Air compressors are essential to many industrial and manufacturing processes, and equipment malfunctions can result in costly downtime. To minimize this downtime, it's essential to have a solid understanding of common air compressor problems and how to resolve them quickly
If you're experiencing issues with your Atlas Copco air compressor, you need a reliable air compressor troubleshooting guide to get it back up and running.
In this article, we'll provide you with expert tips and techniques for troubleshooting. We'll cover the most common issues you may encounter. From a compressor that won't start to high element outlet temperatures, and offer practical solutions to get your compressor back to optimal performance or when to call Atlas Copco service.
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 model-specific troubleshooting guidance. Or login to SMARTLINK to view real-time fault diagnostics and troubleshooting steps tailored to your specific compressor.
Always isolate the compressor from its power supply and release all system pressure before opening any panels or inspecting internal components. Follow the isolation procedure described in the machine’s instruction manual to ensure safe access.
When to call a professional for compressor repair?
Routine tasks such as replacing air filters, checking the oil level, or resetting a tripped overload can be performed by self-service.
More complex issues—like inlet valve inspections, oil separator element replacements, or any refrigerant circuit faults should be handled by Atlas Copco service, as indicated in the troubleshooting chart.
Not found the issue? Below air compressor troubleshooting chart maps the most common Atlas Copco compressor faults to their causes and recommended actions. Before working on machines, always check the manual and follow the safety instructions. In case of doubt, contact Atlas Copco
1. Compressor does not start or stops during operation. Elektronikon shows motor overload problem
Motor overload relay (F21) open
Reset the overload once, if the issue keeps reoccurring consult Atlas Copco
Circuit breaker (Q15) or fan motor overload (F15) open
Reset the overload once, if the issue keeps reoccurring consult Atlas Copco
Motor thermistor (K34) tripped or defective
Reset the overload once, if the issue keeps reoccurring consult Atlas Copco
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
Consult Atlas Copco
2. Compressor air delivery or pressure below normal.
Air consumption exceeds air delivery of compressor
Check air requirements of equipment connected
Clogged air filters Air filters to be replaced
Air leakages Check and correct
3. Compressor elements outlet temperature or delivery air temperature above normal
Insufficient cooling air
- Check for cooling air restriction
- Improve ventilation of compressor room
- Avoid recirculation of cooling air
Oil level too low Check and correct as necessary
Oil cooler dirty
Clean cooler from any dust and ensure cooling air is free from dirt
Oil cooler clogged
Consult Atlas Copco service people
On watercooled units, cooling water temperature too high or flow too low
Increase water flow and check temperature
On watercooled units, restriction in cooling water system due to dirt or formation of scale
Check and clean the water circuit and coolers
4. Safety valve blows after loading
Safety valve out of order
Check the pressure setpoint and consult Atlas Copco service people
Inlet valve malfunctioning
Consult Atlas Copco service people
Minimum pressure valve malfunctioning
Consult Atlas Copco service people
Oil separator element clogged
Oil, oil filter and oil separator element to be replaced
Dryer piping clogged because of ice formation
Inspect the freon circuit and leaks, Contact Atlas Copco
5. Condensate is not discharged from condensate trap(s) during loading
Discharge pipe of condensate trap clogged Check and correct as necessary.
Float valve of condensate trap(s) malfunctioning Float valve assembly to be removed, cleaned and checked. Contact Atlas Copco
6. Compressor starts running, but does not load after a delay time
Solenoid valve out of order
Solenoid valve to be replaced
Inlet valve stuck in closed position
Inlet valve to be inspected by Atlas Copco service people
Leak in control air tubes
Inspect and Replace leaking tubes
Minimum pressure valve leaking (when air net is depressurized)
Minimum pressure valve to be inspected by Atlas Copco service people
7. Compressor does not unload, safety valve blows
Solenoid valve out of order
Solenoid valve to be replaced
Inlet valve does not close
Inlet valve to be inspected by Atlas Copco service people
8. Compressor air output or pressure below normal
Air consumption exceeds air delivery of compressor
- Eliminate possible compressed air leaks.
- Increase delivery capacity by adding or replacing the air compressor
Clogged air filters
Air filters to be replaced
Solenoid valve malfunctioning
Solenoid valve to be replaced.
Oil separator element clogged
Oil, oil filter and oil separator element to be replaced.
Air leakage
Have leaks repaired. Leaking tubes to be replaced
Safety valve leaking
Safety valve to be replaced.
Inlet valve does not fully open
Inlet valve to be inspected by Atlas Copco service people
9. Pressure dewpoint too high
Air inlet temperature too high
Check and correct; if necessary, install a pre-cooler
Ambient temperature too high
Check and correct; if necessary, draw cooling air via a duct from a cooler place or relocate the dryer
Air inlet pressure too low
Increase inlet pressure
Dryer capacity exceeded
Reduce the air flow
Shortage of refrigerant
Have circuit checked for leaks and recharged, Contact Atlas Copco
Refrigerant compressor does not run
Check the electric power supply to refrigerant compressor
Condenser pressure too high
Check fan/fan motor, Contact Atlas Copco
Evaporator pressure is too high or too low at unload
Have hot gas by-pass valve adjusted, Contact Atlas Copco
A high element outlet temperature alarm is one of the most common faults on rotary screw compressors. Addressing the root cause quickly prevents automatic shutdown and unplanned downtime. Overheating can reduce compressor performance, shorten component life, and lead to costly interruptions. Implementing a few targeted measures to control temperature helps keep your compressor running reliably, even in demanding conditions.
Read more the causes of compressor overheating and how to prevent it
When it comes to air compressors operating in high-temperature environments, prevention is crucial. Overheating can significantly impact both performance and durability, resulting in costly downtime and maintenance.
Instead of troubleshooting and doing all the routine maintenance, let Atlas Copco's service engineers take care of your compressor room and proactively detect and repair any developing problems.
SMARTLINK gives you the opportunity to keep track of the status and efficiency of your compressed air system without even visiting the compressor room.
