Atlas Copco

Oil injected rotary screw compressors

G 2, G 3, G 4, G 5

Instruction book
Atlas Copco
Oil injected rotary screw compressors

G 2, G 3, G 4, G 5
From following serial No. onwards: WUX 200 511

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.

2015 - 07
No. 2920 7170 30

www.atlascopco.com
 Instruction book

Table of contents

1 Safety precautions..........................................................................................................4

1.1 SAFETY ICONS................................................................................................................................... 4

1.2 GENERAL SAFETY PRECAUTIONS............................................................................................................4

1.3 SAFETY PRECAUTIONS DURING INSTALLATION........................................................................................... 5

1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 6

1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 7

2 General description........................................................................................................ 9

2.1 INTRODUCTION...................................................................................................................................9

2.2 OPERATING PRINCIPLE.......................................................................................................................13

2.3 CONTROL PANEL ............................................................................................................................. 16

2.4 ELECTRICAL DIAGRAMS......................................................................................................................17

2.5 PROTECTION OF THE COMPRESSOR......................................................................................................18

2.6 AIR DRYER......................................................................................................................................20

3 Installation.....................................................................................................................21

3.1 INSTALLATION PROPOSAL................................................................................................................... 21

3.2 DIMENSION DRAWINGS.......................................................................................................................23

3.3 ELECTRICAL CONNECTIONS ................................................................................................................25

3.4 PICTOGRAPHS................................................................................................................................. 25

4 Operating instructions................................................................................................. 27

4.1 INITIAL START-UP..............................................................................................................................27

4.2 STARTING....................................................................................................................................... 29

4.3 STOPPING.......................................................................................................................................31

4.4 TAKING OUT OF OPERATION................................................................................................................32

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5 Maintenance.................................................................................................................. 33

5.1 PREVENTIVE MAINTENANCE SCHEDULE..................................................................................................33

5.2 DRIVE MOTOR .................................................................................................................................34

5.3 OIL SPECIFICATIONS..........................................................................................................................34

5.4 OIL, FILTER AND OIL SEPARATOR CHANGE............................................................................................. 35

5.5 PDX/DDX FILTER CHANGE (OPTION).................................................................................................. 36

5.6 STORAGE AFTER INSTALLATION........................................................................................................... 37

5.7 SERVICE KITS.................................................................................................................................. 37

5.8 DISPOSAL OF USED MATERIAL............................................................................................................. 37

6 Adjustments and servicing procedures..................................................................... 38

6.1 AIR FILTER......................................................................................................................................38

6.2 COOLERS....................................................................................................................................... 39

6.3 SAFETY VALVE ................................................................................................................................39

6.4 BELTS MAINTENANCE........................................................................................................................ 40

7 Problem solving............................................................................................................42

8 Technical data...............................................................................................................45

8.1 READINGS ON CONTROL PANEL........................................................................................................... 45

8.2 ELECTRIC CABLE SIZE....................................................................................................................... 46

8.3 SETTINGS FOR OVERLOAD RELAY AND FUSES......................................................................................... 46

8.4 REFERENCE CONDITIONS AND LIMITATIONS............................................................................................ 47

8.5 COMPRESSOR DATA..........................................................................................................................47

9 Instructions for use...................................................................................................... 49

10 Guidelines for inspection.............................................................................................50

11 Pressure equipment directives................................................................................... 51

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1 Safety precautions

1.1 Safety icons

Explanation

Danger for life

Warning

Important note

1.2 General safety precautions

1. The operator must employ safe working practices and observe all related work safety requirements
and regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the
two shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel. The personnel should apply safe working practices by use of personal
protection equipment, appropriate tools and defined procedures.
4. The compressor is not considered capable of producing air of breathing quality. For air of breathing
quality, the compressed air must be adequately purified according to the applicable legislation and
standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks:
• Stop the machine
• Press the emergency stop button
• Switch off the voltage
• Depressurize the machine
• Lock Out - Tag Out (LOTO):
• Open the power isolating switch and lock it with a personal lock
• Tag the power isolating switch with the name of the service technician.
• On units powered by a frequency converter, wait 10 minutes before starting any electrical repair.
• Never rely on indicator lamps or electrical door locks before maintenance work, always
disconnect and check with measuring device.

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, Atlas
Copco recommends, for optimal safety, the use of certified Class 0 compressors in combination with
appropriate filtration depending on the application. Please contact your Atlas Copco Customer Center
for advice on specific filtration.

1.3 Safety precautions during installation

All responsibility for any damage or injury resulting from neglecting these precautions, or
non observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.

Precautions during installation

1. The machine must only be lifted using suitable equipment in accordance with the applicable safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to
dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept
within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
2. The unit is designed for indoor use. If the unit is installed outdoors, special precautions must be taken;
consult your supplier.
3. In case the device is a compressor, place the machine where the ambient air is as cool and clean as
possible. If necessary, install a suction duct. Never obstruct the air inlet. Care must be taken to
minimize the entry of moisture at the inlet air.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the
working pressure.
6. In case the device is a compressor, the aspirated air must be free of flammable fumes, vapors and
particles, e.g. paint solvents, that can lead to internal fire or explosion.
7. In case the device is a compressor, arrange the air intake so that loose clothing worn by people cannot
be drawn in.
8. Ensure that the discharge pipe from the compressor to the aftercooler or air net is free to expand under
heat and that it is not in contact with or close to flammable materials.
9. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
10. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is
remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and depressurized and that the electrical
isolating switch is open, locked and labelled with a temporary warning before any maintenance or
repair. As a further safeguard, persons switching on or off remotely controlled machines shall take
adequate precautions to ensure that there is no one checking or working on the machine. To this end,
a suitable notice shall be affixed to the start equipment.
11. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available
and that the exhausted air does not recirculate to the compressor air inlet or cooling air inlet.
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.

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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.

1.4 Safety precautions during operation

All responsibility for any damage or injury resulting from neglecting these precautions, or
non observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.

Precautions during operation

1. Never touch any piping or components of the machine during operation.
2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose
or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make
sure that a hose is fully depressurized before disconnecting it.
3. 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.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors
or particles.
5. Never operate the machine below or in excess of its limit ratings.
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

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• 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.

1.5 Safety precautions during maintenance or repair

All responsibility for any damage or injury resulting from neglecting these precautions, or
non observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.

Precautions during maintenance or repair

1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
2. Use only the correct tools for maintenance and repair work.
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.

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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 2, G 3, G 4 and G 5 are air-cooled, single stage, oil-injected screw compressors, driven by an electric
motor.
The compressors are belt driven.
The compressors are enclosed in sound insulating bodywork.
The control panel at the front includes a pressure gauge and a start/stop switch. See section Control panel
for details.
Available versions:
Pack versions do not include an air dryer.
Full-Feature versions are fitted with an air dryer (DR). The dryer removes moisture from the compressed
air by cooling the air to near the freezing point and automatically draining the condensate.
The compressor is mounted on top of an air receiver.

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G 2 Pack, tank mounted

Reference Description
1 Control panel
AO Air outlet
AR Air receiver
Dm2 Condensate drain on air receiver

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G 2 Full-Feature, tank mounted (front view)

Reference Description
1 Control panel
AR Air receiver
DR Dryer
Dm2 Manual condensate drain valve
OT Oil separator tank
Co Oil cooler
OF Oil filter

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G 2 Full-Feature, tank mounted (rear view)

Reference Description
AO Air outlet connection
AR Air receiver
DR Dryer
E Compressor element
OS Oil separator
OF Oil filter
AF Air filter

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2.2 Operating principle

Pack units

Flow diagram, tank mounted Pack units

Air flow
Air drawn in through air filter (AF) and open inlet valve (IV) is compressed in compressor element (E).
Compressed air and oil flow into oil separator/tank (OT) where most of the oil is removed by centrifugal
action. The remaining oil is removed by oil separator (OS). The air flows to the outlet (AO) via minimum
pressure valve (Vp).
Oil flow
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
returns to the oil circuit via a separate line. The minimum pressure valve (Vp) ensures a minimal pressure
in the tank, required for oil circulation under all circumstances.
The oil circuit has a thermostatic bypass valve (BV). The oil cooler is bypassed until the oil is warm.
Cooling
A fan on the drive motor shaft provides air flow to cool the oil and the other components of the
compressor. On tank mounted compressors, the air receiver is used as air cooler. The condensate is drained
by means of a manual drain valve.

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Full-Feature

Flow diagram, tank mounted Full-Feature units

Air flow
The compressed air flows from the receiver and the dryer to the outlet (AO).
Oil flow
See above
Cooling
The dryer (DR) of Full-Feature versions has a separate cooling fan and an automatic condensate drain.

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Regulating system

The main components of the regulating system are:

• Pressure switch (PSR11)
• Blow-off valve (Y1)
The contacts of pressure switch (PSR11) open and close at preset pressures. During loaded operation, the
contacts are closed: the motor is running.
When the working pressure reaches the upper limit, the contacts of the pressure switch open: the motor
stops. Blowoff valve (Y1) opens and the pressure in the air/oil separator is released. When the working
pressure decreases to the preset minimum pressure, the contacts of the pressure switch close and the motor
restarts. Blowoff valve Y1 closes and compressed air supply is resumed.

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2.3 Control panel

Control panel

Reference Designation Function

1 Main switch To power the unit. Also used to stop the compressor in the
event of an emergency and to reset the thermal overload of the
electric motor by switching it to 0 and back to I. Also overload
protection (only for IEC).
2 Dryer ON/OFF button To start and stop the dryer (Full-Feature units only)
3 ON/OFF switch To start and stop the compressor.
Hm Hour meter Indicates the total running time.
Gpa Working pressure The white pointer indicates the actual working pressure.
H1 Lamp Lights up when the machine is operating.

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2.4 Electrical diagrams

Service diagram - IEC - 3 ph DOL

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Service diagram - IEC - 3 ph Y-D

Text on image

(1) Main switch and fuses to be installed by customer.

2.5 Protection of the compressor

Safety valve on the compressor

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Safety valve on the air receiver (tank-mounted units)

Reference Designation Function

IG Motor overload relay To shut down the compressor in case the motor current
See also section is too high.
Electrical diagrams
TSH Temperature shut-down To shut down the compressor if the temperature at the
See also section switch outlet of the compressor element is too high.
Electrical diagrams
SV Safety valve To protect the air outlet system if the outlet pressure
exceeds the opening pressure of the valve.

After tripping of the temperature protection: switch off the voltage and depressurise. Check and remedy.
See section Problem solving. Wait a few minutes to let the machine cool down.
To reset and restart, switch on the voltage and press the red reset button after unscrewing its cover: the
machine will restart.

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2.6 Air dryer

Air dryer (Full-Feature compressors)

Wet compressed air (B) enters the dryer and flows through a heat exchanger (2) where refrigerant
evaporates, withdrawing heat from the air. The cold air then flows through a condensate trap (1) which
separates condensate from the air. The condensate is automatically drained and this is regulated by a timer.
The dried air is then discharged from the dryer.

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3 Installation

3.1 Installation proposal

Outdoor/altitude operation
If the compressor is installed outdoors or if the ambient temperature can be below 0˚C (32˚F), precautions
must be taken. In this case, and also if operating at high altitude, consult Atlas Copco.

Moving/lifting

Transport by a pallet truck

To prevent a tank-mounted model from falling over during transport by a pallet truck:
push the forks underneath the air receiver and place a wooden beam (1) (cross-section
approx. 4 x 6 cm / 1.6 x 2.4 in) through the supports on both sides of the receiver. While
holding the compressor, slowly lift the forks until the receiver is secured between the
beams.

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Installation proposal

Installation proposal, tank mounted units

Ref. Description/recommendation
1 Isolating switch, compressor
2 Isolating switch, dryer
3 Front panel, compressor
4 Dryer
(1) Minimum 1.5 m
(2) Space for maintenance, minimum 2 m
(3) Single-phase dryer supply
(4) Three-phase screw compressor supply
(5) The power cable should be protected so that it complies with local codes

Step Action
1 Install the compressor on a solid, level floor suitable for taking the weight.
The recommended minimum distance between the top of the unit and the ceiling is 1.5 m (58.5
in).
The minimum distance between the wall and the back of the compressor must be 200 mm (7.8
in).
The pipes between a floor- mounted compressor and air receiver are hot.

2 Position of the compressed air outlet valve.

Close the valve.
Connect the air net to the valve.

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Step Action
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
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.
5 Lay out the condensate drain flexible from timer drain (T) as well as the flexible from condensate
drain valve (4) towards a drain collector. The drain pipes to the drain collector must not dip into
the water of the drain collector.

3.2 Dimension drawings

Tank mounted Pack units

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Ref. Designation
(1) Condensate drain pipe, valve included
(2) Cooling air outlet
(3) Electrical cable entry
(4) Cooling air inlet
(5) Compressed air outlet

Tank mounted Full—Feature units

Ref. Designation
(1) Condensate drain pipe, valve included
(2) Cooling air outlet
(3) Electrical cable entry
(4) Cooling air inlet
(5) Compressed air outlet

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3.3 Electrical connections

Always disconnect the power supply before working on the electrical circuit!

General instructions

Step Action
1 Ensure that the supply voltage matches the voltage on the data plate.
2 Install an isolating switch near the compressor.
For Full-Feature compressors: fit an isolating switch near the dryer.
3 Fit fuses in the incoming wiring. Check the condition of all incoming wiring and make
connections. See section Electrical diagrams.

3.4 Pictographs

Ref. Description
1 Warning: possible air/fluid discharge
2 Warning: voltage
3 Warning: air must not be inhaled
4 Warning: wear ear protectors
5 Warning: machine may start automatically
6 Warning: pressure
7 Warning: hot parts

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Ref. Description
8 Warning: moving parts
9 Warning: rotating fan
10 Drain the condensate daily and inspect the vessel yearly. Note down the inspection
dates.
11 Read the instruction manual

Ref. Description
12 Working pressure
13 Hour meter
14 Reset of temperature protection
15 High temperature outlet of the compressor element
16 Read instruction manual before carrying out maintenance or repair work
17 Lightly oil gasket of oil filter, screw filter on and tighten by hand

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4 Operating instructions

4.1 Initial start-up

Safety

The operator must apply all relevant Safety precautions.

General preparation

Air outlet valve

Step Action
1 Consult the installation instructions (see section Installation proposal).
2 Check that the electrical connections correspond to the local codes. The installation
must be earthed and protected against short circuits by fuses in all phases. An isolating
switch must be installed near the compressor.
3 Fit the outlet valve, close it and connect the air net to the valve.
Close the drain valve on the receiver.

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Lubrication

Oil level sight glass (SG)

Step Action
If more than 3 months have passed between assembly and installation, be sure to
lubricate the compressor before starting up:
• Remove the front panel.
• Unscrew the fixing bolts of the top panel and remove the panel.
• Unscrew the cover of the air filter (AF) and remove the filter element.
• Open valve (7) and drain approximately 0.2 l (0.05 US gal / 0.04 Imp gal) of oil into
a clean receptacle. Carefully pour this oil through the filter housing into the
compressor element.
• Fit the air filter and screw on the filter cover.
• Refit the top and front panel.
Check the oil level.
The oil level sight-glass (SG) should be between 1/4 and 3/4 full. If the oil level is below
the minimum level, top up to the middle. Do not overfill.

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Start-up

Label on the top

Step Action
1 Check that all bodywork panels are fitted.
Check that sheet (5) (explaining the procedure for checking the motor rotation direction)
is affixed to the cooling air outlet of the compressor (grating on the compressor top).
Consult section Dimension drawings.
Switch on the voltage. Start the compressor and stop it immediately.
Check the rotation direction of the motor. 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.
If the rotation direction is incorrect, switch off the voltage, open the isolating switch and
reverse two incoming electric lines.
All electrical work should be carried out by professionally qualified people.
2 Start and run the compressor for a few minutes. Check that the compressor operates
normally.

4.2 Starting

Dew point temperature gauge

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Starting the air dyer

Dryer on/off switch

Switch on the voltage to the dryer and start it by moving switch (3) to position I.
• Switch on the dryer before starting the compressor.
• The dryer must remain switched on when the compressor is operating to ensure
that the air piping remains condensate-free.
• If the dryer is switched off, wait at least 5 minutes before restarting the dryer; this
allows for balancing of the internal pressure in the dryer.

Timer drain (rear side of the dryer)

Starting the compressor

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Step Action
1 Check the oil level sight glass (SG). The oil level should be in the middle. If it is below
the minimum level, top up to the middle. Do not overfill.
2 Switch on the voltage.
3 Open air outlet valve (2).
4 Move start/stop switch (1) to position I.
If the compressor has been exposed to low temperatures (below 0˚C/32˚F), it may have
difficulty starting due to high oil viscosity. In this case, depress yellow button (5) while
starting using button (1).
Button (5) should only be depressed for a few seconds while starting.
Button (5) should only be used if experiencing difficulty due to low temperatures.
5 Regularly check the working pressure (Gpa).
6 On Full-Feature compressors, regularly check that condensate is drained during
operation.

4.3 Stopping

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Step Action
1 On Full-Feature units: move the dryer switch (2) to position 0.
To stop the compressor, move start/stop switch (1) to position 0.
2 Close the air outlet valve 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.
The air dryer and the air receiver remain under pressure.
The integrated filter (if installed) remains pressurized.
If maintenance or repair work is necessary, consult section Safety precautions during
maintenance or repair for all relevant safety precautions.
4 Wait at least 30 seconds before restarting the machine.

4.4 Taking out of operation

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 Depressurize the compressor by opening plug (3) one turn.
Open condensate drain valve (Dm).
4 Shut off and depressurize 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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5 Maintenance

5.1 Preventive maintenance schedule

Warning

Before carrying out any maintenance, repair work or adjustments, proceed as

follows:
• Stop the compressor.
• Switch off the voltage and open the isolating switch.
• Close the air outlet valve and open the manual condensate drain valves.
• Depressurize the compressor.
For detailed instructions, see the next sections.
The operator must apply all relevant Safety precautions during maintenance or repair.

Warranty-Product Liability
Use only authorised parts. Any damage or malfunction caused by the use of unauthorized parts is not
covered by Warranty or Product Liability.

General
When servicing, replace all removed gaskets, O-rings and washers.

Intervals
Carry out maintenance at the interval which comes first. The local Atlas Copco Customer Centre may
overrule the maintenance schedule, especially the service intervals, depending on the environmental and
working conditions of the compressor.
The "longer interval" checks must also include the "shorter interval" checks.

Preventive maintenance schedule

Period (1) Running hours Action

(1)
Daily -- After stopping, drain the condensate from the air receiver .
Check the oil level.
Monthly 50 For Full-Feature versions: check that condensate from the dryer is
draining automatically.
“ For floor mounted versions: inspect the prefilter at the rear side of
the compressor. Clean if necessary.
3-monthly 500 (2) Inspect the air filter. Clean if necessary.
“ 500 Check the belt tension.
“ “ For compressors with PDX filter: check the service indicator, replace
the filter if necessary.
3-monthly 1000 (2) Inspect the oil cooler; clean if necessary.
“ “ For Full-Feature versions: inspect the condenser of the dryer; clean if
necessary.

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Period (1) Running hours Action

(1)
Yearly 2000 (2) Replace the air filter.
“ 2000 (3) If Roto-Inject Fluid is used, change the oil and the oil filter.
“ 2000 For compressors with PDX filter: replace the filter.
“ 4000 (3) If Roto-Xtend Duty Fluid is used, change the oil and the oil filter.
“ 4000 Replace the oil separator.
“ -- Have the safety valve tested.
“ -- Inspect the air receiver.
The air receiver must no longer be used and must be replaced if the
wall thickness is less than the minimum value, specified in the
technical documentation of the air receiver.

(1): whichever comes first.

(2): more frequently in a dusty environment
(3): The indicated oil exchange intervals are valid for standard operating conditions (see section Reference
conditions and limitations) and nominal operating pressure (see section Compressor data). Exposure of the
compressor to external pollutants or operation at high humidity combined with low duty cycles may require
a shorter oil exchange interval. Contact Atlas Copco if in doubt.

Important

• Always consult Atlas Copco if a service timer setting has to be changed.

• For the change interval of oil and oil filter in extreme conditions, consult your Atlas
Copco Customer Centre.
• Any leakage should be attended to immediately. Damaged hoses or flexible joints
must be replaced.

5.2 Drive motor

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 their expected service life.

5.3 Oil specifications

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.

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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.

5.4 Oil, filter and oil separator change

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.

Step Action
1 Run the compressor until warm. Stop the compressor, close the air outlet valve and
switch off the voltage.

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Step Action
2 Remove the front and top panels.
3 Depressurize the compressor by unscrewing filler plug (8) one turn to permit any
pressure in the system to escape.
4 Depressurize the air receiver by opening drain valve (4).
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 oil filter (3) and separator (2). Clean the seats on the manifold.
7 Oil the gaskets of the new filter and separator and screw them into place. Tighten firmly
by hand.
8 Remove filler plug (8) and fill oil tank (7) 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).
9 Unscrew the air filter cover (1), remove the filter element and carefully pour approx. 0.1 l
(0.03 US gal / 0.02 Imp gal) of oil into the compressor element. Do not overfill.
10 Re-assemble the inlet filter
11 Fit the bodywork panels.
12 Close drain valve (4) of the air receiver.
13 Run the compressor for a few minutes. Check the oil level.

5.5 PDX/DDX filter change (option)

Oil filler plug

Drain valve, 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 mounted units, depressurize the filter by opening its drain valve.
If the compressor is fitted onto an air receiver, depressurize 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
depressurized. 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.
6 Refit the filter bowl.
7 Tighten oil filler plug (3).
8 Close condensate drain valve (4) (tank mounted units).

5.6 Storage after installation

If the compressor is stored without running from time to time, consult Atlas Copco as protective measures
may be necessary.

5.7 Service kits

Service kits
For overhauling and for preventive maintenance, a wide range of service kits is available. Service kits
comprise all parts required for servicing the component and offer the benefits of genuine Atlas Copco parts
while keeping the maintenance budget low.
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.

5.8 Disposal of used material

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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6 Adjustments and servicing procedures

6.1 Air filter

Changing the air filter

Air filter (1)

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 (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 top and front panels.

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6.2 Coolers

Oil cooler

Step Action
1 Keep oil cooler (Co) clean to maintain the cooling efficiency.
2 Stop the compressor, close the air outlet valve and switch off the voltage. Remove any
dirt from the cooler with a fibre brush. Never use a wire brush or metal objects. Then
clean using an air jet.

6.3 Safety valve

Condensate drain valve on air receiver

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Oil filler plug

Testing
The valve can be tested on a separate compressed air line.
Before removing the valve, stop the compressor (see section Stopping).
On a Full-Feature unit also stop the dryer.
Close the air outlet valve, switch off the voltage, open drain valves (4) (if applicable) 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.

6.4 Belts maintenance

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Read the warning in section Preventive maintenance.

Belt tensioning procedure

Step Action
1 Stop the compressor, close the air outlet valve and switch off the voltage.
Full-Feature versions: also stop the dryer.
2 Remove the front panel of the compressor housing.
3 Remove the side, back and top panels of the compressor housing.
4 Loosen the 4 bolts (2) by one turn.
5 Adjust the belt tension by turning tensioning nut (1).
6 The tension is correct when a force of 50 N (11.25 lbf) applied at the midpoint of the belt
causes a deflection of 6 mm (0.23 in).
7 Retighten bolts (2).
8 Refit the bodywork panels.

Belt replacement procedure

Step Action
1 Stop the compressor, close the air outlet valve and switch off the voltage.
Full-Feature versions: also stop the dryer.
2 Remove the front panel of the compressor housing.
3 Remove the side, back and top panels of the compressor housing.
4 Loosen the 4 bolts (2) by one turn.
5 Release the belt tension by loosening tensioning nut (1).
6 Remove the fan cowl.
7 Remove the belt via the fan cowl opening. Install the new belt via the same opening.
8 Tension belt (3) as described above.
9 Re-assemble the fan cowl.
10 Refit the bodywork panels.
11 Check the belt tension after 50 running hours.

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7 Problem solving

Main switch

Oil filler plug

Dryer on/off switch

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Use only authorized parts. Any damage or malfunction caused by the use of
unauthorized parts is not covered by Warranty or Product Liability.
Apply all relevant Safety precautions during maintenance or repair.
Stop the compressor before carrying out any maintenance or repair work on the
compressor. See section Stopping for details.
Move dryer on/off switch (6) to position 0.
Wait until the compressor has stopped and switch off the voltage.
Open the isolating switch to prevent an accidental start.
Close air outlet valve (2) and depressurize 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 with the wrench delivered with the
compressor.
• Lift the handle and turn it until the slot of the handle fits over the blocking edge on
the valve body.
• Fit the screw.

Faults and remedies

Compressor

Condition Fault Remedy

1 The machine does not start No power Check power supply
Fuse (F1) blown Replace fuse
The main motor thermal Check and let motor cool down; to
protection has tripped reset/restart, move compressor start/
stop switch to 0, then to I
2 The machine does not start, Oil cooler is dirty Clean cooler
high oil temperature lamp is Ambient temperature too high Improve ventilation in compressor
on (temperature switch room
tripped)
Oil level too low Top up oil tank
3 The compressor does not Blow-off solenoid valve (Y1) Check; replace valve if necessary
reach working pressure remains open
4 Excess oil consumption Oil separator (OS) clogged Replace oil separator
Oil level too high Drain to correct level

Air dryer

Condition Fault Remedy

1 No compressed air passes Pipes are frozen inside Hot-gas by-pass valve
through the dryer malfunctioning; consult Atlas Copco
2 Condensate in the piping Insufficient condensate drain Check the operation of timer (T)
The dryer is working outside Check room temperature - air
its rating temperature at dryer. Clean the
condenser and check operation of
fan

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Condition Fault Remedy

3 The compressor head is very The dryer is working outside Check room temperature - air
hot (above 55˚C / 131˚F) - its rating temperature at dryer. Clean the
motor overload condenser and check operation of
fan
Insufficient refrigerant in dryer Have system checked for leaks or
refilled
4 The motor is humming but Line voltage too low Check power supply
does not start The machine was switched off Wait a few minutes before starting
and on again too rapidly (not the machine again
enough time for the pressure
equalization)

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8 Technical data

8.1 Readings on control panel

Pressure gauge

Hourmeter

Dewpoint indicator

Ref. Name
Gpa Air outlet pressure
Reading: Modulates between preset unloading/stopping pressure and loading pressure
Gdp Dew point temperature
Hm Hour meter
Reading: Total running time

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8.2 Electric cable size

Attention

Local regulations remain applicable if they are stricter than the values proposed below.
The voltage drop must not exceed 5 % of the nominal voltage. It may be necessary to
use cables of a larger size than those stated to comply with this requirement.

G2 G3 G4 G5
Frequency Voltage Cable size Cable size Cable size Cable size
(Hz) (V)
IEC
50 400 - 3 1 mm2 1 mm2 1.5 mm2 1.5 mm2

8.3 Settings for overload relay and fuses

G 2 and G 3

Frequency Voltage (V) Overload Circuit breaker, G Overload Circuit breaker, G Circuit breaker,
(Hz) relay (IG), 2 (A) (see note 1) relay (IG), 3 (A) (see note 1) dryer supply (A)
G 2 (A) G 3 (A) (see note 1)
IEC DOL Max. Setting Max Setting Max Setting
capacity capacity capacity
50 400 8 10 8 10 10 10 6.3 2

G 4 and G 5

Frequency Voltage (V) Overload Circuit breaker, G Overload Circuit breaker, G Circuit breaker,
(Hz) relay (IG), 4 (A) (see note 1) relay (IG), 5 (A) (see note 1) dryer supply (A)
G 4 (A) G 5 (A) (see note 1)
IEC DOL Max. Setting Max Setting Max Setting
capacity capacity capacity
50 400 11 16 11 - - - 6.3 2
IEC Y-D
50 400 11 16 11 13.5 16 13.5 6.3 2

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8.4 Reference conditions and limitations

Reference conditions

Air inlet pressure (absolute) bar 1

Air inlet temperature ˚C 20
Relative humidity % 0
Working pressure bar(e) See Compressor data

Limitations

Maximum working pressure bar(e) See Compressor data

Minimum working pressure bar(e) 4
Minimum ambient temperature ˚C 0

8.5 Compressor data

50 Hz 10 bar (under reference conditions)

Compressor type G2 G3 G4 G5
Frequency Hz 50 50 50 50
Maximum (unloading) pressure, bar(e) 10 10 10 10
Pack
Maximum (unloading) pressure, bar(e) 9.75 9.75 9.75 9.75
Full-Feature
Nominal working pressure bar(e) 9.5 9.5 9.5 9.5
Pressure drop over dryer bar(e) 0.15 0.15 0.15 0.15
Motor shaft speed rpm 3000 3000 3000 3000
Set-point, thermostatic valve ˚C 71 71 71 71
Temperature of air leaving ˚C 33 33 33 33
receiver (approx.), Pack
Pressure dew-point, Full-Feature ˚C 3 3 3 3
Power input, Pack at maximum kW 3.8 4.1 4.9 6.6
working pressure
Power input, Full-Feature at kW 4.1 4.4 5.2 6.9
maximum working pressure
Power consumption, dryer at full kW 0.3 0.3 0.3 0.3
load
Power consumption, dryer at no kW 0.2 0.2 0.2 0.2
load
Refrigerant type R134a R134a R134a R134a
Total amount, refrigerant kg 0.4 0.4 0.4 0.4
Oil capacity l 2.5 2.5 2.5 2.5

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Compressor type G2 G3 G4 G5
Sound pressure level (according dB(A) 61 61 62 64
to ISO 2151 (2004))

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9 Instructions for use

Oil separator vessel

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.
7 In case of misuse of the units (frequent operation with too low oil temperature or long
interval of shut down), a certain amount of condensate can gather in the oil separator
vessel which must be properly drained. To do so, disconnect the unit from the power
line, wait till it is cooled down and depressurized and drain the water by the oil drain
valve, positioned at the bottom side of the oil separator vessel.
Local legislation may require an periodic inspection.

Air receiver (on tank-mounted units)

1 Corrosion must be prevented: depending on the conditions of use, condensate

may accumulate inside the tank and must be drained every day. This may be done
manually by opening the drain valve, or by means of the automatic drain, if fitted to the
tank. Nevertheless, a weekly check of correct functioning of the automatic valve is
needed. This has to be done by opening the manual drain valve and check for
condensate. Verify that no rust obstructions affect the drain system.
2 Yearly service inspection of the air receiver is needed, as internal corrosion can
reduce the steel wall thickness with the consequent risk of bursting. Local rules
need to be respected, if applicable. The use of the air receiver is forbidden once the wall
thickness reaches the minimum value as indicated in the service manual of the air
receiver (part of the documentation delivered with the unit).
3 Lifetime of the air receiver mainly depends on the working environment. Installing the
compressor in a dirty and corrosive environment is not allowed, as this can reduce the
vessel lifetime dramatically.
4 Do not anchor the vessel or attached components directly to the ground or fixed
structures. Fit the pressure vessel with vibration dampers to avoid possible fatigue
failure caused by vibration of the vessel during use.
5 Use the vessel within the pressure and temperature limits stated on the nameplate and
the testing report.
6 No alterations must be made to this vessel by welding, drilling or other mechanical
methods.

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10 Guidelines for inspection

Guidelines
On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other
standards that have been used for the design are shown and/or referred to.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is
supplied with this compressor.
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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11 Pressure equipment directives

Components subject to 97/23/EC Pressure Equipment Directive

Components subject to 97/23/EC Pressure Equipment Directive greater than or equal to category II:
Safety valves.
See the spare parts book for part numbers.

Overall rating
The compressors conform to PED smaller than category I.

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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.

No. 2920 7170 30 / 2015 - 07 - Printed in Belgium

www.atlascopco.com