The failure of the air compressor does not appear suddenly. It is generally caused by various small problems. Many large failures have certain omens before they occur. Today, I will talk to you about what factors may be caused by the high exhaust temperature. .
The exhaust temperature of the air compressor is too high, which is mainly reflected in these two aspects: the exhaust temperature of the air compressor is too high; the running part is hot.
Specifically, the symptoms and causes of the failure are as follows:
1. Failure of the oil shut-off valve The function of the oil shut-off valve is to ensure that the oil supply to the working chamber of the main engine is stopped when the machine is shut down, so as to prevent the lubricating oil from being ejected from the air inlet. When the oil shut-off valve cannot be opened, because there is no lubricating oil to lubricate and cool the machine head and compressed air, the temperature of the compressor rises rapidly after starting, and it will automatically stop in about 1 minute. Disassemble the temperature plug at the exhaust end of the compressor main engine, you will find that the plug is dry and oil-free, and there will be blue smoke floating out of the air. At this time, it is necessary to open the inspection hole at the bottom of the air compressor, remove the oil shut-off valve, and gently move the valve stem with your fingers to see if it can be pushed back and forth and whether it can be easily reset. If it is difficult to switch or return, it is necessary to further disassemble the fuel cut-off valve. If the valve stem and valve bore are dirty, sand them until they slide easily. If the spring is disassembled or a foreign object is stuck, it will also affect the movement of the valve stem. At this time, the spring should be replaced or the spring and the spring seat should be cleaned.
2. The fan belt of the air-cooled compressor is broken and loose. When the belt is broken, the air compressor will automatically stop due to excessive temperature after running for a period of time. If the belt is too loose, it will slip and the fan speed will be too low, which will also affect the cooling effect. At this time, the tightness of the fan belt should be replaced or adjusted. At this point, it should be noted that the replacement of the belt should be a complete replacement, not a mixture of the old and the new.
3. Reasons for cooling water in water-cooled compressors The most common causes of such failures are insufficient cooling water, too low pressure, and too low flow rate. In some enterprises, because the compressor and other production equipment share circulating cooling water, the cooling water quality is poor, and the impurities and calcification are too much, which will form scale around the cooling water pipe and affect the cooling effect.
4. The cooling oil level is too low. The refueling amount of the compressor can be observed in the display window. It is normal if the center red dot is submerged in the middle of the oil sight glass, or if there is a cursor in the green area. It should be noted that the oil level will be different when the equipment is stationary and running.
5. The radiator is blocked. When the surrounding environment of the air compressor is not good, long-term operation will cause the radiator fins to adhere to a layer of dust, oil stains or a mixture of wool debris and metal particles, and the internal copper pipes are also prone to accumulation of grease. blockage, thereby affecting the cooling effect.
6. Failure of oil and gas separator filter element Oil and gas separator, as the name suggests, is a device used to separate gas and oil in compressed air. In the process of using the oil and gas separator filter element, the separation layer can hold a certain amount of dust. When the air compressor continuously inhales air, many dust particles smaller than 5um enter the fine separation layer of the oil and gas separator filter element, which not only makes the air The processing flow of the fine separation layer will continue to decrease, and the pressure difference of the oil and gas separator filter element will continue to increase. When the oil and gas separator filter element reaches a pressure difference of 1 bar in normal use, it is necessary to purge or replace the oil and gas separator filter element. Improper use of lubricating oil will also cause the pressure difference of the oil-air separator filter element to increase.
7. The oil filter is too dirty When it is too dirty, the oil cannot enter the compressor according to the normal flow, and the compressor heats up rapidly due to insufficient lubrication. When the oil difference between inlet and outlet exceeds the set value, the filter element needs to be replaced.
8. Poor ventilation and heat dissipation of the environment There are three main situations in which the surrounding environment of the air compressor affects heat dissipation: too close to wall obstacles, so that the hot air cannot be dissipated; there are other heat sources near the air compressor,
Make the suction temperature of the compressor too high; the front door and side door of the air compressor are open during operation, and the fan cannot form a strong airflow; many users will fall into a misunderstanding when the equipment is running and the exhaust temperature is high: thinking that opening the compressor cover can Speed up ventilation and heat dissipation. In fact, this is an incorrect approach.
When the compressor manufacturer designs the shape and casing of the compressor, it is not only for aesthetics and noise reduction, but also to make the circulating air form a reasonable flow and help the equipment to dissipate heat. If the casing is removed rashly, it will adversely affect the heat dissipation of the compressor.
The overheating of the compressor can sometimes be directly reflected through the instrument panel and warning lights, but sometimes it needs to be checked by temperature inspection.
Causes of air compressor overheating
Identifying the core problem that is causing the compressor to overheat may not be an easy task. That being said, four common causes of overheating are:
1. Lack of Maintenance If your compressor is not regularly maintained, broken or dirty filters, clogged pipes and clogged internal components can all lead to overheating.
Second, the "age" of the compressor Older compressors or compressors that have been subjected to extreme use are more likely to overheat.
3. Insufficient ventilation The compressor system must be able to cool itself, so if the compressor room is not properly ventilated, it may cause overheating.
Fourth, the temperature is too high The high temperature in summer makes the surrounding environmental conditions more and more hot, hot, hot! The warmer it is outside, the warmer your compressor room will be. If the compressor room is too hot, so is your air compressor! Is my air compressor overheating? When your compressor starts to behave abnormally, it is wise to start investigating the problem early; completing necessary maintenance or repairs and quickly identifying the problem will prevent unnecessary downtime or future lost production. But how do you tell an overheating problem?
Some common signs of compressor overheating include:
1. Compressor won't start If your compressor stalls during startup - or, yes, won't cut off at all - overheating may be the root cause. Other relevant signs are that the compressor requires longer rest periods between cycles and the compressor is much slower at peak operation.
2. The compressor is messing up. Hear squeaks and crackles from the compressor - or smell burnt oil? This may indicate that the internal components of the compressor are not sufficiently lubricated. Since the lubricant is used as a coolant, there is little chance of lubricant = overheating. How can I prevent my air compressor from overheating? Prevention is the key! Instead of focusing on ways to cool an overheated compressor, work on preventing overheating from happening!
Three key ways to achieve this are:
A Improve internal and external ventilation Check the compressor vents to make sure they are not only clean but also sized to suit the machine's requirements. You should also make sure the compressor room is well ventilated - if not, consider relocating the compressor to a more suitable space. NOTE: These checks should be performed regularly!
B Checking the Oil and Lubrication Levels As mentioned above, the lubricant acts as a coolant, so the oil and lubricant levels in the compressor are frequently monitored. Also, if the oil is thin or appears watery, the heat may already be too high.
C Routine Maintenance To prevent overheating, the easiest operation is to perform routine maintenance on the compressor!