Screw Air Compressor Failure And Solution

Screw air compressor with a simple structure, reliable and easy to operate a series of unique advantages, and thus since the date of birth by the industry's attention. But in the daily production of enterprises, often need to replace some of the air compressor fragile parts, if not handled properly, will directly affect the normal operation of air compressor and equipment safety. In the following, we will be the screw air compressor parts to be summarized, summed up the common parts of the defective appearance and processing methods.

1.Air filter

Air compressor filter (Air compressor filter) is composed of air filter and filter element, the external through the joints and threaded pipe connected to the air compressor inlet valve, so as to filter into the air of dust, particles and other impurities. Different air compressor models can be selected according to the size of the air intake to install the air filter.

Fault appearance: filter blocked

Plug the air filter will let the air compressor energy consumption loss, waste of electricity, easy to be dust through. Excessive dust into the air compressor inside, will affect the life of air compressor oil, but also cause oil and gas separator blockage.

Troubleshooting: 1, the filter is the core of the filter components, made of special materials, are vulnerable parts, the need for special maintenance, maintenance. 2, when the filter after a long period of time, one of the filter has been blocked a certain amount of impurities, will lead to increased pressure, flow reduction, this time on the need for timely cleaning. 3, when cleaning, be sure to not make the filter deformation or damage.

Equipment in the filter paper is one of the key, high-quality filter equipment in the filter paper is usually filled with synthetic resin superfine fiber paper, it can effectively filter impurities and strong sewage capacity. Equipment for the strength of the filter paper also has a great demand, due to the large flow of air, filter paper strength against live strong air to ensure the efficiency of filtration and extend the service life of equipment.

Filtration paper porosity of about 10um or so, usually every 1000 hours should be removed to remove the surface of the dust, the method is to use low-pressure air blowing from the inside out. The air filter is equipped with a differential pressure controller. If the air filter is blocked on the display panel, it means that the air filter must be cleaned or replaced.

2. oil filter

Oil filter is generally a paper filter, its function is to remove impurities in the oil such as metal particles, oil deterioration, etc., filtration accuracy between 5um-10um, the bearing and the rotor has a protective effect.

Fault appearance: oil filter failure

Troubleshooting: Whether to replace the oil filter can be judged by its differential pressure indicator, if the pressure indicator light, indicating that the oil filter block, must be replaced. The new machine after the first operation of 500 hours after the need to replace the oil and oil filter, and then in accordance with the pressure indicator light and replacement. If the oil filter pressure is large and no replacement, it may lead to insufficient fuel intake, while the exhaust temperature of the machine at the same time due to lack of oil will affect the bearing life.

The effective use of oil filter by the two factors: First, the number of impurities. When the oil filter to absorb impurities to reach the limit, the effective use of oil filter to the; Second, the machine temperature and filter paper resistance to carbonation. The machine is high temperature and room temperature, the oil filter life is not the same, high temperature models will greatly accelerate the carbonization of filter paper to shorten the effective use of filter paper time; In addition, the poor effective use of filter paper will be very short, under normal circumstances, good quality The effective filtration time of the oil filter is about 2000-2500 hours.

Frequency conversion screw machine long-term low-frequency use, usually lower temperature, oil tank barrels more water, the filter paper waterproof capacity is higher; frequency screw machine low frequency use, will lead to oil system pressure is low, oil filter must be small, Good sex.

Many people may think that the oil filter is by interception filter, the higher the accuracy, the better the filtration effect, while worrying about the filter is too high, easy to plug the filter. But there are studies that, in fact, this into a misunderstanding. Oil filter filtration accuracy and filter effect is some relationship, but the real decision to filter the effect, not the filter accuracy, but the oil filter paper adsorption capacity. The greater the dust capacity, the stronger the adsorption force, the better the filtration effect. Fiber filter paper filter effect is good, because the dust a lot of capacity, adsorption capacity is very strong, strong anti-carbonation. However, the price of fiber filter paper is very expensive, and the filter paper mill is not retail, need large quantities of special custom, if the oil filter is not particularly large sales, it is difficult to do custom fiber filter paper, which is very few people use fiber filter the reason.

3. oil core

Oil and gas separator filter with a multi-layer fine glass fiber, compressed air contained in the mist oil and oil through the oil fine separator can be almost completely filtered. Under normal operation, the oil fine separator can be used for about 3000 hours.

Oil-water separation filter is mainly for the oil - water separation design, it contains two kinds of filter, namely: filter and separation filter. Separation efficiency is poor, resulting in a lot of oil consumption and compressed air oil-bearing heavy, affecting the back-end purification equipment operation and gas equipment can not work; blockage increased resistance, resulting in the actual unit exhaust pressure increases, unit energy consumption increased ; Failure after the glass fiber filter separation material into the oil, resulting in shorten the life of the oil filter and the host of abnormal wear and tear; oil core broken, the oil ran away directly lead to oil loss, but also because of the small oil and high temperature caused serious May cause the head to hold.

Fault appearance: jam / damage / burn / separation effect is poor

Troubleshooting: Lubricant oil and the surrounding environment, the degree of pollution has a great impact on its life, if the environmental pollution is very serious, consider the installation of pre-installed air filter.

1. Blocking: oil core blockage will cause air compressor motor current is too large. There may be too high pressure makes the oil core deformation, ranging from serious motor overload will make the host locked. In addition, the current is too large to shorten the contactor life or contact burn caused a major accident. General screw air compressor opportunity before the filter before the pressure gauge, when the filter before the pressure gauge and the pressure difference between the supply pressure gauge to 0.08MPa when the oil core to be replaced.

2. Damage. When the oil core broken damage will be found in the air compressor fuel consumption is very serious, but also in the gas tank and pipeline will have a lot of oil. Serious discharge of air compressor oil directly when the tank is discharged.

The main cause of this failure is:

(1) not on time to replace the oil core;

(2) the use of poor quality of the oil core;

(3) the installation process is not in accordance with the procedures, such as the installation of oil return pipe when the oil core broken and so on.

3. burn. Oil core burned in the air compressor operation is not common but also occasional. Mainly for the oil core filter part or all of the carbonization, and even oil core metal shell are burned.

The main cause of such failure is:

(1) air compressor oil quality is poor;

(2) the oil core itself is too poor;

(3) When installing the oil core, there is no reliable connection between the oil core shell and the oil tank. It can cause the oil mist to be ignited when there is static electricity to burn the oil core.

4. The separation effect is poor. Mainly for the compressed air oil content is too large, the post-processing equipment and user equipment damage.

The main reason for this failure is:

(1) the oil core itself is poor quality;

(2) the installation did not follow the procedures.

4. lubricants

The role of air compressor oil is in the friction between the two critical points to form a protective film to avoid contact between the screw, thus buffering the friction effect, play a role in lubrication, reduce wear and tear; in addition to cooling, noise reduction, Sealed, rust and other effects.

Fault appearance: Lubricant failure

Troubleshooting: Indeed, whether the new air compressor is running 500 hours to replace the oil or after every 4000 hours to replace once, which are in the standard environment, and in the practical use of screw-type air compressor , A lot of factors will affect the performance of lubricants, but also because of this, so we need to determine the replacement environment according to the specific use of the environment.

So what factors will affect the screw-type air compressor lubricating oil replacement cycle? At present we are more agree with the main points are:

1. Lubricant quality: the quality of lubricants directly determine the cycle of its use. As long as the regular manufacturers produced by the quality of qualified qualified lubricants, can be in the standard environment 4000 hours to replace once, and poor quality of the oil replacement cycle is very short;

2. Air humidity: the greater the humidity in the air, it means that the air into the air compressor inside the more water, and moisture and lubricants mixed together will lead to deterioration of lubricating oil, which will affect its service life;

3. Impurities: including impurities with the air into the air compressor and the internal friction caused by impurities and so on. Impurities will pollute the oil, resulting in its failure;

4. Acid and alkaline gas: Some air compressor use of the environment there will be a lot of acid and alkali gas, the type of gas will also affect the performance of lubricating oil, resulting in shorten its service life.

5.belt

Belt with good flexibility, in the work to ease the impact and vibration, smooth and no noise. When the load is too large, the belt slips on the wheel, which can prevent damage to other parts, from the safety protection.

Fault appearance: belt elasticity

Troubleshooting: After the air compressor is closed, wait for the temperature in the body to cool and without pressure, check the current state of the drive belt. From the screw air compressor structure of the particularity, as to how to replace and adjust, but also according to its tight state. If there is no serious problems such as deformation, only need to bolt the appropriate optional, and then to meet the requirements of the situation can be. However, when the damage has been made to repair, you must replace the new pieces.

The note is that the tension around the belt must be consistent, and prepared to prevent slipping. After the installation, try running for thirty hours or so to observe the changes. In fact, this is the most critical of the strength, master this degree, you can avoid the accident and so on.

Screw-type air compressor drive belt replacement and adjustment If you can do well, but also beneficial to the motor and other accessories work, virtually reduced the load. After completing all the steps, do the head fixed. Orderly progress, the implementation must be rigorous, can not be wrong, many times the occurrence of damage due to operational errors caused. Keep enough vigilance, be well prepared, and make timely adjustments to each data.

6.solenoid valve

Fault appearance: no action

Troubleshooting: screw air compressor on the solenoid valve failure will directly affect the switching valve and control valve action, the common solenoid valve does not move, should be investigated from the following aspects:

1, screw-type air compressor solenoid valve terminal loose or thread drop, solenoid valve can not be electric, can be tightened thread to solve the problem.

2, screw air compressor solenoid valve coil burned. Solenoid valve coil burned, can remove the solenoid valve wiring, with a multimeter to measure, if open, then the solenoid valve coil burned. The reason there is a coil damp, resulting in poor insulation and magnetic flux leakage, the formation of the coil current is too large and burned, so to avoid rain into the solenoid valve. In addition, the torsion spring is too strong, the reaction force is too large, the coil turns too little, suction can not make the coil burned. In case of emergency disposal, the manual button on the coil can be hit by the "0" bit in normal operation to the "1" position, causing the valve to open.

3, screw-type air compressor solenoid valve stuck. Solenoid valve slide valve sleeve and spool cooperation gap is very small (less than 0.008m), usually a single piece of installation, when there are mechanical impurities into or less oil, it is easy to stuck. Disposal method: available wire from the head hole into the hole, so that bounce back. A thorough solution is to remove the solenoid valve, remove the spool and spool sleeve, with CCI4 clean, making the spool in the valve sleeve action sensitive. When disassembling, please pay attention to the installation order of each part and the external wiring direction, so as to re-install and wiring the correct, but also to see the oil mist spray hole is not blocked, the oil is not satisfied.

4, screw air compressor solenoid valve leakage. Leakage will form a lack of air pressure, making the valve opening and closing difficult, the reason is the damage to the gasket or slip valve wear and form a few cavity channeling gas.

Check the solenoid valve failure should wait for the solenoid valve in the event of power loss, direct replacement of the solenoid valve to burn the coil, or repair the valve body leakage.