Chapter 2 Fundamentals of Fault Diagnosis-KIMAIR.-The source of power for air compressors

Language

Section 1 Types of Faults and Causes

During the operation of KIMAIR air compressors, various types of faults may occur. Understanding these faults and their causes is essential for timely troubleshooting and ensuring the proper functioning of the equipment. Below are some common fault types and their possible causes: 1. Electrical fault ▪ Power Supply Issues: Unstable voltage, poor power line connections, blown fuses, etc. ▪ Motor Issues: Motor overheating, difficulty in starting, abnormal operating noises, etc. ▪ Control Circuit Issues: Faulty relays, burnt-out contactor points, PLC program errors, etc. 2. Mechanical Faults ▪ Bearing Issues: Bearing wear, insufficient lubrication, improper installation, etc. ▪ Belt Issues: Belt slippage, belt wear, improper belt tension, etc. ▪ Air System Issues: Cylinder leaks, damaged valves, leaks at pipe joints, etc. 3. Control System Faults ▪ Sensor Issues: Malfunctioning pressure sensors, faulty temperature sensors, abnormal humidity sensors, etc. ▪ Controller Issues: PLC controller malfunctions, abnormal touchscreen display, incorrect control program, etc. 4. Lubrication System Faults ▪ Lubricant Issues: Deteriorated lubricant, insufficient lubrication oil, incorrect lubricant type, etc. ▪ Oil Circuit Issues: Blocked oil passages, oil pump failures, clogged oil filters, etc. 5. Cooling System Faults ▪ Cooling Fan Issues: Non-functional cooling fans, excessive fan noise, damaged fan motors, etc. ▪ Radiator Issues: Clogged radiators, damaged radiators, poor heat dissipation, etc. 6. Air Quality Issues ▪ Air Contamination: High levels of dust, moisture, or oil in the compressed air. ▪ Filter Issues: Clogged air filters, damaged air filters, delayed filter replacements, etc. Understanding these fault types and their causes enables quick problem identification and effective troubleshooting, thereby reducing downtime and maintenance costs.

Section 2 Diagnostic Process and Methods

When diagnosing faults in KIMAIR air compressors, following a structured process and method can enhance accuracy and efficiency. Below is a comprehensive fault diagnosis process and methodology:1. Preliminary Inspection ▪ Environmental Inspection: Check whether the installation environment meets the required conditions, such as temperature, humidity, and ventilation. ▪ Appearance Inspection: Examine the equipment for visible damage or abnormalities, such as casing cracks or worn cables. ▪ Operating Status Inspection: Observe the operating status of the equipment, including motor running sounds, pressure gauge readings, and temperature displays. 2. Fault Confirmation ▪ Record Fault Phenomena: Document detailed fault symptoms, such as motor startup failure, insufficient air pressure, or abnormal noise. ▪ Fault Reproduction: Attempt to reproduce the fault to more accurately determine the root cause. 3. Fault Classification ▪ Electrical Faults: Inspect the power supply, motor, and control circuits. ▪ Mechanical Faults: Check bearings, belts, and air pathways. ▪ Control System Faults: Examine sensors and controllers. ▪ Lubrication System Faults: Inspect lubrication oil and oil circuits. ▪ Cooling System Faults: Check cooling fans and radiators. 4. Fault Localization ▪ Use of Diagnostic Tools: Utilize instruments such as multimeters, clamp meters, and oscilloscopes to measure electrical components. ▪ Reference Equipment Manuals: Consult user and maintenance manuals to understand normal operating parameters and fault codes. ▪ Data Analysis: Analyze operating data, such as current, voltage, temperature, and pressure, to identify anomalies. 5. Fault Troubleshooting ▪ Replace Damaged Components: Replace faulty components such as fuses, motors, and sensors. ▪ Repair Faulty Parts: Repair components that can be restored, such as bearings, belts, and oil circuits. ▪ Adjust Equipment Parameters: Correct improperly configured settings, such as motor startup parameters or pressure setpoints. ▪ Clean the Equipment: Perform cleaning on clogged or contaminated components, such as radiators and filters. 6. Verification of Repair Effectiveness ▪ Restart the Equipment: After troubleshooting, restart the equipment and observe its operating status. ▪ Document the Repair Process: Record the details of the troubleshooting process and results for future reference and experience-sharing. 7. Preventive Measures ▪ Regular Maintenance: Develop a routine maintenance schedule for periodic inspections and servicing. ▪ Operator Training: Provide training to operators to enhance their ability to identify and address equipment faults. ▪ Establish a Fault Archive: Maintain a fault log documenting each issue in detail to assist with future diagnostics. By following the above process and methods, KIMAIR air compressors can be effectively diagnosed and repaired, ensuring their normal operation and high efficiency.