I got a reply from Ben Kardoosh at Hill Pumps today.
I am really shocked at the detailed instruction he gave me to solve my problem.
I looking forward to dig into them this weekend.
I hope these instruction can help others as well
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From what you have described, I can think of two likely possibilities.
1. Not all three compression stages are pulling their weight.
Most likely stage 2. This causes stage 1 to have to take up the slack and produce more of the pressure.
Stage 1 being a large volume stage with a large piston area can easily cause the compressor to stall if it is fighting too much downstream pressure.
This will be more likely to happen as the motor attempts to start, since starting already requires more current than running.
To fix this, check the stage 2 ball valve and spring valve for dirt/debris/fragmentation, and clean/replace where necessary.
2. The final stage piston seal has a partial leak.
Usually if the final stage is not producing any pressure, the PRV will start to make hissing and popping sounds as it as it passes gas, and the compressor will struggle to get past 100 bar.
However, if the final stage piston seal has a slow leak, it may not produce this symptom. In this case it is possible for the compressor to function almost normally, apart from when it is paused at pressure (such as during a cooling cycle) in which case high pressure gas can slowly leak past the stage 3 seal and directly into stage 1. If the stage 1 intake valve happens to be paused in the closed position (which is a 50% chance) then the pressure in stage 1 and the various downstream pipes could increase to above the usual operating pressure of stage 1. Again, this can cause stage 1 to stall the compressor upon start-up.
To fix this, examine the stage 3 piston seal for signs of wear/damage/ embedded swarf, also examine the anodised surface of the cylinder bore for signs of scraping, and replace components where necessary.
A slow leak in the final stage spring valve (A.K.A bullet valve) can also contribute to this effect. It may be worth examining this for signs of fragmentation/ embedded swarf.
To summarise I would advise to first check your valves (since this is the least invasive process), and failing that, check the final stage piston seal.
Below is a link to a video showing how to access various components for maintenance. (you will need to remove the green shroud first)
https://www.youtube.com/watch?v=j9ARFfEtv9s