What Impacts Are Caused by Failures of Internal Components of Screw Air Compressors?
How to quickly diagnose the root causes of air compressor faults? Only with an in-depth understanding of the internal structure of the air compressor, as well as the functions of each component, can faults be identified promptly. Below lists the impacts caused by failures of various air compressor components to facilitate timely fault judgment and troubleshooting.
1. Impacts of Clogged Oil Filter
Increased airend discharge temperature
Shortened service life of lubricating oil
(1) Normally, the pressure difference of the oil filter is within 1 kg. Exceeding this value indicates clogging. Inspection method: Measure the oil temperature at the inlet and outlet of the oil cooler. An excessive temperature difference means the oil filter is blocked.
(2) Persistently high oil temperature accelerates oil deterioration (normal operating temperature range: 75–95°C).
2. Consequences of Clogged Oil Separator
Rising pressure inside the oil separator tank
Reduced outlet pressure
Increased motor current
Compressor shutdown triggered by protection
Safety valve venting with oil ejection
Excessive pressure ruptures the oil separator, leading to loss of cooling oil. Replace the oil separator element (normal pressure difference: within 0.8 kg).
3. Impacts of Blocked Fins on the Oil Cooler
Higher airend discharge temperature, resulting in shutdown.
Main motor overload shutdown caused by high temperature.
Fan motor overload shutdown due to excessive negative pressure. Remove the cooler for cleaning and maintenance.
4. Impacts of Poor Ventilation and Heat Dissipation in the Compressor Station
High airend discharge temperature leading to over-temperature shutdown.
Main motor overload.
Fan motor overload.
Elevated compressed air outlet temperature increases the load of the refrigerated dryer. It is recommended to install air guide ducts and exhaust systems for customers.
5. Consequences of Failed Minimum Pressure Check Valve (Unable to Close)
Pressure in the oil tank cannot build up after startup, so the compressor fails to load.
Higher oil content in outlet compressed air.
Backflow of pipeline air into the unit prevents pressure reduction in the oil tank during unloading, and causes oil ejection from the compressor after shutdown. Remove the minimum pressure check valve for maintenance; replace it with a new one if defective.
6. Consequences of Broken Drive Belt
The compressor cannot load after startup.
The pressure in the oil tank drops to 0 kg during operation, and compressed air supply stops. Investigate the root cause of belt breakage and install a new belt.
7. Consequences of Intake Valve Failing to Close
Pressure continues to rise after unloading, triggering safety valve venting.
Increased pressure in the oil tank during unloading.
Cooling oil flows backward and sprays out from the air inlet upon shutdown. Remove the intake valve for maintenance; replace it with a new one if defective.
8. Impacts of Poor Contact at Starter Terminals
Increased motor operating current leading to motor overload.
Starter overheating and malfunction.
Fuse burnout. Remove the starter for maintenance.
9. Impacts of Undervoltage, Overvoltage or Three-Phase Unbalance of External Power Supply
Undervoltage causes motor overload.
Overvoltage reduces motor winding resistance and leads to motor burnout.
Three-phase voltage unbalance results in motor overload.
1. Impacts of Clogged Oil Filter
Increased airend discharge temperature
Shortened service life of lubricating oil
(1) Normally, the pressure difference of the oil filter is within 1 kg. Exceeding this value indicates clogging. Inspection method: Measure the oil temperature at the inlet and outlet of the oil cooler. An excessive temperature difference means the oil filter is blocked.
(2) Persistently high oil temperature accelerates oil deterioration (normal operating temperature range: 75–95°C).
2. Consequences of Clogged Oil Separator
Rising pressure inside the oil separator tank
Reduced outlet pressure
Increased motor current
Compressor shutdown triggered by protection
Safety valve venting with oil ejection
Excessive pressure ruptures the oil separator, leading to loss of cooling oil. Replace the oil separator element (normal pressure difference: within 0.8 kg).
3. Impacts of Blocked Fins on the Oil Cooler
Higher airend discharge temperature, resulting in shutdown.
Main motor overload shutdown caused by high temperature.
Fan motor overload shutdown due to excessive negative pressure. Remove the cooler for cleaning and maintenance.
4. Impacts of Poor Ventilation and Heat Dissipation in the Compressor Station
High airend discharge temperature leading to over-temperature shutdown.
Main motor overload.
Fan motor overload.
Elevated compressed air outlet temperature increases the load of the refrigerated dryer. It is recommended to install air guide ducts and exhaust systems for customers.
5. Consequences of Failed Minimum Pressure Check Valve (Unable to Close)
Pressure in the oil tank cannot build up after startup, so the compressor fails to load.
Higher oil content in outlet compressed air.
Backflow of pipeline air into the unit prevents pressure reduction in the oil tank during unloading, and causes oil ejection from the compressor after shutdown. Remove the minimum pressure check valve for maintenance; replace it with a new one if defective.
6. Consequences of Broken Drive Belt
The compressor cannot load after startup.
The pressure in the oil tank drops to 0 kg during operation, and compressed air supply stops. Investigate the root cause of belt breakage and install a new belt.
7. Consequences of Intake Valve Failing to Close
Pressure continues to rise after unloading, triggering safety valve venting.
Increased pressure in the oil tank during unloading.
Cooling oil flows backward and sprays out from the air inlet upon shutdown. Remove the intake valve for maintenance; replace it with a new one if defective.
8. Impacts of Poor Contact at Starter Terminals
Increased motor operating current leading to motor overload.
Starter overheating and malfunction.
Fuse burnout. Remove the starter for maintenance.
9. Impacts of Undervoltage, Overvoltage or Three-Phase Unbalance of External Power Supply
Undervoltage causes motor overload.
Overvoltage reduces motor winding resistance and leads to motor burnout.
Three-phase voltage unbalance results in motor overload.
