Compressors are essential tools in many industries, from manufacturing and construction to the food industry. However, they can sometimes malfunction, leading to production delays, revenue loss, and potential safety risks.
Below, we present the 10 most common compressor faults and their solutions:
1- Motor Overheating
Motor overheating can be caused by a variety of reasons, such as insufficient ventilation, low oil levels, or excessive use.
The solution is to regularly clean the motor components, ensure the oil level is adequate, and avoid overloading the compressor.
An additional cooling system can also be installed to prevent motor overheating.
2- Air Leaks
Air leaks are one of the main problems that can affect compressor efficiency. Leaks can be caused by loose fittings, faulty valves, or damaged pipes.
The solution is to perform regular visual inspections of the compressed air system to detect and repair leaks immediately.
3- Clogged Air Filter
A clogged air filter can reduce the intake airflow and decrease compressor efficiency.
The solution is to replace the air filter regularly and always keep it clean.
4- Worn Compressor Belts
Worn belts can cause damage to the motor and air (screw) bearings. This wear can be caused by incorrect tension, excessive use, or using belts that do not match the manufacturer’s specifications.
The solution is to perform maintenance at the indicated intervals, replace worn belts, and adjust the tension correctly.
5- Pressure Problems
Pressure problems can be caused by a variety of factors, including a faulty minimum pressure valve and/or a malfunction of the intake valve/system.
The solution is to regularly inspect the minimum pressure valve and/or the intake solenoid valve, as well as the intake valve. Perform preventive maintenance at the indicated intervals. If you detect any anomaly, call Jender’s technical service to provide you with the defective parts and replace them.
6- Lubrication Problems
Inadequate lubrication can damage the air (screw) end, which can sometimes be irreversible.
The solution is to ensure the oil level is adequate, replace it every 2,000 – 3,000 hours if it is mineral oil and/or every 8,000 hours if synthetic oil is used. It is also important to check the oil filter and replace it following maintenance intervals, as well as keeping the oil cooler clean.
7- Electrical Problems
Electrical problems can be caused by a variety of factors, such as loose wires not properly checked during startup, the use of inadequate circuit breakers, or incorrect power cable cross-sections.
The solution is to conduct recurrent inspections to prevent the deterioration of the various electrical components and ensure compressor performance.
8- Increased Operating Temperature
During summer, production stoppages due to high compressor operating temperatures are very common.
The solution is to keep both air and oil coolers clean and ensure a good hot air extraction system in the compressor room.
9- Condensation in the Oil Tank
Condensation problems often occur in the oil tank, causing oxidation in critical compressor parts. This happens because the compressor does not reach the proper operating regime.
The solution involves proper compressor sizing in the first place and correct adjustment of load and idle cycle times.
10- Starting Problems
Starting problems can be caused by a variety of factors such as the installation of protective differential switches with inadequate operating curves, cable cross-sections smaller than required, failure to check the electric motor’s direction of rotation, or failure to check the oil level.
The solution involves following the guidelines established by the manufacturer and the instructions of a service technician.
In conclusion, these are the 10 most common compressor faults and their solutions. It is important to perform regular compressor maintenance with Jender’s technical service to prevent these problems and ensure proper operation.
Furthermore, it is important to note that each compressor is unique and may require specific solutions depending on its design and use.
Therefore, it is important to follow the instructions that Jender, as a manufacturer, provides you and to call our technical service if you have any questions or concerns. Our experts will provide a solution to any fault your compressor may have.
