Compressors are essential in many sectors—from manufacturing and automotive to medical and food processing. Nevertheless, when they malfunction, it can disrupt productivity and raise expenses. This guide outlines eight of the most common compressor issues, how to troubleshoot them, and tips to get your system back online quickly.
Key Takeaways
- No control voltage
- Malfunctioning control or time relay
- Verify if control voltage is present
Compressor Fails to Start
Possible Root causes:
- No control voltage
- Blown fuse
- Malfunctioning control or time relay
Fault diagnosis Steps:
- Verify if control voltage is present
- Inspect fuses and replace if necessary
- Test control relays and timer relays for proper operation
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Compressor Starts but Shuts Off Immediately
Symptoms:Compressor turns on but stops within a few seconds.
Checkpoints:
- Guarantee automatic circuit breaker hasn’t tripped
- Confirm proper input voltage
- Inspect air intake butterfly valve (starting under load may cause breakdown)
- Check Y-Δ starter (wye-delta) for contactor issues or phase imbalance
No Air Output from the Compressor
Possible Root causes:
- Control cylinder not actuating
- Butterfly valve breakdown
- Solenoid valve coil (ISV) not energizing
Action Steps:
- Check mechanical integrity of valves
- Verify electrical signal to ISV solenoid
- Test control circuit step by step
Low Discharge Pressure
Root Root causes:
- Pressure loss before/after separator
- Leaking manual or solenoid valve (2SV)
- Leaks in piping or air connections
- Intake regulator malfunction
- Misadjusted pressure switch (IPS)
Fault diagnosis:
- Check for leaks in valves and piping
- Confirm that intake butterfly valve is fully open
- Test pressure sensor settings and recalibrate if needed
Oil Carryover or Oil Spitting from Compressor
Most likely in screw compressors.
Main Root causes:
- Faulty oil stop valve (5SV)
- Check valve damage
- Improper assembly or internal wear
Remedy:
- Verify voltage to 5SV
- Inspect the check valve for wear or debris
- Replace damaged parts
Excessively High Discharge Temperature
Normal Range: 80–95°CCommon Root causes:
- Low or degraded lubricating oil
- Dirty oil cooler or aftercooler
- Faulty temperature control valve
- Fan motor breakdown
- High ambient temperature
Remedies:
- Check and refill lubricant
- Clean or replace the cooler
- Replace malfunctioning thermostatic valve or damaged diaphragm
- Test the lubricant filter and replace if clogged
High Oil Consumption
Possible Problems:
- Overfilled oil tank
- Blocked oil return line
- Oil separator core deterioration
- Steam trap releasing oil-laden condensate
- Incorrect pressure valve settings
Prevention:
- Maintain correct oil levels
- Inspect and clean return lines
- Replace separator and filters as needed
- Use OEM parts for consistency and durability
Unexpected Auto Power-down During Operation
Triggers Include:
- Overheat protection
- Overpressure power-down
- Cooling fan breakdown
- Electrical issues (thermal relay, breaker)
How to Diagnose:
- Monitor exhaust temperature and system pressure
- Check fan motor and protective relays
- Use diagnostic tools or controller display for malfunction codes
Bonus Tips: Preventative upkeep Best Practices
- ✅ Schedule regular inspections for filters, separators, and valves
- ✅ Maintain proper ventilation in compressor rooms
- ✅ Monitor operating temperatures and pressures in real-time
- ✅ Always use manufacturer-recommended lubricants and parts
- ✅ Train personnel on proper startup/power-down procedures
The Unsung Heroes Behind Dependable Air Compression – Our Operators!
- Technology configuration
- Strike Cost
- Import and ship assistance
Frequently Asked Questions
What should I check first when a compressor will not start?
Confirm power supply, control settings, and emergency stop status, then check the pressure switch and any start protection devices.
Why does my compressor run hot?
Common causes are restricted airflow, low oil level, a blocked cooler, or high ambient temperature. Clean the cooler and verify lubrication first.
What does excessive oil consumption mean?
It usually indicates worn separator elements, overfilling, or a leak in the oil circuit. Inspect the separator and seals.
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