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1) 2008 Instruction Manual for Atlas Copco Compressor Model GX-7

1. 1266 a 640 L 1205 al 1 61 50 590 5 8 Caes F LE A 6 AIR OUTLET delivered A o Tipos loose 9 p 257 66 5 8 D HHHH DRYERAR 3 AME E Sch II Gomm 7 e FE 8 3 E i e T t 8 T 395 LL BLE 420 30 COOLING AR Ze INLET 2 COOLING AR 2 eme e 8 39m 4 p 3 a 1 1 I f md D e moo am cos en i 6 E iD HI T 54 i L 601 159 L 66 80666D L 604 J 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 Motor cooling air inlet oio JO NM A OINI gt Outlet valve delivered loose 2920 7054 00 31 Atlas Copco 3 3 Electric cable size Instruction book Attention Local regulations remain applicable if they are stricter than the values proposed below A 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 GX7 GX 11 Frequency Voltage Cable size Cable size Hz V IEC mm mm 50 200 16 6 XLPE or EPR 25 16 XLPE or EPR 50 230 10 16 10 XLPE or EPR 50 400 4 6 50 500 4 6 60 440 460 4 6 60 380 4 6 CSA UL AWG AWG 60 200 6 6 60 208 230 460 8 8 10 6 6
2. Compressor type GX7 GX11 GX7 GX11 Nominal motor power rating kW 7 5 11 7 5 11 Nominal motor power rating hp 10 15 10 15 Dryer power consumption at full kW 0 44 0 44 0 44 0 44 load Full Feature units Dryer power consumption at full hp 0 59 0 59 0 59 0 59 load Full Feature units Oil capacity 3 3 2 3 3 2 Oil capacity US gal 0 8 0 84 0 8 0 84 Oil capacity Imp gal 0 65 0 7 0 65 0 7 Oil capacity cu ft 0 1 0 11 0 1 0 11 Sound pressure level according dB A 67 68 67 68 to ISO 2151 2004 60 Hz 150 175 psi under reference conditions Compressor type GX7 GX11 GX7 GX11 Frequency Hz 60 60 60 60 Maximum unloading pressure bar e 10 8 10 8 12 5 12 5 Pack Maximum unloading pressure psig 157 157 181 181 Pack Maximum unloading pressure bar e 10 55 10 55 12 25 12 25 Full Feature Maximum unloading pressure psig 153 153 178 178 Full Feature Nominal working pressure bar e 10 3 10 3 12 12 Nominal working pressure psig 149 149 174 174 Set point thermostatic valve jo 75 75 75 75 Set point thermostatic valve F 167 167 167 167 Temperature of air leaving outlet valve approx Pack Tank mounted C 38 43 38 43 e Tank mounted E 100 109 100 109 Floor mounted C 60 66 60 66 e Floor mounted F 140 151 140 151 Temperature of air leaving outlet C 23 25 23 25 valve approx Full Feature Temperature of air leaving outlet F 73 77 73 77 valve approx Full Feature Nominal motor power rating k
3. 1145 60 80664D 2920 7054 00 HHH 344 415 i 601 Atlas Copco 840 s 590 J f 5 270 Manual drain G38 Female 2 GX 7 and GX 11 Tank mounted 500 I optional Full Feature 29 Atlas Copco Instruction book aaa 810 o o O EH me i uo og GX11 i i wo De 65 130 420 130 65 700 640 1 COOLING AIR OUTLET 50 590 e f Ka ol 266 55 2 2 COOLING AIR d ian D EN delivered S 2 loose 9 1 E g T 1 ZP 395 AW ete FEMALE 260 2 COOLING AIR COMPRESSED INLET 2 COOLING AIR AIR OUTLET 350 INLET e 3 ELECTRICAL h CABLE ENTRY a uf wo i iy ii 80665D Hs 5 gt GX 7 and GX 11 Floor mounted Pack 2920 7054 00 Instruction book Atlas Copco
4. 6 4 Unload stop pressure switch Pressure switch GX 7 up to GX 11 2920 7054 00 57 Atlas Copco Instruction book EE aay The switch allows the operator to select the unloading stopping pressure see Regulating system EC 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 See also below drawing The pressure difference between unloading and loading is adjusted by means of the same knob Push down the knob and turn it clockwise to reduce the pressure difference counter clockwise to increase it EN IEC 60947 5 1 AC 15 E CAUTION Pressure setting is only possible when applying pressure to the switch Differential Ap Ap p Cut out pressure Po E Sc P Press wheel downwards qm em Po Po higher 1 SW tum whee to the left tum wheel to the right IAN GPS GER O Ap bower Api apti D 2 tum wheel to the right tum wheel to the left Sapi EE If the spindle moves when lowest possible amp phas been reached In order to loosen tum wheel to the left holding the 80762D spindie tight 58 2920 7054 00 Instruction book Atlas Copco 6 5 Belt set exchange and tensioning 80688F GX 7 and GX 11 d Read the warning in the Preventive maintenance schedule section
5. 80649F Front view GX 7 and GX 11 Full Feature GX 7 and GX 11 are mounted on a large air receiver AR of 270 1 71 28 US gal 59 40 Imp gal 9 45 cu ft or an optional air receiver of 500 1 132 US gal 110 Imp gal 17 50 cu ft 10 2920 7054 00 Instruction book Atlas Copco Ref Name 1 Control panel AF Air filter AO Air outlet AR Air receiver Ca Air cooler Co Oil cooler Da Automatic drain Dm1 Manual condensate drain DR Dryer E Compressor element OF Oil filter OS Oil separator OT 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 GX Pack The compressor is not fitted with an air cooler air dryer and condensate drain system as standard 2920 7054 00 11 Atlas Copco Instruction book 2 2 Air flow Flow diagram 80650D 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 12 2920 7054 00 Instruction book Atlas Copco 80651D Air flow GX 7 and GX 11 Full Feature tank mounted
6. Release the belt tension by loosening tensioning nut 1 a Remove the fan duct 4 Remove the belts Install the new belts Tension belts 3 as described above Re assemble the fan duct 4 the pulley protection and the internal protection panel Re assemble left side and top panel cover 2 O 0O NJ O Check the belt tension after 50 running hours 2920 7054 00 Instruction book 7 Problem solving 7 1 Problem solving Start stop switch Gpa 80656F GX 7 and GX 11 Air outlet valve 80676F GX 7 and GX 11 2920 7054 00 Atlas Copco p Gdp Hm S3 2 61 Atlas Copco Oil filler plug Drain valve air receiver Attention Instruction book 80683F GX 7 and GX 11 GX 7 and GX 11 A 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 Before carrying out any maintenance or repair work on the compressor push the stop button 2 Wait until the compressor has stopped and switch off the voltage See the Stopping section Open the isolating switch to prevent an accidental start Close air outlet valve 2 and depressurise the compressor by opening the oil filler plug 3 one turn Open manual condensate drain valves 4 and or 5 The air outlet valve 2 can be locked during maintenance or repair a
7. Instruction book Atlas Copco Period Running hours Operation Yearly Have the safety valve tested Have the operation of sensors electrical interlockings and components checked Have the temperature shut down switch tested 4000 Replace the air filter 4000 Replace the oil filter 4000 Replace the oil separator 4000 For compressors with PDX filter replace the filter 4000 If Atlas Copco Roto Inject Fluid is used change the oil i 8000 If Atlas Copco Roto Xtend Duty Fluid is used indicated by a specific label on the oil vessel change the oil Clean the compressor 5 2 Drive motor Description The motor bearings are greased for life 5 3 Oil specifications A Never mix oils of different brands or types It is strongly recommended to use Atlas Copco lubricants See Preventive maintenance schedule for recommended oil change intervals 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 Service kits Atlas Copco Roto Xtend Duty Fluid Atlas Copco Roto Xtend Duty Fluid is a high quality synthetic lubricant for oil injected scroll and screw compr
8. The operator must apply all relevant Safety precautions Warranty Product Liability Use only authorised parts Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability General 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 The longer interval checks must also include the shorter interval checks Preventive maintenance schedule for GX 7 and GX 11 50 Period Running hours Operation Daily Check the oil level before starting Drain the condensate after stopping For tank mounted units also drain the air vessel by means of the manual drain valve 4 see Stopping 3 Monthly Check for possible leaks i 1000 Inspect the oil cooler clean if necessary 1000 For Full Feature versions inspect the condenser of the dryer clean if necessary 1000 Inspect the air filter Inspect the condensate trap clean the filter DA for location of DA see Introduction For compressors with PDX filter check the service indicator replace the filter if necessary 1000 Check the tension and the condition of the belts Adjust if necessary 2920 7054 00
9. at O0l0prB2B6 Jakup e x A 403293u02 au A XIYd dHOT ASZS Q0090 v8286 4au403suo4301no akap OISOEPB2g6 avant AIM 3d gt P Aoja4 poo 4a O J4010u JOSSaJduo i Ji OSSOE P8286 J4ossaJduo2 uiu A EE Una dva o SE Se t SUOSJ A 40552Jduo2 Jo Ujou 002 o m d A 44 dH A09 A USADA A de ro up A 403 4 sasny 11 14 MINA dHSI ASS 0990 8 8286 33 dHOT A002 3d Meum ampou jo44u02 vossaudwod 13 d A OESOE P8286 YOSSeAGWOD uu waka 0010778286 JS Sam Dua TA AIVA dH OL A09v 0E2 802 pp90evez86 Ee Ey OI90EP8286 49u4035uo44 Ja Jp ns Surium HSI wien uossaucuo gt ow GeSteyaseg cs aossadduos ume DOSER Jesse MD y A ud A 4010 JOSSaJduo2 TA HIVd dH EI A09b A0 2 A802 Oesoersess dd dHST A002 Instruction book SWVADVIT 32IAS3S AVIN SN ISYYA SMTP a d WNVaDOVIG N LAYa JAL 33S ASA OIJIO3dS HIV JOY ILOJ3NNHO MALIA WdasNa5D Electrical diagram GX 7 and GX 11 CSA UL 39 2920 7054 00 Atlas Copco Instruction book 3 6 Pictographs 40 Hon BH E DO E M As S DNR 13 9 A fon Oe 56667P Pictographs Ref Description 1 Working pressure 2 Hour meter 3 Dew point temperature 4 Start 5 Stop 6 Warning voltage 7 Lightly oil gasket of oil filter screw filter on and tighten by hand 9 Warning switch off voltage and depressurise compressor before carrying out maintenance work 10 Warning hot parts 11 Loc
10. 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 2920 7054 00 13 Atlas Copco Instruction book ENEERKEHS 5 0 0 0 OO 0 2 3 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 the rest is removed by separator OS 14 2920 7054 00 rx rmn Instruction book Atlas Copco LLL AEN The oil system is fitted with a by pass valve BV When the oil temperature is below the set point of the valve the by pass valve shuts off the oil supply from oil cooler The by pass valve starts opening the supply from cooler Co when the oil temperature exceeds the setting of the valve The setting of the by pass valve depends on the model See the section Compressor data 2 4 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 An air cooler Ca is available as option 2920 7054 00 15 Atlas Copco Instruction
11. Checking the belt tension on GX 7 and GX 11 Step Action 1 Stop the compressor close the air outlet valve and switch off the voltage 2 Remove the front door and the internal panel 3 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 4 Refit the bodywork panels Adjusting the tension of the drive belts for GX 7 and GX 11 Step Action 1 Stop the compressor close the air outlet valve and switch off the voltage 2 Remove the front door the internal panel the top cover and the pulley protection 3 Loosen the 4 bolts 2 by one turn 4 Adjust the belt tension by turning tensioning nut 1 5 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 6 Retighten bolts 2 7 Refit the bodywork panels 2920 7054 00 59 Atlas Copco Instruction book Replacing the drive belts for GX 7 and GX 11 60 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 Remove the front door the internal panel the top cover the pulley protection and the left side panel Loosen the 4 bolts 2 by one turn
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13. 1935 500 L 1875 120 Gallons 2920 7054 00 Atlas Copco 63 Female 4 GX 7 and GX 11 Tank mounted 500 I optional Pack COOLING Al INLET 80662D Atlas Copco Instruction book aa ARMES 8 aromer 1 a lt gt s m e 9 delivered E loose o FEMALE COMPRESSED AIR OUTLET 5 fe C 767 3415 Bg 750 Ile 55 1533 d 149 1205 D filum fugas GX der 3 Ple Le 130 420 130 1015 1150 101 5 6B um 801 i i 54 i i J ER D UU S 3 I T EH 80663D E uf D 9 GX 7 and GX 11 Tank mounted 270 I Full Feature 28 2920 7054 00 Instruction book 345 m 1205 o m lil 257 665 eme ena di exis t MH HERE Kai 80 500 L 50 120 Gallone n 130 420 130 200 1500 500 L 1440 120 Gallons 200 MOTOR COOLING COOLING ARNET 8 aromer 1 P lt p EZ
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15. 40ssa4duo2 uou AAA piuajs TA SuojSaa 44 N O M HdE ADDS 09v A00p A08 u21IS aunjiv4edue HSI yams aJnssaJd Sd 40310u 40ssauduo2 IW SNOISSSA JAI SWVADVIC 32IAeS AWINDILAVA AHL 33s JSN JIAIDAdS HIVI 8D A oh soni cada ap ure Hat QS ft NIDO 1 209 aaka i i 5 A 5 Y H sta 5 Tg j 118 3 113 I 1 I Fg I e et 1 vi v mi J PE Es Du gt 339 x e SWWAOWIC NNOD N3AB 33S 3d suorsaa gossauduo2 uow Age 404 4ahug T Lei te A TZ XD 403 ANva9Y1d NDIILO3NNDO MAILA Wa83N39 sae SWvHOVIG NNOJ a3WWJSNvSI 83480 NV 83480 335 Susan 0Ssauduoo 40 UDU ANS 40j Alt 80667D Electrical diagram GX 7 and GX 11 IEC 2920 7054 00 38 Atlas Copco er tr ol 6 8 d i 9 S v e T 01 eor TOI 001 66 SOLOW M3YIS zs 888 8 ER KE Eg S 2 es s 13231 18 zl e ES S z Ej IW l a e Bs a z 8 m e 52 T m lt E El EO b S e kg 1 Ji a re 001 66 T T Te Iflo TA T Ki Dr TU me ox 2 12 iet t T M UO o ja Im zh 2 gv ev 2v jew CI 5 3 mi l SU gt K H L 24 Ave UA u o j tfiv fiv fiy 2
16. ArAAr AARAA COACE DAERA CCA r Annn A AEE C AEn n ennnen 53 5 6 STORAGE AFTER INSTALLATION ceccceccecececcececeeceuecuceceeeueececeeeeeeeaueeueeeeeeaeeeaeeaeeeaeeueeaeeeaeeaeesaneaeeeaeenaeeas 54 5 7 SI C Un M AD e AD Ene 54 6 Adjustments and servicing procedures eeeeeeneeneennenennnnnnnnnnnnnnn 55 6 1 PUE EIEIBR S E E o IU ELEM Ee 55 6 2 COOPERS PHAR HP HERE 56 6 3 SAFE RT RECEPERAT 56 6 4 UNLOAD STOP PRESSURE SWITCH cceeeeeI IRI em ene EEN mese RER REEL EL ese ese ese re sre tere eret rre ener ene teneras 57 6 5 BELT SET EXCHANGE AND TENSIONING ee eene ener nemen mee eee ee re rre tret rere rre ressentir sens nnne 59 7 Problem solvind MeeR TED a 61 7 1 PROBLEMS INC corintio 61 8 DI EC EE 64 8 1 READINGS ON CONTROL PANEL intorn rrene Ao EE EEA AE REDERE EAA CRECE EAER ADEE PEEAEE REDEE PEERKE REDEE Enna 64 8 2 SETTINGS FOR OVERLOAD RELAY AND EUSES 65 8 3 REFERENCE CONDITIONS AND LIMITATIONS ssassoiseneekenonnttntortr trette torr r rAr EErEE EEAA DEERE ERE DEEDEE EREE ennn nnne 65 8 4 COMPRESOR DA NUNT a a a O 66 9 Instructions for use of air FECEIVEN c cccccceeeceeccecceesesueeeeeueeeueeeeeueeeauseueenaeeueeueeeeesans 70 9 1 INSTRUCTIONS FOR USE tooro nn nren AoAo APAE EAE CoE DEADE EREE EAE CADRE EEEERE DEE OEEDE EREE CE OOED EEERE CRECE DEERE 70 10 PED E E E EA UU dias 71 2920 7054 00 3 mmm CC O O Atlas Copco Instruction book Say 10 1 PRESSURE EQUIPMENT DIRECTI
17. The operator must employ safe working practices and observe all related local work safety requirements and regulations Ifany of the following statements does not comply with local legislation the stricter of the two shall apply Installation operation maintenance and repair work must only be performed by authorised trained specialised personnel The compressor is not considered capable of producing air of breathing quality For air of breathing quality the compressed air must be adequately purified according to local legislation and standards Before any maintenance repair work adjustment or any other non routine checks stop the compressor press the emergency stop button switch off the voltage and depressurise the compressor In addition the power isolating switch must be opened and locked 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 Precautions during maintenance or repair Cho ANS Always wear safety glasses Use only the correct tools for maintenance and repair work Use only genuine spare parts All maintenance work shall only be undertaken when the machine has cooled down A warning sign bearing a legend such as work in progress do not start shall be attached to the starting equipment Persons switching on remotely controlle
18. by people cannot be sucked in Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under heat and that it is not in contact with or close to flammable materials No external force may be exerted on the air outlet valve the connected pipe must be free of strain If remote control is installed the machine must bear a clear sign stating DANGER This machine is remotely controlled and may start without warning The operator has to make sure that the machine is stopped and that the isolating switch is open and locked before any maintenance or repair As a further safeguard persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine To this end a suitable notice shall be affixed to the start equipment Air cooled machines must be installed in such a way that an adequate flow of cooling air is available and that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet The electrical connections must correspond to the local codes The machines must be earthed and protected against short circuits by fuses in all phases A lockable power isolating switch must be installed near the compressor On machines with automatic start stop system or if the automatic restart function after voltage failure is activated a sign stating This machine may start without warning must be affixe
19. check capacity of compressor room fan Oil level too low Check and correct as necessary Cooler clogged Clean cooler Temperature switch malfunctioning Have switch tested Compressor element E out of order Consult Atlas Copco GX 7 up to GX 11 with air cooler Condition Fault Remedy 1 Condensate is not discharged during loading Discharge flexible clogged Check and correct as necessary Float valve malfunctioning Remove float valve assembly clean or replace as necessary 2920 7054 00 63 8 1 64 Instruction book Technical data Readings on control panel Gpa 807 79F Pressure gauge GX 7 up to GX 11 Haat 55630F Hourmeter 2 Gdp 55631F Dewpoint indicator The readings mentioned below are valid under the reference conditions see Reference conditions and limitations Ref Name Gpa Air outlet pressure Reading Modulates between preset unloading stopping pressure and loading pressure Gdp Dew point temperature Reading approx 5 C 41 F at 20 C 68 F ambient temperature Hm Hour meter Reading Total running time 2920 7054 00 Instruction book 8 2 Settings for overload relay and fuses GX 7 and GX 11 Atlas Copco Frequency Voltage V GX 7 GX 11 Hz IEC Star
20. parts or rags are left in or on the machine All regulating and safety devices shall be maintained with due care to ensure that they function properly They may not be put out of action Before clearing the machine for use after maintenance or overhaul check that operating pressures temperatures and time settings are correct Check that all control and shut down devices are fitted and that they function correctly If removed check that the coupling guard of the compressor drive shaft has been reinstalled 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 Protect the motor air filter electrical and regulating components etc to prevent moisture from entering them e g when steam cleaning Make sure that all sound damping material e g on the bodywork and in the air inlet and outlet systems of the compressor is in good condition If damaged replace it by genuine material from the manufacturer to prevent the sound pressure level from increasing Never use caustic solvents which can damage materials of the air net e g polycarbonate bowls The following safety precautions are stressed when handling refrigerant Never inhale refrigerant vapours Check that the working area is adequately ventilated if required use breathing protection Always wear special gloves In case of refrigerant c
21. relevant safety precautions 2920 7054 00 47 lr 7 Atlas Copco Instruction book ENERKEEEE 1 02025 2005050505 90 4 4 Taking out of operation 80676F Air outlet valve 80683F Filler plug GX 7 and GX 11 This procedure should be carried out at the end of the compressor s service life Step Action 1 Stop the compressor and close the air outlet valve 2 48 2920 7054 00 Instruction book Atlas Copco 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 Drain the oil and condensate circuits Disconnect the compressor condensate outlet and valve from the condensate net 2920 7054 00 49 Atlas Copco 5 5 1 Instruction book Maintenance Preventive maintenance schedule Warning A Before carrying out any maintenance repair work or adjustments proceed as follows Stop the compressor Switch off the voltage and open the isolating switch Close the air outlet valve and open the manual condensate drain valves Depressurise the compressor For detailed instructions see Problem solving
22. the oil level The oil level sight glass SG should be between 1 4 and 3 4 full 42 2920 7054 00 Instruction book Atlas Copco Start up c 5 Put ft WAIT FOR 1 SECOND erus s pagues 1 amera mooo rmerne 8 server T amenpe 1secome a apen 0 nederen T ent sckuspEN WARTEN DR CHEM s mase T s espere s secunna PULSE E Label on the top Step Action 1 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 If the motor rotation direction is correct the label on the top grating will be blown upwards If the sheet remains in place the rotation direction is incorrect see the pictographs on the label If the rotation direction is incorrect switch off the voltage open the isolating switch and reverse two incoming electric lines 2 Start and run the compressor for a few minutes Check that the compressor operates normally 4 2 Starting 2920 7054 00 Air outlet valve 43 Atlas Copco Instruction book Gpa 807 79F Gdp 8068 1F Control panel GX 7 up to GX 11 44 2920 7054 00 Instruction book Atlas Copco Position of oil sight glass and filler plug on GX 7 and GX 11 Step Action Before star
23. 1 with the 10 3 x 38mm 1 A or 2 A fuses provided see further Modify the motor terminal bridge configuration in the main cubicle for the desired voltage Replace the voltage sticker by the appropriate voltage sticker provided Oc cg gt On FF units replace the power fuses F10 in the main cubicle F11 in the power transformer cubicle with the CC type 5 A respectively 7 5 A fuses provided Modify the power transformer terminal bridge configuration in the transformer cubicle for the desired voltage To adjust the motor overload FM 1 setting simply rotate the adjustment screw 1 on the front of the overload relay to the required setting see table below 34 80670D Adjustment screw of the motor overload 2920 7054 00 Instruction book Atlas Copco _ r motor overload FM1 settings 7 5 kW 11 kw 10 hp 15 hp 208V 36 3 48 230V standard factory setting 34 4 45 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 dior gt ao El E Pt Transformer T Transformer T1 Transformer T1 80671D Replace the two fuses marked F1 by opening the fuse holder an Use the 2 A fuses for 208 230 V and the 1 A fuses for 460 V supplied with the compressor 80672D Fuses F1 Fuses F10 Fuses fuse rating V
24. 208 V 230 V 460 V Class F1 600 V AC 2A 2A 1A UL class JDYX or JDYX2 10 3 x 38mm F1 600 V AC 2A 2A 1A UL class JDYX or JDYX2 10 3 x 38mm F2 250 V AC 3A 3A 3A UL class JDYX or JDYX2 5 x 20 mm F3 250 V AC 1A 1A 1A UL class JDYX or JDYX2 5 x 20 mm F3 250 V AC 1A 1A 1A UL class JDYX or JDYX2 5 x 20 mm F10 600 V AC 7 5A 7 5A 5A UL guide JDDZ class CC type FNQ R 10 3 x 38 mm F10 600 V AC 7 5A 7 5A 5A UL guide JDDZ class CC type FNQ R 10 3 x 38 mm Note fuses F10 are only applicable to FF units See also Electric diagrams 2920 7054 00 35 Atlas Copco Instruction book away To modify the terminal bridge configuration to the motor configure the terminal bridges for the desired voltage 208 V 230 V or 460V according to the diagram below The terminal bridges 1 can be easily removed using a pair of pliers Additional terminal bridges are provided with the compressor The connections for 230 V are the factory standard 200 208V Bridge Pont Bridge Pont Bridge Pont 8 6 7 4 8 5 6 1 7 4 2 8 5 3 9 6 1 7 4 2 8 5 3 9 80673D Locate the yellow voltage labels provided with the compressor Replace the existing label with the appropriate voltage label 200 208 V 230V or 460V Fuses 1A 2A 10 3x38 F10 Fuses 5A 7 5A 10 3x38 CC type o e De 230 V 80 Hz 460 V 60 Hz c 52 three phase three phase 2 S Lee ges vd dam Soa V 230 V 80 Hz 460 V 60 Hz ve three phase NU three phase im uae A e Stic
25. 8 60 575 12 10 3 4 Electrical connections A Always disconnect the power supply before working on the electrical circuit 32 2920 7054 00 Instruction book Atlas Copco General instructions F1 F2 F3 F1 KMD 1 KMD 1 F10 1 T1 KL FA 1 T1 KY FM1 KD XM1 2 IEC CE CSA UL cULus Electrical connection GX 7 and GX 11 Step Action 1 Install an isolating switch near the compressor 2 Check the fuses and the setting of overload relay See Settings for overload relay and fuses 3 If fitted check transformers for correct connection 4 Connect the power supply cables to terminals L1 L2 and L3 1X0 and the neutral conductor 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 2920 7054 00 33 Atlas Copco 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 80669F 1 Required modifications in the compressor cubicle Step Action Adjust the motor overload FM1 setting Rewire the control transformer T1 Replace the control fuses F
26. Discard the air filter element 4 Fit the new element and screw on the filter cover 5 Refit the top and front panels 2920 7054 00 55 Atlas Copco Instruction book away 6 2 Coolers Ca Co 80686F GX 7 and GX 11 Step Action 1 Keep oil cooler Co clean to maintain the cooling efficiency For versions with air cooler also keep cooler Ca 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 oil cooler 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 6 3 Safety valve 80678F Condensate drain valve Tank mounted GX 7 and GX 11 56 2920 7054 00 Instruction book Atlas Copco 80683F Filler plug GX 7 and GX 11 Testing The valve can be tested on a separate compressed air line Before removing the safety valve stop the compressor see Stopping close the air outlet valve switch off the voltage open drain valves 4 tank mounted units and the manual drain valve 5 if fitted on floor mounted units and unscrew filler plug 3 one turn to permit any pressure in the system to escape If the valve does not open at the set pressure stamped on the valve replace the valve NM No adjustments are allowed Never run the compressor without a safety valve
27. GX 7 GX 11 Instruction book 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 2007 11 No 2920 7054 00 Ss www atlascopco com Atlas Copco Atlas Copco Instruction book em Table of contents 1 1 1 2 1 3 1 4 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 3 1 3 2 3 3 3 4 3 5 3 6 4 1 4 2 4 3 Safety CN 5 SAFETY CONS a a a E EAEE A ENE canoa 5 SAFETY PRECAUTIONS DURING INSTALLATION ccecceeccececeeceseceeeceeceeecececeeeceeeseeeeseseeeaeeeeeeseeeneesaeeneeeaeeeneenens 5 SAFETY PRECAUTIONS DURING OPERATION s ss ssssssossenreroniorrntin torir n rnrn to AE rA EAE ERA DEE DEPAR RECAE DERRER ACEEA rannen nne 6 SAFETY PRECAUTIONS DURING MAINTENANCE OR BEDAIR 8 General description Me c 10 INTRODUCTION BEE 10 rage M re SEN een 12 GIESSEN 14 COOLING SYSTEM 15 REGULATING SYSTEM ieancaeccacaasccenceseacadh sauicesanaptenatean gan ant EaD ATD ATON DEEE a Tia TONEDE aE adian 16 CONTROL PANEL ccccecceeecececeecececececeeceeecececeeeeeesecenevecsenseeneeeceueeeese
28. M1 is off the motor The NC contact of FM1 is closed again but the fault is not yet reset open Not applicable Not applicable 2920 7054 00 Instruction book Atlas Copco during start up transitory star contactor energized Symbol Led flashing Led on Oil 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 Y A On star delta started compressors Compressor running loaded General alarm O Not enabled Not enabled i Compressor running unloaded idle before stopping Q Compressor ready to start Stand by Compressor operating 4 Main power on 4 To start up again after a protection has been triggered alarm press the RESET button followed by the START button 1 The motor will start after a delay of 25 seconds Operation of the central control unit The central control unit is programmed for Energy Saving It will automatically start and stop the compressor depending on the need for compressed air Before switching off the compressor will run idle unloaded The idling period decreases when the air consumption decreases thus reducing idle running to a minimum See also Regulating system Reference Designation Function 1 Start button To start or stop the co
29. VES ssssesoniotrneintietrtnrt tettert onana Aen A DEEE EAEA RAPE EEEEERAE DEEDEE EEERE OREORE En Enn Ee 71 4 2920 7054 00 Instruction book Atlas Copco 1 1 1 Safety precautions Safety icons Explanation A Danger for life A Warning 4 Important note 1 2 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 General precautions l The operator must employ safe working practices and observe all related local work safety requirements and regulations Ifany ofthe following statements does not comply with local legislation the stricter of the two shall apply Installation operation maintenance and repair work must only be performed by authorised trained specialised personnel The compressor is not considered capable of producing air of breathing quality For air of breathing quality the compressed air must be adequately purified according to local legislation and standards Before any maintenance repair work adjustment or any other non routine checks stop the compressor press the emergency stop button switch off the voltage and depressurise the compressor In addition the power isolating switch must be opened and locke
30. W 7 5 11 7 5 11 Nominal motor power rating hp 10 15 10 15 Dryer power consumption at full kW 0 44 0 44 0 44 0 44 load Full Feature units Dryer power consumption at full hp 0 59 0 59 0 59 0 59 68 load Full Feature units 2920 7054 00 Instruction book Atlas Copco Compressor type GX7 GX11 GX7 GX11 Oil capacity 3 3 2 3 3 2 Oil capacity US gal 0 8 0 84 0 8 0 84 Oil capacity Imp gal 0 65 0 7 0 65 0 7 Oil capacity cu ft 0 1 0 11 0 1 0 11 Sound pressure level according dB A 67 68 67 68 to ISO 2151 2004 2920 7054 00 69 Atlas Copco Instruction book 9 Instructions for use of air receiver 9 1 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 No alterations must be made to this vessel by welding drilling or other mechanical methods without the written permission of the manufacturer The pressure and temperature of this vessel must be clearly indicated There is no intrinsic need for service inspection of the vessel when used within the design limits for its intended application Corrosion must be prevented under the conditions of use Condensation may accumulate inside the tank and this must be drained every day T
31. a 50 Hz 7 5 13 bar under reference conditions Compressor type GX7 GX11 GX7 GX11 GX7 GX11 Frequency Hz 50 50 50 50 50 50 Maximum bar e 7 5 7 5 10 10 13 13 unloading pressure Pack Maximum psig 109 109 145 145 189 189 unloading pressure Pack Maximum bar e 7 25 7 25 9 75 9 75 12 75 12 75 unloading pressure Full Feature Maximum psig 105 105 141 141 185 185 unloading pressure Full Feature Nominal working bar e 7 7 9 5 9 5 12 5 12 5 pressure Nominal working psig 102 102 138 138 181 181 pressure Set point C 75 75 75 75 75 75 thermostatic valve Set point F 167 167 167 167 167 167 thermostatic valve Temperature of air leaving outlet valve approx Pack e Tank mounted C 38 43 38 43 38 43 e Tank mounted F 100 109 100 109 100 109 e Floor mounted C 61 5 65 61 5 65 61 5 65 e Floor mounted F 143 149 143 149 143 149 Temperature of air C 25 26 25 26 25 26 leaving outlet valve approx Full Feature Temperature of air F 77 79 77 79 77 79 leaving outlet valve approx Full Feature 66 2920 7054 00 Instruction book Atlas Copco Sars Compressor type GX7 GX11 GX7 GX11 GX7 GX11 Nominal motor power kW 7 5 11 7 5 11 7 5 11 rating Nominal motor power hp 10 15 10 15 10 15 rating Dryer power kW 0 36 0 36 0 36 0 36 0 36 0 36 consumpti
32. and continuously doing things better but it goes much further creating advances in technology through innovation 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 No 2920 7054 00
33. book A me de e Co Ca 80655D 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 2 5 Regulating system Main components 80740F Detail view of unloader assembly UA The main components of the regulating system are Pressure switch which opens and closes at preset pressure limits See Protection of compressor e Unloader UA including inlet valve IV and unloading valve UV 16 2920 7054 00 Instruction book Atlas Copco Loading solenoid valve Y1 The Elektronikon 001 regulator Loading As long as the working pressure is below the maximum limit the solenoid valve is energised allowing control air to flow to the unloader the inlet valve opens completely and the unloading valve closes completely The compressor will run fully loaded 10096 output Unloading Ifthe working pressure reaches the maximum limit the solenoid valve is de energised venting the control air the inlet valve closes completely and the unloading valve opens completely The compressor will run fully unloaded 096 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 When the unloading pressure is rea
34. ched after the first start and if there is no air consumption the compressor will run unloaded during 2 minutes and than stop If there is a pressure request within the first 2 minutes after being stopped the controller is expecting a higher air consumption the next time the unit will stop after 5 minutes of unloaded operation Ifthere is no pressure request earlier than 2 minutes after being stopped the controller is expecting a lower air consumption the next time again it stops after 2 minutes of unloaded operation Ifthe compressor is stopped manually it stops after 2 minutes unloaded operation The compressor will automatically restart when the net pressure drops to the minimum limit 2920 7054 00 17 Atlas Copco 2 6 18 Instruction book Control panel Gpa Gdp Hm S3 1 2 LL e amp S 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 START button Pressing the button switches on the compressor The motor starts 25 seconds after the button is pushed STOP button Pressing the button starts the compressor switch off phase the compressor runs idle during 120 seconds 2 minutes before stopping Led flashing Led on The motor overload FM1 has switched The NC contact of motor overload F
35. d 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 Precautions during installation l 2 3 The machine must only be lifted using suitable equipment in accordance with local safety regulations Loose or pivoting parts must be securely fastened before lifting It is strictly forbidden to dwell or stay in the risk zone under a lifted load Lifting acceleration and deceleration must be kept within safe limits Wear a safety helmet when working in the area of overhead or lifting equipment 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 minimise the entry of moisture at the inlet air Any blanking flanges plugs caps and desiccant bags must be removed before connecting the pipes 2920 7054 00 5 Atlas Copco Instruction book AAA 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 The aspirated air must be free of flammable fumes vapours and particles e g paint solvents that can lead to internal fire or explosion Arrange the air intake so that loose clothing worn
36. d machines shall take adequate precautions to ensure that there is no one checking or working on the machine To this end a suitable notice shall be affixed to the remote start equipment Close the compressor air outlet valve before connecting or disconnecting a pipe Before removing any pressurized component effectively isolate the machine from all sources of pressure and relieve the entire system of pressure Never use flammable solvents or carbon tetrachloride for cleaning parts Take safety precautions against toxic vapours of cleaning liquids Scrupulously observe cleanliness during maintenance and repair Keep dirt away by covering the parts and exposed openings with a clean cloth paper or tape 2920 7054 00 Instruction book Atlas Copco 13 14 15 20 21 22 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 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 Never use a light source with open flame for inspecting the interior of a machine pressure vessel etc Make sure that no tools loose
37. d near the instrument panel In multiple compressor systems manual valves must be installed to isolate each compressor Non return valves check valves must not be relied upon for isolating pressure systems Never remove or tamper with the safety devices guards or insulation fitted on the machine Every pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be protected by a pressure relieving device or devices as required Pipework or other parts with a temperature in excess of 80 C 176 F and which may be accidentally touched by personnel in normal operation must be guarded or insulated Other high temperature pipework must be clearly marked 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 If the ground is not level or can be subject to variable inclination consult the manufacturer Also consult following safety precautions Safety precautions during operation and Safety 4 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 Some precautions are general and cover several machine types and equipment hence some statements may not apply to
38. delta Overload relay Disc switch Overload relay Disc switch FM1 A motor circuit FM1 A motor circuit breaker curve D breaker curve D residual current residual current device device 50 200 20 5 50 29 5 63 50 230 18 40 25 5 50 50 400 11 25 15 32 50 500 9 25 12 32 60 380 12 25 15 7 32 60 440 460 10 25 13 5 32 CSA UL DOL Overload relay Main fuses A Overload relay Main fuses A FM1 A class J or RK FM1 A class J or RK Disc switch size Disc switch size gt 1 25 x FLA see gt 1 25 x FLA see conn diagram conn diagram 60 200 40 60 55 70 60 208 230 460 36 3 34 4 16 9 50 45 25 48 45 22 5 70 70 35 60 575 14 20 18 5 25 8 3 Reference conditions and limitations Reference conditions Air inlet pressure absolute bar 1 Air inlet pressure absolute psi 14 5 Air inlet temperature C 20 Air inlet temperature F 68 Relative humidity 0 Working pressure bar e See Compressor data Working pressure psi See Compressor data Limitations Maximum working pressure bar e See Compressor data Maximum working pressure psig See Compressor data Minimum working pressure bar e 4 Minimum working pressure psig 58 Maximum air inlet temperature C 46 2920 7054 00 65 Atlas Copco Instruction book Maximum air inlet temperature F 115 Minimum ambient temperature C 0 Minimum ambient temperature F 32 8 4 Compressor dat
39. dle of sight glass 4 Ensure no dirt gets into the system Refit and tighten filler plug 2 Close drain valve 8 of the air receiver 10 Run the compressor for a few minutes 11 Stop the compressor and wait a few minutes to allow the oil to settle 12 Check the oil level Add oil if necessary If the oil level is too low depressurise the system by unscrewing filler plug 2 one turn to permit any pressure in the system to escape Depressurise the air receiver by opening drain valve 8 52 2920 7054 00 Instruction book Atlas Copco Step Action 13 Add oil as necessary The sight glass should be 3 4 full Retighten plug 2 and close drain valve 8 of the air receiver 5 5 PDX DDX filter change Oil filler plug Drain valve air receiver 80683F GX 7 and GX 11 GX 7 and GX 11 Step Action Stop the compressor close the air outlet valve switch off the voltage and depressurise by unscrewing oil filler plug 3 one turn to permit any pressure in the system to escape See Stopping If the compressor is fitted onto an air receiver depressurise the air receiver by opening condensate drain valve 4 On floor mouned units depressurise the filter by loosing its drain valve 2920 7054 00 53 Atlas Copco Instruction book Step Action Unscrew the filter bowl A whistling noise will warn you if the bowl
40. e protection Precautions during operation l Use only the correct type and size of hose end fittings and connections When blowing through a hose or air line ensure that the open end is held securely A free end will whip and may cause injury Make sure that a hose 1s fully depressurized before disconnecting it Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine To this end a suitable notice shall be affixed to the remote start equipment Never operate the machine when there is a possibility of taking in flammable or toxic fumes vapours or particles Never operate the machine below or in excess of its limit ratings Keep all bodywork doors shut during operation The doors may be opened for short periods only e g to carry out routine checks Wear ear protectors when opening a door People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB A shall wear ear protectors Periodically check that All guards are in place and securely fastened All hoses and or pipes inside the machine are in good condition secure and not rubbing There are no leaks All fasteners are tight Allelectrical leads are secure and in good order Safety valves and other pressure relief devices are not obstructed by dirt or paint e Air outlet valve and air net i e pipes couplings manifolds valves hoses e
41. essors which keeps the compressor in excellent condition Roto Xtend Duty Fluid can be used for compressors operating at ambient temperatures between 0 C 32 F and 40 C 104 F see Service kits 2920 7054 00 51 Atlas Copco Instruction book 5 4 Oil filter and separator change Important 4 Never mix oils of different brands or types 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 oa Bb O Action Run the compressor until warm Stop the compressor close the air outlet valve and switch off the voltage See Stopping Depressurise the compressor by unscrewing filler plug 2 one turn to permit any pressure in the system to escape Remove the plug after the system is depressurised Depressurise the air receiver by opening drain valve 8 Remove plug 5 drain the oil by opening drain valve 6 Close the valve and refit the plug after draining Deliver the drained oil to the local oil collection service Remove oil filter 7 and separator 1 Clean the seats on the manifold Oil the gaskets of the new filter and separator and screw them into place Tighten firmly by hand Fill oil separator tank 3 with oil until the level reaches the mid
42. his may be done manually by opening the drain valve or by means of the automatic drain if fitted to the tank Nevertheless a weekly check by opening of the manual drain valve is necessary 70 2920 7054 00 Instruction book 10 PED 10 1 Pressure equipment directives Components subject to 97 23 EC Pressure Equipment Directive Atlas Copco 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 IV 2200 9507 75 Safety valve IV 0830 1009 71 Safety valve IV 0830 1009 72 Safety valve IV Overall rating The compressors conform to PED smaller than category II 2920 7054 00 71 What sets Atlas Copco apart as a company is our conviction that we can only excel in what we do if we provide the best possible know how and technology to really help our customers produce grow and succeed There is a unique way of achieving that we simply call it the Atlas Copco way It builds on interaction on long term relationships and involvement in the customers process needs and objectives It means having the flexibility to adapt to the diverse demands of the people we cater for It s the commitment to our customers business that drives our effort towards increasing their productivity through better solutions It starts with fully supporting existing products
43. is not fully depressurised If this occurs the bowl should be screwed back and the venting should be repeated Remove and discard the filter element Clean the bowl and replace its O ring Fit the new filter element Refit the bowl Tighten oil filler plug 3 c o o0 BI QW Close condensate drain valve 4 5 6 Storage after installation 5 7 54 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 Also a full range of extensively tested lubricants suitable for your specific needs is available to keep the compressor in excellent condition Consult the Spare Parts List for part numbers 2920 7054 00 Instruction book Atlas Copco 6 Adjustments and servicing procedures 6 1 Air filter Changing the air filter 80685F Position of air filter for GX 7 and GX 11 Air filter change on GX 7 up to GX 11 Step Action 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 Unscrew the filter cover 1 and remove the filter element
44. k all doors of the bodywork and push the start button Ifthe sheet is pulled downwards Stop the compressor immediately and switch off the voltage Reverse two incoming electric lines Repeat the previous step e Ifthe sheet is blown away the motor rotation direction is correct 12 Manual condensate drain 13 Automatic condensate drain 2920 7054 00 Instruction book Atlas Copco 4 Operating instructions 4 1 Initial start up Safety A The operator must apply all relevant Safety precautions Moving To safely move a Tank mounted model see Installation General preparation Air outlet valve 80677F Condensate drain GX 7 up to GX 11 2920 7054 00 41 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 Fit outlet valve 2 close it and connect the air net to the valve Connect condensate drain valve Dm and automatic drain outlet Da to a drain collector Close the valve Connect condensate drain valve 4 of the air receiver to a drain collector Close the valve Oil system 80679F Oil level sight glass GX 7 and GX 11 Step Action Check
45. kers Terminal Bridges 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 F11 is not to be used for a supply voltage of 208 230 V STANDARD SETTING 208 230V SETTING 460V SETTING Briiges between terninols 66 61 und 68 63 Me between mee 61 62 63 64 ond 67 68 REPE mms O TO THE DRYER TO THE DRYER Don t mount fuse Fil I Mount fuse Fl FU fus FU fun A nee 34 F11 Fuse 7 5A 10 3x38 CC type 80675F 36 2920 7054 00 Instruction book Atlas Copco Fuses V AC DC 208V 230V 460V Class F11 600 V AC 7 5A UL guide JDDZ class CC type FNQ R 10 3 x 38 mm 2920 7054 00 37 Instruction book 3 5 Electrical diagrams a u or 6 8 n 9 s D D 2 t o 20 Tor oot 66 ag EES Ze Lee c 4 s is d E 4 B E S 83 H TW gt e T foal a i aaa 2 A S cwm UI clan los engangang t IMP TAG TA Le E ba H H H ZE TH Fam ha 4 E D E re S b A El lev fav kv ev lev N E LII wu a D d Ave uA kt i uv xw Div Ai gem nd 1 7 5 4 Tiv Ase E o e 3 D 3 Di m E zl P 4 4 x AA au lg lo la p lo a lo bk bk LES 2 3 ol an elei x vo M i fk EI s e3 ll HRH PRR MG d E 4 I Ta ta a v D a A g j 2 E gt TIE ww ES el z
46. level can only be checked after stopping following the described procedure Always stop the compressor as explained in Stopping Never use the emergency stop button for normal stopping 2920 7054 00 45 AAA Atlas Copco Instruction book em 4 3 Stopping Air outlet valve Condensate drain valve Tank mounted GX 7 and GX 11 46 2920 7054 00 Instruction book Gpa Gdp Hm S3 1 2 LL e 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 the Control panel section After remedying the fault unlock the button by pulling it out Only use emergency stop button in the event of an emergency Avoid using the button for normal stopping of the compressor Close air outlet valve 2 and switch off the voltage to the compressor Open condensate drain valve Dm for a few seconds to drain any condensate and then close the valve Open condensate drain valve 4 of the air receiver for a few seconds to drain any condensate and then close the valve The air dryer and the air receiver remain under pressure The PDX filter if installed remains under pressure If maintenance or repair work is necessary consult the Problem solving section for all
47. mpressor After the stop command 2 Stop button the compressor will run unloaded for a period of 120 seconds and then stop Hm Hour meter Indicates the total running time Gdp Dew point gauge Indicates the dew point temperature Not installed on Pack versions Gpa Working pressure The white pointer indicates the actual working pressure The red one indicates the maximum limit S3 Emergency stop button To stop the compressor immediately only to be used in the event of an emergency Must be unlocked before starting by pulling it out 4 Only use emergency stop button S3 in the event of an emergency 2920 7054 00 19 Atlas Copco Instruction book ENEENREKEAEEE lLLG0 2 7 Protection of compressor F1 F2 F3 F1 KMD 1 KMD 1 F10 1 T1 KL FA 1 Ti KY FM1 KD XM1 2 IEC CE CSA UL cULus Electric cubicle Legend Ref Designation 1 only on Full Feature versions 2 only on multi voltage versions Ref Designation F1 2 3 4 10 Fuses F10 only on Full Feature units see 1 on figure FM1 Motor overload relay KL Line contactor 20 2920 7054 00 Instruction book Atlas Copco MA Ref Designation KY Star contactor KD Delta contactor T1 Transformer KMD Dryer relay only on FF versions see 1 on figure XM1 Connection terminals only available on multi voltage versions see 2 on figure SV Safety valve on the co
48. mpressor and on the vessel Reference Designation Function TSH Temperature shut down To shut down the compressor if the temperature at the See also the switch outlet of the compressor element is too high Electrical diagrams section SV Safety valve To protect the air outlet system if the outlet pressure exceeds the opening pressure of the valve 2920 7054 00 21 Atlas Copco Instruction book 2 8 Air dryer 22 80659F 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 The condensate is automatically drained The cold dried air then flows through heat exchanger 3 where it is warmed up by the incoming air 2920 7054 00 Instruction book Atlas Copco 3 Installation 3 1 Installation proposal Important 80660F Transport by a pallet truck For transport with a fork truck use the openings in the frame Move the compressor gently AN 2920 7054 00 23 Atlas Copco Instruction book eeng Proposal n 500 N AL mn 30D 500 9820 4256 00 00 55650D fi Installation proposal GX 7 and GX 11 Action 1 I
49. necseneueseceseeeneenseeneeensenseeneneneeneeneeees 18 PROTECTION OF COMDRESSCOR kreton nenn r Arrn AnA CR ADEE EEEEEEAAE OAE DEE EEEE ERRE DEED EEEE EREEREER EOE E nnn 20 PAIR DRYER E E E A A E E E EE A E E EE 22 Ee a EEN 23 INSTALLATION PROPOSAL ecc cence dakta aaa DEER dana daaarna aiia 23 DIVINOA aANT 26 ELECTRIC CABLE zE ase 32 ELECTRICAL CONNECTIONS ccccecceeecececucecececececeeeaueceeeeueecueeauceaaesaseeneeeaeeeaeeeeeeeaeeseeeueeeneesanetseesaeenaenaees 32 EUECTRIGALJBIAGRAMSu s er reir tete eebe acia 38 D roepapus EEEE EEEE EEEE 40 Operating instructions coos tieccicctiecaceeteecatcetenentecteecetentenestentateetectenestecteteetectetestectatz lt s 41 INTA ES TARTA 41 S ARING ean a a a 43 SHKO AE ee 46 2920 7054 00 Instruction book Atlas Copco 4 4 TAKING OUT OF OPERATION ssssessesonnonnntnntintrtto tkt torton r ernn AEDn APEE EE REESE EDERE ERREPARA DEEP EEAEE RECEA EEEE ARRECADA EEEE 48 5 ETA A 50 5 1 PREVENTIVE MAINTENANCE SCHEDULE osssustseieetottrtrnt terion r nnr n Ann A r AEDE EE AEE RE CAERE EEEE REED EEEE EEEE RE DEEDEE EEn EE ne 50 5 2 DRIVE SC TR S 51 5 3 Olle zieisels ewe iR 51 5 4 OIL FILTER AND SEPARATOR CHANGE cceccsececceeceeceeeceuceeeuueeeueeauueeueeeeueeuueeueeeueeeaueeaseeeaueeeuneeaneeens 52 5 5 PDX DDX FILTER CHANGE a asoennsnasnnannenrnnnionontrtonirarrar trnto naran rrn
50. nstall 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 The air receiver must not be bolted to the floor For tank mounted units the minimum distance between the wall and the back of the compressor is 500 mm 19 5 in 2 Position of the compressed air outlet valve Close the valve Connect the air net to the valve 3 The pressure drop over the delivery pipe can be calculated from the following formula dp L x 450 x Qc1 85 d x P dp pressure drop recommended maximum 0 1 bar 1 5 psi L length of delivery pipe in m d inner diameter of the delivery pipe in mm Pzabsolute pressure at the compressor outlet in bar a e Qc free air delivery of the compressor in l s 24 2920 7054 00 Instruction book Atlas Copco 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 Qv required ventilation capacity in m3 s N nominal motor power of compressor in kW dT tempera
51. on at full load Full Feature units Dryer power hp 0 48 0 48 0 48 0 48 0 48 0 48 consumption at full load Full Feature units Oil capacity 3 3 2 3 3 2 3 3 2 Oil capacity US gal 0 8 0 84 0 8 0 84 0 8 0 84 Oil capacity Imp gal 0 65 0 7 0 65 0 7 0 65 0 7 Oil capacity cu ft 0 1 0 11 0 1 0 11 0 1 0 11 Sound pressure level dB A 65 67 65 67 65 67 according to ISO 2151 2004 60 Hz 100 125 psi under reference conditions Compressor type GX7 GX11 GX7 GX11 Frequency Hz 60 60 60 60 Maximum unloading pressure bar e 7 4 7 4 9 1 9 1 Pack Maximum unloading pressure psig 107 107 132 132 Pack Maximum unloading pressure bar e 7 15 7 15 8 85 8 85 Full Feature Maximum unloading pressure psig 103 7 103 7 128 128 Full Feature Nominal working pressure bar e 6 9 6 9 8 6 8 6 Nominal working pressure psig 100 100 125 125 Set point thermostatic valve C 75 75 75 75 Set point thermostatic valve F 167 167 167 167 Temperature of air leaving outlet valve approx Pack Tank mounted C 38 43 38 43 Tank mounted F 100 109 100 109 Floor mounted CG 60 66 60 66 Floor mounted F 140 151 140 151 Temperature of air leaving outlet C 23 25 23 25 valve approx Full Feature Temperature of air leaving outlet F 73 77 73 77 valve approx Full Feature 2920 7054 00 67 Atlas Copco Instruction book
52. ontact with the skin rinse the skin with water If liquid refrigerant contacts the skin through clothing never tear off or remove the latter flush abundantly with fresh water over the clothing until all refrigerant is flushed away then seek medical first aid Protect hands to avoid injury from hot machine parts e g during draining of oil Also consult following safety precautions Safety precautions during installation and Safety 4 precautions during operation 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 hence some statements may not apply to your machine 2920 7054 00 9 Atlas Copco Instruction book 2 General description 2 1 Introduction Introduction GX 7 and GX 11 are single stage oil injected screw compressors The compressor is air cooled and belt driven by an electric motor The compressor is enclosed in sound insulated bodywork An easy to operate control panel 1 is provided including the start stop switch and the emergency stop button A cabinet housing the regulator pressure switch and motor starter is integrated into the bodywork Floor mounted model The compressor is installed directly on the floor Tank mounted model DR www atta teopeo cem Da Dm1
53. s follows Close the valve Remove the screw fixing the handle Remove the handle Fitthe screw 62 2920 7054 00 Instruction book Faults and remedies Atlas Copco For all references given hereafter see Air flow diagram Initial start up or Regulating system For GX 7 and GX 11 Condition Fault Remedy 1 Compressor starts running but does not load after a delay time Solenoid valve Y1 out of order Replace valve Inlet valve IV stuck in closed position Have valve checked Leak in control air flexibles Replace leaking flexible Minimum pressure valve Vp leaking when net is depressurised Have valve checked Timer out of order Replace timer 2 Compressor air output or pressure below normal Air consumption exceeds air output of compressor Check equipment connected Choked air inlet filter element AF Replace filter element Solenoid valve Y1 malfunctioning Replace valve Leak in control air flexibles Replace leaking flexible Inlet valve IV does not fully open Have valve checked Oil separator OS clogged Replace separator element Safety valves leaking Replace valves 3 Air outlet temperature above normal Insufficient cooling air or cooling air temperature too high Check for cooling air restriction or improve ventilation of compressor room Avoid recirculation of cooling air If installed
54. tc are in good repair free of wear or abuse 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 Do not remove any of or tamper with the sound damping material Neverremove 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 2920 7054 00 7 Atlas Copco Instruction book Also consult following safety precautions Safety precautions during installation and Safety 4 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 Some precautions are general and cover several machine types and equipment hence some statements may not apply to your machine 1 4 Safety precautions during maintenance or repair A 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 General precautions 1
55. ting the oil level sight glass SG should be between 1 4 and 3 4 full Switch on the voltage Open air outlet valve 2 AION Push the start button 1 The motor starts running after 25 seconds and automatic operation led 3 alights On compressors with a star delta starter the drive motor switches over from star to delta 10 seconds after starting 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 If the oil level is too low stop the compressor depressurise the oil system by unscrewing oil filler plug FC one turn and wait a few minutes Remove the plug and top up the oil until the sight glass is 3 4 full Do not overfill Fit and tighten plug FC When automatic operation LED 3 is lit the regulator is automatically controlling the compressor i e loading unloading stopping of the motors and restarting Regularly check the working pressure Gpa and the dew point gauge Gdp FF units Regularly check that condensate is drained Da during running During normal operation the oil level should be at approximately half of the sightglass Under certain conditions it is possible that only foam is visible In that case the oil
56. ture increase in compressor room Position of the mains cable entry The drain pipes to the drain collector must not dip into the water of the drain collector 2920 7054 00 25 Atlas Copco 3 2 Dimension drawings Dimension drawings GX 7 and GX 11 Instruction book COOLING 640 AIR OUTLET e 590 ys 0 N t 281 Ce Ex 4 A 8 R COOLING AR INLET ZR 2 VD B e 147 i Miro qe Manual del jua drain wie TED Bo Female GAREENTRY 55 1533 3 2094 ee 810 D POZA o i Sch Cle liso 420 1915 1150 1915 D uf ol HH x Il 80661D 159 66 26 GX 7 and GX 11 Tank mounted 270 I Pack 2920 7054 00 Instruction book 540 m 810 S Sieten o H Gah D BH g u 80 500 L 50 120 Gallons i C f 120 420 Lan 200 1500 500 L 1440 120 Gallons 200 aromer 1 a 9 i i e KE 2 C 6 942 335 S 1145 55
57. your machine 1 3 Safety precautions during operation A 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 2920 7054 00 Instruction book Atlas Copco General precautions l The operator must employ safe working practices and observe all related local work safety requirements and regulations Ifany ofthe following statements does not comply with local legislation the stricter of the two shall apply Installation operation maintenance and repair work must only be performed by authorised trained specialised personnel The compressor is not considered capable of producing air of breathing quality For air of breathing quality the compressed air must be adequately purified according to local legislation and standards Before any maintenance repair work adjustment or any other non routine checks stop the compressor press the emergency stop button switch off the voltage and depressurise the compressor In addition the power isolating switch must be opened and locked 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 ey

1) 2008 Instruction Manual for Atlas Copco Compressor Model GX-7

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