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Broken Air Compressors: Recognizing and Addressing Common Issues

Air compressors are versatile and necessary pieces of equipment. While usually associated with industrial and construction applications, they also support HVAC and boiler operations.

When these vital machines go on the fritz, they can have a devastating effect on your building. Discover how to recognize and address a broken air compressor and why maintenance and inspections are essential to consistent system operations.

7 Common Signs and Causes of a Damaged or Broken Air Compressor

1. No Power

An air compressor that doesn’t turn on when expected is often shocking or alarming. Despite the initial surprise, the issue is relatively common and easy to diagnose. There are four primary causes of power failure: lack of power supply, absence of oil, power switch failure, and pressure disparity.

The most obvious problem is with the power supply. A professional will check the circuit breakers and power button on the compressor. They will assess the circuit and connections, ruling out any supply issues before moving on.

Oil is essential to the operation of an air compressor and most machinery. Often, users overlook critical maintenance tasks like resupplying the oil tank, which can cause the air compressor to operate on an inefficient supply. When the oil supply gets low enough, the machine may not power on.

If the issue does not result from an absent electrical supply or lack of oil, it may stem from a self-contained problem like a faulty power switch. Sometimes, the power switch does not provide enough contact between the pressure switch and internal circuitry, meaning the system cannot turn on. A professional can remedy the issue by adjusting the pressure switch.

Finally, a broken air compressor may result from a pressure disparity. For an air compressor to work correctly, it requires a balanced relationship between the tank and cut-in pressure. If tank pressure is too low or high, a professional can replace the pressure switch to adjust the cut-in value.

2. Air Leak

Air leaks are relatively common with air compressors, especially ones that undergo a lot of use and stress. The gauge will register an air leak faster than your ears may hear hissing.

A professional may test the system by allowing the compressor to fill its tank before shutting it down. If the tank holds the pressure, there is no leak, but if pressure immediately falls, a leak is present.

A licensed technician with Antler Pumps may listen or feel for the leak. If they cannot find the leak, they may apply a dish soap solution to the connection points, looking for bubbles.

3. Unusual Noise

Air compressors are noisy machines, but they can become excessively noisy when malfunctioning or damaged. The noise level may get so loud that working around the device is uncomfortable and nearly impossible. Despite the volume, noise issues do not always mean immediate repair is necessary or that a broken air compressor is imminent. Still, the noise indicates a problem that, if left uncorrected, could lead to significant repairs and damages later.

The air compressor likely requires minimal corrections in the earliest phase of excessive or unusual noises. For example, the noises can stem from loose parts, improper mounting, problem pistons, or a troubled crankcase. When tackled quickly, each problem is minor, with relatively quick repairs. By leaving the repairs until later, you allow the excessive noise to disrupt workflows and the additional vibrations to wreak havoc on the system’s internal components.

4. Humming

When an air compressor hums without producing air or functioning as intended, the motor is powering on without operating the system. Leaving the system alone risks rapid overheating and motor damage. You should immediately shut down the compressor and call a professional.

A professional from Antler Pumps reviews the power supply, intake filter, and unloader valve before considering other issues. Sometimes, people assume they have a broken air compressor when the problem stems from an unclean or unpure power supply. You never want your air compressor plugged into an extension cord or power strip; always plug the device directly into an appropriate outlet.

Also, clogs in intake filters can disrupt the flow and operation of an air compressor. Professionals remove intake filters, examine them, and may even try running the system without the filter to see if regular operation resumes. If it does, they can replace the filter to resolve the issue.

If intake filter replacements and clean power supplies don’t resolve the problem, it is possible that air gets trapped above the pistons during operation. The extra load above the pistons can cause the motor to stall or malfunction, causing a humming.

5. Rapid Oil Use or Unusual Discharge

Older air compressors may use oil quicker than they did when they were new. Still, while not always a sign of a broken air compressor, when the device uses or goes through more oil than usual, it can represent several potential issues, including leaks, intake obstructions, improper viscosity, and worn piston wings.

Another common oil issue with a damaged or faulty compressor is discharge in the air. Excessive or unusual oil discharge can damage connected components or systems. The problem usually stems from one of several issues, including:

• – Expired piston rings
• – Inverted piston rings
• – Overfilled oil tank
• – Restricted intake
• – Wrong oil viscosity

6. Unusual Vibration

All mechanical devices vibrate to an extent. Because of frequent vibrations, most devices require routine rebalancing. Suppose building or tool owners do not rebalance systems. In that case, air compressors may display unusual or excessive vibrations, which can stem from loose mounting bolts, old belts, bent crankshafts, or misaligned parts.

7. Inadequate Pressure

An air compressor should create and hold specific pressure levels. If the device cannot maintain adequate pressure levels, several things might be wrong. A professional will need to assess several system components to determine the underlying cause of the issue.

Importance of Routine Maintenance and Inspections To Avoid a Broken Air Compressor

Call Antler Pumps for Service

A broken air compressor can affect your building’s operations and your tenants’ comfort and safety. Routine maintenance and inspections are vital to ensuring your system runs as intended. Call Antler Pumps at 212-534-2500 to schedule air compressor and pump service; also, talk to a representative about annual service contracts to ensure consistent operations.