Load and unload functions are crucial for the effective operation of vi̇dali hava kompresörleri̇. Without the ability to load or unload, the compressor becomes ineffective. If the compressor cannot load, there will be no compressed air output. If it cannot unload, imagine constantly inflating a balloon—this results in excessive pressure buildup. Let’s look into some common load and unload failures and their causes.
1. Load and Unload: Basic Functions of a Screw Air Compressor
The ability to load and unload is fundamental to the operation of screw air compressors. When the compressor cannot load, no compressed air is output. If it cannot unload, it continues compressing air, causing the pressure to rise, which can trigger an automatic overpressure protection or open the safety valve. Here are some causes for these issues:
- Cannot Load: If the compressor cannot load, it will run idle without producing compressed air, wasting electricity. To troubleshoot, check the time relay. If the display does not show a “load” signal, the time relay might be faulty. If the display shows loading but no compressed air is output, the loading solenoid valve or the intake valve may be malfunctioning, or there could be an air leak.
- Cannot Unload: If the compressor fails to unload, it will continue to build pressure. Once the pressure exceeds the preset protection value, the compressor will automatically activate the overpressure protection or the safety valve will open. In this case, check the unload solenoid valve and the PLC main controller.
2. Failure to Build Pressure
When the compressor cannot build pressure, there could be issues in the electrical and mechanical components.
Electrical Issues:
- Loading Solenoid Valve Failure: If the loading solenoid valve fails, it will not open even when the PLC sends a signal. This prevents the compressed air from passing through and opening the intake valve.
Mechanical Issues:
- Severely Clogged Air Filter: A clogged air filter will restrict airflow, preventing adequate air intake for compression.
- Intake Valve Stuck: If the intake valve is stuck in the closed position, air cannot enter the compressor.
- Airline Leaks: Leaks in the air pipes will prevent air from reaching the compressor.
- Minimum Pressure Valve Leak: A leaking minimum pressure valve can cause issues with maintaining pressure.
3. Clogged Air Filter
If the air filter is severely clogged, it will prevent the compressor from taking in a sufficient amount of air for compression. Similarly, if the intake valve is unable to open, the compressor cannot compress air. During loading, the solenoid valve opens, and the air passes through the piping to the intake valve. If there are air leaks in the piping, the intake valve may fail to open. A leaking minimum pressure valve can also prevent the intake valve from opening. To check this, remove the air filter from the intake valve, start the compressor, and observe whether the intake valve opens during loading. If the valve doesn’t open, check the solenoid valve. If there is a cylinder next to the intake valve, manually lift the cylinder with a screwdriver to check further.
4. Inability to Unload or Unloading While Pressure Remains High, Triggering the Safety Valve
In this case, the compressor continues to pressurize even when it should have unloaded, and the safety valve opens due to excessive pressure.
Electrical Issues:
- Unload Solenoid Valve Failure: If the unload solenoid valve fails, the valve will not close even when the control panel indicates unloading. This means compressed air will continue to pass through, preventing the intake valve from closing.
Mechanical Issues:
- Pressure Switch Failure: If the pressure switch fails, the compressor will not unload even when the preset pressure is reached. For example, if the unloading pressure is set at 0.8 MPa, the compressor will continue operating in load mode despite reaching this pressure.
- Faulty Intake Valve: If the intake valve does not close properly when unloading, the compressor will continue generating compressed air, causing the safety valve to open.
- Oil Separator Filter Blockage: During loading, when the compressor’s production rate exceeds the discharge rate, the internal pressure of the oil separation tank slowly rises, leading to the safety valve being activated.
- Lower Air Consumption Than Output: If the air demand is lower than the compressor’s output capacity, the compressor will continue to show “loading.”
Sonuç
Load and unload issues in vi̇dali hava kompresörleri̇ are often caused by electrical and mechanical failures. Regular maintenance and troubleshooting can help resolve these issues before they cause significant damage. If your compressor is experiencing loading or unloading issues, check the electrical components, such as the solenoid valves, and inspect mechanical components like the air filter, intake valve, and pressure switch.
For more detailed information on troubleshooting and optimizing the performance of your vidalı hava kompresörü, ziyaret edin Baldor Hava.
