TECHNICAL CONCEPT OF LOADER AND

UNLOADER VALVE.
So 1st question in mind is what is it?
Firstly let me clear that loader and unloader valve is very
different in reciprocating type than screw type. May be the same
functions but working principle is different from it.
And loader valve is also termed as intake valve and or an inlet
valve. It functions is to regulate the air intake to the air
compressor part. i.e to regulate the supply of air sucked up into
compressor part.
And it is one kind of pneumatic actuator valve which operates
with a feedback signal system and works on a principle of pilot
pressure which is the same pressure maintained by the MPV to
operate that valve.
It functions with two modes: Loading and unloading mode.
For unloading mode: when the desired pressure is reached, it
goes to unload mode and closes the supply of air intake to
compressor unit thus the compressor just rotates but do not
produces any compressed air further. In this way no more air to
be sucked in and get compressed.
But there still remains the air inside the compressor element.
This is then passed gently through Blow down valve (BDV).thus
get a sound like psccchhhhhhh.
Again a question rises in mind? If compressor element is
rotating so how does it gets the lubrication facility?
The answer is there is always a small hole called free hole of
1mm in unloader valve which never closes completely. This
maintains the minimum pressure to regulate the oil flow for the
lubrication of compressor element.
Selection of machine in terms of load:

The machine should be selected neck to neck capacity. But

practically if the selection done is more than the 90 percent of
loading capacity then its efficiency is good.
How to check this load and unload:
This is to be checked in load relay (Read parameter) in panel.
Let us understand this with an example:
If a machine is serviced with a new spare AOS installed, then in
read parameter note down the value =1000(assume); load relay
value
And in next changing time of AOS, the value is= 2000.(load relay
value).
So the difference is (2000-1000)/running hours.
Let say running hours is 250 hrs.
Then separator use is: (2000-1000)/250 = 1000/250 = 4.
Permissible:
1.
2.

Max unloads /load condition: 10nos/hrs.

But practically it is not possible for any industry to maintain
this limit.

Effect on AOS:
More the load and unload condition. More will be the hitting
effect to AOS since there is sudden flow released which impact
the AOS.and stress produced in it thus decreasing the AOS Life.
So we see baffle plate is used in Atlas copco to get rid from
direct hitting thus reduces the stress produced from impact.
But the effect is seen on Elgi/IR machine.