Air compressor is a universal equipment widely used in industrial production and plays an important role in all walks of life.However,air compressors are often plagued by problems such as high temperature,changes in air pressure,loading and unloading,and noise.How to troubleshoot the operation of the air compressor?Let's take a look together:

1.The outlet temperature or exhaust temperature of the compressor head is high

Excessive temperature rise is a common fault during the operation of screw air compressors.Long-term operation of screw air compressors at high temperatures will seriously affect the displacement and service life of the machine.When the temperature rises too high,a high-temperature shutdown fault will occur.The reasons are:

(1)The temperature sensor is faulty.If the temperature sensor fails,it will cause the PLC to falsely report that the temperature is too high and cause a shutdown.

(2)Environmental temperature factors.The outlet temperature of the screw air compressor head is generally set at about 110°C,and the outlet temperature of the head is equal to the ambient temperature plus 60°C.The ventilation environment is poor,and most of the high temperatures are caused by this.

(3)The temperature control valve is faulty.When the compressor is cold-started,the temperature control valve can make the oil bypass the cooler and directly spray into the main engine head,accelerate the rise of oil temperature and prevent condensation in the compressor.After the compressor is running normally,it can be adjusted to flow through the cooling according to the oil temperature.The ratio of the fuel volume between the device and the side road controls the fuel injection temperature.If the temperature control valve is damaged or the action is not sensitive,a large amount of high temperature oil will directly circulate into the main engine head without the cooler,resulting in high temperature of the main engine.

(4)The oil filter is faulty.The oil filter is used to filter the dust and impurities in the oil circuit.After a period of use,it is easy to block,and the blockage will cause poor oil return and high temperature of the host.(It often occurs at the moment of loading).

(5)The oil shutoff valve is faulty.The oil cut-off valve controls its reciprocating oil injection through the air pressure of the gas storage tank. If a fault occurs, the oil circuit is not smooth and the oil temperature is high.The sundries block the oil circuit or the control air circuit,causing the shutoff valve to close and no fuel injection,and also cause the main engine head to have a high temperature due to lack of oil or poor heat dissipation.

(6)Insufficient amount of lubricating oil,dirty or clogged oil cooler will cause excessive temperature.

(7)The cooling fan fails, the air cooler is blocked,and the exhaust resistance is too large,resulting in poor heat dissipation and high temperature.The external dust and internal oil stains of the cooler should be cleaned.

2.The output exhaust pressure is too low

(1)The actual gas consumption is greater than the gas output of the unit,the connected equipment and pipe network should be checked,and if there is a leak,it should be repaired in time.If the air consumption of the system is greater than the air output of the compressor unit under normal use conditions,a large-size compressor unit should be replaced or a compressor unit should be added.

(2)The set value of unloading pressure is too low.Set the unloading pressure value correctly to give full play to efficiency.

(3)The filter element of the air filter is dirty and clogged,resulting in insufficient air intake of the compressor unit and low exhaust pressure.The condition of the air filter should be checked and replaced if necessary.

(4)The solenoid valve is faulty. The main vent solenoid valve and cold start vent solenoid valve on the exhaust pipeline are leaking and need to be replaced.

(5)Leakage of gas pipe hose. Replace the control air hose.

(6)The intake valve is not sensitive and not fully opened.Need to overhaul and check the control system condition.

(7)The oil separator is blocked, and the filter element of the oil separator needs to be replaced.

(8)The safety valve leaks. Need to recalibrate or replace the valve.

(9)After the drain valve of the gas-water separator is opened, it gets stuck and leaks, which should be checked and repaired.

(10)The vent valve is faulty and cannot be closed when the compressor unit is loaded. Need to be overhauled or replaced.

3.The output exhaust pressure is too high

(1)The intake valve is faulty. Need to be overhauled or replaced.

(2)The setting of loading and unloading pressure is unreasonable. The loading and unloading pressure value should be set according to the actual air consumption.

(3)The pressure sensor is faulty,replace it.

(4)The unloading valve is not closed,the unloading valve is stuck or closed tightly,and the solenoid valve is malfunctioning.Check and repair the unloading valve and solenoid valve,and replace if necessary.

4. Frequent load unloading

(1)The loading and unloading pressure difference of the pressure controller is too small,reset the loading and unloading pressure value.

(2)The pressure sampling pipe is blocked or leaked,and the pressure decays too fast.The sampling pipeline needs to be overhauled.

(3)The actual production air consumption is unstable,sometimes large,sometimes small or discontinuous.A gas storage tank can be added after the compressor unit.

(4)When the compressor unit is unloaded,the minimum pressure valve is not closed in time or tightly closed.Repair the minimum pressure valve and replace it if necessary.

(5)The loading control solenoid valve is faulty.The solenoid valve should be checked.It may be affected by oil,water and gas,which may cause insensitive action or burn out of the coil.Check and replace if necessary.

(6)The pressure sensor that controls the start and stop of the unit is faulty or damaged.Should be overhauled and replaced.

5.The compressor unit has not been unloaded after being loaded

(1)The actual production air consumption is greater than the air output of the compressor unit,and the compressor unit is always in the loading operation state.

(2)Check whether there is air leakage in the connecting pipe network.

(3)Check whether the loading and unloading solenoid valve is active or damaged.

(4)Check whether the intake valve of the compressor unit is tightly closed.

(5)Check whether there is leakage in the drain valve of the gas-water separator.

(6)Check the safety valve and oiler separator for internal leakage.

6.Excessive oil consumption of the compressor unit or the discharged compressed air contains oil

(1)Too much fuel.If the oil level is too high, the air flow will entrain the oil in the oil separator into the compressed air.Cause the oil content in the discharged compressed air to exceed the standard.Therefore,the amount of fuel should be controlled below the red line and the yellow line.

(2)The failure of the minimum pressure spring causes the opening pressure to be too low,the pressure difference between the front and rear of the oil separator is too large,the flow rate of the oil and gas mixture in the tank is high,and the condensed oil on the cylinder wall and the oil separator filter element will be taken away by the high-speed airflow.Thereby affecting the effect of oil and gas separation.

(3)The filter element of the oiler separator is blocked or damaged.Check and clean and replace if necessary.

(4)The oil return pipe of the oil separator is blocked,check and clean.

(5)There is a leak in the air cooler system,check and repair and make up for the leak.

(6)The oil has been used for an extended period of time and the oil quality has deteriorated.Clean the compressor unit and replace the qualified oil.

7.The compressor unit is noisy

(1)The compressor unit is faulty, the bearing is damaged or the rotor of the main machine head is faulty.Stop the machine immediately and contact the after-sales service center.

(2)The cover panel is not installed properly,and the sound insulation cotton is damaged.

(3)If the parts are loose, check carefully and strengthen the connecting parts.