ATLAS COPCO Screw Air Compressor Specialized Pressure Sensor
1. Core Functions and Roles
Pressure Monitoring and Feedback: Real-time detection of pressure values at different parts of the air compressor (such as 0-16bar, 0-25bar, etc., common ranges), providing data basis for the control system to ensure stable operation within the set pressure range.
Safety Protection: When pressure exceeds the safety threshold (such as overpressure), it sends a signal to the controller, triggering shutdown or unload protection to prevent equipment damage due to overpressure.
Intelligent Control: Cooperates with PLC control system to achieve automatic loading/unloading, frequency adjustment and other functions. For example, when the pipeline pressure reaches the upper limit, the sensor signal triggers the compressor to unload; when the pressure drops to the lower limit, it triggers loading, thereby saving energy and reducing consumption.
2. Applicable Models and Specifications
Applicable Series: Widely used in GA, ZR, ZT, GHS and other mainstream screw air compressor series. Different models correspond to different installation dimensions, interface types (such as G1/4 threaded interface, M12, etc.) and signal output methods.
Signal Type: Common output signals are 4-20mA current signal (strong anti-interference ability, suitable for long-distance transmission) or 0-10V voltage signal. Some intelligent sensors support Modbus and other digital communication protocols.
Measurement Medium: Designed for compressed air, oil-gas mixtures, etc., the housing and sensing element use oil-resistant, temperature-resistant materials (such as stainless steel 316L), adapting to the oil mist and temperature environment inside the compressor (-20~85℃).
3. Common Faults and Replacement Scenarios
Fault Manifestations:
Abnormal pressure display (such as drift in value, no signal, inconsistent display value with actual pressure).
Frequent loading/unloading of the air compressor, failure to reach the set pressure or unexpected shutdown.
Loose sensor wiring, interface leakage or shell damage.
Replacement Timing: When the sensor exhibits the above faults and the wiring or pipeline issues have been ruled out, it is necessary to replace it promptly; it is recommended to calibrate regularly (usually 1-2 years) and replace if the accuracy is insufficient after calibration.
4. Replacement and Installation Tips
Preparation Before Installation:
Shut down the machine and release the system pressure, cut off the power supply, ensuring safety during operation.
Confirm that the new sensor model is consistent with the original part (refer to the equipment manual or old part number), and check if the interface threads, sealing rings are intact.
Replacement Steps:
Remove the wiring terminals of the old sensor (record the wiring sequence to avoid wiring errors).
Use a wrench to unscrew the old sensor, clean the sealing surface of the installation interface, check for debris or damage.
Wrap the sealing thread of the new sensor with tape (or use the matching sealing ring), tighten it to the specified torque (usually 15-25N·m), ensuring no leakage.
Connect the signal lines in the original wiring sequence, ensuring firm connection and good insulation.
Debugging and Inspection:
After starting the machine, observe whether the pressure value displayed by the controller is consistent with the actual pressure (compare with the pressure gauge).
Test the loading/unloading process of the air compressor to confirm normal pressure control logic and no abnormal alarms.
