Thread Content
Common faults of Atlas air compressors and their solutions: 1. Excessively high exhaust temperature of the main unit. If the temperature in the machine room is within the acceptable range and the oil level is normal, first check whether there is a fault with the machine’s temperature sensing element; this can be done by using another temperature measuring instrument for verification. If it is confirmed that the temperature sensing element is functioning properly, then check the temperature difference between the inlet and outlet of the oil cooler, which should normally be between 5–8°C. If the temperature is above this range, it indicates insufficient oil flow, a blockage in the oil circuit, or a thermostat valve that has not opened fully. It is necessary to check the oil filter. In some models, there is a mechanism for adjusting the oil flow; in such cases, adjust it to its maximum setting first. Check whether the thermostat valve is functioning properly by removing its valve element and blocking one end of the valve, thereby forcing all the oil to pass through the cooler. If these methods do not resolve the issue, then it is possible that there are foreign objects blocking the oil circuit. If the temperature difference is below the normal range, it may be due to poor heat dissipation. Check whether there is insufficient water flow into the coolant unit, whether the temperature of the incoming water is too high, whether scale has formed in the water channels of the cooler, whether there is oil residue in the oil channels of the cooler, whether the radiator is too dirty, whether there is oil residue inside the radiator, and whether the cooling fans are functioning properly. If the temperature difference is within the normal range but the machine still runs at high temperatures, it indicates that the heat generation in the machine head exceeds the normal level. It is necessary to check whether the machine is operating under excessive pressure, whether the oil used is inappropriate, whether the oil has deteriorated in quality, whether there are issues with the bearings in the machine head, or even friction at the end faces. Additionally, for those equipped with a fuel cut-off valve, it is necessary to check whether there is any malfunction with it; a faulty fuel cut-off valve usually causes the machine to shut down as soon as it starts operating, and the temperature to rise sharply. 2. The diagnostic steps for low exhaust pressure (low air volume) are as follows: (1) Check whether the manual valves for the \"pre-separation\" and \"post-separation\" stages sowie the pressure gauge are leaking; if there is a leak, replace the manual valve or fix the leakage issue ； (2) Check whether the control solenoid is leaking air; if it is, resolve the fault ； Replace the control solenoid valve if necessary ； (3) Check for leaks in the pipelines. If so, the leak point needs to be identified and eliminated ； (4) Check whether all butterfly valves are open. If so, check the butterfly valve mechanism and solenoid valve ； Check whether the solenoid valve is leaking air; if so, identify the cause and it may be necessary to replace the solenoid valve ； (5) Check whether the regulator is working properly; if there are issues, replace the solenoid valve or readjust the pressure switch ； Check whether the upper and lower limits of the pressure switch are normal; if so, the pressure switch needs to be readjusted, and replaced if necessary. 3. The diagnostic steps for excessively high exhaust temperature are as follows: (1) Check whether the specified ambient temperature and exhaust pressure have been exceeded; if so, adjust to the specified ambient temperature or exhaust pressure ； Check whether the lubricating oil is clean and the oil level is normal; if so, replace the oil or top up the oil level ； Check whether the lubricant grade is correct; if so, replace it with the correct grade of lubricant. (2) Has the fan airflow decreased? If so, check the fan motor speed and whether the exhaust outlet is blocked ； After inspection, check whether the outside of the cooler is clean, and clean the outer surface of the cooler. (3) Check whether the environment has an impact on the intake and exhaust air of the unit; if so, eliminate external factors to ensure normal ventilation of the unit. (4) Check whether the temperature control valve components are damaged; if so, replace them ； Check whether the solenoid valve and solenoid coil are damaged ； Check whether the solenoid valve diaphragm is damaged; if so, replace the coil and the diaphragm. (5) Replace the oil filter element. The solution is to perform maintenance on the oil circuit system by replacing the lubricating oil, air filter, oil filter, and other related components. In the case of water-cooled models, the oil circuit system should be soaked in a scale remover. When cleaning the oil circuit, a carbon deposit cleaner should be used. Store 45.46 m’ of compressor oil in each machine, and add 4.546 m’ of the concentrate. First, ensure that enough compressor lubricating oil is drained so that the liquid can be added to the storage tank. Then run the compressor continuously for 40 to 60 hours. To prevent the redeposition of suspended pollutants, it is necessary to completely drain the lubricating oil from the compressor while the oil is still hot in order to achieve the best results. 6. Analysis of the causes and solutions for oil leakage at the outlet of screw compressors (1) Excessively high oil level, too much oil injected. After relieving the pressure, drain the oil to the normal level ； (2) The return oil pipe is blocked. It can be checked and replaced ； (3) The installation of the oil return pipe (the distance from the bottom part of the oil separation element) does not meet the requirements; it can be adjusted again ； (4) The exhaust pressure is too low during unit operation; this phenomenon does not occur because the pressure in the air storage tank remains high ； (5) Damage inside the oil essence separator tank can only be detected through disassembly and inspection ； (6) Oil deterioration or use beyond the expiration date ； (7) If the return oil check valve loses control, oil will flow back into the oil fine separator after the unit stops operating; this will result in oil leakage when the unit is started again ； (8) Damage or rupture of the oil essence separator core. 7. Analysis of the reasons for degraded air compressor oil and a shortened oil change cycle: The original air compressor room in the machinery factory was located below the electrostatic precipitator and flue gas desulfurization units, resulting in a poor environment with high dust levels in the air. During operation, air compressors frequently experience problems such as oil degradation and clogged filters, which leads to a shorter oil change interval and an **increase in operational and maintenance costs**. Treatment method (1): Select the appropriate lubricant and establish a comprehensive management system for the procurement, inspection, and acceptance of lubricants for air compressors. (2) Determine the appropriate oil supply volume. If too much lubricating oil is supplied, carbon deposits are likely to form. However, it cannot be too low either; insufficient oil supply leads to poor lubrication of the cylinder block and rotor, increasing the risk of cylinder scoring. (3) Establish a minor maintenance cycle focused on inspection and cleaning. Fully synthetic oil (the highest quality air compressor oil): must be replaced every 6,000–8,000 hours. 8. Analysis of the reasons for compressor not loading: (1) The pressure in the pipeline exceeds the rated load pressure, causing the pressure regulator to shut off. (2) The minimum pressure valve fails to function and does not operate during loading, preventing high-temperature compressed air from entering the cooler. (3) There is a leak in the control pipeline between the separator and the unloading valve; inspect the pipeline and connections, and repair any leaks that are found. Handling method: If the gas supply pressure exceeds the rated value, no action is required. When the pressure in the pipeline is lower than the setting pressure of the pressure regulator, the compressor will activate automatically. If the minimum pressure valve fails, remove it for inspection and replace it if necessary. If there is a leak in the control pipeline between the separator and the unloading valve, inspect the pipeline and connections; if a leak is found, it must be repaired.