1900520013 atlas copco Parts Compressor Controller

I. Environmental Erosion

Dust and Moisture Contamination

The air compressors operate in factory workshops, construction sites, etc. If not properly protected, dust, oil, and moisture will invade the internal components of the controller:

Dust accumulates on the surface of the circuit board, causing component short circuits or poor heat dissipation;

In a humid environment (relative humidity > 85%), the copper foil of the circuit board will oxidize and solder joints will corrode, especially during rainy seasons or in high-humidity areas, leading to control signal drift and button malfunctions.

Case Study: A controller without a protective enclosure operated in a dust-laden workshop for 1-2 years, often experiencing relay sticking and display screen flickering due to accumulated dust on the circuit board.

High Temperature and Vibration Impact

When the controller is close to the main unit or heat dissipation components and remains in an environment above 50°C (more than the rated operating temperature by 40°C), it will accelerate the aging of capacitors, chips, etc., and shorten their lifespan (for every 10°C increase in temperature, the lifespan of electronic components may be halved);

The high-frequency vibration during the operation of the air compressor will cause loose wiring inside the controller and dislodged solder joints, especially when not firmly fixed, leading to poor power supply contact and interrupted sensor signals.

II. Circuit Abnormalities and Power Issues

Voltage Fluctuations and Surge Impacts

The factory power grid has complex loads (such as welding machines, large motor start-stop), which can easily cause sudden voltage surges or instantaneous high-voltage surges:

Low voltage (below the rated voltage by 15%) will cause insufficient power supply to the controller CPU, disorder in program operation, and data loss;

High-voltage surges (such as lightning strikes, power grid switching) may break through the power module and voltage stabilizing chip, directly burning out the circuit board.

In scenarios without a stabilized power supply or surge protection device, the failure rate of the controller will increase by more than 30%.

Short Circuit and Overload Faults

Old external lines and incorrect sensor wiring (such as connecting a 220V power supply to a 5V signal terminal) can cause the input circuit of the controller to short circuit, burning out fuses or core chips;

When the actuating elements (such as solenoid valves, relays) overload, the reverse electromotive force may break through the output port of the controller, causing control signal failure.

III. Component Aging and Quality Defects

Natural Aging of Core Components

After 3-5 years of use, the electrolytic capacitor (responsible for filtering and stabilizing voltage) in the controller will gradually dry out, its capacity will decrease, resulting in increased power supply ripple and CPU reset, display flickering;

Relay contacts that are frequently activated (such as those in frequently started and stopped air compressors) will become poorly conductive due to arc burn, manifested as "commands issued but no action from the actuating element" (such as inability to load/unload).

Design or Manufacturing Defects

Low-priced controllers may use inferior components (such as counterfeit capacitors, low-specification chips), or have unreasonable circuit designs (such as poor heat dissipation layout, missing protection circuits), which are prone to early failure even during normal use;

Compatibility Issues: Some third-party controllers do not match well with air compressor sensors and actuators, and may cause program crashes due to signal conflicts after long-term operation.

IV. Improper Use and Maintenance

Incorrect Parameter Settings and Operational Errors

Non-professionals randomly modifying controller parameters (such as overload protection threshold, pressure upper and lower limits) may cause the controller to lose its protective function, or even trigger internal program disorder due to logical conflicts;

Forcibly shutting down (not following the normal shutdown procedure) may cause the controller's stored data to be damaged, making it unable to load the program upon startup.

Failure of Wiring and Sensor Faults Leading to Component Damage

When sensors (such as pressure sensors, temperature probes) short circuit or age, if the controller does not have an overcurrent protection circuit, it may reverse-burn the signal acquisition module;

Incorrect external wiring (such as connecting motor wires to the controller's signal terminals) will directly cause high-voltage intrusion, burning out weak electrical components.

Lack of Regular Cleaning and Inspection

Failure to clean the dust and oil stains on the controller's surface for a long time will clog the heat dissipation holes, causing excessive internal temperature;

If the wiring terminals are not inspected regularly, loose wires may cause sparking, which could damage the terminal block or the circuit board.