • Best 25 HP Air Compressors

    Some of the best 25 hp air compressors are installed in granite fabrication shops, automotive service and body shops, manufacturing plants and at universities around the World.  When you install a 25 hp air compressor (piston or rotary screw), you generally have demands that fall between 60 and 100 CFM, any demand under 60 cfm should install a 20 hp piston or rotary screw air compressor.

    Compressor World offers a variety of different compressor manufactures that make 25 hp air compressors.  The most popular brands we offer are;

    You will also find 25 hp air compressors in a few different configurations;
    - Base Mounted 25 hp air compressors
    - Tank Mounted 25 hp air compressors
    - Total Air Systems (25 hp air compressors)
    - Variable Speed Drive 25 hp air compressors

    Every 25 hp air compressor Compressor World sells offers a bumper to bumper warranty, 1 year parts and labor.  You will also receive a factory start up when buying rotary screw compressors larger than 20 hp from Compressor World.  This allows the buyer to meet their local service center as well as receive start-up and training.  To confirm, Compressor World offers air compressor brands that make some of the best 25 hp air compressors, followed by great aftermarket service.

    If you're looking for the best 25 HP compressor, search online within our site; best 25 HP rotary screw or two stage air compressors.

    When doing research on buying the best 25 hp air compressor, make sure you review the client reviews.  Stay away from factory reviews on 25 hp air compressors as they are just promoting the product.  Look for authentic client reviews, hopefully showing pictures of their 25 hp air compressor in operation.

    When you are searching for your 25 hp compressor, remember to ask about the controls. "How does the control system work?" Especially when you are buying a used 25 hp compressor. The older compressors had modulation controls and were very inefficient. For example, at 50% of full load the motor was operating at 89% bhp. Newer machines run with load/no load controls with timed shutdown. Ask one of our compressed air experts to see which compressor would work best air compressor for your application; 866.778.6572.

  • Air Compressor Service & Back Up Air Compressors

    What to expect when you are having service performed on your Air Compressor

    It’s that time again, time to perform your scheduled preventative maintenance service, “PM”, on your air compressor system.  What will that mean for your business?  Will there be time where you will be out of air?  How long will it last?  When can we start production again?  These are the common questions when scheduling service. 

    During a PM, there are many variables that determine the time of “down time” in the air production, as well as ways you can minimize this down time and eliminate it all together.

    • A “typical” PM on an Air Compressor (Rotary Screw, Piston, Oilless Scroll) if under 50 Horsepower, will range from 2-6 hours on site.
      • This includes Air filter, oil filter, separator, belt change and complete oil change (if applicable to the system).
      • A full inspection of the equipment, checking of the electrical connections and tightening as needed, cleaning out any dryer cooler & condensers and drains checked for blockage.
      • Any inline filtration elements are changed as well as oil/water separator elements
      • System as a whole is checked and any issues identified during the visit are documented and brought to the person in charge’s attention and addressed for quote for repair or noted for observation.
    • Units over 50 Horsepower or systems where there are multiple units can range from 4+ hours to multiple visits on site.  It will all depend if you are having a minor or major service on your compressor.
    • Down Time can range from 30 minutes to multiple hours depending on the system.  Having a reliable backup air compressor to take over during a PM helps eliminate down time all together.

    Is Having Backup Air Compressors Worth it?

    Quick Answer… YES… having a backup compressor is one of the best decisions to make if your business depends on air.  Whether you are a large production plant, with dozens of machines working or you work out of your home garage, your need for having a constant flow of air is vital to your business and keeping production going.

    • Backup compressors eliminate having down time with your air. 
    • Multiple machines in tandem will evenly disburse the working hours
      • Creating an environment where wear and tear will be minimized
      • PM expenses will be minimal and routine
    • Scheduled PM services for both compressors can be worked on at the same visit. 
      • No down time, and no lag in air

    Backup compressors are also essential in production as if the compressor goes down and is not usable, you are still with air and won’t lose production time.

    Without a backup unit, and your compressor goes down, so does your production… which means lost revenue.   

    So do not sell your back up compressor on craigslist or eBay… keep it for back up!

    Feel free to contact anyone at Compressor World with any questions or concerns.  866.778.6572 or info@compressorworld.com

  • Air Compressor Maintenance

    Performing regular scheduled service on your compressor system is a vital key to your compressors longevity, performance level and “uptime” with your production. Regular maintenance will ensure clean, dry air and like your car, your air compressors need to be serviced regularly. 

    Regular service helps to ensure your machine and all in line equipment are running at maximum efficiency.  Your business is important, if your air compressor shuts down, so does your business.   Regular service will also help to identify and head off any potential issues before they cause longterm damage to your air compressor. 

    Each compressor type i.e.; Rotary Screw, Piston, Oilless Scroll has a unique service schedule, and each manufacturer has a specific schedule and maintenance kit they recommend to do proper service. Here are a few generic standards for service, you should follow your recommended service schedule outline in your compressor manual.

    Rotary Screw Air Compressor Schedule

    Quarterly:

    • Replace Oil Filter element
    • Oil top off
    • Inspect and Tighten Electrical Connections
    • Inspect the Air Filter Element
    • Sample Lubricant
    • Inspect the after cooler

    Annually

    • Replace Oil filter, Air filter & Separator elements
    • Complete Oil change
    • Check Belts – Tighten as needed or replace from wear
    • Inspect and Tighten Electrical Connections
    • Clean the after cooler from debris and dust

    Piston (Two-Stage) Compressors

    Quarterly:

    • Inspect and Tighten Electrical Connections
    • Change Air Filter Element
    • Change Lubricant
    • Tighten and Inspect Belts

    Oilless Scroll Compressors

    Quarterly:

    • Inspect Air filter elements
    • Grease Motor
    • Check Belts – Tighten as needed or replace from wear
    • Replace Tip Seals (Every 7-10,000 hours)

    *MAKE SURE YOU FOLLOW THE MANUFACTURERS MAINTENANCE SCHEDULE TO MAINTAIN THE WARRANTY. 

    Air Compressors are only one piece of the air system.  Other pieces of equipment in line also need regular maintenance.

    Air Dryers

    • Desiccant Air Dryers
      • Inspect and replace the desiccant when needed.  It is recommended to replace the desiccant every 3 to 5 years
    • Refrigerated Air Dryers (High-Temperature, Cycling)
      • Blow out the exchanger, inspect the drain and check the ambient and inlet air temperature to ensure the dryer is working properly
    • Membrane Air Dryers
      • Inspect and check the dew point.  Change the membrane every 3 to 5 years

    In-Line Filtration

    • Coalescing, Fine Coalescing, Particulate & Active Carbon Filters
      • Replace the element annually
    • Pre & Post Filtration
      • Replace the element annually

    Oil/Water Separators

    • Annual replacement of the internal media is recommended

    Air Tanks

    • Condensation can build up inside the tank, daily drainage should be performed either by a manual tank drain, or continuous with an automatic tank drain.
  • Air Compressor Parts Aftermarket vs. OEM

    Every air compressor manufacturer offers a warranty on their product.  To maintain the warranty, you must follow the manufacturers maintenance schedule.  Which means using all OEM parts, sampling the compressor lubricant during the warranty period.   Should a problem arise during the warranty period, make sure you have all of your records; ie., receipts, oil sampling results and maintenance logs.  Your factory service center will need this information to submit a claim.  It is recommended to read the operation and maintenance manual and create a maintenance log for your equipment.   

    Again, to maintain warranty you should follow these guidelines:

    • Use machine as factory intended
    • Register your machine online with the factory (For example, here is the link to Quincy Compressors online registration)
    • Follow the factory recommended maintenance schedule
    • Have service performed by a factory recommended service company (not required but recommended)
    • Use OEM parts & lubricant
    • Perform Oil Sampling
    • Keep records of all service visits

    Once you have surpassed the warranty period, using OEM parts and lubricants is not mandatory.  Aftermarket parts are available and can save your and your company substantial amounts of money.   In some cases 200-300%.

    Not all parts will have an aftermarket version.  The most common parts are the regular maintenance parts.  Air filter, oil filter, separator elements, in-line filtration elements, hoses, fuses, belts and other “consumables” most likely have an aftermarket cross-over.  The more “internal” parts may not.  Items such as motor components, air end parts, temperature probes, sensors and control panels most likely will need original OEM parts replacement through the factory.

    Switching to aftermarket parts is a safe change.  Many customers are cautious to switch over but there are many reputable companies that manufacture durable and long lasting aftermarket parts.  Your local compressor service company will most likely have several companies they work with regularly and use their aftermarket parts to perform service.  Customer beware, if you outsource the service to your air compressor, check to see what they are using.  Service companies have been known bill for OEM parts and install aftermarket parts.  A good way to check would be to ask for pricing on both OEM and aftermarket, control your service center before they control you.   

    Regarding aftermarket parts, there are many benefits:

    • Maintenance costs (regular scheduled service visits) are reduced
    • Parts are more readily available
    • Aftermarket parts are direct replacements.

    Compressor World recommends using aftermarket parts after the warranty period.  Use the savings and buy a new air dryer, additional air storage tank or put it aside for a new energy efficient variable speed compressor :)

    Have a question?   Feel free to contact any of our sales experts at Compressor World @ 866.778.6572 or email info@compressorworld.com

  • Air Compressor Guarantee

    Compressor World - 3/2017

    The Compressor World "Air Compressor Guarantee" Overview

    Every product Compressor World sells offers a 1 year parts and labor warranty (some rotary compressors offer a extended warranty), if a product has manufacturer's defect, and the factory cannot correct the problem by a factory trained service technician, Compressor World will offer a 100% refund or exchange.  

    Start Up

    Start up and training is included on all rotary screw compressors 20 hp and larger by the local service center.  In many cases, this start-up will extended the warranty from 1 year to 5 years.  Contact one of Compressor World’s experts to buy the right industrial air compressor.  This cost is included in the purchase price of the compressor.

    Who will service my Air Compressor?

    Once you make the purchase from Compressor World, you will receive a package containing your operating manuals and information containing your contacts for your local service and/or warranty center.  You will also receive a list of spare parts that is recommended for stock.

    About Compressor World

    Compressor World sells air compressors, air dryers, air tanks and accessories from only the BEST manufacturers and takes pride in their offered equipment.  Our expert team specializes in selling all types of air compressors, especially rotary screw compressors and dryers.

  • Sizing Air Compressor for Sandblasters

    Sizing Air Compressor for Sandblasters

    Are you buying a new sandblaster?   Here are a few research tips and questions to ask your supplier as you'll need to know how much air is required.

    1.  What size nozzle are you using?
    2.  Does the nozzle wear?
    3.  What size air compressor do you recommend?   Have your supplier give you the CFM required per nozzle.   Understanding how much air is required can help you size the right compressor and/or how much air you'll be taking from the current house compressor system.
    4.  If you need a new air system, make sure you know what power supply do you have available to operate the compressor, 115/1/60, 230/1/60, 208/3/60, 230/3/60 or 460/3/60.  Remember, single phase limits you on the air compressor size, you are maxed at using a single 7.5 hp compressor or multiple units or what we call a duplex 7.5 hp air compressor system.

    Once you get your air and voltage requirements, you can then size the air compressor for your sandblaster.   It is recommended to size the air compressor 20% over the sandblaster demand/requirement.

    Here are a few sizing tips when sizing air compressor for sandblasters
    15-17 CFM = 5 Horsepower Air Compressor
    18-25 CFM = 7.5 Horsepower Air Compressor
    26-37 CFM = 10 Horsepower Air Compressor
    38-60 CFM = 15 Horsepower Air Compressor
    60-80 CFM = 20 Horsepower Air Compressor
    80-110 CFM = 25 Horsepower Air Compressor
    110-125 CFM = 30 Horsepower Air Compressor
    125-180 CFM = 40 Horsepower Air Compressor

    If you plan on operating the sandblaster on a continuous duty, it is recommended to install a rotary screw air compressor as they are rated for 100% duty.  People think rotary screw compressors never turn off...not true, the new rotary compressors have built in timers where they'll turn off with no demand.   If you plan on running the sandblaster at a lower duty cycle, a two stage air compressor would work just fine.

    Call our hotline for any related questions or help with sizing air compressor for sandblasters.  866.778.6572 or info@compressorworld.com

  • Air Compressors for Screen Printing Equipment

    Screen printing companies are converting over to machines that require air, dry air.  When buying a new, pneumatic screen printing machine or equipment, remember to ask the manufacturer/supplier for the required capacity or cfm that is needed to run the equipment.

    Normally the air compressor sizing is based on the number of stations.  The screen printing machine can have 4, 6, 8, 10, 12, etc.. The more stations, the larger air demand/supply.

    Typically, buyers will invest in the total air system which incorporates the compressor, tank and dryer.  These compressor systems are compact and quiet, great for installations near work stations.  Here are a few questions you'll need to ask when specifying a new compressor from your screen printer;

    1.  How much air (cfm) is required?
    2.  What pressure (psi)?
    3.  Know your power requirements, what power do you have in your warehouse as this could limit the compressor size.  For example, if you only have 1-phase, a 7.5 hp compressor (20-30 cfm) is the largest single phase compressor you can install.
    4.  Space, you should have 24-36" around the compressor for preventative maintenance.

    Existing Screen Printers with the Compressor - NO DRYER
    What do you do when you already have the compressor but no air dryer or filtration?   You have two options;
    1.  Install the dryer after the compressor and dry the whole air system
    2.  Install the dryer at the point of use, directly before the screen printer.

    Answer:   We recommend installing a new air dryer after the compressor.  Dry the whole air system vs. one section.  What if you add new air lines and want the new section to be dry?   It's cheaper to have one dryer than multiple dryers.

    Feel free to contact a staff member at Compressor World for additional support; 866.778.6572 or email info@compressorworld.com

  • How Can I Know If I Need a Piston Compressor or a Rotary Air Compressor?

    Two of the most popular air compressor configurations are the piston type or reciprocating and rotary screw compressors. There are a few factors that set the two apart based on the way in which they have been set up and the method employed to compress air.

    blog-image

    Let us start with piston or reciprocating air compressors. These are easily the most commonly used air compressors across the world. They run on the same mechanical principle as the combustion engine. A crank that turns a connecting rod, which in turn moves the piston up and down inside the cylinder head. The inlet valve lets air into the cylinder when the piston is in its lowermost position, the latter is then driven upward to compress the air, converting electric energy to kinetic energy in the process. A typical piston air compressor is oil-cooled, that results in the release of oil residue when the compressed air is discharged.

    Rotary air compressors, on the other hand, are typically configured with two interlocking helical rotors fit with a small gap between them and soaked in an oil bath inside a housing. The inlet valve lets air in, which is compressed in the space between the screws when they turn, reducing the volume and increasing the pressure.

    There are oil-free rotary screw air compressors available as well. In fact, there are some air compressors that even come equipped with just one screw, but again, these are not very common.

    Here we have a list of factors compared which will let you determine which of the two types of compressors might suit your needs better.

    Rotary air compressors and piston compressors - Comparison

    1. Maintenance and wear and tear – In piston compressors, the wear and tear is greater due to a large number of moving parts. This results in more maintenance compared to a rotary screw processor. However, because of the simple mechanical setup of a piston compressor, it is easier to maintain and fix, despite the greater frequency of maintenance required.

     

    1. Operating temperature, noise and vibration – Typically, a rotary compressor has lower operating temperatures than piston compressors. Friction is the lead cause for this, because the rotors in the screw compressor don’t come in contact, whereas piston rings are in constant contact with the cylinder walls, creating greater friction and raising temperatures. The former also generates less noise and vibrates lesser than the latter due to the same reason.

     

    1. Air flow and operation time – Because of the high temperatures in a piston type compressor, it cannot be run non-stop due to the risk of overheating. Furthermore it is also typically run at only 50% of its total CFM or air flow capacity. The rotary screw compressor, however, is capable of being run continuously. You can also purchase a rotary screw compressor that is rated as close as possible to your required air flow capacity rather than one rated at double the capacity.

     

    1. Space required and energy efficiency – Since rotary screws are encased next to one another in one chamber, the whole setup usually takes up less space than a piston compressor which requires cylinder heads for the vertical movement of the pistons. The former are also more energy efficient than the latter with fewer transmission losses as well. However, the effects are only discernable in compressors of 20 HP or more horsepower.

     

    1. Pressure ratio and volume – The compression range is much greater on a piston configuration when compared to a rotary screw type. There is also more flexibility in terms of pressure ratio and capacity. However, in rotary compressors, while the flexibility is limited, the comparative volume capacity is much greater than that of reciprocating air compressors.

     

    1. Oil carry-over – Piston compressors typically discharge more oil into the stream of compressed air than rotary screw compressors do. Due to the high-friction moving parts, wear-and-tear leads to more oil carry-over than in rotary screw compressors.

     

    1. Price – Due to the above mentioned factors, the cost of a piston compressor is a lot lesser than that of a rotary screw compressor.

    Now that you know the major differences between the two type of compressors – piston and rotary, and what advantages and disadvantages either brings to the table, you can make an informed investment. Before you decide either way, make sure to check out some great deals and one of the widest ranges of compressors available at our online store. If you have more questions, our air compressor experts at Compressor World will be more than happy to help you out.

  • A Buyer's Guide to Rotary Vane Air Compressors

    blog-rotaryvane

    Buying an air compressor can be a difficult given the variety available today. There are so many options when it comes to configuration, size, capacity and brand that potential buyers can end up confused about which compressor is right for their business.

    Introduction

    Rotary pumps are widely used across industries and applications, from supercharging and power steering in cars, to providing the pressure for soda dispensers and coffee machines.

    Here is a brief look at the mechanical structure of rotary vane air compressors.

    The rotary vane compressor comprises of a cylindrical rotor that is placed inside a cavity or a housing. The rotor also has a few grooves or slots inside which the vanes are placed. The rotor is intentionally placed in a position where it almost comes into contact with the housing it is encased in. This off-center placement allows the vanes to be pushed out through the use of centrifugal force, allowing air to be trapped between them. This air is then reduced in volume and pressurized by the rotating motion of the rotor.

    At Compressor World, we want our customers to get the most value for their money and this can happen only when you are rightly informed about any product we offer. So we have prepared a rotary vane air compressor buying guide that will help you consider important factors you should know before buying rotary vane compressors.

    Read this guide before you invest your money, and understand which factors matter most in your context and to decide if rotary vane compressors will suit your needs best or not.

     

    Factors to consider when buying a rotary vane compressor

    Duty cycle

    The duty cycle is essentially the capacity for the compressor to run at peak performance before it starts to overheat or massively deteriorate. Typically measured as a percentage, the duty cycle is an extremely important factor to consider when purchasing a compressor. If you need something heavy duty to run for extended periods of time without issues, a high duty cycle percentage is a must.

    Not all compressor configurations allow for a high duty cycle percentage. However, the rotary vane typically offers close to a 100% duty cycle figure. Lower revolutions and operating temperatures coupled with liquid cooling mean the rotary vane compressor can typically run at full tilt without causing excessive temperatures or wear in the moving parts.

    Maintenance

    The major maintenance for rotary vane air compressors comes from replacing the oil, cleaning out the oil filters and air filters, and replacing both the aforementioned filters at a certain point in time after continuous use. None of these components are too expensive, and they are relatively easily available and easy to replace. The rotary vane air compressor also tends to have a long operational life if its maintenance plans and schedules are followed accurately. The vanes are the main moving components in a rotary vane, and usually the moving components face the most wear. Not in this case though, because rotary vane compressors have oil films to protect the vanes. This means they don’t come in direct contact with either the grooves or the inside of the rotor during the compression process. As long as you ensure basic and timely maintenance for your compressor as mentioned earlier happens, you won’t need to worry about any short term expenditure that involve replacing or repairing moving parts.

    Long term costs

    We have already established that rotary vane compressors are relatively cheap to maintain. They are also low on power consumption, which is a good thing economically in the long run. A tight, leak-free air seal results in less air loss. Other types of compressors usually need to compensate for air loss at higher rotating speeds, but this is not the case with rotary vane air compressors. The speeds at which the rotor turns here is relatively low, typically between 1000-1500 RPM based on the compressor make and manufacturer. This results in lower power consumption figures of course, but also has the added benefit of lower temperatures and lesser noise from the device.

    Initial costs

    While rotary vane compressors are typically more expensive than regular piston compressors, if you want to run your compressor smoothly over long periods, the performance of vane compressors definitely justify the initial cost. At Compressor World we offer both finance solutions and a price match guarantee on a wide range of rotary vane air compressors.

    Popular rotary vane compressor brands

    Here are some of the most popular, reliable and respected brands that manufacture rotary vane air compressors.

    • Mattei Compressors
    • Hydrovane
    • Champion
    • Chicago Pneumatic Air Compressors

     

    Now that you are up to speed on what a rotary vane compressor is, how it works, and what its primary attributes and advantages are, you will know exactly what you are getting for the money you put in to buying one. If you want the best rotary vane air compressors out there, you can only go to one place – Compressor World.

    Check out our wide variety of compressors today, and if you have any doubts or need further assistance to decide the right compressor, contact our experts today.

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