Related Manuals for Atlas Copco GX 2 EP
Summary of Contents for Atlas Copco 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 3 Atlas Copco Oil-injected rotary screw compressors GX 2 EP, GX 3 EP, GX 4 EP, GX 5 EP, GX 7 EP From following serial No. onwards: CAI 544 242 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited.
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Page 4: Table Of Contents
Instruction book Table of contents Safety precautions......................4 ...........................4 AFETY ICONS ......................4 ENERAL SAFETY PRECAUTIONS ...................5 AFETY PRECAUTIONS DURING INSTALLATION ....................6 AFETY PRECAUTIONS DURING OPERATION ................7 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description......................9 ...........................9 NTRODUCTION ............................11 IR FLOW ............................14 IL SYSTEM ..........................16 OOLING SYSTEM ........................17... - Page 5 Instruction book ........................46 AKING OUT OF OPERATION Maintenance........................48 ....................48 REVENTIVE MAINTENANCE SCHEDULE ..........................49 RIVE MOTOR ..........................50 IL SPECIFICATIONS ....................50 FILTER AND SEPARATOR CHANGE ......................52 TORAGE AFTER INSTALLATION ..........................52 ERVICE KITS ......................52 ISPOSAL OF USED MATERIAL Adjustments and servicing procedures..............53 ............................53 IR FILTER ............................54 OOLERS...
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Page 6: Safety Precautions
Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note General safety precautions 1. The operator must employ safe working practices and observe all related work safety requirements and regulations. 2. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply. -
Page 7: Safety Precautions During Installation
Instruction book 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 16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentally touched by personnel in normal operation must be guarded or insulated. Other high temperature piping must be clearly marked. 17. For water-cooled machines, the cooling water system installed outside the machine has to be protected by a safety device with set pressure according to the maximum cooling water inlet pressure. -
Page 9: Safety Precautions During Maintenance Or Repair
Instruction book • Air cooling filters of the electrical cabinet are not clogged 9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take precautions against air pollution and possible contamination of the breathing air. 10. - Page 10 Instruction book 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; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted. 13.
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Page 11: General Description
General description Introduction Introduction GX 2 EP, GX 3 EP, GX 4 EP, GX 5 EP and GX 7 EP are air-cooled, single-stage, oil-injected screw compressors, driven by an electric motor. The compressors are belt driven. The compressors are enclosed in sound-insulating bodywork. - Page 12 Instruction book Tank-mounted model Tank-mounted units are supplied with an air receiver of 200 l (52.80 US gal / 44 Imp gal / 7 cu.ft) and are available in Pack and Full-Feature version. GX 5 FF EP, tank-mounted Ref. Description Control panel Air outlet Air receiver...
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Page 13: Air Flow
Instruction book Air flow Pack Air flow, floor-mounted Pack units 2920 7105 31... - Page 14 Instruction book Air flow, tank-mounted Pack units Air drawn in through air filter (AF) and open inlet valve (IV) is compressed in compressor element (E). Compressed air and oil flow into oil separator/tank (OT) where most of the oil is removed by centrifugal action.
- Page 15 Instruction book Full-Feature Air flow, GX tank-mounted Full-Feature units Air drawn in through air filter (AF) and open inlet valve (IV) is compressed in compressor element (E). Compressed air and oil flow into oil separator/tank (OT) where most of the oil is removed by centrifugal action.
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Page 16: Oil System
Instruction book Oil system GX Pack 2920 7105 31... - Page 17 Instruction book GX Full-Feature Air pressure in the oil separator tank (OT) forces the oil from the tank to compressor element (E) via oil cooler (Co) and oil filter (OF). Compressed air and oil flow into oil separator/tank (OT) where most of the oil is separated from the air by centrifugal action.
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Page 18: Cooling System
Instruction book Cooling system Pack units 2920 7105 31... -
Page 19: Regulating System
Instruction book Full-Feature units A fan on the drive motor shaft provides air flow to cool the oil and the other components of the compressor. On tank-mounted 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 dryer). - Page 20 Instruction book • Pressure switch (PSR11) • Blow-off valve (Y1) The contacts of pressure switch (PSR11) open and close at preset pressures. During loaded operation, the contacts are closed: the motor is running. When the working pressure reaches the upper limit, the contacts of the pressure switch open: the motor stops. Blow-off valve (Y1) opens and the pressure in the air/oil separator is released.
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Page 21: Control Panel
The pointer indicates the actual working pressure. Hour meter Indicates the total running time. Lamp Lights up when the machine is operating. Switch Start/Stop switch (GX 2 EP up to GX 5 EP) Load/unload switch (GX 7 EP) 2920 7105 31... -
Page 22: Electrical Diagrams
Instruction book Electrical diagrams Service diagram GX 2 - IEC - 1 ph Service diagram GX 2 up to GX 5 - IEC - 3 ph DOL 2920 7105 31... - Page 23 Instruction book Service diagram GX 2 up to GX 5 - IEC - 3 ph Y-D Single phase dryer - 230 V 50/60 Hz 2920 7105 31...
- Page 24 Instruction book Electrical diagram GX 2 - cULus - 1 ph Electrical diagram GX 4 and GX 5 - cULus - 1 ph 2920 7105 31...
- Page 25 Instruction book 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 2920 7105 31...
- Page 26 Instruction book Electrical diagram 575 V 60 Hz cULus Single phase dryer - 115 V 60 Hz Text on image Main switch and fuses to be installed by customer. 2920 7105 31...
- Page 27 Instruction book GX 7 EP IEC units with Y-D start 2920 7105 31...
- Page 28 Instruction book GX 7 EP for 208/230/460V 60 Hz DOL 2920 7105 31...
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Page 29: Protection Of The Compressor
Instruction book Diagram for 575 V CSA-UL Fuses and main switch to be installed by the customer. For full details, always consult the complete service diagram, included in the cubicle of the compressor. Protection of the compressor Safety valve on the compressor 2920 7105 31... - Page 30 Instruction book Safety valve on the air receiver (tank-mounted units) Reference Designation Function IG (IEC) Motor overload relay To shut down the compressor in case the motor current OL (cULus) is too high. See also section Electrical diagrams TSH (IEC), TS Temperature shut-down To shut down the compressor if the temperature at the (cULus)
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Page 31: Air Dryer
Instruction book Air dryer Air dryer (Full-Feature compressors) Wet compressed air (B) enters the dryer. The air then flows through a 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. -
Page 32: Installation
Outdoor/altitude operation If the compressor is installed outdoors or if the ambient temperature can be below 0˚C (32˚F), precautions must be taken. In this case, and also if operating at high altitude, consult Atlas Copco. Moving/lifting Transport by a pallet truck To prevent a tank-mounted model from falling over during transport by a pallet truck: push the forks underneath the air receiver and place a wooden beam (1) (cross-section approx. - Page 33 Instruction book Installation proposal Installation proposal, Floor-mounted GX Ref. Description Outlet valve Installation proposal, tank-mounted GX Ref. Description/recommendation Isolating switch, compressor 2920 7105 31...
- Page 34 Instruction book Ref. Description/recommendation Isolating switch, dryer Front panel, compressor Dryer Minimum 1.5 m Space for maintenance, minimum 2 m Single-phase dryer supply Three-phase screw compressor supply The power cable should be protected so that it complies with local codes Step Action Install the compressor on a solid, level floor suitable for taking the weight.
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Page 35: Dimension Drawings
Instruction book Dimension drawings GX Pack, floor-mounted Ref. Designation Cooling air outlet Electrical cable entry Cooling air inlet Compressed air outlet 2920 7105 31... - Page 36 Instruction book GX 2 up to GX 5 Pack on 200 l receiver Cooling air outlet Cooling air inlet Compressed air outlet Power supply cable External box (only on GX 5 EP 230/1/60 and on all GX 7 EP) Location of the centre of gravity (G) Manual condensate drain 2920 7105 31...
- Page 37 Instruction book GX 7 EP Pack on 200l receiver Cooling air inlet 2920 7105 31...
- Page 38 Instruction book GX 2 up to GX 5 Full-Feature on 200 l receiver Cooling air outlet Cooling air inlet Compressed air outlet Power supply cable Dryer, cooling air inlet Dryer, cooling air outlet External box (only on GX 5 EP 230/1/60 and on all GX 7 EP) Location of the centre of gravity (G) 2920 7105 31...
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Page 39: Electrical Connections
Instruction book Manual condensate drain (10) Power switch, dryer (11) Power switch, compressor GX 7 Full-Feature on 200 l receiver Power supply cable, dryer Power supply cable, compressor Cooling air inlet Electrical connections Always disconnect the power supply before working on the electrical circuit! 2920 7105 31... -
Page 40: Pictographs
Instruction book General instructions Step Action Ensure that the supply voltage matches the voltage on the data plate. Install an isolating switch near the compressor. For Full-Feature compressors: fit an isolating switch near the dryer. Fit fuses in the incoming wiring. Check the condition of all incoming wiring and make connections. - Page 41 GX 7 EP Ref. Description Hour meter Start GX 2 EP up to GX 5 EP: Stop • GX 7 EP: Unload • Read instruction manual before carrying out maintenance or repair work Lightly oil gasket of oil filter, screw filter on and tighten by hand...
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Page 42: Operating Instructions
Instruction book Operating instructions Initial start-up Safety The operator must apply all relevant Safety precautions. General preparation Air outlet valve Condensate drain valve on air receiver 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. - Page 43 Instruction book Oil system Step Action If more than 3 months have passed between assembly and installation, be sure to lubricate the compressor before starting up: • Remove the front panel. • Unscrew the fixing bolts in the top and remove the panel. •...
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Page 44: Starting
Instruction book Step Action Check that all bodywork panels are fitted. Check that sheet (5) (explaining the procedure for checking the motor rotation direction) is affixed to the cooling air outlet of the compressor (grating on the compressor top). Consult Dimension drawings. - Page 45 Instruction book Starting the air dyer Dryer on/off switch Switch on the voltage to the dryer and start it by moving switch (3) to position I. • Switch on the dryer before starting the compressor. • The dryer must remain switched on when the compressor is operating to ensure that the air piping remains condensate-free.
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Page 46: Stopping
Instruction book Starting the compressor Step Action Check the oil level sight glass (SG). The oil level should be in the middle. If it is below the minimum level, top up to the middle. Do not overfill. Switch on the voltage by turning switch (1) to position I Open air outlet valve (2). - Page 47 Instruction book Condensate drain valve on air receiver Control panel GX 2 up to GX 5 EP Control panel GX 7 EP 2920 7105 31...
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Page 48: Taking Out Of Operation
Instruction book Dryer on/off switch Step Action On Full-Feature units: move switch (3) of the dryer to position 0. GX 2 EP to GX 5 EP: • Move start/stop switch (S) to position 0. • Turn off main switch (1) GX 7 EP: •... - Page 49 Instruction book Oil filler plug 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). Switch off the voltage and disconnect the compressor from the mains. Depressurise the compressor by opening plug (3) one turn.
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Page 50: 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 51: Drive Motor
Contact Atlas Copco if in doubt. Important Always consult Atlas Copco if a service timer setting has to be changed. • For the change interval of oil and oil filter in extreme conditions, consult your Atlas •... -
Page 52: Oil Specifications
For part numbers, consult the Spare Parts List. Roto-Inject Fluid Atlas Copco's Roto-Inject Fluid is a specially developed lubricant for use in single stage oil-injected screw compressors. Its specific composition 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). - Page 53 Instruction book GX 2 up to GX 5 Step Action Run the compressor until warm. Stop the compressor, close the air outlet valve and switch off the voltage. Remove the front and top panels. Depressurise the compressor by unscrewing filler plug (8) one turn to permit any pressure in the system to escape.
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Page 54: Storage After Installation
Instruction book 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 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 55: Adjustments And Servicing Procedures
Instruction book Adjustments and servicing procedures Air filter Changing the air filter Air filter (1) Procedure: Step Action Stop the compressor, close the air outlet valve and switch off the voltage. Remove the front panel and the top panel of the compressor housing. Unscrew the filter cover (1) and remove the filter element. -
Page 56: Coolers
Instruction book Coolers Oil cooler Step Action Keep oil cooler (Co) clean to maintain the cooling efficiency. 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. -
Page 57: Belt Set Exchange And Tensioning
Instruction book Testing The valve can be tested on a separate compressed air line. Before removing the valve, stop the compressor (see section Stopping). On a Full-Feature unit also stop the dryer. Close the air outlet valve, switch off the voltage, open drain valves (4) (if applicable) and unscrew filler plug (3) one turn to permit any pressure in the system to escape. - Page 58 Instruction book Step Action 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). Retighten bolts (2). Refit the bodywork panels. Belt replacement procedure Step Action Stop the compressor, close the air outlet valve and switch off the voltage.
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Page 59: Problem Solving
Instruction book Problem solving Air outlet valve Dryer on/off switch GX Full-Feature 2920 7105 31... - Page 60 Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability. Apply all relevant Safety precautions during maintenance or repair. GX 2 EP to GX 5 EP: • Move start/stop switch (S) to position 0. • Turn off main switch (1) GX 7 EP: •...
- Page 61 Instruction book Condition Fault Remedy Condensate in the piping Insufficient condensate drain Check the operation of timer (T) The dryer is working outside its Check room temperature - air rating temperature at dryer. Clean the condenser and check operation of fan The compressor head is very The dryer is working outside its Check room temperature - air...
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Page 62: Technical Data
Instruction book Technical data Readings on control panel Pressure gauge Hourmeter 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 Hour meter Reading: Total running time Electric cable size... -
Page 63: Settings For Overload Relay And Fuses
Instruction book GX 2 GX 3 GX 4 GX 5 GX 7 Frequency Voltage Cable size Cable size Cable size Cable size Cable size (Hz) 200 - 3 2.5 mm 6 mm 230 - 1 2.5mm 230 - 3 2.5 mm 2.5 mm 4 mm 4 mm... - Page 64 Instruction book (1): Motor circuit breaker with residual current device type D GX 4 and GX 5 Frequency Voltage (V) Overload Circuit breaker, Overload Circuit breaker, Circuit breaker, (Hz) relay (IG), GX 4 (A) (see note relay (IG), GX 5 (A) (see note dryer supply (A) GX 4 (A) GX 5 (A)
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Page 65: Reference Conditions And Limitations
Instruction book Frequency Voltage (V) Overload Main fuses, Main fuses, dryer (Hz) relay (OL), compressor supply (A) GX 7 (A) supply, GX 7 (A) cULus Type J or Type Type J or Type 200-208 36.3 34.4 16.9 13.8 (1): Motor circuit breaker with residual current device type D Reference conditions and limitations Reference conditions Air inlet pressure (absolute) - Page 66 Instruction book 50 Hz 10 bar Compressor GX 2 GX 3 GX 4 GX 5 GX 7 type Frequency Maximum bar(e) (unloading) pressure, Pack Maximum psig (unloading) pressure, Pack Maximum bar(e) 9.75 9.75 9.75 9.75 9.75 (unloading) pressure, Full- Feature Maximum psig (unloading)
- Page 67 Instruction book Compressor GX 2 GX 3 GX 4 GX 5 GX 7 type Power input, Full- 9.25 Feature at maximum working pressure Power input, Full- 6.97 9.25 12.61 Feature at maximum working pressure Power 0.23 0.23 0.23 0.23 0.26 consumption, dryer at full load Power...
- Page 68 Instruction book Compressor type GX 2 GX 4 GX 5 GX 7 Pressure drop over dryer bar(e) 0.15 0.15 0.15 0.25 Pressure drop over dryer psig 2.18 2.18 2.18 3.62 Motor shaft speed 3495 3490 3495 3525 Set-point, thermostatic valve ˚C Set-point, thermostatic valve ˚F...
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Page 69: Instructions For Use
Instruction book Instructions for use Oil separator vessel The vessel can contain pressurised air. This can be potentially dangerous if the equipment is misused. This vessel must only be used as a compressed air/oil separator tank and must be operated within the limits specified on the data plate. No alterations must be made to this vessel by welding, drilling or other mechanical methods without the written permission of the manufacturer. -
Page 70: Guidelines For Inspection
Instruction book Guidelines for inspection Guidelines On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this compressor. -
Page 71: Pressure Equipment Directives
Instruction book 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: safety valves. See the spare parts book for part numbers. Overall rating The compressors conform to PED smaller than category I. 2920 7105 31... -
Page 72: Declaration Of Conformity
Instruction book 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 2920 7105 31... - Page 73 Instruction book On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards that have been used for the design are shown and/or referred to. The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied with this device.
- Page 76 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.