9 Common faults of air compressors

When you use an air compressor, you might encounter these nine common faults: it does not start, it does not stop, air leaks, pressure issues, excessive noise or shaking, overheating, oil or water in the lines, electrical issues, and parts that are old or broken. Identifying these air compressors common faults quickly helps you prevent excessive pressure, save energy, and maintain a safe workplace.

Regularly checking your screw-air-compressor or rotary-air-compressor, along with utilizing sollant’s trusted solutions, makes addressing these problems easier and more effective.

Key Takeaways

Find common air compressor faults early to stop expensive repairs and lost time. – Do regular maintenance like checking for air leaks and cleaning filters. This helps your compressor work well. – Knowing about pressure problems helps keep the compressor working right and stops damage. – Fix loud noises or shaking quickly to help your air compressor last longer. – Use good parts and smart technology to make your compressor more reliable and use less energy.

Air Compressors Common Faults

Air compressors common faults can mess up your work. They can make you less productive. If your air compressor has problems, it might stop working. It could make weird sounds. Sometimes, it does not give enough air. These problems can slow down your job. They can also make things cost more. When your air compressor stops, you lose time and money. Even a small air leak can waste a lot of energy. It can use up to 30% more power. This makes your system work less well.

Shanghai Sollant Energy Saving Technology Co., Ltd. is a factory in China. They make air compressors for people all over the world. Sollant uses smart designs and good parts. This helps you avoid air compressors common faults. They work hard to make new and better products. Their machines are reliable. You can trust your air compressor to work well.

Won’t Start

A common air compressor problem is when it will not start. This can happen for many reasons. It is important to find out why quickly. This helps you avoid losing time.

Symptoms

Here are some signs your air compressor will not start:

The motor does not turn on when you press start.
You hear a humming noise, but it does not run.
The control panel shows an error or warning light.
The compressor tries to start but shuts off right away.

The table below shows some main reasons for this problem:

Cause of Failure	Description
Power Supply Issues or Blown Fuses	The compressor does not get power because of a tripped breaker or blown fuse.
Failed Capacitors	The motor cannot make enough power to start.
Overload Protection Activation	Too much heat or current turns off the system.
Blocked Intake Filters	Air cannot move, so the compressor cannot start.
Damaged Motor Windings	The motor’s electric field does not work right.

Troubleshooting

You can try these steps if your air compressor will not start:

Check all power cords and make sure it is plugged in.
Look at the check valve and intake filters for clogs.
Check the control panel for errors or warning lights.
Change the cut-in pressure settings if they are too low.
If it still does not start, call an expert for help.

If you know about air compressors common faults like not starting or stopping, you can keep your machine working. This helps you avoid expensive fixes. Sollant’s smart technology and strong parts help you stop these problems. You can keep your work running smoothly.

Air Compressor Failure to Stop

If your air compressor does not stop, it is a big problem. This can waste energy and wear out parts faster. It can also be unsafe. You should know the signs early and learn what causes this.

Signs

Here are some signs your air compressor does not stop:

The compressor keeps running after it reaches the set pressure.
The pressure gauge shows numbers that are too high.
The machine feels hot or sounds strange.
The compressor does not turn off when you try.

If you notice these signs, do something fast. If the compressor keeps running, it can break and cost more money.

Solutions

You can fix an air compressor that does not stop by checking some important parts. Most problems come from the pressure switch or a valve. Here are the main reasons:

Faulty pressure release valve: If this valve gets stuck or breaks, it cannot let out extra pressure. The compressor keeps running.
Defective power switch: If the switch is broken, it cannot tell the compressor to turn off.
Defective pressure switch: If the switch does not sense the right pressure, the compressor will keep going.

The table below shows how these parts can cause problems:

Cause	Explanation
Faulty Pressure Switch	The switch does not turn off the compressor at the right pressure.
Unloader Valve Problems	A stuck or broken valve keeps the compressor running.

You can fix these issues by:

Looking at the pressure switch and changing it if it is bad.
Checking the power switch for any damage.
Cleaning or changing the pressure release valve.

Sollant puts good pressure control systems in every air compressor. These systems help stop air compressor failure and keep your machine safe. If you need more help, Sollant has experts who can help with any air compressor problem.

Air Leaks – Common Issues

Air leaks are one of the most common problems you will face with an air compressor. Even a small air leak can waste a lot of energy and money. In many factories, up to 20-30% of compressed air is lost because of leaks and poor usage. This waste can make your business less efficient and increase your costs.

Detection

You can find air leaks by checking the most common spots where leaks happen. These include:

Quick couplers
Filters
Pneumatic cylinders
Dryer assemblies
Pressure regulators
Rubber pipes
Lubricator assemblies
Isolation valves
Automatic drain traps

You might also notice leaks at couplings, hoses, tubes, and fittings. Sometimes, open condensate traps and shut-off valves cause problems. Pipe joints and thread sealants can also let air escape.

To detect air leaks, you can use several methods. Some are simple, while others use special tools. Here is a table to help you understand the main ways to find leaks:

Method	Description
Load Time Measurement	Measure how long the compressor runs and rests to estimate the leak rate.
Pressure Drop Test	Watch how fast the pressure drops when the compressor is off.
Ultrasonic Leak Detection	Use a detector to hear leaks you cannot hear with your ears.
Flow Monitoring	Use flow meters to spot sudden rises in air use that signal leaks.

You can also listen for hissing sounds or use soapy water to look for bubbles at joints.

Quick Fixes

If your compressor constantly leaks air, you need to act fast. First, tighten all fittings and replace any worn rubber pipes or seals. Change out damaged couplers or valves. Make sure you use high-quality seals and fittings, like those from Sollant, to prevent future leaks. Regular checks and quick repairs will keep your air compressor running smoothly and save you money.

Tip: Fixing air leaks right away helps you avoid bigger problems and keeps your system efficient.

Pressure Problems

Pressure problems can affect how well your air compressor works. You may notice low pressure or high pressure during operation. Both issues can slow down your work or even damage your equipment. Knowing what causes these problems helps you fix them quickly.

Low Pressure

Low pressure is a common problem. You might see your tools lose power or your machines run slowly. Here are some reasons for low pressure:

You use more air than the compressor can supply.
The system has leaks or poor connections.
The pipes or hoses are too small for the airflow.
Air quality issues, like water vapor or oil, block the flow.
The compressor is too far from where you use the air.

You can check the pressure at the compressor and at the tool. This helps you find where the pressure drops. If you see a big difference, look for leaks or blockages in the system.

Tip: Clean filters and check for leaks often. This keeps your pressure steady.

High Pressure

High pressure can also cause trouble. You may hear strange noises or see the pressure gauge go above normal. Some causes include:

Poor pressure control settings.
Users increase pressure to make up for leaks.
Hoses or pipes are too small, so you raise the pressure.
Faulty valves or attachments restrict airflow.

High pressure can wear out parts faster and make your system unsafe. Always check your settings and replace broken parts right away.

Adjustments

Modern air compressors use advanced sensors and controls to keep pressure stable. These features help you avoid both low and high pressure problems.

Feature	Description
Sequencing Algorithms	Choose which compressors to run based on real-time demand.
Load Balancing	Spread the workload evenly to make compressors last longer.
System-Wide Pressure Control	Keep pressure steady and save energy.

Smart controls, like PID controllers and predictive algorithms, watch the system and make changes as needed. Sollant uses these technologies to help you get the best performance from your air compressor.

Excessive Noise or Vibration – Common Problems

Causes

Sometimes your compressor gets very loud or shakes a lot. This can happen because something is wrong inside the machine. Loose bolts, piston problems, or crankcase issues can make it noisy. How you use the compressor and where you put it also matter. The type of compressor can change how much noise it makes.

Here is a table that lists where noise or shaking comes from:

Source Type	Description
Mechanical Issues	Loose mounting, piston problems, and crankcase issues contribute to excessive noise and vibration.
Operational Causes	The type of compressor and environmental factors also play a significant role in noise levels.

If you hear loud sounds or feel shaking, do not ignore it. These signs mean something might be wrong inside. If you do not fix it, parts can wear out or break.

Tip: Loud noises or shaking can mean bigger problems. Fixing them soon helps your compressor last longer.

Solutions

You can fix these problems with some easy steps. Keep your compressor clean so dirt does not hurt the parts. Oil the machine often to help it run quietly. Check for loose bolts or broken parts. Tighten bolts and replace anything that is damaged.

New compressors have special parts to make them quieter. Sollant uses low-noise motors and soundproofing to help. Vibration dampeners and special mounts keep the compressor steady. Sound covers help block loud noises.

Here are some ways to make your compressor quieter and more stable:

Use motors that are not loud.
Add materials that block sound.
Put in vibration dampeners.
Use special mounts under the compressor.
Cover the compressor with sound enclosures.
Take care of your compressor often.

Sollant builds strong compressors with smart designs. This helps you avoid noise and shaking. Your compressor will be quieter and last longer.

Overheating – Air Compressor Problems

Overheating is a big reason piston air compressors fail. If your compressor gets too hot, it might stop or break parts. You should know what causes this and how to stop it.

Causes

Many things can make your compressor overheat. Here are the most common reasons:

Poor ventilation keeps hot air near the machine.
Bad or not enough oil makes more friction inside.
High temperatures outside make cooling harder.
Broken parts keep heat from leaving the compressor.
Dirty filters block air from moving.
Blocked condenser coils trap heat inside.
Running the compressor too long makes it too hot.
Wrong voltage makes the motor work too hard.

If you ignore these problems, the compressor gets hotter. This can cause more breakdowns and cost more to fix.

Tip: Look for signs like hot surfaces, weird smells, or the compressor turning off by itself.

Prevention

You can stop overheating with easy steps. Here are ways to avoid these problems:

Make sure air moves well in the compressor room.
Clean coolers often to help cooling.
Change dirty air and oil filters.
Check oil quality and change it when needed.
Clear drains so water does not build up.
Adjust water cooling if your compressor uses it.
Keep the room cooler than 100°F.
Check airflow and ventilation often.

Sollant uses good cooling and oil separation in every compressor. These features help move heat away and keep oil clean. Better airflow, strong fans, and good heat exchangers lower overheating risk. Oil separation keeps oil safe, so your compressor works longer and better.

Doing regular checks and using smart designs helps you avoid overheating. This keeps your equipment safe and your work going.

Oil or Moisture in Lines

Oil or moisture in your compressed air lines can cause big trouble. These problems can hurt your machines and products. Sometimes, contamination starts in places you do not expect. You should know where these problems come from and how they affect your work.

Causes

Oil or moisture can get into your air lines in different ways:

Ambient Air brings water vapor, oil vapor, and germs.
Air Compressor can add oil, water, and tiny drops to the air.
Air Receiver tanks can collect rust and germs if not cleaned.
Distribution Piping can build up rust and germs without care.

When oil or moisture gets in, it can damage your tools. It can also make your products worse. Here are some things that can happen:

Moisture can make metal parts rust or freeze in cold weather.
Oil can get on your products or inside machines and break them.
Water can mix with oil and make it less useful. This causes more wear on moving parts.
Too much moisture can freeze at tool exhaust ports and stop them.

If you see water or oil in your lines, fix it fast. These problems can cost a lot to repair and waste time.

Prevention

You can stop oil and moisture by using good filters and separators. Sollant has smart solutions to keep your air clean and dry. Here is a table with some common separator types:

Separator Type	How It Works	Best For	Limitations
Gravity/API Separator	Lets oil float up and solids sink down with baffles and time	Refineries, chemical plants	Not good for tiny oil drops
Coalescing Separator	Makes small oil drops join together and separate faster	Food production, compressed air systems	Needs cleaning often; can clog with dirt
Skimmer-Assisted System	Uses belts or tubes to pull oil from the top	Steel mills, heavy oil loads	Needs more space and care

Sollant’s air compressor systems use strong coalescing filters and separators. These remove oil and moisture before they reach your tools. If you do regular checks and use the right filters, you can stop most problems. Clean air lines help your tools last longer and make your products better.

Electrical Air Compressor Problems

Electrical problems can make your compressor stop working. You should know the signs of trouble. This helps you fix problems fast. Many compressor issues start with the electrical system. If you ignore these, your compressor might break. Other machines could get damaged too.

Faults

Your air compressor can have different electrical faults. Here are some common ones:

Short circuits happen when wires touch or insulation breaks. This can trip breakers or blow fuses.
Voltage imbalance means the power is not even. Motors can get too hot or work badly.
Motor overheating comes from too much current or blocked airflow. The motor may shut off or burn out.

You might see other problems, like flickering lights or strange noises. These signs mean you should check your system soon.

Tip: Always turn off the power before checking electrical parts. Safety is very important.

roubleshooting

Start with easy checks when you have electrical problems. Look for loose wires or burned connectors. Replace bad fuses or reset tripped breakers. If the motor is hot, let it cool before trying again. Make sure the voltage is right for your compressor.

Good electrical parts help stop many problems. They keep your system working well and give clean air. Oil-free compressors help by keeping oil out of sensitive parts. This protects your electronics and lowers repair needs. Reliable air systems protect your equipment and help you do better work.

Sollant uses strong electrical parts in every compressor. These parts help your system work well and avoid downtime. If you check your compressor often and use good parts, you can stop most electrical faults before they cause trouble.

Worn or Damaged Parts – Common Issues

Parts inside your air compressor can wear out over time. Moving parts break down after lots of use. This can cause leaks, loud sounds, and poor performance. If you do not fix these problems, your machine might stop when you need it.

Signs

You can find worn or broken parts by looking for these signs: Air leaks from hoses or fittings. The air pressure is low. There is less airflow than normal. Warning lights show up on the control panel. The compressor uses more energy or works less well. Oil pressure drops. You hear strange or loud noises. The compressor gets hot while running. Oil has metal bits in it. The system trips often. The compressor shakes more than usual. Oil ends up in the air lines.

If you see any of these signs, check your compressor quickly. These signs mean there are problems that need fixing soon.

Replacement

Changing old parts helps your compressor work better and last longer. You should replace hoses, belts, seals, and other parts before they break. This keeps your compressor working and stops long delays.

Here are some good things about changing parts often: It stops surprise breakdowns. It helps your compressor stay strong. It saves energy and money. It keeps other parts safe from damage.

Sollant makes parts that last and are easy to change. You can pick from many strong and custom parts. The table below lists important parts and what they do:

Component	Description
Rotors	Compress air at high pressure in rotary screw compressors
Piston Rods	Drive the crankshaft in reciprocating compressors
Gaskets	Seal gaps and keep air in
Seals	Hold oil in and keep pressure steady
Couplings	Stop leaks from pressure changes
Bushings	Reduce movement between parts and prevent breakdown
Bearings	Help parts spin smoothly and cut down on wear

Sollant gives help with maintenance so you can fix problems. With good parts and regular checks, your air compressor will stay in great shape.

Taking care of your air compressor often helps it work well. You can find small problems early and fix them fast.

This saves you money because your machine does not stop.
Your equipment lasts longer when you check it often.
You use less energy and save power.

Using a simple checklist for common faults makes your job easier. The table below shows why a checklist is helpful:

Benefit	Explanation
Consistency in Maintenance	Makes sure you do important tasks every time, so you do not forget steps and can plan better.
Simplified Troubleshooting	Helps you find problems quickly, so you can fix small issues right away.
Standardization Across Teams	Makes sure everyone does the same job, no matter who is working.
Better Air Quality	Keeps filters and dryers clean, so dirt does not get in and machines stay safe.
Stable and Predictable Energy Usage	Helps your system use less energy, so you pay less and your power stays steady.

Sollant gives you smart tools to help your air compressor stay strong and work well.

FAQ

What should you do if your air compressor keeps shutting off?

First, check the power supply and reset any tripped breakers. Clean the air filters and make sure the oil level is correct. If the problem continues, contact a professional for help.

How often should you check for air leaks?

You should check for air leaks every month. Use soapy water on joints and listen for hissing sounds. Regular checks help you save energy and keep your compressor working well.

Why does your air compressor make loud noises?

Loud noises can mean loose bolts, worn parts, or blocked filters. Tighten bolts, replace damaged parts, and clean filters. If the noise stays, ask a technician to inspect your compressor.

Can you use your air compressor in a dusty area?

Risk	Solution
Dust buildup	Use intake filters
Overheating	Clean vents regularly

You should keep your compressor away from dust. If you must use it in a dusty place, clean it often and use filters.

What makes Sollant air compressors reliable?

Sollant uses high-quality parts and advanced designs. You get strong performance, energy savings, and fewer breakdowns. Sollant also offers support and custom solutions for your needs.

9 Common faults of air compressors

Key Takeaways