Atlas Copco G 2 Instruction Book Download Page 52

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Dimension drawing

Model

9828 0842 33

G 2, G 3, G 4, G 5, G 7 Pack, floor-mounted

9828 0842 34

G 2, G 3, G 4, G 5, G 7 Full-Feature, floor-mounted

9828 0842 35

G 2, G 3, G 4, G 5, G 7 Pack, tank-mounted

9828 0842 36

G 2, G 3, G 4, G 5, G 7 Full-Feature, tank-mounted

Text on drawings

Translation or explanation

Emergency stop switch

Emergency stop switch button (only compressor)

Main power supply

Compressor power supply (supply cable)

Cooling air and compressor inlet

Cooling air outlet of compressor and motor

Air inlet filter

Air inlet filter (only floor-mounted)

Service panel

Compressor service panel

External box

External box on back panel (depends on model)

Extra venting

Extra openings for venting on back panel (depends
on model)

Compressor controller

Compressor controller (Base controller)

Oil level indicator

Compressed air outlet

Air delivery

Compressed air outlet delivery line

Forklift openings

Forklift openings (only floor-mounted, Full-Feature)

Valve (supplied loose)

Valve air outlet (only air receiver)

Center of gravity

Cubicle door fully open

Air receiver manual drain

Condensate drain dryer

Condensate drain from integrated dryer

Dryer inlet cooling air

Dryer outlet cooling air

Dryer switch

Dryer switch ON/OFF

Dryer service panel

Dryer service panel for maintenance

Dryer power supply

Dryer power supply (supply cable)

4.3

Electrical connections

Always disconnect the power supply before working on the electrical circuit!

Instruction book

2920 7199 10

Summary of Contents for G 2

Page 1: ...INSTRUCTION BOOK OIL INJECTED ROTARY SCREW COMPRESSORS G 2 G 3 G 4 G 5 G 7 ...

Page 2: ......

Page 3: ...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 2021 01 No 2920 7199 10 www atlascopco com ...

Page 4: ...SPOSAL 10 2 General description 11 2 1 INTRODUCTION 11 2 2 AIR FLOW 13 2 3 OIL SYSTEM 16 2 4 COOLING SYSTEM 18 2 5 REGULATING SYSTEM 20 2 6 CONTROL PANEL 22 2 7 ELECTRICAL SYSTEM 23 2 8 PROTECTION OF THE COMPRESSOR 25 2 9 AIR DRYER 26 3 Controller 27 3 1 CONTROLLER 27 3 2 CONTROL PANEL 29 3 3 ICONS USED ON THE DISPLAY 30 3 4 MAIN SCREEN 31 3 5 MAIN FUNCTION 32 3 6 SHUTDOWN WARNING 34 3 7 SHUTDOWN ...

Page 5: ...ALLING UP MODIFYING THE UNIT OF TEMPERATURE 44 3 19 CALLING UP MODIFYING THE UNIT OF PRESSURE 44 3 20 CALLING UP MODIFYING BACKLIGHT TIME 45 3 21 ACTIVATING AUTOMATIC RESTART AFTER VOLTAGE FAILURE 45 3 22 KEYBOARD LOCK 46 4 Installation 47 4 1 INSTALLATION PROPOSAL 47 4 2 DIMENSION DRAWINGS 49 4 3 ELECTRICAL CONNECTIONS 50 4 4 PICTOGRAPHS 53 5 Operating instructions 55 5 1 INITIAL START UP 55 5 2 ...

Page 6: ... 3 SAFETY VALVE 73 7 4 BELT SET EXCHANGE AND TENSIONING 75 8 Problem solving 77 9 Technical data 80 9 1 ELECTRIC CABLE SIZE 80 9 2 SETTINGS FOR OVERLOAD RELAY AND FUSES 81 9 3 REFERENCE CONDITIONS AND LIMITATIONS 82 9 4 COMPRESSOR DATA 82 10 Instructions for use 86 11 Guidelines for inspection 87 12 Pressure equipment directives 88 13 Declaration of conformity 89 Instruction book 4 2920 7199 10 ...

Page 7: ... the voltage Depressurize the machine 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 w...

Page 8: ...ccant 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...

Page 9: ...tem 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...

Page 10: ...amper 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 instructio...

Page 11: ...th 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 tempe...

Page 12: ...nts e g drain oil from oil containing parts 4 Refer to the disposal topic mentioned below Disposal of electrical and electronic appliances WEEE This equipment falls under the provisions of the European Directive 2012 19 EU on waste electrical and electronic appliances WEEE and may not be disposed as unsorted waste The equipment is labelled in accordance with the European Directive 2012 19 EU with ...

Page 13: ...controller and the emergency stop button A cabinet housing the controller pressure sensor 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 c...

Page 14: ...Imp gal 17 50 cu ft and are available in Pack and Full Feature version G 5 Full Feature tank mounted Ref Description 1 Electric cabinet ER Elektronikon Base controller S3 Emergency stop button AO Air outlet AR Air receiver Dm2 Manual condensate drain valve air receiver SV Safety valve DR Integrated dryer Instruction book 12 2920 7199 10 ...

Page 15: ...2 2 Air flow Pack Air flow floor mounted Pack units Instruction book 2920 7199 10 13 ...

Page 16: ...V 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 14 2920 7199 10 ...

Page 17: ...ed 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 2920 7199 10 15 ...

Page 18: ...2 3 Oil system Oil system Pack Instruction book 16 2920 7199 10 ...

Page 19: ...bypass valve BV When the oil temperature is below the set point of the valve the by pass valve shuts off the oil supply from oil cooler The by pass valve starts opening the supply from cooler Co when the oil temperature exceeds the setting of the valve The setting of the by pass valve depends on the model See section Compressor data In the oil separator vessel there might be formation of condensat...

Page 20: ...2 4 Cooling system Pack units Instruction book 18 2920 7199 10 ...

Page 21: ...ol 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 The dryer DR of Full Feature versions has a separate cooling fan and an automatic condensate drain see also section Air dryer Instruction book 2920 7199 10 19 ...

Page 22: ...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 When the working pressure reaches the maximum limit the Base controller stops the main motor and opens the blow off valve The Instruction book 20 2920 7199 10 ...

Page 23: ... reached the machine will run unloaded Unloading When the working pressure reaches the unload pressure solenoid valve Y1 is de energized and therefore open The signal air flow goes directly through the non return valve NRV into the unloader UA keeping the inlet valve closed The compressor will run unloaded 0 output and the pressure is discharged into the air filter AF The compressors are equipped ...

Page 24: ...nd the pressure is below 2 3 of the pressure band the compressor goes into loading mode If the unit is restarting frequently or is manually restarted by the operator the controller will extend the unload period in order to ensure proper motor cooling This overrules the standard unload period The compressor will automatically restart when the net pressure drops to the minimum limit In order to avoi...

Page 25: ...nation 1 Electric cabinet ER Elektronikon Base controller S3 Emergency stop button 3 Dryer switch Full Feature 2 7 Electrical system Electrical components The electrical system comprises the following components Instruction book 2920 7199 10 23 ...

Page 26: ...rence 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 Instruction book 24 2920 7199 10 ...

Page 27: ...ice 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 The complete electrical diagram can be found on the USB supplied with the machine 2 8 Protection of the compressor Safety valve on the compressor Instruction book 2920 7199 10 25 ...

Page 28: ...ir 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 The condensate is automatically drained The cold dried air then flows through the heat exchanger 3 where it is warmed up by the incoming air then finally discharged from the dryer out...

Page 29: ...units the controller maintains the net pressure between programmable limits by automatically loading and unloading the compressor A number of programmable settings are taken into account e g the unloading and loading pressures the minimum stop time and the maximum number of motor starts The controller stops the compressor whenever possible to reduce power consumption and restarts it automatically ...

Page 30: ...opped This will be indicated on the display of the controller Service warning If the service timer exceeds the preset value the controller advises the operator via the display to carry out the service maintenance Automatic restart after voltage failure The controller has a built in function to automatically restart the compressor when the voltage is restored after voltage failure This function is ...

Page 31: ... 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 6 LED Service Is lit when service is needed 7 Enter button Press 3 seconds to enter in menu Use this button to confirm the last action Press 5 seconds to reset alarm 8 Scroll button Use these buttons to scroll...

Page 32: ...Compressor status Motor stopped Running unloaded Running unloaded blinking for manual stop Only for 5 5 7 5 kW 7 5 10 HP units Running loaded Machine control mode Remote start stop active Automatic restart after voltage failure Automatic restart after voltage failure is active Active protection functions Emergency stop Service Service required Instruction book 30 2920 7199 10 ...

Page 33: ... 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 4 Main screen At power on the first screen is a test screen Icon digit and led are on The next screen is the Main screen shown automatically The Main screen shows The compressor status by means of pictographs The air outlet pressure In...

Page 34: ...ain 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 The compressor immediately unloads only for 5 5 7 5 kW units or stops 2 2 4 kW units Instruction book 32 2920 7199 10 ...

Page 35: ...n 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 To end the current action push start stop 3 button If the emergency stop button is pushed the compressor stops immediately and the following screen will appear Ins...

Page 36: ...n warning will appear in the event of A too high temperature at the outlet of the compressor element Compressor element outlet temperature If the outlet temperature of the compressor element exceeds the shutdown warning level factory set at 110 C 230 F warning LED 5 is on Press Scroll up or down buttons 4 8 The screen shows the temperature at the compressor element outlet Instruction book 34 2920 ...

Page 37: ... case the temperature at the outlet of the compressor element exceeds the shutdown level detected by the temperature sensor or by the temperature switch In case of error of the outlet pressure sensor or temperature sensor In case of overload of the compressor motor Compressor element outlet temperature If the outlet temperature of the compressor element exceeds the shutdown level factory setting 1...

Page 38: ...creen 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 When rSt appears on the display the compressor can be restarted Error pressure temperature sensor In the event of an error of the outlet pressure sensor PT20 or temperature sensor TT11 The compressor will stop The following screen will...

Page 39: ... fault troubleshooting When the shutdown condition has been solved press the enter button 7 for 5 seconds When rSt appears on the display the compressor can be restarted 3 8 Service warning Description A service warning will appear when the service timer has reached the preset time interval If the service timer exceeds the programmed time interval alarm LED 6 is blinking with a following screen In...

Page 40: ...Press enter button 7 The actual reading of the service timer is shown in hrs 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 After servicing reset the service timer See section Calling up resetting the service timer Instruction book 38 2920 7199 10 ...

Page 41: ...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 2920 7199 10 39 ...

Page 42: ...r Timer SrV d Maintenance warning diSP Display tEMP Calling up or modifying unit of temperature PrES Calling up or modifying unit of pressure bC LG Calling up or modifying time of backlight Ctrl Control Lo rE Local remote start stop Ar Af Automatic restart after voltage failure Ar d Delay time of automatic restart after voltage failure nHCA Maximum number of compressor starts per hour Only for 5 5...

Page 43: ...to enter the Main menu Select dAtA and press Enter button 7 to enter the Data menu Scroll Up or Down buttons 4 8 until d 2 and the motor symbol is shown Press Enter button 7 the number of motor starts is shown This screen shows the number of motor starts x1 or if x1000 lights up x1000 In the above example the number of motor starts is 10100 3 12 Calling up module hours Starting from the Main scree...

Page 44: ...ed symbol is shown Press Enter button 7 the loading time is shown The screen shows the unit used hrs or x1000 hrs and the value 1755 the compressor has been running loaded during 1755 hours 3 14 Calling up load solenoid valve Only for 5 5 7 5 kW 7 5 10 HP units Starting from the Main screen Press Enter button 7 for 3 seconds to enter the Main menu Select dAtA and press Enter button 7 to enter the ...

Page 45: ...4 8 until d 6 and hrs is shown Press Enter button 7 the service timer is shown This screen shows the unit used hrs or x1000 hrs and the value In the example shown the compressor has run 1191 hours since the previous service 3 16 Calling up modifying pressure band selection Starting from the Main screen Press Enter button 7 for 3 seconds to enter the Main menu Select ProG and press Enter button 7 t...

Page 46: ... parameter The actual pressure used is shown Scroll Up or Down buttons 4 8 to set pressure value and press Enter button 7 to confirm The unit blinks and the new setting is saved 3 18 Calling up modifying the unit of temperature The unit of temperature measurement can only be changed when the compressor is stopped Starting from the Main screen Press Enter button 7 for 3 seconds to enter the Main me...

Page 47: ...lect ProG and press Enter button 7 to enter the Programming menu Scroll Up or Down buttons 4 8 to diSp for display settings Press Enter button 7 to enter the submenu Scroll Up or Down buttons 4 8 to bC LG and press Enter button 7 The current backlight setting is shown It is possible to set a value between 0s and 120s Scroll Up or Down buttons 4 8 to set the time of backlight and press Enter button...

Page 48: ...nds to lock or unlock the keyboard The display will show the label Loc blinking for 3 seconds if the keyboard has been locked The display will show the label UnLo blinking for 3 seconds if the keyboard has been unlocked Example Lock unlock screen Instruction book 46 2920 7199 10 ...

Page 49: ...opco 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 Move ...

Page 50: ...proposal Installation proposal floor mounted Ref Description 6 Outlet valve Installation proposal tank mounted Ref Description 1 Isolating switch compressor 2 Isolating switch dryer Instruction book 48 2920 7199 10 ...

Page 51: ...Qc 1 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 T...

Page 52: ...nings for venting on back panel depends on model Compressor controller Compressor controller Base controller Oil level indicator Oil level indicator Compressed air outlet Compressed air outlet Air delivery Compressed air outlet delivery line Forklift openings Forklift openings only floor mounted Full Feature Valve supplied loose Valve air outlet only air receiver Center of gravity Center of gravit...

Page 53: ...leave the factory the units are connected for 230 V 3 phase To modify the wiring for an operating voltage of 208 V or 460 V the main cubicle should be rewired as described below Modifications to the compressor cubicle Step Action 1 Adjust the motor overload F21 setting 2 Control transformer T1 Move the primary connection from 230V to the desired voltage 3 Replace the control fuses F1 10 3 x 38mm w...

Page 54: ...onnection 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 52 2920 7199 10 ...

Page 55: ...nhaled 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 Instruction book 2920 7199 10 53 ...

Page 56: ...Ref Description 12 Read the instruction manual before carrying out any maintenance or repair work 13 Lightly oil gasket of oil filter screw filter on and tighten by hand Instruction book 54 2920 7199 10 ...

Page 57: ...ructions 5 1 Initial start up Safety The operator must apply all relevant Safety precautions General preparation Air outlet valve on air receiver Condensate drain valve on air receiver Instruction book 2920 7199 10 55 ...

Page 58: ...arthed 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 and if Full Feature version the automatic drain outlet Da to a drain collector Close the valve Oil system Air filter Instruction book 56 2920 7199 10 ...

Page 59: ...ately 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 Stop the unit and wait for the foam to disappear normally about 3 minutes The oil level should be visible on the sight glass SG Never measure the oil lev...

Page 60: ...Start up Start up sheet Label on the top Instruction book 58 2920 7199 10 ...

Page 61: ...otation direction is correct the sheet 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 disconnector switch IG and reverse two phases of the supply cable Switch on the voltage and restart the compressor All electrical work should be carried out by professionall...

Page 62: ...pressor 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 Starting the compressor Position of oil sight glass and filler plug Instruction book 60 2920 7199 10 ...

Page 63: ...ndensate in the oil 5 Regularly check the oil level 10 to 15 minutes after stopping the sight glass SG should be between 1 4 and 3 4 full If the oil level is too low stop the compressor depressurise the oil system by unscrewing oil filler plug FC one turn and wait a few minutes Remove the plug and top up the oil until the sight glass is 3 4 full Do not overfill Fit and tighten plug FC 6 In automat...

Page 64: ...5 3 Stopping Air outlet valve Condensate drain valve on air receiver Dryer manual drain Instruction book 62 2920 7199 10 ...

Page 65: ...Only use emergency stop button in the event of an emergency Avoid using the button for normal stopping of the compressor 2 Close air outlet valve 2 and switch off the voltage to the compressor 3 Push condensate manual drain Dm for a few seconds to release any condensate from the dryer Open condensate drain valve 4 of the air receiver for a few seconds to drain any condensate and then close the val...

Page 66: ...5 4 Taking out of operation Air outlet valve Condensate drain valve on air receiver Oil filler plug Instruction book 64 2920 7199 10 ...

Page 67: ...he 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 Open condensate drain valve 4 of the air receiver 4 Shut off and depressurize 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 co...

Page 68: ...er 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 for G 2 G 7 Period 1 Running hours 1 Action Daily Check the oil level After stopping drain the condensate from the air receiver by means of the manua...

Page 69: ... 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 ...

Page 70: ... shorter exchange interval Consult Atlas Copco Atlas Copco s Roto Inject Fluid Ndurance is a premium mineral oil based 4000 hours lubricant specially developed for use in single stage oil injected screw compressors running in mild conditions Its specific formulation keeps the compressor in excellent condition Roto Inject Fluid Ndurance can be used for compressors operating at ambient temperatures ...

Page 71: ...sult Atlas Copco Atlas Copco s Roto Synthetic Fluid XTEND DUTY is a high quality synthetic 8000 hours lubricant for oil injected screw compressors which keeps the compressor in excellent condition Because of its excellent oxidation stability Roto Synthetic Fluid XTEND DUTY can be used for compressors operating at ambient temperatures between 0 C 32 F and 46 C 115 F Roto Synthetic Fluid XTEND DUTY ...

Page 72: ...iver by opening drain valve 4 5 Drain the oil by opening drain valve 5 Close the valve after draining Deliver the drained 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 r...

Page 73: ...er installation If the compressor is stored without running from time to time consult Atlas Copco as protective measures may be necessary 6 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 main...

Page 74: ...r 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 72 2920 7199 10 ...

Page 75: ...fficiency 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 7 3 Safety valve Condensate drain valve on air receiver Instruction book 2920 7199 10 73 ...

Page 76: ...o 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 Instruction book 74 2920 7199 10 ...

Page 77: ...sen the 4 bolts 2 by one turn 5 Adjust the belt tension by turning tensioning nut 1 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...

Page 78: ...a 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 76 2920 7199 10 ...

Page 79: ...8 Problem solving Air outlet valve Condensate drain valve on air receiver Dryer on off switch Instruction book 2920 7199 10 77 ...

Page 80: ...emedy 1 The machine does not start No power Check power supply Fuse F1 blown Replace fuse The main motor thermal protection has tripped Check and let motor cool down to reset restart move compressor start stop switch to 0 then to I 2 The machine does not start high oil temperature lamp is on temperature switch tripped Oil cooler is dirty Clean cooler Ambient temperature too high Improve ventilatio...

Page 81: ...an the condenser and check operation of fan Insufficient refrigerant in dryer Have system checked for leaks or refilled 4 The motor hums and does not start Line voltage too low Check power supply The machine was switched off and on again too rapidly not enough time for the pressure equalization Wait a few minutes before starting the machine again Instruction book 2920 7199 10 79 ...

Page 82: ...ecommended cable size Cable size IEC Voltage V Frequency Hz Cable size IEC G 2 G 3 G 4 G 5 G 7 230 1 50 4 mm2 230 3 50 1 5 mm2 2 5 mm2 4 mm2 4 mm2 6 mm2 380 3 60 0 75 mm2 1 5 mm2 2 5 mm2 4 mm2 400 3 50 0 75 mm2 1 mm2 1 5 mm2 2 5 mm2 4 mm2 Cable size UL CSA Voltage V Frequency Hz Cable size UL CSA G 2 G 4 G 5 G 7 230 1 60 AWG10 AWG8 AWG8 208 3 60 AWG12 AWG10 AWG8 AWG8 230 3 60 AWG14 AWG10 AWG10 AWG...

Page 83: ...3 60 12A 25A 30A 45A 460 3 60 7A 12A 15A 25A 575 3 60 6A 10A 12A 15A F21 setting IEC Voltage V Frequency Hz F21 setting IEC G 2 G 3 G 4 DOL G 4 YD G 5 G 7 230 1 50 20 0A 230 3 50 12 5A 15 5A 19 0A 11 0A 15 0A 23 3A 380 3 60 7 5A 12 5A 7 5A 9 0A 10 5A 400 3 50 7 0A 9 0A 11 0A 6 5A 8 5A 13 5A F21 setting UL CSA Voltage V Frequency Hz F21 setting UL CSA G 2 G 4 G 5 G 7 230 1 60 20 0A 33 0A 38 0A 208 ...

Page 84: ...Minimum ambient temperature F 32 9 4 Compressor data All data specified below apply under reference conditions see section Reference conditions and limitations 50 Hz 10 bar Compressor type G 2 G 3 G 4 G 5 G 7 Frequency Hz 50 50 50 50 50 Maximum unloading pressure Pack bar e 10 10 10 10 10 Maximum unloading pressure Pack psig 145 145 145 145 145 Maximum unloading pressure Full Feature bar e 9 75 9 ...

Page 85: ...77 Oil capacity l 2 5 2 5 2 5 3 15 3 15 Oil capacity US gal 0 66 0 66 0 66 0 83 0 83 Sound pressure level floor mounted units according to ISO 2151 2004 dB A 61 61 62 65 67 50 Hz 8 bar Compressor type G 2 G 3 G 4 G 5 G 7 Frequency Hz 50 50 50 50 50 Maximum unloading pressure Pack bar e 8 8 8 8 8 Maximum unloading pressure Pack psig 116 116 116 116 116 Maximum unloading pressure Full Feature bar e ...

Page 86: ... Full Feature bar e 9 75 9 75 9 75 9 75 Maximum unloading pressure Full Feature psig 141 141 141 141 Nominal working pressure bar e 9 5 9 5 9 5 9 5 Nominal working pressure psig 138 138 138 138 Pressure drop over dryer bar e 0 15 0 15 0 25 0 25 Pressure drop over dryer psig 2 18 2 18 3 62 3 62 Motor shaft speed rpm 3550 3480 3520 3540 Set point thermostatic valve C 71 71 71 71 Set point thermostat...

Page 87: ...ve C 71 71 71 71 Set point thermostatic valve F 160 160 160 160 Temperature of air leaving receiver approx Pack C 33 33 33 33 Temperature of air leaving receiver approx Pack F 91 91 91 91 Pressure dew point Full Feature C 3 3 3 3 Pressure dew point Full Feature F 37 37 37 37 Power input Pack at maximum working pressure kW 3 6 5 5 7 6 9 4 Power input Pack at maximum working pressure hp 4 8 7 4 10 2...

Page 88: ...c 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 b...

Page 89: ...or 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 Instruction book 2920 7199 10 87 ...

Page 90: ... 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 88 2920 7199 10 ...

Page 91: ...ium 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 The Declaration of Conformity Declaration by the Manufacturer is part of the documentation that is supplied with this device Instruction book 2920 7199 10 89 ...

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Page 94: ...nvironment 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 ...

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