Air Compressor Pressure Switch Wiring Guide 2024

Pressure switch wiring is a smooth task unless you’re a professional. Because pros have experience. They know different compressor parts by their very definitions.

And of course, they know how these parts work. But as for beginners, they try to repair their air compressors without knowing the basics. And finally, end up with a dead weight.

In this guide, I am going to show you how to wire a pressure switch on an air compressor with step-by-step instructions.

Safety tips and warnings about different situations. So, at the end of this guide, you are ready to fix your pressure switch without any confusion in your mind.

So, here we are… Before we move towards wiring I’ll point out the list of items you need for the pressure switch wiring.

Important Tools And Accessories Needed For Pressure Switch Wiring

Below are the tools and accessories that you need and why and where you need them to fix your compressor.

Heat Gun

The heat gun belongs to the class of versatile power tools. They are used in paint removal, welding, plumbing, bending plastic, DIY, crafting, and loosening up screws and bolts. It emits hot air usually within a temperature range of 100 to 500°C.

In our air pressure Witch wiring guide, we’ll use the heat gun for the outlet, pipe, gauge thread, and other joints. Because, in some cases, the joint due to the old compound doesn’t even move. So, the heat gun softens up the old sealant so it can easily be unscrewed.

Small Wire Brush

The small wire brush is used for cleaning out the rust, dust, and old sealants accumulated in the threads of tank pipes, safety valves, and other pipe joints.

If you don’t do it then the pipe thread sealant i.e., the Pipe Dope or Teflon Tape you apply will not be effective and the joint will not sit as tight as it should be. This can also cause the ring to become free. In the worst case, compressor air leaks.

Needle Nose Pliers

These are special types of pliers used for handling mini-jobs where our fingers can’t reach. They are mostly used for handling wiring in tight places.

Here we’re gonna use the needle nose pliers for connecting and disconnecting the pressure switch wiring to their respective terminals. Since it is difficult for our fingers to do that.

Simple Wrench Set

The simple wrench set or also known as screw wrench has specifically sized wrenches used for screwing and bolting small bolts and pipe joints.

Here we’re gonna use this wrench set for unscrewing the check valve, and tube fittings, and removing other small joints.

Ratcheting Screwdriver Set

The ratcheting screwdriver set is a multi-purpose screwdriver with different types of screwdriver bits. The bits are detachable and can be used for small screws and bolts.

Here we’re gonna use it for removing different screws and wire connections in the pressure switch.

Adjustable Wrench Or Slip Joint Pliers

The adjustable wrenches or split joint pliers are phenomenal hand tools. They have an adjustable jaw that can be used for removing and tightening up large bolts, nuts, and pipe joints.

We’re gonna use one of these to remove or tighten up the pressure gauge, pressure regulator, and switch assembly.

Pipe Thread Sealant (Pipe Dope Or Teflon Tape)

The pipe thread sealants are adhesive compounds specially used in the pipe joint threads for a tighter and more secure fit.

These sealants remove joint leakage and the free joint problem. The most commonly used pipe thread sealants are Pipe Dope and Teflon tape.

Air Compressor Pressure Switch

Choose the best-rated pressure switch for your air compressor and check your compressor manual if it’s compatible with your air compressor or not.

The reason is pressure switch comes in various types ranging from Square D, Condor, to Hubbell pressure switch also known as Furnace pressure switch.

Wire Strippers

Suppose the wires are not stripped. You have to strip them yourself. Well, I usually remove 1 inch of the insulation of the wire. You can do it according to your needs.

Solderless Ring Terminals

The solderless ring terminals work as a hook anchor system on switch terminals. They are needed when you want to replace the old pair of solderings. Most of the time you don’t need them.

Safety Gloves

Having safety gloves adds an extra layer of protection against electric shocks as well as scratches from rough, edgy areas.

If you ask me I use gloves whenever I wanna fix my compressor or verify if there is any problem or not.

How To Wire A Pressure Switch on Air Compressor?

A Video For Condor, Furnas & Square D Pressure Switch Wiring

Here is a video on how to wire different pressure switches. In this video, the three popular types of pressure switches are used. The Condor, Furnace (Hubbell), and finally, the Square D Pressure Switch.

How To Adjust Pressure Switch

As far as I am concerned with pressure switch adjustment. We can divide them into two types.

Adjustable Pressure Switch

The adjustable pressure switch has an adjustable screw present on it. With this, you can adjust the cut-in cut-out pressure and set the pressure differential. Such as Condor MDR-2 and Square D Pressure Switch.

In the Condor MDR-2 model, there are two large screws with large springs. Rotate these springs in a clockwise manner and you can increase the cut-in pressure. And if you want to decrease the cut-in pressure then rotate them in an anti-clockwise manner.

Non Adjustable Pressure Switch

These pressure switch types are factory preset. You cannot adjust them because the adjustment screw is not present on them. In some cases, there is a silicone seal on it by the respective company.

These types of pressure switches are auto cut-in and cut-out at a preset pressure. Such as the Furnas Pressure Switch.

How To Adjust Pressure Switch

Here is another epic video on how to adjust your pressure switch. In this case, we’re going to use a Square D Pressure Switch Type.

air compressor safety precautions

In the Instructions Section, I already talked with you about the safety tips. Before taking any action, you should know the safety tips and warnings.

I know your work is important. But your health and life are more important than the work itself. What’s the point of that work when you are going to get hurt at the end of the day? Thus, you’ll be in no shape to perform other crucial tasks in your life.

Power Source

Whenever you are going to wire, adjust, or replace the air compressor. First, cut the electric supply as it is a rule of thumb.

Before you do any circuit work also turn off the air compressor from its switch. So, you can avoid electric shock or life-threatening incidents.

Protective Wears

My advice to you is to always wear safety gloves that are shock and scratch-resistant. Sometimes electricity doesn’t get you. But, anything sharp or with a harsh surface can cause scratches to your hands while wiring and adjusting.

Air Compressor Performance

I would also recommend you check the health of your equipment. If the equipment is in a bad shape and is not able to work with the flow then don’t continue to use it. Faulty equipment is more dangerous in my book.

Air Compressor Wiring

When wiring you should be cautious. Check the wire colors and terminal labels before connecting the terminals with the respective cord. A wrong connection might cause a major malfunction or short-circuit.

Insulation

Now, this one is very important. Before starting wiring or adjusting your switch, check the cords i.e., motor, power, and other circuit contacts for proper insulation. Sometimes the insulation gets damaged or melted due to excessive electricity passage.

Air Compressor Pressure Switch Wiring Warnings

Here are warnings you need to be aware of to avoid any mishap and damage.

Compatibility

Always, keep in mind the compatibility of the pressure switches with your air compressor. If you use a switch that is not up to the specified requirements of your air compressor then don’t use it. Check the specifications manual with the product.

Capacity

Do not burden the device with excessive voltage and load more than its capacity. If you do, the switch is going to get burned. In another case scenario, the switch is not burned but its lifespan will be shortened.

Quality

Another important factor is the quality of the pressure switch. Don’t put your hand on the top of the shelf brand with sparkles.

My advice to you is to look for high-quality products with the best ratings and reviews. The brand is not going to give you anything unless the product is up to the challenges.

Leakages

Another issue I have seen a lot is the leakage problem. So, check the pipes and the compressor tank carefully for any leakages before making any judgment. And if there is any leakage then fix them.

Seek Professional Help

Lastly, I would recommend you call the professionals in your area or contact the company for issues that are beyond your expertise. If you are not able to do it yourself then leave the work to the pros.

Trying to do it yourself only causes you hundreds of dollars worth of loss. It’s better to spend a few dollars and get a professional rather than lose hundreds of dollars of air compressors.

Compressor Pressure Switch Wiring FAQs