Tips for Preventing Heatstroke in Air Compressors

1. High ambient temperature and poor ventilation

Firstly, the higher the ambient temperature, the higher the air temperature sucked in by the air compressor. The operating temperature range of most air compressors is 0°C to 45°C, and the discharge temperature of the compressor head is around the cooling medium temperature + 60°C. If the ambient temperature exceeds the operating temperature, it will significantly increase the cooling system load of the air compressor, reduce heat dissipation performance, and in some cases, result in high-temperature alarms or even shutdowns. Lowering the ambient temperature and maintaining good ventilation are the main methods to effectively solve the air compressor's high-temperature issues.

2. Insufficient oil level in the air compressor

Insufficient oil level in the air compressor can also cause high temperatures. Therefore, regularly check the oil level in the oil and gas barrel, and during the equipment operation, the oil level should not be lower than the lower level of the oil level gauge. If the oil level cannot be observed or the machine temperature is too high, please stop the machine immediately and add oil.

3. Dirty or clogged oil filter

A clogged oil filter, with the bypass valve closed, will prevent the compressor oil from reaching the head position, causing the main engine to quickly heat up due to oil shortage. Furthermore, a clogged oil filter reduces the flow rate, resulting in insufficient lubricating oil being sprayed into the main engine, which hinders the efficient cooling of the heat generated by the head compression, leading to high machine temperature.

4. Malfunctioning temperature control valve

The temperature control valve is responsible for controlling the flow of lubricating oil to ensure that the oil entering the compressor head is at an appropriate temperature. When the refrigeration system starts, the temperature control valve closes, and the lubricating oil goes into the small circulation, directly entering the head. When the oil temperature rises to the opening value of the temperature control valve, the valve opens, and the lubricating oil goes into the large circulation, passing through cooling before being sprayed into the head. A damaged temperature control valve will cause uncooled lubricating oil to enter the main engine, resulting in excessive temperatures. Regularly inspecting the temperature control valve can effectively prevent high temperatures in the machine.

5. Use of poor quality lubricating oil or exceeding the recommended usage period

Low-quality lubricating oil, although cheaper, often has inferior additives and base oil, resulting in poor temperature resistance and easy coking. This can affect the rotor and bearings of the compressor head, causing frequent high-temperature issues and impacting its overall service life. It is recommended for users to use original manufacturer lubricating oil and adhere to regular maintenance intervals as per recommendations. Using expired original lubricating oil can also lead to emulsification and coking, increasing the risk of equipment failure and downtime.

6. Oil cooler issues

- Water-cooled models: Check the temperature difference between the inlet and outlet water pipes, which should ideally be between 5°C to 8°C. If it is lower than 5°C, there might be scaling or blockage issues, affecting the heat exchange efficiency of the cooler and causing poor heat dissipation. In such cases, the cooler should be removed and cleaned. Also, check if the cooling water's inlet temperature, pressure, and flow rate are normal.

- Air-cooled models: Mainly check whether the temperature difference between the inlet and outlet oil is around 10°C. If it is lower, inspect the surface fins of the radiator for dirt or blockage. If dirty, clean the fins with compressed air and check for corrosion. If severe corrosion is present, consider replacing the radiator.

7. Air-cooled mechanical fan issues

Check the air-cooled compressor's mechanical fan for problems such as non-rotation, reverse rotation, or partial rotation.

8. Air-cooled model exhaust duct issues

Check if there are any issues with the exhaust duct, such as insufficient ventilation area, excessive length, or too many bends in the middle. If the exhaust duct is too long, consider installing an exhaust fan in the middle, and ensure the exhaust fan's flow rate is higher than the original air compressor's cooling fan.

By understanding the factors contributing to high temperatures in the air compressor and regularly inspecting the mentioned issues, one can effectively address high-temperature problems and ensure the stable operation of the air compressor.