Rotary screw compressors are known for their reliability and efficiency, but like any complex system, they can encounter issues over time. Whether it’s insufficient air pressure, unusual noises, or frequent shutdowns, these problems can disrupt operations and increase costs if not addressed promptly.
This guide is here to help. We’ll walk you through common rotary screw compressor issues and provide troubleshooting tips to get your system back on track.
With a little knowledge and proactive care, you can minimize downtime and keep your operations running smoothly. Let’s dive in!
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COMPRESSOR WON'T START
One of the most common and frustrating issues with rotary screw compressors is when they simply won’t start. You hit the power button, and nothing happens.
This problem can bring your operations to a standstill, but don’t worry—there are a few likely culprits and straightforward steps to troubleshoot the issue.
Possible Causes
The first place to check is the power supply. A faulty connection, a loose wire, or an interruption in voltage could be preventing the compressor from starting.
This is especially common if there’s been a recent power outage or electrical work near your facility.
Another potential issue is an overloaded motor or a tripped circuit breaker. When the motor works harder than it’s designed to, such as during a high-demand period, the system can trip to prevent damage.
Lastly, the issue could lie in the starter or control system. If these components are worn out or malfunctioning, they may not signal the compressor to begin operation.
Troubleshooting Steps
Start with the basics: check the power supply. Ensure that all connections are secure and that the voltage matches the compressor’s requirements. A multimeter can be helpful here to test the circuit.
Next, reset the circuit breaker or motor overload protection. If the breaker trips again, you may need to inspect for deeper issues, such as excessive demand or motor wear.
Finally, examine the starter and control system. Look for visible signs of wear, such as burned contacts or loose wiring. If these components appear damaged, reach out to your trusted service provider for repairs or replacements.
Getting your compressor back online quickly is critical for minimizing downtime, and with these steps, you can often identify and resolve the issue before it escalates. If you need expert support, our brands are always here to help.
INSUFFICIENT AIR PRESSURE
Few things are as frustrating as a rotary screw compressor that can’t deliver the air pressure your system demands. Without sufficient pressure, tools and equipment fail to operate efficiently, slowing down your processes and causing unnecessary headaches.
The good news? This problem is often solvable with some straightforward troubleshooting.
Possible Causes
One of the most common culprits is air leaks in the piping system. Even a small crack or loose fitting can lead to significant pressure loss over time.
It’s an invisible issue that can quietly reduce efficiency while driving up energy costs.
Another frequent cause is blocked or dirty air filters. Filters are essential for keeping contaminants out of your system, but if they’re clogged, they can restrict airflow and prevent your compressor from achieving the desired pressure.
Finally, faulty pressure regulators or valves may be to blame. If these components aren’t functioning correctly, they can disrupt the balance of pressure within the system, making it difficult to meet operational needs.
Troubleshooting Steps
Start by inspecting your piping system for leaks. Listen for hissing sounds and check all connections, joints, and fittings. Damaged pipes or loose connections should be repaired or replaced immediately.
Next, check the air filters. If they’re dirty or clogged, clean them if possible or replace them with new ones. Keeping filters in good condition ensures proper airflow and protects the compressor from unnecessary strain.
Finally, test the pressure regulators and valves. Make sure they are set correctly and functioning as intended. If a valve or regulator is worn or damaged, replacing it may be the key to restoring proper pressure.
Solving insufficient air pressure is critical for maintaining productivity and avoiding further system stress.
OVERHEATING COMPRESSOR
When a rotary screw compressor begins overheating, it’s a clear sign that something is amiss. High operating temperatures can lead to inefficiencies, system shutdowns, and even long-term damage to critical components.
Addressing this issue promptly is essential to keeping your compressor running smoothly.
Possible Causes
One of the most common causes of overheating is insufficient cooling due to dirty or clogged aftercoolers. Over time, dust and debris can accumulate on the cooling fins, reducing airflow and preventing the system from dissipating heat effectively.
Another potential issue is low oil levels in oil-injected compressors. Oil plays a critical role in cooling the compression chamber, and without enough oil, temperatures can quickly rise to unsafe levels.
Finally, ambient temperature can also contribute to overheating. Compressors located in hot, poorly ventilated spaces may struggle to maintain optimal operating temperatures, especially during periods of high demand.
Troubleshooting Steps
Start by inspecting and cleaning the aftercooler. Dust, dirt, or blockages can severely limit its ability to cool the compressed air. Make sure the cooler fins are clean and airflow isn’t obstructed.
Next, check the oil levels in oil-injected systems. If the oil level is low, refill it with the manufacturer-recommended oil type. Regular oil checks are crucial for preventing overheating and maintaining system efficiency.
Finally, evaluate the compressor’s location and ventilation. If the ambient temperature is too high or airflow is restricted, consider relocating the compressor to a cooler, more ventilated area.
Installing additional fans or improving ventilation in the existing space can also help keep temperatures in check.
By addressing these overheating issues quickly, you can prevent costly shutdowns and extend the life of your compressor.
EXCESSIVE OIL CONSUMPTION
Excessive oil consumption in a rotary screw compressor is more than just a minor inconvenience—it’s a costly issue that can impact the efficiency and lifespan of your system.
When a compressor uses more oil than expected, it’s essential to identify and address the root cause to avoid escalating operational costs and potential downtime.
Possible Causes
A common culprit behind excessive oil consumption is a faulty oil separator or worn seals. These components play a crucial role in keeping oil where it belongs—inside the system.
If they’re damaged or deteriorated, oil can escape into the compressed air or leak out of the machine altogether.
Another possibility is an overfilled oil reservoir. While it may seem counterintuitive, too much oil can cause carryover into the air system, leading to higher consumption and contamination of downstream equipment.
Lastly, an improperly functioning air/oil separator can allow excessive oil to escape along with the compressed air. This not only increases oil use but also reduces air quality and efficiency.
Troubleshooting Steps
Start by inspecting the oil separator. If it’s clogged, damaged, or worn out, replacing it with a new one can resolve the issue and restore normal oil consumption.
Next, check the oil reservoir level. Drain excess oil if necessary and ensure the system is filled to the manufacturer-recommended level. Maintaining proper oil levels is critical for seamless operation.
Finally, examine the seals within the system. Look for visible wear, cracks, or leaks, and replace any damaged seals to prevent further oil loss.
By addressing excessive oil consumption promptly, you can save on operating costs and ensure your compressor performs at its best.
UNUSUAL NOISES OR VIBRATIONS
Rotary screw compressors are known for their smooth and quiet operation, so when you hear unusual noises or feel excessive vibrations, it’s a sign that something isn’t right.
Ignoring these symptoms can lead to more serious issues down the line, so it’s important to address them promptly.
Possible Causes
One common cause of abnormal noises is misaligned or worn rotors. These precision-engineered components must work in perfect synchronization to compress air efficiently.
Misalignment or wear can create grinding or rattling sounds, signaling the need for attention.
Another potential culprit is loose or damaged internal components. Bolts, fasteners, or other internal parts can loosen over time due to normal wear and tear, leading to vibrations or clanging noises during operation.
Lastly, worn-out bearings can contribute to both noise and vibration. Bearings support the rotors and ensure smooth motion.
When they become damaged or dry from lack of lubrication, they produce a distinctive humming or rumbling sound.
Troubleshooting Steps
Start by inspecting the rotor alignment. If the rotors appear misaligned or damaged, consult a technician to recalibrate or replace them as necessary.
Next, check for loose components. Tighten any bolts, fasteners, or connections that may have come loose over time. If parts are damaged or missing, replace them immediately to restore stability.
Finally, examine the bearings for signs of wear. Replace any bearings that are worn out and apply the appropriate lubricant (buy compressor lubrication here)to ensure smooth operation moving forward.
Addressing unusual noises and vibrations early can prevent further damage and keep your compressor running efficiently.
MOISTURE IN COMPRESSED AIR
Excessive moisture in compressed air can cause significant problems for your equipment and processes. From corrosion in piping to reduced efficiency in air-powered tools, moisture can wreak havoc if not properly managed.
Identifying the cause and addressing it promptly is essential for maintaining a reliable system.
Possible Causes
One likely cause of moisture in compressed air is an inefficient aftercooler or air dryer. These components are responsible for removing heat and moisture from compressed air, but when they’re dirty, damaged, or undersized for the application, they can fail to do their job effectively.
Another common factor is high ambient humidity. If your compressor is operating in a humid environment, the air it compresses will naturally contain more moisture, putting extra strain on the aftercooler and air dryer.
Finally, a malfunctioning drain system can lead to moisture buildup. If the drains aren’t functioning correctly, condensed moisture can accumulate and find its way into your system.
Troubleshooting Steps
Begin by inspecting and cleaning the aftercooler. Remove any debris or buildup that may be restricting its performance. If it’s still underperforming, consider replacing it.
Next, check the air dryer. Ensure it’s functioning properly and sized correctly for your compressor. Replace filters or desiccants as needed to improve its moisture-removal capabilities.
Examine the drain system to ensure it’s working correctly. Clear any blockages and repair or replace faulty components to prevent moisture from pooling in the system.
If high humidity continues to be a problem, consider upgrading to a more efficient air dryer. Refrigerated or desiccant dryers are highly effective at reducing moisture levels and ensuring high-quality compressed air.
By addressing moisture issues promptly, you’ll protect your equipment, improve efficiency, and prevent costly repairs.
FREQUENT TRIPPING OR SHUTDOWNS
When your rotary screw compressor frequently trips or shuts down during operation, it can disrupt workflows and lead to costly delays. While this issue may seem alarming, it’s often tied to identifiable causes that can be resolved with proper troubleshooting.
Possible Causes
One of the most common culprits is electrical issues, such as overloaded circuits or insufficient power supply. Compressors draw significant energy, and if the system exceeds its electrical capacity, it may trip the circuit to prevent damage.
Another possible cause is a problem with the compressor’s thermal protection system. Faulty sensors, control errors, or overheated components can trigger safety mechanisms, causing the system to shut down repeatedly.
Lastly, mechanical obstructions or wear can interfere with the compressor’s operation. Components like rotors, bearings, or belts may become worn or misaligned, leading to unnecessary strain on the motor and causing shutdowns.
Troubleshooting Steps
Start by inspecting the electrical circuits for faults or overloads. Verify that the power supply is consistent with the compressor’s requirements and that circuit breakers are functioning correctly. Address any loose connections or replace damaged wiring.
Next, test the thermal protection system. Reset the thermal overload switch and monitor the system’s performance. If the issue persists, replace faulty sensors or contact a technician for further diagnostics.
Finally, check for mechanical obstructions or wear. Inspect critical components like rotors, belts, and bearings for signs of damage or misalignment. Addressing these wear-related issues early can prevent further strain on the compressor.
Frequent shutdowns can be frustrating, but with these steps, you can often identify and resolve the root cause quickly.
OIL CARRY OVER IN AIR LINES
Oil carryover, or the presence of oil in compressed air, is a problem that can lead to contamination, damage downstream equipment, and compromise air quality. If left unresolved, this issue can disrupt operations and increase maintenance costs, making it essential to address promptly.
Possible Causes
One common cause of oil carryover is a worn or faulty air/oil separator. This critical component is responsible for removing oil from the compressed air, and when it fails, excessive oil can enter the air lines.
Another issue could be excessive oil injection or poor maintenance of the separator. If the oil injection system isn’t calibrated correctly, too much oil may enter the compression chamber, overwhelming the separator’s capacity to remove it.
Lastly, operating the compressor beyond its recommended capacity can strain the system and cause oil carryover. Compressors are designed to handle specific workloads, and exceeding these limits can lead to inefficiencies and contamination.
Troubleshooting Steps
Start by inspecting the air/oil separator for wear or damage. If it’s clogged, degraded, or faulty, replacing it can often resolve the issue and restore clean air output.
Next, check the oil injection system. Ensure it’s set to the manufacturer’s recommended levels, and adjust if necessary. Over-injecting oil not only increases carryover risk but can also drive up operating costs.
Finally, evaluate whether the compressor is operating within its capacity limits. If the system is consistently pushed beyond its design specifications, consider upgrading to a larger compressor to meet your demand without compromising performance.
Oil carryover can undermine the reliability of your compressed air system, but with these steps, you can identify and address the root cause.
HIGH ENERGY CONSUMPTION
When your rotary screw compressor uses more energy than expected, it can lead to higher operational costs and reduced efficiency. High energy consumption often indicates underlying issues that, when addressed, can significantly lower your expenses and improve system performance.
Possible Causes
One common cause of excessive energy use is in efficient variable speed drive (VSD) settings. If the VSD isn’t calibrated to match your air demand, the compressor may run harder than necessary, wasting energy.
Another likely culprit is dirty filters or restricted airflow. When air filters are clogged, the compressor works overtime to compensate for reduced airflow, increasing energy use and straining the system. (top of the line air treatment products)
Lastly, worn rotors or poorly maintained components can reduce the overall efficiency of the compression process. These mechanical inefficiencies require more power to achieve the same output, driving up energy consumption.
Troubleshooting Steps
Start by reviewing and optimizing the VSD settings. Adjust the drive to match your specific air demand, ensuring the compressor operates efficiently during low-demand periods without consuming unnecessary energy.
Next, check the filters and airflow. Clean or replace air filters to prevent restrictions, and inspect the system for any blockages that could impede performance.
Finally, examine the rotors and other key components for wear or damage. Worn rotors, bearings, or seals can lead to inefficiencies that force the compressor to work harder than it should. Replace any components that show signs of wear to restore optimal performance.
By addressing these energy-related issues, you can reduce operational costs while extending the life of your compressor.
CLOSING
Troubleshooting rotary screw compressors doesn’t have to be overwhelming. By identifying common issues like insufficient air pressure, oil carryover, or high energy consumption, and taking proactive steps to address them, you can keep your system running smoothly and efficiently.
For more complex challenges or expert support, trust our network of brands to provide the solutions you need. We’re here to help keep your operations moving forward.
