13 Common Air Compressor Problems and How to Fix Them

Air compressors are vital in many industries, powering everything from tools to machinery. But what happens when they fail? In this post, you'll learn about the most common air compressor problems and how to fix them, ensuring your operations run smoothly and efficiently.

Types of Air Compressors

When choosing an air compressor, understanding the different types is essential. Each type has unique advantages and is suited for specific applications.

Reciprocating Air Compressors

Reciprocating air compressors, also known as piston compressors, are widely used. They work by using a piston to compress air within a cylinder. These compressors are typically used in smaller applications, like automotive repair shops, because they are efficient for lower air demands. Reciprocating compressors can be single-stage or two-stage, depending on the pressure requirements.

Key Features:

• Suitable for small to medium-scale operations.

• Available in single-stage and two-stage versions.

• Often used in automotive and DIY applications.

Rotary Screw Air Compressors

Rotary screw air compressors are the workhorses of the industrial world. They use two rotors that spin in opposite directions to compress air. This design allows for continuous operation and a steady flow of compressed air, making them ideal for large-scale industrial use. These compressors are more efficient than reciprocating types and are used in factories, construction sites, and other demanding environments.

Key Features:

• Continuous operation without downtime.

• High efficiency for large-scale industrial applications.

• Lower maintenance needs compared to reciprocating compressors.

Centrifugal Air Compressors

Centrifugal air compressors are used when large volumes of air are needed at high pressures. They work by converting kinetic energy from a spinning impeller into potential energy in the form of compressed air. These compressors are typically found in large-scale industrial applications like chemical plants and refineries. Their design is complex, but they offer high efficiency and reliability.

Key Features:

• Ideal for high-volume, high-pressure applications.

• Commonly used in large industrial facilities.

• Higher initial cost but low operational cost.

Scroll Air Compressors

Scroll air compressors are relatively new in the market. They use two interleaving scrolls to compress air, which results in a smooth and quiet operation. Scroll compressors are typically used in environments where noise reduction is important, like medical facilities and laboratories. They are also known for their efficiency and durability, making them a good choice for smaller, sensitive applications.

Key Features:

• Quiet and smooth operation.

• Efficient and durable, perfect for sensitive environments.

• Low maintenance, but limited to low-to-medium pressure applications.

Common Air Compressor Problems

1. Compressor Failure

Compressor failure is one of the most common issues faced by air compressor users. Let's take a closer look at some of the reasons why your compressor might fail and what you can do about it.

Compressor Fails to Start

If your compressor won't start, it could be due to several reasons:

• Power connection issues

• Check if the power cord is properly plugged in

• Ensure the power switch is turned on

• Inspect the circuit breakers

• Insufficient air pressure in relation to cut-in pressure

• Check the cut-in pressure settings

• Adjust them if necessary

• Lack of oil

• Verify the oil levels

• Change or add oil as needed

Compressor Fails to Stop

When your compressor doesn't stop running, it may be caused by:

• Faulty pressure release valve

• If the valve doesn't release pressure properly, the compressor won't stop

• Replace the valve if it's defective

• Defective power switch

• A broken switch may fail to send a signal to the internal controls

• Install a new switch to resolve the issue

Failure to Provide Adequate Pressure

Is your compressor running but not providing enough pressure? It could be due to:

• Issues with the air-intake pump

• Check for any problems with the pump

• Replace it if necessary

• Gasket problems between low-pressure and high-pressure compartments

• Inspect the gasket for wear or damage

• Replace it to improve compressor performance

2. Bogged Down Issues

Air compressors can struggle to maintain efficiency, often bogging down due to several reasons.

• Motor Problems: A faulty motor can reduce performance, causing the compressor to run sluggishly. Regular checks and timely repairs are crucial.

• Sharing Power Supply: Compressors often share power with other equipment, leading to insufficient power. Ensure it has a dedicated power supply.

• Faulty Unloader Valve: If the unloader valve fails, the compressor may bog down. Draining the tank and replacing the valve can restore performance.

3. Air Leaks

Air leaks are a common and costly problem but can be fixed easily if identified early.

• Identifying Air Leaks: Listen for a hissing sound or apply soapy water to the connections. Bubbles indicate a leak.

• Fixing Air Leaks: Tighten loose couplers, or if the tank check valve is faulty, replace it to stop pressure loss.

4. Pressure and Flow Problems

Pressure and flow issues can arise from various components within the compressor.

• Component Issues: Problems with the intake valve, pressure valve, gasket, piston seal, or tank check valve can cause irregular pressure. Regular inspections help in early detection.

• Obstructed Intake Filters: Dirty or blocked filters can restrict airflow, reducing pressure. Clean or replace filters regularly to maintain optimal performance.

• Ill-fitting Coupler: An ill-fitting coupler can block airflow, leading to pressure drops. Ensure all couplers fit tightly.

• Pressure Gauge Set Too Low: Sometimes, the pressure gauge is simply set too low. Adjusting it to the correct setting can resolve flow issues.

5. Uncharacteristic Noise and Vibrations

When your air compressor starts making unusual noises or vibrating excessively, it's time to check a few critical areas.

• Loose Parts: Loose bolts, belts, or pulleys are common culprits. Inspect and tighten them regularly to prevent unnecessary noise.

• Faulty Crankcase: A faulty or worn-out crankcase can lead to loud noises and vibrations. Check the crankcase for defects, and consider replacing it if necessary.

• Problem Pistons: Pistons hitting the valve plate create a lot of noise. If you notice this, inspect the pistons and adjust them to reduce friction.

• Improper Mounting: If the compressor isn’t securely mounted, it may vibrate excessively. Ensure it's properly bolted down, and add vibration pads if needed to minimize movement.

6. Oil Problems

Oil problems are often overlooked, yet they can lead to significant damage if not addressed promptly.

Oil Expires Quickly

If you find that oil is expiring faster than expected, several factors might be at play:

• Intake Obstruction: A blocked air intake can cause the compressor to overheat, leading to rapid oil degradation. Regularly check and clean intake filters to prevent this.

• Oil Leaks: Leaks are another reason oil levels drop quickly. Inspect all seals, gaskets, and connections for leaks and tighten or replace them as needed.

• Worn Piston Rings: Worn rings can allow oil to seep into the air stream, reducing oil life. Replacing these rings can help maintain proper oil levels.

• Improper Oil Viscosity: Using oil with the wrong viscosity can cause it to break down faster. Always use the recommended oil type for your compressor.

Aerosolized Oil

When oil becomes aerosolized, it contaminates the compressed air, leading to various issues:

• Restricted Air Intake: A restricted air intake can cause oil to mix with the air. Ensure the intake is clean and unobstructed to prevent this.

• Expired or Inverted Piston Rings: Piston rings that are worn or installed incorrectly can cause oil to aerosolize. Regularly check and replace these rings to avoid this problem.

• Excessive Oil in the Tank: Overfilling the oil tank leads to oil being expelled into the air stream. Always fill the tank only to the recommended level.

• Wrong Oil Viscosity: Using oil with the incorrect viscosity can also result in aerosolized oil. Make sure the oil matches the compressor’s specifications.

7. Extremely Hot Emissions

High temperatures in your air compressor’s emissions can indicate several underlying issues.

• Dirt Accumulation Inside the Compressor: Dirt and debris can build up inside the compressor, restricting airflow and causing it to overheat. Regular cleaning of the internal components is crucial to prevent this.

• Poor Ventilation or Hot Environment: Compressors placed in poorly ventilated or overly hot areas are more likely to overheat. Ensure your compressor has adequate ventilation, and consider installing fans or cooling systems if the environment is too hot.

• Worn Head Gasket and Valves: A worn head gasket or faulty valves can lead to inefficient compression, increasing the temperature of the emissions. Inspect and replace these parts as necessary to maintain optimal performance.

• Limited Air Intake: A restricted or blocked air intake can cause the compressor to overheat due to insufficient cooling. Regularly check and clean the intake to ensure it’s allowing proper airflow.

8. Excessive Belt Wear

Belts in air compressors are prone to wear, and if not addressed, this can lead to serious mechanical problems.

• Misaligned Pulley: A pulley that’s out of alignment puts uneven stress on the belt. Regularly check the alignment and adjust it to ensure even wear.

• Incorrect Belt Tension: If the belt is too tight or too loose, it can cause excessive wear. Adjust the tension according to the manufacturer's specifications to prevent premature failure.

• Worn Crankshaft, Keyway, or Pulley Bore: These components wear out over time, leading to belt issues. Inspect these parts regularly and replace them as needed to maintain smooth operation.

9. Excessive Fuse Blowing

Frequent fuse blowing in your air compressor can be a sign of deeper electrical issues.

• Improper Fuse Ampere and Rating: Using a fuse with the wrong ampere rating can cause it to blow frequently. Always check that the fuse matches the compressor’s requirements.

• Low Voltage to the System: Insufficient voltage can cause the compressor to draw more current, blowing fuses. Ensure that your compressor is receiving the correct voltage from the power supply.

• Defective Unloader or Check Valve: These components, if faulty, can cause the compressor to overwork, leading to blown fuses. Regularly inspect and replace any defective parts to avoid this issue.

• Tight Belt: A belt that is too tight increases the load on the motor, which can cause the fuse to blow. Adjust the belt tension to alleviate this problem.

10. Excessive Moisture in Air

Moisture in compressed air can damage equipment and affect production quality. Managing it is crucial.

• Water in the Compressor Tank: Moisture often accumulates in the tank, especially in humid environments. Regularly drain the tank to remove excess water and prevent it from entering the air stream.

• Installing an Air Dryer or Air Filter: To reduce moisture in the air, consider installing an air dryer or filter. These devices remove water from the air before it reaches your tools or machinery, ensuring dry and clean compressed air.

11. Compressor Vibration

Excessive vibration in your air compressor can lead to wear and tear on the equipment.

• Loose Mounting Bolts: If the compressor vibrates excessively, loose mounting bolts could be the cause. Tighten these bolts regularly to secure the compressor and reduce vibration.

• Installing Vibration Pads: Adding vibration pads under the compressor can absorb shocks and prevent excessive movement. These pads help protect both the compressor and the surrounding equipment from damage.

12. No Pressure in Receiver When Compressor is Off

If your compressor's receiver has no pressure when the unit is off, the problem might be with a critical component.

• Faulty Check Valve: A check valve that fails to close properly can allow air to escape from the receiver. Inspect the check valve for wear and replace it if necessary to maintain proper pressure.

13. Compressor Stopped Working

When your compressor stops working suddenly, it can halt operations and cause frustration.

• Loss of Power: The most common cause is a loss of power. Check the power source, cords, and breakers to ensure the compressor is receiving electricity.

• Bad Unloader Valve: A bad unloader valve can prevent the compressor from restarting. If the valve is faulty, replace it to restore normal operation.

Preventive Maintenance for Air Compressors

Preventive maintenance is key to ensuring your air compressor runs smoothly and avoids costly breakdowns. Let’s explore some essential steps.

Regular Inspection and Cleaning

Regularly inspecting and cleaning your air compressor keeps it in top shape. Check for dirt, debris, and any signs of wear. Cleaning the air intake filters and internal components prevents blockages that can lead to overheating and reduced efficiency.

Proper Lubrication

Lubrication is vital for the smooth operation of your air compressor. Without proper lubrication, parts can wear out quickly, leading to breakdowns. Always use the manufacturer-recommended oil, and regularly check oil levels to ensure they’re adequate.

Timely Replacement of Filters, Seals, and Gaskets

Filters, seals, and gaskets play critical roles in your compressor’s operation. Over time, these components wear out and lose their effectiveness. Replacing them on schedule prevents air leaks, contamination, and pressure loss, ensuring optimal performance.

Addressing Air Leaks Promptly

Air leaks are common but should never be ignored. They can significantly reduce efficiency and increase energy costs. As soon as you detect a leak—whether through a hissing sound or a pressure drop—fix it immediately to avoid further damage.

Monitoring for Unusual Noise and Vibration

Unusual noise or vibration often signals a problem. Regularly monitor your compressor for changes in sound or movement. Addressing these issues early, like tightening loose bolts or replacing worn parts, can prevent larger problems down the line.

When to Call a Professional

While many air compressor issues can be handled in-house, some problems require the expertise of a professional. Here’s when to make that call.

Complex Electrical Issues

Electrical problems can be dangerous and tricky to resolve. If you’re facing issues like frequent fuse blows, faulty wiring, or motor failures, it’s best to bring in an expert. Professionals can diagnose and fix electrical issues safely, preventing further damage.

Major Mechanical Failures

Mechanical failures, like a broken crankshaft or seized motor, are beyond basic maintenance. These issues require specialized tools and knowledge to repair. Attempting to fix major mechanical problems without proper expertise can lead to costly mistakes.

Compressor Rebuilds or Overhauls

If your compressor needs a rebuild or a complete overhaul, it’s time to call a professional. These tasks involve disassembling and inspecting the compressor’s core components, something only an experienced technician should handle.

Persistent Problems Despite Troubleshooting Efforts

Sometimes, despite your best efforts, problems persist. Whether it’s a recurring air leak, unexplained pressure drops, or ongoing overheating, a professional can provide the expertise needed to resolve these stubborn issues.

Conclusion

Air compressors face many common problems, from air leaks to mechanical failures. Addressing these issues quickly can prevent costly downtime. Regular maintenance, like inspecting and cleaning components, is crucial. A well-maintained compressor boosts productivity and efficiency, keeping your operations running smoothly. By understanding and fixing these problems, you can extend your compressor's lifespan and avoid unexpected breakdowns. Keep your compressor in top shape, and it will keep your business running efficiently.