Spooky Compressed Air Warning Signs to Pay Attention To

Higher Operating Temperatures

Air compressors generally operate at high temperatures, but a sudden increase in operating temperature that exceeds the machine’s normal operating temperature ranges can indicate a major problem. If an air compressor becomes too hot it can fully overheat, causing the machine to shut down and stall all operations. Some causes of increased operating temperatures can be low levels of or incorrect lubrication, poor environmental ventilation, hot ambient temperatures, clogged equipment or parts, faulty cooling systems, an undersized air compressor, or lack of rest periods.

What To Do: 

• Inspect your compressed air system for any obstructions, inadequate lubrication levels, incorrect lubricant types, or generally dirty parts.
• Remove/clean any blockages and replace any dirty or worn-out parts.
• Ensure the air compressor is in an area with a suitable climate for the compressor’s requirements that has adequate ventilation.
• Regularly maintain proper oil levels.
• Upgrade your air compressor to the correct size when your operations outgrow your compressor’s capabilities.
• Confirm that the compressed air-cooling system is functioning properly.

Increased Noise Levels

Air compressors are noisy machines while operating, but when a compressor starts sounding louder or inconsistent with its normal operating noise levels, this could signal there is an underlying problem that needs attention. Examples of inconsistent noises from your compressor could be sounds like clicks, rattles, hissing, knocking sounds or excessive vibrations that don’t usually occur. Louder or odd noises coming from your compressor could indicate an issue with internal parts, lack of lubrication, damaged internal moving mechanisms, worn motor bearings, or improper mounting of the compressor.

What To Do: 

• Inspect internal parts, screws, belts, and moving pieces for excessive wear and tear, misalignment, looseness, and contaminant buildup. Realign, replace, or clean any parts that appear to be showing any of these signs.
• Ensure the air compressor is properly mounted and is not encountering any surfaces that may increase vibration and noise levels. Vibration pads can help reduce noise levels in environments that may naturally amplify operating sounds of a compressor.
• Refill lubrication levels when they become too low to prevent noise from increased friction.

Low or Inconsistent Pressure Levels

If an air compressor is properly sized to the facilities demand and operations, then the compressor should be able to supply a sufficient flow of pressure to satisfy these applications. If an air compressor is suddenly unable to provide the required pressure or maintain consistent pressure levels, this not only indicates a larger problem but also will directly impact production and revenue. An incorrectly sized air compressor, whether it be incorrectly sized from the start or the company’s operations have outgrown the current compressor’s capacity, is one of the most common reasons one may observe pressure issues in their facility. Low or inconsistent pressure levels can also indicate other issues such as problems with the piping system, air leaks, a faulty air end, blocked or stuck open valves and drains, or excessive wear and tear on internal parts. 

What To Do: 

• Have a compressed air expert from Zorn come out and audit your system to properly identify the air demand for your operations and properly size the correct type of air compressor to your facility. They can also identify any major issues like rotor misalignment or internal leaks.
• Identify any air leaks or piping issues such as blockages, poor design, or cracks that may be leading to a decrease in pressure. Fix or replace these issues immediately.
• Confirm your pressure regulator is functioning properly and is programmed to the correct settings.
• Inspect filters and valves for blockages, excessive wear and tear, or any other faults that may cause pressure loss. Fix, replace, or clean any parts causing issues.

Over-cycling

If your unit is over cycling, this means that it is turning off and on too frequently. If this happens, it can cause a plethora of other serious issues including overheating, oil or moisture carryover, energy waste, excessive wear and tear on internal components, and a decreased unit lifespan. If your unit is over cycling, the bottom line is that it will burn out fast, so it is important to address this issue immediately. Issues such as insufficient storage, a small difference between your load and unload pressures, an incorrectly sized air compressor, faulty switches and sensors, and high environmental temperatures can cause over cycling. 

What You Can Do: 

• Reevaluate your compressor size and kind for your intended applications. You may need a smaller compressor or one that operates by modulation.
• Add air receiver tanks to increase air storage and give your compressor longer rest periods in between cycles.
• Inspect internal components and any switches or sensors for proper functioning. Make any repairs or adjustments if any pieces seem to be faulty or overused.
• Consider a different control system or monitor that can offer more advanced options to regulate the difference between your load and unload pressures.

Oil Levels Decreasing Rapidly

If your oil levels are decreasing at an abnormally fast rate, then there is an issue with your system that needs to be addressed quickly. Issues such as leaks, poor air pressure, high temperatures, incorrect oil levels, or clogged oil return lines can be causes of oil loss. 

What To Do: 

• Observe the oil reservoir and keep oil levels filled at the recommended level by the manufacturer. Overfilling or under filling the reservoir will affect system lubrication and how the oil is consumed throughout the system.
• Make sure the compressor’s environment is well ventilated and your compressor is not being overworked to the point of overheating.
• Check return lines for any damage or blockages that could cause oil buildups or losses.
• Inspect your system for any leaks and repair them immediately.

Breakers Frequently Tripping & Fuses Blowing

Generally, if breakers and fuses are constantly blowing, this indicates an electrical problem that should be addressed immediately.  Common causes of breakers tripping or fuses blowing are overloaded electrical circuits, a damaged or expired motor, wiring issues, an overheated unit, a compressor being used above its limits, damage to the power cable, or insufficient voltage being provided. 

What You Can Do: 

• Call an electrician to inspect and repair any faulty wiring or connections and locate any overloaded circuits.
• Inspect the internal motor for excessive wear and tear or end of life signs. Replace the motor or upgrade your unit immediately if your motor is past its productive lifespan.
• Ensure that your compressor is not overworked, causing overheating, and that the area is well ventilated. Your compressor should not be operating past its intended PSI ratings, if it is, you need to upgrade your unit.

Increased Moisture Collection

Some moisture collection is normal due to the temperature changes throughout the compression process, but a lot of moisture accumulation is an indication of a problem, most likely with your air treatment. Excessive moisture in your system can cause serious issues such as increased corrosion- internally and in the piping, excessive equipment wear and tear, air and product contamination, electrical damage, and faulty valve operation.

What You Can Do: 

• Evaluate your air treatment equipment to ensure they are operating properly and sized correctly to your compressor.
• Ensure the environment is properly ventilated. If there is excessive moisture buildup, this could be a sign that your system needs to be in a better temperature-controlled environment.
• Observe and replace filters and valves as needed.
• Drain the system regularly or upgrade to automatic drain valves. If you already have automatic drain valves and are still having issues, confirm that these valves are well maintained and operate properly.
• Consider adding other air treatment options.

Problems With Turning Unit On

If your air compressor will not start at all, it can be difficult to identify the problem. The first step would be to locate the reset switch and try that. It is possible that this is a one-time issue and after a reset, the compressor will run fine. However, if this does not solve the issue, there are a handful of reasons why your compressor is not turning on including incorrect wiring, a damaged motor, check valve failure, blocked intake filters, faulty capacitors, power supply concerns, improper pressure settings, defective electrical components and connections, a broken starter, and other similar concerns.

What To Do: 

• Reset the unit and try to start it again.
• Check all power connections to confirm that there are no blown fuses, tripped breakers, or faulty wiring.
• Set the pressure settings to the proper options.
• Assess all internal components, especially the motor. If the motor is showing any signs of distress, excessive wear and tear, or damage have a professional run further testing and conduct repairs.

Contaminants in Discharge Air

Contaminants in your discharge air such as particles, moisture, or oil need to be addressed and removed immediately. These contaminants can ruin your products and cause major profit loss. Oil carryover is one of the most common contaminants that can enter the system and appear in discharge air if the system is not maintained properly. Common causes of oil carryover include a faulty oil separator, excess oil in the sump, a blocked or leaking return line, or the use of an improper oil type and viscosity. Other contaminants like particles that may enter the system and come out through the discharge air can be due to a dirty environment or broken and clogged filters. If condensation is the cause of discharge air contamination, refer to the increased moisture collection section of this blog post.

What You Can Do: 

• Clean the environment around your air compressor.
• Observe and replace any dirty filters.
• Maintain oil levels and ensure it is the proper oil type for your unit and the quality has not degraded over time.
• Inspect the oil return line for any blockages or leaks. Clean or replace as needed.
• Upgrade your entire filtration system.

If any of these issues do arise, it is best to call Zorn Compressor & Equipment to inspect your system and have an expert diagnose and repair any concerns. 

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Zorn is the Midwest leader of custom, engineered compressed air and vacuum solutions. We provide the best customer experience by understanding your applications and needs and offering an unparalleled commitment to customer satisfaction. 

Our comprehensive product and service solutions keep you running 24/7.

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Our compressed air experts look forward to meeting you to discuss your equipment and support needs. Please contact us directly at (262) 695-7000 with any questions or to schedule service for your system moving forward.

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