G 7-11 Instruction Book EN Wuxi
G 7-11 Instruction Book EN Wuxi
G 7, G 11
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.
2021 - 04
No. 2920 7160 22
www.atlascopco.com
Instruction book
Table of contents
1 Safety precautions..........................................................................................................5
2 General description...................................................................................................... 11
2.1 INTRODUCTION.................................................................................................................................11
3.1 CONTROLLER...................................................................................................................................15
3.4 MENU............................................................................................................................................ 19
4.1 CONTROLLER...................................................................................................................................34
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5 Installation.....................................................................................................................59
5.4 PICTOGRAPHS................................................................................................................................. 63
6 Operating instructions................................................................................................. 64
7 Maintenance.................................................................................................................. 68
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9 Problem solving............................................................................................................78
10 Technical data...............................................................................................................79
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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 center
for advice on specific filtration.
10. The service switch should only be operated by a trained service specialist from the
manufacturer.
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12. The electrical connections must correspond to the applicable 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.
13. 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
affixed near the instrument panel.
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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6. 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.
On machines without bodywork, wear ear protection in the vicinity of the machine.
7. People staying in environments or rooms where the sound pressure level reaches or
exceeds 80 dB(A) shall wear ear protectors.
8. 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
• No leaks occur
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in
good repair, free of wear or abuse
• Air cooling filters of the electrical cabinet are not clogged
9. If warm cooling air from compressors is used in air heating systems, e.g. to warm up a
workroom, take precautions against air pollution and possible contamination of the breathing
air.
10. On water-cooled compressors using open circuit cooling towers, protective measures must
be taken to avoid the growth of harmful bacteria such as Legionella pneumophila bacteria.
11. Do not remove any of, or tamper with, the sound-damping material.
12. Never remove or tamper with the safety devices, guards or insulations fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure shall be protected by a pressure relieving device or devices as
required.
13. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book
must be respected. Local regulations remain applicable if they are more strict.
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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3. Use only genuine spare parts for maintenance or repair. The manufacturer will disclaim all
damage or injuries caused by the use of non-genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached
to the starting equipment.
6. 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.
7. Close the compressor air outlet valve and depressurize the compressor before connecting
or disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all
sources of pressure and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety
precautions against toxic vapors of cleaning liquids.
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.
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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 and G 11 are air-cooled, single-stage, oil-injected screw compressors, driven by an electric
motor.
The motor runs at fixed speed and drives the compressor by means of V belts.
The compressors are enclosed in sound-insulating bodywork.
The compressors are controlled by an electronic controller (ER), mounted on the front panel of
the control cabinet (1). The panel also includes an emergency stop button (S3).
The compressors are available as Floor mounted (FM) and as Tank mounted (TM) version.
Pack (P) versions have no dryer, while Full-Feature (FF) versions include a refrigerant dryer to
remove moisture from the compressed air.
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Air flow
Air, drawn in through the air filter, passes the open inlet valve of the unloading valve assembly
(UA) and is compressed by the compressor element (E), where it mixes with the injected oil (see
Oil circuit).
The mixture of compressed air and oil flows via the oil separator tank (OT) to the oil separator
element (OS), where the oil is separated from the compressed air.
Next, the compressed air passes the minimum pressure valve and flows via the aftercooler (if
fitted) into the air receiver (AR) (on tank mounted versions) or directly to the outlet valve (AV) (on
Floor mounted models).
The minimum pressure valve gets its name from the fact that it only opens from the moment a
certain minimal pressure is reached in the oil separator tank (OT). This pressure is required for
injecting the oil into the compressor element during loaded operation.
Oil circuit
In the oil separator tank (OT), most of the oil is separated from the mixture of compressed air and
oil by centrifugal action. The oil collects at the bottom of the tank. The remaining oil is removed
from the compressed air by the oil separator element (OS) and is returned to the oil circuit via a
separate line. The pressure in the oil separator tank (OT) forces the oil from the tank through oil
cooler (Co) and oil filter (OF) to the compressor element (E).
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A thermostatic bypass valve bypasses the oil cooler when the oil is cold, thus decreasing the risk
for accumulation of condense in the lubricating oil.
Cooling
The compressors are air cooled.
Cooling air, generated by the fan on the motor shaft is blown over the cooler(s) (Co).
Every compressor has an oil cooler. An air cooler is standard on the Full-Feature Tank mounted
models and available as standard option on the Pack versions.
Condensate system
Compressors with an air cooler have a manual drain valve.
On Tank mounted compressors, the air receiver serves as water separator. The air receiver is
equipped with a manual drain valve (Dm, see section Introduction).
A dryer is also equipped with a water separator with an automatic and a manual drain.
Regulating system
The compressors are equipped with an unloading valve assembly (UA) to prevent too frequent
starting and stopping in periods of fluctuating compressed air demand. When there is no demand
for compressed air, the compressor will run unloaded with reduced energy consumption.
Loaded operation
With the compressor running loaded and as long the working pressure is below the programmed
maximum pressure, solenoid valve (Y1) is energised, allowing control air from the oil separator
tank (OT) to the unloading valve (UV). The inlet valve opens completely against spring force and
the compressor runs loaded (100 % output).
Unloaded operation
When the pressure reaches the programmed maximum (unloading) pressure, solenoid valve (Y1)
is de-energised and the control air is vented to atmosphere. The inlet valve closes by spring force
and the compressor runs unloaded (0 % output).
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The electronic controller will stop the compressor after a predefined period of unloaded operation,
unless the pressure in the air net decreases within this time interval. The compressor will
automatically restart as soon the pressure drops below the programmed minimum (loading)
pressure.
Air dryer
The air dryer on Full-Feature versions reduces the water content of the compressed air by
cooling the compressed air to near the freezing point. Doing so, the water vapor condenses and
the water is drained by an automatic water separator.
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3.1 Controller
Introduction
The controller has following functions:
• Controlling the unit
• Protecting the unit
• Monitoring components subject to service
• Automatic restart after voltage failure (ARAVF)
A number of time based automatic start/stop commands may be programmed. Take into
account that a start command will be executed (if programmed and activated), even after
manually stopping the unit.
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Shutdown warning
A shutdown warning level is a programmable level below the shutdown level.
If one of the measurements exceeds the programmed shutdown warning level, a message will
appear on the display and the general alarm LED will light up to warn the operator before the
shutdown level is reached.
The message disappears as soon as the warning condition disappears or after a manual warning
reset on the display.
A warning will also appear if the dew point temperature is too high in relation to the ambient
temperature (on units with integrated dryer).
When the shutdown warning is shown, press stop button to stop the unit and wait until the unit
has stopped. Switch off the voltage, inspect the unit and remedy if necessary. The warning
message will disappear as soon as the warning condition disappears.
Service warning
The service timer has a programmed time interval. If the service timer exceeds the programmed
value, this will be indicated on the display to warn the operator to carry out the service actions.
When the service warning is shown, stop the unit, switch off the voltage and carry out the
required service actions. See section Preventive Maintenance.
If the function is activated and provided the controller was in the automatic operation
mode, the unit will automatically restart if the supply voltage to the module is restored.
The ARAVF label (see section Pictographs) shall be glued near to the controller.
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Control panel
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Menu icons
Menu Icon
Main screen
Machine Settings
Data
Service
Controller Settings
Information
Status icons
Icon Description
Motor Stopped
Running Unloaded
Manual Unload
Running Loaded
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System icons
Icon Description
Basic User
Advanced User
Service User
Reset
This chapter gives a general survey of available icons. Not all icons mentioned in this
chapter are applicable to every machine.
3.4 Menu
Procedure
Starting from the main screen, use the left vertical swipe bar to navigate through the menu items.
Use the horizontal swipe bar to navigate through the different screens of a menu item.
The page indicator
shows how many screens there are available for the current menu item, depending on the user
access level.
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Menu structure
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This is the main menu structure. The structure can be different depending on the configuration of
the unit.
Select
In these examples, the upper value is selected.
To select the lower value, swipe down on the left vertical swipebar.
Modify
To modify the selected value, tap the right vertical swipebar.
Function
The Main screen is the screen that is shown automatically when the voltage is switched on. It is
switched off automatically after a few minutes when there is no touch input.
Swipe left to navigate to the following screens:
• Predefined IO or counter data (optional)
• Setpoint used (optional)
• Manual unload (optional)
• Status
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Description
Parameters
Starting from the main screen, swipe left to scroll through predefined IO or counter data.
(optional)
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Example
Setpoint used
Starting from the main screen, swipe left until the Setpoint used screen is shown.
To switch to a different setpoint, swipe up or down on the left vertical swipebar or tap next to the
corresponding square.
Manual unload
Starting from the main screen, swipe left until the Manual unload screen is shown.
Manual unload can only be activated when the machine is in LOAD and Local control.
To manually unload the unit, tap on the left vertical swipebar.
Status
Starting from the main screen, swipe left until the Status screen is shown.
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To reset the alarm, press the confirm button under the reset icon.
To cancel without resetting, press the cancel button under the red ‘X’ icon.
Function
The Machine Settings menu provides the ability to view and modify several machine settings.
Swipe left to navigate to the following screens:
• Setpoint 1 (optional)
• Setpoint 2 (optional)
• Regulation
• Control Mode
• Auto Restart
Procedure
To view the Machine Settings menu:
1. Tap the Home button
Setpoint 1
Starting from the Machine Settings menu, swipe left until the Setpoint 1 screen is shown.
To select a load and unload setpoint, or to modify the values, see section Select or modify a
setting.
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Setpoint 2
Starting from the Machine Settings menu, swipe left until the Setpoint 2 screen is shown.
To select a load and unload setpoint, or to modify the values, see section Select or modify a
setting.
Regulation
Starting from the Machine Settings menu, swipe left until the Regulation screen is shown.
To select a menu item, or to change the setting, see section Select or modify a setting.
Control Mode
Starting from the Machine Settings menu, swipe left until the Control Mode screen is shown.
Auto Restart
Starting from the Machine Settings menu, swipe left until the Auto Restart screen is shown.
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The controller has a built-in function to automatically restart the compressor when voltage is
restored after voltage failure. This function is deactivated in compressors leaving the factory and
can only be modified after entering a password, please consult your supplier to activate this
function.
To select a menu item, or to change the setting, see section Select or modify a setting.
Function
The Aux. Equipment parameters menu provides the ability to view and modify several settings
related to the auxiliary equipment of the unit.
Swipe left to navigate to the following screens:
• Dryer (optional)
• Fan (optional)
• Phase sequence detection (optional)
• Internal or External SmartBox
Procedure
To view the Aux. Equipment parameters menu:
1. Tap the Home button
Dryer
Starting from the Aux. Equipment parameters menu, swipe left until the Dryer screen is shown.
To select a menu item, or to change the setting, see section Select or modify a setting.
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SmartBox
Starting from the Aux. Equipment parameters menu, swipe left until the Internal SmartBox screen
is shown.
To select a menu item, or to change the setting, see section Select or modify a setting.
Function
The Data menu provides the ability to view several important values.
Swipe left to navigate to the following screens:
• Counters
• Inputs
• Outputs
Procedure
To view the Data menu:
1. Tap the Home button
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Counters
Starting from the Data menu, swipe left until the Counters screen is shown.
Select
To select a different item, swipe up or down on the left vertical swipebar.
Inputs
Starting from the Data menu, swipe left until the Inputs screen is shown.
Select
To select a different item, swipe up or down on the left vertical swipebar.
Outputs
Starting from the Data menu, swipe left until the Outputs screen is shown.
Select
To select a different item, swipe up or down on the left vertical swipebar.
Function
The Service menu provides the ability to reset the service timer. This menu is only available as
Service user.
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Procedure
To view the Service menu:
1. Use the controller as a Service user
.
See Controller settings menu to change the user profile.
2. Tap the Home button
Next Service
Starting from the Service menu, swipe left until the Next Service screen is shown.
The Next Service will be triggered after the Running Hours value exceeds the Next Service value.
Reset
Tap the right vertical swipebar, the following screen is now shown:
To cancel without resetting, press the cancel button under the red ‘X’ icon.
To reset the alarm, press the confirm button under the reset icon. The following screen is now
shown:
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Function
The Controller Settings menu provides the ability to view and modify several settings of the
controller.
Swipe left to navigate to the following screens:
• Access Level
• Language
• Units
• CAN Settings
• Ethernet Settings
• Display Timeout
Procedure
To view the Controller Settings menu:
1. Tap the Home button
Access Level
Starting from the Controller Settings menu, swipe left until the Access Level screen is shown.
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Enter a password
The Service user profile is protected by a password. After selecting the Service user profile, the
following screen pops up:
The user can enter the password by swiping up or down on the right vertical swipebar to select
the first digit.
Tap ‘→’ to be able to enter the second digit.
Once the 4 digits are entered, the user can confirm by tapping ‘V’ or decline by tapping ‘X’.
Language
Starting from the Controller Settings menu, swipe left until the Language screen is shown.
Units
The units displayed can be modified through this menu.
CAN Settings
The list of CAN Settings is shown. When CAN is turned off, the settings can be modified.
Ethernet Settings
The list of Ethernet Settings is shown. When ethernet is turned off, IP address, Subnet mask and
Gateway can be modified.
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Do not forget to turn on ethernet settings after changing these settings. Otherwise the
controller can’t connect anymore!
Display Timeout
Starting from the Controller Settings menu, swipe left until the Display Timeout screen is shown.
Display timeout is used to save energy and save the lifetime of the display. Timer starts after last
operator actions on the push buttons or swipe bars.
Function
The Information menu provides the ability to view important information.
Swipe left to navigate to the following screens:
• Help
• Information
Procedure
To view the Information menu:
1. Tap the Home button
Help
Starting from the Information menu, swipe left until the Help screen is shown.
The manufacturer’s website is shown.
Info
Starting from the Information menu, swipe left until the Info screen is shown.
Following items are displayed:
• Mac Address
• Application Description
• Application Software: nr + version
• Operation: nr + version
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• BOOT Software: nr
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4.1 Controller
Introduction
The controller has the following functions:
• Controlling the unit
• Protecting the unit
• Monitoring components subject to service
• Automatic Restart After Voltage Failure (ARAVF)
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Shutdown warning
A shutdown warning level is a programmable level below the shutdown level.
If one of the measurements exceeds the programmed shutdown warning level, a message will
appear on the display and the general alarm LED will light up to warn the operator before the
shutdown level is reached.
The message disappears as soon as the warning condition disappears.
A warning will also appear if the dew point temperature is too high (on units with integrated
dryer).
When the shutdown warning is shown, press stop button to stop the unit and wait until the unit
has stopped. Switch off the voltage, inspect the unit and remedy if necessary. The warning
message will disappear as soon as the warning condition disappears.
Service warning
A number of service operations are grouped as a Service Plan. Each Service Plan has a
programmed time interval. If the service timer exceeds a programmed value, this will be indicated
on the display to warn the operator to carry out the service actions belonging to that Service Plan.
When the service warning is shown, stop the unit, switch off the voltage and carry out the
required service actions. See section Preventive maintenance schedule.
If the function is activated and provided the regulator was in the automatic operation
mode, the unit will automatically restart if the supply voltage to the module is restored.
The ARAVF label shall be glued next to the controller.
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Control panel
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Menu icons
Inputs
Outputs
Counters
Service Plan
Service History
Service
functions
Clean Screen
Remaining
Running Time
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Regulation
Control
Parameters
Fan
Internal
SmartBox
Auto Restart
CAN Settings
Localisation Language
Date/Time
Units
User Password
Help
Information
Status icons
Icon Description
Motor Stopped
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Running Unloaded
Manual Unload
Running Loaded
Failed to Load
Manual Stop
System icons
Icon Description
Basic User
Advanced User
Service User
Antenna 25%
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Antenna 50%
Antenna 75%
Antenna 100%
Energy recovery
Dryer
Element
Drain(s)
Analogue Output
Menu
Reset
Auto Restart
Filter(s)
Cooler
Valve(s)
Power Meter
Input icons
Icon Description
Pressure
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Temperature
Special Protection
Open
Closed
This chapter gives a general survey of available icons. Not all icons mentioned in this
chapter are applicable to every machine.
Function
The Main screen is the screen that is shown automatically when the voltage is switched on. It is
switched off automatically after a few minutes when there is no touch input.
Description
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Function
The screen is used to directly access some frequently used functions.
Procedure
The Quick access screen can be viewed by swiping left, starting from the main screen.
Description
Through this screen, several important settings can be viewed and modified.
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Function Description
Setpoints Several setpoints can be modified by tapping this icon.
Control mode The control mode can be changed by tapping this icon.
• Local control via start/stop buttons
• Remote control via digital input(s)
• LAN control via the network.
When in Remote or LAN control, the start/stop buttons on the controller will not work.
Display language The display language of the controller can be changed by tapping this icon.
Manual unload (only When tapped, the machine will go in Manual unload mode until the icon is tapped
on fixed speed units) again.
Week timer Week timers can be set by tapping this icon.
Remaining running The Remaining running time can be set and modified by tapping this icon.
time
Internal SmartBox The reception quality of the internal antenna can be monitored.
Each bar represents 25% reception strength. If the four bars are filled, the reception
strength is 100%. If only one bar is filled, the reception strength is just 25%.
Auto restart Auto restart can be activated by tapping this icon.
Function
This screen is used to display the different menus where settings can be viewed or changed.
Procedure
The Menu screen can be viewed by tapping the Menu button or by swiping right, starting from the
main screen.
Description
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Menu structure
Operating the controller can be done by swiping through screens and tapping icons or menu
items.
This is the main menu structure. The structure can be different depending on the configuration of
the unit.
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Function
This screen is used to display the following submenus:
• Status
• Inputs
• Outputs
• Counters
• Aux. Equipment
These submenus can be entered by tapping the icons.
Procedure
To enter the Data menu screen:
1. Tap the Menu button
2. Tap the Data icon
Description
Reference Designation
(1) Status menu
(2) Inputs menu
(3) Outputs menu
(4) Counters menu
(5) Auxiliary equipment menu
Status menu
Tap the Status icon to enter the Status menu.
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If an alarm is active, it can be viewed by tapping the alarm message. To reset an alarm, tap the
reset button (1).
Inputs menu
Tap the Inputs icon to enter the Inputs menu.
Outputs menu
Tap the Outputs icon to enter the Outputs menu.
Counters menu
Tap the Counters icon to enter the Counters menu.
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This menu shows an overview of all actual hours and counters of the unit and controller.
Function
This screen is used to display the following submenus:
• Service
• Service functions (Only visible as advanced user)
• Clean screen
These submenus can be entered by tapping the icons.
Procedure
To enter the Service menu screen:
1. Tap the Menu button
2. Tap the Service icon
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Description
Reference Designation
(1) Service
(2) Service functions (Only visible as advanced user)
(3) Clean screen
Service menu
Tap the Service icon to enter the Service menu.
This menu shows the remaining Running Hours and the remaining Real Time Hours until the next
service. The first row (A) shows the Running Hours when the first service is needed (green), the
second row shows the Real Time Hours (blue)
A service overview can be viewed by tapping icon (1).
The service plan can be viewed by tapping icon (2). Through this menu, the service plan can be
modified:
1. Tap the desired service plan. A selection screen will pop up.
2. Change the Running Hours by tapping ‘–’ or ‘+’.
3. Confirm by tapping ‘V’ or decline by tapping ‘X’.
The service history can be viewed by tapping icon (3).
When a service plan interval is reached, a message will appear on the screen. When service has
been performed, the service timer can be reset by tapping the reset button (4).
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Depending on the machine, this menu can have a different set of functions. Many of them are
password protected, as they are only accessible for authorized personnel.
Clean screen
Tap the Clean Screen icon to start the 15 seconds countdown to perform cleaning of the
touchscreen.
The touchscreen and the start and stop button become inactive for 15 seconds.
Function
This screen is used to set up to 4 different week timers with each up to 8 settings per day.
The week timers can be activated through this screen.
A Remaining Running Time can be set from 5 up to 240 minutes.
Procedure
To enter the Week Timer menu screen:
1. Tap the Menu button
2. Tap the Week Timer icon
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Description
Function
This screen is used to display the saved data in case of an alarm.
These submenus can be entered by tapping the icons.
Procedure
To enter the Event history menu screen:
1. Tap the Menu button
2. Tap the Event History icon
Description
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Reference Designation
(1) Saved Data
Saved data
Tap the Saved Data icon to enter the Saved Data menu.
Scroll through the items swiping up and down in this list. The event date and time is shown at the
right side of the screen.
Press on one of the items in the list for more information reflecting the status of the unit when the
shutdown occurred.
Function
This screen is used to display the following submenus:
• Alarms
• Regulation
• Control Parameters
Only visible if the machine has adaptable parameters.
• Aux. Equipment parameters
• Auto Restart
These submenus can be entered by tapping the icons.
Procedure
To enter the Machine settings menu screen:
1. Tap the Menu button
2. Tap the Machine Settings icon
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Description
Reference Designation
(1) Alarms menu
(2) Regulation menu
(3) Control Parameters menu
(4) Aux. Equipment Parameters menu
(5) Auto Restart menu
Alarms menu
Tap the Alarms icon to enter the Alarms menu.
Regulation menu
Tap the Regulation icon to enter the Regulation menu.
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When tapping a list item, a selection screen pops up. The user can modify the setting by tapping
‘–’ or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.
Change a selection
When tapping a list item, a selection screen pops up. The user can change the selection by
swiping up or down and confirm by tapping ‘V’ or decline by tapping ‘X’.
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Through this menu, the automatic restart can be activated. The activation is password protected.
The automatic restart settings can also be changed.
Enter a password
When tapping a password protected item, a selection screen pops up. The user can enter the
password by swiping up or down to select the desired number. Once the 4 digits are entered, the
user can confirm by tapping ‘V’ or decline by tapping ‘X’.
Modify a setting
When clicking a list item, a selection screen pops up. The user can modify the setting by tapping
‘–’ or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.
Function
This screen is used to display the following submenus:
• Network Settings
• Localisation
• User Password
• Help
• Information
These submenus can be entered by tapping the icons.
Procedure
To enter the Controller Settings menu screen:
1. Tap the Menu button
2. Tap the Controller Settings icon
Description
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Reference Designation
(1) Network Settings menu
(2) Localisation menu
(3) User Password menu
(4) Help menu
(5) Information menu
Ethernet Settings
The list of Ethernet Settings is shown. When ethernet is turned off, the settings can be modified.
CAN Settings
The list of CAN Settings is shown. When CAN is turned off, the settings can be modified.
Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping
‘–’ or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.
Change a selection
When tapping a list item, a selection screen pops up. The user can change the selection by
swiping up or down and confirm by tapping ‘V’ or decline by tapping ‘X’.
Localisation menu
Tap the Localisation icon to enter the Localisation menu.
Language
The language setting of the controller can be modified through this menu.
Date/Time
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The date and time settings of the controller can be modified through this menu.
Units
The units displayed can be modified through this menu.
Modify a setting
When tapping a list item, a selection screen pops up. The user can modify the setting by tapping
‘–’ or ‘+’ and can confirm by tapping ‘V’ or decline by tapping ‘X’.
Change a selection
When tapping a list item, a selection screen pops up. The user can change the selection by
swiping up or down and confirm by tapping ‘V’ or decline by tapping ‘X’.
The user password can be activated or deactivated through this menu. Enter and confirm a user
password to activate, repeat to deactivate.
Enter a password
When tapping a password protected item, a selection screen pops up. The user can enter the
password by swiping up or down to select the desired number. Once the 4 digits are entered, the
user can confirm by tapping ‘V’ or decline by tapping ‘X’.
Help menu
Tap the Help icon to enter the Help menu.
This menu can show a link to the web page of your supplier, a helpdesk phone number or other
helpful information.
Information menu
Tap the Information icon to enter the Information menu.
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Function
Through this pop-up screen the access level settings can be viewed or changed.
Procedure
The Access Level screen can be viewed or changed by tapping the Access Level button at the
upper right corner of the screen.
Description
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Tap the Service access level icon (1) and confirm (2).
The screen information bar (1) now shows the current status of the unit instead of the machine
serial number.
The Received Signal Strength Indicator (RSSI) value is now shown in the Internal SmartBox
menu. See Quick access screen.
In the service menu, an extra menu item is now available. See Service menu.
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5 Installation
Moving/lifting
The compressor can be moved by a lift truck using the slots in the frame. Make sure that the
forks protrude from the other side of the frame. The compressor can also be lifted after inserting
beams in the slot. Make sure that the beams cannot slide and that they protrude from the frame
equally. The chains must be held parallel to the bodywork by chain spreaders in order not to
damage the compressor. The lifting equipment must be placed in such way that the compressor
is lifted perpendicularly. Lift gently and avoid twisting.
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General instructions
Installation proposal
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1. Compressor unit
Install the compressor on a level floor, capable of taking the weight of the compressor.
The recommended minimum distance between top of unit and ceiling is 900 mm. Stated
distances between units and walls are minimum. A distance of 150 mm between the back of
the compressor and the wall is the minimum. 500 mm is recommended for easy access.
The air receiver may not be bolted onto the ground.
2. Position of the compressed air outlet valve.
3. Delivery pipe
The pressure drop over the air pipes can be calculated from:
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 = air flow in l/s
4. Ventilation:
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The inlet grids and ventilation fan should be installed in such a way that any recirculation of
cooling air to the compressor is avoided. The maximum air velocity through the grids is 5
m/s (16.5 ft/s). The maximum air temperature at the compressor intake is 46 °C (115 °F),
( minimum 0 °C / 32 °F ).
Ventilation alternative 1 :
The required ventilation to limit compressor can be calculated from :
Qv = 1.06 N / ΔT for Pack units
Qv = (1.06 N + 1.2)/ ΔT for Full Feature units
Qv = required cooling air flow in m3/s
N = Nominal motor power of the compressor in kW
ΔT = Temperature increase in the compressor room in °C
Ventilation alternative 2 :
The fan capacity should match the compressor fan capacity at a pressure head equal to the
pressure drop caused by cooling air ducts. The ducting for the cooling air outlet of the dryer
(4b) also should be separated from the ducting for the cooling air outlet of compressor (4a).
The maximum allowable pressure drop in ducting before or after the compressor is 30 Pa.
5. Control cubicle with monitoring panel.
6. Main cable entry.
To preserve the protection degree of the electric cubicle and to protect its components from
dust from the environment, it is absolutely necessary to use a proper cable gland when
connecting the power supply cable to the compressor.
7. Drain pipe to condensate collector. The drain pipe may not dip into the water of the collector.
Instructions
Step Action
1 Ensure that the supply voltage matches the voltage on the data plate.
2 Install an isolating switch near the compressor and provide fuses in the supply line.
For Full-Feature compressors: install also an isolating switch near the dryer.
3 Connect the power supply cables to L1, L2 and L3 and connect the Neutral conductor (if
applicable) to the appropriate connector (N). Connect the earth connector to bolt (PE).
More details can be found on the Service diagram, included in the electric cubicle.
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5.4 Pictographs
Pictographs
Reference Designation
1 Manual condensate drain
2 Automatic condensate drain
3 Warning: voltage
4 Warning: switch off the voltage and depressurize compressor before repairing
5 Warning: before connecting compressor electrically, consult Instruction book for motor
rotation direction
6 Torques for steel (Fe) or brass (CuZn) bolts
7 Consult instruction book before replacing the oil
8 Lightly oil gasket of oil filter, screw it on and tighten by hand (approx. half a turn)
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6 Operating instructions
Safety
Initial start-up
• Consult the installation instructions (see section Installation proposal).
• Remove bolt(s) "A" (transport fixture).
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If the supply phases are connected correctly, the compressor will start. If the compressor
does not start, the built-in protection against rotation in the wrong direction. Switch off the
voltage and switch two of the supply cables.
• Run the compressor for a few minutes. Check that the compressor operates normally.
• Push the stop button (6) to stop the compressor.
Starting
• Check the oil level.
• Switch on the voltage. Voltage On LED (5) lights up.
• Push the start button (7) on the controller panel. Automatic Operation LED (4) lights up. The
compressor starts. The controller will now load and unload, start and stop and protect the
compressor automatically, until the stop button (6) or the alarm button (S3) is pushed.
• In order to ensure optimal cooling, the doors must be closed during operation and
may be opened for short periods only to carry out checks.
• Compressors with an air cooler have a water separator with a manual drain valve.
Regularly release condensate during operation.
• On tank mounted compressors, the air receiver serves as water separator.
Regularly drain the air receiver by means of the manual drain valve (Dm, see
section Introduction). See also section Air receiver instructions.
When the motor is stopped but the Automatic Operation LED (4) is alight, the motor may
start automatically!
For trouble free operation, the compressor should run loaded during at least 40 % of the
running time. If this is not the case, the oil temperature risks to remain under the
condensation limit and the oil will start collecting condensate. In such case, a tropical
thermostat should be installed to minimize the risk.
Stopping
• Push the stop button (6) on the controller panel. Automatic Operation LED (4) goes out. The
compressor stops.
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To stop the compressor in case of emergency, press the emergency stop button (S3).
Alarm LED (2) blinks.
After remedying the problem cause, unlock the button by pulling it out again.
Do not use emergency stop button (S3) for normal stopping of the compressor!
Warning
Procedure
1 Stop the compressor, press the emergency stop button and close the air outlet valve.
2 Switch off the voltage and disconnect the compressor from the mains.
3 Open the manual drain valve(s) and wait until the compressor has depressurised.
4 Shut off and depressurize the part of the air net which is connected to the outlet valve.
Disconnect the compressor air outlet pipe from the air net.
5 Drain the oil.
6 Disconnect the condensate piping from the condensate net.
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7 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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Avoid mixing lubricants of different brands or types as they may not be compatible and
the oil mix may have inferior properties. A label, indicating the type of oil filled ex factory,
is stuck on the air receiver/oil tank.
It is strongly advised to use the recommended lubricants. See section Preventive maintenance
schedule for recommended oil change intervals.
For part numbers, consult the Spare Parts List.
Relation between operating conditions and duty type
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Note: The presence of dust and/or high humidity may require a shorter exchange interval.
Consult Atlas Copco.
Atlas Copco's Roto-Inject Fluid Ndurance is a premium mineral oil based 4000 hours lubricant,
specially developed for use in single stage oil-injected screw compressors running in mild
conditions. Its specific formulation keeps the compressor in excellent condition. Roto-Inject Fluid
Ndurance 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), it is recommended to use Roto Synthetic Fluid ULTRA or Roto Synthetic
Fluid XTEND DUTY.
Note: The presence of dust and/or high humidity may require a shorter exchange interval.
Consult Atlas Copco.
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Roto Synthetic Fluid ULTRA is a synthetic oil based 4000 hours lubricant, specially developed for
use in single stage oil-injected screw compressors running in demanding conditions. Roto
Synthetic Fluid ULTRA can be used for compressors operating at ambient temperatures between
0 °C (32 °F) and 45 °C (113 °F). For more extreme conditions or when longer oil life is required, it
is recommended to use Roto Synthetic Fluid XTEND DUTY.
Note: The presence of dust and/or high humidity may require a shorter exchange interval.
Consult Atlas Copco.
Atlas Copco's Roto Synthetic Fluid XTEND DUTY is a high quality synthetic 8000 hours lubricant
for oil injected screw compressors which keeps the compressor in excellent condition. Because
of its excellent oxidation stability, Roto Synthetic Fluid XTEND DUTY can be used for
compressors operating at ambient temperatures between 0 ˚C (32 ˚F) and 46 ˚C (115 ˚F). Roto
Synthetic Fluid XTEND DUTY is the standard lubricant for oil injected screw compressors
equipped with freeze protection or Energy Recovery.
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.
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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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Step Action
1 Stop the compressor, close the air outlet valve and switch off the voltage.
2 Remove the cover (2).
3 Unscrew the filter cover (1) and remove the filter element. Discard the air filter element.
4 Fit the new element and screw on the filter cover.
5 Refit the front panel.
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.
2 Remove the front panel.
3 Depressurise the compressor by unscrewing filler plug (8) one turn to permit any
pressure in the system to escape.
4 Depressurise the air receiver by opening the drain valve (tank mounted units).
5 Drain the oil by opening drain valve (5). Close the valve after draining. Deliver the spent
oil to the local oil collection service.
6 Remove the cover (1)
7 Remove oil filter (3) and oil separator (2). Clean the seats on the manifold.
8 Oil the gaskets of the new filter and separator and screw them into place. Tighten firmly
by hand.
9 Remove filler plug (8) and fill oil tank with oil until the level reaches the middle of sight-
glass (6). Ensure no dirt gets into the system. Refit and tighten filler plug (8)
10 Close the drain valve of the air receiver (tank mounted units).
11 Run the compressor for a few minutes. Check the oil level.
12 Refit the body panel and the cover (1).
General
Keep the outside of the electric motor clean for efficient cooling. If necessary, remove dust with a
brush and/or compressed air jet.
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Instructions
Step Action
1 Stop the compressor, close the air outlet valve and switch off the voltage.
2 Remove the rear panel.
3 Remove any dirt from the cooler (Co) with a fibre brush. Never use a wire brush or metal
objects. Then clean using an air jet.
4 Refit the body panel.
General
The oil separator vessel is protected by a safety valve. A separate safety valve protects the air
receiver on tank mounted units.
Operation
From time to time, operate the safety valve, depending on the type of valve:
• By unscrewing the cap one or two turns and retightening it
• By pulling the valve lifting lever
Testing
The safety valve can be tested on a separate compressed air line.
Before removing the valve, stop the compressor (see section Starting and stopping).
On a Full-Feature unit also stop the dryer.
Close the air outlet valve, switch off the voltage, open drain valves (if applicable) and unscrew the
oil filler plug one turn to permit any remaining 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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Tensioning
Step Action
1 Stop the compressor, close the air outlet valve and switch off the voltage.
2 Remove the front panel and the right panel.
3 Loosen locking nuts (1) and bolts (2) by one turn.
4 Adjust the belt tension by turning tensioning nut (1).
The tension is correct when a force of between 18 N and 22 N, applied at the midpoint
of the belt causes a deflection of 5 mm.
5 Retighten locking nuts (1) and bolts (2).
6 Refit the bodywork panels.
Belt replacement
The belts must always be replaced as a set, even if only one of the belts is worn. Only
use genuine Atlas Copco belts.
Step Action
1 Stop the compressor, close the air outlet valve and switch off the voltage.
2 Remove the front panel and the right panel.
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Step Action
3 Loosen locking nuts (1) and bolts (2) by one turn. Release the belt tension by loosening
tensioning nut (1).
4 Replace the belts and then tension them as described above.
5 Rotate the belts a few times by hand to equalise the belt tension.
6 Refit the bodywork panel.
7 Check the belt tension after 50 running hours.
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9 Problem solving
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.
Stop the compressor and the dryer before carrying out any maintenance or repair work
on the compressor.
Open the isolating switch to prevent an accidental start.
Close air outlet valve and depressurise the compressor by opening the oil filler plug one
turn. Open the manual condensate drain valves (if present).
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10 Technical data
Type V Hz Approva I dryer (A) Itot max (A) Fuse (A) Cable
l
G7 200 50 IEC 2.065 39.0 50 5 x 16 mm²
G7 200 60 IEC 2.64 39.6 50 5x 16 mm²
G7 230 60 IEC 2.64 34.8 50 5x 10 mm²
G7 380 60 IEC 2.64 22.3 40 5 x 6 mm²
G7 400 50 IEC 2.065 20.4 25 5 x 6 mm²
G7 440 60 IEC 2.64 19.6 25 5 x 6 mm²
G7 460 60 IEC 2.64 18.9 25 5 x 6 mm²
G11 200 50 IEC 3.348 55.7 50 5x 16 mm²
G11 200 60 IEC 4.73 57.2 50 5 x 16 mm²
G11 230 60 IEC 4.73 50.4 50 5 x 16 mm²
G11 380 60 IEC 4.73 32.6 50 5 x 10 mm²
G11 400 50 IEC 3.348 29.4 40 5 x 10 mm²
G11 440 60 IEC 4.73 28.9 40 5 x 10 mm²
G11 460 60 IEC 4.73 27.9 40 5 x 10 mm²
The suggested cable size is valid for PVC insulated cables with copper conductors (maximum
conductor temperature 70 °C) and is calculated according to standard 60364-5-52 - electrical
installations of buildings part 5 - selection and erection equipment and section 52 - current
carrying capacities in wiring systems for installation method B2 and ambient temperatures up to
45 °C.
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Frequency Voltage G7 G7 G 11 G 11
(Hz) (V) Overload relay Main fuses Overload relay Main fuses
(A) (A) (A) (A)
60 200 21.2 50 30 50
60 230 18.4 50 26.1 50
60 380 11.2 40 15.8 50
50 400 11.0 25 14.9 40
60 440 9.7 25 13.7 40
60 460 9.2 25 13.1 40
Fuse calculations for IEC are done according to 60364-4-43 electrical installations of buildings,
part 4: protection for safety- section 43: protection against overcurrent. Fuse sizes are calculated
in order to protect the cable against short circuit. Fuse type aM is recommended but gG/gL is
also allowed.
Reference conditions
Limitations
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G 11
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1 The vessel can contain pressurized 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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No. 2920 7160 22 / 2021 - 04 - Printed in Belgium Atlas Copco Airpower NV. All rights reserved. Designs and specifications are subject to change without notice or obligation.
COMMITTED TO SUSTAINABLE PRODUCTIVITY
We stand by our responsibilities towards our customers, towards the
environment and the people around us. We make performance stand
the test of time. This is what we call — Sustainable Productivity.
www.atlascopco.com