Air Compressor Maintenance
Maintenance of your compressed air system is of great importance yet it is often left undone or half done. Neglect of an air system will ultimately "poison7" the entire downstream air system and cause many problems. Clean, dry air supplies start at the air compressor package. The small amount of time you spend maintaining the system is well worth the effort.
General Requirements for a Safe and Efficient Air Compressor
- Always turn power off before servicing.
- Monitor compressor oil and oil cleanliness:
- Change the oil according to manufacturer's recommendations.
- Use a high-quality oil and keep the level where it's supposed to be.
- Sample the oil every month.
- Monitor condensate control:
- Drain fluid traps regularly or automatically.
- Drain receiving tanks regularly or automatically.
- Service air-drying systems according to manufacturer's recommendations.
- Keep air inlet filters clean.
- Keep motor belts tight.
- Minimize system leaks.
Common Causes of Air Compressor Poor Performance
| Problem | Probable Cause | Remedial Action |
|---|---|---|
| Low Pressure at point of use | Leaks in distribution piping | Check lines, connections, and valves for leaks. Clean or replace filter elements |
| Clogged filter elements | ||
| Fouled dryer heat exchanger | Clean heat exchanger | |
| Low Pressure at compressor discharge | ||
| Low pressure at compressor discharge | Improper adjustment of air capacity control (for systems with modulating load controls) | Follow manufacturer's recommendation for adjustment of control |
| Worn or broken valves | Check valves and repair or replace as required | |
| Improper air pressure switch | Follow manufacturer's recommendation for setting air pressure switch | |
| Water in lines | Failed condensate traps | Clean, repair, or replace the trap |
| Failed or undersized compressed air dryer | Repair or replace dryer | |
| Liquid oil in air lines | Faulty air/oil separtation | Check air/oil separation system and change the separator element |
| Dirt, rust, or scale in air lines | In the absence of liquid water, normal aging of the air lines | Install filters at point of use |
| Excessive service to load per hour ratio | System idling too much | For multiple compressor systems, consider sequencing controls to minimize compressor idle time. Adjust idle time according to manufacturer's recommendations. |
| Improper pressure switch setting | Re-adjust according to manufacturer's recommendations. | |
| Elevated compressor temperature | Restricted air flow | Clean cooler exterior and check inlet filter mats |
| Low oil level | Check compressor oil level and add oil as required | |
| Restricted oil flow | Remove restriction and replace parts as required | |
| Excessive ambient temperatures | Improper ventilation to compressor; check with manufacturer to determine maximum operating temperature. |
