Air Compressor Selection & Troubleshooting

More Troubleshooting

PROBLEM

CAUSE

REMEDY

Compressor trips due to over temperature

Compressor operating above rated pressure.

Set pressure to correct rating for machine.

Package pre–filter blocked.

Clean / replace package pre–filter.

Cooler blocked.

Clean cooler.

Missing or incorrectly fitted enclosure panels

Ensure that all enclosure panels are correctly fitted

Low coolant level.

Top up coolant and check for leaks.

High ambient temperature.

Re–site compressor.

Restricted cooling air flow.

Ensure correct air flow to compressor.

Excessive coolant consumption

Separator cartridge leak.

Fit new Separator cartridge.

Blocked separator cartridge drain.

† Remove fittings and clean.

Compressor operating below rated pressure.

Set pressure to correct rating for machine.

Coolant system leak.

† Fix leaks.

Excessive noise level

Air system leaks.

† Fix leaks.

Airend defective.

† Change Airend.

Drive belt slipping.

Replace belt and tensioner.

Motor defective.

† Replace motor.

Loose components.

† Retighten loose items.

Shaft seal leaking

Defective shaft seal.

† Fit Airend shaft seal kit.

Pressure relief valve opens

Defective switch or incorrect pressure switch setting.

Replace or set pressure to correct rating for machine.

Minimum pressure valve malfunction.

† Fit Minimum pressure valve service kit.

Load solenoid valve defective.

† Fit load solenoid service kit.

Blowdown valve defective.

† Fit blowdown solenoid service kit.

Inlet valve malfunction.

† Fit inlet valve service kit.

Black residue on belt guard/cooler box

Drive belt slipping.

Replace belt and tensioner.

Pulleys misaligned.

Re–align pulleys.

Worn pulleys.

† Replace pulleys and belt.

Gas strut failed.

Replace belt and tensioner.

DRYER OPTION

High Dew Point (Indicator Red)

Dryer compressor or fan failed.

Check electrical supply and repair as required.

Low refrigerant charge.

Check for leaks.

High pressure switch tripped.

Check condenser coil for debris. Check fan operation. Clean / repair as required. Reset manual switch.

Low Dew Point (Indicator Blue)

OR Compressor runs unloaded with no system pressure

HGBV out of adjustment / defective.

Adjust valve or replace as required.

 

Never adjust thermal expansion valve. It has been factory set

Water Down stream of dryer (Indicator OK)

Restricted / defective drain valve.

Clean / replace drain valve.

Clean / replace condensate check valves.

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Troubleshooting

PROBLEM

CAUSE

REMEDY

Compressor fails to start

Mains power or Control voltage not available.

§ Check incoming power supply.

§ Check the control circuit fuse.

§ Check the transformer secondary windings for the control voltage.

Defective Star / Delta timer.

§ Change Star / Delta timer.

Machine shuts down periodically

High airend temperature.

Top up coolant.

Motor overload.

§ Set overload to correct value and switch to manual reset.

Belt stretch protection (when fitted).

Change belt.

Line voltage variation.

§ Ensure voltage does not drop below 10% on start up and 6% running.

High current draw

Compressor operating above rated pressure.

Set pressure to correct rating for machine.

Separator cartridge contaminated.

Change air filter, and separator cartridge.

Low voltage.

§ Ensure voltage does not drop below 10% on start up and 6% running.

Unbalanced voltage.

Correct incoming supply voltage.

Damaged airend.

† Change Airend.

Low current draw

Air filter contaminated.

Change air filter.

Compressor operating unloaded.

Set pressure to correct rating for machine.

High voltage.

Reduce site voltage to correct operating voltage.

Defective inlet valve.

† Fit inlet valve service kit.

High discharge pressure

Defective or incorrect pressure switch setting.

Replace or set pressure to correct rating for machine.

Load solenoid valve defective.

† Fit load solenoid service kit.

Blowdown valve defective.

† Fit blowdown solenoid service kit.

Inlet valve malfunction.

† Fit inlet valve service kit.

Low system air pressure

Separator cartridge contaminated.

Fit new Separator cartridge.

Incorrect pressure switch setting.

Set pressure to correct rating for machine.

Minimum pressure valve malfunction.

† Fit Minimum pressure valve service kit.

Load solenoid valve defective.

† Fit load solenoid service kit.

Blowdown valve defective.

† Fit blowdown solenoid service kit.

Drive belt slipping.

Fit new belt and tensioner.

Air system leaks.

† Fix leaks.

Inlet valve malfunction.

† Fit inlet valve service kit.

System demand exceeds compressor delivery.

Reduce demand or install additional compressor.

Safety valve blows when compressor goes on load.

MPV STUCK CLOSED.

Strip MPV, examine and repair if necessary.

SAFETY VALVE FAULTY

Check the setting of the safety valve and the

rated pressure.

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Air compressor selection 101

When purchasing an air compressor there are several things to consider

How much ACFM (actual cubic feet per minute) "free air" do I need? ACFM is often confused with pressure PSI. Many people think as long as the compressor will build let's say 100 PSI that will be fine. You can build 100 PSI with a bicycle pump but it wont operate air tools or plant equipment. Therefore you need to know the total ACFM for all of your equipment. Lets say you have a body shop and your grinders, files and sanders consume 15 ASCM @ 90 PSIG if they were all operating at once. You would need an air compressor that would produce a minimum of 15 ACFM to operate everything. But lets go one step further. Unless you are willing to purchase a rotary screw air compressor that has a duty cycle of 100%, you would need to oversize a reciprocating compressor by a minimum of 30%. That means you would need a compressor that produces a minimum of 19 ACFM "free air" to operate your equipment and give the air compressor a rest. Many people guess at things, buy a compressor that has an attractive price and when it burns up from over duty cycle( they really don't know what caused it) then they are dismayed. Of course most equipment is not operating all at the same time but its better to over calculate some than to wear out the compressor.
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Air compressor overheating 101

Air compressor overheating can come from several factors. 

 

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Compressed air water problems 101

Due to the nature of a compressed air system water can become a problem. Many people are unaware that when you compress air you are compressing the moisture in the air and as the air cools you experience condensation.

The first step in solving this problem is to drain your air receiver tank. How often to drain depends on many factors. Most systems need to be drained multiple times daily so you just have to experiment. An automatic drain is an inexpensive way to remove condensate without having to manually drain the receiver multiple times daily. 

Draining the receiver is a must and in some cases will eliminate enough moisture for your application. If after draining you still have moisture an air dryer will be the next step

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