Atlas Copco GX 7 Instruction Book
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Atlas Copco GX 7 Instruction Book

Atlas Copco GX 7 Instruction Book

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GX 7, GX 11
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Summary of Contents for Atlas Copco GX 7

  • Page 1 GX 7, GX 11 Instruction book...
  • Page 3 Atlas Copco GX 7, GX 11 Instruction book 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 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.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions......................5 ...........................5 AFETY ICONS ...................5 AFETY PRECAUTIONS DURING INSTALLATION ....................6 AFETY PRECAUTIONS DURING OPERATION ................8 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description......................10 ..........................10 NTRODUCTION ............................12 IR FLOW ............................14 IL SYSTEM ..........................15 OOLING SYSTEM ........................16 EGULATING SYSTEM ..........................18...
  • Page 5 Instruction book ........................48 AKING OUT OF OPERATION Maintenance........................50 ....................50 REVENTIVE MAINTENANCE SCHEDULE ..........................51 RIVE MOTOR ..........................51 IL SPECIFICATIONS ....................52 FILTER AND SEPARATOR CHANGE PDX/DDX .......................53 FILTER CHANGE ......................54 TORAGE AFTER INSTALLATION ..........................54 ERVICE KITS Adjustments and servicing procedures..............55 ............................55 IR FILTER ............................56 OOLERS ..........................56...
  • Page 6 Instruction book 10.1 ......................71 RESSURE EQUIPMENT DIRECTIVES 2920 7054 00...

  • Page 7: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note Safety precautions during installation All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.

  • Page 8: Safety Precautions During Operation

    Instruction book 4. 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. 5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can lead to internal fire or explosion.
  • Page 9 Instruction book General precautions 1. The operator must employ safe working practices and observe all related local work safety requirements and regulations. 2. If any of the following statements does not comply with local legislation, the stricter of the two shall apply. 3.

  • Page 10: Safety Precautions During Maintenance Or Repair

    Instruction book Also consult following safety precautions: Safety precautions during installation Safety precautions during maintenance. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein.
  • Page 11 Instruction book 11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely purged, e.g. by steam-cleaning, before carrying out such operations. Never weld on, or in any way modify, pressure vessels. 12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has elapsed;...

  • Page 12: General Description

    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 air receiver of 500 l (132 US gal / 110 Imp gal / 17.50 cu.ft).
  • Page 13 Instruction book Ref. Name Control panel Air filter Air outlet Air receiver Air cooler Oil cooler Automatic drain Manual condensate drain Dryer Compressor element Oil filter Oil separator 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).

  • Page 14: Air Flow

    Instruction book Air flow Flow diagram Air flow, GX 7 and GX 11 Pack (tank-mounted) Air flow (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).
  • Page 15 Instruction book 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).

  • Page 16: Oil System

    Instruction book Oil system GX 7 and GX 11 Pack GX 7 and GX 11 Full-Feature Air pressure 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;...

  • Page 17: Cooling System

    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.

  • Page 18: Regulating System

    Instruction book GX 7 and GX 11 Full-Feature The cooling system of the Full Feature version comprises oil cooler (Co) and air cooler (Ca). A fan (FN), mounted directly onto the motor shaft, generates the cooling air in order to cool the oil and the compressed air.
  • Page 19 The compressor will run fully unloaded (0% output). The GX 7 and GX 11 is equipped with the Elektronikon 001, an intelligent controller that will stop the compressor after a variable period of unloaded operation: •...

  • Page 20: Control Panel

    Instruction book Control panel Control panel GX 7 and GX 11 Symbol Description RESET button. Pressing the button cancels the stored alarm indication. When pressing the button during more than 3 seconds, the central control unit is tested: all the LEDs must be on.
  • Page 21 Instruction book Symbol Led flashing Led on The oil temperature switch (TSH) has The NC contact of the oil temperature switch is switched off the motor. The NC contact closed again, but the fault is not yet reset. is open. On star/delta started compressors, during start-up (transitory: star contactor energized)

  • Page 22: Protection Of Compressor

    Instruction book Protection of compressor Electric cubicle Legend Ref. Designation only on Full Feature versions only on multi-voltage versions Ref. Designation F1-2-3-4-10 Fuses (F10 only on Full Feature units - see (1) on figure) Motor overload relay Line contactor 2920 7054 00...
  • Page 23 Instruction book Ref. Designation Star contactor Delta contactor Transformer Dryer relay (only on FF versions - see (1) on figure) Connection terminals (only available on multi-voltage versions - see (2) on figure) Safety valve on the compressor and on the vessel Reference Designation Function...

  • Page 24: Air Dryer

    Instruction book Air dryer Air Dryer Wet compressed air enters the dryer and is further cooled by the outgoing, dried air (2). Moisture in the incoming air condenses. The air 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.

  • Page 25: Installation

    Instruction book Installation Installation proposal Important Transport by a pallet truck For transport with a fork truck, use the openings in the frame. Move the compressor gently. 2920 7054 00...
  • Page 26 Instruction book Proposal Installation proposal, GX 7 and GX 11 Action Install the rubber pads (delivered loose with the compressor) to the compressor supports. Install the compressor on a solid, level floor suitable for taking its weight. The recommended minimum distance between the top of the unit and the ceiling is 900 mm (35.1 in).
  • Page 27 Instruction book Action 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. The air velocity to the grids must be limited to 5 m/s (200 in/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...

  • Page 28: Dimension Drawings

    Instruction book Dimension drawings Dimension drawings, GX 7 and GX 11 GX 7 and GX 11 Tank-mounted (270 l), Pack 2920 7054 00...
  • Page 29 Instruction book GX 7 and GX 11 Tank-mounted (500 l, optional), Pack 2920 7054 00...
  • Page 30 Instruction book GX 7 and GX 11 Tank-mounted (270 l), Full-Feature 2920 7054 00...
  • Page 31 Instruction book GX 7 and GX 11 Tank-mounted (500 l, optional), Full-Feature 2920 7054 00...
  • Page 32 Instruction book GX 7 and GX 11 Floor-mounted , Pack 2920 7054 00...
  • Page 33 Instruction book GX 7 and GX 11 Floor-mounted , Full-Feature Ref. Name Cooling air outlet Cooling air inlet Location of supply cable entry Manual drain (G 3/8 female) Compressed air outlet (G 1/2 female) Dryer air outlet Dryer air inlet...

  • Page 34: Electric Cable Size

    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. GX 7 GX 11 Frequency...

  • Page 35: General Instructions

    (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 for 230 V / 3 phase.
  • Page 36 Instruction book To modify the wiring for an operating voltage of 208 V or 460 V , both compressor main cubicle and transformer dryer cubicle should be rewired as described below: 1. Required modifications in the compressor cubicle: Step Action Adjust the motor overload (FM1) setting.
  • Page 37 Instruction book motor overload (FM1) settings 7,5 kW 11 kW 10 hp 15 hp 208V 36.3 230V (standard factory setting) 34.4 460V 16.9 22.5 To rewire the control transformer (T1), move the wire of the transformer to the terminal marked with the desired voltage (208 V, 230 V or 460 V).
  • Page 38 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.
  • Page 39 Instruction book Fuses V (AC/DC) 208V 230V 460V Class 600 V AC 7,5 A UL guide JDDZ class CC type FNQ-R 10,3 x 38 mm 2920 7054 00...

  • Page 40: Electrical Diagrams

    Instruction book Electrical diagrams Electrical diagram, GX 7 and GX 11 IEC 2920 7054 00...
  • Page 41 Instruction book Electrical diagram, GX 7 and GX 11 CSA/UL 2920 7054 00...

  • Page 42: Pictographs

    Instruction book Pictographs Pictographs Ref. Description Working pressure Hour meter Dew-point temperature Start Stop Warning: voltage Lightly oil gasket of oil filter, screw filter on and tighten by hand Warning: switch off voltage and depressurise compressor before carrying out maintenance work Warning: hot parts Lock all doors of the bodywork and push the start button.

  • Page 43: Operating Instructions

    Instruction book Operating instructions Initial 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 2920 7054 00...
  • Page 44 Instruction book Condensate drain valve, GX 7 and GX 11 Step Action Consult the installation instructions (see Installation). 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.

  • Page 45: Starting

    Instruction book Start-up Label on the top Step Action Affix sheet (5) explaining the procedure for checking the motor rotation direction to the cooling air outlet of the compressor (consult Dimension drawings). Switch on the voltage. Start the compressor and stop it immediately. Check the rotation direction of the motor using sheet (5).
  • Page 46 Instruction book Condensate drain valve, GX 7 and GX 11 Pressure gauge Dew-point temperature gauge Control panel GX 7 up to GX 11 2920 7054 00...
  • Page 47 Instruction book Position of oil sight glass and filler plug on GX 7 and GX 11 Step Action Before starting, the oil level sight-glass (SG) should be between 1/4 and 3/4 full. Switch on the voltage. Open air outlet valve (2).

  • Page 48: Stopping

    Instruction book Stopping Air outlet valve Condensate drain valve, Tank-mounted GX 7 and GX 11 2920 7054 00...
  • Page 49 Instruction book Control panel GX 7 up to GX 11 Step Action Push the stop button (2) on the control panel. The compressor will switch to unloaded operation and stops after 120 seconds. The automatic operaion LED goes out. To stop the compressor immediately in the event of an emergency, press button (S3). See Control panel section.

  • Page 50: Taking Out Of Operation

    Instruction book Taking out of operation Air outlet valve Condensate 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 Stop the compressor and close the air outlet valve (2).
  • Page 51 Instruction book Step Action Switch off the voltage and disconnect the compressor from the mains. Depressurise the compressor by opening plug (3) one turn. Open condensate drain valve (Dm). Open condensate drain valve (4) of the air reciever. 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.

  • Page 52: Maintenance

    When servicing, replace all removed gaskets, O-rings and washers. Intervals Carry out maintenance at the interval which comes first. The local Atlas Copco Customer Centre may overrule the maintenance schedule, especially the service intervals, depending on the environmental and working conditions of the compressor.

  • Page 53: Drive Motor

    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 compressors operating at ambient temperatures between 0˚C (32˚F) and 40˚C (104˚F)(see...

  • Page 54: Oil, Filter And Separator Change

    If the compressor is exposed to external pollutants, is being used at high temperatures (oil temperature above 90˚C / 194˚F) or is being used under severe conditions, it is advisable to change the oil more frequently. Consult Atlas Copco. Location of oil filter and separator...

  • Page 55: Pdx/Ddx Filter Change

    Add oil as necessary. The sight-glass should be 3/4 full. Retighten plug (2) and close drain valve (8) of the air receiver. PDX/DDX filter change Oil filler plug GX 7 and GX 11 Drain valve, air receiver GX 7 and GX 11 Step...

  • Page 56: Storage After Installation

    Tighten oil filler plug (3). Close condensate drain valve (4). Storage after installation If the compressor is stored without running from time to time, consult Atlas Copco as protective measures may be necessary. 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.

  • Page 57: Adjustments And Servicing Procedures

    Instruction book Adjustments and servicing procedures Air filter Changing the air filter Position of air filter for GX 7 and GX 11 Air filter change on GX 7 up to GX 11 Step Action Stop the compressor, close the air outlet valve and switch off the voltage.

  • Page 58: Coolers

    (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. Safety valve Condensate drain valve, Tank-mounted GX 7 and GX 11 2920 7054 00...

  • Page 59: Unload/Stop Pressure Switch

    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. Unload/stop pressure switch Pressure switch, GX 7 up to GX 11 2920 7054 00...
  • Page 60 Instruction book The switch allows the operator to select the unloading/stopping pressure (see Regulating system). Adjustment can only be carried out when the pressure switch is pressurised. The loading/starting pressure is controlled by adjusting knob (2). Remove blocking device (3) and turn the knob clockwise to raise the pressure, anti-clockwise to lower it.

  • Page 61: Belt Set Exchange And Tensioning

    The tension is correct when a force of between 20 N (4.5 Ibf) and 25 N (5.63 Ibf) applied at the midpoint of the belts causes a deflection of 5 mm (0.2 in). Refit the bodywork panels. Adjusting the tension of the drive belts for GX 7 and GX 11 Step Action Stop the compressor, close the air outlet valve and switch off the voltage.
  • Page 62 Instruction book Replacing the drive belts for GX 7 and GX 11 Step Action The belts (3) must be replaced as a set, even if only one of the belts is worn. Only use genuine Atlas Copco belts. Stop the compressor, close the air outlet valve and switch off the voltage.

  • Page 63: Problem Solving

    Instruction book Problem solving Problem solving Start/stop switch GX 7 and GX 11 Air outlet valve GX 7 and GX 11 2920 7054 00...
  • Page 64 Instruction book Oil filler plug GX 7 and GX 11 Drain valve, air receiver GX 7 and GX 11 Attention Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability.
  • Page 65 Clean cooler Temperature switch Have switch tested malfunctioning Compressor element (E) out of Consult Atlas Copco order GX 7 up to GX 11 with air cooler Condition Fault Remedy Condensate is not discharged Discharge flexible clogged Check and correct as necessary...

  • Page 66: Technical Data

    Instruction book Technical data Readings on control panel Pressure gauge GX 7 up to GX 11 Hourmeter Dewpoint indicator The readings mentioned below are valid under the reference conditions (see Reference conditions and limitations). Ref. Name Air outlet pressure Reading: Modulates between preset unloading/stopping pressure and loading pressure Dew-point temperature Reading: approx.

  • Page 67: Settings For Overload Relay And Fuses

    Instruction book Settings for overload relay and fuses GX 7 and GX 11 Frequency Voltage (V) GX 7 GX 11 (Hz) Star-delta Overload relay Disc. switch + Overload relay Disc. switch + FM1 (A) motor circuit FM1 (A) motor circuit...

  • Page 68: Compressor Data

    Instruction book Maximum air inlet temperature ˚F Minimum ambient temperature ˚C Minimum ambient temperature ˚F Compressor data 50 Hz 7.5-13 bar (under reference conditions) Compressor type GX11 GX11 GX11 Frequency Maximum bar(e) (unloading) pressure, Pack Maximum psig (unloading) pressure, Pack Maximum bar(e) 7.25...
  • Page 69 Instruction book Compressor type GX11 GX11 GX11 Nominal motor power rating Nominal motor power rating Dryer power 0.36 0.36 0.36 0.36 0.36 0.36 consumption at full load, Full Feature units Dryer power 0.48 0.48 0.48 0.48 0.48 0.48 consumption at full load, Full Feature units Oil capacity...
  • Page 70 Instruction book Compressor type GX11 GX11 Nominal motor power rating Nominal motor power rating Dryer power consumption at full 0.44 0.44 0.44 0.44 load, Full Feature units Dryer power consumption at full 0.59 0.59 0.59 0.59 load, Full Feature units Oil capacity Oil capacity US gal...
  • Page 71 Instruction book Compressor type GX11 GX11 Oil capacity Oil capacity US gal 0.84 0.84 Oil capacity Imp gal 0.65 0.65 Oil capacity cu.ft 0.11 0.11 Sound pressure level (according dB(A) to ISO 2151 (2004)) 2920 7054 00...

  • Page 72: Instructions For Use Of Air Receiver

    Instruction book Instructions for use of air receiver Instructions for use This vessel can contain pressurised air; this can be potentially dangerous if the equipment is misused. This vessel must only be used as compressed air/oil separator and must be operated within the limits specified on the data plate.

  • Page 73: Ped

    Instruction book 10.1 Pressure equipment directives Components subject to 97/23/EC Pressure Equipment Directive Components subject to 97/23/EC Pressure Equipment Directive greater than or equal to category II Compressor type Part number Description PED Class GX7 and GX11 2200 9507 74 Safety valve 2200 9507 75 Safety valve...
  • Page 76 Not for the sake of technology, but for the sake of our customer’s bottom line and peace-of-mind. That is how Atlas Copco will strive to remain the first choice, to succeed in attracting new business and to maintain our position as the industry leader.

This manual is also suitable for:

Gx 11

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