Zero level air generator is a key equipment for providing high-purity air in laboratories and industrial production, and its stable operation is crucial for the accuracy of analysis results. However, it is inevitable to encounter various faults during long-term use. The following are common faults and their systematic solutions:
1、 Abnormal output pressure and flow rate
-Unstable or continuously decreasing pressure
-Abnormal operation of compressor: Check if the compressor is running normally, and if there are any problems, repair or replace it in a timely manner.
-Pipeline leakage: Apply soapy water to the interface, observe the bubbles to determine the leakage point, and re tighten (usually with a torque of 15N · m) or replace the seal.
-Desiccant failure: If the compressed air has a high water content causing pressure fluctuations, it is necessary to replace the high-efficiency desiccant and blow the pipeline with high-purity nitrogen for 5 minutes before replacement to avoid residual impurities contaminating the new filter element.
-Insufficient traffic
-Filter blockage: Clean or replace the intake filter to ensure smooth airflow.
-Unreasonable pipeline layout: Check whether the pipeline is bent or flattened, and adjust the pipeline layout if necessary.
2、 Startup and operation failures
-The device cannot start
-Power issue: Check the power cord connection, fuse (usually 5A specification), and cooling fan status.
-Internal component failure: Open the instrument side cover, check if the transformer is working properly, if the pressure switch is conducting, and replace the faulty component if necessary.
-Abnormal shutdown or abnormal noise during operation
-Thermal protection trigger: The compressor automatically shuts down due to overheating, which may be caused by blocked air inlet, lack of oil, or leakage of one-way valve. It is necessary to clean the air filter, add specialized lubricating oil (such as No. 18 refrigeration oil), and inspect the check valve.
-Mechanical wear: Metal friction noise occurs during operation, mostly due to compressor bearing wear. The bearings should be replaced in a timely manner and special lubricating oil should be replenished to prevent motor burnout.
3、 Gas quality issues
-Purity does not meet the standard (total hydrocarbon content exceeds the standard)
-Activated carbon filter failure: When adsorption is saturated, hydrocarbons such as methane and propane in the air cannot be effectively removed, and the activated carbon filter needs to be replaced.
-Molecular sieve becomes damp: Remove it and dry it in a 180 ℃ oven for 4 hours before reinstalling, ensuring that the dew point is below -40 ℃.
-Compressed air has a high moisture content
-Desiccant failure: Replace with a new desiccant to ensure its drying effect.
-Poor condensate discharge: Check if the condensate discharge system is working properly and clean any blockages.
-High environmental humidity: Consider adding dehumidification equipment or improving the working environment.
4、 Daily maintenance and preventive measures
-Regular maintenance plan
-Cleaning and replacement of consumables: Check the intake filter, separator, and dryer monthly, and replace the activated carbon filter every quarter (the regular cycle is 3 months, shortened to 1 month in harsh environments).
-Lubrication and calibration: Regularly check the oil level and quality of equipment lubricating oil, and replace it if necessary; Regularly calibrate the flow and pressure to ensure that the equipment operates in optimal condition.
-Operating standards
-Avoid overload operation: strictly follow the equipment manual to avoid prolonged overload operation.
-Environmental control: Place the equipment in an environment with moderate temperature and humidity, and install a constant temperature and humidity device if necessary.