INSTRUCTION BOOK OIL-INJECTED ROTARY SCREW COMPRESSORS G 2, G 3, G 4, G 5, G 7
Atlas Copco Oil-injected rotary screw compressors G 2, G 3, G 4, G 5, G 7 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.
Instruction book Table of contents 1 Safety precautions..........................................................................................................5 1.1 SAFETY ICONS................................................................................................................................... 5 1.2 GENERAL SAFETY PRECAUTIONS............................................................................................................5 1.3 SAFETY PRECAUTIONS DURING INSTALLATION.........
Instruction book 3.9 SCROLLING THROUGH ALL SCREENS.....................................................................................................39 3.10 CALLING UP RUNNING HOURS..............................................................................................................40 3.11 CALLING UP MOTOR STARTS............................................................................................................... 41 3.12 CALLING UP MODULE HOURS.....................................
Instruction book 6.3 OIL SPECIFICATIONS..........................................................................................................................68 6.4 OIL, FILTER AND SEPARATOR CHANGE ................................................................................................. 69 6.5 STORAGE AFTER INSTALLATION........................................................................................................... 71 6.6 SERVICE KITS.............................................
Instruction book 1 Safety precautions 1.1 Safety icons Explanation Danger to 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.
Instruction book 9. If compressed air is used in the food industry and more specifically for direct food contact, it is recommended, for optimal safety, to use certified Class 0 compressors in combination with appropriate filtration depending on the application. Please contact your customer center for advice on specific filtration. 1.
Instruction book 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.
Instruction book 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 machines 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.
Instruction book 3. Use only genuine spare parts for maintenance or repair. The manufacturer will disclaim all damage or injuries caused by the use of non-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.
Instruction book 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. 1.
Instruction book 2 General description 2.1 Introduction Introduction G 2, G 3, G 4, G 5 and G 7 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 electronic Base controller and the emergency stop button. A cabinet housing the controller, pressure sensor and motor starter is integrated into the bodywork.
Instruction book 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) or 500 l (132 US gal / 110 Imp gal / 17.50 cu.ft) and are available in Pack and Full-Feature version. G 5, Full-Feature, tank-mounted 12 Ref.
Instruction book 2.
Instruction book 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).
Instruction book Full-Feature Air flow, 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).
Instruction book 2.
Instruction book Oil system, 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.
Instruction book 2.
Instruction book Full-Feature units The cooling system of the Pack version comprises oil cooler (Co) and fan (FN). The fan, mounted directly onto the motor shaft, generates the cooling air in order to cool the oil and the internal parts of the compressor. On tank-mounted compressors, the air receiver is used as air cooler. The condensate must be drained manually on a regular basis, see section Preventive maintenance schedule.
Instruction book 2.5 Regulating system G 2 up to G 4 The main components of the regulating system are: • Blow-off valve (Y1) • The Elektronikon™ Base controller that starts/stops the compressor based on the pressure settings and readings of the pressure sensor. As long as the working pressure is below the preset maximum, the compressor will run fully loaded (100% output) and the blow-off valve will be closed.
Instruction book compressor will automatically restart and then the blow-off valve will be closed, when the net pressure drops to the minimum limit set in the controller. G 5 up to G 7 The main components of the regulating system are: • • • • Unloader (UA), including inlet valve (IV) and non-return valve (NRV). Loading solenoid valve (Y1), normally open. Pressure signal (PS) from the instrument block.
Instruction book b. If the calculated virtual temperature of the motor (which increases each motor start) is above the safety limit, the compressor will go in unload mode until the temperature is decreased below the safety limit. c. At the end of the unload period the controller checks the pressure. If there is no pressure request at the end of the cycle and the pressure is above 2/3 of the pressure band, the compressor stops.
Instruction book Control panel, Full-Feature 2.
Instruction book Electric cubicle IEC (DOL and YD) Electric cubicle UL/CSA (only DOL) 24 Reference Designation F1-3 Fuses F21 Overload relay, compressor motor K7 Auxiliary circuit relay K21 Line contactor K22 Star contactor K23 Delta contactor T1 Transformer 1x1 Terminal block, voltage change of the motor (only on tri-voltage units) 2920 7199 10
Instruction book Reference Designation 1x3 Terminal block of earth protection 1x5 Terminal block of control unit Electrical diagram 2205 0161 00 Service diagram G 2 – G 3 – G 4 DOL IEC 2205 0161 50 Service diagram G 4 – G 5 – G 7 YD IEC 2205 0347 00 Service diagram G 2 – G 4 – G 5 – G 7 DOL UL 2205 0347 50 Service diagram G 2 – G 4 – G 5 – G 7 DOL CSA The complete electrical diagram can be found in the electric cubicle.
Instruction book Safety valve on the air receiver (tank-mounted units) 2.9 Reference Designation Function SV Safety valve To protect the air outlet system if the outlet pressure exceeds the opening pressure of the valve. Air dryer Air Dryer Wet compressed air (B) enters the dryer. The air then flows through 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.
Instruction book 3 Controller 3.1 Controller Control panel Introduction In general, the controller has the following functions: • • • • Controlling the compressor; Protecting the compressor; Monitoring service intervals; Automatic restart after voltage failure (made inactive); Automatic control of the compressor For 2.2 - 4 kW (3 - 5.5 HP) units, the controller automatically switches the units on/off to maintain pressure in the desired range. For 5.5 - 7.5 kW (7.
Instruction book The shutdown temperature warning is a programmable warning that advises the operator that the shutdown temperature is nearly reached. If the measured temperature exceeds the programmed shutdown warning temperature, this will be indicated on the controller display before the shutdown temperature is reached. Shutdown If the compressor element outlet temperature exceeds the programmed shutdown level or the overload relay of the main motor trips, the compressor will be stopped.
Instruction book 3.2 Control panel Reference Designation Function 1 Display Shows icons and operating conditions. 2 LED, Voltage on Indicates that the voltage is switched on. 3 Start/stop button Keep pressed for 3 seconds to start compressor. Press to stop compressor if running. Use this button to go to previous screen or to end the current action. 4 Scroll button Use these buttons to scroll through the menu. 5 LED, Warning Is lit if a warning condition exists.
Instruction book 3.3 Icons used on the display Function Icon Description Stopped/Running When the compressor is stopped, the icon stands still. When the compressor is running, the icon is rotating. Compressor status Motor stopped Running unloaded Running unloaded (blinking for manual stop) Only for 5.5 - 7.5 kW (7.5 - 10 HP) units.
Instruction book Function Units Icon Description Pressure unit (Mega Pascal) Pressure unit (pounds per square inch) Pressure unit (bar) Temperature unit (degree Centigrade) Temperature unit (degree Fahrenheit) Motor A time/delay parameter is displayed. NOTE: • x1000: ON if the displayed value is in thousands of • hrs: ON if the displayed value is in hours • s: ON if the displayed value is in seconds Element outlet temperature 3.
Instruction book Main screen with pressure (stopped compressor) From the Main screen it is possible with up and down buttons (4-8) to change the view from pressure to temperature of the element outlet. Main screen with temperature (stopped compressor) 3.5 Main function To switch on the compressor, press the start/stop button (3) for 3 seconds. The compressor starts and the status is shown: Screen with running compressor To stop the compressor, push the start/stop button (3).
Instruction book Screen with unloading compressor After the unload time has elapsed (only for 5.5 - 7.5 kW units), the compressor is stopped, and the controller goes back to the main screen: Main screen with pressure (stopped compressor) To enter the main menu (starting from the Main screen), press the enter button (7) for 3 seconds. The main menu is shown: First screen of main menu It is possible to scroll in the menu with the up or down buttons (4-8). To select one item push the enter button (7).
Instruction book Emergency stop When the emergency push button is restored, reset the alarm by pressing the enter button (7) for 5 seconds. The following screen will appear: Alarm reset 3.6 Shutdown warning Description A shutdown warning will appear in the event of: • A too high temperature at the outlet of the compressor element.
Instruction book It remains possible to check the actual status of other parameters by pressing the enter button (7) for 3 seconds. Press button (3) to stop the compressor and wait until the compressor has stopped. The warning message will disappear as soon as the warning condition disappears. 3.7 Shutdown Description The compressor will stop: • In case the temperature at the outlet of the compressor element exceeds the shutdown level, detected by the temperature sensor or by the temperature switch.
Instruction book Main screen with shutdown indication, element outlet temperature • The related pictograph will appear flashing. • Scroll Up or Down buttons (4-8) until the current element outlet temperature appears. Shutdown screen, element outlet temperature The screen shows that the temperature at the outlet of the compressor element is 117 ˚C. • When the shutdown condition has been solved, press the Enter button (7) for 5 seconds.
Instruction book Example of error sensor Motor overload In the event of motor overload: • The compressor will stop. • Alarm LED (5) will flash. • The following screen will appear: Main screen with shutdown indication, motor overload • Contact your supplier for fault troubleshooting • When the shutdown condition has been solved, press the enter button (7) for 5 seconds. • When appears on the display, the compressor can be restarted. 3.
Instruction book Blinking screen • • • • • Press Enter button (7) to enter the main menu. Select and press Enter button (7) to enter the data menu. Scroll (buttons 4-8) until and the service symbol is shown. Press enter button (7). The actual reading of the service timer is shown in . Example of running hours screen The example screen shows that the service timer is at 2002 hours. Stop the compressor, switch off the voltage and carry out the required service actions.
Instruction book 3.9 Scrolling through all screens Control panel General overview of the menu structure From the Main screen press the enter button (7) for 3 seconds to enter the Menu. You will find the following items: dAtA Data counters parameters. ProG Submenu of Regulation pressure, Timer, Display setting and Control setting. tESt Display test. InFo Information of firmware release.
Instruction book Overview of the screens Menu item Submenu (Data) (Programming) Digital input screen Designation Running hours. Motor starts. Module hours. Loading hours. Load solenoid valve. Only for 5.5 - 7.5 kW (7.5 - 10 HP) units. Service timer. Calling up or modifying pressure band selection. Calling up or modifying lower pressure setting. Calling up or modifying upper pressure setting.
Instruction book • • • • Press Enter button (7) for 3 seconds to enter the Main menu. Select and press Enter button (7) to enter the Data menu. Scroll Up or Down buttons (4-8) until and the motor stopped symbol is shown. Press Enter button (7): the running hours are shown. The screen shows the unit used and the value <11.25>: the running hours of the compressor are 11250 hours. 3.
Instruction book In the example shown, the screen shows the unit used and the value <5000>: the controller module has been in service during 5000 hours. 3.13 Calling up loading hours Starting from the Main screen: • • • • Press Enter button (7) for 3 seconds to enter the Main menu. Select and press Enter button (7) to enter the Data menu. Scroll Up or Down buttons (4-8) until and the running loaded symbol is shown. Press Enter button (7): the loading time is shown.
Instruction book This screen shows the number of loading actions (x1 or - if lights up - x1000). In the above example, the number of unload to load actions is 10100. 3.15 Calling up/resetting the service timer Starting from the Main screen: • • • • Press Enter button (7) for 3 seconds to enter the Main menu. Select and press Enter button (7) to enter the Data menu. Scroll Up or Down buttons (4-8) until and is shown. Press Enter button (7): the service timer is shown.
Instruction book • Scroll Up or Down buttons (4-8) until is shown and then press Enter button (7). • Pressure band 1 () is shown. Scroll Up or Down buttons (4–8) to pressure band 2 (). • Press Enter button (7) on the desired pressure band. 3.17 Calling up/modifying pressure band settings Starting from the Main screen: • • • • Press Enter button (7) for 3 seconds to enter the Main menu. Select and press Enter button (7) to enter the Programming menu.
Instruction book Starting from the Main screen: • • • • • • • Press Enter button (7) for 3 seconds to enter the Main menu. Select and press Enter button (7) to enter the Programming menu. Scroll Up or Down buttons (4-8) to for display settings. Press Enter button (7) to enter the submenu. Scroll Up or Down buttons (4-8) to and press Enter button (7). The actually used unit is shown. Possible settings are , and .
Instruction book 3.22 Keyboard lock Keep both Up and Down buttons pressed for more than 3 seconds to lock or unlock the keyboard. • The display will show the label blinking for 3 seconds if the keyboard has been locked. • The display will show the label blinking for 3 seconds if the keyboard has been unlocked. Example Lock/unlock screen.
Instruction book 4 Installation 4.1 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.
Instruction book Installation proposal Installation proposal, floor-mounted Ref. Description 6 Outlet valve Installation proposal, tank-mounted 48 Ref.
Instruction book Ref. Description 3 Front panel, compressor 4 Dryer (1) Minimum 1.5 m (59 in) (2) Space for maintenance, minimum 1.5 m (59 in) (3) Single-phase dryer supply (4) Three-phase screw compressor supply (5) The power cable should be protected so that it complies with local regulations 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).
Instruction book 4.
Instruction book General instructions Step Action 1 Install an isolating (disconnector) switch near the compressor. 2 Check the fuses and the setting of overload relay. See Settings for overload relay and fuses. 3 If fitted, check transformers for correct connection. 4 See Electric cable size for selection of power supply line cable. Connect the power supply cables to terminals L1, L2 and L3 (terminal block 1X0) and the neutral conductor (if applicable) to terminal (N).
Instruction book Fuses F1: The fuses are supplied with the compressor. Motor terminal bridge configuration: Factory standard connection is 230 V and can be changed to 208 V or 460 V. Terminal bridges (1) can be removed using a pair of pliers. Voltage stickers: Locate the yellow voltage labels provided with the compressor. Replace the existing label with the appropriate voltage label (208 V, 230 V or 460 V).
Instruction book 4.4 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.
Instruction book 54 Ref.
Instruction book 5 Operating instructions 5.1 Initial start-up Safety The operator must apply all relevant Safety precautions.
Instruction book Automatic condensate drain 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.
Instruction book Oil level sight-glass Step Action If more than 3 months have passed between assembly and installation, make sure to lubricate the compressor before starting up: • Remove the front panel. • Unscrew the fixing bolts on 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.
Instruction book Start-up Start-up sheet Label on the top 58 2920 7199 10
Instruction book 5.2 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. Press the start button for at least 3 seconds and stop it immediately by using the emergency button. Check the rotation direction of the motor.
Instruction book 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 balancing the internal pressure of the dryer.
Instruction book Control panel Step Action 1 Before starting, check the oil level in accordance with step 5 of this table. 2 Switch on the voltage. 3 Open air outlet valve (2). 4 Push the start button (6). The motor starts running after 25 seconds. On compressors with a star-delta starter, the drive motor switches over from star to delta 10 seconds after starting. The maximum number of motor starts must be limited to 20 per hour.
Instruction book 5.
Instruction book Dryer on/off switch Control panel Step Action 1 On Full-Feature units: move switch (3) of the dryer to position 0. Push the start/stop button (6) on the controller. The compressor will unload. When the unload time has elapsed, the compressor is stopped and the controller goes back to the main screen. To stop the compressor immediately in the event of an emergency, press button (S3). See section Control panel. After remedying the fault, unlock the button by pulling it out.
Instruction book 5.
Instruction book Dryer manual drain This procedure should be carried out at the end of the compressor’s service life. Step Action 1 On Full-Feature units: move switch (3) of the dryer to position 0. Stop the compressor and close the air outlet valve (2). 2 Switch off the voltage and disconnect the compressor from the mains. 3 Depressurize the compressor by opening plug (3) one turn. Push condensate manual drain (Dm) for a few seconds to release any condensate from the dryer.
Instruction book 6 Maintenance 6.1 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. • Depressurize the compressor. For detailed instructions, see the next sections. The operator must apply all relevant Safety precautions. Warranty-Product Liability Use only authorized parts.
Instruction book Period (1) Running hours (1) Action “ 4000 (3) If Roto-Inject Fluid Ndurance is used, change the oil. “ 4000 (2) Replace the air filter. “ 4000 (2) Replace the oil separator. “ 4000 Check and, if needed, replace the belts. “ -- Have the safety valve tested. “ “ Have the operation of sensors, electrical interlockings and components checked. “ “ Have the temperature shut-down switch tested. “ -- Inspect the air receiver.
Instruction book 6.3 Oil specifications Avoid mixing lubricants of different brands or types as they may not be compatible and the oil mix may have inferior properties. A label, indicating the type of oil filled ex factory, is stuck on the air receiver/oil tank. It is strongly advised to use the recommended lubricants. See section Preventive maintenance schedule for recommended oil change intervals. For part numbers, consult the Spare Parts List.
Instruction book Roto Synthetic Fluid ULTRA is a synthetic oil based 4000 hours lubricant, specially developed for use in single stage oil-injected screw compressors running in demanding conditions. Roto Synthetic Fluid ULTRA can be used for compressors operating at ambient temperatures between 0 °C (32 °F) and 45 °C (113 °F). For more extreme conditions or when longer oil life is required, it is recommended to use Roto Synthetic Fluid XTEND DUTY.
Instruction book Procedure Location of oil filter and separator Drain valve of air receiver 70 Step Action 1 Run the compressor until warm. Stop the compressor, close the air outlet valve and switch off the voltage. (See section Stopping) 2 Remove the front and top panels. 3 Depressurize the compressor by unscrewing filler plug (8) one turn to permit any pressure in the system to escape. Remove the plug after the system is depressurized.
Instruction book 6.5 Step Action 12 Stop the compressor and wait a few minutes to allow the oil to settle and the foam disappears. 13 If the oil level is too low, depressurize the system by unscrewing filler plug (8) one turn to permit any pressure in the system to escape. Depressurize the air receiver by opening drain valve (4). 14 Add oil as necessary. The sight-glass should be 3/4 full. Retighten plug (8) and close drain valve (4) of the air receiver.
Instruction book 7 Adjustments and servicing procedures 7.1 Air filter Changing the air filter Air filter Procedure: 72 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 (AF) 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.
Instruction book 7.2 Coolers Oil cooler 7.3 Step Action 1 Keep the 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. Then clean using an air jet. Never use a wire brush or metal objects.
Instruction book 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.
Instruction book 7.4 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. (See section Stopping) 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.
Instruction book Step Action 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. Tensioning of the belts must be performed with specific dedicated tooling.
Instruction book 8 Problem solving Air outlet valve Condensate drain valve on air receiver Dryer on/off switch 2920 7199 10 77
Instruction book Attention Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. Apply all relevant Safety precautions during maintenance or repair. Before carrying out any maintenance or repair work on the compressor: push the stop button (6). Wait until the compressor has stopped and switch off the voltage. See the Stopping section. Open the isolating switch to prevent an accidental start.
Instruction book 3 Condition Fault Remedy 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.
Instruction book 9 Technical data 9.1 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. Recommended cable size Cable size, IEC Voltage (V) Frequency (Hz) IEC Cable size G2 G3 G4 G5 G7 - - - - 230/1 50 4 230/3 50 1.5 mm2 2.
Instruction book 9.
Instruction book 9.3 Reference conditions and limitations Reference conditions Air inlet pressure (absolute) bar 1 Air inlet pressure (absolute) psi 14.
Instruction book Compressor type G2 G3 G4 G5 G7 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 dew-point, Full-Feature ˚C 3 3 3 3 3 Pressure dew-point, Full-Feature ˚F 37 37 37 37 37 Power input, Pack at maximum working pressure kW 3.9 4.4 5.5 7.6 9.
Instruction book Compressor type G2 G3 G4 G5 G7 Power input, Pack at maximum working pressure kW 3.9 4.4 5.5 7.6 9.5 Power input, Pack at maximum working pressure hp 5.2 5.9 7.4 10.2 12.7 Power consumption, dryer at full load kW 0.24 0.24 0.24 0.26 0.47 Power consumption, dryer at full load hp 0.32 0.32 0.32 0.35 0.63 Power consumption, dryer at no load kW 0.16 0.16 0.16 0.19 0.29 Power consumption, dryer at no load hp 0.22 0.22 0.22 0.26 0.
Instruction book Compressor type G2 G4 G5 G7 Oil capacity l 2.5 2.5 3.15 3.15 Oil capacity US gal 0.66 0.66 0.83 0.83 61 62 65 67 G2 G4 G5 G7 Sound pressure level floor-mounted units (according to ISO dB(A) 2151 (2004)) 60 Hz 8 bar (116 psi) Compressor type Frequency Hz 60 60 60 60 Maximum (unloading) pressure, Pack bar(e) 8 8 8 8 Maximum (unloading) pressure, Pack psig 116 116 116 116 Maximum (unloading) pressure, Full-Feature bar(e) 7.75 7.75 7.75 7.
Instruction book 10 Instructions for use Oil separator vessel 1 The vessel can contain pressurized 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.
Instruction book 11 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.
Instruction book 12 Pressure equipment directives Components subject to 2014/68/EU Pressure Equipment Directive (PED) Components subject to 2014/68/EU PED 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.
Instruction book 13 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 (2): Applicable directives (3): Standards used On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other standards that have been used for the design are shown and/or referred to.
We stand by our responsibilities towards our customers, towards the environment and the people around us. We make performance stand the test of time. This is what we call — Sustainable Productivity. www.atlascopco.com No. 2920 7199 10 / 2021 - 01 - Printed in Belgium Atlas Copco Airpower NV. All rights reserved. Designs and specifications are subject to change without notice or obligation.
