Screw Air Compressor Failure Repair Method

A screw air compressor is a highly efficient device that uses an electric motor to compress air in a specialized compression chamber, resulting in pressurized air for various applications. Proper maintenance and swift troubleshooting are critical for ensuring optimal performance and longevity. This guide outlines common issues and their resolutions to help operators maintain seamless operations.

Key Features of Screw Air Compressors

• Efficient Compression: Utilizes twin rotary screws for effective air compression.
• High Reliability: Designed for continuous operation with minimal wear.
• Wide Applications: Suitable for industrial, automotive, and manufacturing sectors.

Common Screw Air Compressor Failures and Solutions

1. Pressure Reaches Upper Limit Immediately at Startup

Symptom:
Upon starting, the pressure gauge instantly shows the maximum limit, but the compressed air fails to discharge.

Cause:
A stuck pressure-maintaining valve, often due to freezing in low temperatures.

Solution:

• Inspect the pressure-maintaining valve for obstructions or frost.
• Clean or replace the valve as necessary.
• If freezing is the issue, consider installing a heating system or insulating the valve.

2. Time Relay Damage

Symptom:
The pressure reaches 0.8 MPa, the full-load indicator lights up, but the pressure begins to fall back. Meanwhile, the motor runs, and the exhaust solenoid valve activates. When pressure drops to 0.5 MPa, the compressor restarts.

Cause:
A faulty time relay causing inconsistent control of the compressor’s cycles.

Solution:

• Inspect the time relay for signs of wear or damage.
• Replace the relay if it fails to regulate the load-unload cycle properly.
• Regularly test the relay to ensure it operates within specified parameters.

3. Over-Temperature Alarm and Shutdown

Symptom:
The compressor triggers an over-temperature alarm and stops running. Upon restart, it operates briefly, but the temperature quickly exceeds 100°C, causing another alarm.

Cause:
Insufficient cooling, clogged cooling components, or low-quality lubrication oil.

Solution:

• Check and clean the cooling system, including the cooler and fan.
• Ensure proper levels and quality of lubricating oil.
• Replace the temperature sensor if resistance values deviate from standards.
• Inspect the ambient temperature to ensure it aligns with the compressor’s operational range.

4. High Exhaust Temperature

Symptom:
The compressor trips during operation, with the exhaust high-temperature indicator illuminated.

Cause:

• Malfunctioning temperature sensor.
• Poor airflow or heat dissipation.

Solution:

• Test the temperature sensor’s resistance and replace it if readings are inconsistent.
• Ensure unobstructed airflow and clean the cooler regularly.
• Verify the lubricating oil quality and replace it as per manufacturer recommendations.

5. Normal Rotation but No Pressure

Symptom:
The compressor motor runs, but no pressure builds up.

Cause:

• Pipeline leaks.
• Intake system issues, such as:
  • Clogged air filter element.
  • Faulty intake valve operation.

Solution:

• Inspect pipelines for leaks and repair them promptly.
• Replace the air filter element if dirty or clogged.
• Test the intake valve’s functionality and ensure the solenoid valve is working correctly. Replace if needed.

Maintenance Tips for Screw Air Compressors

1. Regular Inspections: Schedule periodic checks to identify potential issues early.
2. Lubrication Management: Use high-quality lubricants and replace them at recommended intervals.
3. Clean Components: Prevent clogging by cleaning the air filter, cooler, and other critical components.
4. Monitor Sensors and Gauges: Ensure accurate readings to avoid operational failures.
5. Environmental Control: Maintain appropriate ambient conditions to support efficient operation.

4 Reasons for Changes in the Exhaust Volume of Screw Compressors

Analysis of the reasons for insufficient exhaust volume of air compressors