Fault Diagnosis and Solutions for Diaphragm Compressors

      The following are common fault diagnosis and solutions for diaphragm compressors:

      1、 Abnormal pressure

      Unstable or fluctuating pressure:

      Reason: Unstable gas source pressure;The air valve is not sensitive or faulty;Poor cylinder sealing.

      Solution: Check the air source pressure to ensure its stability;Check the working status of the air valve and replace it if there are any problems;Check the cylinder seal and replace the seal if any problems are found.

      2、 Insufficient displacement or insufficient exhaust pressure:

      Reason: Blockage or leakage of import and export pipelines;Wear of piston rings and cylinders.

      Solution: Clean or repair blocked or leaking inlet and outlet pipelines;Replace worn piston rings and cylinders.

      3、 Noise issue

      Compressor noise is loud:

      Reason: Poor cylinder sealing;The diaphragm is loose or damaged;The foundation of the compressor is not firm; Loose or worn internal components of the compressor.

      Solution: Check and replace the cylinder seal;Check the tightness of the diaphragm and whether it is damaged or aged, and replace the diaphragm as appropriate;Strengthen the foundation of the compressor; Check and replace loose or worn components.

      4、 Leakage fault

      Compressor leakage:

      Reason: Damaged diaphragm;Poor cylinder sealing.

      Solution: Check the diaphragm and replace it promptly if it is damaged; Check the cylinder seal and replace the seal.

      5、 The temperature is too high

      Compressor temperature too high:

      Reason: Insufficient or poor quality lubricating oil;The diaphragm is loose or damaged.

      Solution: Check the oil quantity and quality of the lubricating oil, and replace it with the appropriate lubricating oil;Check the tightness of the diaphragm and whether it is damaged or aged, and replace the diaphragm as necessary.

      6、 Oil circuit malfunction

      Low or no oil pressure, but normal exhaust pressure:

      Reason: Damaged pressure gauge or blocked damper; The oil drain valve is not tightly closed; The throttle valve in the oil drain valve is blocked.

      Solution: Replace the pressure gauge or clean the damper;Tighten the handle of the oil drain valve, and replace the oil drain valve if oil is discharged;Clean the throttle valve in the oil drain valve and pay attention to the installation sequence and orientation of the ball, piston, spring, and spring seat.

      Oil pressure too low or no oil pressure, and no exhaust pressure:

      Reason: Low oil level; Compensate for oil pump malfunction; Oil cylinder inlet valve issue; The valve core and seat of the pressure reducing valve are worn or stuck by foreign objects; The piston ring and cylinder liner are damaged.

      Solution: Add lubricating oil to the normal oil level; Check the compensating oil pump, clean or replace the inlet and outlet valves, replace worn plungers
and plunger sleeves; Clean the oil cylinder inlet valve; Replace the valve core and seat of the pressure reducing valve;Replace the piston rings and cylinder liners.

      7、 Oil pressure too high:

      Reason: Insufficient intake volume;Valves, especially bypass valves, are stuck or damaged; The pressure reducing valve core is stuck.

      Solution: Check the intake pressure and intake pipeline, and clean any blockages;Check and clean or replace valves;Check the pressure reducing valve, clean or replace the valve core.

      8、 Diaphragm related faults

      Short service life of membrane:

      Reason: The inlet pipeline was not blown clean, and impurities such as welding slag got stuck in the inlet and exhaust valves, causing damage to the diaphragm.

      Solution: Before putting the unit into operation, ensure that the inlet pipeline is blown clean, regularly check the diaphragm, and replace it promptly if severe wear is found.

      Membrane rupture:

      Reason: Metal shavings or sand particles or other hard objects are introduced during the installation of the membrane;The loosening of the oil cylinder sleeve increases the piston oil discharge area, causing the oil discharge pressure to exceed the strength limit of the diaphragm.

      Solution: Replace the new membrane strictly according to the requirements;Repair the fixed loose cylinder liner.

      9、 Other faults

      Some working cylinders are not working, and the pressure and flow cannot meet the requirements:

      Reason: There are debris stuck in the inlet pipeline, causing damage to the air valve.

      Solution: Check if the inlet pipeline is blown clean. If there are any debris, use appropriate tools to remove them and replace the damaged air valve.

      The manual unloading handle of the pressure regulating valve often leaks oil, and the connecting rod between the pressure regulating valve and the oil cylinder often breaks and sprays oil:

      Reason: Sealing failure of the handle; Insufficient strength of the connecting rod.

      Solution: Replace the O-ring seal;Regularly check the strength of the connecting rod and replace it promptly if it breaks.

      Cylinder not working or unstable:

      Reason: Cylinder leakage or blockage;The internal oil circuit of the cylinder is not unobstructed.

      Solution: Repair or replace leaking or blocked cylinders; Clean and unclog the internal oil circuit of the cylinder.

      The cooling system of the compressor has malfunctioned:

      Reason: Leakage or blockage of the cooling system;Cooler and water pump malfunction.

      Solution: Repair the leakage of the cooling system and clean the blockage; Check and replace the faulty cooler and water pump.