What are the common spare parts of the air compressor, and how to replace them?

What are the components of an air compressor?

1. Sensors

Temperature sensors, pressure sensors.

2. Controllers

Computer boards, relay boards, PLC controllers, control panels, operator panels.

3. Valves

Solenoid valves, rotary valves, pneumatic valves, blowdown valves, temperature control valves, thermal control valves, temperature control valve cores, proportional valves, capacity adjustment valves, pressure maintenance valves, intake valves, safety valves, regulating valves, expansion valves, check valves, shuttle valves, automatic drain valves, pressure reducing valves, pressure regulators.

4. Filters and Oil

Air filters, oil filters, fine oil filters, lubricating oil, pipeline filters, automatic drain valves, water filter cups.

5. Main Unit

Main unit (compressor head), bearings, shaft seals, shaft sleeves, gears, gear shafts.

6. Maintenance Kits

Maintenance kits for main units, unloading valve, pressure maintenance valve, rotary valve, temperature control valve core, intake valve, flexible coupling, etc.

7. Cooling

Fans, radiators, heat exchangers, oil coolers, rear coolers. (Water-cooled pipeline/water tower)

8. Switches

Pressure switches, temperature switches, emergency stop switches, differential pressure switches.

9. Transmission

Couplings, elastic elements, plum blossom pads, elastic blocks, gears, gear shafts.

10. Hoses

Inlet hoses, high-pressure hoses.

11. Starters

Contactors, thermal protectors, reverse-phase protectors, terminal blocks, relays, transformers, etc.

12. Buffering Components

Shock absorber pads, expansion joints, expansion valves, elastic elements, plum blossom pads, elastic blocks.

13. Instruments

Timers, temperature switches, temperature displays, pressure gauges, pressure reducing gauges.

14. Motors

Permanent magnet motors, frequency conversion motors, asynchronous motors.

How to maintain and replace common components of air compressors?

1. Air Filter:

The air filter is a component that filters out dust and impurities from the air, allowing clean air to enter the compression chamber of the screw rotor for compression.

If the air filter element is clogged or damaged, a large amount of particles larger than the allowable size may enter the screw compressor, leading to a significant reduction in the service life of the oil filter and oil separator element. Moreover, a large number of particles can directly enter the bearing chamber, accelerating bearing wear, increasing rotor clearance, reducing compression efficiency, and even causing rotor seizure.

2. Oil Filter:

After the initial 500 hours of operation of a new compressor, the oil filter element should be replaced. Use a specialized wrench to unscrew the old oil filter element, and before installing the new filter element, it is recommended to add screw compressor oil. Hand-tighten the filter element to the oil filter housing, and then use force to securely tighten it.

It is recommended to replace the oil filter element every 1500-2000 hours. If you are changing the oil, it is best to replace the oil filter element at the same time. In harsh environments, the replacement interval should be shortened.

Using the oil filter element beyond its recommended service life is strictly prohibited. Otherwise, due to severe clogging of the filter element, the pressure difference may exceed the bypass valve's limit, causing the bypass valve to automatically open. This will allow a large amount of dirt and particles to directly enter the screw compressor, leading to serious consequences.

Misconception: It is not true that the higher the filter precision of the filter, the better. Instead, the best choice is to select the appropriate air compressor filter. The filter precision refers to the maximum diameter of solid particles that the air compressor filter element can block. The higher the filter precision, the smaller the diameter of the solid particles it can block, but it is also more prone to blockage by larger particles.

When selecting an air compressor filter, choosing a high-precision filter without considering the specific application may not guarantee an improvement in the filter's filtration efficiency (which is related to the penetration rate, a critical criterion for measuring the filter's quality) and could affect its service life. The filter precision should be selected based on the filtration target and the desired outcomes.

3. Separator:

The oil-gas separator is a component that separates lubricating oil from compressed air. Under normal operation, the service life of the oil-gas separator is around 3000 hours, but the quality of the lubricating oil and the precision of the air filtration greatly influence its lifespan.

In harsh operating environments, it is necessary to shorten the maintenance and replacement cycle of the air filter element, and consider installing a pre-air filter. The oil-gas separator must be replaced when it reaches its service life or when the pressure difference before and after exceeds 0.12 MPa. Otherwise, it may cause motor overload and oil leakage from the separator.

When replacing the separator, follow these steps:

1) Remove the various control pipe connectors installed on the oil-gas barrel cover.

2) Take out the return pipe that extends into the oil-gas barrel from the cover.

3) Remove the fastening bolts securing the oil-gas barrel cover.

4) Lift off the oil-gas barrel cover and take out the oil separator.

5) Clean any asbestos gasket and dirt adhering to the cover plate.

6) Install the new oil-gas separator. Ensure that the upper and lower asbestos gaskets are properly aligned and secured with bolts or clips to prevent displacement during compression, which could cause failure.

7) Reassemble the cover plate, return pipe, and various control pipes, and check for any leaks.

It's essential to follow these steps carefully during the replacement process to ensure the proper functioning of the oil-gas separator and avoid any potential issues.