Here are the most common causes,
categorized from simplest to most complex:
1. Cooling and Ventilation Issues (Most
Common)
- Poor Ventilation: The
compressor is installed in a confined, hot, or poorly ventilated room with
no fresh air circulation. It needs cool intake air to function correctly.
- Solution: Ensure the
compressor has ample space (at least 1 meter on all sides), especially
around the air intake and cooling fins. Move it to a cooler,
well-ventilated location.
- Clogged Cooling Fins/Ribs: The
radiator fins (often located around the cylinder) are blocked with dust,
dirt, oil, and debris. This acts like an insulator, preventing heat from
escaping.
- Solution: With the power
off, thoroughly clean the cooling fins using compressed air or a soft
brush. Ensure the air passage is completely clear.
- Faulty Cooling Fan: The fan
may be running slow, not running at all, or its blades may be damaged. In
belt-driven models, the belt could be loose or slipping.
- Solution: Check the fan
motor, power supply, and blades. For belt-driven models, tighten or
replace the belt.
2. Lubrication Problems (Critical)
- Low or High Oil Level:
- Low Oil: Insufficient oil
means there's not enough fluid to carry heat away from the piston and
cylinder, leading to rapid temperature rise and severe wear.
- High Oil: Excess oil causes
increased fluid friction (churning) and resistance, which also generates
excessive heat.
- Solution: Check the oil sight
glass when the compressor is off. The oil level must be between the
"Min" and "Max" marks. Always use the
manufacturer-recommended type and viscosity of compressor oil.
- Degraded or Incorrect Oil: Over
time, oil oxidizes, contaminates, and loses its lubricating and cooling
properties. Using the wrong type of oil (e.g., automotive motor oil) can
cause carbon buildup and poor performance.
- Solution: Change the oil
according to the manufacturer's service interval (e.g., every 500-800
hours). If the oil is dark, thick, or has a burnt smell, change it
immediately.
3. Air Intake and System Pressure Issues
- Clogged Air Filter: A dirty
air filter restricts intake air. The compressor has to work much harder
(higher load) to draw in air, generating more heat for the same amount of
output.
- Solution: Clean or replace
the air filter. In dusty environments, this needs to be done more
frequently.
- Faulty Valves (Inlet/Discharge): Worn,
broken, or leaking valve plates/springs reduce compression efficiency. Air
can be trapped and re-compressed within the cylinder, creating massive
amounts of excess heat.
- Symptoms: Longer cycle times
to reach pressure, increased electricity consumption, and high
temperatures.
- Solution: This requires a
professional technician to inspect and rebuild or replace the valve
assembly.
- High Operating Pressure: The
pressure switch might be set too high, forcing the compressor to operate
beyond its design limits.
- Solution: Check and adjust
the cut-out pressure to the compressor's specified rating.
4. Mechanical Wear
- Worn Piston Rings or Cylinder: Over
time, these components wear out, causing internal blow-by (air leaking
past the piston). This drastically reduces compression efficiency and
increases heat generation.
- Solution: This is a major
overhaul requiring disassembly and replacement of parts by a qualified
technician.
From Sino Beverage Machinery Co., Ltd China.
Email: sinobema@gmail.com
WhatsApp: 0086 137 2866 8423
www.sinobema.com
