Air Compressor Troubleshooting and Solutions

With the advancement of automotive technology, compressor is considered a “standard equipment”, especially in the coal chemical industry, machinery industry and other industries.

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An efficient compressor determines the safe operation of an air conditioner or refrigerator. For example, during operation of a piston compressor, there will be fatigue, oiler failure or low pressure and gas shortages. Once these problems have occurred, the tool will not work properly.

How can you find them quickly and accurately and solve these problems while affecting the compressor performance rate and output of the product.

This article will analyze all common errors of AC compressors and provide solutions.

From the point of view of airflow, the error is that the air pressure or the pressure of the compressed air is too high, which can cause the automatic heating of the carbon offset and the explosion of the pressure vessel if the shield does not work.

Another potential problem is that the air volume is insufficient or the air volume is too low, which will affect production.

From the compressor’s point of view, there are four types of problems: compression system problems, regional water cooling, air and air pressure and mechanical failure.

1. Compressor Shell Burnout
When using a piston compressor, the Babbitt layer of a large carrying shell or shell bearing rod can be burned or dropped. This causes the temperature of the loaded shell to rise, producing high temperatures and smoke, causing the Babbitt alloy to melt.

-1.1 Low Oil Temperature

In the past, we were concerned about the high temperature of crankcase oil which could cause burns. It is stated in the manual that the oil temperature cannot exceed 60 ℃ or 70 ℃, but there is no minimum limit.

However, low oil temperatures can cause the same error. In winter, after the compressor is turned off, the oil temperature in the compressor credit drops. So the oil looks great and the shell is burned after the machine is reopened. Therefore, it is best to use a low-grade oil that is consistent in winter.

-1.2 Low Oil Level in Crankcase

If the lower level of the oil level is blocked, the falling oil level is not detected. And if the crankcase oil level is too low, the oil pump will be **** in the air from time to time.

Inhalation is performed on a dip, which causes the oil film of the carrier shell to be damaged. After that, the compressor shell will be softened gradually, and lead to a final burn.

-1.3 Removal Between Carrying Shell And Shaft

We used to adopt a pressure lead method to measure the opening between the bearing shell and the shaft.

This method is suitable for measuring a large carrying shell because the main bearing is suspended and the upper shell cover is fastened to a large magazine that will not move when the bolt is tightened.

However, this method is not suitable for measuring the connection of the rod carrying the rod. When you tighten the connecting rod, the lead cord will be lightened. If the connecting rod is tilted, it cannot indicate removal.

Therefore, we must use the dialing indicator to measure the approximate size of the shelf.

2. Oil Injector Failure
-2.1 Failure To Fill Oil

If the oil injection is not filled with oil, it should be separated and tested.

If the plunger and body of the pump are too old, causing the gap to widen and the oil pressure to leak back, you must clean, and repair, and replace it.

-2.2 Failure **** Fat

If the oil injection is non-oily, and you do not drip the oil when viewed from the oil cover, it means that the oil pump is clogged, or the oil cover is not tightly closed, and air enters.

It is necessary to clean the oil pump valve at the oil injection pump and replace the rubber cover with an oil cover.

-2.3 Inadequate Oil Supply

Lack of adequate oil injector for oil is due to long-term operation of the contaminant system, which has led to the blockage of the pipeline in the end. Or it may be that the nut has not been strengthened after repair, resulting in oil leakage. To fix it, you need to clean the pipe and tighten the joints.

3. Low Pressure and Insufficient Air Volume
When the compressor pressure is low and the air volume is insufficient, if there is no air leak in the compressed air pipe, it is usually a compressor component of the compressor itself.

There are several problems that create insufficient output capacity of the compressor unit.

-3.1 Timely Maintenance

First, check that the compressor release is reduced after maintenance. How long is the service? If the environment is bad, check that the air filter is blocked when the compressor is operating for 2000 hours.

If the air filter is not too blocked, you can simply perform the dust removal procedure. If the blockage is severe, you should install a new air filter.

Most of the time, there is no major problem when the compressor output drops. The problem is that the customer neglects maintenance and the compressor air filter is closed. After installing a new air filter, the compressor can operate normally.

In addition to air filter, lubricant and other filtering materials are also important. Check that the grease is within the normal range. If it is lost, please add it accordingly.

-3.2 Turn on Enough Value

If the compressor output decreases, check the unit.

If your compressor has recently been serviced by a maintenance service, and there are no problems with the three filters and oil products, a specialist should check the compressor feed valve.

Remove the hose hose, turn on the compressor, and check that the opening of the feed valve is normal.

Generally, the service life of the valve construction service is 100000 times. Due to the different products and collections of each manufacturer, the quality may vary. Thus the failure of the feed valve can lead to a decrease in the output volume of the unit.

If the inlet valve is not fully opened when the compressor is loaded, it can be concluded that the discharge volume drop is a fault of the feed valve, which must be removed for maintenance or replacement.

-3.3 Traffic Failure

After resolving the problem of the inlet valve and the output volume of the unit has not changed, you should consider whether the vehicle is operating properly.

Due to the short local circuit in the car coil, or the wear and tear of the car shaft, the car speed is lower than the average speed, which reduces the output power of the compressor. The motor and carrier coil must be repaired, and the compressor output power must be checked after repair.

Operating Pressure -3.4 Set to Low

If the compressor operating pressure switch is set to be lower than normal, it should be raised to a higher value.

When repairing a factory compressor error, operating pressure is set according to customer requirements. During customer use, it may be set to different pressures. For example, when a compressor starts pumping air into an air tank, and then the pressure reaches 10kg, the compressor stops or stops. When the pressure reaches 7kg, the compressor starts again. There is a pressure difference between them. This process can leave the compressor at rest to protect it.

Different compressor replacement has different fixing methods. Another is that the pressure difference is adjusted by the switch itself, which controls only the automatic shut-off pressure and the maximum pressure. This type of switch has two buttons adjusted by a screwdriver with spaces. The two buttons should be adjusted in the same way. Otherwise, they will move and stop, stop and start again, and then burn electrical appliances.

Other controls are the initial pressure (low pressure) and the stop pressure (high pressure).

4. Converter Pressure Correction
Adjust the pressure gauge ***** clockwise to increase the closing pressure on and off at the same time. Rotate the pressure adjustment clockwise to minimize closing and closing at the same time.

Different Pressure Correction
When the separation pressure adjustment is rotated clockwise, the closing pressure does not change and the opening pressure increases. When the pressure adjustment difference ***** is rotated inconsistently, the closing pressure remains constant and the opening pressure decreases.

If the pressure compression failure causes the operating pressure error, you must change the pressure button if it cannot be corrected.

-3.5 Environmental Change

If the compressor was used in a low-level environment at first and was moved to a much higher level with other equipment due to factory degradation, the environment became humid, which could lead to a decrease in unit emissions.

The higher the altitude, the thinner the air will be and the less gas will be produced each time. If there is too much water in the air, the compressed air will contain more water naturally. In subsequent studies, the participation of water vapor will result in reduced emissions.

-3.6 Compressor Drive Belt

In this case, you need to adjust the drive belt. If it is damaged, replace it with a new one.

Depending on the design of the pulley and shaft, the correct positioning method should be selected.

The pulley is mounted on the compressor head shaft and compressor motor. First, the compressor head pulley is fixed and locked.

If open, you can secure it with soft copper, aluminum or rubber hammers.

If it is solid, the red pressure or heat method can be used for mixing, and the temperature range should be controlled at 120-150 ℃.

If the tolerance balance of the taper sleeve pulley is slightly tight, the inner hole of the cone sleeve can be slightly extended and inserted into the shaft.

The position of the two-belt wheels and the same reference plane will be measured with a horizontal ruler (accuracy ≤ 0.5mm), and the allowable error is ≤ 0.5mm.

The verticality error is greater than 0.5mm. The base of the compressor head installation or oil gas tank can be adjusted using a gasket, ensuring that the direct error of the same datum plane is not more than 0.5mm.

You should also tighten the compressor head or compressor oil and gas cylinder bolts. Place the belt on the pulley according to the principle that the trademark is in the same position. Take a small pulley as a measure, measure the shape of the two wheels of the belt with a metal or laser measuring tool, and the allowable error is ≤ 0.5mm.

Attach the belt to the compressor equipment *****. Conversely, take a large pulley as a benchmark, re-check the durability of the two pulses, and the allowable error is less than 0.5mm. Finally, lock to fix ***** and nut.

The belt change is the same as the belt adjustment. Consideration should only be given to the replacement of the belt, not only one belt, otherwise, but also the new belt will be damaged due to the condition of the different belt.

Do not spray lubrication on the belt or pulley in case the belt slips. Check the belt after the first operation of the new machine at 30h. If there is a leak in the compressor belt, it should be repaired immediately.

Problems and Solutions with Compressor Types
There are several types of compressors depending on various parameters and parameters, including piston compressor, rotary compressor, centrifugal compressor and axial flow compressor. And the application times and operating methods for each type of compressor are different, different failures will occur.

For a more detailed introduction to compressor types, check out this article:

Typical Types of Computer Refrigerators: Complete Directory

After that, we will analyze the specific problems of conventional compressors and propose solutions, such as piston compressors, centrifugal compressors, and ***** compressors.

-4.1 Troubleshooting Piston Compressor

Common problems with piston compressors can be summarized as follows:

  • The compressor cannot start normally
  • The compressor starts and stops frequently
  • Compressor water hose condition
  • Extreme noise is active
  • Unusual pressure of discharge and exhaust temperature
  • Unusual compressor oil pressure

-4.2 Troubleshooting Centrifugal Compressor

The typical errors of centrifugal compressors can be summarized as the following 11 points.

  • Unusual vibrations and sounds
  • Carrying failure
  • The oil seal ring and the seal ring are faulty and the seal is not stable
  • The branding system is unstable and unconventional
  • Performance does not meet requirements Increase The impeller is damaged
  • Leakage
  • Insufficient flow and discharge
  • Excessive movement of the prime mover

-4.3 ***** Problem solving Compressor problem

compressors as one of the most widely used compressors, with 11 common errors.

  • Compressor cannot be started
  • The compressor cannot create pressure
  • Exhaust too high temperature or over heat protection
  • Frequent switching between full functionality and unloading
  • Failure to work without load; cannot store compression or security action when unloaded
  • Release volume or pressure is lower than normal
  • High oil content in exhaust, high consumption of compressor oil
  • Oil spills
  • Unusual unit noise
  • Excessive protection

During the initial process, the manager is overstretched or blocked. The main contact you usually make

In general, there are a variety of compressors, and they can have a variety of problems due to the different workplaces and methods of operation. At this point, various solutions are needed. However, the constitution is almost identical, with the same basic operating procedures. So, in fact, the same problems of different compressors can be used for reference.

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