Atlas Copco GX5 Manual (No Screen)
Atlas Copco
Oil-injected rotary screw compressors
GX 2 EP, GX 3 EP, GX 4 EP, GX 5 EP, GX 7 EP
Instruction book
Atlas Copco
Oil-injected rotary screw compressors
GX 2 EP, GX 3 EP, GX 4 EP, GX 5 EP, GX 7 EP
From following serial No. onwards: CAI 544 242
Instruction book
Original instructions
Copyright notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity.
2012 - 03
No. 2920 7105 30 www.atlascopco.com
Table of contents
1.2 SAFETY PRECAUTIONS, GENERAL 4
1.3 SAFETY PRECAUTIONS DURING INSTALLATION 5
1.4 SAFETY PRECAUTIONS DURING OPERATION 6
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR 7
2.8 PROTECTION OF COMPRESSOR 27
4.4 TAKING OUT OF OPERATION 46
5.1 PREVENTIVE MAINTENANCE SCHEDULE 48
5.4 OIL, FILTER AND SEPARATOR CHANGE 50
5.5 STORAGE AFTER INSTALLATION 52
6 Adjustments and servicing procedures 53
6.4 BELT SET EXCHANGE AND TENSIONING 55
8.1 READINGS ON CONTROL PANEL 60
8.3 SETTINGS FOR OVERLOAD RELAY AND FUSES 61
8.4 REFERENCE CONDITIONS AND LIMITATIONS 63
10 Guidelines for inspection 68
11 Pressure equipment directives 69
12 Declaration of conformity 70
1 Safety precautions
1.1 Safety icons
Explanation
Danger for life |
|
Warning |
|
Important note |
1.2 Safety precautions, general
General precautions
- The operator must employ safe working practices and observe all related work safety requirements and regulations.
- If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.
- Installation, operation, maintenance and repair work must only be performed by authorized, trained, specialized personnel.
- The compressor is not considered capable of producing air of breathing quality. For air of breathing quality, the compressed air must be adequately purified according to the applicable legislation and standards.
- Before any maintenance, repair work, adjustment or any other non-routine checks, stop the compressor, press the emergency stop button, switch off the voltage and depressurize the compressor. In addition, the power isolating switch must be opened and locked.
On units powered by a frequency converter, wait six minutes before starting any electrical repair.
If the machine is equipped with an automatic restart after voltage failure function and if this function is active, be aware that the machine will restart automatically when the power is restored if it was running when the power was interrupted! |
- Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear eye protection.
- The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories shall be replaced if unsuitable for safe operation.
- It is not allowed to walk or stand on the unit or on its components.
1.3 Safety precautions during installation
All responsibility for any damage or injury resulting from neglecting these precautions, or non observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. |
Precautions during installation
- The machine must only be lifted using suitable equipment in accordance with the applicable safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
- The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken; consult your supplier.
- Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction duct. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air.
- Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
- Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working pressure.
- The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can lead to internal fire or explosion.
- Arrange the air intake so that loose clothing worn by people cannot be sucked in.
- Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under heat and that it is not in contact with or close to flammable materials.
- No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
- If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine isremotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and that the isolating switch is open and locked before any maintenance or repair. As a further safeguard, persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the start equipment.
- Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available andthat the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.
- The electrical connections must correspond to the applicable codes. The machines must be earthed andprotected against short circuits by fuses in all phases. A lockable power isolating switch must be installed near the compressor.
- On machines with automatic start/stop system or if the automatic restart function after voltage failure isactivated, a sign stating "This machine may start without warning" must be affixed near the instrument panel.
- In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-returnvalves (check valves) must not be relied upon for isolating pressure systems.
- Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressurevessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be protected by a pressure relieving device or devices as required.
- Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentally touchedby personnel in normal operation must be guarded or insulated. Other high temperature piping must be clearly marked.
- For water-cooled machines, the cooling water system installed outside the machine has to be protected bya safety device with set pressure according to the maximum cooling water inlet pressure.
- If the ground is not level or can be subject to variable inclination, consult the manufacturer.
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Also consult following safety precautions: Safety precautions during operation and Safety precautions during maintenance. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment; hence some statements may not apply to your machine. |
1.4 Safety precautions during operation
All responsibility for any damage or injury resulting from neglecting these precautions, or non observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. |
Precautions during operation
- Never touch any piping or components of the compressor during operation.
- Use only the correct type and size of hose end fittings and connections. When blowing through a hose or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make sure that a hose is fully depressurized before disconnecting it.
- Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment.
- Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors or particles.
- Never operate the machine below or in excess of its limit ratings.
- Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to carry out routine checks. Wear ear protectors when opening a door.
On compressors without bodywork, wear ear protection in the vicinity of the machine.
- People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A) shall wear ear protectors.
- Periodically check that:
- All guards are in place and securely fastened
- All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
- There are no leaks
- All fasteners are tight
- All electrical leads are secure and in good order
- Safety valves and other pressure relief devices are not obstructed by dirt or paint
- Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of wear or abuse
- If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take precautions against air pollution and possible contamination of the breathing air.
- On water-cooled compressors using open circuit cooling towers, protective measures must be taken toavoid the growth of harmful bacteria such as Legionella or pneumophila bacteria.
- Do not remove any of, or tamper with, the sound-damping material.
- Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be protected by a pressure relieving device or devices as required.
|
Also consult following safety precautions: Safety precautions during installation and Safety precautions during maintenance. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment; hence some statements may not apply to your machine. |
1.5 Safety precautions during maintenance or repair
All responsibility for any damage or injury resulting from neglecting these precautions, or non observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. |
Precautions during maintenance or repair
- Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
- Use only the correct tools for maintenance and repair work.
- Use only genuine spare parts.
- All maintenance work shall only be undertaken when the machine has cooled down.
- A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to the starting equipment.
- Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote start equipment.
- Close the compressor air outlet valve before connecting or disconnecting a pipe.
- Before removing any pressurized component, effectively isolate the machine from all sources of pressure and relieve the entire system of pressure.
- Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic vapours of cleaning liquids.
- Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the partsand exposed openings with a clean cloth, paper or tape.
- Never weld or perform any operation involving heat near the oil system. Oil tanks must be completelypurged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way modify, pressure vessels.
- Whenever there is an indication or any suspicion that an internal part of a machine is overheated, themachine shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted.
- Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
- Make sure that no tools, loose parts or rags are left in or on the machine.
- All regulating and safety devices shall be maintained with due care to ensure that they function properly.They may not be put out of action.
- Before clearing the machine for use after maintenance or overhaul, check that operating pressures,temperatures and time settings are correct. Check that all control and shut-down devices are fitted and that
they function correctly. If removed, check that the coupling guard of the compressor drive shaft has been reinstalled.
- Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separator vessel for carbon deposits; if excessive, the deposits should be removed.
- Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from enteringthem, e.g. when steam cleaning.
- Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodyworkand in the air inlet and outlet systems of the compressor, is in good condition. If damaged, replace it by genuine material from the manufacturer to prevent the sound pressure level from increasing.
- Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
- The following safety precautions are stressed when handling refrigerant:
- Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, use breathing protection.
- Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical first aid.
|
Also consult following safety precautions: Safety precautions during installation and Safety precautions during operation. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein. Some precautions are general and cover several machine types and equipment; hence some statements may not apply to your machine. |
2 General description
2.1 Introduction
Introduction
GX 2 EP, GX 3 EP, GX 4 EP, GX 5 EP and GX 7 EP are air-cooled, single-stage, oil-injected screw compressors, driven by an electric motor.
The compressors are belt driven.
The compressors are enclosed in sound-insulating bodywork.
An easy-to-operate control panel is provided, including the start/stop switch and the emergency stop button. A cabinet housing the regulator, pressure switch and motor starter is integrated into the bodywork.
Pack versions do not include an air dryer.
Full-Feature versions are fitted with an air dryer (DR). The dryer removes moisture from the compressed air by cooling the air to near the freezing point and automatically draining the condensate.
Floor-mounted model
The compressor is installed directly on the floor.
The floor-mounted model is available as Pack version only.
GX 5 Pack EP, floor-mounted
Ref. |
Description |
1 |
Control panel |
Tank-mounted model
Tank-mounted units are supplied with an air receiver of 200 l (52.80 US gal / 44 Imp gal / 7 cu.ft) and are available in Pack and Full-Feature version.
GX 5 FF EP, tank-mounted
Ref. |
Description |
1 |
Control panel |
AO |
Air outlet |
AR |
Air receiver |
Dm2 |
Condensate drain valve, air receiver |
SV |
Safety valve |
DR |
Integrated dryer |
2.2 Air flow
Pack
Air flow, floor-mounted Pack units
Air flow, tank-mounted Pack units
Air drawn in through air filter (AF) and open inlet valve (IV) is compressed in compressor element (E). Compressed air and oil flow into oil separator/tank (OT) where most of the oil is removed by centrifugal action. The remaining oil is removed by oil separator (OS). The air flows to the outlet (AO) via minimum pressure valve (Vp).
Full-Feature
Air flow, GX tank-mounted Full-Feature units
Air drawn in through air filter (AF) and open inlet valve (IV) is compressed in compressor element (E). Compressed air and oil flow into oil separator/tank (OT) where most of the oil is removed by centrifugal action. The remaining oil is removed by oil separator (OS). The air is discharged via minimum pressure valve (Vp), air receiver (AR) and dryer (DR) towards the air outlet (AO).
2.3 Oil system
GX Pack
GX Full-Feature
Air pressure in the oil separator tank (OT) forces the oil from the tank to compressor element (E) via oil cooler (Co) and oil filter (OF). Compressed air and oil flow into oil separator/tank (OT) where most of the oil is separated from the air by centrifugal action. The remaining oil is removed by oil separator (OS) and returns to the oil circuit via a separate line. The minimum pressure valve (Vp - see section Air flow) ensures a minimal pressure in the tank, required for oil circulation under all circumstances.
The oil circuit has a thermostatic bypass valve (BV). The oil cooler is bypassed until the oil is warm.
2.4 Cooling system
Pack units
Full-Feature units
A fan on the drive motor shaft provides air flow to cool the oil and the other components of the compressor. On tank-mounted compressors, the air receiver is used as air cooler. The condensate is drained manually.
The dryer (DR) of Full-Feature versions has a separate cooling fan and an automatic condensate drain (see also section Air dryer).
2.5 Regulating system
GX 2 up to GX 5
The main components of the regulating system are:
- Pressure switch (PSR11)
- Blow-off valve (Y1)
The contacts of pressure switch (PSR11) open and close at preset pressures. During loaded operation, the contacts are closed: the motor is running.
When the working pressure reaches the upper limit, the contacts of the pressure switch open: the motor stops. Blow-off valve (Y1) opens and the pressure in the air/oil separator is released. When the working pressure decreases to the pre-set minimum pressure, the contacts of the pressure switch close and the motor restarts. Blow-off valve Y1 closes and compressed air supply is resumed.
GX 7
Detail view of unloader assembly (UA)
The main components of the regulating system are:
- Pressure switch, which opens and closes at preset pressure limits. See also section Protection of the compressor.
- Unloader (UA), including inlet valve (IV) and unloading valve (UV).
- Loading solenoid valve (Y1).
As long as the working pressure is below the preset maximum, the solenoid valve is energised, allowing control air to the unloader: the inlet valve opens completely and the unloading valve closes completely. The compressor will run fully loaded (100% output).
When the working pressure reaches the maximum limit, the solenoid valve is de-energised, venting the control air: the inlet valve closes completely and the unloading valve opens completely. The compressor will run unloaded (0% output). If the compressor keeps running unloaded for an uninterrupted period of 240 seconds, it will be stopped. If the pressure reaches the minimum pressure level before the 240 seconds are reached, the compressor will automatically start running loaded again.
The compressor will automatically restart when the net pressure drops to the minimum limit.
2.6 Control panel
Control panel GX 2 up to GX 5 EP
Control panel GX 7 EP
Reference |
Designation |
Designation |
1 |
Main switch emergency switch |
To power the unit. Also used to stop the compressor in the event of an emergency and to reset the thermal overload of the electric motor by switching it to 0 and back to I. |
3 |
Dryer ON/OFF switch |
(On Full-Feature units) |
Gpa |
Pressure gauge |
The pointer indicates the actual working pressure. |
Hm |
Hour meter |
Indicates the total running time. |
H1 |
Lamp |
Lights up when the machine is operating. |
S |
Switch |
Start/Stop switch (GX 2 EP up to GX 5 EP) Load/unload switch (GX 7 EP) |
2.7 Electrical diagrams
Service diagram GX 2 - IEC - 1 ph
Service diagram GX 2 up to GX 5 - IEC - 3 ph DOL
Service diagram GX 2 up to GX 5 - IEC - 3 ph Y-D
Single phase dryer - 230 V 50/60 Hz
Electrical diagram GX 2 - cULus - 1 ph
Electrical diagram GX 4 and GX 5 - cULus - 1 ph
Electrical diagram GX 2 up to GX 5 - cULus - 200-208-230-460 V 3 ph
Settings GX 2 up to GX 5 for 208-230-460 V 3 ph
Electrical diagram 575 V 60 Hz cULus
Single phase dryer - 115 V 60 Hz
Text on image
(1) |
Main switch and fuses to be installed by customer. |
GX 7 EP
IEC units with Y-D start
GX 7 EP for 208/230/460V 60 Hz DOL
Diagram for 575 V CSA-UL
Fuses and main switch to be installed by the customer. For full details, always consult the complete service diagram, included in the cubicle of the compressor.
2.8 Protection of compressor
Safety valve on the compressor
Safety valve on the air receiver (tank-mounted units)
Reference |
Designation |
Function |
|
IG (IEC) OL (cULus) See also section Electrical diagrams |
Motor overload relay |
To shut down the compressor in case the motor current is too high. |
|
TSH (IEC), TS (cULus) See also section Electrical diagrams |
Temperature shut-down switch |
To shut down the compressor if the temperature at the outlet of the compressor element is too high. |
SV |
Safety valve |
To protect the air outlet system if the outlet pressure exceeds the opening pressure of the valve. |
After tripping of the temperature protection: switch off the voltage and depressurise. Check and remedy. See Problem solving. Wait a few minutes to let the machine cool down. To reset and restart, switch on the voltage and press the red reset button after unscrewing its cover: the machine will restart.
2.9 Air dryer
Air dryer (Full-Feature compressors)
Wet compressed air (B) enters the dryer. The air then flows through a heat exchanger (2) where refrigerant evaporates, withdrawing heat from the air. The cold air then flows through a condensate trap (1) which separates condensate from the air. The condensate is automatically drained and this is regulated by a timer. The dried air is then discharged from the dryer.
3 Installation
3.1 Installation proposal
Outdoor/altitude operation
If the compressor is installed outdoors or if the ambient temperature can be below 0˚C (32˚F), precautions must be taken. In this case, and also if operating at high altitude, consult Atlas Copco. Moving/lifting
Transport by a pallet truck
To prevent a tank-mounted model from falling over during transport by a pallet truck: push the forks underneath the air receiver and place a wooden beam (1) (cross-section approx. 4 x 6 cm / 1.6 x 2.4 in) through the supports on both sides of the receiver. While holding the compressor, slowly lift the forks until the receiver is secured between the beams. |
Installation proposal
Installation proposal, Floor-mounted GX
Ref. |
Description |
(6) |
Outlet valve |
|
Installation proposal, tank-mounted GX |
|
Ref. |
Description/recommendation |
1 |
Isolating switch, compressor |
Ref. |
Description/recommendation |
|
2 |
Isolating switch, dryer |
|
3 |
Front panel, compressor |
|
4 |
Dryer |
|
(1) |
Minimum 1.5 m |
|
(2) |
Space for maintenance, minimum 2 m |
|
(3) |
Single-phase dryer supply |
|
(4) |
Three-phase screw compressor supply |
|
(5) |
The power cable should be protected so that it complies with local codes |
|
Step |
Action |
|
1 |
Install the compressor on a solid, level floor suitable for taking the weight. The recommended minimum distance between the top of the unit and the ceiling is 1.5 m (58.5 in). The minimum distance between the wall and the back of the compressor must be 200 mm (7.8 in). Floor-mounted versions must be installed with suitable air receiver. |
|
The pipes between a floor-mounted compressor and air receiver are hot. |
||
2 |
Position of the compressed air outlet valve. Close the valve. Connect the air net to the valve. |
|
3 |
The pressure drop over the air delivery pipe can be calculated as follows: Δp = (L x 450 x Qc1.85) / (d5 x P), with d = Inner diameter of the pipe in mm Δp = Pressure drop in bar (recommended maximum: 0.1 bar (1.5 psi)) L = Length of the pipe in m P = Absolute pressure at the compressor outlet in bar Qc = Free air delivery of the compressor in l/s |
|
4 |
Ventilation: the inlet grids and ventilation fan should be installed in such a way that any recirculation of cooling air to the compressor or dryer is avoided. |
|
5 |
Lay out the condensate drain flexible from timer drain (T) as well as the flexible from condensate drain valve (4) towards a drain collector. The drain pipes to the drain collector must not dip into the water of the drain collector. See the Starting section for the location of the components. |
|
3.2 Dimension drawings
GX Pack, floor-mounted
Ref. |
Designation |
(2) |
Cooling air outlet |
(3) |
Electrical cable entry |
(4) |
Cooling air inlet |
(5) |
Compressed air outlet |
GX 2 up to GX 5 Pack on 200 l receiver
(1) |
Cooling air outlet |
(2) |
Cooling air inlet |
(3) |
Compressed air outlet |
(4) |
Power supply cable |
(5) |
External box (only on GX 5 EP 230/1/60 and on all GX 7 EP) |
(6) |
Location of the centre of gravity (G) |
(7) |
Manual condensate drain |
GX 7 EP Pack on 200l receiver
(2) |
Cooling air inlet |
GX 2 up to GX 5 Full-Feature on 200 l receiver
(1) |
Cooling air outlet |
(2) |
Cooling air inlet |
(3) |
Compressed air outlet |
(4) |
Power supply cable |
(5) |
Dryer, cooling air inlet |
(6) |
Dryer, cooling air outlet |
(7) |
External box (only on GX 5 EP 230/1/60 and on all GX 7 EP) |
(8) |
Location of the centre of gravity (G) |
(9) |
Manual condensate drain |
(10) |
Power switch, dryer |
(11) |
Power switch, compressor |
GX 7 Full-Feature on 200 l receiver
(1) |
Power supply cable, dryer |
(2) |
Power supply cable, compressor |
(3) |
Cooling air inlet |
3.3 Electrical connections
Always disconnect the power supply before working on the electrical circuit! |
General instructions
Step |
Action |
1 |
Ensure that the supply voltage matches the voltage on the data plate. |
2 |
Install an isolating switch near the compressor. For Full-Feature compressors: fit an isolating switch near the dryer. |
3 |
Fit fuses in the incoming wiring. Check the condition of all incoming wiring and make connections. See Electrical diagrams. |
3.4 Pictographs
Ref. |
Description |
1 |
Warning: possible air/fluid discharge |
2 |
Warning: voltage |
3 |
Warning: air must not be inhaled |
4 |
Warning: wear ear protectors |
5 |
Warning: machine may start automatically |
6 |
Warning: pressure |
7 |
Warning: hot parts |
8 |
Warning: moving parts |
9 |
Warning: rotating fan |
10 |
Drain condensate daily |
11 |
Read the instruction manual |
13 |
Hour meter |
16 |
Read instruction manual before carrying out maintenance or repair work |
17 |
Lightly oil gasket of oil filter, screw filter on and tighten by hand |
18 |
Start |
19 |
|
4 Operating instructions
4.1 Initial start-up
Safety
The operator must apply all relevant Safety precautions. |
General preparation
Air outlet valve
Condensate drain valve on air receiver
Step |
Action |
1 |
Consult the installation instructions (see Installation). |
2 |
Check that the electrical connections correspond to the local codes. The installation must be earthed and protected against short circuits by fuses in all phases. An isolating switch must be installed near the compressor. |
3 |
Fit outlet valve (2), close it and connect the air net to the valve. Connect condensate drain valve (4) of the air receiver to a drain collector. Close the valve. |
Oil system
Oil level sight-glass, GX
Step |
Action |
|
If more than 3 months have passed between assembly and installation, be sure to lubricate the compressor before starting up:
|
|
|
Check the oil level. The oil level sight-glass (SG) must be above the minimum level. If the oil level is below the minimum level, top up to the middle. Do not overfill. Always use the same type of oil. |
Start-up
Label on the top
Step |
Action |
1 |
Check that all panels of the compressor housing are fitted. Check that sheet (5) (explaining the procedure for checking the motor rotation direction) is affixed to the cooling air outlet of the compressor (grating on the compressor top). Consult Dimension drawings. Switch on the voltage. Start the compressor and stop it immediately. Check the rotation direction of the motor. If the motor rotation direction is correct, the label on the top grating will be blown upwards. If the sheet remains in place, the rotation direction is incorrect. If the rotation direction is incorrect, switch off the voltage, open the isolating switch and reverse two incoming electric lines. All electrical work should be carried out by professionally qualified people. |
2 |
Start and run the compressor for a few minutes. Check that the compressor operates normally. |
4.2 Starting
Air outlet valve
Condensate drain valve on air receiver
Starting the air dyer
Dryer on/off switch
|
Switch on the voltage to the dryer and start it by moving switch (3) to position I. |
|
Timer drain (rear side of the dryer)
Starting the compressor
Step |
Action |
1 |
Check the oil level sight glass (SG). The oil level should be in the middle. If it is below the minimum level, top up to the middle. Do not overfill. |
2 |
Switch on the voltage by turning switch (1) to position I |
3 |
Open air outlet valve (2). |
4 |
Start the unit by moving selector switch (S) to position I |
5 |
Regularly check the working pressure (Gpa). |
6 |
On Full-Feature compressors, regularly check that condensate is drained during operation. |
4.3 Stopping
Air outlet valve
Condensate drain valve on air receiver
Dryer on/off switch
(82878F)
Step |
Action |
1 |
On Full-Feature units: move switch (3) of the dryer to position 0. GX 2 EP to GX 5 EP:
|
2 |
Close air outlet valve (2) and switch off the voltage to the compressor. On Full-Feature units: switch off the voltage to the dryer. |
3 |
Open condensate drain valve (4) of the air receiver for a few seconds to drain any condensate and then close the valve. |
|
The air dryer and the air receiver remain under pressure. The integrated filter (if installed) remains pressurised. If maintenance or repair work is necessary, consult the Problem solving section for all relevant safety precautions. |
4.4 Taking out of operation
Air outlet valve
Oil filler plug
This procedure should be carried out at the end of the compressor’s service life.
Step |
Action |
1 |
Stop the compressor and close the air outlet valve (2). |
Step |
Action |
2 |
Switch off the voltage and disconnect the compressor from the mains. |
3 |
Depressurise the compressor by opening plug (3) one turn. Open condensate drain valve (4) of the air receiver. |
4 |
Shut off and depressurise the part of the air net which is connected to the outlet valve. Disconnect the compressor from the air net. |
5 |
Drain the oil and condensate circuits. |
6 |
Disconnect the compressor condensate outlet and valve from the condensate net. |
5 Maintenance
5.1 Preventive maintenance schedule
Warning
|
Before carrying out any maintenance, repair work or adjustments, proceed as follows:
For detailed instructions, see the next sections. The operator must apply all relevant Safety precautions. |
Warranty-Product Liability
Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability.
General
When servicing, replace all removed gaskets, O-rings and washers.
Intervals
Carry out maintenance at the interval which comes first. The local Atlas Copco Customer Centre may overrule the maintenance schedule, especially the service intervals, depending on the environmental and working conditions of the compressor.
The "longer interval" checks must also include the "shorter interval" checks.
Preventive maintenance schedule
Period (1) |
Running hours (1) |
Action |
Daily |
-- |
After stopping, drain the condensate from the air receiver . Check the oil level. |
Monthly |
50 |
For Full-Feature versions: check that condensate from the dryer is draining automatically. |
“ |
|
For Floor-mounted versions: inspect the prefilter at the rear side of the compressor. Clean if necessary. |
3-monthly |
500 (2) |
Inspect the air filter. Clean if necessary. |
“ |
500 |
Check the belt tension. |
“ |
“ |
For compressors with PDX filter: check the service indicator, replace the filter if necessary. |
3-monthly |
1000 (2) |
Inspect the oil cooler; clean if necessary. |
Period (1) |
Running hours (1) |
Action |
“ |
“ |
For Full-Feature versions: inspect the condenser of the dryer; clean if necessary. |
Yearly |
2000 (2) |
Replace the air filter. |
“ |
2000 (3) |
If Roto-Inject Fluid is used, change the oil and the oil filter. |
“ |
2000 |
For compressors with PDX filter: replace the filter. |
“ |
4000 (3) |
If Roto-Xtend Duty Fluid is used, change the oil and the oil filter. |
“ |
4000 |
Replace the oil separator. |
“ |
-- |
Have the safety valve tested. |
(1): whichever comes first.
(2): more frequently in a dusty environment
(3): The indicated oil exchange intervals are valid for standard operating conditions (see section Reference conditions and limitations) and nominal operating pressure (see section Compressor data). Exposure of the compressor to external pollutants or operation at high humidity combined with low duty cycles may require a shorter oil exchange interval. Contact Atlas Copco if in doubt.
Important
• |
Always consult Atlas Copco if a service timer setting has to be changed. |
|
• |
For the change interval of oil and oil filter in extreme conditions, consult your Atlas Copco Customer Centre. |
|
• |
Any leakage should be attended to immediately. Damaged hoses or flexible joints must be replaced. |
5.2 Drive motor
General
Keep the outside of the electric motor clean for efficient cooling. If necessary, remove dust with a brush and/ or compressed air jet.
Description
The motor bearings are greased for life.
5.3 Oil specifications
Never mix oils of different brands or types as they may not be compatible and the oil mix will have inferior properties. A label, indicating the type of oil filled ex-factory, is stuck on the air receiver/oil tank. |
It is strongly recommended to use Atlas Copco lubricants. See section Preventive maintenance schedule for recommended oil change intervals.
For part numbers, consult the Spare Parts List.
Roto-Inject Fluid
Atlas Copco's Roto-Inject Fluid is a specially developed lubricant for use in single stage oil-injected screw compressors. Its specific composition keeps the compressor in excellent condition. Roto-Inject Fluid can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 40 ˚C (104 ˚F). If the compressor is regularly operating in ambient temperatures between 40 °C and 46 °C (115 °F), oil lifetime is reduced significantly. In such case it is recommended to use Roto-Xtend Duty Fluid.
Roto-Xtend Duty Fluid
Atlas Copco's Roto-Xtend Duty Fluid is a high quality synthetic lubricant for oil-injected screw compressors which keeps the compressor in excellent condition. Because of its excellent oxidation stability, Roto-Xtend Duty Fluid can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 46 ˚C (115 ˚F).
Roto-Foodgrade Fluid
Special oil, delivered as an option.
Atlas Copco's Roto-Foodgrade Fluid is a unique high quality synthetic lubricant, specially created for oilinjected screw compressors providing air for the food industry. This lubricant keeps the compressor in excellent condition. Roto-Foodgrade Fluid can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 40 ˚C (104 ˚F).
5.4 Oil, filter and separator change
Important
|
Never mix oils of different brands or types. A label, indicating the type of oil filled ex-factory, is stuck on the air receiver/oil tank. Always drain the compressor oil at all drain points. Used oil left in the compressor can shorten the lifetime of the new oil. If the compressor is exposed to external pollutants, is being used at high temperatures (oil temperature above 90˚C / 194˚F) or is being used under severe conditions, it is advisable to change the oil more frequently. Consult Atlas Copco. |
GX 2 up to GX 5
Step |
Action |
1 |
Run the compressor until warm. Stop the compressor, close the air outlet valve and switch off the voltage. |
2 |
Remove the front and top panels. |
3 |
Depressurise the compressor by unscrewing filler plug (8) one turn to permit any pressure in the system to escape. |
4 |
Depressurise the air receiver by opening drain valve (4). |
5 |
Drain the oil by opening drain valve (5). Close the valve after draining. Deliver the spent oil to the local oil collection service. |
6 |
Remove oil filter (3) and separator (2). Clean the seats on the manifold. |
7 |
Oil the gaskets of the new filter and separator and screw them into place. Tighten firmly by hand. |
8 |
Remove filler plug (8) and fill oil tank (7) with oil until the level reaches the middle of sightglass (6). Ensure no dirt gets into the system. Refit and tighten filler plug (8). |
9 |
Unscrew the air filter cover (1), remove the filter element and carefully pour approx. 0.1 l (0.03 US gal / 0.02 Imp gal) of oil into the compressor element. Do not overfill. |
10 |
Re-assemble the inlet filter |
11 |
Fit the bodywork panels. |
12 |
Close drain valve (4) of the air receiver. |
13 |
Run the compressor for a few minutes. Check the oil level. |
5.5 Storage after installation
If the compressor is stored without running from time to time, consult Atlas Copco as protective measures may be necessary.
5.6 Service kits
Service kits
For overhauling and for preventive maintenance, a wide range of service kits is available. Service kits comprise all parts required for servicing the component and offer the benefits of genuine Atlas Copco parts while keeping the maintenance budget low.
Also a full range of extensively tested lubricants, suitable for your specific needs is available to keep the compressor in excellent condition.
Consult the Spare Parts List for part numbers.
6 Adjustments and servicing procedures
6.1 Air filter
Changing the air filter
Air filter (1)
Procedure:
Step |
Action |
1 |
Stop the compressor, close the air outlet valve and switch off the voltage. |
2 |
Remove the front panel and the top panel of the compressor housing. |
3 |
Unscrew the filter cover (1) and remove the filter element. Discard the air filter element. |
4 |
Fit the new element and screw on the filter cover. |
5 |
Refit the top and front panels. |
6.2 Coolers
Oil cooler
Step |
Action |
1 |
Keep oil cooler (Co) clean to maintain the cooling efficiency. |
2 |
Stop the compressor, close the air outlet valve and switch off the voltage. Remove any dirt from the cooler with a fibre brush. Never use a wire brush or metal objects. Then clean using an air jet. |
6.3 Safety valve
Condensate drain valve on air receiver
Oil filler plug
Testing
The valve can be tested on a separate compressed air line.
Before removing the valve, stop the compressor (see section Stopping).
On a Full-Feature unit also stop the dryer.
Close the air outlet valve, switch off the voltage, open drain valves (4) (if applicable) and unscrew filler plug (3) one turn to permit any pressure in the system to escape.
If the valve does not open at the set pressure stamped on the valve, replace the valve. No adjustments are allowed. Never run the compressor without a safety valve. |
6.4 Belt set exchange and tensioning
Read the warning in the Preventive maintenance schedule section. |
Belt tensioning procedure
Step |
Action |
1 |
Stop the compressor, close the air outlet valve and switch off the voltage. For Full-Feature versions: also stop the dryer. |
2 |
Remove the front panel of the compressor housing. |
3 |
Remove the side, back and top panels of the compressor housing. |
4 |
Loosen the 4 bolts (2) by one turn. |
5 |
Adjust the belt tension by turning tensioning nut (1). |
Step |
Action |
6 |
The tension is correct when a force of 50 N (11.25 lbf) applied at the midpoint of the belt causes a deflection of 6 mm (0.23 in). |
7 |
Retighten bolts (2). |
8 |
Refit the bodywork panels. |
Belt replacement procedure
Step |
Action |
1 |
Stop the compressor, close the air outlet valve and switch off the voltage. For Full-Feature versions: also stop the dryer. |
2 |
Remove the front panel of the compressor housing. |
3 |
Remove the side, back and top panels of the compressor housing. |
4 |
Loosen the 4 bolts (2) by one turn. |
5 |
Release the belt tension by loosening tensioning nut (1). |
6 |
Remove the fan cowl. |
7 |
Remove the belt via the fan cowl opening. Install the new belt via the same opening. |
8 |
Tension belt (3) as described above. |
9 |
Re-assemble the fan cowl. |
10 |
Refit the bodywork panels. |
11 |
Check the belt tension after 50 running hours. |
7 Problem solving
Air outlet valve
Dryer on/off switch
GX Full-Feature
Attention
|
Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability. Apply all relevant Safety precautions during maintenance or repair. |
|
|
GX 2 EP to GX 5 EP:
Move dryer on/off switch (6) to position 0. Wait until the compressor has stopped and switch off the voltage. See the Stopping section. Open the isolating switch to prevent an accidental start. Close air outlet valve (2) and depressurise the compressor by opening the oil filler plug (3) one turn. Open manual condensate drain valves (4 and/or 5). |
|
|
The air outlet valve (2) can be locked during maintenance or repair as follows:
|
Faults and remedies
For all references given hereafter, see Air flow diagram, Initial start-up or Regulating system.
Compressor
|
Condition |
Fault |
Remedy |
1 |
The machine does not start |
No power |
Check power supply |
Fuse (F1) blown |
Replace fuse |
||
The main motor thermal protection has tripped |
Check and let motor cool down; to reset/restart, move compressor start/ stop switch to 0, then to I |
||
2 |
The machine does not start, high oil temperature lamp is on (temperature switch tripped) |
Oil cooler is dirty |
Clean cooler |
Ambient temperature too high |
Improve ventilation in compressor room |
||
Oil level too low |
Top up oil tank |
||
3 |
The compressor does not reach working pressure |
Blow-off solenoid valve (Y1) remains open |
Check; replace valve if necessary |
4 |
Excess oil consumption |
Oil separator (OS) clogged |
Replace oil separator |
Oil level too high |
Drain to correct level |
Air dryer
|
Condition |
Fault |
Remedy |
1 |
No compressed air passes through the dryer |
Pipes are frozen inside |
Hot-gas by-pass valve malfunctioning; consult Atlas Copco |
|
Condition |
Fault |
Remedy |
2 |
Condensate in the piping |
Insufficient condensate drain |
Check the operation of timer (T) |
The dryer is working outside its rating |
Check room temperature - air temperature at dryer. Clean the condenser and check operation of fan |
||
3 |
The compressor head is very hot (above 55˚C / 131˚F) motor overload |
The dryer is working outside its rating |
Check room temperature - air temperature at dryer. Clean the condenser and check operation of fan |
Insufficient refrigerant in dryer |
Have system checked for leaks or refilled |
||
4 |
The motor hums and does not start |
Line voltage too low |
Check power supply |
The machine was switched off and on again too rapidly (not enough time for the pressure equalization) |
Wait a few minutes before starting the machine again |
8 Technical data
8.1 Readings on control panel
Pressure gauge
Hourmeter
The readings mentioned below are valid under the reference conditions (see Reference conditions and limitations). |
|
Ref. |
Name |
Gpa |
Air outlet pressure Reading: Modulates between preset unloading/stopping pressure and loading pressure |
Hm |
Hour meter Reading: Total running time |
8.2 Electric cable size
Attention
Local regulations remain applicable if they are stricter than the values proposed below. The voltage drop must not exceed 5 % of the nominal voltage. It may be necessary to use cables of a larger size than those stated to comply with this requirement. |
|||||||
|
|
GX 2 |
GX 3 |
GX 4 |
GX 5 |
GX 7 |
|
|
Frequency (Hz) |
Voltage (V) |
Cable size |
Cable size |
Cable size |
Cable size |
Cable size |
|
IEC |
|
|
|
|
|
|
|
50 |
200 - 3 |
2.5 mm2 |
- |
- |
6 mm2 |
|
|
50 |
230 - 1 |
2.5mm2 |
- |
- |
- |
|
|
50 |
230 - 3 |
2.5 mm2 |
2.5 mm2 |
4 mm2 |
4 mm2 |
6 mm2 |
|
50 |
400 - 3 |
1 mm2 |
1 mm2 |
1.5 mm2 |
1.5 mm2 |
4 mm2 |
|
60 |
200 - 3 |
2.5 mm2 |
- |
4 mm2 |
6 mm2 |
|
|
60 |
230 - 1 |
2.5 mm2 |
- |
- |
- |
|
|
60 |
230 - 3 |
2.5 mm2 |
2.5 mm2 |
4 mm2 |
4 mm2 |
|
|
60 |
380 - 3 |
1 mm2 |
1 mm2 |
1.5 mm2 |
1.5 mm2 |
4 mm² |
|
CSA/UL |
|
|
|
|
|
|
|
60 |
230 - 1 |
AWG10 |
- |
AWG8 |
AWG6 |
|
|
60 |
208-230-460 |
AWG12 |
- |
AWG10 |
AWG10 |
AWG8 |
|
60 |
575 |
AWG14 |
- |
AWG14 |
AWG14 |
AWG14 |
|
8.3 Settings for overload relay and fuses
GX 2 and GX 3
|
Frequency (Hz) |
Voltage (V) |
Overload relay (IG), GX 2 (A) |
Circuit breaker, GX 2 (A) (see note 1) |
Overload relay (IG), GX 3 (A) |
Circuit breaker, GX 3 (A) (see note 1) |
Circuit breaker, dryer supply (A) (see note 1) |
|||
IEC |
DOL |
|
Max. capacity |
Setting |
|
Max capacity |
Setting |
Max capacity |
Setting |
50 |
200 |
15 |
16 |
15 |
- |
- |
- |
6.3 |
2 |
50 |
230 |
11.8 |
16 |
14 |
16 |
16 |
16 |
6.3 |
2 |
50 |
230, 1-ph |
20 |
20 |
20 |
- |
- |
- |
6.3 |
2 |
50 |
400 |
8 |
10 |
8 |
10 |
10 |
10 |
6.3 |
2 |
60 |
200 |
15 |
16 |
15 |
- |
- |
- |
6.3 |
2 |
60 |
380 |
8 |
10 |
8 |
10 |
10 |
10 |
6.3 |
2 |
|
Frequency (Hz) |
Voltage (V) |
Overload relay (OL), GX 2 (A) |
Main fuses, compressor supply, GX 2 (A) |
Overload relay (OL), GX 3 (A) |
Main fuses, compressor supply, GX 3 (A) |
Main fuses, dryer supply (A) |
|||
cULus |
DOL |
|
Type J or RK |
Type CC |
|
Type J or RK |
Type CC |
Type J or RK |
Type CC |
60 |
200-208 |
14 |
20 |
- |
- |
- |
- |
4.5 |
8 |
60 |
230 |
11.8 |
20 |
- |
- |
- |
- |
4.5 |
8 |
60 |
230, 1-ph |
21.5 |
30 |
- |
- |
- |
- |
4.5 |
8 |
60 |
460 |
6 |
10 |
15 |
- |
- |
- |
4.5 |
8 |
60 |
575 |
5 |
8 |
12 |
- |
- |
- |
4.5 |
8 |
(1): Motor circuit breaker with residual current device type D
GX 4 and GX 5
|
Frequency (Hz) |
Voltage (V) |
Overload relay (IG), GX 4 (A) |
Circuit breaker, GX 4 (A) (see note 1) |
Overload relay (IG), GX 5 (A) |
Circuit breaker, GX 5 (A) (see note 1) |
Circuit breaker, dryer supply (A) (see note 1) |
|||
IEC |
DOL |
|
Max. capacity |
Setting |
|
Max capacity |
Setting |
Max capacity |
Setting |
50 |
230 |
19 |
20 |
20 |
- |
- |
- |
6.3 |
2 |
50 |
400 |
11 |
16 |
11 |
- |
- |
- |
6.3 |
2 |
60 |
200 |
19 |
20 |
19 |
- |
- |
- |
6.3 |
2 |
60 |
380 |
11 |
16 |
11 |
13.5 |
16 |
13.5 |
6.3 |
2 |
IEC |
Y-D |
|
|
|
|
|
|
|
|
50 |
200 |
- |
- |
- |
25 |
32 |
25 |
6.3 |
2 |
50 |
230 |
19 |
20 |
20 |
23.5 |
25 |
23.5 |
6.3 |
2 |
50 |
400 |
11 |
16 |
11 |
13.5 |
16 |
13.5 |
6.3 |
2 |
60 |
200 |
- |
- |
- |
25 |
32 |
25 |
6.3 |
2 |
|
Frequency (Hz) |
Voltage (V) |
Overload relay (OL), GX 4 (A) |
Main fuses, compressor supply, GX 4 (A) |
Overload relay (OL), GX 5 (A) |
Main fuses, compressor supply, GX 5 (A) |
Main fuses, dryer supply (A) |
|||
cULus |
DOL |
|
Type J or RK |
Type CC |
|
Type J or RK |
Type CC |
Type J or RK |
Type CC |
60 |
200-208 |
21.2 |
30 |
- |
24.7 |
40 |
- |
4.5 |
8 |
60 |
230 |
18.2 |
30 |
- |
22.5 |
40 |
- |
4.5 |
8 |
60 |
230, 1-ph |
30.8 |
60 |
- |
41 |
60 |
- |
4.5 |
8 |
60 |
460 |
9.1 |
12 |
25 |
11.4 |
15 |
25 |
4.5 |
8 |
60 |
575 |
7.5 |
10 |
15 |
9.5 |
12 |
20 |
4.5 |
8 |
(1): Motor circuit breaker with residual current device type D
GX 7
|
Frequency (Hz) |
Voltage (V) |
Overload relay (IG), GX 7 (A) |
Circuit breaker, GX 7 (A) (see note 1) |
Circuit breaker, dryer supply (A) (see note 1) |
||||
IEC |
Y-D |
|
|
|
Max capacit y |
Setting |
||
50 |
230 |
19.1 |
32 |
31.5 |
6.3 |
2 |
||
50 |
400 |
11 |
20 |
18 |
6.3 |
2 |
||
60 |
380 |
11 |
20 |
19 |
6.3 |
2 |
||
|
Frequency (Hz) |
Voltage (V) |
Overload relay (OL), GX 7 (A) |
Main fuses, compressor supply, GX 7 (A) |
Main fuses, dryer supply (A) |
||||
cULus |
DOL |
|
Type J or RK |
Type CC |
Type J or RK |
Type CC |
||
60 |
200-208 |
36.3 |
50 |
- |
4.5 |
8 |
||
60 |
230 |
34.4 |
45 |
- |
4.5 |
8 |
||
60 |
460 |
16.9 |
25 |
25 |
4.5 |
8 |
||
60 |
575 |
13.8 |
20 |
15 |
4.5 |
8 |
||
(1): Motor circuit breaker with residual current device type D
8.4 Reference conditions and limitations
Reference conditions
Air inlet pressure (absolute) |
bar |
1 |
Air inlet pressure (absolute) |
psi |
14.5 |
Air inlet temperature |
˚C |
20 |
Air inlet temperature |
˚F |
68 |
Relative humidity |
% |
0 |
Working pressure |
bar(e) |
See Compressor data |
Working pressure |
psi |
See Compressor data |
Limitations
Maximum working pressure |
bar(e) |
See Compressor data |
Maximum working pressure |
psig |
See Compressor data |
Minimum working pressure |
bar(e) |
4 |
Minimum working pressure |
psig |
58 |
Maximum air inlet temperature |
˚C |
46 |
Maximum air inlet temperature |
˚F |
115 |
Minimum ambient temperature |
˚C |
0 |
Minimum ambient temperature |
˚F |
32 |
8.5 Compressor data
All data specified below apply under reference conditions, see section Reference conditions and limitations.. |
50 Hz 10 bar
Compressor type |
GX 2 |
GX 3 |
GX 4 |
GX 5 |
GX 7 |
|
Frequency |
Hz |
50 |
50 |
50 |
50 |
50 |
|
Maximum (unloading) pressure, Pack |
bar(e) |
10 |
10 |
10 |
10 |
10 |
|
Maximum (unloading) pressure, Pack |
psig |
145 |
145 |
145 |
145 |
145 |
|
Maximum (unloading) pressure, FullFeature |
bar(e) |
9.75 |
9.75 |
9.75 |
9.75 |
9.75 |
|
Maximum (unloading) pressure, FullFeature |
psig |
141 |
141 |
141 |
141 |
141 |
Nominal working pressure |
bar(e) |
9.5 |
9.5 |
9.5 |
9.5 |
9.5 |
Nominal working pressure |
psig |
138 |
138 |
138 |
138 |
138 |
Pressure drop over dryer |
bar(e) |
0.15 |
0.15 |
0.15 |
0.15 |
0.25 |
Pressure drop over dryer |
psig |
2.18 |
2.18 |
2.18 |
2.18 |
3.62 |
Motor shaft speed |
rpm |
2840 |
2840 |
2840 |
2840 |
2940 |
Set-point, thermostatic valve |
˚C |
71 |
71 |
71 |
71 |
71 |
Set-point, thermostatic valve |
˚F |
160 |
160 |
160 |
160 |
160 |
Temperature of air leaving receiver (approx.), Pack |
˚C |
33 |
33 |
33 |
33 |
33 |
Temperature of air leaving receiver (approx.), Pack |
˚F |
91 |
91 |
91 |
91 |
91 |
Pressure dewpoint, Full-Feature |
˚C |
3 |
3 |
3 |
3 |
3 |
Pressure dewpoint, Full-Feature |
˚F |
37 |
37 |
37 |
37 |
37 |
Power input, Pack at maximum working pressure |
kW |
3.8 |
4.1 |
4.9 |
6.6 |
9.0 |
Power input, Pack at maximum working pressure |
hp |
5.1 |
5.5 |
6.57 |
8.85 |
12.27 |
Compressor type |
GX 2 |
GX 3 |
GX 4 |
GX 5 |
GX 7 |
|
Power input, FullFeature at maximum working pressure |
kW |
4.1 |
4.4 |
5.2 |
6.9 |
9.25 |
Power input, FullFeature at maximum working pressure |
hp |
5.5 |
5.9 |
6.97 |
9.25 |
12.61 |
|
Power consumption, dryer at full load |
kW |
0.23 |
0.23 |
0.23 |
0.23 |
0.26 |
|
Power consumption, dryer at full load |
hp |
0.31 |
0.31 |
0.31 |
0.31 |
0.35 |
Power consumption, dryer at no load |
kW |
0.16 |
0.16 |
0.16 |
0.16 |
0.19 |
Power consumption, dryer at no load |
hp |
0.21 |
0.21 |
0.21 |
0.21 |
0.25 |
Refrigerant type |
R134a |
R134a |
R134a |
R134a |
R134a |
|
Total amount, refrigerant |
kg |
0.17 |
0.17 |
0.17 |
0.17 |
0.29 |
Total amount, refrigerant |
lb |
0.37 |
0.37 |
0.37 |
0.37 |
0.64 |
Oil capacity |
l |
2.5 |
2.5 |
2.5 |
2.5 |
2.5 |
Oil capacity |
US gal |
0.66 |
0.66 |
0.66 |
0.66 |
0.66 |
|
Sound pressure level floormounted units (according to ISO 2151 (2004)) |
dB(A) |
61 |
61 |
62 |
64 |
66 |
60 Hz 10 bar
Compressor type |
GX 2 |
GX 4 |
GX 5 |
GX 7 |
|
Frequency |
Hz |
60 |
60 |
60 |
60 |
|
Maximum (unloading) pressure, Pack |
bar(e) |
10 |
10 |
10 |
10 |
|
Maximum (unloading) pressure, Pack |
psig |
145 |
145 |
145 |
145 |
|
Maximum (unloading) pressure, Full-Feature |
bar(e) |
9.75 |
9.75 |
9.75 |
9.75 |
|
Maximum (unloading) pressure, Full-Feature |
psig |
141 |
141 |
141 |
141 |
Nominal working pressure |
bar(e) |
9.5 |
9.5 |
9.5 |
9.5 |
Nominal working pressure |
psig |
138 |
138 |
138 |
138 |
Compressor type |
GX 2 |
GX 4 |
GX 5 |
GX 7 |
|
Pressure drop over dryer |
bar(e) |
0.15 |
0.15 |
0.15 |
0.25 |
Pressure drop over dryer |
psig |
2.18 |
2.18 |
2.18 |
3.62 |
Motor shaft speed |
rpm |
3495 |
3490 |
3495 |
3525 |
Set-point, thermostatic valve |
˚C |
71 |
71 |
71 |
71 |
Set-point, thermostatic valve |
˚F |
160 |
160 |
160 |
160 |
|
Temperature of air leaving receiver (approx.), Pack |
˚C |
33 |
33 |
33 |
33 |
|
Temperature of air leaving receiver (approx.), Pack |
˚F |
91 |
91 |
91 |
91 |
Pressure dew-point, Full-Feature |
˚C |
3 |
3 |
3 |
3 |
Pressure dew-point, Full-Feature |
˚F |
37 |
37 |
37 |
37 |
Power input, Pack at maximum working pressure |
kW |
3.7 |
4.7 |
6.3 |
9.0 |
Power input, Pack at maximum working pressure |
hp |
4.96 |
6.3 |
8.45 |
12.27 |
Power input, Full-Feature at maximum working pressure |
kW |
4 |
5 |
6.6 |
9.25 |
Power input, Full-Feature at maximum working pressure |
hp |
5.36 |
6.71 |
8.85 |
12.61 |
Power consumption, dryer at full load |
kW |
0.24 |
0.24 |
0.24 |
0.32 |
Power consumption, dryer at full load |
hp |
0.33 |
0.33 |
0.33 |
0.44 |
Power consumption, dryer at no load |
kW |
0.17 |
0.17 |
0.17 |
0.22 |
Power consumption, dryer at no load |
hp |
0.23 |
0.23 |
0.23 |
0.30 |
Refrigerant type |
R134a |
R134a |
R134a |
R134a |
|
Total amount, refrigerant |
kg |
0.17 |
0.17 |
0.17 |
0.29 |
Total amount, refrigerant |
lb |
0.37 |
0.37 |
0.37 |
0.64 |
Oil capacity |
l |
2.5 |
2.5 |
2.5 |
2.5 |
Oil capacity |
US gal |
0.66 |
0.66 |
0.66 |
0.66 |
Sound pressure level floormounted units (according to ISO 2151 (2004)) |
dB(A) |
61 |
62 |
64 |
66 |
9 Instructions for use
Oil separator vessel
1 |
The vessel can contain pressurised air. This can be potentially dangerous if the equipment is misused. |
2 |
This vessel must only be used as a compressed air/oil separator tank and must be operated within the limits specified on the data plate. |
3 |
No alterations must be made to this vessel by welding, drilling or other mechanical methods without the written permission of the manufacturer. |
4 |
The pressure and temperature of this vessel must be clearly indicated. |
5 |
The safety valve must correspond with pressure surges of 1.1 times the maximum allowable operating pressure. It should guarantee that the pressure will not permanently exceed the maximum allowable operating pressure of the vessel. |
6 |
Use only oil as specified by the manufacturer. |
7 |
In case of misuse of the units (frequent operation with too low oil temperature or long interval of shut down), a certain amount of condensate can gather in the oil separator vessel which must be properly drained. To do so, disconnect the unit from the power line, wait till it is cooled down and depressurised and drain the water by the oil drain valve, positioned at the bottom side of the oil separator vessel. Local legislation may require an periodic inspection. |
Air receiver (on tank-mounted units)
1 |
Corrosion must be prevented: depending on the conditions of use, condensate may accumulate inside the tank and must be drained every day. This may be done manually by opening the drain valve, or by means of the automatic drain, if fitted to the tank. Nevertheless, a weekly check of correct functioning of the automatic valve is needed. This has to be done by opening the manual drain valve and check for condensate. Verify that no rust obstructions affect the drain system. |
2 |
Yearly service inspection of the air receiver is needed, as internal corrosion can reduce the steel wall thickness with the consequent risk of bursting. Local rules need to be respected, if applicable. The use of the air receiver is forbidden once the wall thickness reaches the minimum value as indicated in the service manual of the air receiver (part of the documentation delivered with the unit). |
3 |
Lifetime of the air receiver mainly depends on the working environment. Installing the compressor in a dirty and corrosive environment is not allowed, as this can reduce the vessel lifetime dramatically. |
4 |
Do not anchor the vessel or attached components directly to the ground or fixed structures. Fit the pressure vessel with vibration dampers to avoid possible fatigue failure caused by vibration of the vessel during use. |
5 |
Use the vessel within the pressure and temperature limits stated on the nameplate and the testing report. |
6 |
No alterations must be made to this vessel by welding, drilling or other mechanical methods. |
10 Guidelines for inspection
Guidelines
On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor.
Local legal requirements and/or use outside the limits and/or conditions as specified by the manufacturer may require other inspection periods as mentioned below.
11 Pressure equipment directives
Components subject to 97/23/EC Pressure Equipment Directive
Components subject to 97/23/EC Pressure Equipment Directive greater than or equal to category II: safety valves.
See the spare parts book for part numbers.
Overall rating
The compressors conform to PED smaller than category I.
12 Declaration of conformity
Typical example of a Declaration of Conformity document
(1): Contact address:
Atlas Copco Airpower n.v.
P.O. Box 100
B-2610 Wilrijk (Antwerp)
Belgium
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