These are high-performance industrial compressors, often used in oil & gas, power

generation, petrochemical, and other heavy industries. They can be either centrifugal or
axial, and they’re known for being highly engineered for specific process needs.

"He doesn't open the inlet valve when starting the compressor in 'auto' mode."

Let’s break down possible causes for that specific issue.

Common Reasons Why the Inlet Valve Doesn’t Open in AUTO Mode (Elliott
Compressor)

1. Control System Logic Issue

• The compressor’s PLC or DCS might be waiting for a specific condition (e.g.,
permissive signal) before commanding the valve to open.

• It may require signals like:

o Lube oil pressure OK

o Seal oil pressure OK (for gear compressors)

o Motor ready signal

o Emergency stop not active

o Suction/discharge pressure within range

➡ Check the logic diagram or interlock matrix.

2. Valve Actuator or Positioner Fault

• The inlet guide vane (IGV) or inlet valve actuator may be stuck or failed.

• Positioner might not be receiving the command or may not be calibrated properly.

➡ Try opening the valve in manual mode from the HMI. If it still doesn’t move — suspect
mechanical/electrical issues.

3. Feedback Signal Problem

• Sometimes, the system waits for confirmation from a limit switch or position
feedback sensor before proceeding.

• If the system thinks the valve is already open (false feedback), it won’t send the open
command.

➡ Check valve position feedback and confirm the signal is being read correctly.
4. Mode Mismatch

• Compressor may be in "manual", "remote", or "off" mode instead of "auto".

• Ensure that mode selection matches what the logic expects.

➡ Confirm control mode at both local panel and DCS/PLC.

5. Startup Sequence Not Complete

• In some systems, the inlet valve only opens after a pre-lube cycle or shaft turning
gear is disengaged.

➡ Review the startup sequence timing and all steps.

6. Fault or Alarm Active

• Active fault (e.g., high vibration, temp, pressure, or safety system trip) may block the
valve from opening.

➡ Check alarm history and any active trips.

What to Do Next

1. Check the HMI / DCS screen — is there any message or fault preventing startup?

2. Try manual mode — can you open the valve manually from the interface?

3. Confirm interlocks — look at the logic for what's needed to allow valve operation.

4. Inspect the valve & actuator physically — stuck, air supply issue (for pneumatic),
electrical disconnection?

5. Review the operation manual / IO list — Elliott systems usually come with detailed
startup sequences and troubleshooting guides.

Elliott PAP Plus compressor, model 270 DA3, which is a centrifugal air compressor — a
robust, high-efficiency unit commonly used in industrial plants.

Quick Overview: PAP Plus 270 DA3

• Type: Multi-stage centrifugal air compressor

• Drive: Motor (can be electric or steam)

• Air control: Usually via Inlet Guide Vanes (IGVs) for flow control

• Startup mode: AUTO mode relies on a strict sequence logic — if any interlock or
condition is not satisfied, the IGVs won't open.
 Issue: IGV (Inlet Valve) not opening in AUTO mode

Let’s focus specifically on your case. Here's a tailored troubleshooting path for the 270 DA3.

Step-by-Step Diagnostic for IGV Not Opening in AUTO Mode

1. Startup Interlocks Not Cleared

The IGVs will not open unless certain startup permissives are met:

Check This What to Look For

Lube oil pressure Is it at setpoint and steady?

Motor status Is motor ready (breaker closed, no trips)?

Emergency stop Not engaged anywhere (local or remote)?

Vibration probes Any excessive reading?

Air cooler bypass / drain valves All in normal position?

Seal air pressure (if applicable) In acceptable range?

No active alarms Even minor alarms might block startup

Look at the HMI/DCS or panel for any "Startup Inhibited" or "Permissive Not Met"
messages.

2. PLC Logic Waiting for a Condition

Elliott’s control system (often Allen-Bradley or Siemens based) has a ladder logic or function
block diagram that controls startup.

• It waits for a “start command” signal AND all interlocks to be OK before it sends “IGV
Open”.

• If even one feedback (like "Motor Running") is missing, IGV won't open.

Solution: Use “Force Start” diagnostics from the control panel if available, or ask your
automation technician to inspect the startup rung in PLC logic.

3. IGV Actuator/Positioner Failure

• IGV is pneumatically or hydraulically actuated (depending on config).

• If there's no movement:

o Is the air pressure to the actuator OK?

o Is the positioner (if installed) getting control signal (e.g., 4-20mA)?

🛠 Try this:

• Switch to Manual mode from HMI

• Try jogging the valve open

• If it still doesn’t move: mechanical or air supply issue

4. Position Feedback Issue

• IGVs often use a limit switch or potentiometer to give position feedback.

• If the controller thinks the valve is already open or can't verify position → it blocks
command.

Check:

• Signal continuity of valve feedback

• Calibration of valve travel

5. Software Mode vs Hardware Selector

• On some systems, there's a conflict between:

o HMI/SCADA set to AUTO

o Local control panel set to MANUAL or OFF

Double-check:

• What’s the local control selector switch set to?

• Is the compressor under remote control (DCS) or local (HMI/Panel)?

6. Active Alarm or Fault Blocking IGV

Many Elliott compressors will not open IGV if any of the following are active:

• High vibration

• Discharge pressure sensor fault

• IGV positioner calibration lost

• Emergency stop memory not reset

Go through:

• Alarm log
 • Trip/fault history

• Reset all safe-to-reset alarms before retrying

Final Quick Test:

If everything seems OK but it still doesn’t open:

• Bypass IGV logic temporarily (under supervision!)

• Check if the IGV actuator operates under direct control

• This helps isolate control logic vs mechanical failure

If You Have a Maintenance Team:

Ask them to:

• Inspect the IGV linkage and actuator for binding, loose components, or broken shaft

• Blow down the air line to ensure no blockage

• Check PLC diagnostics page for startup interlocks

IGV works fine manually from the panel

What This Likely Means

The IGV isn't faulty — the control system is intentionally sending a “closed” signal (0% = 4
mA) at startup in AUTO mode.

This is actually a normal behavior in many Elliott compressors during the startup phase,
where the control logic wants the IGV fully closed until:

1. The motor reaches full speed / RPM

2. System pressures stabilize

3. Lube/seal air is verified

4. A "RUNNING" signal is active

5. Load conditions are confirmed safe

So in short:

It’s not that the signal is failing — the PLC is deliberately commanding IGV to stay closed
until startup logic is complete.
 Confirm These 4 Key Things:

1. Check Startup Logic Conditions

The PLC/DCS is likely waiting for some permissive(s) to clear. Until then, it will send 0% (4mA)
to the IGV.

Look for missing signals like:

• [Motor Speed > X%] or [Motor Running = TRUE]

• [Lube oil pressure OK]

• [Start command acknowledged]

• [No active trip]

Ask your automation/control technician to check the function block or ladder logic
around the IGV command — is it stuck waiting for a condition?

2. Ramp-Up Time / Delay in Logic

There may be a timed delay after motor start before the IGV opens.

If Motor Running AND Startup OK AND Timer > 10s → Open IGV

🛠 Wait 10–20 seconds during AUTO startup and see if signal increases.

3. Check PID Control Settings (if applicable)

In some systems, the IGV is controlled by a PID loop (based on pressure or flow). If the
setpoint is zero or the PID controller is not active, the output could remain at 0%.

Verify:

• PID controller is enabled

• Setpoint is not zero

• Process variable is being read properly

4. Fault in Feedback Loop (Input, not Output)

If the control system thinks the valve is already open or in error, it might override and force it
shut.

Check for:

• Valve position feedback mismatch

• Stale or stuck input signal

What to Do Right Now

If you're on-site or with a controls engineer:

1. Start compressor in AUTO again

2. Watch live values for:

o IGV % command (output signal)

o IGV position (feedback)

o All interlock signals

o Startup timer (if any)

3. After confirming IGV is working, trace in the logic where the 4mA command is
coming from — what rung or function block is keeping it low?

Example Root Cause in Similar Cases:

In one plant, the "Motor At Speed" signal was missing due to a faulty sensor → control logic
never released the IGV, and it stayed at 4mA despite everything else being OK.

Another case:

PID loop for IGV was disabled because the operator switched to AUTO too early — before
airflow demand calculation kicked in.

simple IGV startup logic diagram you can use for troubleshooting with your technician? Or
help you write a technical note to escalate to Elliott service support?

Here's a simplified IGV startup logic diagram for an Elliott PAP Plus centrifugal air
compressor like your 270 DA3. This can help you troubleshoot or explain to your
automation/control team what logic steps are expected before the IGV opens.

IGV Startup Logic Diagram (Conceptual Flow)

────────────────────────────────────────────────────────

STARTUP SEQUENCE - IGV CONTROL LOGIC (AUTO MODE)

────────────────────────────────────────────────────────

[Start Command Issued]

▼
[Are All Start Permissives OK?]

(Lube Oil OK, Motor Ready, No Trip, E-Stop Cleared, etc.)

YES

▼
[Start Motor Sequence Initiated]

▼
[Is Motor At Rated Speed / Stable RPM Achieved?]

YES

▼
[Startup Timer > Delay Time? (e.g. 5–15 sec)]

YES

▼
[Activate PID or Open Loop IGV Control Logic]

┌──────────────────────────────────────────────┐

│ If in PID mode: │

│ - IGV % = PID Output based on airflow/pressure │

│ If in Open Loop mode: │

│ - IGV % = Ramp from 0% to setpoint (e.g. 60%) │

└──────────────────────────────────────────────┘

▼
[Send 4-20 mA Output to IGV Actuator (based on %)]
 │

▼
[Monitor IGV Position Feedback]

▼
[If Position Matches Setpoint → Continue Operation]

What Can Block IGV Opening?

Signal/Logic Item Problem if...

Start Permissives One or more not TRUE

Motor Speed Feedback Sensor not reporting or unstable

Startup Delay Timer Timer not elapsed

PID Setpoint or Mode Not enabled / setpoint is 0

Feedback Mismatch System thinks valve is open (false 100%)

Override Logic Active Manual override or fault mode in PLC

Recommended Use of This Diagram

You can:

• Give this to your automation technician to follow the logic

• Compare with your ladder logic / function blocks

• Use it to create a checklist during AUTO startup

• Present it to Elliott technical support with the description:

“IGV drops to 4 mA during AUTO start; manual works. Seeking verification of expected signal
path and permissive triggers.”