Atlas Copco G 15L Instruction Book
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Atlas Copco G 15L Instruction Book

Atlas Copco G 15L Instruction Book

Oil-injected screw compressors
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Oil-injected screw compressors
G 15L, G 22

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Summary of Contents for Atlas Copco G 15L

  • Page 1 Instruction book Oil-injected screw compressors G 15L, G 22...
  • Page 3 Atlas Copco Oil-injected screw compressors G 15L, G 22 Instruction book Original instructions 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.

  • Page 4: Table Of Contents

    Instruction book Table of contents Safety precautions ...................... 5 SAFETY ICONS ............................5 GENERAL SAFETY PRECAUTIONS ......................5 SAFETY PRECAUTIONS DURING INSTALLATION .................. 6 SAFETY PRECAUTIONS DURING OPERATION ..................7 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR ............8 DISMANTLING AND DISPOSAL ....................... 10 General description ....................
  • Page 5 Instruction book 3.10 CALLING UP RUNNING HOURS ......................33 3.11 CALLING UP MOTOR STARTS ........................ 33 3.12 CALLING UP MODULE HOURS ....................... 34 3.13 CALLING UP LOADING HOURS ......................34 3.14 CALLING UP LOAD SOLENOID VALVE ....................35 3.15 CALLING UP/RESETTING THE SERVICE TIMER .................. 35 3.16 CALLING UP/MODIFYING PRESSURE BAND SELECTION ..............
  • Page 6 Instruction book DRIVE MOTOR ............................59 OIL SPECIFICATIONS ..........................59 OIL, FILTER AND OIL SEPARATOR CHANGE ..................60 PDX/DDX FILTER CHANGE (OPTION) ....................62 STORAGE AFTER INSTALLATION ......................63 SERVICE KITS ............................63 DRAINING CONDENSATE FROM THE OIL TANK ................. 63 DISPOSAL OF USED MATERIAL ......................

  • Page 7: Safety Precautions

    Instruction book Safety precautions Safety icons Explanation Danger to life Warning Important note General safety precautions The operator must employ safe working practices and observe all related work safety requirements and regulations. If any of the following statements does not comply with the applicable legislation, the stricter of the two shall apply.

  • Page 8: Safety Precautions During Installation

    Instruction book If compressed air is used in the food industry and more specifically for direct food contact, it is recommended, for optimal safety, to use certified Class 0 compressors in combination with appropriate filtration depending on the application. Please contact your customer center for advice on specific filtration.

  • Page 9: 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. If the ground is not level or can be subject to variable inclination, consult the manufacturer. 18.

  • Page 10: Safety Precautions During Maintenance Or Repair

    Instruction book 11. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be protected by a pressure relieving device or devices as required. 12.
  • Page 11 Instruction book 17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separator vessel for carbon deposits; if excessive, the deposits should be removed. 18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering them, e.g.

  • Page 12: Dismantling And Disposal

    Instruction book Dismantling and disposal Dismantling Once the end of life of the machine is reached, please follow next steps: Stop the machine. Check all safety precautions mentioned in the previous chapters to secure safe handling (e.g. LOTO, cool-down, depressurize, discharge, ...). Separate the harmful from the safe components (e.g.

  • Page 13: General Description

    Floor mounted models Floor mounted G 15L-22 are available in Pack and Full- Feature version. A free-standing refrigerant dryer, matching the compressor capacity is available for each compressor size. Figure 1: Front view, G 15L-22 Floor Mounted...
  • Page 14 Instruction book Figure 2: Rear view, G 15L-22 Floor Mounted Reference Description Compressor element Motor Electronic controller Emergency stop button 9095 1100 81...
  • Page 15 Tank mounted G 15-22 include a 500 L air receiver and are available in Pack and Full- Feature version. On the Full-Feature version of Tank mounted models, the dryer (DR) is positioned aside of the compressor. Figure 3: Front view, G 15L-22 Full Feature Tank Mounted Reference...

  • Page 16: Operating Principle

    Instruction book Operating principle Pack units Figure 4: Flow diagram, Pack units Air flow 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 17 Instruction book Full-Feature Figure 5: Flow diagram, Full-Feature units Air flow 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 18 Instruction book Figure 6: Flow diagram, tank mounted Full-Feature units Air flow 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 19: Regulating System

    Instruction book Regulating system Figure 7: Detail view of unloader assembly (UA) The main components of the regulating system are: • Unloader (UA), including inlet valve (IV) and unloading valve (UV). • Loading solenoid valve (Y1). • The BASE controller that regulates the compressor based on the pressure settings and readings of the pressure sensor.

  • Page 20: Air Dryer

    Instruction book Air dryer Figure 8: Air dryer (Full-Feature compressors) Wet compressed air (B) enters the dryer and 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 21: Electrical Diagrams

    Instruction book Electrical diagrams The complete electrical diagram can be found in the electric cubicle supplied with the machine. 9097511411 Service diagram G 15L, G 22 Figure 10: Service diagram 9095 1100 81...

  • Page 22: Elektronikon Tm Base Controller

    Instruction book Elektronikon Base controller Controller functions General Introduction The Elektronikon Base controller has following functions: • Controlling the compressor • Protecting the compressor • Monitoring service intervals • Automatic restart after voltage failure (made inactive). Automatic control of the compressor The controller maintains the net pressure between programmable limits by automatically loading and unloading the compressor.
  • Page 23 Instruction book Shutdown If the compressor element outlet temperature exceeds the programmed shutdown level or the overload relay of the main motor trips, the compressor will be stopped. This will be indicated on the display of the controller. Service warning If the service timer exceeds the preset value, the controller advises the operator via the display, to carry out the service maintenance.

  • Page 24: Control Panel

    Instruction book Control panel Detailed description Figure 11: Control panel of the Elektronikon Base Controller Reference Designation Function Display Shows icons and operating conditions. Indicates that the voltage is switched on. LED, Voltage on Keep pressed for 3 seconds to start compressor. Press to stop compressor if running.

  • Page 25: Icons Used On The Display

    Instruction book Icons used on the display Function Icon Description When the compressor is stopped, the icon stands still. Stopped/Running When the compressor is running, the icon is rotating. Motor stopped Running unloaded Compressor status Running unloaded (blinking for manual stop) Running loaded Machine control mode Remote start/stop active...

  • Page 26: Main Screen

    Instruction book Function Icon Description Motor A time/delay parameter is displayed. NOTE: • x1000: ON if the displayed value is in thousands of hrs: ON if the displayed value is in hours • s: ON if the displayed value is in sec •...

  • Page 27: Menu Function

    Instruction book Menu function To switch on the compressor, press start/stop button (3) for 3 seconds. The compressor starts and the status is shown: Figure 14: Screen with running compressor To stop the compressor, push start/stop button (3). The compressor unloads: Figure 15: Screen with unloading compressor When the unload time is elapsed, the compressor is stopped and the controller goes back to main screen: Figure 16: Main screen with pressure (stopped compressor)
  • Page 28 Instruction book Figure 17: First screen of main menu It is possible to scroll in the menu with the up or down buttons (4-8). To select one item, push the enter button (7). To end the current action push start/stop (3) button. If the emergency stop button is pushed, the compressor stops immediately, and the following screen will appear: Figure 18: Emergency stop...

  • Page 29: Shutdown Warning

    Instruction book Shutdown warning Description A shutdown warning will appear in the event of: • A too high temperature at the outlet of the compressor element. Compressor element outlet temperature • If the outlet temperature of the compressor element exceeds the shutdown warning level (factory set at 110˚C/ 230˚F), warning LED (5) is on.

  • Page 30: Shutdown

    Instruction book Shutdown Description The compressor will shutdown: • In case the temperature at the outlet of the compressor element exceeds the shutdown level (detected by temperature sensor (TT11) or by temperature switch (TSHH11)). • In case of error of the outlet pressure sensor (PT20) or temperature sensor (TT11). •...
  • Page 31 Instruction book Motor overload In the event of motor overload: • The compressor will shutdown. • Alarm LED (5) will flash. • The following screen will appear: Figure 22: Main screen with shutdown indication, motor overload • Contact you dealer for fault troubleshooting •...

  • Page 32: Service Warning

    Instruction book Service warning Description A service warning will appear when the service timer has reached the preset time interval. If the service timer exceeds the programmed time interval, alarm LED (6) is blinking with a following screen: Figure 24: Blinking screen •...

  • Page 33: Scrolling Through All Screens

    Instruction book Scrolling through all screens Control panel Figure 26: General overview of the menu structure From the Main screen press the enter button (7) for 3 seconds to enter the Menu. You will find the following items: • Data menu: Data counters parameters. •...
  • Page 34 Instruction book Overview of the screens Menu item Submenu Digital input screen Designation <d.1> Calling up running hours <d.2> Calling up motor starts <d.3> Calling up module hours <dAtA> Data <d.4> Calling up loading hours <d.5> Calling up load solenoid valve <d.6>...

  • Page 35: Calling Up Running Hours

    Instruction book 3.10 Calling up running hours Starting from the Main screen: • Press Enter button (7) for 3 seconds to enter the Main menu. • Select <dAtA> and press Enter button (7) to enter the Data menu. • Scroll Up or Down buttons (4-8) until <d.1> and the motor stopped symbol is shown. •...

  • Page 36: Calling Up Module Hours

    Instruction book 3.12 Calling up module hours Starting from the Main screen: • Press Enter button (7) for 3 seconds to enter the Main menu. • Select <dAtA> and press Enter button (7) to enter the Data menu. • Scroll Up or Down buttons (4-8) until <d.3> and <hrs> is shown. •...

  • Page 37: Calling Up Load Solenoid Valve

    Instruction book 3.14 Calling up load solenoid valve Starting from the Main screen: • Press Enter button (7) for 3 seconds to enter the Main menu. • Select <dAtA> and press Enter button (7) to enter the Data menu. • Scroll Up or Down buttons (4-8) until <d.5>...

  • Page 38: Calling Up/Modifying Pressure Band Selection

    Instruction book 3.16 Calling up/modifying pressure band selection Starting from the Main screen: • Press Enter button (7) for 3 seconds to enter the Main menu. • Select <ProG> and press Enter button (7) to enter the Programming menu. • After <PASS>...

  • Page 39: Calling Up/Modifying The Unit Of Temperature

    Instruction book 3.18 Calling up/modifying the unit of temperature The unit of temperature measurement can only be changed when the compressor is stopped. Starting from the Main screen: • Press Enter button (7) for 3 seconds to enter the Main menu. •...

  • Page 40: Activating Automatic Restart After Voltage Failure

    Instruction book 3.21 Activating automatic restart after voltage failure Description This function allows the compressor to restart automatically after voltage failure. The activation can only be done by your dealer. Please contact him for further details. After any power failure, before restarting, the compressor will wait for a fixed time. When delay time is running, the display will show the related countdown value as below: Figure 27: Example countdown delay time of automatic restart after power failure.

  • Page 41: 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 if operating at high altitude, consult Atlas Copco. Moving/lifting The compressor can be moved by a lift truck using the slots in the frame. Make sure that the forks protrude from the other side of the frame.
  • Page 42 Instruction book Installation proposal Figure 29: Installation proposal, G 15L-22 9095 1100 81...
  • Page 43 Instruction book Step Action Compressor unit: 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). The air receiver must not be bolted to the floor. The pipes between a floor- mounted compressor and air receiver are hot.

  • Page 44: Dimension Drawings

    9097 5114 72 G 15L-22 Pack, tank mounted 500L 9097 5114 73 G 15L-22 Full Feature, floor mounted 9097 5114 74 G 15L-22 Full Feature, tank mounted 500L Text on drawings Translation or explanation Emergency stop switch Emergency stop switch...
  • Page 45 Instruction book Figure 30: Dimension drawing G 15L-22 Pack, Floor Mounted 9095 1100 81...
  • Page 46 Instruction book Figure 31: Dimension drawing G 15L-22 Pack, Tank Mounted 500L 9095 1100 81...
  • Page 47 Instruction book Figure 32: Dimension drawing G 15L-22 Full-Feature, Floor Mounted 9095 1100 81...
  • Page 48 Instruction book Figure 33: Dimension drawing G 15L-22 Full-Feature, Tank Mounted (500L) 9095 1100 81...

  • Page 49: Electrical Connections

    Fit fuses in the incoming wiring. Check the condition of all incoming wiring and make connections. Service diagram The service diagram can be found in electric cubicle supplied with the unit. Model Service diagram number G 15L-22 9097 5114 11 9095 1100 81...

  • Page 50: Pictographs

    Instruction book Pictographs Figure 34: Pictographs Ref. Description Manual condensate drain Automatic condensate drain Warning: voltage Warning: switch off the voltage and depressurize compressor before repairing Warning: before connecting compressor electrically, consult Instruction book for motor rotation direction Torques for steel (Fe) or brass (CuZn) bolts Consult instruction book before replacing the oil Lightly oil gasket of oil filter, screw it on and tighten by hand (approx.

  • Page 51: Operating Instructions

    Instruction book Operating instructions Initial start-up Safety The operator must apply all relevant Safety precautions. General preparation Step Action Consult the installation instructions (see Installation proposal). 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 52 Instruction book Start-up Figure 36: Label on the top 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 (consult Dimension drawings).

  • Page 53: Starting

    Instruction book Starting Starting the air dyer Step Action Switch on the voltage to the dryer and start it by moving switch 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.
  • Page 54 Instruction book Figure 40: Position of oil sight glass and filler plug Figure 41: Control panel 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). Push the start button (6).
  • Page 55 Instruction book Step Action The maximum number of motor starts must be limited to 20 per hour. It is strongly recommended to operate the compressor with a load factor of more than 10% to avoid condensate in the oil. Regularly check the oil level. 10 to 15 minutes after stopping, the sight glass (SG) should be between 1/4 and 3/4 full.

  • Page 56: Stopping

    Instruction book Stopping Figure 42: Air outlet valve Figure 43: Condensate drain valve on air receiver Figure 44: Control panel 9095 1100 81...

  • Page 57: Taking Out Of Operation

    Instruction book Step Action Push the start/stop button (6) on the controller. The compressor will unload. When the unload time is elapsed, the compressor is stopped and the controller goes back to the main screen. To stop the compressor immediately in the event of an emergency, press button (S3). See section Control panel.
  • Page 58 Instruction book Figure 47: 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. Depressurize the compressor by opening plug (3) one turn.

  • Page 59: 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 60 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 if a service timer setting has to be changed.

  • Page 61: Drive Motor

    Note: The presence of dust and/or high humidity may require a shorter exchange interval. Consult Atlas Copco. Atlas Copco's Roto-Inject Fluid Ndurance is a premium mineral oil based 2000 hours lubricant, specially developed for use in single stage oil-injected screw compressors running in mild conditions. Its specific formulation keeps the compressor in excellent condition.

  • Page 62: Oil, Filter And Oil 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. Figure 48: Location of oil filter, and oil separator...
  • Page 63 Instruction book Step Action Run the compressor for a few minutes. Stop the compressor and wait a few minutes to allow the oil to settle. If the oil level is too low, depressurize the system by unscrewing filler plug (8) one turn to permit any pressure in the system to escape.

  • Page 64: Pdx/Ddx Filter Change (Option)

    Instruction book PDX/DDX filter change (option) PDX/DDX filters Figure 49: Oil filler plug Figure 50: Drain valve, air receiver Step Action Stop the compressor, close the air outlet valve, switch off the voltage and depressurize by unscrewing oil filler plug (3) one turn to permit any pressure in the system to escape. See section Stopping.

  • Page 65: 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 66: Disposal Of Used Material

    Instruction book Proceed as follows: Step Action Stop the machine, turning in “OFF” position the isolating switch. Press the button switch (on the dryer if fitted). Turn on the differential supply switch, (on the screw-compressor) and (on the dryer if fitted). Disposal of used material Used filters or any other used material (e.g.

  • Page 67: Adjustments And Servicing Procedures

    Instruction book Adjustments and servicing procedures Air filter Changing the air filter Figure 52: Air filter (1) Procedure: Step Action Stop the compressor, close the air outlet valve and switch off the voltage. Remove the front panel and maintenance cover on the left panel of the compressor housing.

  • Page 68: Coolers

    Instruction book Coolers Figure 53: Oil cooler Step Action Stop the compressor, close the air outlet valve and switch off the voltage. Remove the rear panel. Remove any dirt from the cooler (Co) with a fibre brush. Never use a wire brush or metal objects.

  • Page 69: Safety Valve

    Instruction book Safety valve General The oil separator vessel is protected by a safety valve. A separate safety valve protects the air receiver on tank mounted units. Operation From time to time, operate the safety valve, depending on the type of valve: •...

  • Page 70: Belts Maintenance

    Instruction book Belts maintenance Read the warning in the Preventive maintenance schedule section. Tensioning Figure 54: Belt tensioning components Belt tensioning procedure Step Action Stop the compressor, close the air outlet valve and switch off the voltage. Remove the cover on the right-side panel. Loosen bolts (1), (2), (3) and (4) by one turn.
  • Page 71 Instruction book Belt replacement procedure The belts must always be replaced as a set, even if only one of the belts is worn. Only use genuine Atlas Copco belts. Step Action Stop the compressor, close the air outlet valve and switch off the voltage.

  • Page 72: Problem Solving

    Instruction book Problem solving Attention Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product Liability. Apply all relevant Safety precautions during maintenance or repair. • Stop the compressor before carrying out any maintenance or repair work on the compressor.
  • Page 73 Check and correct as Oil level too low necessary Cooler clogged Clean cooler Temperature switch malfunctioning Test the switch Compressor element (E) out of order Consult Atlas Copco Table 1: Compressor Condition Fault Remedy Hot-gas by-pass valve malfunctioning; No compressed air passes...

  • Page 74: Technical Data

    Instruction book Technical data Electric cable size Attention • The voltage on the compressor terminals must not deviate more than 10% from the nominal voltage. • It is however highly recommended to keep the voltage drop over the supply cables at nominal current below 5% of the nominal voltage (IEC 60204-1).
  • Page 75 Instruction book Installation method B2 according to table B.52.1. Multi-core cable in conduit on a wooden wall. Maximum allowed current in function of the ambient temperature for installation method C. Cable section Ambient temperature 30 °C 40 °C 45 °C 50 °C 55 °C 4 mm²...

  • Page 76: Back-Up Fuse Rating

    Instruction book Calculation method for IEC: • Single supply cables (3 phases + PE - configuration (1)): • Add 10 % to the total compressor current (ItotPack or ItotFF from the tables) • Install the prescribed fuse on each cable •...

  • Page 77: Reference Conditions And Limitations

    Instruction book Reference conditions and limitations Reference conditions Air inlet pressure (absolute) Air inlet pressure (absolute) 14.5 Air inlet temperature ˚C Air inlet temperature ˚F Relative humidity Working pressure bar(e) Compressor data Working pressure Compressor data Limitations Maximum working pressure bar(e) Compressor data Maximum working pressure...

  • Page 78: Compressor Data

    Instruction book Compressor data 50Hz P FM Pressure Model Cooling Elektronikon (Bar) G15L Basic G15L Basic G15L Basic Basic Basic Basic Basic Basic Basic 50Hz FF TM Pressure Model Cooling Dryer Elektronikon (Bar) G15L IDF65 Basic G15L IDF65 Basic G15L IDF65 Basic IDF65...
  • Page 79 Instruction book G 15L Compressor type G 15L Frequency Voltage Maximum (unloading) bar(e) pressure, Pack Maximum (unloading) psig pressure, Pack Maximum (unloading) bar(e) 7.25 9.75 12.75 pressure, Full-Feature Maximum (unloading) psig pressure, Full-Feature Nominal working pressure bar(e) 12.5 Nominal working pressure...
  • Page 80 Instruction book Compressor type G 15L Refrigerant quantity, Workplace 0.75 Full-Feature units Oil capacity Oil capacity US gal Sound pressure level (ISO 2151 - dB(A) 2004) G 18 (under reference conditions) Compressor type G 18 Frequency Voltage Maximum (unloading) bar(e)
  • Page 81 Instruction book Compressor type G 18 Nominal motor power rating 18.5 Nominal motor power rating Dryer power consumption at full 1.26 load, Full Feature units Dryer power consumption at full 1.689 load, Full Feature units Dryer power consumption at no 1.055 load, Full Feature units Dryer power consumption at no...
  • Page 82 Instruction book Compressor type G 22 Temperature of air leaving outlet valve (approx.), Full- ˚C Feature Temperature of air leaving outlet ˚F valve (approx.), Full- Feature Pressure dew point, Workplace ˚C Full- Feature units Pressure dew point, Workplace ˚F 44.6 Full- Feature units Nominal motor power rating Nominal motor power rating...

  • Page 83: Instructions For Use

    Customer shall ensure yearly service inspection to be done by competent professional under relevant law or by Atlas Copco professional, as internal corrosion can reduce the steel wall thickness with the consequent risk of bursting leading to serious risk of injury or damage to person or property.
  • Page 85 atlascopco.com...

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G 22

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