Atlas Copco
Atlas Copco
Atlas Copco
G 7, G 11, G 15
Instruction book
Atlas Copco
Oil-injected rotary screw compressors
G 7, G 11, G 15
From following serial No. onwards: CAI 933 415
Instruction book
Original instructions
Copyright notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as
identified in the Declaration of Conformity.
2016 - 08
No. 2920 7191 00
www.atlascopco.com
Instruction book
Table of contents
1 Safety precautions..........................................................................................................5
2 General description...................................................................................................... 10
2.1 INTRODUCTION.................................................................................................................................10
3.7 SHUTDOWN..................................................................................................................................... 33
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4 Installation.....................................................................................................................44
4.4 PICTOGRAPHS................................................................................................................................. 50
5 Operating instructions................................................................................................. 51
5.2 STARTING....................................................................................................................................... 54
5.3 STOPPING.......................................................................................................................................56
6 Maintenance.................................................................................................................. 60
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7.2 COOLERS....................................................................................................................................... 67
8 Problem solving............................................................................................................72
9 Technical data...............................................................................................................76
13 Declaration of conformity............................................................................................ 84
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1 Safety precautions
Explanation
Danger to life
Warning
Important note
If the machine is equipped with an automatic restart after voltage failure function and if
this function is active, be aware that the machine will restart automatically when the
power is restored if it was running when the power was interrupted!
6. 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.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.
8. It is prohibited to walk or stand on the unit or on its components.
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9. If compressed air is used in the food industry and more specifically for direct food contact, it is
recommended, for optimal safety, to use certified Class 0 compressors in combination with
appropriate filtration depending on the application. Please contact your customer centre for advice on
specific filtration.
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14. 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.
15. 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.
16. Piping or other parts with a temperature in excess of 70˚C (158˚F) and which may be accidentally
touched by personnel in normal operation must be guarded or insulated. Other high temperature
piping must be clearly marked.
17. For water-cooled machines, the cooling water system installed outside the machine has to be
protected by a safety device with set pressure according to the maximum cooling water inlet pressure.
18. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
19. If the device is a dryer and no free extinguishing system is present in the air net close to the dryer,
safety valves must be installed in the vessels of the dryer.
Also consult following safety precautions: Safety precautions during operation and
Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
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Also consult following safety precautions: Safety precautions during installation and
Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
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10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or tape.
11. Never weld or perform any operation involving heat near the oil system. Oil tanks must be completely
purged, e.g. by steam cleaning, before carrying out such operations. Never weld on, or in any way
modify, pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. 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.
16. 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.
17. Every time the separator element is renewed, examine the discharge pipe and the inside of the oil
separator vessel for carbon deposits; if excessive, the deposits should be removed.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material 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.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
21. Only if applicable, the following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapors. Check that the working area is adequately ventilated; if
required, use breathing protection.
• Always wear special gloves. In case of refrigerant contact 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.
Also consult following safety precautions: Safety precautions during installation and
Safety 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.
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2 General description
2.1 Introduction
Introduction
G 7, G 11 and G 15 are air-cooled, single-stage, oil-injected screw compressors, driven by an electric
motor.
The compressors are enclosed in sound-insulating bodywork.
An easy-to-operate control panel is provided, including the start/stop switch and the emergency stop
button. A cabinet housing the controller, pressure sensor and motor starter is integrated into the bodywork.
Floor-mounted model
The compressor is installed directly on the floor.
Tank-mounted model
G 7, G 11 and G 15 tank-mounted are supplied with an air receiver of 270 l (71.28 US gal / 59.40 Imp gal /
9.45 cu.ft) or 500 l (132 US gal / 110 Imp gal / 17.50 cu.ft).
Reference Designation
1 Electric cabinet
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Reference Designation
ER Elektronikon Base Controller
S3 Emergency stop button
AO Air outlet
AR Air receiver
Dm1 Manual condensate drain
DR Dryer
D Dewpoint indicator (Only on Full Feature units)
Reference Designation
Co Oil cooler
OF Oil filter
OS Oil separator
OT Oil separator tank
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Air filter
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Reference Designation
Ca Air cooler (Only on Full Feature units)
E Compressor element
AF Air filter
Pack
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).
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Full-Feature
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).
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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. The remaining oil is removed by oil separator (OS) and
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returns to the oil circuit via a separate line. The minimum pressure valve (Vp - see section Air flow)
ensures a minimal pressure in the tank, required for oil circulation under all circumstances.
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.
The cooling system of the Pack version comprises oil cooler (Co) and fan (FN). The fan, mounted directly
onto the motor shaft, generates the cooling air in order to cool the oil and the internal parts of the
compressor.
An air cooler (Ca) is available as option.
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The cooling system of the Full Feature version comprises oil cooler (Co), air cooler (Ca) and fan (FN).
The dryer (DR) of Full-Feature versions has a separate cooling fan and an automatic condensate drain (see
also section Air dryer).
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• The BASE controller that regulates the compressor based on the pressure settings and readings of the
pressure sensor.
Loading
As long as the working pressure is below the preset maximum, the solenoid valve is energised, allowing
control air to the unloader: the inlet valve opens completely and the unloading valve closes completely.
The compressor will run fully loaded (100% output).
Unloading
When the 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 unloaded (0% output).
The G 7, G11 and G 15 are equipped with the BASE controller, an intelligent controller that will stop the
compressor after a variable period of unloaded operation using following algorithm:
• If the unloading pressure is reached after the first start and if there is no air consumption, the
compressor will run unloaded during 2 minutes and then 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.
• If there 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.
• If the compressor is stopped manually, it stops after 2 minutes of unloaded operation.
The compressor will automatically restart when the net pressure drops to the minimum limit.
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Control panel
Reference Designation
1 Electric cabinet
ER Elektronikon Base controller
S3 Emergency stop button
Electrical components
The electrical system comprises following components:
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Reference Designation
F1 Primary fuse, transformer of the control circuit
F2–3 Fuses
F4 Fuse
F5 Fuse
FM1 Motor overload relay
KA Auxiliary circuit relay
KD Delta contactor
KL Line contactor
KMD Dryer relay (Only on Full-Feature)
KY Star contactor
T1 Transformer
X1 Terminal block of the control circuit
X2 Terminal block, voltage change of the motor (Only on tri-voltage units)
X5 Terminal block, voltage change of the dryer transformer (Only on tri-voltage FF units)
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Electrical diagram
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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.
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Control panel
Introduction
In general, the ElektronikonTM Base Controller has following functions:
• Controlling the compressor;
• Protecting the compressor;
• Monitoring service intervals;
• Automatic restart after voltage failure (made inactive);
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If one of the measurements exceeds the programmed shutdown warning level, this will also be indicated to
warn the operator before the shutdown level is reached.
Shutdown
If the compressor element outlet temperature exceeds the programmed shutdown level or the overload relay
of the main motor trips, the compressor will be stopped. This will be indicated on the display of the
controller.
Service warning
If the service timer exceeds the preset value, the controller advises the operator via the display, to carry out
the service maintenance.
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Detailed description
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Running unloaded
Running unloaded (blinking for manual stop)
Running loaded
Motor
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From the Main screen it is possible with up and down buttons (4-8) to change the view from pressure to
temperature of the element outlet.
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To stop the compressor, push start/stop button (3). The compressor unloads:
When the unload time is elapsed, the compressor is stopped and the controller goes back to main screen:
To enter the main menu (starting from the Main screen), press the enter button (7) for 3 seconds. The main
menu is shown:
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It is possible to scroll in the menu with the up or down buttons (4-8). To select one item push the enter
button (7). To end the current action push start/stop (3) button.
If the emergency stop button is pushed, the compressor stops immediately and the following screen will
appear:
Emergency stop
When the emergency push button is restored, reset the alarm by pressing the enter button (7) for 5 seconds.
The following screen will appear:
Alarm reset
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Description
A shutdown warning will appear in the event of:
• A too high temperature at the outlet of the compressor element.
It remains possible to check the actual status of other parameters by pressing the enter button (7) for 3
seconds. Press button (3) to stop the compressor and wait until the compressor has stopped. The warning
message will disappear as soon as the warning condition disappears.
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3.7 Shutdown
Description
The compressor will shutdown:
• In case the temperature at the outlet of the compressor element exceeds the shutdown level (detected
by temperature sensor (TT11) or by temperature switch (TSHH11)).
• In case of error of the outlet pressure sensor (PT20) or temperature sensor (TT11).
• In case of overload of the compressor motor (M1)
The screen shows that the temperature at the outlet of the compressor element is 117 ˚C.
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• When the shutdown condition has been solved, press the Enter button (7) for 5 seconds.
• When <rSt> appears on the display, the compressor can be restarted.
Motor overload
In the event of motor overload:
• The compressor will shutdown.
• Alarm LED (5) will flash.
• The following screen will appear:
Description
A service warning will appear when the service timer has reached the preset time interval.
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If the service timer exceeds the programmed time interval, alarm LED (6) is blinking with a following
screen:
Blinking screen
The example screen shows that the service timer is at 2002 hours.
Stop the compressor, switch off the voltage and carry out the required service actions.
After servicing, reset the service timer.
See section Calling up/resetting the service timer.
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Control panel
From the Main screen press the enter button (7) for 3 seconds to enter the Menu. You will find the
following items:
• Data menu: Data counters parameters.
• Programming menu: Submenu of Regulation pressure, Timer, Display setting and Control setting.
• Test menu: Display test.
• Info menu: Information of firmware release.
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The screen shows the unit used <x1000 hrs> and the value <11.25>: the running hours of the compressor
are 11250 hours.
This screen shows the number of motor starts (x1 or - if <x1000> lights up - x1000). In the above example,
the number of motor starts is 10100.
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In the example shown, the screen shows the unit used <hrs> and the value <5000>: the controller module
has been in service during 5000 hours.
The screen shows the unit used <hrs> (or <x1000 hrs>) and the value <1755>: the compressor has been
running loaded during 1755 hours.
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This screen shows the number of loading actions (x1 or - if <x1000> lights up - x1000). In the above
example, the number of unload to load actions is 10100.
This screen shows the unit used <hrs> (or <x1000 hrs>) and the value <1191>. In the example shown, the
compressor has run 1191 hours since the previous service.
To reset the timer, contact your supplier.
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• Scroll Up or Down buttons (4-8) until <PrSL> is shown and then press Enter button (7).
• Pressure band 1 (<SEL.1>) is shown. Scroll Up or Down buttons (4–8) to pressure band 2 (<SEL.2>).
• Press Enter button (7) on the desired pressure band.
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Description
This function allows the compressor to restart automatically after voltage failure. The activation can only
be done by your dealer. Please contact him for further details.
After any power failure, before restarting, the compressor will wait for a fixed time. When delay time is
running, the display will show the related countdown value as below:
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4 Installation
Outdoor/altitude operation
If the compressor is installed outdoors or if the ambient temperature can be below 0˚C (32˚F), precautions
must be taken. In this case, and also if operating at high altitude, consult Atlas Copco.
Moving/lifting
For transport with a fork truck, use the openings in the frame.
Move the compressor gently.
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Installation proposal
Ref. Action
1 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 300 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 air delivery pipe can be calculated as follows:
Δp = (L x 450 x Qc1..85) / (d5 x P), with
d = Inner diameter of the pipe in mm
Δp = Pressure drop in bar (recommended maximum: 0.1 bar (1.5 psi))
L = Length of the pipe in m
P = Absolute pressure at the compressor outlet in bar
Qc = Free air delivery of the compressor in l/s
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Ref. Action
4 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 / ΔT
Qv = Required ventilation capacity in m3/s
N = Shaft input of compressor in kW
ΔT = Temperature increase in the compressor room in °C
5 Position of the mains cable entry.
6 The drain pipes to the drain collector must not dip into the water of the drain collector.
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General instructions
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.
The power supply cable delivered with the compressor must be protected by raceway or
by a suitable conduit system.
Specific voltage change instructions for G 7 – G 15 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.
To modify the wiring for an operating voltage of 208 V or 460 V, the main cubicle should be rewired as
described below:
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Step Action
1 Adjust the motor overload (FM1) setting.
2 Control transformer (T1) – Move the primary connection from 230V to the desired voltage.
3 Replace the control fuses (F1) 10.3 x 38mm with the ones provided (see further).
Use 1A fuses for 460V or 2A for 208V
On FF units, replace the power fuses (F4) with the CC type provided.
Use 6A for 460V, and 15A for 208V.
4 Modify the motor terminal bridge configuration in the cubicle (X2). See further for details.
5 Replace the voltage sticker by the appropriate voltage sticker provided.
6 Modify the transformer terminal (X5) wire configuration for the desired voltage.
Transformer T1
Fuses F1 – F4:
The fuses are supplied with the compressor.
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(1): Fuse F4 only applicable to FF units. See also Electrical system for the service diagrams.
Motor terminal bridge configuration:
Factory standard connection is 230 V and can be changed to 208 V or 460 V.
Dryer terminal X5
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4.4 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 With all bodywork panels in place, push the start button.
• If the sheet is pulled downwards:
• Stop the compressor immediately and switch off the voltage.
• Reverse two incoming electric lines and repeat the previous step.
• If the sheet is blown away, the motor rotation direction is correct.
12 Manual condensate drain
13 Automatic condensate drain
14 Drain the condensate daily and inspect the vessel yearly. Note down the inspection
dates.
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5 Operating instructions
Safety
General preparation
Condensate drain
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Step Action
1 Consult the installation instructions (see Installation).
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.
3 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
Step Action
1 Check the oil level.
The oil level sight-glass (SG) should be between 1/4 and 3/4 full.
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Start-up
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.
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5.2 Starting
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Control panel
Step Action
1 Before starting, the oil level sight glass (SG) should be between 1/4 and 3/4 full.
2 Switch on the voltage.
3 Open air outlet valve (2).
4 Push the start button (6). The motor starts running after 25 seconds.
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.
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Step Action
5 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).
6 In automatic operation, the regulator is automatically controlling the compressor, i.e.
loading, unloading, stopping of the motors and restarting.
7 Regularly check the working pressure and the dew point (FF units).
8 Regularly check that condensate is drained (Da) during operation.
5.3 Stopping
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Control panel
Step Action
1 Push the start/stop button (6) on the controller. The compressor will unload. When the
unload time is elapsed, the compressor is stopped and the controller goes back to the
main screen.
To stop the compressor immediately in the event of an emergency, press button (S3).
See section Control panel. 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.
2 Close air outlet valve (2) and switch off the voltage to the compressor.
3 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 integrated filter (if installed) remains pressurised.
If maintenance or repair work is necessary, consult the Problem solving section for all
relevant safety precautions.
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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).
2 Switch off the voltage and disconnect the compressor from the mains.
3 Depressurise the compressor by opening plug (3) one turn.
Open condensate drain valve (Dm).
Open condensate drain valve (4) of the air receiver.
4 Shut off and depressurise the part of the air net which is connected to the outlet valve.
Disconnect the compressor from the air net.
5 Drain the oil and condensate circuits.
6 Disconnect the compressor condensate outlet and valve from the condensate net.
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6 Maintenance
Warning
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.
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Important
General
Keep the outside of the electric motor clean for efficient cooling. If necessary, remove dust with a brush
and/or compressed air jet.
Description
The motor bearings are greased for life.
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Never mix oils of different brands or types as they may not be compatible and the oil mix
will have inferior properties. A label, indicating the type of oil filled ex-factory, is stuck on
the air receiver/oil tank.
It is strongly recommended to use Atlas Copco lubricants. See section Preventive maintenance schedule for
recommended oil change intervals.
For part numbers, consult the Spare Parts List.
Roto-Inject Fluid
Atlas Copco's Roto-Inject Fluid is a specially developed lubricant for use in single stage oil-injected screw
compressors. Its specific composition keeps the compressor in excellent condition. Roto-Inject Fluid can be
used for compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 40 ˚C (104 ˚F). If the
compressor is regularly operating in ambient temperatures between 40 °C and 46 °C (115 °F), oil lifetime
is reduced significantly. In such case it is recommended to use Roto-Xtend Duty Fluid.
Important
Never mix oils of different brands or types. A label, indicating the type of oil filled ex-
factory, is stuck on the air receiver/oil tank.
Always drain the compressor oil at all drain points. Used oil left in the compressor can
shorten the lifetime of the new oil.
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.
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Step Action
1 Run the compressor until warm. Stop the compressor, close the air outlet valve and
switch off the voltage. See Stopping.
2 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.
3 Depressurise the air receiver by opening drain valve (8).
4 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.
5 Remove oil filter (7) and separator (1). Clean the seats on the manifold.
6 Oil the gaskets of the new filter and separator and screw them into place. Tighten firmly
by hand.
7 Fill oil separator/tank (3) with oil until the level reaches the middle of sight-glass (4).
Ensure no dirt gets into the system.
8 Refit and tighten filler plug (2).
9 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 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).
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.
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Step Action
1 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 section Stopping..
On floor-mouned units, depressurise the filter by opening its drain valve.
If the compressor is fitted onto an air receiver, depressurise the air receiver by opening
condensate drain valve (4).
2 Unscrew the filter bowl. A whistling noise will warn you if the bowl is not fully
depressurised. If this occurs, the bowl should be screwed back and the venting should
be repeated.
3 Remove and discard the filter element.
4 Clean the bowl and replace its O-ring.
5 Fit the new filter element.
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Step Action
6 Refit the filter bowl.
7 Tighten oil filler plug (3).
8 Close condensate drain valve (4).
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.
Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must
be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations
and environmental legislation.
Electronic components are subject to the EU Directive 2012/19/EC for Waste Electrical and Electronic
Equipment (WEEE). As such, these parts must not be disposed of at a municipal waste collection point.
Refer to local regulations for directions on how to dispose of this product in an environmental friendly
manner.
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Air filter
Procedure:
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 (AF) and remove the filter element. Discard the air filter
element.
4 Fit the new element and screw on the filter cover.
5 Refit the top and front panels.
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7.2 Coolers
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.
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Testing
The valve can be tested on a separate compressed air line.
Before removing the safety valve, stop the compressor (see section 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.
No adjustments are allowed. Never run the compressor without a safety valve.
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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 force and deflection varies with the power of the unit, and with the total running
hours of the belt.
The values to be measured are indicated with a sticker (1) on the frame:
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Adjusting the tension of the drive belts for G7, G11 and G15
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 force and deflection varies with the power of the unit, and with the total running
hours of the belt.
The values to be measured are indicated with a sticker (1) on the frame:
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.
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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, the pulley protection and the
left side panel.
3 Loosen the 4 bolts (2) by one turn.
4 Release the belt tension by loosening tensioning nut (1).
5 Remove the fan duct (4).
Remove the belts.
6 Install the new belts.
7 Tension belts (3) as described above.
8 Re-assemble the fan duct (4), the pulley protection and the internal protection panel.
9 Re-assemble left side and top panel cover.
10 Check the belt tension after 50 running hours.
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8 Problem solving
Control panel
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Attention
Use only authorised parts. Any damage or malfunction caused by the use of
unauthorised parts is not covered by Warranty or Product Liability.
Apply all relevant Safety precautions during maintenance or repair.
Before carrying out any maintenance or repair work on the compressor: push the stop
button (6).
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 as follows:
• Close the valve.
• Remove the screw fixing the handle.
• Remove the handle.
• Fit the screw.
2 Compressor air output or Air consumption exceeds air Check equipment connected
pressure below normal output of compressor
Choked air inlet filter element Replace filter element
(AF)
Solenoid valve (Y1) Replace valve
malfunctioning
Leak in control air flexibles Replace leaking flexible
Inlet valve (IV) does not fully Have valve checked
open
Oil separator (OS) clogged Replace separator element
Safety valves leaking Replace valves
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9 Technical data
Attention
The voltage on the compressor terminals must not deviate more than 10% from the
nominal voltage.
It is however highly recommended to keep the voltage drop over the supply cables at
nominal current below 5% of the nominal voltage (IEC 60204-1).
If cables are grouped together with other power cables, it may be necessary to use
cables of a larger size than those calculated for the standard operating conditions.
Use the original cable entry. See section Dimension drawings.
The compressor is delivered with 3 m (10 ft.) cable and a fitting cable gland.
This cable gland is necessary to ensure the protection degree of the electric cubicle and
to protect its components from dust from the environment.
Local regulations remain applicable if they are stricter than the values proposed below.
G7 G 11 G 15
Frequency Voltage Cable size Cable size Cable size
(Hz) (V)
IEC
50 230 10 mm2 16 mm2 (16 mm2 XLPE 16 mm2 (16 mm2 XLPE
or EPR) or EPR)
50 400 4 mm2 6 mm2 6 mm2
50 500 4 mm2 6 mm2 6 mm2
60 460 4 mm2 6 mm2 6 mm2
60 380 4 mm2 6 mm2 6 mm2
CSA/UL
60 208-230 / 460 AWG8 AWG6 AWG4
60 575 AWG12 AWG10 AWG10
G 7, G 11 and G 15
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Reference conditions
Limitations
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Compressor type G7
Frequency Hz 50 60
Maximum (unloading) bar(e) 7.5 10 13 7.4 9.1 10.8 12.5
pressure, Pack
Maximum (unloading) psig 109 145 189 107 132 157 181
pressure, Pack
Maximum (unloading) bar(e) 7.25 9.75 12.75 7.15 8.85 10.55 12.25
pressure, Full-Feature
Maximum (unloading) psig 105 141 185 103.7 128 153 178
pressure, Full-Feature
Nominal working pressure bar(e) 7 9.5 12.5 6.9 8.6 10.3 12
Nominal working pressure psig 102 138 181 100 125 149 174
Set-point, thermostatic valve ˚C 75
Set-point, thermostatic valve ˚F 167
Temperature of air leaving outlet valve (approx.), Pack
Tank-mounted ˚C 33
Tank-mounted ˚F 91
Floor-mounted ˚C 60
Floor-mounted ˚F 140
Temperature of air leaving ˚C 24
outlet valve (approx.), Full-
Feature
Temperature of air leaving ˚F 75
outlet valve (approx.), Full-
Feature
Nominal motor power rating kW 7.5
Nominal motor power rating hp 10
Dryer power consumption at kW 0.36 0.44
full load, Full Feature units
Dryer power consumption at hp 0.48 0.59
full load, Full Feature units
Oil capacity l 3.2
Oil capacity US gal 0.84
Sound pressure level (ISO dB(A) 65 67
2151 - 2004)
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Compressor type G 11
Frequency Hz 50 60
Maximum (unloading) bar(e) 7.5 10 13 7.4 9.1 10.8 12.5
pressure, Pack
Maximum (unloading) psig 109 145 189 107 132 157 181
pressure, Pack
Maximum (unloading) bar(e) 7.25 9.75 12.75 7.15 8.85 10.55 12.25
pressure, Full-Feature
Maximum (unloading) psig 105 141 185 103.7 128 153 178
pressure, Full-Feature
Nominal working pressure bar(e) 7 9.5 12.5 6.9 8.6 10.3 12
Nominal working pressure psig 102 138 181 100 125 149 174
Set-point, thermostatic valve ˚C 75
Set-point, thermostatic valve ˚F 167
Temperature of air leaving outlet valve (approx.), Pack
Tank-mounted ˚C 38
Tank-mounted ˚F 100
Floor-mounted ˚C 62
Floor-mounted ˚F 143
Temperature of air leaving ˚C 25
outlet valve (approx.), Full-
Feature
Temperature of air leaving ˚F 77
outlet valve (approx.), Full-
Feature
Nominal motor power rating kW 11
Nominal motor power rating hp 15
Dryer power consumption at kW 0.36 0.44
full load, Full Feature units
Dryer power consumption at hp 0.48 0.59
full load, Full Feature units
Oil capacity l 3.2
Oil capacity US gal 0.84
Sound pressure level (ISO dB(A) 67 68
2151 - 2004)
Compressor type G 15
Frequency Hz 50 60
Maximum (unloading) bar(e) 7.5 10 13 7.4 9.1 10.8 12.5
pressure, Pack
Maximum (unloading) psig 109 145 189 107 132 157 181
pressure, Pack
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Compressor type G 15
Maximum (unloading) bar(e) 7.25 9.75 12.75 7.15 8.85 10.55 12.25
pressure, Full-Feature
Maximum (unloading) psig 105 141 185 103.7 128 153 178
pressure, Full-Feature
Nominal working pressure bar(e) 7 9.5 12.5 6.9 8.6 10.3 12
Nominal working pressure psig 102 138 181 100 125 149 174
Set-point, thermostatic valve ˚C 75
Set-point, thermostatic valve ˚F 167
Temperature of air leaving outlet valve (approx.), Pack
Tank-mounted ˚C 42
Tank-mounted ˚F 108
Floor-mounted ˚C 65
Floor-mounted ˚F 149
Temperature of air leaving ˚C 24
outlet valve (approx.), Full-
Feature
Temperature of air leaving ˚F 75
outlet valve (approx.), Full-
Feature
Nominal motor power rating kW 15
Nominal motor power rating hp 20
Dryer power consumption at kW 0.54 0.76
full load, Full Feature units
Dryer power consumption at hp 0.73 1.0
full load, Full Feature units
Oil capacity l 3.2
Oil capacity US gal 0.84
Sound pressure level (ISO dB(A) 71 72
2151 - 2004)
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1 The vessel can contain pressurised air. This can be potentially dangerous if the
equipment is misused.
2 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.
3 No alterations must be made to this vessel by welding, drilling or other mechanical
methods without the written permission of the manufacturer.
4 The pressure and temperature of this vessel must be clearly indicated.
5 The safety valve must correspond with pressure surges of 1.1 times the maximum
allowable operating pressure. It should guarantee that the pressure will not permanently
exceed the maximum allowable operating pressure of the vessel.
6 Use only oil as specified by the manufacturer.
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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.
Local legal requirements and/or use outside the limits and/or conditions as specified by the manufacturer
may require other inspection periods as mentioned below.
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Overall rating
The compressors conform to PED smaller than category II.
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13 Declaration of conformity
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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.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is
supplied with this device.
2920 7191 00 85
In order to be First in Mind—First in Choice® for all your quality
compressed air needs, Atlas Copco delivers the products and
services that help to increase your business’ efficiency and
profitability.
Atlas Copco's pursuit of innovation never ceases, driven by our
need for reliability and efficiency. Always working with you, we
are committed to providing you the customized quality air
solution that is the driving force behind your business.
www.atlascopco.com