8 warning signs, you need to replace the compressor or dryer
A good air compressor and dryer system is a valuable asset for many different types of enterprises. Many facilities rely on them to continue operating, so reliable compressors are essential. If your compressor system fails, the cost may be very high, seriously affecting your production efficiency and profits. Maintaining good maintenance of compressors and dryers is essential for businesses that rely on them. Excellent maintenance can extend the service life of the system, improve its performance and make it more reliable.
Why does the air compressor fail?
Why does the air compressor fail? There are many reasons for air compressor failure. When they fail, they may bring trouble to the productivity and bottom line of the factory. You can solve some problems faced by the air compressor through maintenance, but the repair cost of other problems is higher. In this case, it sometimes makes more sense to buy a new one completely. The following are some common causes of air compressor failure.
Air leakage:
air leakage is a common problem of air compressors, and most facilities have taken extensive measures to check and prevent it. It is a good idea to check for air leaks regularly. However, they do occur and may be the cause of the air compressor failure. The compressor may restart automatically to cope with the pressure drop, otherwise you will lose a tank full of air after the compressor is stopped. Fortunately, air leaks are usually repairable. If it comes from the connector, it can usually be tightened. If the valve is worn and causes leakage, it can be replaced. Any hoses or oil filler pipes may also be leaking.
Motor and power supply problems:
If your power supply is unreliable or intermittent, your motor or power supply may have problems. Due to motor problems, the compressor may blow a fuse and trip the circuit breaker. If the compressor trips the circuit breaker when it is started, it may also be due to air entrapment on the piston, which usually comes from a faulty unloading valve. In addition, wear of the starting capacitor may cause the light to dim during startup. Professionals can usually solve these problems, but if you try to solve these problems, you may cause more damage to the compressor and need to replace it.
Poor maintenance:
air filter blockage and insufficient lubrication will cause serious problems in the air compressor system. These elements are used to keep the air clean and prevent accumulation or damage to internal components. If maintenance is not carried out, the air may become dirty, or the system may be difficult to operate due to increased friction of components. If a system is not properly maintained during its life cycle, it will wear out faster and may see more destructive problems. Proper maintenance procedures are a key part of keeping the air compressor running as long as possible.
Worn parts:
Parts will wear over time. They may not work efficiently or perform critical functions. For example, seals wear and allow compressed air to pass through. Many components in the air compressor system may be damaged, which is part of the reason why proper maintenance can help extend its life. Fortunately, most parts can be replaced. This does not always mean that you need to replace the entire system. You can replace many things such as valves, seals, gaskets and diaphragms with new options.
8 Signs You Need to Replace or Repair Your Air Compressor or Air Dryer
It is difficult to know what is wrong with the compressor due to various reasons that these tools stop working. Thankfully, some basic air dryer and air compressor troubleshooting can often help you narrow the problem. You may be able to determine if your compressor requires simple repair or complete replacement. The following are some signs that you may need to replace or repair the air compressor or dryer.
1.The compressor cannot be started
The compressor in the final stage may stop energizing and indicate that it is time to replace the compressor. On the other hand, if your compressor is still in good condition, one of the following problems may occur. The compressor may refuse to start for several reasons, some of which are more harmful than others. Before troubleshooting, do not forget to find obvious faults, such as the compressor is not pulled out.
One cause of startup problems may be related to the circuit breaker. The compressor may trip at some time during operation. Check the circuit breaker and switch connected to the compressor. If it is in the "off" position, you know it has been triggered. Reopen. If the problem still exists, please find a professional to determine whether the problem is an electrical problem or a compressor problem. Another electrical problem may be in the fuse box, you should check whether the fuse is blown.
Another condition that may cause the compressor to fail to start is insufficient air pressure. Your cut in pressure determines the pressure at which the compressor starts to operate, which needs to be proportional to the air stored in the oil tank. If they do not match, the compressor may not start. Changing the cut in setting on the pressure switch can solve this problem.
Other problem areas may include:
Pressure switch: the power supply will stop flowing and cannot reach the motor.
Motor: may overheat or overload.
Unloading valve: if it stops working, it needs to be replaced.
If these conditions can be eliminated, the compressor may be faulty.
2.The compressor will not stop
As long as a compressor keeps running, it will not stop, and there may be pressure switch or pressure relief valve failure. When the oil tank pressure reaches the cut-off point, the operation shall be stopped. The bad pressure relief valve can not release the pressure, so that the oil tank pressure is too high, and the motor can not stop running. If the pressure switch is broken, it will not remind the internal control pressure is at the correct level, so they do not know when to close it. In both cases, the replacement part should solve the problem.
3.You hear strange noise from the compressor
If your compressor makes a loud noise, such as rattling, you may encounter some different problems.
Electrical failure is a problem that often causes the compressor to make a rattling sound.
Another possibility is that the components are loose and need to be tightened or replaced.
The distributor motor may also be loose.
If any of these problems occur, you need to call an expert immediately to prevent irreparable damage to your air compressor. If the noise lasts for some time and you encounter other problems, you may need to replace the air compressor with a new one.
4.You have a circuit breaker problem
If your compressor continues to trip the circuit breaker, you may need a new compressor. It may consume too much energy. Although you may open the circuit repeatedly and continue to work as usual, do not do so. It does not solve the problem and can be dangerous because the circuit breaker trips to prevent a fire. At this time, ask a professional to check whether there is an electrical problem or whether a new compressor or repair is required.
5.Compressor vibrates or clicks
Generally, unstable compressor will bring troubles to the system. It can indicate that it is trying to start or run. If you ignore it, you are likely to further damage your system, making it irreparable. Usually, this kind of shaking and chattering means that something is not in the right place, which may damage expensive components. If it is not resolved, a new compressor is required. On the other hand, if you can catch it immediately and hire a professional, you may be able to repair the compressor and determine what part is causing the problem. Do not continue to use a compressor that vibrates and clicks.
6.Your system blows out warm air
The compressor needs to pump refrigerant to cool the air. If this does not happen, you will get warm or hot air from the opening. If the condenser works normally, it may be related to the refrigerant supply. Check for refrigerant leaks and seek expert help to determine if the problem can be resolved. Refrigerant problems can come from many different sources, some of which can damage the compressor and cause other problems.
7.You Find Moisture in or Around Your System
Each compressor system has a certain amount of condensate, but it should not be excessive. If you have a river flowing through your compressor, you will encounter various problems. Too much free water in the system will seriously affect the quality of air supply, the function and life of the system. When water pulls material through the system, rust or contaminants are introduced into the air. When water is mixed with pollutants such as rust and viscous substances, the air movement will pull the mud through the system. When the compressor is turned off and the temperature drops, these viscous substances will dry to the side of the internal components, blocking the air flow when the power is turned on next time.
If the water reaches the end point, the water itself will also damage tools and equipment. Remember to keep the condensate pipe clean. If you find that there is too much water in your system, your dryer may have failed and no longer work. The dryer may have drainage failure, which will basically flood the system, and excessive inlet temperature will increase overheating and other problems.
Another component that can cause moisture problems is the dew point reader. If this part does not work normally, it may indicate that the dew point is within the safe range, but this is not the case. If the dew point reader is turned off, it may display only a single value or a rapid change in reading. You can also see readings that are inconsistent with your environmental observations.
Depending on your application, a dryer may be required to obtain extremely dry air. If you find that the moisture in your air exceeds the range of your task, you may need to add, upgrade or replace your dryer type. Work such as painting and laboratories may require extremely dry air. For example, in paint applications, you can get small spots on the entire paint coating from where water enters the air stream and prevents paint from adhering to the surface. If you use a dryer and find that there is still too much water in the air, your dryer may not meet your requirements for it. Titus's compressed air system review can help you accurately measure your needs.
8.Your compressor lags in use
If your rotary screw compressor feels stuck or hard to keep up, it may be the pump itself. Since this is an important part of the operation of the air compressor, the problems here may be harmful. Some of the reasons why a pump may fail before its expected life include:
1.Excessive moisture in the system, which can come from condensate buildup
Overheating
2.System shake
3.Residue from lubrication
Think about how often your company uses compressed air tools. If they stop working, how many tasks will be difficult or impossible to complete? Maintaining your compressed air system is essential to keep it running for years to come.
