How to Keep an Air Compressor Running in Cold Weather? Here Are Some Effective Tips
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Cold weather affects the compressed air system to a great extent. Your air compressor, dryer and other accessories can be adversely affected by the cold temperature. Therefore, maintenance and operation of air compressors demand some extra care during the winters. This is because most compressed air systems are designed to function effectively in temperature that is above 40° Fahrenheit (4.4° Celsius). So, if the temperature drops further down, it may have an adverse effect on the compressor. This may cause short-term or long-lasting damage to the compressed air system. If your facility requires an air compressor to run in colder temperatures, there are some tips that may help you. Customers can also seek clarification from the industrial air compressor manufacturers while purchasing the product.
Why air compressor cannot work efficiently in cold temperatures?
Compressed air systems generally generate condensate which has a tendency to freeze and clog. This may lead to cracks in vulnerable air compressor components like heat exchanger and drain valves. In addition to that control lines in air compressors can freeze in cold temperatures. Even small negligence in temperature maintenance can lead to a damaged air compressor and air dryers. Genuine air compressor manufacturers always inform customers about what effect cold temperature may have on air compressors. Let’s have a look.
Oil may freeze:
Oil has a tendency to get thicker when the temperatures drop. The same applies to the oil used in the air compressor. This leads to reduced lubrication capabilities. The machine, therefore, may demand more power to operate the pump. The higher motor amp draw and increased strain on the entire drive train ultimately reduce lifespan of the air compressor’s motor.
Control lines may clog or freeze:
The function of control lines in an air compressor is to accumulate moisture from condensate. It can run smoothly as long as the temperature is controlled. Cold temperature may cause control lines to clog or freeze which adversely impact the performance of the system.
Rotary screw air compressors:
Rotary screw compressors are the most vulnerable to cold ambient temperatures. It comprises a low ambient air temperature limit switch (fault). This switch does not allow the system to run if the temperature is lower than 40°F. Yes, if the compressor is already running, it will most likely continue to run. The heat generated from the compressor will keep the machine’s temperature above the freezing temperature. However, this does not mean that the cold ambient temperature has no side effect on your system’s other parts.
Best practices to keep the compressor running in cold weather:
Be ready to spend a huge amount after repairs and unplanned downtime if you are not taking enough care of your air compressor during winter months or in cold ambient temperatures. Some preventive measures can help you to run the compressor effectively even during the cold weather. It will help you maintain your air compressor, air dryer and accessories.
Use synthetic oil:
Try using a blended synthetic air compressor oil in the pump crankcase. Especially, if you have an old air compressor or a compressor that uses a standard summer weight oil, you should consider switching to a full synthetic or blended synthetic air compressor oil. Synthetic oil can resist great temperature ranges and can maintain proper viscosity. An additional benefit is that you do not have to change your oil quite frequently.
Keep the exteriors clean:
Cleaning the equipment at regular intervals is a great preventive measure. During spring and summer, a lot of dust and mud can accumulate on the dryer. Cleaning it up regularly may help in preventing corrosion. It becomes easier to spot oil leaks. In addition to that, if your compressor has suffered wear and tear, you can easily inspect it.
Check condition of the rubber feet:
Cold temperature may generally damage rubber feet of your air compressor. So, during winters, keep checking them. Due to worn or broken rubber feet, your compressor may suffer excessive vibration. This may lead to major problems and repairs.
There are some other tips you can keep in mind to keep the air compressor running effectively in a cold environment.
Keep the compressor in a controlled environment:
During cold weather, you can keep the compressor in a controlled environment using proper ventilation methods and heaters. This will help you maintain the temperature above 40°F. The other way is to weatherproof the area in which the compressed air system is installed. If the temperature is consistently maintained above 45°F, the air compression system would run effectively for a long duration. However, choose the heating source wisely. Ensure that its installation and operation does not trigger fire hazard in the area. It is advisable to take guidance from HVAC providers.
Cold-proof the system:
If it is not possible to keep the room temperature above 40°F, you should try maintaining the temperature of the air compression system by cold-proofing it. Installing a low ambient air temperature limit switch is one way of doing it. This will ensure that in adverse situations like cold ambient temperature, no permanent damage is done to the system. You can cold-proof the system by-
– Installing a trace heating around pipes so that they do not freeze. It will further prevent condensation. It can prevent ice obstruction and leads to the effective performance of the dryers.
– Fit an internal sump heater. This will help you maintain temperatures above 40°F.
– To prevent the risk of freezing, add appropriate insulation for pipes and other system components.
Check what is the low ambient temperature for your system as it may vary from different system types and models. Refrigerated dryers do not come with low ambient temperature options.
Preventive measures:
It is possible to protect components of the air compressor and air dryer even in cold weather. You will need to take some extra care for that.
– Keep an eye on the moisture and ice built-up in the compressor and its components. Pipes and components that are far from the compressor motor do not get enough heat and they can easily freeze in low ambient temperature.
– Ensure that icing and obstructions do not clog the drain system. If your system does not have an auto drain valve, daily condensate the drain manually.
– Keep checking oil levels regularly. During winter, the system may use more oil as it has to work harder. Change the oil as per season. For example, during winter, you may shift to a lighter weight winter-grade oil. If you seek guidance, your air compressor manufacturer will be more than happy to do so.
– Ensure no icing or blockage is there in the filters by regularly checking it. It is time to change the filters when they become iced over.
How to restart a frozen air compressor?
It is likely that even if you have taken enough preventive measures, your compressor may freeze during the cold weather. Follow the below-mentioned procedure to restart it.
– Shut off outside air sources.
– If the compressor is in an enclosed unit, remove or open doors or panels of the compressor.
– Add a heat source to the room to raise the temperature above 45°F.
– Warm up the oil at the bottom of the sump tank up to 70°F by using a heat source.
– Once the temperature comes above the set limit (40°F to 45°F), reset the alarm on the control panel. The air compressor should work just fine after that.
– Ensure whether there is some leak while the compressor is running.
– Inspect drain valves for condensation.
It is better to keep the air compressor in a controlled environment since its performance is compromised in the low temperatures. However, if you want to keep running it, always keep these tips in mind.
