Causes of compressor overheating and how to prevent it

25 March, 2024

When it comes to air compressors operating in high-temperature environments, prevention of temperature related shutdowns is crucial. Overheating can significantly impact both performance and durability, resulting in costly downtime and maintenance. To ensure optimal air compressor operation, consider implementing effective strategies to minimize overheating risks.

Why is my compressor overheating?

During the compression process heat is generated in the compressor element, this heats need to be extracted to keep the compressor running in optimal conditions. In high-temperature environments, air compressors are prone to overheating due to various underlying factors. Understanding these causes is essential for effectively preventing overheating issues. Below, we delve into the common culprits in detail:

High ambient temperatures
Especially during summer, elevated external temperatures contribute to overheating. Monitoring the compressor room temperature regularly can help you identify abnormal temperature fluctuations and address the issue promptly. Fresh and clean air circulation inside the compressor room is essential to avoid these situations.
Insufficient ventilation
Inadequate ventilation or recirculation of hot air can impede the heat dissipation necessary for proper compressor operation, leading to overheating. Additional ducting can guide hot air out of the facility and ensure the supply of cool and clean air to the compressor inlet.
Low oil levels or non genuine oil
In an oil injected compressor, the compressor oil is used as cooling media to dissipate the heat of the compression process. Insufficient lubrication or the use of oils with a low heat transfer capability generates excess heat within the compressor.
Lack of maintenance
Keeping the compressor coolers clean is mandatory to guarantee good cooling performance, but also regular service and replacement of compressor oil and filters are crucial to keep the operating temperature of the compressor under control.

How to prevent your air compressor from overheating?

Prevention is key. Instead of focusing on ways to cool down an overheated compressor, put your effort into preventing overheating from happening at all;

Choose Genuine Atlas Copco parts
Each component of your compressor is vital for its overall performance, giving you the reliability, long lifetime and energy efficiency, you expect. Every part and lubricant is expertly designed, manufactured and tested according to the most stringent standards.
Inspect oil and lubrication levels
Lubrication acts as a coolant, so monitor the oil and lubricant levels in your compressor often. Additionally, select the correct compressor oil for your application and replace the oil according the scheduled service visits.
Routine maintenance
The simplest action to prevent overheating is to have routine maintenance performed on your compressor according manufacturers recommendation. Atlas Copco service technicians are trained to know which parts need to be replaced, spot any abnormalities and take actions to avoid shutdowns from happening.
Ensure proper ventilation in the compressor room
Proper ventilation plays a vital role in preventing air compressors from overheating. Adequate airflow around the compressor helps dissipate heat and maintain optimal operating temperatures. Regularly inspect and clear any obstructions that may impede airflow to and from the compressor.
Adjust water cooling systems
For water-cooled compressors, adjust the temperature and flow of water entering the compressor. This will ensure the compressor is cool enough for summer conditions.
Monitor your equipment

Prevention is key. Instead of focusing on ways to cool down an overheated compressor, put your effort into preventing overheating from happening at all;
- Choose Genuine Atlas Copco parts
  Each component of your compressor is vital for its overall performance, giving you the reliability, long lifetime and energy efficiency, you expect. Every part and lubricant is expertly designed, manufactured and tested according to the most stringent standards.
- Inspect oil and lubrication levels
  Lubrication acts as a coolant, so monitor the oil and lubricant levels in your compressor often. Additionally, select the correct compressor oil for your application and replace the oil according the scheduled service visits.
- Routine maintenance
  The simplest action to prevent overheating is to have routine maintenance performed on your compressor according manufacturers recommendation. Atlas Copco service technicians are trained to know which parts need to be replaced, spot any abnormalities and take actions to avoid shutdowns from happening.
- Ensure proper ventilation in the compressor room
  Proper ventilation plays a vital role in preventing air compressors from overheating. Adequate airflow around the compressor helps dissipate heat and maintain optimal operating temperatures. Regularly inspect and clear any obstructions that may impede airflow to and from the compressor.
- Adjust water cooling systems
  For water-cooled compressors, adjust the temperature and flow of water entering the compressor. This will ensure the compressor is cool enough for summer conditions.
- Monitor your equipment
  
  Prevention is key. Instead of focusing on ways to cool down an overheated compressor, put your effort into preventing overheating from happening at all;
  - Choose Genuine Atlas Copco parts
    Each component of your compressor is vital for its overall performance, giving you the reliability, long lifetime and energy efficiency, you expect. Every part and lubricant is expertly designed, manufactured and tested according to the most stringent standards.
  - Inspect oil and lubrication levels
    Lubrication acts as a coolant, so monitor the oil and lubricant levels in your compressor often. Additionally, select the correct compressor oil for your application and replace the oil according the scheduled service visits.
  - Routine maintenance
    The simplest action to prevent overheating is to have routine maintenance performed on your compressor according manufacturers recommendation. Atlas Copco service technicians are trained to know which parts need to be replaced, spot any abnormalities and take actions to avoid shutdowns from happening.
  - Ensure proper ventilation in the compressor room
    Proper ventilation plays a vital role in preventing air compressors from overheating. Adequate airflow around the compressor helps dissipate heat and maintain optimal operating temperatures. Regularly inspect and clear any obstructions that may impede airflow to and from the compressor.
  - Adjust water cooling systems
    For water-cooled compressors, adjust the temperature and flow of water entering the compressor. This will ensure the compressor is cool enough for summer conditions.
  - Monitor your equipment
    
    Prevention is key. Instead of focusing on ways to cool down an overheated compressor, put your effort into preventing overheating from happening at all;
    - Choose Genuine Atlas Copco parts
      Each component of your compressor is vital for its overall performance, giving you the reliability, long lifetime and energy efficiency, you expect. Every part and lubricant is expertly designed, manufactured and tested according to the most stringent standards.
    - Inspect oil and lubrication levels
      Lubrication acts as a coolant, so monitor the oil and lubricant levels in your compressor often. Additionally, select the correct compressor oil for your application and replace the oil according the scheduled service visits.
    - Routine maintenance
      The simplest action to prevent overheating is to have routine maintenance performed on your compressor according manufacturers recommendation. Atlas Copco service technicians are trained to know which parts need to be replaced, spot any abnormalities and take actions to avoid shutdowns from happening.
    - Ensure proper ventilation in the compressor room
      Proper ventilation plays a vital role in preventing air compressors from overheating. Adequate airflow around the compressor helps dissipate heat and maintain optimal operating temperatures. Regularly inspect and clear any obstructions that may impede airflow to and from the compressor.
    - Adjust water cooling systems
      For water-cooled compressors, adjust the temperature and flow of water entering the compressor. This will ensure the compressor is cool enough for summer conditions.
    - Monitor your equipment
      SMARTLINK captures live data from your compressed air equipment and translates it to clear insights. At a glance, you can check uptime, energy efficiency and the health of your complete installation. Alerts warn you if the compressor temperature goes out of control, allowing you to take corrective actions before a shutdown could occur. Atlas Copco also offers the solution to monitor your compressor 24/7 by our remote diagnostic services.

Frequently asked questions

What are the common signs of compressor overheating?

Compressors have built-in safety measurements against overheating such as discharge temperature switches that will shut down the compressor in case of excessive heat. It is however important to check if the discharge temperature is increasing due to external conditions and take appropriate actions.

Rising discharge temperatures
Low refrigerant levels (oil free compressors) or poor lubrication (oil injected compressors) can cause high discharge temperatures. If the discharge temperatures consistently rise above normal operating ranges, it is essential to investigate the cause and take immediate action to address issues causing elevated discharge temperatures. Regularly checking these temperatures helps prevent damage to internal compressor components.
Frequent shutdowns due to temperature limits
Frequent shutdowns of air compressors can occur when the temperature limits are reached. These temperature limit settings are built-in safety features designed to protect against overheating. When a compressor repeatedly shuts down due to temperature limits, it is a clear indication of overheating. Automatic shutdown features help prevent further damage and allow the compressor to cool down. It is important to investigate potential causes, such as inadequate ventilation or mechanical problems, to address this issue.
Abnormal noise levels or unusual vibrations
Observing high noise levels are unusual vibrations may indicate overheating problems due to mechanical wear and tear. Addressing and resolving the cause of these vibrations and noise levels can prevent further damage to the compressor.

What happens if an air compressor overheats?

When your compressor begins acting unusual, it’s wise to start investigating the concerns early on. Quickly identifying the problems will prevent unnecessary downtime. An overheated compressor can lead to internal component damage, shortening of the lifespan and safety risks.

Can I recover my waste heat?

As much as 94% of the energy consumed by an air compressor is converted into heat. Energy Recovery can recover much of that heat for reuse. It enables you to save costs, while reducing your environmental impact.