When one thinks of a reciprocating air compressor, they generally pull to mind the old portable compressors that were common tag a longs to power tools. The governor on these traditionally compressors was quite simplistic; they generally only had two main gears. These consisted of an idling gear where the compressor was on and running. There was also a high gear. This gear was engaged when the compressor was actually being used to power a tool or other accessory.

Today's reciprocating air compressors are not too different from these earlier models, though their construction, longevity and other aspects have certainly improved with time. Reciprocating air compressors are also referred to as piston compressors. These units use a piston that moves in a vertical motion, and a crankshaft that moves the piston up and down. The motion of the pistons and the crankshaft are what provides the gaseous materials at a high rate of pressure.

The reciprocating air compressor uses the pistons as the main components to compress the air. As the piston moves in an up and down vertical motion, the air is pushed into a compartment. As the amount of the air increases in the compartment, the pressure on the air builds up. The denser the air becomes, the greater the pressure. When the correct pressure is reached, then it is ready for use.

Compressors are used in a large variety of applications. Oil refineries, factories, and machine shops all have a use for air compressors. For those looking to purchase a compressor, there are a few factors to consider. The first thing that must be determined is how many cubic feet per minute you need for the application you intend to use the compressor for. After this has been determined, then you can start shopping for the ideal air compressor.

There are a variety of reciprocating air compressors to choose from. The air tank size and the number and size of the cylinders are two things that offer a number of different options. Do you need a more portable compressor, or is a larger stand-alone compressor more suited to the environment in which you will be working?. There are also multi-stage units available on the market. These offer multiple cylinders that can compress the air to an even higher density than the single cylinder units.

A condensate drain is a necessary component of a compressed air system because it disposes of potentially harmful condensates in a safe way. Condensates form from the cooling of moisture in the air system, and must be drained properly and regularly. If the condensate is not drained, water vapor and other contaminants would not be properly removed via refrigerated air dryers or mist eliminators. These drains are categorized into zero air loss drains and timed electric drain traps.

Zero air loss drains operate automatically via pneumatic power and waste no compressed air when they discharge condensate. These condensates are continuously measured by ultrasonic sensing technology systems, allowing for constant monitoring of the process. The discharge from these drains can be executed at a rate of up to 60 gallons of condensate per hour. The state of the condensate is irrelevant and, as such, it can be dirty, emulsified, or clean. Regardless of the state it is in, all condensate is discharged through this process. Zero air loss drains expel no compressed air, hence the term “zero air loss”. Once a predetermined amount of condensate has accumulated in a reservoir, the drain discharges the condensate safely and efficiently.

The second type of condensate drains are timed electric drains. These drains are programmed to drain condensates at specific time intervals, and are designed to discharge condensates at pressure ratings as high as 720psi. External knobs adjust the open time and duration between cycles, while valve-open lights display operating conditions. A motorized ball valve is also used for the timing of these electric drains.

The third type of condensate drains are automatic drain traps, also known as float drains. These drains operate without electricity and are used to discharge both clean and heavy emulsion condensates. These automatic drain traps are relatively compact in size and operate automatically, saving both space and energy costs.
After the drains have discharged the condensate, oil and water separators are used to reduce hazardous waste in these condensates. Oil and water separators work by siphoning out materials such as mineral oils, semi-synthetic lubricants, synthetic lubricants, 24KT fluids, and polyglycols from the compressed air. Because oil and water mixtures are not safe to release back into the environment, the lubricants are trapped in these systems, allowing water to pass through.

All these drains are used in compressed air systems to keep the air free of water vapor and other contaminants. Draining condensates is one of the most important aspects when dealing with industrial air compressor maintenance. Not only will a well drained system function more smoothly, but it will also save you valuable time and money.

Customized air compressors have a number of useful benefits and are used every day by a variety of businesses. The majority of air compressors are very durable and can easily be transported.

There are a variety of types of customized air compressors that are used for a variety of useful purposes. Types of air compressors include industrial, portable, dental, electric, and gas as well as diesel air. Customized air compressors vary in price and they can be purchased new or used.

The way in which air compressors work are that they release pressurized air which then can be used in various industries, including industrial manufacturing and processes that make products used every day.
Some of the different types of air compressors are reciprocating, rotary screw, and rotary centrifugal. Air compressors are either positive air placement or dynamic type machines, meaning that they automatically increase air pressure, as well as, elevate the air to a higher pressure.

Most rotary air compressors are comprised of two rotors within a casting device which compresses the air internally. They employ a rotary type positive expulsion system, which conveys pressurized air to power drills, pumps and other types of machinery. There are no valves built within this type of compressor, it is oil cooled.

Dynamic air compressors produce high pressure by the conversion of angular momentum imported by a rotating impeller device. This impeller device must be checked on a regular basis to make sure it is functioning at a normal capacity. Air compressors of this type are also created for a high capacity because the flow through the compression chain or device is continual. These types of compressors are built oil free and very easy to operate as well as maintain.

Air compressors are designed for industrial use, contractors and commercial applications. In addition, air compressors are designed as portable, electric air as well as gas air compressors.

Clients may actually view, as well as, purchase air compressors on line. The Internet gives the client the ability to shop by style, size, CFM as well as price. Customized air compressors are also available.

Air compressors are used everyday in many different industries and applications. Prices on these machine vary according to brand and type.

Rotary screw compressors are just one of a variety of air compressors. They employ a rotary type positive expulsion system, which conveys pressurized air to power drills, pumps and other types of machinery. Rotary screw compressors, also known as positive displacement compressors, deliver a determinate amount of highly pressurized air.

Rotary screw compressors contain the following components, all enclosed in a sealed case: the compressor unit, systems that maintain proper lubrication, proper temperature control, proper capacity control and the system that cleans the discharged air. Inside of the compressor unit itself there are two interlocking corkscrew-shaped augers or rotors. Each auger or screw has a wide end and a narrow end. The wide end of the screw is the inlet that allows free air to flow into the screw housing upon demand, helped along by the partial vacuum caused by the screws rotating inside the housing.
The air and oil combination flows downward from the wide ends to the narrow ends of the screw. This increases the vacuum, pulling more air into the housing. As the mixture is pulled downward through the grooves of the auger, the space where the air was narrows. At the narrow end of the screw, a valve tunnels the condensed air and oil into a separator, removing as much oil as possible from the condensed air. It is then released into the compressor receiver.

Rotary screw compressors are available in oil cooled and oil free. When comparing the oil cooled model to the oil free model, the procedure for compressing the air is basically the same, although the medium in which the procedure is carried out is different. One is performed in an oil filled chamber which provides coolant and sealant properties. The byproducts of the oil filled units are gas and oil instead of air and oil, which are the byproducts of the oil free systems. Oil free rotary screw compressors work the same except that in the absence of the oil the process does create higher temperatures and it is less energy efficient.

When choosing a rotary screw air compressor there are some important things to remember and take into consideration. What type of project are you working on? Does your compressor need to be transportable? Do you want oil cooled or oil free? Many consumers report that rotary screw compressors are easy to maintain and have a long life. They are known for their above average production abilities in a small package.

Using compressed air as an efficient kinetic energy resource requires a simple machine and holding tank. All compressors will have the same basic parts: receiving tank, pressure gauge and compression machinery. The identifying difference between two-stage and single-stage compressors is the number of compression cylinders incorporated.

Single-stage air compressors follow a few simple principles. When the compressor’s piston is actuated it literally squeezes the air contained inside its cylinder until the PSI is strong enough to release a one-way valve connection between the cylinder and the receiving tank. As the piston cycles, the receiving tank is filled with compressed air. A pressure switch is located on the receiving tank to regulate the tank's maximum PSI with a mechanical relief valve attached for safety purposes. When the set maximum air pressure is achieved in the tank, a switch connected to the pressure switch will signal the motor to turn off. The pressure inside the receiving tank is continually monitored by the pressure gauge. When the PSI in the receiving tank drops below a preset level, the pressure switch will activate the motor to add more compressed air to restore the overall pressure of the receiver.

A two-stage air compressor follows the exact same principles as the single-stage but there are two actuating pistons. The first stage will produce compressed air at a lower pressure than is ultimately desired for the end use. As the pressure in the first receiving stage builds it supplies air to the second stage's cylinder. The air is again compacted before being released into the output receiving tank. The advantage of a two-stage compressor is that it distributes the work load between two components to achieve a higher level of compressed air without having to overwork a single piston. The higher PSI offerings of two-stage compressors make them the better choice for industrial use and high torque pneumatic tools.

A single-stage compressor is a highly efficient machine. Choosing an oil-less type will ensure long use with little maintenance required. The disadvantage to a single stage compressor is that its output is limited to providing air below 125 PSI.

Two-stage compressors require slightly more maintenance because they have more parts. The advantage is that greater PSI offerings can be efficiently maintained without over-exerting the machine. Two-stage compressors also generate less heat than single-stage compressors do, which means that parts may not wear out as quickly and your compressor will likely have a longer life.

With any large machine such as an air compressor, there is always the chance of it breaking down due to mechanical failure. These breakdowns are not only a hazard to the machine, but to you and your workplace. Anyone working around an air compressor should be aware of how to handle these emergency situations.  
Too much pressure is a major, and common, problem of air compressor issues. Oftentimes, a machine cannot handle pressure levels above its recommended limit, so be sure to follow the manufacturer’s recommendations for PSI limits. Check all your gauges routinely to ensure that you are getting the proper reading from the machine.

An effect of pressure misuse is leakage, which occurs in the pneumatic hoses attached to the machine. If too much pressure is being put out; rips and tears can occur in the hoses, which cause leakage. Not only is this situation hazardous, but it is also a serious financial problem as well. Leaks can cost a company thousands of dollars a year if not properly treated and corrected.

A third problem that might arise has to deal with the condensates in your system. Compressed air causes moisture such as water vapor and oil to build up in the system, both the hoses and the unit itself. This can cause corrosion in the pipes and hoses, once again leading to tears and leakage. Condensate build ups can also block air flow from moving throughout the system, another problem that will cause it to rupture. In order to prevent this from happening, having an industrial air compressor dryer, either a desiccant or refrigerated dryer, will eliminate the condensates from your unit.

As with most problems involving your industrial air compressor, preventative maintenance goes a long way in ensuring that you keep those problems to a minimum. Checking valves and gauges regularly ensures that your PSI readings are correct, preventing any ruptures, tears, or leaks. Managing your condensates is another step that goes a long way in caring for your compressor, as getting rid of all the condensates in your system will increase the efficiency of your compressor. Finally, make sure everyone who handles the air compressor is qualified to do so. Accidents are the worst thing that can happen on a work site, and knowledge is the best way you can keep everyone safe.