Air compressor not working or not turning on is a common problem happens as the increased time of use. Air compressors are essential tools for a wide range of industries. However, like any other machine, they can develop problems over time. When air compressor problems do occur, being able to troubleshoot and resolve them can save time, money, and delays in your work and production. This blog introduces common reasons and offers feasible solutions on why an air compressor not working.
Why is my air compressor not working?
Air compressor not working troubleshooting
Regarding the problem of air compressor turning on, it is most common in the summer when the temperature is high. The main types of failure can be classified into power failure, motor failure, cooling system failure, pressure failure, gas circuit failure, control system failure, mechanical failure, etc.
The problem that air compressor stop working can occur in two situations. One is that the air compressor is not turning on after a short time break or a long time shut down, and the other is that the air compressor suddenly stops working during operation.
The sudden shut down of air compressor can be very dangerous for the sudden stop of air supply may cause damage to the downstream air treatment equipment or air-using equipment. And the internal pressure of the air compressor that has not passed the normal shutdown process may continue to maintain or suddenly deflate, which may cause danger to the staff who approach to check. So it is important to be aware of the causes and emergency service method of air compressor failure.
Causes of the air compressor not working
Circuit or power failure
If a circuit component failure occurs, such as a blown fuse, a faulty pressure switch, a protective relay/start relay failure; loose connection, damage of power/cables; poor contact of the start button; or if there is voltage instability, the air compressor will not be able to start or will stop working.
Air compressor motor not working
The motor is the core component of the air compressor. If the motor is not working, the motor winding is burned, the motor bearing is damaged, or the motor rotor is stuck, etc., the air compressor will not work properly or will stop running.
(Air compressor motor not working)
Compressor running but not cooling
Radiator blockage, insufficient or deteriorated lubricating oil, fan stoppage, etc. will prevent the accumulated heat of the air compressor from being effectively dissipated, causing high-temperature shutdown and damage to the air compressor.
Pipeline system failure
Blockage of air and oil filters and air-oil separator element will increase the pressure difference and make the load of compressor heavier. If the air circuit pipeline is blocked, leaking or the valve fails, the air compressor will not start or work properly.
Control system failure
The control system is the command center of the air compressor. If the loading and unloading regulator is not able to work properly, the air compressor may not be able to maintain the correct pressure. And if the control system circuit board is damaged or the control program is wrong, it may cause the air compressor not turning on or stop working.
Mechanical failure
If the mechanical parts or spare parts of the air compressor are aging, worn or damaged, the air compressor will not work properly. If the pressure in the oil and gas tank reaches the upper limit but cannot be released or vented normally, the air compressor will stop working. This may be caused by a minimum pressure valve failure, exhaust pipe blockage or safety valve failure.
Technical failure
This involves problems with sensors, gearboxes and heat exchangers, etc. For example, air compressor is equipped with multiple temperature and pressure sensors. If one of the measured values exceeds the set shutdown level, the compressor will stop running.
Overload tripping
Air compressor overload will also cause the air compressor to stop working or fail to start. Click to learn why and how to fix the air compressor overload tripping.
Pressure problems
Starting the compressor with too much pressure and insufficient pressure can both cause the compressor to fail to turn on. If the air compressor did not completely released the pressure inside after the last use, the internal pressure of the system still exists, which will cause the air compressor starting current to be too high, causing the air switch to trip in order to protect the unit, so the air compressor cannot start.
The other issue is having insufficient pressure for the machine either to start up at all, or to run properly. This may be due to a faulty pressure switch or a clogged air filter, but the most common reason is that there is an air leak that prevents the air compressor from accumulating enough starting pressure.
Lubricating oil problem
The air compressor may not work due to lubricating oil deterioration, compressor oil pipe blockage, use of inferior lubricating oil, etc. Lubricating oil plays a vital role in air compressors, including lubrication, cooling, sealing, noise reduction, etc. Inferior or deteriorated lubricating oil or oil pipe blockage can cause excessive wear of the rotor and bearings, shaft jamming, and air compressor shutdown or failure to start.
Improper operation
Another possible reason for the air compressor not working is that the equipment is damaged due to failure to strictly follow the operating procedures or failure to carefully check the compressor before starting. Operating beyond the rated power or pressure or tampering with the data set by the compressor system may also cause air compressor failure or damage.
In addition, the failure of the air compressor to start may also be caused by water, dirt or corrosive material deposition, untimely maintenance, and the use of non-original parts. For example: using non-original parts can lead to reduced performance, increased wear, and even damage to the compressor.
In addition, the use of non-original parts may invalidate the warranty. Understanding all these common fault types will help to diagnose and solve the problem in a timely manner, ensuring that the air compressor can resume normal operation as soon as possible.
Solutions to the air compressor not working problem
After locating the fault, you need to start solving the problem. Some problems can be judged and solved by users themselves, but if the fault cannot be repaired by individuals, it is recommended to hand it over to professional maintenance personnel to avoid causing more damage to yourself and the air compressor. The following are some repair methods for air compressor not working for reference.
Solutions to circuit and power failure
Check the fuse and power supply: check and replace the fuse, power supply, start switch, test pressure switch, ensure that the fuse, power socket, start switch and cable are intact, and the power supply is stable.
Check the control system: check whether the control panel and related buttons are faulty, check the calibration relay, and repair or replace it if necessary.
Solutions to air compressor motor not working
Check the motor and starter: check and eliminate the motor fault, test the continuity, insulation and phase sequence of the motor, and check whether the contactor and relay of the starter are working properly. If the fault cannot be eliminated, contact professionals for help.
Solutions to system leakage and reduced compression efficiency
Find the leak point: Check the pipe connection, valve and joint for leaks by unusual sounds or using soapy water or a special leak detector, and repair them in time.
Clean or replace the filter: Check the air intake filter and oil-gas separator, and clean or replace them if necessary.
Solutions to compressor running but not cooling
Clean the radiator: Clean the external dust and internal oil of the radiator regularly to ensure the heat dissipation effect.
Check the quality and oil level of the lubricating oil: Add or replace the new lubricating oil in time to ensure that the oil level is not lower than the lower mark of the oil level gauge. Click the link to learn the correct air compressor oil types to use.
Check the fan: Check the fan blades and fan motor and ensure they work properly.
Dealing with abnormal noise
If the compressor makes excessive noise, it may be a sign of mechanical failure, such as bearing wear or air leakage.
Check bearings and lubrication: Check all bearings for wear and ensure that the lubrication system is operating effectively.
Tighten loose parts: Check the tightness of screws, bolts and mechanical parts to prevent noise caused by vibration.
Test pipeline: Check whether there is leakage in the compressed air pipeline. When air leaks, it will make a hissing sound. After hearing it, you can try to use your fingers to accurately feel the source of the air leak, and then take measures to repair it.
Maintenance of air oil separator
Check and replace separator elements: Regularly check the working status of the air oil separator, clean or replace the separation elements.
Drain condensate: It is best to regularly drain the condensate in the air oil separator to avoid water accumulation and corrosion inside the air compressor and damage to the quality of the lubricating oil.
If none of the above methods can solve the problem, it is recommended to contact a professional air compressor maintenance personnel for inspection and repair. When using the air compressor in normal times, try to avoid severe vibration and excessive load, replace the filter and check the lubricating oil regularly to protect the equipment and extend its service life.
(KUW Series Silent Oil Free Scroll Air Compressor)
Air compressor preventive maintenance and replacement
Lack of routine maintenance is the main reason of various problems with air compressors. Regular maintenance is essential to ensure that the compressor continues to operate efficiently.
Many users do not know the right way of cleaning air compressor, which includes checking and replacing air filters, oil filters and separators, as well as checking for leaks and other problems. Neglecting maintenance can lead to reduced performance, shortened life, increased energy consumption and increased downtime.
Before starting the air compressor, check the pressure gauge and oil level gauge on the air compressor oil and gas barrel on site. If the pressure gauge indicates pressure, it can be determined that the system may not be fully depressurized, causing the compressor to start under pressure, resulting in excessive starting current and causing the air compressor to trip and fail to start.
If the oil level gauge shows that the oil level is too low, the lubricating oil may be insufficient, which will cause the air compressor to lack lubrication inside, causing the rotor to wear excessively, overheat and stop working.
If the air compressor has a more serious problem, it requires comprehensive professional repairs and it costs almost the same as buying a new air compressor. It makes sense to consider replacing the air compressor.
Older models are often less energy efficient, and long-term use will result in high electricity bills. Newer models are more efficient and have more advanced technology, which can save long-term costs. If your business or production relies heavily on compressors and you cannot afford to have them repaired for a long time, replacing the air compressor may be the most effective method.
Therefore, developing and strictly implementing a regular preventive maintenance plan including routine cleaning, inspection, and replacement of parts, is the best choice to prevent air compressor failures and high repair costs.
(KDP Series Diesel Portable Air Compressor)
FAQ
Why can’t the air compressor stop?
When the pressure in the air receiver reaches the set value, the air compressor will enter the unloading state. At this time, the compressor will not stop working but run without load. This is normal operation. However, if the air compressor continues to compress air after the pressure in the air receiver exceeds the set value, it may cause a dangerous situation.
The main reasons for this situation are pressure sensor failure, intake valve failure, or air compressor control system failure or data tampering. The correct way to deal with it is to press the emergency stop button of the air compressor, try to open the pressure relief valve and cut off the power supply, let the air compressor release the system pressure by itself, and then eliminate the causes of the fault one by one.
Why can’t the compressor exhaust pressure reach the set value?
First, confirm whether the rated power and maximum pressure of your air compressor can meet your needs. Secondly, check the settings of the pressure gauge. If these are all fine, it may be that the air compressor control system has set a lower value. It may also be that the air compressor has air leakage, pressure switch failure, filter blockage, etc.
Why is the air compressor exhaust temperature too high?
The reasons for the high exhaust temperature of the air compressor include high temperature environment, high workload, filter blockage, insufficient oil, radiator blockage, etc. The solutions include: install the air compressor in a well-ventilated place, run the air compressor under appropriate load, clean or replace the filter, replace or add qualified lubricating oil, clean the radiator, etc.
Why does the air compressor discharge air contain oil?
The main reasons for the air compressor discharge air containing too much oil include blockage or damage of the air oil separator element, excessive addition of lubricating oil, shaft seal wear, low pressure, unqualified lubricating oil, etc. Solutions to these problems include replacing a new air oil separator element, discharging excess oil, replacing shaft seals, adjusting pressure to an appropriate level, replacing unqualified lubricating oil, etc.
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