Screw air compressors play a vital role in industrial production. However, high temperature failure is a common operating problem of air compressors. If not handled in time, it may cause equipment damage, production stagnation and even safety hazards. OPPAIR will comprehensively explain the high temperature failure of
screw air compressors from the aspects of cause analysis, diagnostic methods, solutions and preventive measures of high temperature, so as to help users better maintain equipment and extend its service life.
1. The main cause of high temperature of screw air compressors
Cooling system failure
Cooler blockage: dust, oil and other impurities adhere to the surface of the cooler, resulting in reduced heat dissipation efficiency. If it is a water-cooled air compressor, poor water quality or pipe scaling will aggravate the problem.
Abnormal cooling fan: Broken fan blades, motor damage or loose belts will lead to insufficient air volume, which will affect heat dissipation.
Cooling water problem (water-cooled model): Insufficient cooling water flow, too high water temperature, or valve failure may affect the normal circulation of cooling water, causing equipment overheating.
Lubricating oil problem
Insufficient oil or leakage: Insufficient lubricating oil or leakage will lead to poor lubrication and increased friction heat generation.
Oil quality deterioration: After long-term use, the lubricating oil will oxidize and deteriorate, losing its lubrication and cooling properties.
Oil model error: The viscosity of the lubricating oil does not match or the performance does not meet the standard, which can also cause high temperature problems.
Equipment overload operation
Insufficient air intake: The air filter is blocked or the pipeline leaks, forcing the air compressor to operate at high load.
Excessive exhaust pressure: Pipeline blockage or valve failure increases the compression ratio, causing the compressor to generate too much heat.
Continuous operation time is too long: The equipment runs uninterrupted for a long time, and the heat cannot be dissipated in time, causing the temperature to rise.
Control system failure
Temperature control valve stuck: The temperature control valve failure hinders the normal circulation of the lubricating oil and affects the heat dissipation of the equipment.
Temperature sensor failure: The temperature sensor works abnormally, which may cause the equipment temperature to not be monitored or alarmed in time.
PLC program error: The control system logic failure may cause the temperature control to be out of control, resulting in high temperature problems.
Environmental and maintenance factors
High ambient temperature or poor ventilation: The external ambient temperature is too high or the space where the equipment is located is poorly ventilated, resulting in poor heat dissipation.
Equipment aging: After long-term use, equipment parts wear and tear, heat dissipation performance decreases, and high temperature failures are easy to occur.
Improper maintenance: Failure to clean the cooler, replace the filter element, or check the oil circuit on time affects the normal operation of the equipment.
2. High temperature fault diagnosis process of rotary air compressor
Preliminary observation
Check the temperature display on the control panel to confirm whether it exceeds the set threshold (usually ≥110℃ triggers shutdown).
Observe whether the equipment has abnormal vibration, noise, or oil leakage, and discover potential problems in time.
System troubleshooting
Cooling system: Clean the surface of the cooler, check the fan speed, cooling water flow and water quality.
Confirm the oil level through the oil mirror, take samples to test the oil quality (such as oil color and viscosity) to evaluate the oil status.
Load status: Check whether the air intake filter is blocked and the exhaust pressure is normal to ensure that the user’s gas consumption matches the equipment capacity.
Control element: Test whether the temperature control valve is operating normally, check the accuracy of the temperature sensor and whether the PLC control program is normal.
3. Solutions for high temperature failure of screw air compressors
Targeted maintenance
Cooling system: clean or replace blocked coolers, repair damaged fan motors or blades, and dredge cooling water pipes.
Lubricating oil system: add or replace qualified lubricating oil, and repair oil leakage points.
Control system: calibrate or replace faulty temperature sensors, temperature control valves and PLC modules to ensure the normal operation of the control system.
Optimize operation management
Control ambient temperature: add ventilation equipment or air conditioning to avoid excessive temperature in the air compressor room and ensure normal heat dissipation of the equipment.
Adjust operating parameters: reduce exhaust pressure to a reasonable range to avoid long-term overload operation.
Phase operation: reduce the continuous working time of a single device and reduce the risk of overheating by alternating the use of multiple devices.
Regular maintenance plan
Cleaning and replacing filter elements: clean the cooler, replace the air filter element and oil filter every 500-2000 hours.
Lubricating oil replacement: replace the lubricating oil according to the air compressor manual (usually 2000-8000 hours), and regularly test the oil quality.
Control system calibration: Perform a comprehensive calibration of the control system every year, check the electrical connections and mechanical parts for wear, and ensure stable equipment operation.
4. Emergency treatment suggestions
If a high temperature fault causes the equipment to shut down, take the following temporary measures:
Shut down and turn off the power immediately, and check after the equipment cools down naturally.
Clean the external heat sink and ensure that the equipment vents are unobstructed to help heat dissipation.
Contact professionals to check the temperature control valve, sensor status, etc. to avoid forced restarting of the equipment.
Conclusion
High temperature fault of screw air compressor is a common operating problem, but through timely fault diagnosis, reasonable maintenance and optimized management strategies, equipment damage, production stagnation and safety accidents can be completely avoided. Regular maintenance and good operating habits are the key to extending the service life of air compressors and ensuring stable operation.
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Post time: Jul-29-2025
