1. The air output temperature is too high
(1) Reduce the air input temperature. Increase the ventilation of the air compressor room, add an exhaust hood on the roof of the air compressor room to remove heat, and control the indoor temperature not to be too high, especially in the hot summer, the temperature of the air compressor room should not exceed 40℃.
(2) Reduce the input temperature of the cooling water. The water temperature is kept at 18℃ in winter and 24℃ in summer.
(3) Increase the flow of cooling water. According to calculations, the difference between the cooling water input temperature and the output temperature is 15℃, and the cooling water flow is 3.7 liters/second.
(4) Clean the scale or dirty sediment in the cooling water. Add a detergent to the cooling water to dredge the cooling water system.
2. The oil temperature is too high
The air compressor has an oil temperature protection setting. It shuts down when the oil temperature exceeds 70℃, causing the air compressor to shut down frequently. The reason for the high oil temperature is the failure of the oil cooler.
Since the cooling water pipeline in the oil cooler is relatively thin, it is not easy to clean after scaling, which causes the oil temperature to not drop. It costs $2,800 to replace an oil cooler. After research and exploration, the following method to clean the cooler is more effective. After removing the oil cooler, soak it in a detergent for one day, and then use a small water pump to pump pressurized water into the oil cooler for repeated flushing to remove the scale. Using this method, our factory's air compressor has not replaced the oil cooler, and the oil temperature in summer can also be controlled below 60°C.
[Equipment maintenance]
3. Frequent failure of air filters
When the air compressor was first used, the air filter failed after only one month of use. After analysis, the surrounding air environment was dirty. For this reason, a mesh cover (pre-filter) was added above the air filter of the air compressor to extend the service life of the filter.
4. The air compressor frequently burns the motor. During the use of the air compressor, the 25OkW main motor frequently burned out for a period of time. The main reason is that the main motor is overloaded for a long time, which causes the motor to overheat and burn out.
To this end, the pipeline of the automatic winding machine was removed and an 8.0MPa domestic air compressor was used to supply air, which solved the problem of frequent motor burnout.
Conclusion
(1) In summer, the ambient temperature of the air compressor room must be below 40℃ before it can be started normally. When installing the air compressor, pay attention to the distance between the machines being greater than 2.5 meters to facilitate heat dissipation and ventilation of the air compressor room.
(2) The air compressor has two reference data: the maximum working pressure and the general working pressure. When selecting an air compressor, the general working pressure should be used as the reference data to select the air compressor. If the air compressor is selected based on the maximum working pressure, it is easy to cause the air compressor to overload for a long time and burn the motor.
(3) Water-cooled air compressors have high requirements for water quality. Common faults are related to scaling of the cooling system caused by poor water quality. Therefore, when installing an air compressor, a water softening treatment device must be installed to greatly reduce air compressor failures.