Air Compressor Parts Failure Analysis

Failure Analysis

Screw air compressor is a common type of air compressor, screw air compressor failure will affect its service life and operator's personal safety, so in industrial production, it is very important to understand the screw air compressor failure.

1. Screw type air compressor failure phenomenon: large oil consumption of the unit or compressed air containing large amounts of oil

The reasons for this fault are: the amount of cooling oil is too much, the correct position should be observed when the unit is loaded, when the oil level should be in the normal scale range; the oil and gas separator is broken; the secondary return pipe is blocked; the oil quality problem; the precision filter element has not been replaced for a long time; the oil temperature is too high which also leads to the oil content in the working air exceeding the standard.

2. Screw air compressor failure phenomenon: low unit pressure

The reasons for this failure are: the actual air volume is greater than the output volume of the unit; screw compressor air release, air inlet valve failure (can not be closed when loading); transmission system is not normal; ambient temperature is too high; air filter blockage; load solenoid valve (1SV) failure; minimum pressure valve stuck; user pipeline network leakage; pressure sensor, pressure gauge, pressure switch and other work is not normal; screw wear failure will lead to Low unit pressure; air leakage from pressure sensor or pressure gauge input hose.

3. Screw type air compressor fault phenomenon: fan motor overload

Possible causes are: deformation of fan; fan motor bearing failure; fan motor thermal relay failure (aging); loose wiring; voltage lower than rated voltage.

4. Screw type air compressor fault phenomenon: large unit current

The working voltage is more than 5% below the rated voltage; the power supply cable is too long or the wire diameter is too small; the wiring is loose, the set pressure of the unit exceeds the rated pressure; the oil separation core is blocked; the contactor is faulty, the main engine is faulty; the main motor is faulty.

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Failure Phenomenon

Failure phenomenon 1:

Unit exhaust temperature is high (more than 100 °C) - unit coolant level is too low, the oil cooler dirty, how to determine whether the cooler is dirty it, mainly depending on the temperature difference between its inlet temperature and outlet temperature, the normal temperature difference between 20-30 degrees, if the external dust blocking the heat dissipation gas only need to use compressed air to blow dry static can, such as blowing off the radiator internal dirty then need to use Professional cleaning agents to clean, (such as heavy oil cleaning agent, C copper, polyester dust, etc.) such as radiator internal blockage of harmful then need to use; clean water pump cycle cleaning, cleaning time depending on the situation. If the water-cooled radiator is blocked, the best way is to disassemble

The front and rear end cover with iron bars to clean the inside of the copper tube.

-Oil filter core blockage.

-Temperature control valve failure.

-Oil shut-off solenoid valve is not powered or coil damage or solenoid valve diaphragm rupture or aging.

-Cooling fan motor failure.

-The exhaust duct is not smooth or the exhaust resistance (back pressure) is large.

-Ambient temperature exceeding the specified range (38°C or 46°C).

-faulty of the temperature sensor (Intellisys control unit).

Malfunction of the pressure gauge (relay-controlled unit).

Fault phenomenon 2:

high oil consumption of the unit or high oil content of the compressed air - too much cooling dose, the correct position should be observed when the unit is loaded, when the oil level should be no higher than half.

-clogging of the oil return pipe.

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

-The exhaust pressure is too low when the unit is running

-The oil separation core is broken.

-The internal partition of the separation cylinder is damaged

-The unit has oil leakage.

-Coolant is deteriorated or overdue.

-Temperature is too high

Maintenance Task Recommendations

1. Check and reflect whether the unit has abnormal sound and leakage, whether the meter readings are accurate, and whether the temperature display is normal.
2. Check and inspect whether there is rust and looseness in the machine every month, if there is rust and corrosion, remove rust and oil or paint, tighten the looseness and discharge condensate.
3. every three months to purge the surface of the cooler and the electric fan cover, fan blade at the dust, add smooth oil in the electric idea bearing, check and reflect whether the hose aging, cracking scene.