Guide to Diagnosing and Resolving Issues with Your Air Compressor

Air compressors serve as the backbone of numerous manufacturing and industrial procedures, and malfunctions can lead to expensive operational disruptions. Therefore, having a firm grasp of typical air compressor issues, along with quick-fix techniques, is vital to reducing this disruption time.

If you're grappling with problems related to your stationary Atlas Copco air compressor, a trustworthy air compressor diagnostic manual is what you require to restore its functionality.

This article aims to equip you with professional advice and strategies for diagnosing issues. We'll discuss everything from low-pressure anomalies to odd sounds, outlining the most frequently faced challenges, and providing practical solutions to bring your compressor back to its peak performance.

Air Compressor Troubleshooting

Here are some quick tips and focus points to help you diagnose and fix the problem:

Check the power supply: Make sure that your air compressor is properly connected to a power source and that the circuit breaker hasn't tripped.
Check the air filter: A clogged air filter can reduce the efficiency of your compressor and cause it to overheat. Make sure to replace the air filter regularly as per described maintenance interval.
Check the oil level: Low oil levels can cause the compressor to overheat or seize up. Make sure to check and top up the oil levels regularly.
Check the pressure settings:Incorrect pressure settings can cause the compressor to run all the time or not start at all at the desired pressure. Check the instruction book on how to set the correct pressure settings for your machine.
Check the valves and hoses: Leaking valves or hoses can cause your compressor to lose pressure or not work at all. Inspect and repair any leaks in your compressed air network. For internal leakages on the compressor itself contact your local Atlas Copco representative. An AIRScan by an Atlas Copco expert can detect leaks in your compressed air network and propose a solution to fix them.
Consult the manual: Always consult the instruction manual for additional troubleshooting tips to help you identify the root cause of the problem. Or login to SMARTLINK and find troubleshooting advice on your specific air compressor.

1. Why is my Air Compressor running too hot?

Check to see if the oil cooler is blocked/dirty
Isolate the machines and blow out with dry compressed air
Oil level too low
Check and correct as necessary, the machine will need to be stopped and isolated to do this
Insufficient cooling air
- Are there any restrictions to the cooling air flow
- Is there adequate ventilation (make up air) in the room
- Are the louvres open correctly
- Does the air recirculate inside the room
Is the Thermostate operating correctly
Contact Anglian Compressors

2. Why do I have water in my compressed air?

Blocked cooler
Stop the machine and isolate the power, clean the cooler
Air inlet temperature too high
Is the compressor running hot
Ambient temperature too high
is something blocking the air ways. Can cool air be drawn in via a duct from a cooler place. If not, move the dryer to a cool location
Air inlet pressure too low
The lower the air pressure, the harder the less efficient the dryer is. Increase inlet pressure will overcome this
Dryer capacity exceeded
Reduce the air flow or increase the air pressure. Install a new larger dryer
Shortage of refrigerant
Contact Anglian Compressors, possible leak on refrigerant circuit, may need to be
Refrigerant compressor does not run
Check the electric power supply
Condenser pressure too high
Contact Anglian Compressors, possible issue with fan/fan motor
Evaporator pressure is too high or too low at unload
Contact Anglian Compressors, Hot gas by-pass valve needs to be adjusted

3. Why is my compressed air pressure too low

Air consumption exceeds air delivery of compressor
Contact Anglian Compressors
Air Filters are blocked (indicators are in the red)
Replace the Air filters
Air leakages
Identify and fix any leaks. At Anglian Compressors, we can carry out an ultrasonic leak survey to identify the smallest of leaks without having to shut down the factory
Pipework is too small
Small bore pipework, long runs of flexible tube and quick release couplers restrict the air flow and cause pressure drops. Replacing them with large fixed pipework will remove the pressure drop and will reduce the energy usage

4. Why isnt the condensate discharging from the condensate trap(s)

5. Why does my air compressor trip out (not an overheating issue)

Is the electrical supply correct
This could be a lose connection with the wiring
Motor overload relay (F21) open
Reset the overload once (only), if the issue keeps reoccurring contact Anglian Compressors
Circuit breaker (Q15) or fan motor overload (F15) open
Reset the overload once (only), if the issue keeps reoccurring contact Anglian Compressors
Motor thermistor (K34) tripped or defective
Reset the overload once (only), if the issue keeps reoccurring contact Anglian Compressors
Phase sequence relay (K25) open
Check and correct if needed the sequence of the connected phases on the power inlet of the machine
Wiring interrupted
Contact Anglian Compressors

6. Compressor starts running, but does not load after a delay time

Solenoid valve is faulty
Solenoid valve to be replaced, please contact Anglian Compressors
Inlet valve stuck in closed position
Inlet valve to be inspected, please contact Anglian Compressors
Leak in control air tubes
Inspect and Replace leaking tubes, please contact Anglian Compressors
Minimum pressure valve leaking (when air net is depressurised)
Minimum pressure valve to be inspected/serviced, please contact Anglian Compressors

7. Why doesn't my air compressor unload? Safety valve blows

8. Why does the safety valve blow after loading?

Safety valve out of order
Contact Anglian Compressors with the serical number and working pressure for a replacement
Inlet valve malfunctioning
Contact Anglian Compressors
Minimum pressure valve malfunctioning
Contact Anglian Compressors
Oil separator element clogged
Contact Anglian Compressors, Oil, oil filter and oil separator element to be replaced
Dryer piping clogged because of ice formation
Inspect the freon circuit and leaks, Contact Anglian Compressors

Frequently Asked Questions

Do I need an expert service?

Absolutely, as compressors can pose safety risks, any indicators of malfunction or inefficiency require instant attention. Our expert engineers possess comprehensive training and we exclusively use Original Equipment Manufacturer (OEM) parts suited to your specific system.

This approach guarantees optimal functioning and longevity of your compressor. Moreover, it provides safety to your employees and clients, and assists you in fulfilling your obligation of maintaining a Written Scheme of Examination.

How do I know when my compressor requires a service?

A majority of compressors come equipped with integrated diagnostic tools that notify you when maintenance is due. However, it's crucial to routinely inspect your system to detect any irregularities in its performance. Pay close attention to any changes in its operation, such as unusual sounds or vibrations, as these may warrant further investigation.

At Anglian Compressors, we meticulously maintain records of all equipment and their respective services, ensuring we're always up-to-date with impending tasks – be it an oil replacement or a comprehensive service. This way, we guarantee that your service and maintenance schedule remains current and well-managed.