Atlas Copco G 15L User manual

Instruction book
Oil-injected screw compressors
G 15L, G 22

Atlas Copco
Oil-injected screw compressors
G 15L, G 22
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.
January 2023
No. 9095 1100 81
www.atlascopco.com

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Table of contents
1Safety precautions ...................................................................................................... 5
1.1 SAFETY ICONS ..........................................................................................................................................5
1.2 GENERAL SAFETY PRECAUTIONS..........................................................................................................5
1.3 SAFETY PRECAUTIONS DURING INSTALLATION ..................................................................................6
1.4 SAFETY PRECAUTIONS DURING OPERATION ......................................................................................7
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR ............................................................8
1.6 DISMANTLING AND DISPOSAL...............................................................................................................10
2General description................................................................................................... 11
2.1 INTRODUCTION .......................................................................................................................................11
2.2 OPERATING PRINCIPLE..........................................................................................................................14
2.3 REGULATING SYSTEM............................................................................................................................17
2.4 AIR DRYER ...............................................................................................................................................18
2.5 ELECTRICAL DIAGRAMS ........................................................................................................................19
3ElektronikonTM Base controller ................................................................................ 20
3.1 CONTROLLER FUNCTIONS.....................................................................................................................20
3.2 CONTROL PANEL.....................................................................................................................................22
3.3 ICONS USED ON THE DISPLAY ..............................................................................................................23
3.4 MAIN SCREEN ..........................................................................................................................................24
3.5 MENU FUNCTION.....................................................................................................................................25
3.6 SHUTDOWN WARNING...........................................................................................................................27
3.7 SHUTDOWN..............................................................................................................................................28
3.8 SERVICE WARNING.................................................................................................................................30
3.9 SCROLLING THROUGH ALL SCREENS.................................................................................................31

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3.10 CALLING UP RUNNING HOURS .............................................................................................................33
3.11 CALLING UP MOTOR STARTS................................................................................................................33
3.12 CALLING UP MODULE HOURS...............................................................................................................34
3.13 CALLING UP LOADING HOURS ..............................................................................................................34
3.14 CALLING UP LOAD SOLENOID VALVE ..................................................................................................35
3.15 CALLING UP/RESETTING THE SERVICE TIMER ..................................................................................35
3.16 CALLING UP/MODIFYING PRESSURE BAND SELECTION ..................................................................36
3.17 CALLING UP/MODIFYING PRESSURE BAND SETTINGS.....................................................................36
3.18 CALLING UP/MODIFYING THE UNIT OF TEMPERATURE....................................................................37
3.19 CALLING UP/MODIFYING THE UNIT OF PRESSURE ...........................................................................37
3.20 CALLING UP/MODIFYING BACKLIGHT TIME ........................................................................................37
3.21 ACTIVATING AUTOMATIC RESTART AFTER VOLTAGE FAILURE......................................................38
3.22 KEYBOARD LOCK ....................................................................................................................................38
4Installation ................................................................................................................. 39
4.1 INSTALLATION PROPOSAL ....................................................................................................................39
4.2 DIMENSION DRAWINGS .........................................................................................................................42
4.3 ELECTRICAL CONNECTIONS.................................................................................................................47
4.4 PICTOGRAPHS ........................................................................................................................................48
5Operating instructions .............................................................................................. 49
5.1 INITIAL START-UP ...................................................................................................................................49
5.2 STARTING ................................................................................................................................................51
5.3 STOPPING ................................................................................................................................................54
5.4 TAKING OUT OF OPERATION ................................................................................................................55
6Maintenance............................................................................................................... 57
6.1 PREVENTIVE MAINTENANCE SCHEDULE ............................................................................................57

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6.2 DRIVE MOTOR .........................................................................................................................................59
6.3 OIL SPECIFICATIONS..............................................................................................................................59
6.4 OIL, FILTER AND OIL SEPARATOR CHANGE .......................................................................................60
6.5 PDX/DDX FILTER CHANGE (OPTION)....................................................................................................62
6.6 STORAGE AFTER INSTALLATION ..........................................................................................................63
6.7 SERVICE KITS..........................................................................................................................................63
6.8 DRAINING CONDENSATE FROM THE OIL TANK .................................................................................63
6.9 DISPOSAL OF USED MATERIAL ............................................................................................................64
7Adjustments and servicing procedures................................................................... 65
7.1 AIR FILTER ...............................................................................................................................................65
7.2 COOLERS .................................................................................................................................................66
7.3 SAFETY VALVE ........................................................................................................................................67
7.4 BELTS MAINTENANCE ............................................................................................................................68
8Problem solving ........................................................................................................ 70
9Technical data ........................................................................................................... 72
9.1 ELECTRIC CABLE SIZE ...........................................................................................................................72
9.2 BACK-UP FUSE RATING .........................................................................................................................74
9.3 REFERENCE CONDITIONS AND LIMITATIONS .....................................................................................75
9.4 COMPRESSOR DATA ..............................................................................................................................76
10 Instructions for use ................................................................................................... 81

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1 Safety precautions
1.1 Safety icons
Explanation
Danger to 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, 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.
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. 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. 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. 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.
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.

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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. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
18. 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 the following safety precautions: Safety precautions during operation and
Safety precautions during maintenance or repair.
These precautions apply to machinery processing or consuming air or inert gas.
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
• 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. Do not remove any of, or tamper with, the sound-damping material.

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11. 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.
12. Yearly inspect the air receiver. Minimum wall thickness 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 or repair.
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.
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.

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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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1.6 Dismantling and disposal
Dismantling
Once the end of life of the machine is reached, please follow next steps:
1. Stop the machine.
2. Check all safety precautions mentioned in the previous chapters to secure safe handling (e.g. LOTO,
cool-down, depressurize, discharge, ...).
3. Separate the harmful from the safe components (e.g. drain oil from oil containing parts).
4. Refer to the disposal topic mentioned below.
Disposal of electrical and electronic appliances (WEEE)
This equipment falls under the provisions of the European Directive 2012/19/EU on waste electrical and
electronic appliances (WEEE) and may not be disposed as unsorted waste.
The equipment is labelled in accordance with the European Directive 2012/19/EU with the crossed- out
wheelie bin symbol.
At the end of life-time of the electric and electronic equipment (EEE) it must be taken to separate collection.
For more information check with your local waste authority, customer center or distributor.
Disposal of other used material
Used filters or any other used material (e.g. filter bags, filter media, 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.

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2 General description
2.1 Introduction
Introduction
G 15L-22 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 a sound-insulating bodywork.
The compressors are controlled by an electronic controller (ER), mounted on the front panel of the
control cabinet. The panel also includes an emergency stop button (ES).
The basic version has a standard Elektronikon® controller. An Elektronikon® controller with graphic
display is available as an option.
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.
Floor mounted models
Floor mounted G 15L-22 are available in Pack and Full- Feature version. A free-standing refrigerant
dryer, matching the compressor capacity is available for each compressor size.
Figure 1: Front view, G 15L-22 Floor Mounted

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Figure 2: Rear view, G 15L-22 Floor Mounted
Reference
Description
E
Compressor element
M
Motor
ER
Electronic controller
ES
Emergency stop button

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Tank mounted models
Tank mounted G 15-22 include a 500 L air receiver and are available in Pack and Full- Feature version.
On the Full-Feature version of Tank mounted models, the dryer (DR) is positioned aside of the compressor.
Figure 3: Front view, G 15L-22 Full Feature Tank Mounted
Reference
Description
Ca
Air cooler (Only on Full Feature units)
E
Compressor element
AF
Air filter

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2.2 Operating principle
Pack units
Figure 4: Flow diagram, 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) and the air cooler (Ca).
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.
The condensate is drained by means of a manual drain valve.

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Full-Feature
Figure 5: Flow diagram, Full-Feature 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), the air cooler (Ca) and the dryer (DR).
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. The dryer (DR) has a separate cooling fan and an automatic condensate drain. The
condensate is drained by means of a manual drain valve.

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Figure 6: Flow diagram, tank mounted Full-Feature 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 air receiver (AR) via
minimum pressure valve (Vp).
The compressed air flows from the air receiver (AR) and the dryer (DR) to the outlet (AO).
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 dryer (DR) has a separate cooling
fan and an automatic condensate drain. The condensate is drained by means of a manual drain valve.
.

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2.3 Regulating system
Figure 7: Detail view of unloader assembly (UA)
The main components of the regulating system are:
• Unloader (UA), including inlet valve (IV) and unloading valve (UV).
• Loading solenoid valve (Y1).
• The BASE controller that regulates the compressor based on the pressure settings and readings of the
pressure sensor.
Loading
As long as the working pressure is below the preset maximum, the solenoid valve is energized, allowing
control air to the unloader: the inlet valve opens completely, and the unloading valve closes completely.
The compressor will run fully loaded (100% output).
Unloading
When the working pressure reaches the maximum limit, the solenoid valve is de-energized, venting the
control air: the inlet valve closes completely, and the unloading valve opens completely. The compressor
will run unloaded (0% output).
The G15L, and G22 are equipped with the BASE controller, an intelligent controller that will stop the
compressor after a variable period of unloaded operation using following algorithm:
• If the unloading pressure is reached after the first start and if there is no air consumption, the
compressor will run unloaded during 2 minutes and then stop.
• If there is a pressure request within the first 2 minutes after being stopped, the controller is expecting a
higher air consumption: the next time the unit will stop after 5 minutes of unloaded operation.
• If there is no pressure request earlier than 2 minutes after being stopped, the controller is expecting a
lower air consumption: the next time again it stops after 2 minutes of unloaded operation.
• If the compressor is stopped manually, it stops after 2 minutes of unloaded operation.
The compressor will automatically restart when the net pressure drops to the minimum limit.

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2.4 Air dryer
Figure 8: 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.