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Instruction book Oil-injected screw compressors G 2, G 3, G 4, G 5, G 7...
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Atlas Copco Oil-injected screw compressors G 2, G 3, G 4, G 5, G 7 Instruction book Original instructions WARNING Read all safety warnings, instructions, illustrations and specifications provided with this product. Failure to follow all instructions listed in this instruction book may result in personal injury, death and/or property damage.
Instruction book Table of contents Safety precautions......................5 Safety icons..........................5 General safety precautions....................5 Safety precautions during installation................6 Safety precautions during operation..................8 Safety precautions during maintenance or repair.............. 9 Dismantling and disposal......................10 General description...................... 12 Introduction..........................12 Air flow............................. 14 Oil system..........................17 Cooling system.........................19 Regulating system........................
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Instruction book Warning............................. 34 Shutdown..........................35 Service warning........................38 Remote control........................38 Scrolling through screens....................39 3.10 Calling up/ modifying pressure band settings..............39 3.11 Calling up running hours.......................41 3.12 Calling up Software release....................42 3.13 Calling up Bluetooth pairing/ discovery mode..............42 3.14 Advanced menu.........................
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Instruction book Maintenance........................68 Preventive maintenance schedule..................68 Drive motor ..........................69 Oil specifications........................70 Oil, filter and separator change ..................72 Storage after installation....................73 Service kits..........................73 Adjustments and servicing procedures..............74 Air filter............................74 Coolers............................. 75 Safety valve ..........................75 Belt set exchange and tensioning ..................77 Problem solving......................79 Technical data.......................
Instruction book Safety precautions Safety icons DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. NOTICE Indicates a potential situation which, if not avoided, might result in property damage or in an undesirable result or state.
Instruction book • Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme caution and wear eye protection. •...
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Instruction book • Place the machine where the ambient air is as cool and clean as possible. If necessary, install a suction duct. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture via the inlet air. •...
Instruction book 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. Some precautions are general and cover several machine types and equipment;...
Instruction book • Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book must be respected. Local regulations remain applicable if they are more strict. NOTE Also consult the following safety precautions: Safety precautions during operation and Safety precautions during maintenance or repair. These precautions apply to machinery processing or consuming air or inert gas.
Instruction book • Make sure that no tools, loose parts or rags are left in or on the machine. • When replacing the air filter, make sure no dirt, dust, rags, tools or loose parts can fall in the air inlet.
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Instruction book 1. Stop the machine. 2. Check all safety precautions mentioned in the previous chapters to secure safe handling (e.g. LOTO, cool-down, depressurize, discharge, etc.). 3. Have trained personnel dismantle the installation. 4. Separate the harmful from the safe components (e.g. drain oil from parts containing oil). 5.
Instruction book General description Introduction Introduction G 2, G 3, G 4, G 5 and G 7 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.
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Instruction book Reference Description Electric cabinet 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) or 500 l (132 US gal / 110 Imp gal / 17.50 cu.ft) and are available in Pack and Full-Feature version. Figure 2: G 7, Full-Feature, tank-mounted Reference Description...
Instruction book Air flow Pack Figure 3: Floor-mounted 2920 7199 12...
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Instruction book Figure 4: Tank-mounted 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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Instruction book Full-Feature Figure 5: Tank-mounted 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.
Instruction book Oil system Figure 6: Pack 2920 7199 12...
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Instruction book Figure 7: 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.
Preventive maintenance schedule. The dryer (DR) of Full-Feature versions has a separate cooling fan and an automatic condensate drain (see also section Air dryer). Regulating system Main components G 2 up to G 4 2920 7199 12...
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Instruction book The main components of the regulating system are: • Blow-off valve (Y1) • The controller that starts/stops the compressor based on the pressure settings and readings of the pressure sensor. As long as the working pressure is below the preset maximum, the compressor will run fully loaded (100% output) and the blow-off valve will be closed.
Instruction book Loading If the working pressure is below the preset maximum, the solenoid valve (Y1) is energized and therefore closed. There is no signal air flow into unloader allowing the inlet valve to open due to the element suction. The inlet valve opens completely allowing the air through the air filter (AF) and the compressor will run fully loaded (100% output).
Instruction book Reference Description Electric cabinet Controller Emergency stop button Electrical system Electrical components Figure 11: Electrical cubicle IEC (DOL and YD) 2920 7199 12...
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G 4 – G 5 – G 7 YD IEC 2205 0362 00 G 2 – G 4 – G 5 – G 7 DOL UL 2205 0362 30 G 2 – G 4 – G 5 – G 7 DOL CSA The complete electrical diagram can be found in the electric cubicle.
Instruction book Protection of the compressor Figure 13: Safety valve on the compressor Figure 14: Safety valve on the compressor - Detail 2920 7199 12...
Instruction book Figure 15: Safety valve on the air receiver (tank-mounted units) Reference Description Function To protect the air outlet system if the outlet pressure Safety valve exceeds the operning pressure of the valve. Air dryer Figure 16: Air dryer Wet compressed air (B) enters the dryer.
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Instruction book cold, dried air then flows through the heat exchanger (3), where it is warmed up by the incoming air, then finally discharged from the dryer outlet (4). 2920 7199 12...
Instruction book Controller Controller functions ® ™ Figure 17: Elektronikon Nano controller Introduction The controller has the following functions: • Controlling the unit • Protecting the unit • Monitoring components subject to service • Automatic restart after voltage failure (ARAVF) •...
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Instruction book WARNING A number of time-based automatic start/stop commands may be programmed. Take into account that a start command will be executed (if programmed and activated), even after manually stopping the unit. Protecting the unit Shutdown If the outlet element temperature exceeds the programmed shutdown level, the unit will be stopped. This will be indicated on the display of the controller.
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Instruction book activation and use. For this reason due to the safety implications of this function it will be required that, before activating it, every responsible of the machine signs a declaration, which exempts your supplier from every liability. The danger is due to the fact that the machine is remote controlled and could start running without any notice.
Instruction book Control panel Figure 19: Control panel Reference Designation Function Shows the unit operating condition Display and a number of icons to navigate through the menu. Flashes in case of a shutdown, is Warning sign lit in case of a warning condition. Is lit when service is needed and Service sign flashing when the unit is in service...
Instruction book Icons used Status icons Icon Description Motor stopped Running unloaded Running loaded On: Remote Machine Control Mode, active: compressor can start from Bluetooth or via external switch if wired. Automatic Restart After Voltage Failure, active Emergency stop Main motor Element outlet temperature Units of pressure, outlet Units of temperature, outlet...
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Instruction book Icon Description Multiply value x1000 Value in hours Value in seconds Fixed: Week timer, active Blinking: Waiting Fixed: LAN cable connected Blinking: LAN cable not connected Bluetooth connection: appears only when controller is paired to the app through Bluetooth. Wi-Fi signal 100% Wi-Fi signal 75% Wi-Fi signal 50%...
Instruction book Main screen When the voltage is switched on, the first screen is a test screen. The next screen is the Main screen, shown automatically: The Main screen shows: • The unit status by means of pictographs • The air outlet pressure •...
Instruction book Figure 20: Main screen with temperature outlet warning The related pictograph will appear flashing with the temperature unit °C / °F icon. • It remains possible to scroll through other screens, using the scroll buttons up and down (6 and 8) to check the actual status of other parameters.
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Instruction book Figure 21: Main screen with temperature outlet shutdown The related pictograph will appear flashing with temperature unit °C / °F icon. Press the scroll buttons (6-8) until the actual compressor element temperature appears. The screen shows that the temperature at the outlet of the compressor element is 117 ˚C. •...
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Instruction book The related pictograph will appear flashing. Error pressure/temperature sensor In case of an error of the outlet pressure sensor (PT20) or temperature sensor (TT90), the compressor will shut down. The following screen will appear: Figure 23: Error on pressure and temperature sensor Compressor outlet pressure too high If the outlet pressure of the compressor exceeds the shutdown level (factory setting 1.5 bar / 22 psi over the maximum pressure of compressor) the compressor will be shutdown, the alarm LED (2)
Instruction book Motor overload In the event of motor overload, the compressor will shut down, the alarm LED (2) will flash, the automatic operation LED (4) will go out and the following screen will appear: Figure 25: Main screen with shutdown indication, motor overload •...
Instruction book NOTE Have the modifications checked by your supplier. Stop the unit and switch off the voltage before connecting external equipment. Only potential-free contacts are allowed. WARNING Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine.
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Instruction book Figure 26: Pressure setting screen • Press Enter button (9) to modify. Figure 27: Starting/loading pressure changing • The pictograph shows starting/loading pressure and the value starts blinking. • Press Scroll button (6-8) to modify the starting/loading pressure and press enter button (9) to confirm.
Instruction book Figure 28: Stopping/unloading pressure changing • The pictograph shows stopping/unloading pressure and the value starts blinking. • Press Scroll button (6-8) to modify the stopping/unloading pressure and press enter button (9) to confirm. 3.11 Calling up running hours Starting from the Main screen: •...
Instruction book Figure 30: Running hours value The screen shows the unit used (x1000 hrs) and the value (11.25): the running hours of the unit are 11250 hours. 3.12 Calling up Software release Starting from the Main screen: • Press Scroll button (6-8) until SoFt is shown on the display. Figure 31: Software release screen •...
Instruction book The user enters this code to connect for the first time, after this the application allow automatic Bluetooth connection when the unit is in the range. A short video instruction will guide you through the Smartphone App while proceeding with pairing. Starting from the Main screen: •...
Instruction book • Start/stop from Smartphone App • Timer Schedule • Controller firmware over-the-air (OTA) updates When service mode is active, the service icon (3) is blinking. The only available command during Service Mode is from start/stop button (7) to start the unit. Starting from the Main screen: •...
Instruction book 3.18 Connectivity-Smartphone App The controller has been designed as a standalone Internet of Things (IoT) solution. As such it includes integrated connectivity, which allows you to monitor and control your unit by using just your smartphone. To enable this you just need the SMARTLINK application and an internet connection for your unit. Download the SMARTLINK application from the Play Store and App Store to get the full functionality of the unit.
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Instruction book NOTE Have the modifications checked by your supplier. Stop the unit and switch off the voltage before connecting external equipment. Only potential-free contacts are allowed. In the App you will be able to change the settings of “Wi-Fi” or “Ethernet”, see App guidelines document.
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Instruction book When a firmware update is available, the following icon appears on the unit's screen and a message is shown in your App • Before starting the update, press the emergency stop button on the controller. • Open your App tot start the update procedure. •...
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Instruction book Figure 34: Main screen with timer schedule active 2920 7199 12...
Instruction book Installation Installation proposal 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 your supplier. Moving/lifting Figure 35: Transport by a pallet truck WARNING...
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Instruction book Reference Description Front panel, compressor Dryer Minimum 1.5 m (59 in) Space for maintenance, minimum 1.5 m (59 in) Single-phase dryer supply Three-phase screw compressor supply The power cable should be protected so that it complies with local regulations Condensate drain integrated dryer Condensate drain tank 1.
Instruction book 5. Lay out the condensate drain pipe from the dryer automatic drain (D) as well as the pipe from the manual drain valve underneath the tank (T) towards a drain collector. The drain pipes to the drain collector must not dip into the water of the drain collector. See section Starting for the location of the components.
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(if applicable) to terminal (N). Connect the earth conductor to terminal PE/ GND. Specific voltage change instructions for G 2 – G 7 with 208V / 230V / 460V cubicle The standard voltage configuration for the compressor is mentioned on the data plate of the machine.
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Instruction book The fuses are supplied with the compressor. Motor terminal bridge configuration: Factory standard connection is 230V and can be changed to 208V or 460V. Terminal bridges (1) can be removed using a pair of pliers. Voltage stickers: Locate the yellow voltage labels provided with the compressor. Replace the existing label with the appropriate voltage label (208V, 230V or 460V).
Instruction book Pictographs Reference Description Warning: possible air/fluid discharge Warning: voltage Warning: air must not be inhaled Warning: wear ear protectors Warning: machine may start automatically Warning: pressure Warning: hot parts Warning: moving parts Warning: rotating fan Drain the condensate daily and inspect the vessel yearly. Note down the inspection dates.
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Instruction book Reference Description Read the instruction manual before carrying out any maintenance or repair work. Lightly oil gasket of oil filter, screw filter on and tighten by hand. Figure 38: ARAVF label Reference Description ARAVF Automatic restart after voltage failure 2920 7199 12...
Instruction book Operating instructions Initial start-up Safety WARNING The operator must apply all relevant safety precautions. General preparation Figure 39: Air outlet valve on air receiver Figure 40: Condensate drain valve on air receiver 2920 7199 12...
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Instruction book Figure 41: Automatic condensate drain 1. Consult the installation instructions (see Installation proposal). 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.
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Instruction book Figure 42: Air filter Figure 43: Oil level sight-glass 1. Check the oil level. 2. Stop the unit and wait for the foam to disappear (normally about 3 minutes). The oil level should be visible on the sight glass (SG). Never measure the oil level on a unit that has been stopped for more than 10 minutes.
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Instruction book Start-up Figure 44: Start-up sheet Figure 45: Label on the top WARNING All electrical work should be carried out by professionally qualified people. 1. Check that all bodywork panels are fitted. 2. 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).
Instruction book 4. Check the rotation direction of the motor. If the motor rotation direction is correct, the sheet 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 (disconnector) switch (IG) and reverse two phases of the supply cable.
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Instruction book Figure 48: Air outlet valve on air receiver Figure 49: Condensate drain valve on air receiver 1. Before starting, check the oil level in accordance with step 5 of these steps. 2. Switch on the voltage. 3. Open air outlet valve (2). 4.
Instruction book Starting the dryer Figure 50: Dryer on/off switch 1. Switch on the voltage to the dryer and start it by moving switch (3) to position I. WARNING 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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Instruction book Figure 53: Dryer manual drain Figure 54: Dryer on/off switch Figure 55: Control panel 1. On Full-Feature units: move switch (3) of the dryer to position 0. Push the start/stop button (7) on the controller. The compressor will unload. When the unload time has elapsed, the compressor is stopped and the controller goes back to the main screen.
Instruction book To stop the compressor immediately in the event of an emergency, press button (S3), see section Control panel. After remedying the fault, unlock the button by rotating it. NOTE Only use the emergency stop button in the event of an emergency Avoid using the button for normal stopping of the compressor.
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Instruction book Figure 57: Condensate drain valve on air receiver Figure 58: Oil filler plug Figure 59: Dryer manual drain Procedure This procedure should be carried out at the end of the compressor’s service life. 1. On Full-Feature units: move switch (3) of the dryer to position 0. Stop the compressor and close the air outlet valve (2).
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Instruction book 2. Switch off the voltage and disconnect the compressor from the mains. 3. Depressurize the compressor by opening plug (3) one turn. Push condensate manual drain (Dm) for a few seconds to release any condensate from the dryer. Open condensate drain valve (4) of the air receiver.
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 Center may overrule the maintenance schedule, especially the service intervals, depending on the environmental and working conditions of the compressor.
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 DANGER Always consult your supplier if a timer setting has to be changed.
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 4000 hours lubricant, specially developed for use in single stage oil-injected screw compressors running in mild conditions.
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Note: The presence of dust and/or high humidity may require a shorter exchange interval. Consult Atlas Copco. Atlas Copco's Roto Synthetic Fluid XTEND DUTY is a high quality synthetic 8000 hours lubricant for oil injected screw compressors which keeps the compressor in excellent condition. Because of its excellent oxidation stability, Roto Synthetic Fluid XTEND DUTY can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 46 ˚C (115 ˚F).
Instruction book Rotair Foodgrade Fluid Special oil, delivered as an option. Rotair Foodgrade Fluid is a unique high quality synthetic lubricant, specially created for oil-injected screw compressors providing air for the food industry. This lubricant keeps the compressor in excellent condition. Rotair Foodgrade Fluid can be used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 40 ˚C (104 ˚F).
Instruction book Figure 61: Drain valve of air receiver 1. Run the compressor until warm. Stop the compressor, close the air outlet valve and switch off the voltage. (See section Stopping. 2. Remove the front and top panels. 3. Depressurize the compressor by unscrewing filler plug (8) one turn to permit any pressure in the system to escape.
Instruction book Adjustments and servicing procedures Air filter Replacing the air filter Figure 62: Air filter 1. Stop the compressor, close the air outlet valve and switch off the voltage. 2. Remove the front panel and the top panel of the compressor housing. 3.
Instruction book Coolers Cleaning the coolers Figure 63: Oil cooler 1. Keep the oil cooler (Co) clean to maintain the cooling efficiency. 2. Stop the compressor, close the air outlet valve and switch off the voltage. Remove any dirt from the cooler with a fibre brush.
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Instruction book Figure 65: Oil filler plug Testing 1. Before removing the valve, stop the compressor (see section Stopping). On a Full-Feature unit, also stop the dryer. 2. Close the air outlet valve and switch off the voltage. 3. Open drain valves (4) (if applicable) and unscrew filler plug (3) one turn to permit any pressure in the system to escape.
Instruction book Belt set exchange and tensioning Location of parts DANGER Read the warning in section Preventive maintenance. Belt tensioning procedure 1. Stop the compressor, close the air outlet valve and switch off the voltage. For Full-Feature versions: also stop the dryer. (See section Stopping). 2.
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Instruction book 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 fan cowl. 10. Refit the bodywork panels. 11.
Instruction book Problem solving For the location of the components, see sections: • Introduction • Air dryer • Operating instructions Attention WARNING 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.
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Instruction book Condition Fault Remedy Hot-gas by-pass valve No compressed air passes through Pipes are frozen inside malfunctioning; consult Atlas the dryer Copco Insufficient condensate drain Check the operation of timer (T) Check room temperature - air Condensate in the piping The dryer is working outside its temperature at dryer.
Instruction book Technical data Electric cable size Attention DANGER 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.
Instruction book Table 5: Fuse size, IEC Voltage Frequency Fuse size, J or RK5 type (Hz) UL/CSA 230/1 208/3 230/3 460/3 575/3 Table 6: Fuse size, UL/CSA Voltage Frequency F21 setting (Hz) G 4 (DOL) G 4 (YD) 230/1 20.0A 230/3 12.5A 15.5A...
Instruction book Limitations Characteristic Unit Data Maximum working pressure bar(e) See Compressor data Maximum working pressure psig See Compressor data Minimum working pressure bar(e) Minimum working pressure psig Maximum air inlet temperature °C Maximum air inlet temperature °F Maximum ambient temperature °C Maximum ambient temperature °F...
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Instruction book Compressor type Sound pressure level floor-mounted units dB(A) (according to ISO 2151 (2004)) 50 Hz 10 bar Compressor type Frequency Maximum (unloading) pressure, Pack bar(e) Maximum (unloading) pressure, Pack psig Maximum (unloading) pressure, Full-Feature bar(e) 9.75 9.75 9.75 9.75 9.75 Maximum (unloading) pressure, Full-Feature...
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Instruction book Compressor type Set-point, thermostatic valve ˚F Temperature of air leaving receiver (approx.), ˚C Pack Temperature of air leaving receiver (approx.), ˚F Pack Pressure dew-point, Full-Feature ˚C Pressure dew-point, Full-Feature ˚F Power input, Pack at maximum working pressure 4 (3.4*) - Power input, Pack at maximum working pressure 11.3 12.9...
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Instruction book Compressor type Power input, Pack at maximum working pressure 3.9* (only for 230 V / 1-phase units) Power input, Pack at maximum working pressure 5.4* 11.9 (only for 230 V / 1-phase units) Power consumption, dryer at full load 0.24 0.24 0.24...
Instruction book Instructions for use Oil separator vessel The vessel can contain pressurized 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.
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.
Instruction book Pressure equipment directives Components subject to Pressure Equipment Directive (PED) Components subject to 2014/68/EU PED or Pressure Equipment (Safety) Regulations 2016 - S.I. 2016/1105 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 Declaration of conformity Figure 66: Typical example of a Declaration of Conformity document Contact address: Atlas Copco Airpower n.v. P.O. Box 100 B-2610 Wilrijk (Antwerp) Belgium Applicable directives Standards used On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized and/or other standards that have been used for the design are shown and/or referred to.
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