Major wearing parts of screw air compressor: air filter, oil filter, oil separation core, lubricating oil, belt, solenoid valve
Failure appearance: filter clogged
A clogged air filter will cause the air compressor to lose energy, waste electricity, and is easily penetrated by dust. Excessive dust entering the inside of the air compressor will affect the life of the air compressor oil and cause the oil and gas separator to block.
The filter element is the core component of the filter. It is made of special materials and is a vulnerable part that requires special maintenance.
After the filter has been working for a long time, the filter element in it has already intercepted certain impurities, which will cause the pressure to increase and the flow to decrease, and it needs to be cleaned in time.
When cleaning, be careful not to deform or damage the filter element. The filter paper in the equipment is also one of the key points. The filter paper in high-quality filter equipment usually uses superfine fiber paper filled with synthetic resin, which can effectively filter impurities and has a strong dirt storage capacity. The equipment also has great requirements for the strength of the filter paper. Due to the large air flow, the strength of the filter paper can resist the strong airflow, ensuring the efficiency of filtration and prolonging the service life of the equipment. The pore size of the filter paper is about 10um. Usually, it should be removed every 1000 hours to remove the dust on the surface. The cleaning method is to use low pressure air to blow the dust from the inside to the outside. The air filter is equipped with a pressure difference controller. If the air filter is clogged on the display panel, it means that the air filter must be cleaned or replaced
2.Oil separation core
Failure appearance: blockage/breakage/burnt out/poor separation effect
Troubleshooting: The pollution degree of the lubricating oil and the surrounding environment has a great influence on its life. If the environmental pollution is very serious, consider installing a pre-air filter.
Blockage: Blockage of the oil separation core will cause excessive current in the air compressor motor. It is also possible that the oil separation core may be deformed due to excessive pressure, or even if the motor is overloaded, the main engine will lock up. In addition, excessive current will shorten the life of the contactor or burn out the contact and cause a major accident. Generally, the screw air compressor has a pressure gauge before the filter element. When the pressure difference between the pressure gauge before the filter element and the air supply pressure gauge reaches 0.08MPa, the oil separation element is replaced.
Damaged. When the oil separation core is damaged, it will be found that the air compressor consumes a lot of oil, and there will be a large amount of oil in the air storage tank and pipeline. In severe cases, the air compressor oil will be discharged directly when the blowdown valve of the air storage tank is discharged. The main reasons for this failure are:
(1)The oil separation core was not replaced on time;
(2)The oil separation core of poor quality is selected;
(3)Failure to follow the procedures during installation, such as inserting the oil separator core when installing the oil return pipe.
burn. The burning of the oil separation core is not common but occasionally occurs during the operation of the air compressor. The main manifestation is that the filter screen of the oil separation core is partially or completely carbonized, and even the metal shell of the oil separation core is burned. Such failures are mainly:
(1)The quality of air compressor oil is poor;
(2)The quality of the oil separation core is too poor;
(3)When installing the oil separator core, there is no reliable connection between the oil separator core shell and the oil separator barrel and cannot be grounded. When there is static electricity, the oil mist will be ignited and the oil separator core will be burned.
The separation effect is poor. The main manifestation is that the compressed air contains too much oil, causing damage to the post-processing equipment and user equipment. The main reasons for this failure are:
(1)The quality of the oil separation core itself is too poor;
(2)Failure to follow the procedures during installation.
3.The electromagnetic valve
Failure appearance: no action
Troubleshooting: The failure of the solenoid valve on the screw air compressor will directly affect the operation of the switching valve and the regulating valve. The common solenoid valve does not operate, and it should be checked from the following aspects:
The solenoid valve terminal of the screw air compressor is loose or the terminal is dropped. The solenoid valve must not be energized, and the terminal can be tightened to solve the problem.
The solenoid valve coil of the screw air compressor is burnt out. If the solenoid valve coil is burned out, the wiring of the solenoid valve can be removed and measured with a multimeter. If it is open, the solenoid valve coil is burned out. The reason is that the coil is damp, which leads to poor insulation and magnetic leakage, resulting in excessive current in the coil and burns, so rainwater should be prevented from entering the solenoid valve. In addition, the tension spring is too hard, the reaction force is too large, the number of turns of the coil is too small, and the suction force is not enough, which can also cause the coil to burn. For urgent disposal, you can turn the manual button on the coil from the "0" position to the "1" position during normal operation to open the valve.
The solenoid valve of the screw air compressor is stuck. The cooperation gap between the slide valve sleeve and the valve core of the solenoid valve is very small (less than 0.008m), and it is usually installed in a single piece. When mechanical impurities are brought in or there is too little lubricating oil, it is easy to get stuck. Disposal method: Use a steel wire to poke through the small hole in the head to make it bounce back. The complete solution is to remove the solenoid valve, take out the valve core and valve core sleeve, and clean with CCI4 to make the valve core move sensitively in the valve sleeve. When disassembling, pay attention to the installation sequence of the components and the orientation of the external wiring, so that the re-installation and wiring are correct, and check whether the oil spray hole of the lubricator is blocked and whether the lubricating oil is satisfactory.
The solenoid valve of the screw air compressor is leaking. Air leakage will result in a lack of air pressure, making it difficult to open and close the valve. The reason is that the sealing gasket is damaged or the slide valve is worn to form several cavities. When checking the solenoid valve failure, you should wait for the solenoid valve to be dealt with when the solenoid valve is out of power, directly replace the solenoid valve to burn the coil, or repair the leakage of the valve body.