The main functions of the intake control valve of Atlas Copco air compressors
Regulating intake volume: According to the demand for gas consumption in the system, it automatically controls the amount of air entering the main unit of the compressor to stabilize the exhaust pressure (for example, reducing the intake when the system is under partial load and fully opening when at full load).
Unloading and loading control: When the system pressure reaches the set upper limit, the intake control valve closes (or partially closes) to put the compressor into an unloaded state; when the pressure drops to the lower limit, it reopens to restore loading.
Protective function: It is completely closed during shutdown to prevent lubricating oil from flowing back into the intake system; it is gradually opened during startup to avoid excessive load in an instant.
Structure and working principle
The intake control valve of Atlas Copco usually adopts a pneumatic or electromagnetic control butterfly valve / slide valve structure, mainly consisting of the following parts:
Valve body: Connects the intake pipe to the main unit of the compressor, and has adjustable valve plates (such as butterfly plates) inside.
Control mechanism: Includes a cylinder, piston or electromagnetic coil, which receives pressure sensor signals and drives the valve to act.
Pressure sensing element: Monitors the exhaust pressure of the system and feeds back the signal to the controller to achieve automatic regulation.
Working logic: When the system pressure is below the set value, the control valve opens, and air passes through filtration before entering the main unit of the compressor; when the pressure meets the standard, the valve closes or throttles to reduce the intake volume, and the compressor enters an idle (unloading) state.
Applicable models and features
Compatible models: Widely used in GA and G series screw air compressors (such as GA90, GA110VSD, etc.), the valve size and control method of different models vary slightly (such as VSD variable frequency models may use more precise proportional regulating valves).
Technical features:
Fast response, high pressure control accuracy (usually fluctuation ≤ 0.1 bar).
Uses wear-resistant sealing materials to reduce leakage and ensure long-term stable operation.
Linked with the compressor control system (such as Elektronikon) to achieve intelligent regulation and reduce energy consumption.
Common faults and maintenance Common Questions:
Valve jamming: Due to the accumulation of dust and oil or insufficient lubrication, the valve cannot be fully opened or closed, resulting in abnormal exhaust pressure and increased energy consumption.
Leakage: Aging or wear of the sealing components cause air to enter during disassembly, leading to excessive energy consumption when the main unit is idling.
Control failure: Faulty pressure sensors, blocked pneumatic pipelines, or damaged electromagnetic coils cause the valve not to operate.
Maintenance suggestions:
Regular cleaning: Based on the dust situation in the environment, disassemble the valve every 2000-4000 hours to remove internal dust and oil, and check the condition of the sealing components.
Lubrication maintenance: Add special lubricating grease to moving parts (such as bushings, pistons) to prevent jamming.
Timely replacement: If the valve is severely worn or the control mechanism fails, it is recommended to replace the original factory parts (such as model 1622380100, etc., refer to the equipment manual for details) to ensure compatibility with the entire machine.
