Air Compressor Troubleshooting Guide

1. The air compressor is faulty, what should be checked?

(1) Fault phenomenon: low unit pressure

Check the reason:

• The actual gas consumption is greater than the output gas volume of the unit;

• Faulty purge valve (does not close when loaded);

• Intake valve failure;

• hydraulic cylinder failure;

• Load solenoid valve (1SV) failure minimum pressure valve stuck;

• There is leakage in the user pipe network;

• The pressure setting is too low;

• Pressure sensor failure (Intellisys control unit);

•Pressure gauge failure (relay control unit);

•Pressure switch failure (relay control unit);

• Pressure sensor or pressure gauge input hose leaks;

(2) Fault phenomenon: the exhaust pressure of the unit is too high

Check the reason:

• Intake valve failure;

• hydraulic cylinder failure;

•Load solenoid valve (1SV) failure;

• The pressure setting is too high;

• Pressure sensor failure (Intellisys control unit);

•Pressure gauge failure (relay control unit);

•Pressure switch failure (relay control unit)

(3) Fault phenomenon: oil leakage of air compressor

• If the air compressor leaks oil, pay attention to observe the oil seal and check whether the oil seal is cracked, whether the inner lip is cracked or turned over. If there is one of the above conditions, it should be replaced; check whether there are scratches and defects on the joint surface of the oil seal and the main shaft, and if there are scratches and defects, it should be replaced. Check whether the oil return is smooth. If the oil return is not smooth, the pressure of the crankcase is too high and the oil seal leaks or falls off. It is necessary to ensure that the oil return pipe has a minimum diameter, and it is not twisted or bent, and the oil return is smooth. Check the matching dimensions of the oil seal and the box, and replace those that do not meet the standards.

•Forcibly move the spindle to check whether the neck clearance is too large, if the clearance is too large, replace the bearing bush and oil seal at the same time.

• Check the sealing conditions of the gaskets at each junction, repair or replace the gaskets; check the bolts of the inlet and outlet joints and the threads of the box and tighten them.

• Check the oil leakage of the air compressor and re-adjust the tightness of the belt. It is advisable to press down 10mm with the thumb.

• The air compressor leaks oil, and it is necessary to check the casting or processing defects of the box body, and repair or replace the defective parts.

(4) The exhaust temperature of the unit is high (over 100°C)

Check the reason:

• The coolant level of the unit is too low (it should be visible from the oil sight glass, but not more than half); the oil cooler is dirty;

• The oil filter element is clogged;

•Temperature control valve failure (component failure);

• The fuel cut-off solenoid valve is not powered or the coil is damaged;

• The diaphragm of the fuel cut-off solenoid valve is ruptured or aged;

• Faulty fan motor;

• The cooling fan is damaged;

• The exhaust duct is not smooth or the exhaust resistance (back pressure) is large;

• The ambient temperature exceeds the specified range (38°C or 46°C);

• Temperature sensor failure (Intellisys control unit);

• Whether the pressure gauge is faulty (the relay controls the unit).

(5) The oil consumption of the unit is large or the compressed air has a large oil content

Check the reason:

• Too much coolant, the correct position should be observed when the unit is loaded, at this time the oil level should not be higher than half;

• The oil return pipe is blocked;

• The installation of the oil return pipe (the distance from the bottom of the oil separation core) does not meet the requirements;

• Exhaust pressure is too low when the unit is running;

• The oil separation core is broken;

• The separator inside the separation cylinder is damaged;

• The unit has oil leakage;

• The coolant has deteriorated or been used beyond its expiry date.

2. When the air compressor breaks down, it will cause headaches. Is it because the principle is not clear?

Come and see how the air compressor works!

(1) Inhalation process

The suction port on the intake side of the screw type must be designed so that the compression chamber can fully absorb air, while the screw type compressor does not have an intake and exhaust valve group, and the intake air is only regulated by the opening and closing of a regulating valve. When the rotor rotates, the tooth groove space of the main and auxiliary rotors is the largest when it reaches the opening of the intake end wall. At this time, the tooth groove space of the rotor communicates with the free air of the air inlet, because the air in the tooth groove is were all discharged.

At the end of the exhaust, the tooth groove is in a vacuum state. When it turns to the air inlet, the outside air is sucked in and flows into the tooth groove of the main and auxiliary rotors along the axial direction. When the air fills the entire tooth groove, the end surface of the intake side of the rotor turns away from the air inlet of the casing, and the air between the tooth grooves is sealed, and the above is the suction process.

(2) Closing and conveying process

When the main and auxiliary rotors are inhaled, the tooth peaks of the main and auxiliary rotors are closed with the casing. At this time, the air is closed in the tooth groove and no longer flows out, that is, the sealing process. The two rotors continue to rotate, and the tooth peaks and tooth grooves match at the suction end, and the matching surface gradually moves to the exhaust end, which is the conveying process.

(3) Compression and fuel injection process

During the conveying process, the meshing surface gradually moves toward the exhaust end, that is, the tooth groove between the meshing surface and the exhaust port gradually decreases, the gas in the tooth groove is gradually compressed, and the pressure increases, which is the compression process. While compressing, lubricating oil is also sprayed into the compression chamber due to the pressure difference to mix with the chamber air.

(4) Exhaust process

When the meshing end surface of the rotor turns to communicate with the exhaust of the casing, the pressure of the compressed gas is the highest at this time, and the compressed gas starts to be discharged until the meshing surface of the tooth crest and the tooth groove moves to the exhaust end surface. At this time, the meshing surface of the two rotors The space between the tooth gap and the casing exhaust port is zero, that is, the exhaust process is completed. At the same time, the length of the tooth gap between the rotor meshing surface and the casing air inlet reaches the longest, and the suction process is going on again.

Sollant Group-Professional Compressed Gas Solutions Provider