Atlas Copco GX 2 EP Instruction Book Download

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Atlas Copco

Oil-injected rotary screw compressors

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

Instruction book

Summary of Contents for GX 2 EP

Page 1: ...Atlas Copco Oil injected rotary screw compressors GX 2 EP GX 3 EP GX 4 EP GX 5 EP GX 7 EP Instruction book ...

Page 2: ......

Page 3: ...ing of the contents or any part thereof is prohibited This applies in particular to trademarks model denominations part numbers and drawings This instruction book is valid for CE as well as non CE labelled machines It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity 2014 05 No 2920 7105 31 Replaces No 2920 7105 3...

Page 4: ...cription 9 2 1 INTRODUCTION 9 2 2 AIR FLOW 11 2 3 OIL SYSTEM 14 2 4 COOLING SYSTEM 16 2 5 REGULATING SYSTEM 17 2 6 CONTROL PANEL 19 2 7 ELECTRICAL DIAGRAMS 20 2 8 PROTECTION OF THE COMPRESSOR 27 2 9 AIR DRYER 29 3 Installation 30 3 1 INSTALLATION PROPOSAL 30 3 2 DIMENSION DRAWINGS 33 3 3 ELECTRICAL CONNECTIONS 37 3 4 PICTOGRAPHS 38 4 Operating instructions 40 4 1 INITIAL START UP 40 4 2 STARTING 4...

Page 5: ...cing procedures 53 6 1 AIR FILTER 53 6 2 COOLERS 54 6 3 SAFETY VALVE 54 6 4 BELT SET EXCHANGE AND TENSIONING 55 7 Problem solving 57 8 Technical data 60 8 1 READINGS ON CONTROL PANEL 60 8 2 ELECTRIC CABLE SIZE 60 8 3 SETTINGS FOR OVERLOAD RELAY AND FUSES 61 8 4 REFERENCE CONDITIONS AND LIMITATIONS 63 8 5 COMPRESSOR DATA 63 9 Instructions for use 67 10 Guidelines for inspection 68 11 Pressure equip...

Page 6: ... the voltage Depressurize the compressor Lock Out Tag Out LOTO Open the power isolating switch and lock it with a personal lock Tag the power isolating switch with the name of the service technician On units powered by a frequency converter wait 10 minutes before starting any electrical repair Never rely on indicator lamps or electrical door locks before maintenance work always disconnect and chec...

Page 7: ...essor to the aftercooler or air net is free to expand under heat and that it is not in contact with or close to flammable materials 9 No external force may be exerted on the air outlet valve the connected pipe must be free of strain 10 If remote control is installed the machine must bear a clear sign stating DANGER This machine is remotely controlled and may start without warning The operator has ...

Page 8: ...recautions during operation 1 Never touch any piping or components of the compressor during operation 2 Use only the correct type and size of hose end fittings and connections When blowing through a hose or air line ensure that the open end is held securely A free end will whip and may cause injury Make sure that a hose is fully depressurized before disconnecting it 3 Persons switching on remotely...

Page 9: ...njury resulting from neglecting these precautions or non observance of the normal caution and care required for installation operation maintenance and repair even if not expressly stated will be disclaimed by the manufacturer Precautions during maintenance or repair 1 Always use the correct safety equipment such as safety glasses gloves safety shoes etc 2 Use only the correct tools for maintenance...

Page 10: ...rom entering them e g when steam cleaning 19 Make sure that all sound damping material and vibration dampers e g damping material on the bodywork and in the air inlet and outlet systems of the compressor is in good condition If damaged replace it by genuine material from the manufacturer to prevent the sound pressure level from increasing 20 Never use caustic solvents which can damage materials of...

Page 11: ...cy stop button A cabinet housing the regulator pressure switch and motor starter is integrated into the bodywork Pack versions do not include an air dryer Full Feature versions are fitted with an air dryer DR The dryer removes moisture from the compressed air by cooling the air to near the freezing point and automatically draining the condensate Floor mounted model The compressor is installed dire...

Page 12: ... l 52 80 US gal 44 Imp gal 7 cu ft and are available in Pack and Full Feature version GX 5 FF EP tank mounted Ref Description 1 Control panel AO Air outlet AR Air receiver Dm2 Condensate drain valve air receiver SV Safety valve DR Integrated dryer Instruction book 10 2920 7105 31 ...

Page 13: ...2 2 Air flow Pack Air flow floor mounted Pack units Instruction book 2920 7105 31 11 ...

Page 14: ...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 12 2920 7105 31 ...

Page 15: ...ssed 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 7105 31 13 ...

Page 16: ...2 3 Oil system GX Pack Instruction book 14 2920 7105 31 ...

Page 17: ... is separated from the air by centrifugal action The remaining oil is removed by oil separator OS and returns to the oil circuit via a separate line The minimum pressure valve Vp see section Air flow ensures a minimal pressure in the tank required for oil circulation under all circumstances The oil circuit has a thermostatic bypass valve BV The oil cooler is bypassed until the oil is warm Instruct...

Page 18: ...2 4 Cooling system Pack units Instruction book 16 2920 7105 31 ...

Page 19: ...ounted compressors the air receiver is used as air cooler The condensate is drained manually The dryer DR of Full Feature versions has a separate cooling fan and an automatic condensate drain see also section Air dryer 2 5 Regulating system GX 2 up to GX 5 The main components of the regulating system are Instruction book 2920 7105 31 17 ...

Page 20: ...he compressor Unloader UA including inlet valve IV and unloading valve UV Loading solenoid valve Y1 As long as the working pressure is below the preset maximum the solenoid valve is energised allowing control air to the unloader the inlet valve opens completely and the unloading valve closes completely The compressor will run fully loaded 100 output When the working pressure reaches the maximum li...

Page 21: ...y and to reset the thermal overload of the electric motor by switching it to 0 and back to I 3 Dryer ON OFF switch Only on Full Feature units Gpa Pressure gauge The pointer indicates the actual working pressure Hm Hour meter Indicates the total running time H1 Lamp Lights up when the machine is operating S Switch Start Stop switch GX 2 EP up to GX 5 EP Load unload switch GX 7 EP Instruction book 2...

Page 22: ...2 7 Electrical diagrams Service diagram GX 2 IEC 1 ph Service diagram GX 2 up to GX 5 IEC 3 ph DOL Instruction book 20 2920 7105 31 ...

Page 23: ...Service diagram GX 2 up to GX 5 IEC 3 ph Y D Single phase dryer 230 V 50 60 Hz Instruction book 2920 7105 31 21 ...

Page 24: ...Electrical diagram GX 2 cULus 1 ph Electrical diagram GX 4 and GX 5 cULus 1 ph Instruction book 22 2920 7105 31 ...

Page 25: ...Electrical diagram GX 2 up to GX 5 cULus 200 208 230 460 V 3 ph Settings GX 2 up to GX 5 for 208 230 460 V 3 ph Instruction book 2920 7105 31 23 ...

Page 26: ...Electrical diagram 575 V 60 Hz cULus Single phase dryer 115 V 60 Hz Text on image 1 Main switch and fuses to be installed by customer Instruction book 24 2920 7105 31 ...

Page 27: ...GX 7 EP IEC units with Y D start Instruction book 2920 7105 31 25 ...

Page 28: ...GX 7 EP for 208 230 460V 60 Hz DOL Instruction book 26 2920 7105 31 ...

Page 29: ...n switch to be installed by the customer For full details always consult the complete service diagram included in the cubicle of the compressor 2 8 Protection of the compressor Safety valve on the compressor Instruction book 2920 7105 31 27 ...

Page 30: ...ctrical diagrams Temperature shut down switch To shut down the compressor if the temperature at the outlet of the compressor element is too high SV Safety valve To protect the air outlet system if the outlet pressure exceeds the opening pressure of the valve After tripping of the temperature protection switch off the voltage and depressurise Check and remedy See Problem solving Wait a few minutes ...

Page 31: ...at exchanger 2 where refrigerant evaporates withdrawing heat from the air The cold air then flows through a condensate trap 1 which separates condensate from the air The condensate is automatically drained and this is regulated by a timer The dried air is then discharged from the dryer Instruction book 2920 7105 31 29 ...

Page 32: ...onsult Atlas Copco Moving lifting Transport by a pallet truck To prevent a tank mounted model from falling over during transport by a pallet truck push the forks underneath the air receiver and place a wooden beam 1 cross section approx 4 x 6 cm 1 6 x 2 4 in through the supports on both sides of the receiver While holding the compressor slowly lift the forks until the receiver is secured between t...

Page 33: ...n proposal Installation proposal Floor mounted GX Ref Description 6 Outlet valve Installation proposal tank mounted GX Ref Description recommendation 1 Isolating switch compressor Instruction book 2920 7105 31 31 ...

Page 34: ...osition of the compressed air outlet valve Close the valve Connect the air net to the valve 3 The pressure drop over the air delivery pipe can be calculated as follows Δp L x 450 x 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 th...

Page 35: ...3 2 Dimension drawings GX Pack floor mounted Ref Designation 2 Cooling air outlet 3 Electrical cable entry 4 Cooling air inlet 5 Compressed air outlet Instruction book 2920 7105 31 33 ...

Page 36: ...1 Cooling air outlet 2 Cooling air inlet 3 Compressed air outlet 4 Power supply cable 5 External box only on GX 5 EP 230 1 60 and on all GX 7 EP 6 Location of the centre of gravity G 7 Manual condensate drain Instruction book 34 2920 7105 31 ...

Page 37: ...GX 7 EP Pack on 200l receiver 2 Cooling air inlet Instruction book 2920 7105 31 35 ...

Page 38: ...air outlet 2 Cooling air inlet 3 Compressed air outlet 4 Power supply cable 5 Dryer cooling air inlet 6 Dryer cooling air outlet 7 External box only on GX 5 EP 230 1 60 and on all GX 7 EP 8 Location of the centre of gravity G Instruction book 36 2920 7105 31 ...

Page 39: ...ch compressor GX 7 Full Feature on 200 l receiver 1 Power supply cable dryer 2 Power supply cable compressor 3 Cooling air inlet 3 3 Electrical connections Always disconnect the power supply before working on the electrical circuit Instruction book 2920 7105 31 37 ...

Page 40: ...ing wiring and make connections See Electrical diagrams 3 4 Pictographs Ref Description 1 Warning possible air fluid discharge 2 Warning voltage 3 Warning air must not be inhaled 4 Warning wear ear protectors 5 Warning machine may start automatically 6 Warning pressure 7 Warning hot parts 8 Warning moving parts 9 Warning rotating fan 10 Drain the condensate daily and inspect the vessel yearly Note...

Page 41: ... 13 Hour meter 14 Start 15 GX 2 EP up to GX 5 EP Stop GX 7 EP Unload 16 Read instruction manual before carrying out maintenance or repair work 17 Lightly oil gasket of oil filter screw filter on and tighten by hand Instruction book 2920 7105 31 39 ...

Page 42: ...tions see Installation 2 Check that the electrical connections correspond to the local codes The installation must be earthed and protected against short circuits by fuses in all phases An isolating switch must be installed near the compressor 3 Fit outlet valve 2 close it and connect the air net to the valve Connect condensate drain valve 4 of the air receiver to a drain collector Close the valve...

Page 43: ...lve 7 and drain approximately 0 2 l 0 05 US gal 0 04 Imp gal of oil into a clean receptacle Carefully pour this oil through the filter housing into the compressor element Fit the air filter and screw on the filter cover Refit the top and front panels Check the oil level The oil level sight glass SG must be above the minimum level If the oil level is below the minimum level top up to the middle Do ...

Page 44: ...or If the motor rotation direction is correct the label on the top grating will be blown upwards If the sheet remains in place the rotation direction is incorrect If the rotation direction is incorrect switch off the voltage open the isolating switch and reverse two incoming electric lines All electrical work should be carried out by professionally qualified people 2 Start and run the compressor f...

Page 45: ...rting the compressor The dryer must remain switched on when the compressor is operating to ensure that the air piping remains condensate free If the dryer is switched off wait at least 5 minutes before restarting the dryer this allows for balancing of the internal pressure in the dryer Timer drain rear side of the dryer Instruction book 2920 7105 31 43 ...

Page 46: ...iddle Do not overfill 2 Switch on the voltage by turning switch 1 to position I 3 Open air outlet valve 2 4 Start the unit by moving selector switch S to position I 5 Regularly check the working pressure Gpa 6 On Full Feature compressors regularly check that condensate is drained during operation 4 3 Stopping Air outlet valve Instruction book 44 2920 7105 31 ...

Page 47: ...Condensate drain valve on air receiver Control panel GX 2 up to GX 5 EP Control panel GX 7 EP Instruction book 2920 7105 31 45 ...

Page 48: ...ch off the voltage to the compressor On Full Feature units switch off the voltage to the dryer 3 Open condensate drain valve 4 of the air receiver for a few seconds to drain any condensate and then close the valve The air dryer and the air receiver remain under pressure The integrated filter if installed remains pressurised If maintenance or repair work is necessary consult the Problem solving sec...

Page 49: ...essor from the mains 3 Depressurise the compressor by opening plug 3 one turn Open condensate drain valve 4 of the air receiver 4 Shut off and depressurise the part of the air net which is connected to the outlet valve Disconnect the compressor from the air net 5 Drain the oil and condensate circuits 6 Disconnect the compressor condensate outlet and valve from the condensate net Instruction book 2...

Page 50: ...erval which comes first The local Atlas Copco Customer Centre may overrule the maintenance schedule especially the service intervals depending on the environmental and working conditions of the compressor The longer interval checks must also include the shorter interval checks Preventive maintenance schedule Period 1 Running hours 1 Action Daily After stopping drain the condensate from the air rec...

Page 51: ...d oil exchange intervals are valid for standard operating conditions see section Reference conditions and limitations and nominal operating pressure see section Compressor data Exposure of the compressor to external pollutants or operation at high humidity combined with low duty cycles may require a shorter oil exchange interval Contact Atlas Copco if in doubt Important Always consult Atlas Copco ...

Page 52: ...ricant for oil injected screw compressors which keeps the compressor in excellent condition Because of its excellent oxidation stability Roto Xtend Duty Fluid can be used for compressors operating at ambient temperatures between 0 C 32 F and 46 C 115 F Roto Foodgrade Fluid Special oil delivered as an option Atlas Copco s Roto Foodgrade Fluid is a unique high quality synthetic lubricant specially c...

Page 53: ...ter 3 and separator 2 Clean the seats on the manifold 7 Oil the gaskets of the new filter and separator and screw them into place Tighten firmly by hand 8 Remove filler plug 8 and fill oil tank 7 with oil until the level reaches the middle of sight glass 6 Ensure no dirt gets into the system Refit and tighten filler plug 8 9 Unscrew the air filter cover 1 remove the filter element and carefully po...

Page 54: ...ds is available to keep the compressor in excellent condition Consult the Spare Parts List for part numbers 5 7 Disposal of used material Used filters or any other used material e g desiccant lubricants cleaning rags machine parts etc must be disposed of in an environmentally friendly and safe manner and in line with the local recommendations and environmental legislation Electronic components are...

Page 55: ...or 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 7105 31 53 ...

Page 56: ...2 Stop the compressor close the air outlet valve and switch off the voltage Remove any dirt from the cooler with a fibre brush Never use a wire brush or metal objects Then clean using an air jet 6 3 Safety valve Condensate drain valve on air receiver Oil filler plug Instruction book 54 2920 7105 31 ...

Page 57: ... the valve replace the valve No adjustments are allowed Never run the compressor without a safety valve 6 4 Belt set exchange and tensioning Read the warning in the Preventive maintenance schedule section Belt tensioning procedure Step Action 1 Stop the compressor close the air outlet valve and switch off the voltage For Full Feature versions also stop the dryer 2 Remove the front panel of the com...

Page 58: ...re versions also stop the dryer 2 Remove the front panel of the compressor housing 3 Remove the side back and top panels of the compressor housing 4 Loosen the 4 bolts 2 by one turn 5 Release the belt tension by loosening tensioning nut 1 6 Remove the fan cowl 7 Remove the belt via the fan cowl opening Install the new belt via the same opening 8 Tension belt 3 as described above 9 Re assemble the ...

Page 59: ...7 Problem solving Air outlet valve Dryer on off switch GX Full Feature Instruction book 2920 7105 31 57 ...

Page 60: ...slot of the handle fits over the blocking edge on the valve body Fit the screw Faults and remedies For all references given hereafter see Air flow diagram Initial start up or Regulating system Compressor Condition Fault Remedy 1 The machine does not start No power Check power supply Fuse F1 blown Replace fuse The main motor thermal protection has tripped Check and let motor cool down to reset rest...

Page 61: ...131 F motor overload The dryer is working outside its rating Check room temperature air temperature at dryer Clean the condenser and check operation of fan Insufficient refrigerant in dryer Have system checked for leaks or refilled 4 The motor hums and does not start Line voltage too low Check power supply The machine was switched off and on again too rapidly not enough time for the pressure equal...

Page 62: ...odulates between preset unloading stopping pressure and loading pressure Hm Hour meter Reading Total running time 8 2 Electric cable size Attention Local regulations remain applicable if they are stricter than the values proposed below The voltage drop must not exceed 5 of the nominal voltage It may be necessary to use cables of a larger size than those stated to comply with this requirement Instr...

Page 63: ...lay IG GX 2 A Circuit breaker GX 2 A see note 1 Overload relay IG GX 3 A Circuit breaker GX 3 A see note 1 Circuit breaker dryer supply A see note 1 IEC DOL Max capacity Setting Max capacity Setting Max capacity Setting 50 200 15 16 15 6 3 2 50 230 11 8 16 14 16 16 16 6 3 2 50 230 1 ph 20 20 20 6 3 2 50 400 8 10 8 10 10 10 6 3 2 60 200 15 16 15 6 3 2 60 380 8 10 8 10 10 10 6 3 2 Frequency Hz Volta...

Page 64: ... 60 200 25 32 25 6 3 2 Frequency Hz Voltage V Overload relay OL GX 4 A Main fuses compressor supply GX 4 A Overload relay OL GX 5 A Main fuses compressor supply GX 5 A Main fuses dryer supply A cULus DOL Type J or RK Type CC Type J or RK Type CC Type J or RK Type CC 60 200 208 21 2 30 24 7 40 4 5 8 60 230 18 2 30 22 5 40 4 5 8 60 230 1 ph 30 8 60 41 60 4 5 8 60 460 9 1 12 25 11 4 15 25 4 5 8 60 57...

Page 65: ...psi 14 5 Air inlet temperature C 20 Air inlet temperature F 68 Relative humidity 0 Working pressure bar e See Compressor data Working pressure psi See Compressor data Limitations Maximum working pressure bar e See Compressor data Maximum working pressure psig See Compressor data Minimum working pressure bar e 4 Minimum working pressure psig 58 Maximum air inlet temperature C 46 Maximum air inlet t...

Page 66: ...rop over dryer bar e 0 15 0 15 0 15 0 15 0 25 Pressure drop over dryer psig 2 18 2 18 2 18 2 18 3 62 Motor shaft speed rpm 2840 2840 2840 2840 2940 Set point thermostatic valve C 71 71 71 71 71 Set point thermostatic valve F 160 160 160 160 160 Temperature of air leaving receiver approx Pack C 33 33 33 33 33 Temperature of air leaving receiver approx Pack F 91 91 91 91 91 Pressure dew point Full F...

Page 67: ...Total amount refrigerant kg 0 17 0 17 0 17 0 17 0 29 Total amount refrigerant lb 0 37 0 37 0 37 0 37 0 64 Oil capacity l 2 5 2 5 2 5 2 5 2 5 Oil capacity US gal 0 66 0 66 0 66 0 66 0 66 Sound pressure level floor mounted units according to ISO 2151 2004 dB A 61 61 62 64 66 60 Hz 10 bar Compressor type GX 2 GX 4 GX 5 GX 7 Frequency Hz 60 60 60 60 Maximum unloading pressure Pack bar e 10 10 10 10 Ma...

Page 68: ...ck at maximum working pressure hp 4 96 6 3 8 45 12 27 Power input Full Feature at maximum working pressure kW 4 5 6 6 9 25 Power input Full Feature at maximum working pressure hp 5 36 6 71 8 85 12 61 Power consumption dryer at full load kW 0 24 0 24 0 24 0 32 Power consumption dryer at full load hp 0 33 0 33 0 33 0 44 Power consumption dryer at no load kW 0 17 0 17 0 17 0 22 Power consumption drye...

Page 69: ...prevented depending on the conditions of use condensate may accumulate inside the tank and must be drained every day This may be done manually by opening the drain valve or by means of the automatic drain if fitted to the tank Nevertheless a weekly check of correct functioning of the automatic valve is needed This has to be done by opening the manual drain valve and check for condensate Verify tha...

Page 70: ...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 68 2920 7105 31 ...

Page 71: ...Equipment Directive Components subject to 97 23 EC Pressure Equipment Directive greater than or equal to category II safety valves See the spare parts book for part numbers Overall rating The compressors conform to PED smaller than category I Instruction book 2920 7105 31 69 ...

Page 72: ...2 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 Instruction book 70 2920 7105 31 ...

Page 73: ...rer the harmonised and or other standards that have been used for the design are shown and or referred to The Declaration of Conformity Declaration by the Manufacturer is part of the documentation that is supplied with this device Instruction book 2920 7105 31 71 ...

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Page 76: ...s the products and services that help to increase your business efficiency and profitability Atlas Copco s pursuit of innovation never ceases driven by our need for reliability and efficiency Always working with you we are committed to providing you the customized quality air solution that is the driving force behind your business www atlascopco com ...

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