12 common air compressors problems and solutions(Part 2) will be definitely helpful to you! During the operation of this complex and precise machinery—air compressor, you may encounter various problems that caused by a variety of reasons.
Understanding the causes of common air compressor problems and knowing how to fix them is crucial to maintain the efficiency and extend the life expectancy of your air compressor.
Air compressor problems and solutions of high exhaust temperature
The ambient temperature is too high:
The higher the ambient temperature, the higher the temperature of the air inhaled by the air compressor. The load of the air compressor cooling system will increase accordingly, and the heat dissipation performance will decrease. In some cases, it will cause a high temperature alarm or even shut down.
A lot of heat will be generated during the operation of the air compressor. If the air compressor is too close to the wall or obstacles, there are other heat sources near the air compressor, and the front door or side door is open when the air compressor is running, the fan cannot form a strong airflow, which will lead to poor ventilation and heat dissipation of the air compressor environment.
Solution: Lowering the ambient temperature and maintaining good ventilation are the main ways to effectively solve the high temperature problem of the air compressor. Learn more about how to design a optimal air compressor system with great ventilation
Radiator or cooler blockage: When there is a lot of flying dust around the air compressor, the long-term operation of the air compressor will cause a layer of dust or oil to adhere to the surface of the radiator, and the internal structure is also easily blocked due to the accumulation of oil and dirt, affecting the heat dissipation effect.
Solution: Clean the cooler regularly or replace the filter element when it is too dirty.
The oil filter is too dirty: When the oil filter in the compressor is too dirty, the lubricating oil cannot enter the compressor at a normal flow rate. At the same time, the bypass valve is closed, and the air compressor oil cannot reach the head. The main engine will heat up rapidly due to lack of oil and insufficient cooling.
Solution: Clean the oil filter regularly. When the inlet and outlet oil pressure difference exceeds 0.18Mpa, the filter element needs to be replaced.
Insufficient oil level in the air compressor: Insufficient oil level in the air compressor can also cause high temperature.
Solution: Check the oil level of the oil and gas barrel regularly. If the oil level is lower than the oil level mirror, add oil.
Temperature control valve failure: The function of the temperature control valve is to control the flow direction of the lubricating oil and ensure that the oil temperature entering the head is appropriate. If the temperature control valve is damaged, the uncooled lubricating oil will directly enter the main engine, causing the main engine to overheat.
Solution: Regularly checking the temperature control valve can effectively prevent the machine from overheating.
Using inferior or expired lubricating oil: Inferior lubricating oil has poor temperature resistance and is easy to coke, which affects the rotor and bearing of the head and makes the head prone to high temperature. Long-term use of original lubricating oil may cause emulsification or coking.
Solution: It is recommended to use original lubricating oil and replace it regularly.
Air compressor problems and solutions of air delivery decreasing
Internal failure of the compressor: When the mechanical parts inside the compressor fail, such as poor sealing of the sliding valve, wear of the main engine rotor, etc., the compression ratio will be reduced, thereby reducing the output of the air, resulting in insufficient gas production of the compressor.
Blockage of the compressed air pipeline: When there is a blockage or increased resistance in the air pipeline, it will cause energy loss when the air flows through the pipeline and reduce the efficiency of the system, resulting in insufficient gas production. There are many reasons for the blockage, such as pipe bending, filter blockage, dirt, moisture, etc.
Insufficient air intake of the compressor: When the compressor does not have enough air intake, the airflow generated inside the compressor decreases, resulting in insufficient gas production. This situation may be caused by reasons such as the air intake being blocked and the oil content in the airflow being too high.
Air leaks: When there is a leak in the air pipeline, it will cause air leakage, which will affect the gas production of the air compressor.
Altitude or environmental changes: The exhaust volume of the compressor is generally designed according to the suction temperature, humidity and altitude. The higher the altitude, the thinner the air and the smaller the gas output per unit time. If there is too much moisture in the air, the compressed air contains a lot of moisture. In the post-processing, water vapor precipitates, resulting in a decrease in exhaust volume.
Solutions
Replace damaged mechanical parts: When there is a fault inside the compressor, the damaged mechanical parts need to be replaced. For example, if the slide valve seals poorly, a new seal needs to be replaced to ensure that the air compressor operates normally and produces enough gas.
Clean the pipeline: When there is a blockage in the pipeline, the pipeline needs to be cleaned and maintained to remove dirt and moisture in the filter to ensure that the air can pass through the pipeline smoothly, thereby ensuring that the air compressor can produce enough gas.
Detect and fix air leaks: Replace parts or tighten valves to repair the leaking parts of the air compressor to reduce air leakage. For more details about how to detect and fix air leaks in air compressor
Clean the air intake: If the compressor does not have sufficient air intake, you need to first check whether the air intake is blocked, and then check whether the water content in the air flow or the oil content in the compressed air is too high. If so, it it recommend to install pre-treatment equipment, post-treatment equipment or replace more effective filters to solve the problem.
Air compressor problems and solutions of frequent loading and unloading
Compared with power frequency compressors, variable frequency drive air compressors have adjustable air delivery, smooth start-up, and more stable gas supply pressure than fixed speed air compressors. However, they may also have frequent loading and unloading problem just like fixed speed air compressors. A simple analysis of this phenomenon shows that frequent loading and unloading usually occurs in the following situations:
The values set for the supply pressure and unloading pressure are too close. When the compressor reaches the supply pressure, if the gas consumption suddenly decreases, the inverter will not have time to control the motor to slow down, which will cause excessive gas production and unloading.
Solution: Set the difference between the supply pressure and the unloading pressure to be larger, usually >0.05MPa.
The user’s gas consumption is unstable, and the gas consumption increases or decreases suddenly. At this time, the gas supply pressure will change, and the inverter controls the motor to change the frequency to change the output gas volume to maintain the stability of the gas supply pressure. However, the speed of the motor changes at a certain speed. When this speed cannot keep up with the speed of the gas consumption change at the gas user end, it will cause the pressure of the machine to fluctuate, and then loading and unloading may occur.
Solution: Users should not use multiple gas-using devices suddenly. They can turn on the gas-using devices one by one. Adjust the frequency conversion speed of the inverter faster to increase the speed of change of the output gas volume to adapt to the change of gas consumption. Use a large-capacity gas storage tank to buffer the fluctuation of gas consumption.
The user’s gas consumption is too small. Usually, the frequency conversion range of the permanent magnet variable frequency compressor is 30%~100%, and the frequency conversion range of the asynchronous variable frequency compressor is 50%~100%.
When the user’s gas consumption is less than the lower limit output gas volume of the compressor, after the gas volume reaches the set gas supply pressure, the inverter will control the motor to reduce the frequency to the lower limit frequency and the lower limit output gas volume to output compressed gas, but because the gas consumption is too small, the gas supply pressure will continue to rise until the unloading pressure is reached and the machine is unloaded. Then the gas supply pressure drops, and when the pressure drops below the loading pressure, the machine is reloaded.
Solution: Make an analysis of this situation: when the gas consumption is very small and the machine is unloaded, should the compressor be put into sleep mode, or how much time should be unloaded before entering sleep mode. When the machine is unloaded, the gas user is still using gas, but once the compressor enters the dormant state, the compressor no longer generates gas, and the gas supply pressure will drop. After dropping to the loading pressure, the machine is loaded.
Here, there will be a situation that when the machine restarts from the dormant state, the user’s pressure is still dropping, and it is very likely that the gas supply pressure will be lower than the loading pressure, or even much lower than the loading pressure, causing the gas supply pressure to be too low or the gas supply pressure to fluctuate greatly. Therefore, it is recommended that the time to enter the dormant state after unloading should not be too short.
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Air compressor problems and solutions of loud noise
The main reasons for the high noise of the air compressor are the vibration and airflow impact of the compressed air inside the machine, as well as the machine room structure and environmental factors outside the machine. These reasons combined lead to the high noise of the air compressor.
Bearing aging causes noise to increase: Bearings are one of the core components of the air compressor and bear the supporting role when the machine rotates. As the use time increases, the lubricating oil inside the bearing will gradually decrease, causing the bearing surface to be worn due to friction, and may even get stuck. This will cause the noise of the air compressor to increase. The solution is to check and replace the bearings.
Gear wear causes noise to increase: There are also a large number of gears inside the air compressor, which will produce a certain amount of noise when running. However, as the use time increases, the gear surface will wear, causing the noise to increase. If not maintained in time, the gear may break or get stuck, affecting the normal operation of the machine. The solution is to check and replace the worn gears.
Loose connection between components: The piston rod and crankshaft connection loosens over time, causing abnormal operation of the compressor. The piston rod moves up and down continuously. This movement causes the bolts to loosen over time. Loose bolts can cause abnormal noise. In this case, tightening the loose bolts with the support of the compressor service can solve the problem.
Insufficient lubricating oil: When the lubricating oil is insufficient, the friction of the air compressor rotor, screw, and piston becomes more intense, making a lot of noise. The solution is to check the lubricating oil and add or replace the lubricating oil when it is insufficient.
Improper machine room environment and equipment placement: The operation of the air compressor will also produce vibration. If there is no stable foundation or base, the machine will shake and the noise will become louder. Solution: It is recommended to check whether all parts are tightened. If the machine is loose, you can reinforce the fastening screws or positioning pins to ensure that the equipment does not shake during operation.
Add sound insulation measures, you can build sound insulation walls or install sound insulation boards around the equipment to reduce the impact of the equipment’s noise on the surrounding environment and people.
Improper equipment maintenance: Inadequate normal maintenance, such as untimely or incomplete cleaning, and oil and liquid are not cleaned and replaced, can also cause abnormal noise in the equipment. The solution is to maintain the equipment regularly every year, especially pay attention to oil change, filter cleaning, keep the equipment clean and smooth, and ensure the normal operation of the machine.
Air supply pipeline failure: The air supply pipeline is not well sealed or the air flow is unstable, which will affect the use effect and noise level of the equipment. The solution is to wrap the pipeline to prevent the noise from radiating outward; for the aerodynamic noise of the inlet and outlet, a muffler can be installed, and a porous sound-absorbing material can be fixed on the inner wall of the air flow channel. The resistive muffler has a good effect on the silencing of medium and high frequency noise.
Air compressor problems and solutions of fuse blow
A fuse that repeatedly blows in your air compressor may indicate an underlying electrical problem. This can include a range of issues, such as an electrical short, a faulty motor, or an overload of current due to the compressor being overworked. Causes could be:
Overloading the circuit due to other high-power-consuming devices sharing the same circuit as the air compressor.
The air compressor’s motor is faulty or worn, causing it to draw more current than normal.
Wiring issues within the air compressor, including damaged wires or loose connections.
The air compressor is running too hot.
Running the compressor beyond its rated pressure
Solution:
Make sure the circuit the compressor is plugged into is not overloaded by other high-power-consuming devices. Ideally, your air compressor should have its own dedicated circuit. Check to make sure the circuit is rated for the amperage of your compressor.
Inspect the motor for signs of wear or damage. Replacing a faulty motor can often resolve a blown fuse.
Check the motor amps for signs of motor damage.
Look for signs of damaged wires or loose connections and make necessary repairs.
Make sure the compressor is running in a cool, well-ventilated area.
Maintain your compressor regularly to ensure that the compressor’s cooling system is functioning properly.
Do not operate the compressor beyond its rated pressure.
Air compressor problems and solutions of high oil content
Oil-injected air compressors blend lubricating oil and compressed air together, so air compressors produce oil-containing gas during operation. Some factors can cause the oil content of air compressors to increase:
Incorrect oil-gas separators and filters: If the oil-gas separators and filters are not used and maintained correctly, the separation effect will be poor, which will lead to the generation of high-oil gas.
Lubricating oil immersed in compressed air: Even if the lubricating oil is not directly injected into the main air compressor, oil-containing compressed air may be generated. This may be due to the failure of the air compressor that causes the lubricating oil to be immersed in the compressed air. At this time, the content of oil-containing gas will exceed the specified value.
Exhaust temperature is too high: Excessive exhaust temperature will cause the lubricating oil to evaporate in the air compressor, thereby increasing the concentration of oil-containing gas in the compressed air.
Solution:
Use appropriate oil-gas separators and filters: Using appropriate oil-gas separators and filters can effectively remove oil mist and moisture from compressed air.
Use appropriate lubricating oil: If incorrect or poor quality lubricating oil is used, it will easily lead to the generation and increase of oil-containing gas concentration. Therefore, please choose the appropriate lubricating oil and replace it according to regulations.
Maintain proper exhaust temperature: The exhaust temperature of the air compressor needs to be checked and maintained regularly. If the exhaust temperature is too high, necessary cooling measures can be taken to control the exhaust temperature.
Perform regular maintenance: The air compressor needs regular maintenance, especially the oil-gas separator, air filter, oil filter and lubricating oil. The operating conditions of these components directly affect the performance and service life of the air compressor.
Use the air compressor correctly: The correct use of the air compressor is the key to maintaining a good working condition. The air compressor must be operated according to the operating requirements to avoid improper use.
Air compressor problems and solutions relief valve leaks
Causes:
- Poor sealing of the pressure relief valve seat. The long-term use of the air compressor pressure relief valve will cause the seat sealing surface to wear or oxidize, resulting in a decrease in sealing performance, which will cause leakage.
- The pressure relief valve spring is loose. The spring of the pressure relief valve that has been subjected to heavy pressure for a long time will become loose, reducing the tensile force of the spring, causing the pressure relief valve to not close tightly, resulting in air leakage.
- The spring leaf of the pressure relief valve spring is damaged. The pressure relief valve is used for a long time, and the spring leaf is prone to damage, causing the pressure relief valve to not close tightly, resulting in air leakage.
All of the above reasons may cause air compressor pressure relief valve leakage.
Solutions:
- Replace the pressure relief valve seat. If the sealing performance of the pressure relief valve seat is seriously damaged, the pressure relief valve needs to be removed, cleaned and repaired, and the sealing seat needs to be replaced.
- Replace the pressure relief valve spring. Generally, the service life of the pressure relief valve spring is about one year. If the spring is loose, it should be replaced in time.
- Replace the pressure relief valve reed. If the reed is damaged, it is necessary to replace the pressure relief valve reed with the same specification.
Further more help
Need further more help to troubleshooting your air compressor? Whether your air compressor is not functioning properly, has an unknown malfunction, or is simply not operating as efficiently as you would like, Kotech can always help. Kotech has the expertise and experience to diagnose and resolve any air compressor issues, ensuring your system is operating optimally and reliably.
At the same time, we also offer the highest quality of air compressors in the industry, dedicated to providing customized support to meet the specific needs of your compressor.
We offer a wide range of services, including OEM parts supply, 24/7 online/telephone and field technical support, and preventive maintenance programs, so you can have complete peace of mind when it comes to the operation and performance of your industrial air compressor.
Contact us today to discuss your industrial air compressor needs.