The continuous operation of the air compressor does not stop, which may be caused by the following reasons, which need to be investigated and handled one by one:
1. core reason analysis
pressure control system fault
- pressure switch failure: The pressure switch is responsible for monitoring the pressure of the gas tank, and the power supply should be cut off after reaching the set value. If the switch contacts are oxidized, the contact resistance exceeds the standard or the calibration error is too large, the circuit cannot be normally disconnected.
- Relay fault: The relay is used as an actuator. If the coil is burned or the contact is bonded, the shutdown signal cannot be transmitted.
Gas path system abnormality
- pipeline leakage: If there are sand holes, loose joints or valve sealing failure in the pipeline from the gas storage tank to the gas end, the pressure will not accumulate and the compressor will continue to supplement gas.
- Gas consumption exceeds standard: The expansion of production equipment or the new gas point does not match the compressor capacity, resulting in the pressure of the gas storage tank is always lower than the set value.
Wear of power and transmission components
- intake valve failure: If the diaphragm of the intake valve controlled by the stepping motor is damaged or the valve core is stuck, it will not be able to completely close and continue to take air.
- Drop in nose efficiency: Excessive clearance of the screw head rotor or wear of the piston ring causes the compression efficiency to decrease and it takes longer to reach the pressure.
Control system logic is abnormal
- sensor false alarm: The pressure sensor circuit is disturbed or aged, causing the displayed pressure to be lower than the actual value, triggering continuous loading.
- Program Error: If some intelligent controllers have conflicting parameter settings, they may be misjudged as requiring continuous operation.
2. diagnosis and resolution steps
basic investigation
- pressure contrast measure the pressure of the gas tank with a pressure gauge and compare it with the displayed value of the controller to confirm whether there is a sensor error.
- Leak Detection: After the compressor is shut down, close all air valves and observe whether the pressure gauge drops rapidly, which indicates leakage.
Component Level Inspection
- pressure switch test: Remove the pressure switch, check the on-off state of the contact with a multimeter, and check whether the shutdown pressure value is accurate.
- Relay detection: Check the resistance of the relay coil, observe whether the contact has ablation marks, and replace it if necessary.
- Intake valve disintegration: Check whether the stepping motor is stuck, whether the diaphragm is damaged, and whether there are scratches on the sealing surface of the valve core.
System level adjustment
- parameter Reset: Initialize the intelligent controller, reset the loading/unloading pressure value, and confirm that the unit (MPa/Bar) is correct.
- Energy consumption monitoring install the electric energy meter to monitor the operating current of the compressor. If it runs at full load for a long time, it is necessary to evaluate whether it needs to increase the capacity.
3. Preventive Maintenance Recommendations
- periodic check clean the air filter element every 500 hours, and replace the oil filter and lubricating oil every 2000 hours to reduce the risk of head wear.
- intelligent early warning: Install a controller with a pressure curve recording function to monitor pressure fluctuations in real time, and find leaks or efficiency drops in advance.
- Redundant design: For key gas equipment, it is recommended to configure spare compressors or gas storage tanks to avoid production interruption caused by single point failure.
Through the above steps, the system can locate and solve the problem of continuous operation of the air compressor, and ensure the efficient and stable operation of the equipment.
