Reason for sudden insufficient supply of air from the air compressor

The sudden insufficient supply of air from the air compressor may be caused by an acute failure or emergency, and the following directions need to be investigated:

1. Acute leakage

1. Leakage of pipes/joints
   • performance: Leakage sound, rapid pressure drop, frosting of pipes (if compressed air carries water).
   • check: Apply soapy water to the suspicious area and observe whether it bubbles.
2. Leakage from air storage tank or dryer
   • performance: Oil stains are present at the tank or dryer, and the pressure remains low.
   • processing: Stop using it immediately and contact a professional for maintenance.

2. Sudden host failure

1. The piston ring is broken or the main engine head is stuck
   • performance: Shutdown after abnormal noise, sudden rise in current.
   • reason: Insufficient lubrication, metal fatigue or foreign matter stuck.
   • processing: Emergency shutdown and disassembly and inspection of the main engine.
2. Inlet valve stuck
   • performance: There is no increase in pressure after the air compressor is started.
   • check: Whether the manually operated air inlet valve stem is stuck.

3. Electrical or control system failure

1. Motor overload trip
   • performance: The control panel displays an overload alarm.
   • check: Whether the circuit is short-circuited and whether the motor bearing is stuck.
2. Pressure sensor failure
   • performance: The pressure value displays abnormal or fluctuates greatly.
   • processing: Calibrate the sensor or replace it.
3. Control loop failure
   • performance: The air compressor is frequently started and stopped or has no response.
   • check: Whether the PLC or circuit board is damp or short-circuited.

4. Cooling system failure

1. High temperature shutdown
   • reason: Blocked radiator, insufficient coolant, fan failure.
   • performance: Automatic shutdown when the exhaust temperature exceeds 100℃.
   • processing: Clean the radiator and replenish the coolant.

5. Gas consumption has increased sharply

1. Changes in production demand
   • performance: Multiple equipment uses gas at the same time, and the pressure of the gas tank drops rapidly.
   • deal with: Adjust the gas use plan, or activate a standby air compressor.

6. Lubricating oil-related issues

1. Oil level is too low or oil deteriorated
   • performance: The noise of the main engine increases and the exhaust temperature increases.
   • processing: Change lubricating oil (mineral oil every 2000 hours, synthetic oil every 4000 hours).

Quick processing steps

1. immediately checking: Leak point, control panel alarm code, motor temperature.
2. emergency stop: If the main engine makes abnormal noises, smokes, or the pressure is abnormally high/low.
3. Isolation gas equipment: Priority should be given to ensuring gas supply for key equipment.
4. Contact Maintenance: If the fault cannot be located, professional tools are needed to detect it (such as infrared temperature measurement, vibration analysis).

prompt: Regular maintenance (such as daily drainage, weekly oil level inspection) can reduce the probability of sudden failures. If the air compressor alarms frequently, it is recommended to upgrade to a model with remote monitoring function for real-time warning.