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Compressor is loading without unloading

My compressor is loading all the time even though the controller screen, contactor and unloader solenoid is indicating that is at the state of unloading, but pressure out put increasing. the type of the compressor is GA110 atlas copco air cooled.

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Can we save energyIf we decrease the loading pr. of a vertical 125 CFM air compressor from 6.0 kg/cm2 to 5.5 Kg/cm2. If yes how much energy we can save if compressor have 30 KW motor

Posted on Nov 05, 2009

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Hi mate it could iver be a faulty load solenoid valve or the unloader its self is jaming up inside which means you have to strip it away from the air end and replace all the seals inside or give it to a specialst we are compressed air engineers we could sort it i will leave you a number call us anytime 07958354730 or call 01752 848801 many thanks

Posted on Jul 07, 2009

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Try removing the unload solenoid and rotate it 180 degrees before reinstalling it. The control ports and mounting holes on this solenoid are symetrical. Therefore, the solenoid valve can easily be placed back into service incorrectly. Installing it 180 degrees out of rotation will result in the compressor "NOT" unloading when it is supposed to. The Elektronikon controller will show that the compressor is in the unloaded state...when in fact it is not. This will result in overpressurization which will also typically pop the relief valve on the air/oil separator vessel. Hopefully this will be an easy fix for your problem. Good luck!

Posted on Jan 26, 2010

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I got an Ingersol rand Rottary Compressor Model# PX6683U06083 Compressor it releases coolant out of the air intake I belive it was running backwards for a short while now it is rotating the right way, can...


If this type of compressor is run for any length of time in the wrong direction you will do damage for sure now if this unit is shut down while it is loaded (producing air) it will push lubricant out of the inlet filter most of the time people hit the emergency stop button to shut it done which is wrong the compressor should be unloaded first which when unloaded the inlet valve will be closed which then the compressor will be running unloaded and can now be shut down using the off button or switch not sure which one you have other reasons why this could happen failing load/unload solenoid usually the vent is plugged or bad minimum pressure check valve

Feb 27, 2012 | Ingersoll Rand Air Tools & Compressors

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Ingersoll Rand 3 hp air compressor builds correct pressuse but trips rest when called to restart. Changed starter and running capasitors but no change in problem.


You need to check the head unloader.
Compressed air that is trapped over the piston when the compressor shuts off will be evacuated to atmosphere through the unloader valve, to prevent that compressed air pressure from adding load to the start up of the compressor motor, when the pressure switch again calls for air. For example, the last time you did a sit-up, you may have folded your arms over your chest, or if you are particularly masochistic : - ) , even held a weight to your chest. What you were doing is increasing the load against which your muscles have to work to effect the sit up.
Compressed air, captured in the cylinder after the compressor shuts off, would increase the load against which the electric motor would have to work. It may increase the load too much, and the motor may fail to start, or it may pull too many amps and fry a fuse or pop a breaker in the panel.
When the compressor shuts off, the unloader valve operates, it unloads the trapped air to atmosphere, and that problem is solved.
The unloader valve is plumbed somewhere in the line between the compressor and the compressor tank.
It is often part of the pressure switch assembly. It will, in many cases, be opened by the pressure switch, when the air in the compressor air tank reaches the set point and the pressure switch trips the power supply to the motor off, and at the same time, trips the unloader valve to open.

it is normaly on the bottom of the pressure switch it will have a small tube hooked to it



1_4_2012_7_59_34_pm.jpg

Jan 04, 2012 | Air Tools & Compressors

1 Answer

Compressor builds correct pressure but will trip rest before it can restart.


You need to check the head unloader.
Compressed air that is trapped over the piston when the compressor shuts off will be evacuated to atmosphere through the unloader valve, to prevent that compressed air pressure from adding load to the start up of the compressor motor, when the pressure switch again calls for air. For example, the last time you did a sit-up, you may have folded your arms over your chest, or if you are particularly masochistic : - ) , even held a weight to your chest. What you were doing is increasing the load against which your muscles have to work to effect the sit up.
Compressed air, captured in the cylinder after the compressor shuts off, would increase the load against which the electric motor would have to work. It may increase the load too much, and the motor may fail to start, or it may pull too many amps and fry a fuse or pop a breaker in the panel.
When the compressor shuts off, the unloader valve operates, it unloads the trapped air to atmosphere, and that problem is solved.
The unloader valve is plumbed somewhere in the line between the compressor and the compressor tank.
It is often part of the pressure switch assembly. It will, in many cases, be opened by the pressure switch, when the air in the compressor air tank reaches the set point and the pressure switch trips the power supply to the motor off, and at the same time, trips the unloader valve to open.

it is normaly on the bottom of the pressure switch it will have a small tube hooked to i

1_4_2012_8_01_50_pm.jpg

Jan 04, 2012 | Air Tools & Compressors

1 Answer

HIGH TEMP ALARM, UNLOADING AND THEN LOADING OVER AND OVER.


Please check your cooling system including the oil. It may time to replace the oil.
Also please check and set your load - unload pressure to wider range to prevent load-unload in short cycle.

Regards, Jay

Apr 26, 2011 | Eaton 1" Air Compressor Check Valve

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Compressor UP6 25 125, runs all the time but is only under load for a short time, should it shut down between loads?


This unit will shut down if unloaded for a set period of time. Usually 5 to 10 minutes. This time could be longer if some one has changed it from the factory setting. There is a timer in the control box that starts counting down when the unit unloads. If it stays unloaded long enough for the timer to count down the unit will stop until the air pressure drops to the low set point on the pressure switch. It will then start up. If the unit loads before the counter counts down the timer starts from the beginning when it unloads again. This cycle continues until you manually shut it down or you stop using air long enough for the timer to reach Zero and shut down.

Apr 22, 2011 | Ingersoll Rand UP6-25-125 120 Gallon...

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I HAVE ZT30 ATLASCOPCO AIR COMPRESSOR.THE FAULT PROBLEM ON IT NOW IS THAT IT DOES NOT COMPRESS(LOAD) AND DISCHARGE (UNLOAD) AUTOMATICALLY, IT LOADS AND UNLOAD ONLY IF I MANUALLY OPEN THE MANUAL VENT...


It sounds like the unload valve might be clogged up. Try taking it off anf cleaning it back up. If the compressor is older or has had a lot of use sometimnes when the rings wear oil and gunge will get into the valve and gum it up. good luck

Mar 10, 2011 | Air Tools & Compressors

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I have a 5SR EP50SE compressor with an INTELLISYS controller the problem is when the set offline pressure is reached there is no voltage coming out from the controller to trigger the blowdown and the...


The blow down is a normally open valve so there will be no voltage when unloaded. When voltage is applied the blow down valve closes and the load solenoid opens allowing air to the inlet valve which should open. I suspect you have a bad load solenoid. If it leaks by it will keep the inlet valve open to some degree depending on how bad its leaking. If this is an older EP50SE you may have a spring in the bottom of the inlet valve that has broken. then there is not enough pressure to close the inlet valve. These are two common problems with this unit. Also if you look inside the controller panel there should be a wiring diagram. It should show 1SV and 3SV wired together. 1SV is the load solenoid and 3SV is the blow down valve. There is no unload solenoid. There is also a solenoid for line / sump pressure and a modulation solenoid.

Mar 07, 2011 | Ingersoll Rand Stationary Air Cooled...

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No air storage in the tank


so in another word your air compressor is mot pumping air.
(1) check for leaks
(2)check the air filter
(3) check the inlet valve
(4) if their is unloader valve (a) pressure switch
(b) load solenoid valve
(c) unloader valve

Sep 29, 2009 | Air Tools & Compressors

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