Eight common faults of screw air compressors

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Eight common faults of screw air compressors 1. Fault symptoms: High exhaust temperature of the unit (above 100 °C); too low level of the coolant in the unit (it should be visible through the oil sight glass, but not more than half full)； ·If the oil cooler is dirty, how can one determine whether it is indeed dirty? The key is to look at the temperature difference between the inlet and outlet of the oil. A normal temperature difference ranges from 20 to 30 degrees. If external dust has blocked the cooling fins, it suffices to blow them clean with compressed air. If this does not work, and the inside of the cooler is dirty, then a specialized cleaning agent must be used (such as agents for removing heavy grease, CPX, or dust removers). In cases where the inside of the cooler is severely blocked, further action is required ； Use a clean water pump for circulation cleaning; the cleaning time depends on the situation. If a water-cooled radiator is clogged, the best approach is to remove the front and rear covers and use iron bars to clean the inside of the copper tubes. · The oil filter element is clogged ； ·Thermostatic valve failure (component damaged) ； ·The fuel cut-off solenoid is not receiving power, or its coil is damaged, or the solenoid diaphragm is cracked or worn out ； The fuel cut-off solenoid is commonly found in older models. · Cooling fan motor failure ； ·The exhaust duct is not unobstructed, or the exhaust resistance (back pressure) is high ； ·The ambient temperature exceeds the specified range (38°C or 46°C) ； ·Temperature sensor failure (Intellisys control unit) ； ·Is the pressure gauge faulty (relay-controlled unit)? 2. Fault symptoms: High fuel consumption by the unit or high oil content in the compressed air; excessive amount of cooling fluid. The correct level should be checked when the unit is under load, at which point the oil level should not exceed half of the tank’s capacity ； ·Oil return line blocked ； ·The installation of the return oil pipe (distance from the bottom of the oil separation element) does not meet the requirements ； ·The exhaust pressure is too low while the unit is operating ； ·Oil separation core is broken ； ·The partition inside the separation cylinder is damaged ； ·There is oil leakage from the engine unit ； ·The coolant has deteriorated or been used beyond its expiration date. ·Excessively high temperature 3. Fault symptoms: Low pressure in the unit · Actual gas consumption is greater than the gas output of the unit ； ·Vent valve failure (fails to close under load) ； ·Intake valve failure ； ·The transmission system is malfunctioning, the ambient temperature is too high, and the air filter is clogged ； ·Fault in load solenoid valve (1SV) · Stuck minimum pressure valve ； ·There is a leak in the user’s pipeline network ； ·The pressure setting is too low ； ·Pressure sensor failure (Intellisys control unit) ； ·Gauge failure (relay-controlled unit) ； ·Pressure switch failure (relay-controlled unit) ； ·Leak in the input hose of the pressure sensor or gauge ； 4. Fault symptoms: Excessively high exhaust pressure of the unit · Faulty intake valve ； ·Hydraulic cylinder failure ； ·Fault in load solenoid valve (1SV) ； ·The pressure setting is too high ； ·Pressure sensor failure (Intellisys control unit) ； ·Gauge failure (relay-controlled unit) ； ·Pressure switch failure (relay-controlled unit). 5. Fault symptoms: High current in the unit · Too low voltage ； ·Loose connection ； ·The unit pressure exceeds the rated pressure ； ·Oil separation core clogged ； ·Contactor failure ； ·Host failure ； ·Main motor failure ； 6. Fault symptom: The unit cannot start · Fuse is damaged ； ·The temperature switch is broken ； ·The connection is loose ； ·Main motor thermal relay trips ； ·Fan motor thermal relay trips ； ·The transformer is broken ； ·Intellisys without power input (Intellisys control unit) ； ·Fault not resolved (Intellisys control unit) ； ·Intellisys controller failure. 7. Fault symptoms: High current or tripping during unit startup · Issue with the user’s circuit breaker ； ·The input voltage is too low ； ·The star-delta conversion interval is too short (it should be 10 ~ 12 seconds) ； ·Hydraulic cylinder failure (not reset) ； ·Intake valve failure (excessive opening or sticking) ； ·Loose connection ； ·Host failure ； ·Main motor failure ； ·The 1TR time relay is damaged (the relay controls the unit). 8. Fault symptoms: Fan motor overload · Fan deformation ； ·Fan motor failure ； ·Fan motor thermal relay failure (aging) ； ·Loose connection ； ·Cooler clogged ； ·The exhaust resistance is high.