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Atlas Copco

Oil-injected rotary screw compressors

GX 2 EP, GX 3 EP, GX 4 EP, GX 5 EP, GX 7 EP

Instruction book

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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.

2014 - 05
No. 2920 7105 31
Replaces No. 2920 7105 30
www.atlascopco.com

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Instruction book

Table of contents

1 Safety precautions..........................................................................................................4

1.1 SAFETY ICONS...................................................................................................................................4

1.2 GENERAL SAFETY PRECAUTIONS............................................................................................................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 General description........................................................................................................9

2.1 INTRODUCTION...................................................................................................................................9

2.2 AIR FLOW.......................................................................................................................................11

2.3 OIL SYSTEM....................................................................................................................................14

2.4 COOLING SYSTEM.............................................................................................................................16

2.5 REGULATING SYSTEM........................................................................................................................17

2.6 CONTROL PANEL .............................................................................................................................19

2.7 ELECTRICAL DIAGRAMS......................................................................................................................20

2.8 PROTECTION OF THE COMPRESSOR......................................................................................................27

2.9 AIR DRYER......................................................................................................................................29

3 Installation.....................................................................................................................30

3.1 INSTALLATION PROPOSAL...................................................................................................................30

3.2 DIMENSION DRAWINGS.......................................................................................................................33

3.3 ELECTRICAL CONNECTIONS ................................................................................................................37

3.4 PICTOGRAPHS.................................................................................................................................38

4 Operating instructions.................................................................................................40

4.1 INITIAL START-UP..............................................................................................................................40

4.2 STARTING.......................................................................................................................................42

4.3 STOPPING.......................................................................................................................................44

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4.4 TAKING OUT OF OPERATION................................................................................................................46

5 Maintenance..................................................................................................................48

5.1 PREVENTIVE MAINTENANCE SCHEDULE..................................................................................................48

5.2 DRIVE MOTOR .................................................................................................................................49

5.3 OIL SPECIFICATIONS..........................................................................................................................50

5.4 OIL, FILTER AND SEPARATOR CHANGE .................................................................................................50

5.5 STORAGE AFTER INSTALLATION...........................................................................................................52

5.6 SERVICE KITS..................................................................................................................................52

5.7 DISPOSAL OF USED MATERIAL.............................................................................................................52

6 Adjustments and servicing procedures.....................................................................53

6.1 AIR FILTER......................................................................................................................................53

6.2 COOLERS.......................................................................................................................................54

6.3 SAFETY VALVE ................................................................................................................................54

6.4 BELT SET EXCHANGE AND TENSIONING ................................................................................................55

7 Problem solving............................................................................................................57

8 Technical data...............................................................................................................60

8.1 READINGS ON CONTROL PANEL...........................................................................................................60

8.2 ELECTRIC CABLE SIZE.......................................................................................................................60

8.3 SETTINGS FOR OVERLOAD RELAY AND FUSES.........................................................................................61

8.4 REFERENCE CONDITIONS AND LIMITATIONS............................................................................................63

8.5 COMPRESSOR DATA..........................................................................................................................63

9 Instructions for use......................................................................................................67

10 Guidelines for inspection.............................................................................................68

11 Pressure equipment directives...................................................................................69

12 Declaration of conformity............................................................................................70

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1 Safety precautions

1.1 Safety icons

Explanation

Danger for life

Warning

Important note

1.2 General safety precautions


1. The operator must employ safe working practices and observe all related work safety requirements and
regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the two
shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel. The personnel should apply safe working practices by use of personal protection
equipment, appropriate tools and defined procedures.
4. 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.
5. Before any maintenance, repair work, adjustment or any other non-routine checks:
• Stop the compressor
• Press the emergency stop button
• Switch off the voltage
• Depressurize the compressor
• Lock Out - Tag Out (LOTO):
• Open the power isolating switch and lock it with a personal lock
• Tag the power isolating switch with the name of the service technician.
• On units powered by a frequency converter, wait 10 minutes before starting any electrical repair.
• Never rely on indicator lamps or electrical door locks before maintenance work, always disconnect
and check with measuring device.

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!

6. 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.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories shall
be replaced if unsuitable for safe operation.
8. It is prohibited to walk or stand on the unit or on its components.

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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


1. 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.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken;
consult your supplier.
3. In case the device is a compressor, 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.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
5. 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.
6. In case the device is a compressor, the aspirated air must be free of flammable fumes, vapors and particles,
e.g. paint solvents, that can lead to internal fire or explosion.
7. In case the device is a compressor, arrange the air intake so that loose clothing worn by people cannot be
drawn in.
8. 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.
9. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is
remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and depressurized and that the electrical isolating
switch is open, locked and labelled with a temporary warning before any maintenance or repair. As a
further safeguard, persons switching on or off 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.
11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available and
that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.
12. The electrical connections must correspond to the applicable codes. The machines must be earthed and
protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed
near the compressor.
13. On machines with automatic start/stop system or if the automatic restart function after voltage failure is
activated, a sign stating "This machine may start without warning" must be affixed near the instrument
panel.
14. In multiple compressor systems, manual valves must be installed to isolate each compressor. Non-return
valves (check valves) must not be relied upon for isolating pressure systems.
15. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure
vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be
protected by a pressure relieving device or devices as required.

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16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentally touched
by personnel in normal operation must be guarded or insulated. Other high temperature piping must be
clearly marked.
17. For water-cooled machines, the cooling water system installed outside the machine has to be protected by
a safety device with set pressure according to the maximum cooling water inlet pressure.
18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
19. If the device is a dryer and no free extinguishing system is present in the air net close to the dryer, safety
valves must be installed in the vessels of the dryer.

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


1. Never touch any piping or components of the compressor during operation.
2. 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.
3. 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.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors or
particles.
5. Never operate the machine below or in excess of its limit ratings.
6. 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.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)
shall wear ear protectors.
8. 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
• No leaks occur
• 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

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• Air cooling filters of the electrical cabinet are not clogged


9. 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.
10. On water-cooled compressors using open circuit cooling towers, protective measures must be taken to
avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
11. Do not remove any of, or tamper with, the sound-damping material.
12. 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.
13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book must be
respected. Local regulations remain applicable if they are more strict.

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


1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to the starting
equipment.
6. 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.
7. Close the compressor air outlet valve and depressurize the compressor before connecting or disconnecting
a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure
and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against
toxic vapours of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts
and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way modify,
pressure vessels.

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12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine 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.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. 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.
16. 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.
17. 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.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering
them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodywork
and 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.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
21. 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.

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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

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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

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2.2 Air flow

Pack

Air flow, floor-mounted Pack units

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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).

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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).

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2.3 Oil system

GX Pack

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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.

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2.4 Cooling system

Pack units

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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:

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• 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: contact 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.

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2.6 Control panel

Control panel GX Pack

Control panel GX Full Feature

Reference Designation Designation


1 Main switch - To power the unit. Also used to stop the compressor in the event
emergency switch 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 (Only 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)

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2.7 Electrical diagrams

Service diagram GX 2 - IEC - 1 ph

Service diagram GX 2 up to GX 5 - IEC - 3 ph DOL

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Service diagram GX 2 up to GX 5 - IEC - 3 ph Y-D

Single phase dryer - 230 V 50/60 Hz

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Electrical diagram GX 2 - cULus - 1 ph

Electrical diagram GX 4 and GX 5 - cULus - 1 ph

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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

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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.

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GX 7 EP

IEC units with Y-D start

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GX 7 EP for 208/230/460V 60 Hz DOL

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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 the compressor

Safety valve on the compressor

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Safety valve on the air receiver (tank-mounted units)

Reference Designation Function


IG (IEC) Motor overload relay To shut down the compressor in case the motor current
OL (cULus) is too high.
See also section
Electrical diagrams
TSH (IEC), TS Temperature shut-down To shut down the compressor if the temperature at the
(cULus) switch outlet of the compressor element is too high.
See also section
Electrical diagrams
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.

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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.

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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.

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Installation proposal

Installation proposal, Floor-mounted GX

Ref. Description
(6) Outlet valve

Installation proposal, tank-mounted GX

Ref. Description/recommendation
1 Isolating switch, compressor

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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.

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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

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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

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GX 7 EP Pack on 200l receiver

(2) Cooling air inlet

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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)

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(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!

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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 the condensate daily and inspect the vessel yearly. Note down the inspection dates.
11 Read the instruction manual

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GX 2 EP up to GX 5 EP

GX 7 EP

Ref. Description
13 Hour meter
14 Start
15 • GX 2 EP up to GX 5 EP: Stop
• GX 7 EP: Unload
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

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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.

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Oil system

Step Action
If more than 3 months have passed between assembly and installation, be sure to
lubricate the compressor before starting up:
• Remove the front panel.
• Unscrew the fixing bolts in the top and remove the panel.
• Unscrew the cover of the air filter (AF) and remove the filter element.
• Open valve (7) and drain approximately 0.2 l (0.05 US gal / 0.04 Imp gal) of oil into a
clean receptacle. Carefully pour this oil through the filter housing into the compressor
element.
• Fit the air filter and screw on the filter cover.
• Refit the top and front panels.
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

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Step Action
1 Check that all bodywork panels 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

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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.
• Switch on the dryer before starting the compressor.
• The dryer must remain switched on when the compressor is operating to ensure that
the air piping remains condensate-free.
• If the dryer is switched off, wait at least 5 minutes before restarting the dryer; this allows
for balancing of the internal pressure in the dryer.

Timer drain (rear side of the dryer)

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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

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Condensate drain valve on air receiver

Control panel GX 2 up to GX 5 EP

Control panel GX 7 EP

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Dryer on/off switch

Step Action
1 On Full-Feature units: move switch (3) of the dryer to position 0.
GX 2 EP to GX 5 EP:
• Move start/stop switch (S) to position 0.
• Turn off main switch (1)
GX 7 EP:
• Move selector switch (S) to unload position.
• Wait at least 30 seconds and turn off mains switch (1)
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

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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).
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.

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5 Maintenance

5.1 Preventive maintenance schedule

Warning

Before carrying out any maintenance, repair work or adjustments, proceed as


follows:
• Stop the compressor.
• Switch off the voltage and open the isolating switch.
• Close the air outlet valve and open the manual condensate drain valves.
• Depressurise the compressor.
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 Action


(1)
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.

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Period (1) Running hours Action


(1)
“ “ 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.
“ -- Inspect the air receiver.
The air receiver must no longer be used and must be replaced if the
wall thickness is less than the minimum value, specified in the technical
documentation of the air receiver.

(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.

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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 oil-
injected 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.

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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 sight-
glass (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.

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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.

5.7 Disposal of used material

Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must be
disposed of in an environmentally friendly and safe manner, and in line with the local recommendations and
environmental legislation.

Electronic components are subject to the EU Directive 2002/96/EC for Waste Electrical and Electronic
Equipment (WEEE). As such, these parts must not be disposed of at a municipal waste collection point. Refer
to local regulations for directions on how to dispose of this product in an environmental friendly manner.

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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.

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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

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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).

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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.

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7 Problem solving

Air outlet valve

Dryer on/off switch

GX Full-Feature

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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 start/stop switch (S) to position 0.
• Turn off main switch (1)
GX 7 EP:
• Move selector switch (S) to unload position.
• Wait at least 30 seconds and turn off mains switch (1)
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:
• Close the valve.
• Remove the screw fixing the handle
• Lift the handle and turn it until the slot of the handle fits over the blocking edge on the
valve body.
• Fit the screw.

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 Check and let motor cool down; to
protection has tripped reset/restart, move compressor start/
stop switch to 0, then to I
2 The machine does not start, Oil cooler is dirty Clean cooler
high oil temperature lamp is on Ambient temperature too high Improve ventilation in compressor
(temperature switch tripped) room
Oil level too low Top up oil tank
3 The compressor does not Blow-off solenoid valve (Y1) Check; replace valve if necessary
reach working pressure remains open
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 Pipes are frozen inside Hot-gas by-pass valve
through the dryer malfunctioning; consult Atlas Copco

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Condition Fault Remedy


2 Condensate in the piping Insufficient condensate drain Check the operation of timer (T)
The dryer is working outside its Check room temperature - air
rating temperature at dryer. Clean the
condenser and check operation of fan
3 The compressor head is very The dryer is working outside its Check room temperature - air
hot (above 55˚C / 131˚F) - rating temperature at dryer. Clean the
motor overload condenser and check operation of fan
Insufficient refrigerant in dryer Have system checked for leaks or
refilled
4 The motor hums and does not Line voltage too low Check power supply
start The machine was switched off Wait a few minutes before starting the
and on again too rapidly (not machine again
enough time for the pressure
equalization)

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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.

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GX 2 GX 3 GX 4 GX 5 GX 7
Frequency Voltage Cable size Cable size Cable size Cable size Cable size
(Hz) (V)
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 Voltage (V) Overload Circuit breaker, Overload Circuit breaker, Circuit breaker,
(Hz) relay (IG), GX 2 (A) (see note relay (IG), GX 3 (A) (see note dryer supply (A)
GX 2 (A) 1) GX 3 (A) 1) (see note 1)
IEC DOL Max. Setting Max Setting Max Setting
capacity capacity capacity
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 Voltage (V) Overload Main fuses, Overload Main fuses, Main fuses, dryer
(Hz) relay (OL), compressor relay (OL), compressor supply (A)
GX 2 (A) supply, GX 2 (A) GX 3 (A) supply, GX 3 (A)
cULus DOL Type J or Type Type J or Type Type J or Type
RK CC RK CC RK 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

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60 575 5 8 12 - - - 4.5 8

(1): Motor circuit breaker with residual current device type D

GX 4 and GX 5

Frequency Voltage (V) Overload Circuit breaker, Overload Circuit breaker, Circuit breaker,
(Hz) relay (IG), GX 4 (A) (see note relay (IG), GX 5 (A) (see note dryer supply (A)
GX 4 (A) 1) GX 5 (A) 1) (see note 1)
IEC DOL Max. Setting Max Setting Max Setting
capacity capacity capacity
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 Voltage (V) Overload Main fuses, Overload Main fuses, Main fuses, dryer
(Hz) relay (OL), compressor relay (OL), compressor supply (A)
GX 4 (A) supply, GX 4 (A) GX 5 (A) supply, GX 5 (A)
cULus DOL Type J or Type Type J or Type Type J or Type
RK CC RK CC RK 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 Voltage (V) Overload Circuit breaker, Circuit breaker,


(Hz) relay (IG), GX 7 (A) (see note dryer supply (A)
GX 7 (A) 1) (see note 1)
IEC Y-D Max Setting
capacit
y
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

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Frequency Voltage (V) Overload Main fuses, Main fuses, dryer


(Hz) relay (OL), compressor supply (A)
GX 7 (A) supply, GX 7 (A)
cULus DOL Type J or Type Type J or Type
RK CC RK 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..

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Instruction book

50 Hz 10 bar

Compressor GX 2 GX 3 GX 4 GX 5 GX 7
type
Frequency Hz 50 50 50 50 50
Maximum bar(e) 10 10 10 10 10
(unloading)
pressure, Pack
Maximum psig 145 145 145 145 145
(unloading)
pressure, Pack
Maximum bar(e) 9.75 9.75 9.75 9.75 9.75
(unloading)
pressure, Full-
Feature
Maximum psig 141 141 141 141 141
(unloading)
pressure, Full-
Feature
Nominal working bar(e) 9.5 9.5 9.5 9.5 9.5
pressure
Nominal working psig 138 138 138 138 138
pressure
Pressure drop bar(e) 0.15 0.15 0.15 0.15 0.25
over dryer
Pressure drop psig 2.18 2.18 2.18 2.18 3.62
over dryer
Motor shaft speed rpm 2840 2840 2840 2840 2940
Set-point, ˚C 71 71 71 71 71
thermostatic valve
Set-point, ˚F 160 160 160 160 160
thermostatic valve
Temperature of air ˚C 33 33 33 33 33
leaving receiver
(approx.), Pack
Temperature of air ˚F 91 91 91 91 91
leaving receiver
(approx.), Pack
Pressure dew- ˚C 3 3 3 3 3
point, Full-Feature
Pressure dew- ˚F 37 37 37 37 37
point, Full-Feature
Power input, Pack kW 3.8 4.1 4.9 6.6 9.0
at maximum
working pressure
Power input, Pack hp 5.1 5.5 6.57 8.85 12.27
at maximum
working pressure

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Compressor GX 2 GX 3 GX 4 GX 5 GX 7
type
Power input, Full- kW 4.1 4.4 5.2 6.9 9.25
Feature at
maximum working
pressure
Power input, Full- hp 5.5 5.9 6.97 9.25 12.61
Feature at
maximum working
pressure
Power kW 0.23 0.23 0.23 0.23 0.26
consumption,
dryer at full load
Power hp 0.31 0.31 0.31 0.31 0.35
consumption,
dryer at full load
Power kW 0.16 0.16 0.16 0.16 0.19
consumption,
dryer at no load
Power hp 0.21 0.21 0.21 0.21 0.25
consumption,
dryer at no load
Refrigerant type R134a R134a R134a R134a R134a
Total amount, kg 0.17 0.17 0.17 0.17 0.29
refrigerant
Total amount, lb 0.37 0.37 0.37 0.37 0.64
refrigerant
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 dB(A) 61 61 62 64 66
level floor-
mounted units
(according to ISO
2151 (2004))

60 Hz 10 bar

Compressor type GX 2 GX 4 GX 5 GX 7
Frequency Hz 60 60 60 60
Maximum (unloading) pressure, bar(e) 10 10 10 10
Pack
Maximum (unloading) pressure, psig 145 145 145 145
Pack
Maximum (unloading) pressure, bar(e) 9.75 9.75 9.75 9.75
Full-Feature
Maximum (unloading) pressure, psig 141 141 141 141
Full-Feature
Nominal working pressure bar(e) 9.5 9.5 9.5 9.5
Nominal working pressure psig 138 138 138 138

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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 ˚C 33 33 33 33
(approx.), Pack
Temperature of air leaving receiver ˚F 91 91 91 91
(approx.), Pack
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 kW 3.7 4.7 6.3 9.0
working pressure
Power input, Pack at maximum hp 4.96 6.3 8.45 12.27
working pressure
Power input, Full-Feature at kW 4 5 6.6 9.25
maximum working pressure
Power input, Full-Feature at hp 5.36 6.71 8.85 12.61
maximum working pressure
Power consumption, dryer at full kW 0.24 0.24 0.24 0.32
load
Power consumption, dryer at full hp 0.33 0.33 0.33 0.44
load
Power consumption, dryer at no kW 0.17 0.17 0.17 0.22
load
Power consumption, dryer at no hp 0.23 0.23 0.23 0.30
load
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 floor- dB(A) 61 62 64 66
mounted units (according to ISO
2151 (2004))

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Instruction book

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.

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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.

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Instruction book

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.

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Instruction book

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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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 device.

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In order to be First in Mind—First in Choice® for all your quality
compressed air needs, Atlas Copco delivers the products and
services that help to increase your business’ efficiency and
profitability.
Atlas Copco's pursuit of innovation never ceases, driven by our
need for reliability and efficiency. Always working with you, we are
committed to providing you the customized quality air solution that
is the driving force behind your business.

No. 2920 7105 31 / 2014 - 05 - Printed in Belgium

www.atlascopco.com

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