The car compressor has replaced the hand and foot pump for tire inflation. The most pleasant advantage of this device is that it is fully automated and no physical effort is required to inflate the wheel. It is convenient when the compressor is always at hand, wherever you are. However, it happens that it fails and then repair may be required.
Why is a compressor a must-have for a driver today? After all, there are so many service stations and tire shops around where you can pump up tires and, if necessary, make other repairs. Everything is simple. The wheel can be lowered anywhere, for example, in a mountainous area or in a summer cottage, far outside the city - there is not always a specialized workshop nearby. And then, it is better not to lose control over the situation and fix the problem yourself, quickly, without extra spending and hassle.
Causes of compressor failure
The most common cause of a car compressor failure is a banal blown fuse. The fuse of the unit or the one located on the wire may burn out. Such a breakdown is not serious and is very quickly eliminated. Moreover, spare parts for repairs can be bought in almost every store, for example exist.ua here.
Also, one of the options in which the compressor fails involves damage to the power wire. Determining this problem is very simple. It is enough to visually examine the wire and find the place of the tear or break. This problem can also be dealt with easily and quickly, for sure every man changed the plug on the iron wire.
There are other more serious reasons for failure. automotive compressors. For example, when a winding of an electric motor or a vibrating coil ignites, it is rarely possible to save a patient.
If you find that the compressor turns on, but does not give the desired action, that is, it does not pump air, look for a problem in the wear of the piston or the PTFE ring. In this case, it will be cheaper to purchase a new autocompressor than to repair and buy new spare parts.
But most often the problem is not acute and requires a little intervention, replacement of a spare part or component. Usually this is a leaky hose, a valve worn on the nipple of the wheel, a rubber ring-gasket, brushes, nozzles.
Features of autocompressors
Due to the fact that the car compressor comes with various nozzles, it can be used not only for inflating car tires, but also for balls, inflatable boats, bicycles, etc. That is, the compressor plus nozzles is a universal device that allows you to solve several problems at once.
In order to repair the compressor, it is important to know its device and features. So, each representative of automotive compressors is equipped with:
- Electric motor;
- pressure gauge;
- cylinder;
- piston;
- Other accessories (cables, brushes, gaskets, nipples, nozzles).
According to their device, diaphragm and piston compressors are distinguished.. The principle of operation of the membrane compressor is to compress the gas, due to the fact that the translational movements of the membrane reduce the volume of the chamber. The membrane, sandwiched between the cylinder and the cover, begins to oscillate and acts like a piston.
Piston compressors are equipped with a special piston, which, when connected to the crankshaft, sucks in air masses. They are much more popular among car enthusiasts.
To ensure the highest pressure, reciprocating compressors operate in a stepped mode. So, the compressed air mass is distilled from one cylinder to another, through a cooling tube. The volume of one cylinder is intentionally larger than the second, but the latter compresses the air, increasing the efficiency of the device.
Weaknesses of the diaphragm compressor
The weakest part of diaphragm compressors is the diaphragm. If foreign particles accumulate in the gas cavity of the block. Important aspects work with such a compressor are:
- Maintain unit cleanliness.
- Exclusion of moisture and dirt ingress into the membrane unit.
- Timely replacement of spare parts (membrane, gas valve, pressure limiter).
Weaknesses of the piston compressor
The most common piston compressor problems are:
- The compressor refuses to start;
- No air is released into the receiver, although the motor is running;
- Knocks out fuses;
- The air pressure drops sharply;
- Incorrect operation of the thermal protection machine;
- The humidity of the air pumped by the compressor is increased;
- The motor runs on high vibrations;
- The junction of the hose and nozzle is worn out and the air poisons.
What to do if the compressor does not start
If the device refuses to work, you need to perform certain diagnostic actions using an indicator screwdriver. We investigate whether there is a phase, and whether voltage is applied. If everything is in order with the phase, proceed to check the fuses, maybe they have melted. If this is the case, then just replace the fuse. It is important to remember that when making repairs, the installed spare parts must be equivalent.
After replacement, everything should work, however, it happens that the fuse blows again. This suggests a possible short circuit. Repair needed. Call the diagram. When the defective parts are installed, replace them with new, similar parts.
The failure of the compressor may be due to a failure in the settings of the pressure control switch. In order to diagnose this problem, do the following: bleed the air and start the compressor again. If you hear the sound of a running motor, reset the settings, the motor does not function, you need to replace it. Remember that with intensive work of thermal protection, it is necessary to cool the motor for at least 20 minutes, this will normalize the operation of the compressor.
Particular attention deserves the situation when, when the device is turned on, both the fuse and thermal protection fail. If the only problem is that the installed fuse is not designed for the operating power of the unit, then the repair comes down to a simple replacement of the spare part. But if the relay is out of order, do not try to climb there yourself. To receive you need to qualified repair go to service.
In a situation where the piston is faulty, you need to disassemble the device. When making repairs, release the air, clean the valve from dirty formations, if the pressure continues to drop - the problem is in the valve, it needs to be replaced.
Where to get spare parts for compressor repair
With such an abundance of car dealerships and places for the sale of components, your head can just go round and round. Where to buy repair parts or new nozzles. In principle, there is no big difference in the places of sale of spare parts. It's a matter of convenience for everyone. Someone goes to a specialized store, someone goes to meal, and someone finds it convenient and profitable to order spare parts via the Internet. The taste and color as they say.
The main thing is not to run into a fake when making a purchase. Original spare parts are the key to their long service life. Ask for a certificate or warranty card when purchasing new compressor repair parts from the seller.
In general, compressor repair is not difficult and can be done without the appropriate experience or qualifications. Although it is better to prevent damage in advance, simply by caring for the equipment.
Not really
The compressor is quite complex Technical equipment, as it is used, it has the right to wear out and break. In this article, we will consider all the methods of maintenance and operation for its maximum extension of life. Run do-it-yourself compressor repair if it's still broken, maybe.
The reliability of compressor equipment largely depends on timely and high-quality maintenance. A large number of breakdowns of reciprocating compressors is the result of poor-quality cleaning of compressed air (abrasive dust, water, and other inclusions). The use and timely replacement and cleaning of filter elements will delay the repair of the compressor for long time.
The main reasons why an air piston compressor fails are:
- Unfavorable operating conditions
- No scheduled maintenance
- Incompetent service staff
To ensure high-quality maintenance, operation and repair of the compressor with your own hands, it is necessary to solve all the above points.
The main difference between maintenance and compressor repair is that during repair, certain parts are forced to be replaced, while during maintenance, parts are replaced as necessary, depending on their actual condition.
Working principle and components
A compressor is a device for increasing pressure and moving gas to the required source ( , grinders, wrenches, and any other pneumatic equipment). The main demanded equipment in body repair became a piston, oil type compressor. In piston, the volume of the working chambers is changed with the help of pistons that perform reciprocating motion.
Have different amount working cylinders and distinguish them according to the following design arrangement:
- Horizontal
- vertical
- Opposite
- Rectangular
- V and W shaped
- star-shaped
The main design flaws are: incomplete balance of their moving parts, the presence of a large number of friction pairs, etc. All this is the cause of failure and subsequent repair.
Before you repair the compressor with your own hands, you need to study its technical structure. In the photo below, a diagram of a single-stage compressor, a piston group.
- Crankshaft
- Frame
- connecting rod
- piston pin
- Piston
- Cylinder
- valve
- Cylinder head
- Valve plate
- Flywheel
- Oil seals
- crankshaft bearings
On the body near the electric motor there is an automation unit called a pressure switch. With it, you can adjust the compressor. It is possible to lower the pumped pressure or increase it.
Reciprocating Compressor Malfunctions
If any defects are found (the appearance of knocks, jamming of rubbing parts, strong heating, increased consumption of lubricant, etc.), it is necessary to carry out repairs.
It is important to determine the type and scope of repair at the stage of diagnosing the state of the object before repair. Compressor malfunctions can be divided into two groups: technical malfunctions (the working part of the piston group and electrical equipment malfunctions). Below are the most common failures:
- The electric motor hums and does not rotate
- Compressor not spinning up
- Knocking in the cylinder-piston group
- Cylinder too hot
- Decreased performance
- strong vibration
Compressor (motor) does not start
The compressor does not turn on, the most common problem. The main and banal thing that can be in this breakdown is no voltage in the network. The first thing to check is the plug and wire for a break that feeds the electric motor. Using a special "tester screwdriver" check whether voltage is applied to all phases. Check the fuse if there is one. Make sure that the starting capacitors are working (for single-phase compressors, the voltage is 220V).
Pay attention to the pressure level in the tank (receiver). Perhaps the pressure is sufficient and the automation does not start the compressor, as soon as the pressure drops to a certain level, the electric motor will start automatically. This is not a breakdown, many people forget about this nuance and worry ahead of time.
The check valve can also become a problem if the compressor does not turn on. Also, a faulty automation unit (pressostat) affects the breakdown (on, off), perhaps the button on the unit itself has become unusable.
If the electric motor does not start, hums, buzzes, does not gain the necessary speed, or stops during operation, this does not always mean that it is broken.
The main malfunctions of the electric motor that can interfere with its proper uninterrupted operation:
- Low motor power (insufficient mains voltage)
- Loose connections, poor contact
- Out of order check valve(leaks), thereby creating back pressure
- Incorrect start of the compressor (see instruction manual)
- Piston group jammed (due to lack of oil level, overload)
If the compressor motor does not turn on at all and does not make sounds, then this indicates the following:
- The mains power fuse has tripped
- Overload protection tripped
- Bad contact in electrical circuit(wiring problems)
- The worst thing is that the electric motor burned out (often there is a characteristic smell)
Knock and rumble in the cylinder and piston group
One of the causes of compressor failure is a faulty piston group. Recognizing a defect in this system is quite simple. Usually they are accompanied by a knock, rumble, rattle and other sounds of a metallic nature. If the compressor knocks, then its discharge part is faulty, where there are many metal parts that interact with each other. Due to their friction and wear, extraneous noises and unpleasant sounds appear.
You should not run with such a breakdown, if possible, you need to eliminate it as soon as you hear the first signs of their manifestation. The main malfunctions if the compressor began to knock and run louder than before:
- Crashed worn out bearings, connecting rod bushings
- The bearings on the crankshaft failed.
- Worn piston, rings, piston pin
- Worn cylinder
- Loose cylinder and head bolts
- Solid particles have entered the cylinder
- The cooling impeller is loose on the pulley
To repair these breakdowns, in simple cases, it is enough to stretch all the bolts and nuts. If the piston, cylinder, crankshaft or connecting rod are worn out, then a comprehensive overhaul is necessary here. When repairing the piston group, it may be necessary to bore the cylinder, if it is heavily worn and has external defects, select a repair piston according to new dimensions. Below are possible defects piston system:
- Changing the diameter of the piston, cylinder
- Cylinder mirror shape distortion
- Risks, scratches, scuffs on the cylinder walls
- Cracks in the main working part
- Cracks and broken flanges
During long-term operation, due to wear, risks appear on the cylinder mirror, increases inner diameter bushings for the eccentric shaft. During repair, the cylinders are restored by pressing liners into them. Worn bushings for the eccentric shaft are replaced. This repair is quite difficult to do with your own hands without necessary tool and equipment. Since the most time-consuming and responsible stage is the restoration of the cylinder. Boring is performed on a vertical boring machine using a special tool.
This, as far as the cylinder was concerned, below we will consider the main malfunctions of the compressor crankcase.
- Cracks in the walls of the cavities of the crankcase
- Deviations in the size and shape of landing sites
- Warping of seats
- crashed seats for crankshaft bearings
If these nodes are worn out, they must be replaced with new ones. The hole for the bearings is bored on a horizontal boring machine for a larger diameter of the bearings or for pressing the bushing, followed by boring of the pressed bushing to the required diameter. Repair of the compressor of such complexity should be carried out by qualified specialists.
Below, spare parts "repair kit" for overhaul of the compressor, piston group.
The compressor gets very hot
If the compressor is very hot, then this indicates some kind of malfunction. There can be several reasons for overheating. Starting off idle, this is blocked by airflow to the cylinder and crankcase. Check if the impeller is blocked by foreign objects.
One of the main causes of a heating compressor is a lack of oil level. The working units work for wear, high friction is created, as a result, it gets very hot. With further such work, the equipment will quickly fail. Check the oil level, if it is not enough, it is necessary to add to the desired level.
Valve failures due to carbonized contamination or loose valves. There may also be clogged air passages.
Look at the pressure level, the automation may have broken down and the compressor “threshes” to a high pressure, this causes overheating. The relief valve may need to be repaired or replaced.
Try to locate the compressor in a cool, spacious place, especially during the hot season. Whatever cooling it has, it will heat up much less, which will affect its positive and durable operation. "Also, do not forget that the colder the air, the less moisture and oil impurities in it.
Decreased performance
The drop in performance can be due to several reasons. Clogged, clogged air intake. Remove and clean the filter with compressed air or replace it. Basically, in piston compressors, it is made of ordinary foam rubber.
There may be an air leak somewhere. Inspect all incoming and outgoing pipes and hoses. As in the previous case, wear and malfunction of the valves is possible, this greatly affects performance. With a sufficiently long use, piston rings wear out, sealing disappears. In more serious cases, the cylinder and pistons are worn, scratched or have other external defects, which leads to a loss of compression and the compressor stops pumping air.
It is worth checking the tension of the belt connecting the electric motor and the crankshaft of the piston system. When loosened, slippage is possible and the compressor stops pumping air properly.
Oil enters the working chamber
If oil enters the working chamber, these are quite bad signs, of course, this will not lead to a complete failure of the compressor, but it will do harm painting work and the emergence, very much even can. The main reasons for oil to go where it does not need it: Low viscosity oil is filled, that is, the oil is too thin, it seeps through the seals and rings. The oil level is too high. Due to excess oil, it is squeezed out with force and enters the chamber. The wrong oil is being used. Fill only with special compressor oil.
Worn pistons and rings in the cylinder block. Also, the wear of the cylinder itself affects the ingress of oil into the working chamber. To eliminate the malfunction, it is necessary to repair the piston group compressor, which is described above.
Compressor operation and maintenance
A piston compressor, like any technical equipment, requires some maintenance. Proper operation will help extend the life of your compressor equipment. Consider the main activities for the maintenance, repair and operation of the compressor.
1. Replacing and cleaning the air filter. The filter element is mainly made of non-woven material, foam rubber or syntonin. If the compressor is in the same place where the car is being painted, then it gets heavily clogged (sticks) with dust from and another paintwork material. The filter prevents abrasive dust from entering the cylinder, the piston and cylinder wear out less. Change and clean the filter as often as possible, as this will significantly increase the resource and delay repair compressor.
2.
Changing the oil is a very important item. Watch the oil level on a special indicator (window) in the compressor crankcase. Running at a low level or without oil entails a major overhaul. Top up to the required level if it is not enough. Periodically, it is necessary to completely drain and fill in a new one. Use only special compressor oil. Oil for piston compressor Mobil, Fubug, Shell VDL 100, KS 19, 46 or any other branded.
3. Condensate drain. An important item in the maintenance of the compressor. The air is saturated with moisture, it inevitably enters the receiver with the intake air. Over time accumulates in large quantities. With a high content of condensate, it may be released into the air hoses, which leads to defects during painting. Condensation also causes corrosion inside the receiver. Drain condensate as often as possible, at least once a week, especially during hot and humid seasons.
4. Monitor the general condition, periodically blow off dust and other contaminants. Take Special attention impeller on the electric motor, cylinder fins, air cooler, as they are used, dust and dust from paint adhere to them, which reduces the cooling capacity.
5. Inspect the belt drive for wear and tension. When pressing the belt at the midpoint, it should not bend more than 12-15 mm. Tighten all bolts and nuts. Periodically check the operation of the safety valve, which serves to protect against overpressure, due to a breakdown in the pressure switch.
Follow all the above methods and you will delay compressor repair for a long time.
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Operation and repair of a piston compressor 55 069 Views
There are situations when air compressor, peacefully rattling the engine in the corner of the garage, starts to falter, or even completely turns off. And at this moment, as luck would have it, there is a need for it. Do not be afraid, after studying the theoretical information, do-it-yourself compressor repair will not seem unattainable.
Purpose, main elements and principle of operation
The main purpose of air compressor units is to create a continuous uniform jet of compressed air. The flow of dense gas further actuate various pneumatic tools. These can be airbrushes, tire inflation guns, wrenches, cutting machines, pneumatic chisel, nailer and more. In the minimum configuration, the compressor unit is equipped with a blower (an engine that creates an air flow) and a receiver (a container for storing compressed gas).
Compressors with an electric motor of a piston system have found the greatest application in auto repair shops. In the supercharger crankcase, a transmission rod moves along the axis back and forth, giving off an oscillatory moment to the reciprocating movement of the piston with sealing rings. The bypass valve system located in the cylinder head works in such a way that when the piston moves down, air is taken from the inlet pipe, and upwards - return to the outlet.
The gas flow is directed to the receiver, where it is compacted. Due to the design features, the supercharger produces an uneven jet of air. Which is not applicable for using the spray gun. A kind of capacitor (receiver) saves the situation, which smooths out pressure pulsations, giving out a uniform flow at the output.
More complex structure compressor installation involves hanging additional equipment designed to ensure automatic operation, dehumidification and humidification. And if in the case of a simple execution it is easy to localize a malfunction, then the complication of equipment execution makes it difficult to search. The following are the most common faults and solutions for the most common piston-type compressed gas supply systems.
Compressor unit defects
To facilitate the search for a problem, all defects can be classified according to the nature of the malfunction:
- Compressor unit blower does not start
- The compressor motor hums, but does not pump air or fills the receiver too slowly
- At start-up, the thermal protector trips or the mains fuse blows.
- When the blower is turned off, the pressure in the compressed air tank drops.
- Thermal protector trips intermittently
- The outlet air contains a large number of moisture
- Engine vibrates a lot
- Airflow is below normal
Consider all the causes of problems and how to fix them.
System blower does not start
If the engine does not start and does not hum, then the supply voltage is not applied to it. First of all, you should use an indicator screwdriver to check the presence of “zero” and “phase”, as well as the reliability of the connection of the plug to the socket. In case of poor contact, measures are taken for a tighter fit. If there is 220 V at the input of the circuit, the fuses of the compressor unit look.
Those that fail are replaced by passive protection devices of the same rating as the defective ones. In no case are hot-melt inserts designed for a larger electricity. If the fuse blows again, you should find out the cause of the failure - probably a short circuit at the input of the circuit.
The second reason why the unit does not start is that the pressure control switch in the receiver is faulty or the level settings have gone wrong. To check, the gas from the cylinder descends and the supercharger is started trially. If the engine is running, the relay is reset. Otherwise, the defective part is replaced.
Also, the engine will not start when the thermal overload protector trips. This device turns off the power circuit of the winding of the electrical appliance in case of overheating of the piston system, which is fraught with engine jamming. Let the blower cool down for at least 15 minutes. After this time, restart.
The engine hums, but does not work or produces low speeds
With an underestimated mains voltage, the electric motor does not master the scrolling of the axis, while it will buzz. With this malfunction, first of all, we check the voltage level in the network with a multimeter (it must be at least 220 V).
If the voltage is normal, then the pressure in the receiver is probably too high, and the piston does not master the pushing of air. In this case, the manufacturers recommend setting the “AUTO-OFF” automatic switch to the “OFF” position for 15 seconds, and then turning it to the “AUTO” position. If this does not help, then the pressure control switch in the receiver is faulty or the bypass (control) valve is clogged.
The last drawback can be tried to be eliminated by removing the cylinder head and cleaning the channels. Replace the faulty relay or send it to a specialized center for repair.
The start of the compressor is accompanied by a blown fuse or the operation of automatic thermal protection
This malfunction occurs if the installed fuse is lower than the recommended power rating or the supply network is overloaded. In the first case, we check the compliance of permissible currents, in the second, we disconnect part of the consumers from the electrical mains.
A more serious cause of the malfunction is the incorrect operation of the voltage relay or the breakdown of the bypass valve. We bypass the relay contacts according to the scheme, if the engine is running, then the actuator is faulty. In this case, it is more advisable to contact an official service center for technical support or replace the relay yourself.
When the power supply is turned off, the air pressure in the receiver drops.
A drop in compressed air pressure indicates that there is a leak somewhere in the system. Risk areas are: air duct high pressure, piston head check valve, or reservoir bleed valve. We check the entire pipeline with a soapy solution for air leaks. We wrap the detected defects with sealing tape.
The outlet cock may leak if it is loose or defective. If it is closed all the way, and soap solution bubbles on the spout, then we change this part. When screwing in a new one, do not forget to wind the fum-tape onto the thread.
In the case of tightness of the air line and the outlet cock, we conclude that the compressor control valve is not working correctly. To perform further work, be sure to bleed all compressed air from the receiver! Next, we continue to repair the compressor with our own hands, disassembling the cylinder head.
If there is dirt or mechanical damage to the bypass valve, we clean it and try to fix the defects. If the problem persists, then replace the control valve.
Regular operation of automatic thermal protection
This defect is observed when the mains voltage is too low, the air supply is poor, or the air temperature in the room is high. We measure the mains voltage with a multimeter, it must be at least the lower limit of the range recommended by the manufacturer.
Poor air flow into the discharge system is due to a clogged inlet filter. The filter should be replaced or washed according to the maintenance installation. The piston engine is air-cooled and often overheats when in a poorly ventilated area. The problem is solved by moving the compressor unit to a room with good ventilation.
Exhaust gas jet contains a lot of moisture
This situation occurs under the following conditions:
- Large accumulation of moisture in the receiver
- Air intake filter dirty
- Humidity in the compressor room is increased
Moisture in the output jet of compressed air is combated by the following methods:
- Drain the excess liquid from the cylinder regularly
- Clean or replace filter element
- Transfer the compressor unit to a room with drier air or install additional filters-moisture separators
In general, piston engines are characterized by high vibration. But, if earlier a relatively quiet compressor unit starts to rumble, there is a high probability that the engine mounting screws have loosened or the material of the vibration cushions has become very worn. This malfunction is eliminated by pulling all the fasteners in a circle and replacing the polymer vibration isolators.
Compressor runs intermittently
Interruptions in the operation of the engine can be caused by incorrect operation of the pressure control switch or by too intensive selection of compressed air.
Excessive gas consumption occurs due to a mismatch between compressor performance and power consumption. Therefore, before buying a new pneumatic tool, carefully study its characteristics and air consumption per unit of time.
Consumers should not take more than 70% of the compressor power. If the power of the supercharger exceeds the requests of pneumatic tools with a margin, then the pressure switch is faulty. We either repair it or replace it with a new one.
Air flow rate is not correct
This malfunction occurs as a result of a gas leak in the high pressure system or a clogged air intake filter. Air leakage can be nullified by pulling all butt joints and wrapping with sealing tape.
Sometimes it happens that when draining condensate from the receiver, they forget to completely close the outlet cock, which also leads to a gas leak. This problem can be easily solved by tightly closing the valve. If the dust filter is clogged, clean it, or even better, replace it with a new one.
Most the above malfunctions can be avoided by correctly carrying out the first start-up and running-in of the mechanisms, as well as by performing regular maintenance work.
Timely maintenance ensures the performance of the unit
In order for the device to work properly for a long time, you should start the recommended service at early stages operation. Experts recommend the following actions from the moment of purchase:
- When opening the transport package, the presence of a passport for the installation, technical documentation and compliance with the factory inventory of component parts is controlled.
- Before the first start of the engine, the oil level is checked on the dipstick and, if necessary, topped up to the recommended mark. Oil should be filled in recommended by the manufacturer and specified in the technical documentation. For better spreading of the lubricant and checking for proper operation, let the compressor idle for 10 minutes.
- In the absence of comments, the pneumatic tool is connected to the compressor unit and work begins. Note: it is undesirable to supply power to the supercharger if there is excess pressure in the receiver.
- Try to keep a record of the compressor running time and after 500 hours of operation, change the oil to a new one. To do this, the flange cover of the crankcase is removed, mining is drained and accumulated contaminants are cleaned. Only after that fresh grease is poured.
- Clean the air inlet filter weekly.
- After 16 hours of operation, moisture is drained from the receiver using the outlet cock. Manufacturers also recommend cleaning the inner surface of the cylinder every six months using special tools.
- At the end of the work, the compressor unit is disconnected from the supply network, and air is bled from the high-pressure system.
- If the blower has not been used for a long time, the contact areas of the air valve must be cleaned and lubricated before starting.
- Non-current-carrying metal parts must be grounded. As a rule, manufacturers bring the grounding conductor into the Euro plug. And you only need to ground the corresponding contact in the socket into which the compressor unit is connected.
Timely observance of these simple requirements will allow you to keep the mechanism in good condition. Such a time-consuming procedure as do-it-yourself compressor repair will be required extremely rarely. Proper grounding will avoid problems with the electrical part of the device. Regular replacement of oil and cleaning filters will prevent premature wear of rubbing parts.
Good afternoon. A big request to help those who faced a similar problem. Our company has been repairing tools for 5 years, and we have not encountered such a problem before, and now 2 compressors with the same problem. The electric motor is serviceable, the capacitor is also serviceable, for verification there are all devices that can determine the capacitance of the capacitor, and the exact resistance of the windings. The point is in the mechanical part, the compressor pumps up to 4 atmospheres, and the flywheel jams, as if the bypass valve does not work. That is, the pressure from the receiver presses back, and the engine cannot turn the flywheel with such an effort, turn off the compressor, turn the flywheel with great effort, start the engine, it makes one revolution, with the pressure previously pumped up, and stops again, that is, the mechanics jam. The bypass valve is new, they tried to change the piston rings, the same situation, we are at a loss. If anyone has encountered a similar problem, please help with information.
The aunt brought such a compressor, she says the ball is pumping up, but the wheel of the car is not. The pressure gauge on the compressor does not work, I connected my own, for sure, it gives out 0.2 atm. As usual, the hose is intact, which means we check the valves. The inlets, located in the bottom of the piston, are in order, but the outlets, located in the cylinder head, were very surprised. In both cylinders, rubber rings were slipped under the valves, of course, the valves are constantly open and the compressor I just pumped air inside myself without creating pressure. I removed the rings, assembled everything, turned it on, 2 minutes and 3.5 atm on the pressure gauge. Can anyone explain how these rings could get under the valves? by thoughtlessness.
ELITECH TP30G, 30 kW. I suspect that the air supply may be poorly adjusted, because the smell appears very quickly carbon monoxide, when I disassembled the gun, I saw only one adjusting bolt for the hexagon, but I haven’t touched it yet, I’m waiting for your advice, thanks in advance
Possible reasons for insufficient performance of a screw compressor.
Why does the screw compressor not pump?
When screw compressor ceases to produce nominal performance, one often hears phrases from the client: “Maybe the screw block is already old, worn out?”
Many people look at this problem by analogy with a reciprocating compressor, where a drop in performance is often associated with increased wear of the piston rings, the cylinder mirror. Meanwhile, the mechanical wear of the surfaces of the rotors of the helical stage is very rarely the cause of a decrease in the performance of even a fairly old compressor. The point is that while working screw block, unlike a reciprocating compressor, there is practically no mechanical friction between the surfaces of the rotors due to the formation of an oil wedge. In this mode, the screws can work for decades, only the moment of starting the screw compressor is dangerous from the point of view of wear, when the pressure in the system necessary for the operation of the lubrication system has not yet been reached. Only bearings in the screw block wear out, which are changed when overhaul, and this wear is not reflected in productivity. Working out on the screws is a sign that it is time to throw out the screw block; as a rule, very little time passes from the appearance of such a working out to the jamming of the block. The reasons for the decrease in the productivity of a screw compressor are usually quite different. The first step is to check the suction valve - it may not open or does not open completely for some reason. Contaminated air filter can also be the cause of this malfunction - it creates a vacuum at the inlet, does not allow enough air to pass through. The third option is an air leak through the bypass line, through which air must be supplied from the separator tank to the compressor suction during idling and shutdown of the compressor. If this line is not blocked on the working stroke, part of the air will run in a circle. The cause of insufficient performance may also be air leakage through any leaks inside the compressor. We do not consider cases of critical contamination of the compressed air pipelines of the compressor or insufficient oil, since these factors are manifested primarily by other symptoms, and this is not about a lack of performance.
But, frankly, in practice, the most common reason for a performance drop is ... in the absence of such a drop. The reason is not inside compressor, and outside - an increase in the consumption of compressed air in the line. This can happen due to the connection of additional consumers, compressed air leaks through leaks or fistulas that appear as a result of corrosion on pipelines, and simply because someone somewhere forgot to close the tap (it happened, and it is especially interesting when this crane is located in a remote, isolated and long-closed room, where, according to the project, compressed air lines should not pass).
Therefore, when there is a suspicion of a drop in performance, it is worth checking the trunk first. If this is difficult, you can empirically measure performance compressor, and then it will become clear whether it is necessary to call the service department for compressor repair, or it is serviceable and the cause should be sought elsewhere.