Atlas Copco ZR45 Intercooler low pressure trip ?

Question Title: Atlas Copco ZR45 Intercooler low pressure trip ?
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Answers: 1

We recently replaced the intercooler on our Atlas Copco ZR45 control air compressor, this was because before this the intercooler had completely failed causing what we think cooling water into the elements on unload cycle.

The hp element has been changed for brand new, the lp and hp elements rotate freely and the machine was tested with the amps low on no load, the machine went on load, but trips soon after this on Intercooler pressure low (its in a vacuum -1.6b), our other compressor is running with a intercooler pressure around 2.3b.

We are curious to get some ideas for low intercooler pressure trouble shooting, where would you guys start?

thanks and best regards,

Answers & Replies

Cas

9 years ago

we actually found the problem ourselves, turned out to be a faulty unloader solenoid (burkett), causing the unloader not to open at all, this in effect causing there to be no air induced into the lp side and hence vacuum at the intercooler.

the unloader sol valve was changed and machine unloading and loading fine, some adjustment was also made to the manual bypass valve on the unloader to regulate the unload intercooler pressure at a higher pressure.

Our pressures at intercooler are 2.1 bar which is what we might expect given a new hp element in use and a old lp element (over inducing from the hp side) we expect this intercooler pressure to rise slightly as the hp element wears.