What is the fault of the air compressor working constantly?

The air compressor is constantly working and may be caused by a variety of faults. The following are some common causes and corresponding solutions:

Common faults and causes

1. Gas system leakage
   • Cause: When there is leakage in the gas circuit system, such as loose air pipe joints and poor valve sealing, the air compressor needs to continuously work to replenish the leaked gas, resulting in the inability to shut down.
2. Fault of pressure sensor or pressure switch
   • Cause: The pressure sensor or pressure switch is responsible for monitoring the pressure in the air circuit. If they fail, it may cause the air compressor to not correctly sense that the pressure has reached the set value, thereby continuously pumping the air.
3. Pressure regulating valve is misaligned or damaged
   • Cause: The pressure regulating valve is used to control the pressure of the air compressor output gas. If the pressure regulating valve is misaligned or damaged, it may cause the pressure to not be stabilized within the normal range, so that the air compressor can continue to work.
4. Relay failure
   • Cause: When the pressure sensor or pressure switch has given a signal, but the relay has not performed a power-off operation, the air compressor will continue to operate.
5. Intake valve failure
   • Cause: If the intake valve cannot be closed normally, it will cause the air compressor to continue to suck gas and work.
6. Unload valve failure
   • Cause: The unload valve is used to close the air inlet when the air pressure reaches the set value. If the unload valve is damaged or stuck, the air inlet will not be closed normally, causing the air compressor to continue working.
7. Clogged oil and gas separator
   • Cause: Blockage of oil and gas separator will affect the normal exhaust of the air compressor, causing the pressure to not be raised to the set value, thus causing the air compressor to continue working.
8. Using too much gas is used
   • Reasons:When the air compressor’s gas production capacity cannot meet the actual gas usage needs, the air compressor will always work to try to meet the gas usage.
9. Internal failure of the air compressor
   • Causes: Such as piston ring wear, cylinder strain, etc., these failures will affect the compression efficiency of the air compressor, making it unable to reach the set pressure in a short time, thereby continuing to work.

Solution measures

1. Inspect and repair leaks in the gas circuit system
   • Cleanly check all connection parts in the gas circuit, such as tracheal joints, valves, etc., and repair or replace the seals in time when the leakage points are found.
2. Replace the pressure sensor or pressure switch
   • If it is confirmed that the pressure sensor or pressure switch is faulty, replace the new pressure sensor or pressure switch in time.
3. Adjust or replace the pressure regulator
   • Readjust the pressure regulator to ensure that it can control the pressure normally. If the pressure regulator is damaged, it needs to be replaced.
4. Inspect and repair the relay
   • Check the working status of the relay. If the relay is found to have a fault, it should be repaired or replaced in time.
5. Inspect and repair the intake valve
   • Check the working status of the intake valve to ensure it can be closed normally. If the intake valve fails, it should be repaired or replaced in time.
6. Inspect and repair the unloading valve
   • Check the working status of the unloading valve to ensure that it can normally close the air inlet when the air pressure reaches the set value. If the unloading valve fails, it should be repaired or replaced in time.
7. Cleaning or replacing the oil and gas separator
   • Cleaning or replacing the oil and gas separator regularly to ensure it is unobstructed.
8. Evaluate and replace the air compressor with a larger capacity
   • If it is confirmed that the air compressor is continuously working due to excessive gas volume, the air compressor with a larger capacity should be evaluated and replaced according to actual needs.
9. Disassembly and repair the air compressor
   • When it is suspected that the air compressor internal fault caused continuous operation, the air compressor should be disassembly and repaired, and worn parts such as piston rings, cylinders, etc. should be replaced.

Preventive measures

1. Regular inspection and maintenance
   • Regularly inspect and maintain the air compressor’s air circuit system, pressure sensor, pressure regulating valve, relay, intake valve, unloading valve, oil and gas separator and other components to ensure their normal operation.
2. Use high-quality accessories
   • When replacing accessories, high-quality original or certified accessories should be used to ensure the performance and stability of the equipment.
3. Rational setting of working pressure
   • Rational setting of working pressure of the air compressor is based on actual gas use needs to avoid unnecessary energy consumption and failures caused by setting too high or too low.
4. Train operators
   • Train operators to understand the working principles and operating specifications of air compressors and avoid failures caused by improper operation.

Through the implementation of the above measures, the problem of air compressors being constantly working can be effectively solved and similar failures can be prevented.