When air compressors have performance problems, the pro […]
When air compressors have performance problems, the problem can often be traced back to heating problems. In fact, overheating of the air compressor is one of the most common causes of failure, even though the compressor may last for many years. So what causes the compressor to overheat? Lin Sheng analyzes the reasons and preventive measures from several aspects:
Overheated air compressors are the result of internal factors, external conditions or sometimes both. At some point in the system cycle, the air heats up due to the process involved, although it cools rapidly before reaching the end point. However, if the air gets too hot to handle the compressor, the machine does have problems.
For example, in a reciprocating air compressor, the air temperature will drop from 50 degrees Fahrenheit to 75 degrees Fahrenheit in an approximately 6 inch stroke between the discharge port and the discharge line. If the temperature of the discharge port exceeds 300 degrees Fahrenheit, the refrigeration oil and adjacent mechanisms will be damaged.
For the health of the air compressor, the temperature of the discharge line should not exceed 225 degrees Fahrenheit. Anything hotter on the drain line will make the drain dangerously above 300 degrees Fahrenheit. If the temperature of the discharge outlet exceeds 350 degrees Fahrenheit, heat may cause an impending system failure.
So how to prevent the air compressor from overheating? Read the next sections of the Overheating Compressor Troubleshooting Tips to learn how to cool an overheated compressor.
Causes of overheating of the air compressor
When the air compressor overheats, the problem is usually related to factors involving irregular suction or discharge pressure. Or, the problem may stem from inadequate ventilation, corroded oil or any problems associated with wear of machine parts.
Low suction pressure
One of the main problems that can cause overheating of the air compressor is the high compression ratio, which is usually caused by low suction pressure. Problems that cause low suction include:
Improper installation of components
Metering device failure
For example, if a metering device fails, your ability to accurately monitor your system will be affected. In order to maintain a high value of inspiratory pressure, it is important to check the signs of these problems regularly.
Excessive discharge pressure
Air compressor overheating problems are often the result of excessive discharge pressure, which usually stems from one or more of the following problems:
Dirty condensing coil
Unsuitable discharge line
Condenser air blockage
Condenser fan inconsist
In order to control the discharge pressure level, the condensate part should be checked regularly for problems. Even on large systems with built-in discharge monitoring, the problem was not discovered until the problem spread to other parts of the air compressor.
Insufficient cooler space
If the air compressor is in a warm area, it may be more difficult for the machine to adjust the incoming air to the desired level of cooling. For example, if the machine is in a poorly ventilated room, the heat in that room will affect the internal process and result in higher air temperatures and lower efficiency at the end of various pneumatic operations. The surrounding heat can also cause internal moisture and condensate to build up, which can have a negative impact on other important compressor functions.
Insufficient space for proper discharge of the compressor
Another problem that is closely related to the temperature around the air compressor is the amount of ventilation available. Is the machine adequately ventilated or is the vent blocked or narrow? If the machine is placed such that the vents face the wall directly, the air compressor should be turned or the air compressor may be moved to another area. By expanding, if the air compressor lacks sufficient ventilation space, the sweltering and warming of the internal air may cause the machine to lose the desired coolness.
Old or blocked parts
As the components of the air compressor wear out over the life of the machine, the entire machine is forced to work harder to perform its basic functions. For example, if the internal process is blocked in an important area, the air compressor must apply more energy to draw air from the compression chamber and send it to the hose that is connected to the various pneumatic tools. To ensure that internal components continue to operate effectively without generating excessive heat in the process, periodically evaluate internal performance.
Of course, the amount of wear experienced by an air compressor is also susceptible to its ability to operate continuously at the desired temperature. If the compressor is old and used every day, the heating problem may be an inevitable factor in your continued operation of the machine and its various peripheral components.
What is the temperature at your business location? With the increase in temperatures in various regions, conditions suitable for air compressors 20 years ago may now require some adjustment. If climate change trends make your local summer months hotter, it may take time to increase air conditioning in the compressed air system workspace.
A problem closely related to blocked passages in compressed air systems is the problem of reduced oil quality. More specifically, as the oil ages and hardens, the internal components are forced to move without adequate lubrication. The surfaces of the metal parts are ground to each other and the parts are strained because the machine is forced to work extra hard to perform only on its previous level.
Old hardened oil is the chief culprit in the cause of systemic fever. As parts wear, it is often necessary to change the oil more frequently. If the air compressor emits a burning smell of oil, it means that the oil has hardened, and so is the cooling capacity of the compressor. Alternatively, heat can cause the oil to lose its viscosity and cause this further problem.
A failed thermal valve can cause heating problems with the air compressor. If you need to replace the valve already on the machine at any time, it is best to install a replacement hot valve. In this way, you can avoid downtime that can occur in the event of a hot valve failure, and you must wait a few days or weeks to reach the new valve. In addition, new valves can be used for comparison to see if the pre-existing valve is in sufficient operating condition. If not, you may have found the root cause of the heating problem.
Type of air compressor
Some types of air compressors are suitable for more difficult tasks than other types. If you use a small air compressor to run heavy-duty pneumatic machines around the clock, you may experience performance problems that can cause overheating. Similarly, if the compressor has been more than 20 years old, it may just need to be replaced. Consider the size and capacity of the compressed air system based on the needs at hand.
Signs of overheating of your air compressor
If your air compressor behaves abnormally, there is no doubt that the possibility of problems is largely due to heating problems.
The compressor cannot start
If the compressor does not start properly, there is definitely a problem with the machine, which may be due to heating problems. If the compressor requires a longer duration between cycles of use, the internal components may take longer to cool between each cycle. Also, if the machine stalls during startup and eventually takes longer to enter full operation mode, this may be due to the internal mechanism of thermal degradation.
Circuit breaker trip
In an air compressor, the current is regulated by a circuit breaker, and the circuit breaker stops flowing when necessary, as a measure of machine performance and quality. If the circuit breaker acts irregularly and trips at a seemingly random moment, this is an indication that there is a greater problem inside the air compressor.
Air compressors may emit noise or odor, indicating oil erosion. If you can hear the unusually low hum of the machine, it may be a problem of insufficient lubrication of the internal parts. A clearer indicator of oil problems is when the air compressor smells tar. Either way, you should check the problem immediately, because insufficient lubrication and poor oil quality can have a domino effect on the internal mechanism of the air compressor.
When the air compressor begins to accelerate and decelerate, more serious problems may occur. For example, if a machine has performance problems a few weeks after the last repair, some conditions may not be properly evaluated, whether it is oil, vents, refrigerant, or condenser parts. If the air compressor is long before its time and it is no longer sufficient to meet the basic requirements, problems associated with overheating are prone to occur.
Tips for preventing overheating of the air compressor
People often ask how to cool a superheated compressor. However, the better question is how to prevent overheating first.
1. Focus on improving ventilation
The first step in reversing the heat problem of air compressors should be to focus on ventilation inside and around. Inspect each vent to ensure they are adequate for the machine. If not, you will need to change the vents. Ask maintenance personnel about the size of the system and the proper ventilation size for the operation at hand.
Also, consider the external factors of the machine itself. If the machine is in an area that is overheated or under-ventilated, arrange the machine space in a more suitable area. Make sure this new location allows enough ventilation space for each vent.
2. Regularly monitor the oil level and filter of the compressor
As with any mobile machine or vehicle, it is important to ensure that the oil in the air compressor is healthy. Check the oil level regularly to make sure there is enough oil to meet your operational requirements. Also, check the viscosity to make sure the oil does not become too thin or water - this will be an indication of overheating in the system. In addition, the filter is checked during each oil inspection.
3. Monitor ventilation and piping
Even if you have modified the layout of your workspace to better ventilate the air compressor and ambient temperature, check the ventilation and piping regularly. If dirt or dust accumulates along the vents, clean them accordingly. Make sure the pipe is flowing properly and will not curl or puncture anywhere in the system.
Even in all practical situations, you have not found a reason to relocate the machine, and if they don't get the attention they deserve, there may still be problems with the vents. Regardless of where the machine is placed, an air compressor that cannot be properly vented is prone to heating problems.
4. Keep air compressor components up to date
Due to changes in demand, your purchase of a year's air compressor may not be sufficient to meet your operational needs in its initial state. If your operation requires increased aerodynamics since the machine was first purchased, consider using a more optimized component to update the air compressor.
In general, as compressor demand increases, the performance of air compressors will steadily decline. This is due to an increase in demand without regard to the pre-existing capacity of the machine. The same is true for heating problems when strain is installed along various points of the compressed air system. To prevent this from happening on your compressor, have the service specialist evaluate the machine and its peripherals and seek advice on the type of upgrade that may allow the system to reach the full capacity of the current workload.
What if you think your air compressor needs repair?
When you become aware that your air compressor is overheating, contact your service professional immediately. The longer the wait, the farther the problem travels throughout the system and the more serious the consequences.
5. Looking for a trusted service provider
To get the best performance from an air compressor, you must have a trusted service provider. When a problem occurs, the licensing service specialist can evaluate your machine and identify internal or external errors.
If there is a problem with the internal components, the service staff will tell you if the problem is that there is insufficient oil or one or more parts are damaged. In addition, the expert will check the system layout to determine if the settings or connections need to be changed. With regular inspections by air compressor service specialists, you can ensure that your system delivers reliable performance year after year.
6. Consider the benefits of component replacement
If the current demand for your operation is more intense than when you buy an air compressor, then the machine and its accessories are no doubt working harder than ever. With this increased wear, all parts of the system are stressed. If you replace some old, older parts to get newer, better parts, your air compressor can work easier and easier.
For example, consider new valves, filters, hoses and fans. With these new parts, your compressed air system can easily inhale, compress and deliver cleaner, cooler air to a variety of end tools. When you talk to a service specialist, ask which replacement parts are best for your system.
7. Should you or might try to fix yourself?
When you are doing large operations in a factory, workshop or stamping plant, many details require your attention. Because of the need to monitor so many things in daily work, it is difficult to notice the details of the air compressor and its various functions. As a result, the system may begin to lag at the expense of productivity.
Since you own a machine, you may want to handle maintenance yourself. However, air compressors are complex machines that rely on many precise settings, without these settings, are inefficient and burdensome internal components. Even if you follow the instruction manual, your adjustments may be slightly less favorable to the cost of the operation.
To prevent these problems, you should have a licensed service specialist check your air compressor and perform any necessary maintenance on a regular basis. Licensed service personnel will have years of experience in inspecting and repairing all brands and models of air compressors. When you hire air compressor repairers to do what they do best, you can focus on your own operations because you know your machine is in good shape.