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Atlas Copco GX 11, Instruction Book, Page: 15 / 76

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Atlas Copco GX 11 Instruction Book Download Page 15

Air flow, GX 7 and GX 11 Full-Feature (tank-mounted)

Air drawn through filter (AF) and open inlet valve (IV) into compressor element (E) is compressed.
Compressed air and oil flow into oil separator/tank (OT). The air is discharged via minimum pressure valve
(Vp), air cooler (Ca) and air dryer (DR) towards the air outlet (AO).

Instruction book

2920 7054 00

13

Summary of Contents for GX 11

Page 1: ...GX 7 GX 11 Instruction book ...

Page 2: ......

Page 3: ...t thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings This instruction book meets the requirements for instructions specified by the machinery directive 98 37 EC and is valid for CE as well as non CE labelled machines 2007 11 No 2920 7054 00 www atlascopco com ...

Page 4: ...10 2 2 AIR FLOW 12 2 3 OIL SYSTEM 14 2 4 COOLING SYSTEM 15 2 5 REGULATING SYSTEM 16 2 6 CONTROL PANEL 18 2 7 PROTECTION OF COMPRESSOR 20 2 8 AIR DRYER 22 3 Installation 23 3 1 INSTALLATION PROPOSAL 23 3 2 DIMENSION DRAWINGS 26 3 3 ELECTRIC CABLE SIZE 32 3 4 ELECTRICAL CONNECTIONS 32 3 5 ELECTRICAL DIAGRAMS 38 3 6 PICTOGRAPHS 40 4 Operating instructions 41 4 1 INITIAL START UP 41 4 2 STARTING 43 4 ...

Page 5: ... servicing procedures 55 6 1 AIR FILTER 55 6 2 COOLERS 56 6 3 SAFETY VALVE 56 6 4 UNLOAD STOP PRESSURE SWITCH 57 6 5 BELT SET EXCHANGE AND TENSIONING 59 7 Problem solving 61 7 1 PROBLEM SOLVING 61 8 Technical data 64 8 1 READINGS ON CONTROL PANEL 64 8 2 SETTINGS FOR OVERLOAD RELAY AND FUSES 65 8 3 REFERENCE CONDITIONS AND LIMITATIONS 65 8 4 COMPRESSOR DATA 66 9 Instructions for use of air receiver...

Page 6: ...10 1 PRESSURE EQUIPMENT DIRECTIVES 71 Instruction book 4 2920 7054 00 ...

Page 7: ...ment or any other non routine checks stop the compressor press the emergency stop button switch off the voltage and depressurise the compressor In addition the power isolating switch must be opened and locked 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...

Page 8: ... 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 13 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 14 Never remove or tamper with the safety devices gu...

Page 9: ...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 3 Never operate the machine when there is a possibility of taking in flammable or toxic fumes vapours or particles 4 Never operate the machine below or in excess of its limit ratings 5 Keep all bodywork doors shut during operation The doors may ...

Page 10: ...nt or any other non routine checks stop the compressor press the emergency stop button switch off the voltage and depressurise the compressor In addition the power isolating switch must be opened and locked 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 s...

Page 11: ...tect 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 e g 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 u...

Page 12: ...uding the start stop switch and the emergency stop button A cabinet housing the regulator pressure switch and motor starter is integrated into the bodywork Floor mounted model The compressor is installed directly on the floor Tank mounted model Front view GX 7 and GX 11 Full Feature GX 7 and GX 11 are mounted on a large air receiver AR of 270 l 71 28 US gal 59 40 Imp gal 9 45 cu ft or an optional ...

Page 13: ...S Oil separator OT Oil separator tank GX Full feature An air cooler Ca and an air dryer DR are integrated into the bodywork A condensate drain system is provided including a valve for automatic draining during operation Da and a manual drain valve Dm1 GX Pack The compressor is not fitted with an air cooler air dryer and condensate drain system as standard Instruction book 2920 7054 00 11 ...

Page 14: ...low Pack version Air drawn through filter AF and open inlet valve IV into compressor element E is compressed Compressed air and oil flow into oil separator tank OT The air is discharged via minimum pressure valve Vp towards the air outlet AO Instruction book 12 2920 7054 00 ...

Page 15: ...filter AF and open inlet valve IV into compressor element E is compressed Compressed air and oil flow into oil separator tank OT The air is discharged via minimum pressure valve Vp air cooler Ca and air dryer DR towards the air outlet AO Instruction book 2920 7054 00 13 ...

Page 16: ...essure forces the oil from oil separator tank OT through oil cooler Co and filter OF to compressor element E and the lubrication points In oil separator tank OT most of the oil is removed centrifugally the rest is removed by separator OS Instruction book 14 2920 7054 00 ...

Page 17: ...hen the oil temperature exceeds the setting of the valve The setting of the by pass valve depends on the model See the section Compressor data 2 4 Cooling system Cooling system GX 7 and GX 11 Pack The cooling system of the Pack version comprises oil cooler Co A fan FN mounted directly onto the motor shaft generates the cooling air in order to cool the oil An air cooler Ca is available as option In...

Page 18: ... the cooling air in order to cool the oil and the compressed air 2 5 Regulating system Main components Detail view of unloader assembly UA The main components of the regulating system are Pressure switch which opens and closes at preset pressure limits See Protection of compressor Unloader UA including inlet valve IV and unloading valve UV Instruction book 16 2920 7054 00 ...

Page 19: ...roller that will stop the compressor after a variable period of unloaded operation When the unloading pressure is reached after the first start and if there is no air consumption the compressor will run unloaded during 2 minutes and than stop If there is a pressure request within the first 2 minutes after being stopped the controller is expecting a higher air consumption the next time the unit wil...

Page 20: ...n switches on the compressor The motor starts 25 seconds after the button is pushed STOP button Pressing the button starts the compressor switch off phase the compressor runs idle during 120 seconds 2 minutes before stopping Symbol Led flashing Led on The motor overload FM1 has switched off the motor The NC contact of FM1 is open The NC contact of motor overload FM1 is closed again but the fault i...

Page 21: ...start and stop the compressor depending on the need for compressed air Before switching off the compressor will run idle unloaded The idling period decreases when the air consumption decreases thus reducing idle running to a minimum See also Regulating system Reference Designation Function 1 2 Start button Stop button To start or stop the compressor After the stop command the compressor will run u...

Page 22: ...e Legend Ref Designation 1 only on Full Feature versions 2 only on multi voltage versions Ref Designation F1 2 3 4 10 Fuses F10 only on Full Feature units see 1 on figure FM1 Motor overload relay KL Line contactor Instruction book 20 2920 7054 00 ...

Page 23: ...e Safety valve on the compressor and on the vessel Reference Designation Function TSH See also the Electrical diagrams section Temperature shut down switch To shut down the compressor if the temperature at the outlet of the compressor element is too high SV Safety valve To protect the air outlet system if the outlet pressure exceeds the opening pressure of the valve Instruction book 2920 7054 00 2...

Page 24: ...r then flows through heat exchanger 1 where refrigerant evaporates withdrawing heat from the air The cold air then flows through condensate trap 4 which separates condensate from the air The condensate is automatically drained The cold dried air then flows through heat exchanger 3 where it is warmed up by the incoming air Instruction book 22 2920 7054 00 ...

Page 25: ...3 Installation 3 1 Installation proposal Important Transport by a pallet truck For transport with a fork truck use the openings in the frame Move the compressor gently Instruction book 2920 7054 00 23 ...

Page 26: ... mounted units the minimum distance between the wall and the back of the compressor is 500 mm 19 5 in 2 Position of the compressed air outlet valve Close the valve Connect the air net to the valve 3 The pressure drop over the delivery pipe can be calculated from the following formula dp L x 450 x Qc1 85 d5 x P dp pressure drop recommended maximum 0 1 bar 1 5 psi L length of delivery pipe in m d in...

Page 27: ... s The required ventilation capacity to limit the temperature of the compressor room can be calculated from the following formula Qv 0 92 N dT Qv required ventilation capacity in m3 s N nominal motor power of compressor in kW dT temperature increase in compressor room 5 Position of the mains cable entry 6 The drain pipes to the drain collector must not dip into the water of the drain collector Ins...

Page 28: ...3 2 Dimension drawings Dimension drawings GX 7 and GX 11 GX 7 and GX 11 Tank mounted 270 l Pack Instruction book 26 2920 7054 00 ...

Page 29: ...GX 7 and GX 11 Tank mounted 500 l optional Pack Instruction book 2920 7054 00 27 ...

Page 30: ...GX 7 and GX 11 Tank mounted 270 l Full Feature Instruction book 28 2920 7054 00 ...

Page 31: ...GX 7 and GX 11 Tank mounted 500 l optional Full Feature Instruction book 2920 7054 00 29 ...

Page 32: ...GX 7 and GX 11 Floor mounted Pack Instruction book 30 2920 7054 00 ...

Page 33: ...ing air outlet 2 Cooling air inlet 3 Location of supply cable entry 4 Manual drain G 3 8 female 5 Compressed air outlet G 1 2 female 6 Dryer air outlet 7 Dryer air inlet 8 Motor cooling air inlet 9 Outlet valve delivered loose Instruction book 2920 7054 00 31 ...

Page 34: ...n those stated to comply with this requirement GX 7 GX 11 Frequency Hz Voltage V Cable size Cable size IEC mm2 mm2 50 200 16 6 XLPE or EPR 25 16 XLPE or EPR 50 230 10 16 10 XLPE or EPR 50 400 4 6 50 500 4 6 60 440 460 4 6 60 380 4 6 CSA UL AWG AWG 60 200 6 6 60 208 230 460 8 8 10 6 6 8 60 575 12 10 3 4 Electrical connections Always disconnect the power supply before working on the electrical circu...

Page 35: ...correct connection 4 Connect the power supply cables to terminals L1 L2 and L3 1X0 and the neutral conductor if applicable to terminal N Connect the earth conductor Specific instructions for GX 7 and GX 11 with 208 V 230 V 460 V cubicle The standard voltage configuration for the compressor is mentioned on the data plate of the machine When the compressors leave the factory the units are connected ...

Page 36: ...e configuration in the main cubicle for the desired voltage 5 Replace the voltage sticker by the appropriate voltage sticker provided 6 On FF units replace the power fuses F10 in the main cubicle F11 in the power transformer cubicle with the CC type 5 A respectively 7 5 A fuses provided 7 Modify the power transformer terminal bridge configuration in the transformer cubicle for the desired voltage ...

Page 37: ...ompressor Fuses fuse rating V 208 V 230 V 460 V Class F1 600 V AC 2 A 2 A 1 A UL class JDYX or JDYX2 10 3 x 38mm F1 600 V AC 2 A 2 A 1 A UL class JDYX or JDYX2 10 3 x 38mm F2 250 V AC 3 A 3 A 3 A UL class JDYX or JDYX2 5 x 20 mm F3 250 V AC 1 A 1 A 1 A UL class JDYX or JDYX2 5 x 20 mm F3 250 V AC 1 A 1 A 1 A UL class JDYX or JDYX2 5 x 20 mm F10 600 V AC 7 5 A 7 5 A 5 A UL guide JDDZ class CC type ...

Page 38: ...e compressor The connections for 230 V are the factory standard Locate the yellow voltage labels provided with the compressor Replace the existing label with the appropriate voltage label 200 208 V 230V or 460V Voltage labels for GX 7 and GX 11 2 Dryer transformer cubicle modifications Remove the rear panel and the transformer box rear cover Use fuses F11 only for a supply voltage of 460 V F11 is ...

Page 39: ...Fuses V AC DC 208V 230V 460V Class F11 600 V AC 7 5 A UL guide JDDZ class CC type FNQ R 10 3 x 38 mm Instruction book 2920 7054 00 37 ...

Page 40: ...3 5 Electrical diagrams Electrical diagram GX 7 and GX 11 IEC Instruction book 38 2920 7054 00 ...

Page 41: ...Electrical diagram GX 7 and GX 11 CSA UL Instruction book 2920 7054 00 39 ...

Page 42: ...surise compressor before carrying out maintenance work 10 Warning hot parts 11 Lock all doors of the bodywork and push the start button If the sheet is pulled downwards Stop the compressor immediately and switch off the voltage Reverse two incoming electric lines Repeat the previous step If the sheet is blown away the motor rotation direction is correct 12 Manual condensate drain 13 Automatic cond...

Page 43: ...l start up Safety The operator must apply all relevant Safety precautions Moving To safely move a Tank mounted model see Installation General preparation Air outlet valve Condensate drain GX 7 up to GX 11 Instruction book 2920 7054 00 41 ...

Page 44: ...ng 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 Dm and automatic drain outlet Da to a drain collector Close the valve Connect condensate drain valve 4 of the air receiver to a drain collector Close the valve Oil system Oil level sight glass GX 7 and GX 11 Step Action Check the oil level The oil level ...

Page 45: ...motor using sheet 5 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 see the pictographs on the label If the rotation direction is incorrect switch off the voltage open the isolating switch and reverse two incoming electric lines 2 Start and run the compressor for a few minutes Check that...

Page 46: ...Condensate drain valve GX 7 and GX 11 Pressure gauge Dew point temperature gauge Control panel GX 7 up to GX 11 Instruction book 44 2920 7054 00 ...

Page 47: ...he 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 When automatic operation LED 3 is lit the regulator is automatically controlling the compressor i e loading unloading stopping of the motors and restart...

Page 48: ...4 3 Stopping Air outlet valve Condensate drain valve Tank mounted GX 7 and GX 11 Instruction book 46 2920 7054 00 ...

Page 49: ...f 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 Open condensate drain valve Dm for a few seconds to drain any condensate and then close the valve 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 ...

Page 50: ...sate drain valve Tank mounted GX 7 and GX 11 Filler plug GX 7 and GX 11 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 Instruction book 48 2920 7054 00 ...

Page 51: ...valve Dm Open condensate drain valve 4 of the air reciever 4 Shut off and depressurise the part of the air net which is connected to the outlet valve Disconnect the compressor air outlet valve from the air net 5 Drain the oil and condensate circuits 6 Disconnect the compressor condensate outlet and valve from the condensate net Instruction book 2920 7054 00 49 ...

Page 52: ...re 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 GX 7 and GX 11 Period Running hours Operation Daily Check the oil level before starting Drain the condensate after stopping For tank mounted unit...

Page 53: ...s or types It is strongly recommended to use Atlas Copco lubricants See Preventive maintenance schedule for recommended oil change intervals For part numbers consult the Spare Parts List Atlas Copco Roto Inject Fluid Atlas Copco Roto Inject Fluid is special oil for oil injected scroll and screw compressors which keeps the compressor in excellent condition Roto Inject Fluid can be used for compress...

Page 54: ...Remove plug 5 drain the oil by opening drain valve 6 Close the valve and refit the plug after draining Deliver the drained oil to the local oil collection service 5 Remove oil filter 7 and separator 1 Clean the seats on the manifold 6 Oil the gaskets of the new filter and separator and screw them into place Tighten firmly by hand 7 Fill oil separator tank 3 with oil until the level reaches the mid...

Page 55: ... 11 Step Action 1 Stop the compressor close the air outlet valve switch off the voltage and depressurise by unscrewing oil filler plug 3 one turn to permit any pressure in the system to escape See Stopping If the compressor is fitted onto an air receiver depressurise the air receiver by opening condensate drain valve 4 On floor mouned units depressurise the filter by loosing its drain valve Instru...

Page 56: ...If the compressor is stored without running from time to time consult Atlas Copco as protective measures may be necessary 5 7 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 ful...

Page 57: ...ep 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 Instruction book 2920 7054 00 55 ...

Page 58: ...ficiency 2 Stop the compressor close the air outlet valve and switch off the voltage Remove any dirt from the oil cooler Co with a fibre brush For versions with air cooler also remove any dirt from the air cooler Ca Never use a wire brush or metal objects Then clean using an air jet 6 3 Safety valve Condensate drain valve Tank mounted GX 7 and GX 11 Instruction book 56 2920 7054 00 ...

Page 59: ...es 4 tank mounted units and the manual drain valve 5 if fitted on floor mounted units 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 Unload stop pressure switch Pressure switch GX 7 up to GX 11 Instru...

Page 60: ...sure is controlled by adjusting knob 2 Remove blocking device 3 and turn the knob clockwise to raise the pressure anti clockwise to lower it See also below drawing The pressure difference between unloading and loading is adjusted by means of the same knob Push down the knob and turn it clockwise to reduce the pressure difference counter clockwise to increase it Instruction book 58 2920 7054 00 ...

Page 61: ...auses a deflection of 5 mm 0 2 in 4 Refit the bodywork panels Adjusting the tension of the drive belts for GX 7 and GX 11 Step Action 1 Stop the compressor close the air outlet valve and switch off the voltage 2 Remove the front door the internal panel the top cover and the pulley protection 3 Loosen the 4 bolts 2 by one turn 4 Adjust the belt tension by turning tensioning nut 1 5 The tension is c...

Page 62: ...ernal panel the top cover the pulley protection and the left side panel 3 Loosen the 4 bolts 2 by one turn 4 Release the belt tension by loosening tensioning nut 1 5 Remove the fan duct 4 Remove the belts 6 Install the new belts 7 Tension belts 3 as described above 8 Re assemble the fan duct 4 the pulley protection and the internal protection panel 9 Re assemble left side and top panel cover 10 Ch...

Page 63: ...7 Problem solving 7 1 Problem solving Start stop switch GX 7 and GX 11 Air outlet valve GX 7 and GX 11 Instruction book 2920 7054 00 61 ...

Page 64: ...compressor push the stop button 2 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 foll...

Page 65: ...e Leak in control air flexibles Replace leaking flexible Inlet valve IV does not fully open Have valve checked Oil separator OS clogged Replace separator element Safety valves leaking Replace valves 3 Air outlet temperature above normal Insufficient cooling air or cooling air temperature too high Check for cooling air restriction or improve ventilation of compressor room Avoid recirculation of coo...

Page 66: ...id 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 Gdp Dew point temperature Reading approx 5 C 41 F at 20 C 68 F ambient temperature Hm Hour meter Reading Total running time Instruction book 64 2920 7054 00 ...

Page 67: ... relay FM1 A Main fuses A class J or RK Disc switch size 1 25 x FLA see conn diagram 60 200 40 60 55 70 60 208 230 460 36 3 34 4 16 9 50 45 25 48 45 22 5 70 70 35 60 575 14 20 18 5 25 8 3 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 p...

Page 68: ...ressure Full Feature psig 105 105 141 141 185 185 Nominal working pressure bar e 7 7 9 5 9 5 12 5 12 5 Nominal working pressure psig 102 102 138 138 181 181 Set point thermostatic valve C 75 75 75 75 75 75 Set point thermostatic valve F 167 167 167 167 167 167 Temperature of air leaving outlet valve approx Pack Tank mounted C 38 43 38 43 38 43 Tank mounted F 100 109 100 109 100 109 Floor mounted C...

Page 69: ...r type GX7 GX11 GX7 GX11 Frequency Hz 60 60 60 60 Maximum unloading pressure Pack bar e 7 4 7 4 9 1 9 1 Maximum unloading pressure Pack psig 107 107 132 132 Maximum unloading pressure Full Feature bar e 7 15 7 15 8 85 8 85 Maximum unloading pressure Full Feature psig 103 7 103 7 128 128 Nominal working pressure bar e 6 9 6 9 8 6 8 6 Nominal working pressure psig 100 100 125 125 Set point thermosta...

Page 70: ...mum unloading pressure Full Feature bar e 10 55 10 55 12 25 12 25 Maximum unloading pressure Full Feature psig 153 153 178 178 Nominal working pressure bar e 10 3 10 3 12 12 Nominal working pressure psig 149 149 174 174 Set point thermostatic valve C 75 75 75 75 Set point thermostatic valve F 167 167 167 167 Temperature of air leaving outlet valve approx Pack Tank mounted C 38 43 38 43 Tank mounte...

Page 71: ...il capacity l 3 3 2 3 3 2 Oil capacity US gal 0 8 0 84 0 8 0 84 Oil capacity Imp gal 0 65 0 7 0 65 0 7 Oil capacity cu ft 0 1 0 11 0 1 0 11 Sound pressure level according to ISO 2151 2004 dB A 67 68 67 68 Instruction book 2920 7054 00 69 ...

Page 72: ...the written permission of the manufacturer 4 The pressure and temperature of this vessel must be clearly indicated 5 There is no intrinsic need for service inspection of the vessel when used within the design limits for its intended application 6 Corrosion must be prevented under the conditions of use Condensation may accumulate inside the tank and this must be drained every day This may be done m...

Page 73: ...e Equipment Directive greater than or equal to category II Compressor type Part number Description PED Class GX7 and GX11 2200 9507 74 Safety valve IV 2200 9507 75 Safety valve IV 0830 1009 71 Safety valve IV 0830 1009 72 Safety valve IV Overall rating The compressors conform to PED smaller than category II Instruction book 2920 7054 00 71 ...

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Page 76: ...bility to adapt to the diverse demands of the people we cater for It s the commitment to our customers business that drives our effort towards increasing their productivity through better solutions It starts with fully supporting existing products and continuously doing things better but it goes much further creating advances in technology through innovation Not for the sake of technology but for ...

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