ELGi EG 30, EG 37, EG 45 Owners Manual

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Product Manual

EG Series

Electric Powered Screw Air Compressor

EG 37 - 150.0

Air - Cooled, Standard + VFD 460V, 3Ph, 60Hz

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ELGI EQUIPMENTS LIMITED

Coimbatore, TN - 641 005

Part / Document No. 019000165

Contact Info: ELGI EQUIPMENTS LIMITED

Coimbatore, TN - 641 005, India Tel : 91 - 422 2589555 Fax : 91 - 422 2573697 (Domestic Business) Fax : 91 - 422 2589401 (International Business) E-mail : [email protected] Website : www.elgi.com

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Machine Identification and Sale Record

Owner’s name / Company name

: ………………………………………………………………………………………………………

………………………………………………………………………………………………………

Phone number : ………………………………………………………………………………………………………

Contact person : ………………………………………………………………………………………………………

E-Mail address/ Phone number

: ………………………………………………………………………………………………………

………………………………………………………………………………………………………

Model : ………………………………………………………………………………………………………

Fab. No. : ………………………………………………………………………………………………………

Year of manufacture : ………………………………………………………………………………………………………

Motor : ……………………………………………………………………………………………kW (HP)

Capacity : ……………………………………………………………………………………m

/min (cfm)

Rated pressure : ………………………………………………………………………………………bar.g (psi.g)

Date of delivery : ………………………………………………………………………………………………………

Date of commissioning : ………………………………………………………………………………………………………

Dealer name/address : ………………………………………………………………………………………………………

………………………………………………………………………………………………………

Dealer’s signature : ………………………………………………………………………………………………………

NOTE

The warranty on the compressor is valid only if all the details above are filled in and the dealer stamps and signs this page. This report must reach the Regional Office/Head Office of ELGi within seven days of commissioning date.

1.5

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Table of Contents

1.0 About ELGi 1.7

2.0 General functional description 2.1

3.0 GA drawing, P&I diagram 3.1

4.0 Technical data 4.1

5.0 Installation and operation 5.1

6.0 Maintenance 6.1

7.0 Controller 7.1

8.0 Air inlet and control system 8.2

9.0 Drive system 9.1

10.0 Discharge system 10.1

11.0 Cooling system 11.1

12.0 Lubrication system 12.1

13.0 Base and canopy system 13.1

14.0 Spare kit details 14.1

15.0 Electrical drawings 15.1

16.0 VFD setting details 16.1

Chapter Page No.

1.6

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About ELGi 1.0

ELGi, established in 1960, designs and manufactures a wide range of air compressors. The company has gained its reputation for design and manufacture of screw compressors through strategic partnerships and continuous research and development. Over the years, it has emerged as a multi-product, multi-market enterprise providing total compressed air solutions to all segments. ELGi’s design capabilities translated into a wide range of products ranging from oil-lubricated and oil-free rotary screw compressors, reciprocating compressors and centrifugal compressors.

ELGi is one of the few companies in the world capable of manufacturing wide range of airends and compressor packages. ELGi has most modern manufacturing facilities with high precision grinding machines, turning centres, CNC horizontal and vertical machining centres and also the latest self measurement technology to maintain precise, aerospace manufacturing tolerances. ELGi’s manufacturing plants are ISO and EOHS certified.

Over two million ELGi compressors are powering business in 70+ countries worldwide. The company offers a strong sales and service network with a well-knit distribution network of dealers and distribution, worldwide. ELGi has its own manufacturing operations in India, Italy and USA with subsidiary offices in Australia, Bangladesh, Brazil, China, Indonesia, Italy, Malaysia, Middle East, Sri Lanka and Thailand. The company is fast expanding its global footprint, attracting distributors and customers with its new generation products.

Need help…?

In India

You can contact ELGi customer care system (ECCS) to take care of customer complaints. The ELGi CCS works for six days a week from 08:30 to 21:30 IST (Monday to Saturday). The complaints can be logged by calling any of the following toll free numbers or by e–mail.

Toll free : 1800 425 3544

E-Mail : [email protected]

Website : www.elgi.com

Before making service request for your compressor, keep ready the details printed on the name plate of the compressor and machine identification and sale record of this manual. When ordering spare parts, refer to the lists provided in the parts manual and identify the part number. Specify the part number and quantity, in addition to the name plate details.

Refer “ELGi services” for more details about ECCS under chapter “Maintenance”.

1.7

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2.1

General functional description

Contents

Page No.

2.1 Using the manual 2.2

2.1.1. Definitions and symbols 2.2

2.2 Introduction 2.3

2.3 Safety 2.4

2.3.1 Precautions during installation 2.4

2.3.2 Precautions during operation 2.5

2.3.3 Precautions during maintenance 2.7

2.4 Functional description 2.9

2.4.1 Air circuit 2.9

2.4.2 Oil circuit 2.9

2.4.3 Drive system 2.9

2.4.4 Control system 2.10

2.4.5 For retro-fitment of Standalone VFD with Compressor (C) version in field 2.10

General functional description 2.0

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2.2

General functional description

This operation and maintenance manual has been specially designed keeping the customer in mind so that the person can get the most out of this EG compressor. Before starting the compressor, it is requested that the manual should be read thoroughly. It contains vital information about installation, commissioning, operation and useful tips on maintenance to keep the compressor as good as new, year after year. The manual has been prepared with utmost care to help you understand the various systems of the compressor, along with descriptions, information and illustrations.

Following chapters are provided to help operate the compressor in its best way.

 Safety - safety precautions that must be followed while

using the compressor.

 Technical specifications - technical details about the

compressor.

 Installation and commissioning - all site

requirements, procedures to be followed during installation, commissioning, preservation etc.

 Functional description – parts, their function and

working.

 Operating instructions – to operate the compressor

properly.

 Maintenance – how to do the maintenance for the

compressor and their intervals.

 Troubleshooting – identification and solving the

problems.

 Decommissioning – how to decommission the

compressor, its disposal etc.

 ELGi services – services from ELGi: CCS, air audit,

spare parts

 Appendix – conversion tables, torque values, service

log book

Refer to the parts manual to identify the part number of the required spare. Mention the Fab number, model and part number while ordering.

This manual must be made available to the compressor operating and maintenance personnel at all times.

2.1.1 Definitions and symbols

This information is related to your safety and also to prevent any problems relevant to the equipments used. To help recognize this information better, the symbols are illustrated in section “safety”.

All the information, illustrations and specifications in this manual are based on the latest product information at the time of preparation of the manual. Product improvement is a continuous process in ELGi. The details in this manual are likely to change without notice and ELGi reserves the right to incorporate such changes.

Using the manual 2.1

NOTE

Note clarifies procedures or conditions which may otherwise be misinterpreted or overlooked. Note may also be used to clarify apparently contradictory or confusing situations.

Warning calls attention to dangerous or hazardous conditions inherent to the operation, cleaning and maintenance of the compressor which may result in fatal accident and personal injury of the operator or other staff

Caution is to draw attention to a procedure which, if not done correctly can lead to compressor damage.

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2.3

General functional description

Welcome to ELGi customer family. ELGi compressors are the source of compressed air in various segments across the globe.

ELGi compressors are known for

 Greatest reliability

 Fewer maintenance interval

 Ease of use

 Highest safety

ELGi screw compressor is designed to give

 High energy efficiency

 Low maintenance cost

 High discharge air quality

All the above assures a low life-cycle cost.

The rotors incorporate a specially designed eta-v profile – ELGi patented profile-which emphasizes on improving reliability, performance and efficiency. Eta-v profile is the latest and the most energy efficient profile in the industry globally, assuring consistent performance during entire life of the compressor. ELGi screw air compressors have a compact design and compressor run with low noise or vibrations. The capacity control system ensures optimum air intake during start up, normal running and unloading stages, minimizing power consumption. The oil separation system ensures that maximum oil is separated from the compressed air, ensuring the best air quality with very little oil carry-over.

Uptime

At ELGi, we are changing the way you look at compressed

air systems. It’s no longer just about delivering air. It’s

about delivering uptime. Our uptime design ensures that the compressors would run cooler, cleaner and longer with longer service intervals. The uptime components are bests in quality keeps your compressor to run smoothly, efficiently and profitably. With uptime assurance we back our pledge, with industry-leading warranties, parts availability, loaner compressors and call centres staffed by experts. We thank you for purchasing ELGi compressor and assure you the best service during entire life of compressor.

EG Series

Your EG Series compressor belongs to a family of rotary screw compressors from ELGi. The compressor has only two moving parts: the two rotors. A thin film of oil separates the rotors to prevent wear. This also means that the reliability of the compressor is unsurpassed.

The screw compressor technology ensures that output capacity never diminishes even after many years of operation. It involves a continuous flow of air through helical cavities in the screw, ensuring pulsation-free compressed air delivery.

The design of the EG Series gives you a compact and selfcontained compressor. Because it contains no reciprocating parts, it runs quietly and free of vibrations. The discharge temperature of the coolant oil is low, less than 90oC (195oF), under normal conditions and therefore prevents carbonized oil from forming in the compressor.

Salient Features

 Three-stage air filtration

 Improved air filter life cycle

 Noise-free package suitable for in-house operations

 Variable capacity control system*

 High volumetric efficiency

 Efficient air-oil separation by OSBIC (Oil Separation By

Impact and Centrifugal action)

 Reliable fan that works even at high temperature

 Isolated cooling system

 Robust cooling system

 Industrial designed canopy

 Compact and hardly space-intensive

 Split type oil & after coolers for easy serviceability

 Flush type panels for easy handling

 Anti-vibration mounts for restricted vibration

 Increased life of consumables

 Integrated VFD (Variable Frequency Drive) and dryer*.

 Zero-leak flanged joints.

 Oil carry over < 1 ppm

 Advanced Neuron controller

 Globally certified product - CE / UL and other country

specific approvals.

* For selected models.

Introduction 2.2

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2.4

General functional description

The operator must follow the safe working practices, instructions, procedures that this manual describes for safe operation. The maintenance personnel must be adequately trained, and have read and thoroughly

understood this ‘Operation and maintenance manual’.

Decals are affixed at specific locations of the compressor and they illustrate very important safety precautions.

2.3.1 Precautions during installation

 Ensure that you fasten all loose parts before lifting. Select

the appropriate lifting equipment by considering the local safety regulations, size and weight of the compressor. Operate the lifting equipment carefully within the safe operating limits. Ensure all necessary personal protective equipment's (PPEs) is close at hand during this operation.

 Maintain a cool and clean ambient for the compressor

and ensure that the air inlet is not obstructed. Make arrangements to reduce the moisture entry through the incoming air.

 Remove protection such as caps, plugs, desiccant bags

before connecting the air line pipes.

 Remove the red colored protective clamps from the

airend and motor while commissioning the compressor.

 Do not use frayed, damaged or worn hoses. Distribution

pipes and connections must be of the correct size and suitable for working pressure.

 Make sure that the aspirated air by the compressor is

free of flammable fumes, vapors and particles, to prevent internal fire or explosion.

 For remotely controlled compressors and auto-start

compressors, provide a clear caution stating:

“DANGER” – Remotely controlled machine and will start without notice

 Ensure the operator is located far away from the intake

of the compressor.

 Position the after-cooler discharge pipe in a way that it

is free to expand under heat and is not in contact with or close to flammable materials.

 Do not exert external force on the air outlet valve and

keep the connected pipe always free of strain.

 Make available adequate cooling air must be made

available for the compressor particularly air cooled compressors. Make sure that exhausted air does not circulate back to the intake or cooling system.

 Make the electrical connections according to the legal

standards and earth the compressor suitably. Provide a sufficient number of fuses and other protective devices to protect the compressor against short circuits. Good practice is to provide an isolating switch nearby the compressor.

 Install manual valves behind non-return valves (NRV) to

isolate each compressor in multi-compressor systems. Do not rely on NRV for isolating pressure systems.

 Do not bypass, remove or adjust the safety devices or

other attachments residing on the compressor. Every installed pressure vessel or auxiliary outside the compressor should have pressure relieving device or devices, as required.

 Danger! Be aware that compressed air used for

breathing or food processing must meet O.S.H.A.

Safety 2.3

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2.5

General functional description

1910.134 or F.D.A. 21 C.F.R. 178.3570 regulations. Failure to do so may cause severe injury or death.

 Insulate or use protective guards to cover pipes or other

parts that may exceed 80ºC (176ºF). High-temperature pipes must have a clear marking as potentially dangerous.

 Position the compressor on level surface. In case of

inclined surface, contact ELGi.

 Do not allow compressed air to come in contact with

food and related items unless they are compressed airtreated specifically.

 Be aware that this air compressor is intended for

generating only industrial-use compressed air.

2.3.2 Precautions during operations

 When switching on remotely controlled compressors

ensure that no one is checking or working on the compressor at that time.

 Before starting, ensure that no tools or any loose parts

remain inside the compressor.

 Do not operate the compressor if a possibility exists

that it could inhale flammable or toxic fumes, vapors or particles.

 Do not operate the compressor below or above its

operating limits.

 Wear ear protectors if you work in an environment

where the sound pressure level reaches or exceeds 90 dB (A).

 Keep all the compressor doors shut during operation.

For carrying out routine checks, the doors should open only for short durations not more than 10 minutes. Wear ear protectors when opening a door.

 Keep hands, feet, floors, controls and walking surfaces

clean and free of water or other liquid to minimize the possibility of slips and falls.

Pressure release

 Know that annual servicing of the safety valve is

necessary. It should be checked at the prescribed pressure for operation.

 Use correct tools for maintenance and repair work.

Do not allow the manufacturers’ rated safe operating

pressure to exceed for pipes, valves, filters and other fittings.

 It is hazardous to point the compressed air directly

towards any personnel. Keep personnel out of the line of the discharge air when opening hoses or other points of compressed air discharge.

 Use only the correct type and size of hose end fittings

and connections. When blowing through a hose or airline ensure that the open end stays securely. A free end will whip and may cause injury. Make sure to

depressurize a hose fully before disconnecting it.

 Release all the pressure in the compressor system

before servicing or performing any maintenance activity.

 Do not engage in horseplay with air hoses. Serious

injury or death may result.

 Do not use air at a pressure greater than 2.5 bar.g (36

psi.g) for cleaning purpose.

 Open the oil fill cap only when the compressor is not

running and is not pressurized. Shut down the compressor and bleed the receiver tank to zero internal pressure before removing the cap.

Fire and explosion

 Clean up spills of lubricants or other combustible

substances immediately.

 Shut down the compressor and allow it to cool down

before checking or adding oil. Remove sparks, flames and other sources of ignition away from the compressor.

 Do not permit smoking in the vicinity of the compressor.

 Do not use flammable solvents for cleaning purposes.

 Keep electrical wiring and other terminals in good

condition. Replace any wiring that has cracked, cut, abraded or otherwise degraded insulation. Keep all terminals clean and tight.

 Keep grounded conductive objects such as tools away

from exposed live electrical parts like terminals to avoid arcing, which might serve as a source.

 Keep oily rags, trash, dry leaves, litter or other

combustibles out of and away from the compressor.

 Do not operate the compressor without a proper flow of

cooling air or with an inadequate flow of lubricant or with a degraded lubricant.

 Do not attempt to operate the compressor in a

hazardous environment of any classification unless the compressor has been specially designed and manufactured for explosive applications.

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2.6

General functional description

Moving Parts

 Rotating fan blades can cause serious injury. Disconnect

power supply before attempting service.

 Keep compressor doors closed except when servicing or

during maintenance. The sound damping material on the inner side of the compressor body should not be removed or tampered with.

 Wear snug-fitting clothing and tie long hair when

working around the compressor, especially when hot or moving parts such as the cooler, the airend, the thermal valve, the main motor or the fan motor are exposed.

 Keep hands, arms and clothing away from couplings,

fans/belts and other moving parts.

 Do not attempt to operate the compressor with the fan

guards, coupling guards/belt guards or other guards removed.

 Keep hands, feet, floor, controls and walking surfaces

clean and free of fluid, water or other liquids to minimize the possibility of slips and falls.

Hot surfaces

 Avoid bodily contact with hot oil and hot surfaces like

cooler, pipes etc.

 Keep all parts of the body away from all points of air

discharge.

 Keep a first aid kit handy. Seek medical assistance

promptly in case of injury. Do not ignore small cuts and burns.

Toxic and irritating substances

 Do not use air from the compressor for breathing.

 Always wear safety equipment while operating the

compressor. Refer OSHA safety standards.

 Do not allow compressed air to come into contact with

any edible items.

 In the event of ingestion of oils, coolants or lubricants

used in the compressor, seek medical treatment promptly. In case you come in contact with such substances, wash with soap and water. Use MSDS for oil to know more on this.

 If warm cooling air from the compressor is being used

in air heating systems, e.g. to warm up a work room, take precautions against air pollution and possible contamination of the breathing air.

Electric shock

 Keep all parts of the body and any handheld tools or

other conductive objects away from exposed live parts of the electrical system.

 Stand on a dry or insulating surface and do not contact

any other part of the compressor when making adjustments or repairs to exposed live parts of the electrical system.

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2.7

General functional description

 Before switching on the compressor ensure that proper

earthing is done as per recommendation.

 Make all adjustments or repairs with one hand. This

minimizes the risk of creating a current path through the heart.

 Conduct repairs only in a clean, dry, well-lit and

ventilated area.

 Do not leave the compressor unattended with open

electrical enclosures. If necessary to do so, disconnect the power to the compressor at the source and lock it out so that power is not in advertently restored.

 Disconnect, lock out, and tag the power source prior to

attempting repairs or adjustments, turning the compressor manually or handling ungrounded conductors.

 All electrical installation must be in accordance with

recognized electrical codes and any local health & safety codes.

 Recognize that only authorized and qualified trained

personnel should carry out any electrical work on the compressor.

 Regularly check that all electrical connections are tight

and in good condition.

Periodically check whether

 All guards are in place and securely fastened.

 All hoses and pipes inside the compressor are in good

condition, secure and not rubbing against each other.

 Any leaks exists.

 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, i.e. pipes, couplings, manifolds, valves,

hoses, etc. are in good repair, free of wear or abuse.

 The air-oil tank is properly grounded.

2.3.3 Precautions during maintenance

 Use safety glasses and incorporate safe working

practices before maintenance work.

 Use appropriate tools for all maintenance works.

 Use only genuine spare parts. Refer the section “Use

genuine spare parts” in “Maintenance” chapter.

 Ensure that the compressor is cooled down before

maintenance is performed.

 Springs under tension or compression store energy.

Uncontrolled release of this energy can cause serious injury or death. Be cautious while performing the maintenance of components loaded with springs (for example minimum pressure valve, safety valve etc.).

 Display a warning sign that says “Maintenance under

progress, don’t switch on” near the start switch.

 Isolate the compressor from the air line (discharge) and

disconnect the power by opening and locking the isolating switch before maintenance.

 Prior to attempting repairs or adjustments, disconnect

the power at the source and verify at the compressor that the circuits have de-energized. This minimizes the possibility of accidental start-up or operation, especially when the compressor is remotely controlled.

 Open the oil filler cap only when the compressor is not

running and is not pressurized. Shut down the compressor and bleed the receiver tank to zero internal pressure before removing the cap.

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2.8

General functional description

 If you are going to switch on remotely controlled

compressors must ensure that nobody is checking or working on the compressor at that time. A warning sign

near the equipment’s start button is mandatory.

 Wait up to five minutes to ensure that the air in the air-

oil separator tank is released to start routing maintenance.

 Vent all internal pressure prior to opening any line,

fitting, valve, drain plug, connection or other components such as filters. Vent pressure by popping up the safety valve.

 Display a maintenance chart near the compressor to

easily identify the maintenance intervals of regular service items.

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2.9

General functional description

2.4.1 Air circuit

The atmospheric air enters into the airend through the air intake system. The intake filters (pre filter and air filter) prevents the entry of foreign particles (such as dust) into the airend. The intake valve regulates the amount of air sucked into the airend. The opening and closing of the intake valve are controlled by the pneumatic pulse line actuated by an electrically controlled solenoid valve. The clog indicator fitted in the air filter turns red when the filter is clogged.

The filtered air enters into the airend where it mixes with the injected oil. The injected oil acts as a coolant to maintain optimum temperature. It also seals the leaks between the rotors and the housing and lubricates the bearings and gears. The airend consists of two counterrotating intermeshed helical screws - the male and the female rotors - which are driven by electric motor. The air

-oil mixture is trapped between the rotors of the airend and is progressively compressed.

After being compressed, the air-oil mixture enters with high velocity into the air-oil separator tank where it undergoes a unique 3 stage separation process which removes maximum oil content. This highly efficient 3 stage separation process uses the impact velocity of air-oil mixture along with centrifugal action, which makes the mixture very lean. The final stage of this separation consists of passing the lean mixture through the air-oil separator element which leaves the air with an oil content of < 1 ppm.

The oil separated and collected in this element is then returned to the airend through the oil return line. The air passes through a minimum pressure valve (MPV). It maintains a minimum differential pressure which is required for circulation of oil within the compressor unit. The compressed hot air is cooled in the after cooler and is

separated of any moisture content by the moisture separator. The cooled and moisture free compressed air is now discharged to the external receiver, ready to be used.

2.4.2 Oil circuit

The oil in the air-oil separation tank after being separated is fed into the airend. The oil either gets diverted to the oil cooler or oil filter or both depending upon the temperature. The thermal valve governs and controls the oil flow path. The oil before being injected into the airend is filtered. An orifice is provided in oil flow path towards the airend to control the oil flow. The whole oil circulation circuit in the compressor is operated solely by the differential pressure maintained by the minimum pressure valve (MPV) and doesn't require any additional pump.

2.4.3 Drive system

The airend transmission is powered by an electric induction motor through a coupling. When the compressor is turned ON, the motor is started in star mode and takes 6 to 9 seconds to change over to delta mode. During this period the intake valve remains closed and thus the motor starts without load. In delta mode, the motor speed stabilizes, the solenoid valve energizes after 10 seconds of change-over to reduce load on the motor, the blow down valve is closes, intake valve opens and the compressor starts loading. For compressors with variable frequency drive (VFD), speed of the motor gradually increases within 30 seconds (ramp-up time) while the intake valve remains in the closed position. This ensures very little starting load. Next, the intake valve opens and the system starts building up pressure. An adaptor ring connects the airend and the motor. It also helps in maintaining the coupling alignment. The coupling element acts as a safety interlock and it is the first one to fail when coupling elements become over loaded. This architecture saves the whole drive system from failure. Malfunctioning of the coupling

Figure 1. Screw compressor systems - Schematic diagram

Functional description 2.4

Page 18

2.10

General functional description

element will result in noise and vibration. Anti-vibration mountings reside below the air end and the motor. This configuration reduces the transmission of vibration from airend and motor to the structure, reducing noise and ensuring reliability of mounted parts on the structure.

2.4.4 Control system

Load - Unload

Depending on the demand for compressed air from the application at a particular time, the compressor needs to respond accordingly. The compressor, therefore operates in either loading or unloading mode to meet this requirement. The primary objective of these modes is to save energy and reduce wear and tear on the machine. The control system ensures a smooth start without overloading the motor. The compressor is started in star mode, during which most of the compressed air is vented to the atmosphere. This mechanism helps prevent overloading the motor. In delta mode the motor speed stabilizes, the solenoid valve energizes after 10 seconds of change-over to reduce load on the motor, the blow-down valve is closes, and the compressor starts loading.

When the receiver pressure reaches the maximum limit, a signal arrives the solenoid valve from the control system. Next, the inlet valve actuates and closes, and the compressor runs in unloading mode. If unloading mode continues for more than 5 minutes, i.e., compressed air is consumed and thus no decrease in pressure occurs, the system stops and switches to standby mode. If a drop in pressure occurs in the receiver, the compressor returns to loading mode automatically.

Suction modulation

When you operate a compressor without VFD, capacity control occurs via a pressure regulator (for selected models). When the consumption of air is less than the FAD of the compressor, the line pressure will start increasing. Whenever the line pressure goes up constantly beyond the set pressure, the pressure regulator bleeds the excess air to the atmosphere thereby reducing the amount of flow into the actuator. The actuator is spring loaded, which, in turn, closes the intake valve slightly and enables capacity control. Similarly when the consumption of air is more than the FAD, the line pressure starts decreasing and the actuator progressively opens the intake valve. This regulation is called intake modulation by throttling.

VFD modulation

VFD is an efficient way of controlling capacity as per demand. In a compressor with VFD the power of compressor varies proportionally with capacity reduction. The VFD tunes the frequency, thereby adjusting the speed based on the change in line pressure. The incoming flow will automatically reduce because of reduced speed of the motor. Conversely speed increases when line pressure goes down below working pressure.

2.4.5 For retro-fitment of Standalone VFD with Compressor (C) version in field

1. Change the bearings to insulated type for motors >=90kw at Non Drive End side of Motor

2. Turndown only upto 50% for conversion models (considering the motor speed) i.e. motor frequency range is 50 - 25 Hz for 50Hz variant and 60 - 30Hz for 60Hz variant. No pressure turndown is applicable

3. Run the compressor in the VFD operating range (50 to 25Hz) and skip the frequency in VFD controller (within +/1Hz) if abnormal noise / vibration is observed

4. Change the thermal element from 65°C to 75°C

Page 19

AIR INLET FOR MOTOR COOLING

OIL DRAIN

G1/2" MOISTURE

DRAIN

REMARKS

COIMBATORE - INDIA.

ELGI EQUIPMENTS LTD.,

Rev.DESCRIPTION

DRAWING No.

- CRITICAL CHARACTERISTIC (SAFETY/REGULATORY)

- SIGNIFICANT CHARACTERISTIC (FIT/FORM/FUNCTION/FINISH)

OUTLET

DISCHARGE AIR

VENTILATION

FOR PANEL

1-1/4" -BSP(MALE)-EG30&EG37

1-1/2" -BSP(MALE)-EG45

OIL POUR

AIR IN

COMPRESSOR

SUCTION

CENTRE OF GRAVITY

OIL DRAIN

OIL SIGHT

GLASS

SIZE G3/4"

Qty.

EG 30,37,45 (USA & BRAZIL)

24.4" 26.3"

Sl.No.

X Y Z

38.5"

MATERIAL

MODEL.

C AND CV

GA DRAWING-EG SERIES

WEIGHT

1 0 R

REVISIONDRG.SHEET

5 3 1 5 6 1

NEXT ASSY.

1 2

0 1

DRG.No.

NTS

REF.DRG.No.

SCALE

31.01.17

NAME DATE

PMD

APPROVED

CAD

CHECKED

CHKD. BY

2491

2293

2183

UNIT WEIGHT DETAILS (lbs)

MODEL C CV

EG 30

HOT AIR OUTLET (FROM FAN)

VFD DISPLAY

PANEL

2645.5

2513

2447

EG 37

EG 45

ALT. BY

DATEECO.No.REV. NO. DESCRIPTION

EARTHING POINT

ENTRY Ø2.36"

MAIN POWER CABLE

DESCRIPTION QTY

AIR INLET (FOR COOLING FAN)

VARIABLE FREQUENCY DRIVE (VFD)

CONTROLLER

17 1

18 1 PRE FILTER

DRIVE COUPLING

AIR OIL SEPERATOR

SAFETY VALVE

MOISTURE SEPERATOR WITH ADV 15 1

OIL AND AFTER COOLER ASSY 11

14 1

MINIMUM PRESSURE VALVE

CONTROL PANEL

THERMAL VALVE BLOCK

8 COOLING FAN

10 1

AIR - OIL SEPARATOR TANK

4 OIL FILTER 1

2 AIR END 1

5 AIR FILTER 1

6 INTAKE VALVE 1

1 MOTOR 1

S.NO

NOTE :

Pressure drop in conduit should not be more than 0.00435 psi g

4. Minimum distance required around the compressor is 3.3ft

2. All dimensions without tolerance are for reference only

1. Indicates Ducting Dimension

at all sides and 6.6ft at top (Installation requirement)

3. Cooling air flow for duct is 275454 ft³/hr.

5. VFD available in CV version only

Page 20

1 0 R

AIR FILTER

CHOKE INDICATOR

AIR END

INTAKE VALVE (NC)

AIR-OIL SEPERATOR

TANK

AIR - OIL SEPERATOR

AFTER COOLER

MINIMUM PRESSURE

VALVE

THERMAL VALVE

SAFETY VALVE

OIL COOLER

(AUTO DRAIN)

OIL FILTER

MOISTURE SEPERATOR

VALVE (NO)

BLOW DOWN

OIL DRAIN VALVE

SOLENOID VALVE (NC)

REMARKS

ELGI EQUIPMENTS LTD.,

REVISIONDRG.SHEET

COIMBATORE - INDIA.

5 3 1 5 6 1

Rev.DESCRIPTION

101

102

103

104

105

106

107

108

109

110

111

112

113

116

114

115

DRAWING No.

- CRITICAL CHARACTERISTIC (SAFETY/REGULATORY)

- SIGNIFICANT CHARACTERISTIC (FIT/FORM/FUNCTION/FINISH)

Discharge

Compressed Air

Qty.

Sl.No.

EG 30,37,45 (USA & BRAZIL)

MODEL.

MATERIAL

NEXT ASSY.

C AND CV

GA DRAWING-EG SERIES

REF.DRG.No.

31.01.17

NAME DATE

WEIGHT

2 2

0 1

DRG.No.

NTS

SCALE

31.01.17

PMD

APPROVED

CAD

CHECKED

CHKD. BY

ALT. BY

0 - 16 bar

0-150° C

RANGE

1 1/4 , 1 1/2 inch

PIPE SIZE

Air Line

LEGEND

2 inch

3/4 inch

1/4 inch

Air/Oil Line

Oil Line

Pulse Line

LOCATION

DESCRIPTION

Envelope Line

TAG NO

INSTRUMENT

220 V AC - NC

After Air end

After moisture

separator

on intake valve

DATEECO.No.REV. NO. DESCRIPTION

TEMPERATURE SENSOR

PRESSURE SENSOR

SOLENOID VALVE (NC)

TS01

PS01

116

Page 21

4.1

Technical data

Standard

Model - EG 30 EG 37 EG 45

Working pressure psi.g 100 125 150 175 100 125 150 175 100 125 150 175

FAD - Free air delivery

cfm 203 178 152 136 247 212 192 171 300 266 221 197

m3/ min

5.75 5.04 4.30 3.85 6.99 6.00 5.44 4.84 8.49 7.53 6.26 5.58

Unloading pressure psi.g 107 132 157 182 107 132 157 182 107 132 157 182

Nominal power supply conditions

- 208-230 / 460V (+/-10%), 60Hz(+/-5%), 3 Phase

460V (+/-10%), 60Hz(+/-

5%), 3 Phase

Main motor rating hp 40 50 60

Type of motors (main drive & fan drive)

- Squirrel Cage Induction-TEFC & Cooling Fan Integrated Motor

Insulation and protection of main motor

- Class F IP55

Frame size / mounting type

- 324T/L/B35 326T / B35T 364/5T / B35T

Type of starter for main motor

- Automatic Star Delta

Maximum fan motor rating per fan X no. of fans

hp 1.48 (1.1) - 208V-230V & 1.45 (1.1) - 460V X 2 1.45 (1.1) X 2

Rated speed of fan motor rpm 1400 (208V-230V) / 1480 (460V) 1480

Safety valve set pressure psi.g 205

Technical data 4.0

Standard + VFD

Model - EG 30 EG 37 EG 45

Working pressure psi.g 100 125 150 175 100 125 150 175 100 125 150 175

FAD - Free air delivery

cfm 203 178 152 136 247 212 192 171 300 266 221 197

m3/ min

5.75 5.04 4.30 3.85 6.99 6.00 5.44 4.84 8.49 7.53 6.26 5.58

Unloading pressure psi.g 107 132 157 182 107 132 157 182 107 132 157 182

Nominal power supply conditions

- 460V (+/-10%), 60Hz(+/-5%), 3 Phase

Main motor rating hp 40 50 60

Type of motors (main drive & fan drive)

- Squirrel Cage Induction-TEFC & Cooling Fan Integrated Motor

Insulation and protection of main motor

- Class F IP55

Frame size / mounting type

- 324T/L/B35 326T / B35T 364/5T / B35T

Type of starter for main motor

- Through Variable Frequency Drive

Maximum fan motor rating per fan X no. of fans

hp 1.45 (1.1) - 460V X 2 1.45 (1.1) X 2

Rated speed of fan motor rpm 1480

Safety valve set pressure psi.g 205

Page 22

5.1

Installation and operation

Contents Page No.

5.1. Installation and commissioning 5.2

5.1.1 Unpacking 5.2

5.1.2 Disposal of packing materials 5.2

5.1.3 Handling the compressor 5.2

5.1.4 Site requirements 5.2

5.1.4.1 Ventilation 5.3

5.1.5 Electricals 5.4

5.1.6 Air pipe dimensions 5.5

5.1.7 Receivers for compressed air systems 5.7

5.1.8 Possible mistakes 5.7

5.1.9 Commissioning procedure 5.7

5.1.10 Oil fill procedure 5.8

5.2. Preservation for long idle storage 5.9

5.2.1 Airend 5.9

5.2.2 Motor 5.9

5.2.3 Air-oil separator tank 5.9

5.2.4 Rubber hoses 5.9

5.3. Operating instructions 5.10

5.3.1 Initial start-up checks 5.10

5.3.2 Initial start-up 5.10

5.3.3 Pre-start checks 5.10

5.3.4 Starting 5.10

5.3.5 During running 5.10

5.3.6 Stopping 5.11

5.3.7 Changing the compressor settings 5.11

Installation and operation 5.0

Page 23

5.2

Installation and operation

Before the new EG series compressor is operated for the first time, it needs to be installed at your site according to ELGi's installation guidelines.

5.1.1 Unpacking

Unpack the compressor from the packing case by removing the nails. Unscrew the bolts, holding the compressor to the base of the cr ate .

Once the packing material is removed, check the contents against the packing list. The compressor is shipped with the following

 Key for doors

 Operation and maintenance manual

 Checklist of parts of the machine

 Electrical drawing

5.1.2 Disposal of packing material

The wood/cardboard used to make the shipping crates of the EG series compressors are biodegradable.

The polyethylene covers wrapped around the compressor and the polystyrene packing provided around the electrical panels are not recyclable. They must be disposed off in accordance with prevailing local environmental laws.

5.1.3 Handling

1. Lift compressors using either a forklift/pallet truck (Fig.2) or a crane (Fig.3).

2. When using a forklift, ensure padding is used in between the compressor and forklift (as shown in Fig.2) to prevent damage to the compressor’s canopy.

3. When using a crane, please ensure stiff spreader bars are used (as shown in Fig.3) to prevent rope slings from damaging the compressor’s canopy.

4. Do not drop the compressor.

5. Do not attempt to move the compressor by pushing or dragging it as this may cause jerky movements causing damage to the compressor.

5.1.4 Site requirements

 Install the air compressor in a clean, dry, cool and dust

free room as extreme temperatures (hot or cold), moisture, air borne contaminants can significantly affect compressor performance, durability and compressed air quality.

 Be aware the entrance to the compressor room should

be high enough and wide enough to carry the compressor in and out.

 Leave a minimum of 1m (3.28ft) space around the

compressor for safe and proper inspection, cleaning, and maintenance activities.

 Leave minimum of 2m (6.56ft) space above the

compressor for hot air to flow away from the compressor.

 Ensure the compressor is protected against direct

sunlight and rain.

 Avoid exposing the compressor to excessive moisture

(from rain, dryer vent, etc.) as moisture can affect airend lubrication, promote rust formation on the compressor and lead to electrical problems of the motor.

 Neither install the machine in a location where flame is

used nor place any inflammable objects near the compressor.

Installation and commissioning 5.1

Figure 2. Lifting using forklift

PADDING

NOTE

Removal of transit brackets:

Once you have placed the compressor in its final position, remove the red painted transit brackets and store for future use.

Locations:

 Bracket in between the base and airend support

 Bracket in between the base and motor

 Bracket in between the shroud and control panel box

STIFF SPREADER BAR

ROPE / SLING

Figure 3. Lifting using crane

Page 24

5.3

Installation and operation

 Ensure the room temperature is within 50ºC (122ºF) as

high ambient temperatures can reduced oil life due to higher discharge oil temperature (DOT). It also results in high approach temperatures affecting cooling and condensation efficiency in the after-cooler and in air treatment equipment like air dryers.

 Ensure the hot medium of other utility equipments like

genset/dryer/ boilers, etc., hot medium not sucked by compressor inlet or that in any way room temperature does not rise to prevent high discharge oil temperature.

 Ensure the ambient temperature does not drop below

0ºC (32ºF). Provide air supply openings and adjustable louvers to ensure that the minimum temperature does not drop down below 0ºC (32ºF).

 Ensure unevenness of the surface is within 6mm

(0.25").

 If the floor is splashed frequently with water while

cleaning, then place your compressor on a raised concrete plinth 100 to 150 mm (4 to 6 inches) high.

 Ensure the compressor base makes 100% contact

directly with the floor.

 Know that an industrial floor with level surface capable

of supporting the weight if the compressor is sufficient

for installing your compressor. No special foundation or anchoring is necessary for rotary screw compressors.

 Do not store toxic, volatile, or corrosive agents near the

compressor.

 Isolate the compressor from corrosive agents like

ammonia, chlorine, salt spray, and other chemicals as these may erode the internal components and also contaminate the oil and filters.

 Do not allow hot air from additional equipment to blow

towards the compressor.

 If you operate in high dust applications like rice mills,

cement, flour mills, etc., it would be necessary to clean and replace the filters more often.

 Good practice is to have overhead lifting in the

compressor room to facilitate any major overhaul. If an overhead hoist is not available, you should be able to use a mobile crane or forklift truck in your compressor room at a minimum.

5.1.4.1 Ventilation

 A part of electric energy to your compressor motor is

converted into heat and this heat must be removed from the compressor room by suitable ventilation.

 The ventilation requirements of the compressor are

listed in Table 1.

 The ventilation requirements could be achieved by the

following methods.

 Natural ventilation is sufficient if the temperature rise in

the compressor room (measured by a thermometer near the air inlet pre-filter) is within 5ºC (9ºF) when compared with outside temperature

 Forced ventilation with an exhaust fan is necessary if

the temperature rise inside the room (measured by a thermometer near the air inlet pre-filter mesh) is rises above 5ºC (9ºF) .

 Ventilation with ducts: Ensure hot air exhaust from the

compressor is diverted through the ducts when installed in an enclosed area. (contact ELGi for ducting requirements)

 Provide openings on walls/partitions close to the air

suction side of the compressor.

 Provide exhaust openings close to the ceiling for hot air

exit.

 If more than four compressors are installed in a room,

good practice is to provide ducting arrangements. This will avoid hot air recirculation.

 Be aware hot air recirculation in the enclosed area will

affect the compressor performance.

 Ensure the air velocity in the supply and exhaust ducts

does not exceed 4 m/s (13 ft/s).

 Know air velocity is ascertained during commissioning

Figure 4. Vertical clearance around the

compressor

MINIMUM 2 m (6.6 ft) CLEARANCE

CEILING

ELGi SCREW AIR

COMPRESSOR

Figure 5. Horizontal clearance around the

compressor

ELGi SCREW AIR

COMPRESSOR

MINIMUM CLEARANCE, X=1 m (3.5 ft)

WALLS OR OTHER EQUIPMENTS

Page 25

5.4

Installation and operation

using an anemometer.

 Do not connect cool air inlet ducts directly to the

compressor inlet side.

 To eliminate transmission of vibrations, provide a soft

bellows connector between the duct and the compressor.

 Contact ELGi in case you need to provide a duct

connection or filter fitment on the compressor.

5.1.5 Electricals

Figure 6. Forced ventilation with exhaust fan

Figure 7. Ventilation with ducts

Ensure that only authorized service technicians perform electrical work. Study the electrical circuit diagram before starting work.

Model

Minimum

ventilation

requirement

(ft3/h )

Minimum

ventilation

requirement

(m3/h) EG 11 94,537 2,677

EG 15 128,086 3,627

EG 18 157,185 4,451

EG 22 204,154 5,781 EG 30 242,576 6,869

EG 37 299,185 8,472

EG 45 363,847 10,303

EG 55 464,246 13,146

EG 75 631,708 17,888 EG 90 705,481 19,977

EG 110 864,821 24,489

EG 132 1,033,801 29,274

EG 160 1,273,482 36,061

EG 200 1,718,976 48, 676 EG 250 1,718,976 48, 676

EG 90-P 708,765 20,070

EG 110-P 1,218,356 34,500

EG 132-P 1,218,356 34,500

EG 160-P 1,218,356 34,500

Table 1. Global series – Ventilation requirements

Model

Motor power Back up fuse

Incoming Cable

size

Incoming Cable size Earth cable Gland Size

kW H.P

208 230V

460V

Sq.mm

Cu Sq.mm Al Sq.mm Size Dia

EG 11 11 15 100A 63A 4 X 10 4 X 16 4 X 4 4 X 6 2.5 Gauge 25 mm

EG 15 15 20 100A 63A 4 X 16 4 X 25 4 X 6 4 X 10 2.5 Gauge 25 mm

EG 18 18 25 125A 63A 4 X 25 4 X 35 4 X 6 4 X 10 2.5 Gauge 25 mm

EG 22 22 30 160A 63A 4 X 35 4 X 50 4 X 10 4 X 16 4 Gauge 28 mm

EG 30 30 40 200A 100A 4 X 50 4 X 70 4 X 16 3 1/2 X 25 4 Gauge 32 mm

EG 37 37 50 250A 125A 4 X 70 4 X 95 3 1/2 X 25 3 1/2 X 35 6 Gauge 35 mm

EG 45 45 60 125A 3 1/2 X 35 3 1/2 X 50 6 Gauge 35 mm

EG 55 55 75 160A 3 1/2 X 35 3 1/2 X 50 6 Gauge 35 mm

EG 75 75 101 250A 3 1/2 X 70 3 1/2 X 95 8 Gauge 50 mm

EG 90 90 121 250A 3 1/2 X 70 3 1/2 X 95 8 Gauge 50 mm

EG 110 110 147 315A 3 1/2 X 95 3 1/2 X 120 25 x 3 cu flat 1.75 inch

EG 160 160 214 400A 3 1/2 X 150 3 1/2 X 185 35 x 3 cu flat 2.25 inch

Table 2. Global series – Electrical requirements

Page 26

5.5

Installation and operation

1. Supply power to the compressor through a dedicated switch disconnected fuse (SDF) unit of a suitable rating mounted within 5 m (16.4ft) of the compressor. (This architecture lets you isolate the compressor).

2. Use HRC (high rupturing current) fuse instead of an MCCB (moulded case circuit breaker) to avoid possible contactor and motor failure.

3. Refer to Table 2 for fuse and cable specifications for 380/400/415 V, 50Hz, 3-Ph power supplies.

4. Do not use an MCB (miniature circuit breaker) because the selection of contactors is based on Type-2 coordination.

5. Connect the earthling line to the point provided on the base frame at the side of the compressor and motor.

Volume Flow FAD

NPS Pipe size/ Inside diameter (mm)

1/2 3/4 1 1 1/4 1 1/2

15.80 20.93 26.65 35.05 40.89

(m3/min) (cfm) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi)

0.1 4 0.02 0.22

0.2 7 0.06 0.80 0.01 0.20

0.3 11 0.12 1.69 0.03 0.41 0.01 0.12

0.4 14 0.20 2.88 0.05 0.71 0.01 0.21

0.5 18 0.30 4.35 0.07 1.07 0.01 0.32 0.01 0.08

0.6 21 0.43 6.09 0.10 1.49 0.03 0.45 0.01 0.11

0.7 25 0.57 8.10 0.14 1.99 0.04 0.59 0.01 0.15

0.8 28 0.73 10.38 0.18 2.54 0.05 0.76 0.01 0.19 0.01 0.09

0.9 32 0.90 12.90 0.22 3.16 0.07 0.95 0.02 0.24 0.01 0.11

1.0 35 1.10 15.68 0.27 3.84 0.08 1.15 0.02 0.29 0.01 0.13

1.2 42 0.38 5.38 0.11 1.61 0.03 0.41 0.01 0.19

1.4 49 0.50 7.16 0.15 2.14 0.04 0.54 0.02 0.25

1.6 56 0.64 9.16 0.19 2.74 0.05 0.70 0.02 0.32

1.8 64 0.80 11.40 0.24 3.41 0.06 0.87 0.03 0.40

2.0 71 0.97 13.85 0.29 4.14 0.07 1.05 0.03 0.49

2.2 78 1.16 16.52 0.35 4.94 0.09 1.25 0.04 0.58

2.4 85 1.36 19.40 0.41 5.80 0.10 1.47 0.05 0.68

2.6 92 0.47 6.73 0.12 1.71 0.06 0.79

2.8 99 0.54 7.72 0.14 1.96 0.06 0.91

3.0 106 0.61 8.77 0.16 2.23 0.07 1.03

3.5 124 0.82 11.66 0.21 2.96 0.10 1.37

4.0 141 1.05 14.93 0.27 3.79 0.12 1.75

4.5 159 1.30 18.57 0.33 4.71 0.15 2.18

5.0 177 0.40 5.73 0.19 2.65

5.5 194 0.48 6.83 0.22 3.16

6.0 212 0.56 8.02 0.26 3.71

6.5 229 0.65 9.30 0.30 4.30

7.0 247 0.75 10.67 0.35 4.94

7.5 265 0.85 12.12 0.39 5.61

8.0 282 0.96 13.66 0.44 6.32

8.5 300 1.07 15.28 0.50 7.07

9.0 318 1.19 16.99 0.55 7.86

9.5 335 1.32 18.477 0.61 8.69

10.0 353 1.45 20.64 0.67 9.55

15.0 530 1.42 20.22

5.1.6 Air pipe dimensions

Figure 8. Earthing line of compressor

Power cable entry

Earthing point

Page 27

5.6

Installation and operation

1. Use the pipe sizes (as in Table 3) for the delivery pipe that connects to ball valve of the compressor.

2. In case the main delivery pipe is more than 100 m (330 feet) long, use a pipe diameter that is one size bigger than shown in the table.

Table 3. Global series – Air pipeline dimensions

Volume Flow FAD

NPS Pipe size/ Inside diameter (mm)

1 1/2 2 2 1/2 3 4

40.89 52.50 62.71 77.93 102.26

(m3/

min)

(cfm) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi)

0.8 28 0.01 0.09

0.9 32 0.01 0.11

1.0 35 0.01 0.13

1.2 42 0.01 0.19

1.4 49 0.02 0.25 0.01 0.07

1.6 56 0.02 0.32 0.01 0.09

1.8 64 0.03 0.40 0.01 0.11

2.0 71 0.03 0.49 0.01 0.14

2.2 78 0.04 0.58 0.01 0.17

2.4 85 0.05 0.68 0.01 0.20 0.01 0.08

2.6 92 0.06 0.79 0.02 0.23 0.01 0.09

2.8 99 0.06 0.91 0.02 0.26 0.01 0.11

3.0 106 0.07 1.03 0.02 0.30 0.01 0.12

3.5 124 0.10 1.37 0.03 0.39 0.01 0.16

4.0 141 0.12 1.75 0.04 0.50 0.01 0.21

4.5 159 0.15 2.18 0.04 0.63 0.02 0.26 0.01 0.09

5.0 177 0.19 2.65 0.05 0.76 0.02 0.31 0.01 0.11

5.5 194 0.22 3.16 0.06 0.91 0.03 0.37 0.01 0.13

6.0 212 0.26 3.71 0.07 1.06 0.03 0.44 0.01 0.15

6.5 229 0.30 4.30 0.09 1.23 0.04 0.51 0.01 0.17

7.0 247 0.35 4.94 0.10 1.42 0.04 0.58 0.01 0.20

7.5 265 0.39 5.61 0.11 1.61 0.05 0.66 0.02 0.22

8.0 282 0.44 6.32 0.13 1.81 0.05 0.75 0.02 0.25

8.5 300 0.50 7.07 0.14 2.03 0.06 0.83 0.02 0.28 0.01 0.07

9.0 318 0.55 7.86 0.16 2.25 0.06 0.93 0.02 0.31 0.01 0.08

9.5 335 0.61 8.69 0.17 2.49 0.07 1.02 0.02 0.35 0.01 0.09

10.0 353 0.67 9.55 0.19 2.74 0.08 1.13 0.03 0.38 0.01 0.10

15.0 530 1.42 20.22 0.41 5.80 0.17 2.38 0.06 0.80 0.01 0.21

20.0 706 0.69 9.87 0.28 4.06 0.10 1.37 0.02 0.35

25.0 883 1.05 14.92 0.43 6.13 0.15 2.07 0.04 0.53

30.0 1059 1.46 20.90 0.60 8.59 0.20 2.90 0.05 0.75

35.0 1236 0.80 11.43 0.27 3.86 0.07 0.99

40.0 1412 1.03 14.63 0.35 4.94 0.09 1.27

45.0 1589 1.28 18.20 0.43 6.14 0.11 1.58

50.0 1765 0.52 7.46 0.13 1.92

55.0 1942 0.62 8.90 0.16 2.29

60.0 2118 0.73 10.46 0.19 2.69

65.0 2295 0.85 12.13 0.22 3.12

70.0 2471 0.97 13.91 0.25 3.57

75.0 2648 1.11 15.80 0.28 4.06

80.0 2824 1.25 17.81 0.32 4.58

85.0 3001 1.40 19.92 0.36 5.12

90.0 3177 0.40 5.69

95.0 3354 0.44 6.29

100.0 3530 0.48 6.92

150.0 5295 1.03 14.64

NOTE

The above table shows the pressure drops in 100m length schedule 40 steel pipe at 7 bar (abs)

Page 28

5.7

Installation and operation

5.1.7 Receivers for compressed air

systems

5.1.8 Possible mistakes

1. The compressor is installed on the wooden pallet of the packing case.

2. The compressor base is not making 100% contact with the floor.

3. The compressor is mounted on anti-vibration mounts.

4. The isolator is more than 5m (16.40ft) away from the compressor.

5.1.9 Commissioning procedure

1. Please make preparations according to the installation section as given, before the compressor is commissioned.

2. Ensure that the location meets the requirements of accessibility, ventilation and safety.

3. Provide electrical power as recommended in the installation section.

4. Select air pipe lines and receivers for your system according to the tables provided in the installation section.

Checkpoints before commissioning

Replace the parts in compressor if it had been in storage for more than one year.

1. Air filter

2. Oil filter

3. Air oil separator (check and replace)

4. Oil

a. Check for any external / internal damages of the

package.

b. Monger the main motor and fan motor should be

mongered to find the winding insulation conditions if the compressor is not commissioned for more than 1 year

c. Re-grease the main motor if the compressor is not

commissioned for more than 1- ½ years (18 months)

d. Replace the AVMs if you detect any abnormal squeezing

or damage in the rubber part.

e. Check whether all the screws in the control panel are in

place and tightened properly.

f. Check the oil cooler and after-cooler for any external fin

blockage and clear the blockage if necessary

g. Ensure that all the transit brackets are removed.

During commissioning

The servicing technician performs a series of checks on the machine and on the systems to which it connects, to ensure that it is in a condition to function safely and as recommended. The servicing technician will then explain to the operate and maintain the equipment. This procedure is referred to as the commissioning process.

The commissioning of the compressor ensures that it is installed safely.

The general operating conditions of the equipment including the cleanliness of the atmosphere, the temperature and the ventilation are checked. Technical details relating to your system such as particulars of your electrical installation are noted. The operator of the compressor is familiarized with all aspects of both its normal running and dealing with unusual situations.

Upon completion of the commissioning process, the technician will fill in the document known as the commissioning report and the warranty card provided in this manual.

During commissioning any modification suggested by the technician should be performed before the compressor is ready for regular use. Else, warranty becomes void. In case of change of operator other than the person trained, the new operator should be trained before he is dedicated

Receiver

applications

Compressed capacity

Volume On/Off control Modulation control

m3 ft3 m3/min cfm m3/min cfm

0.3 10.59 Up to 1.13 Up to 40 Up to 1.7 Up to 60

0.5 17.66 1.14 - 2.4 41 - 85 1.7 - 3.4 61 - 120

1.0 35.32 2.4 - 4.0 86 - 140 3.4 - 6.7 121 - 235

1.5 52.97 4.0 - 6.4 141 - 225 6.7 - 10.0 236 - 355

2.0 70.63 6.4 - 8.8 226 - 310 10.0 - 13.0 356 - 470

3.0 106.0 8.8 - 12.6 311 - 445 13.0 - 20.1 471 - 710

4.0 141.3 12.6 - 16.1 446 - 570 20.1 - 26.7 711 - 945

5.0 176.6 16.1 - 19.8 571 - 700 26.7 - 33.4 946 - 1180

6.0 211.9 19.8 - 24.0 701 - 850 33.4 - 40.0 1181 - 1415

7.0 247.2 24.0 - 28.0 851 - 990 40.0 - 46.7 1416 - 1650

8.0 282.5 28.0 - 32.0 990 - 1130 46.7 - 53.3 1651 - 1885

Table 4. Global series—Receivers specifications

Page 29

5.8

Installation and operation

for operating the compressor.

5.1.10 Oil fill procedure

Initial oil fill procedure

Check whether your compressor comes with oil filled. This can be checked through the oil sight glass on the air oil separator. If not, follow the oil filling procedure given below.

Oil level check

 The oil level should be half of the oil sight glass after

fumes settle down following shutdown.

 Ensure that the oil level sight glass and eye vision are

parallel while checking the oil level to avoid parallax error.

Sl. No.

Model Volume

of oil required (gallons)

Initial fill (gallons)

Second fill (After cranking) (gallons)

EG 30, EG 37

5.3 3.7 1.6

2 EG 45 6.6 5.0 1.6

NOTE

Refill oil in the tank if the level falls below the minimum level

Figure 9. Oil filling and oil sight glass location on

air oil seperator tank

OIL FILL PORT

(OVER FILL CAP)

OIL SIGHT GLASS

Fill oil in the oil tank up to over fill cap

Close the oil filling plug

Run the compressor for 10 minutes,

until the thermostatic valve opens

Stop the compressor

Unscrew the oil fill plug by 3 turns only

so that any entrapped air inside the

tank will bleed out it. By doing this the

sump pressure drops to atmospheric

pressure before opening the oil fill plug

Refill oil in the tank until max level

indicated on the tank sight glass

Initial fill

Second fill

Close the oil fill plug

Restart the compressor

Page 30

5.9

Installation and operation

If your compressor is going to remain unused for six months or longer, special measures must be undertaken to ensure the protection of the following components

 Airend

 Motors

 Air–oil separator tank

 Rubber hoses

5.2.1 Airend

To prepare the airend for 6-month storage:

 Remove the airend discharge hose/pipe coupling.

 Rotate the drive coupling three times so that the oil

present inside the airend comes out through the discharge port.

 Block the discharge port completely.

 Remove the inlet rubber duct connected to the intake

valve of the air filter assembly.

 Turn the intake valve flap and pour rust preventive oil

(use Castrol DWX 32 or an equivalent grade) into the airend through the intake valve.

 Rotate the coupling five times by hand so that the rust

preventive oil spreads all over the bearings, seals and other parts of the airend.

 Drain the rust-preventive oil by opening the discharge

port plug fully.

 Refit the hose/pipe coupling on the discharge port.

 Take care to ensure that all the openings are plugged

always to avoid dust entry.

 Rotate the compressor shaft once in 7 days and ensure

free rotation.

 Repeat the procedure every six months.

 For more details contact ELGi office or distributer

network.

5.2.2 Motor

To prepare the motor for 1-year storage:

 Check the insulation of the motor winding.

 Remove any moisture in the motor.

 Check junction box terminals for tightness of the wires.

 Apply grease on the motor bearings.

5.2.3 Air-oil separator tank

To prepare the air-oil separator for 2-year storage:

 Drain the oil from the seperator tank.

 Remove the entire tank from the compressor after

disconnecting it from all hoses, the tank top plate, the minimum pressure valve outlet line, and control pulse lines and control switches.

 Clean the tank using ELGi compressor clean flushing oil.

 Check the air-oil separator tank.

 Replace the oil filter element similarly.

 Flush the tank, airend with compressor oil and replace

the separator element before using the compressor again.

5.2.4 Rubber Hoses

Preservation for long idle storage 5.2

Test Recommendations for

Age Recommendations

Up to 3 Use without further testing

3 to 5 years Use after representative samples are

5 to 8 years

Use after representative samples are subjected to proof, impulse, and burst pressure tests and cold bend and

Over 8 years Scrap

Page 31

5.10

Installation and operation

5.3.1 Initial start-up checks

 Check whether the oil level in the tank is up to the

specified level. If not, top up oil as per the oil fill procedure given in the maintenance section.

 Open all doors and visually check the compressor for

abnormality. Make sure all connections are tight.

 Open the electrical panel door of the compressor and

check that the three phases and earth cables are connected securely. (L1, L2, L3, and PE wires)

 Check the necessary earthing line in the panel/

compressor base.

 Ensure that all condensate drains are connected

properly.

 For water cooled compressors, ensure that the water

inlet and outlet valves are opened. Also make sure that the inlet and outlet water drain valves are closed.

 For water cooled compressors, ensure that the water

quality is maintained as specified by ELGi.

5.3.2 Initial start-up

Open the air outlet ball valve, turn on power, and press the start button (Green). Check whether the main motor turns clockwise (when viewed from the main motor fan side of the compressor). The correct direction of rotation is also shown on the motor. Ensure correct direction of rotation. If not, stop the compressor by pressing the stop button (Red) on the control panel. Open the isolating switch and reverse the appropriate lines.

5.3.3 Daily start checks

Before using the compressor everyday, you must prepare it by performing these tasks:

 Check whether the oil level in the tank is up to the

specified level. If not, top up oil as per the oil fill procedure given in the maintenance section.

 Open all doors and visually check the compressor for

abnormality. Make sure all connections are tight.

 Refer section 6.1.1 for how to perform daily

maintenance activities.

5.3.4 Starting

To prepare to start the system, perform these tasks:

 Open the air discharge valve.

 Turn on power.

 If all the inputs from contact switches, pressure and

temperature transducers are normal, the display will indicate "READY''.

 Press the ''START'' (green) button on the controller.

 Machines with an automatic star-delta starter will have

6 seconds changeover time from star to delta and another 10-seconds delta-to-run delay.

5.3.5 During running

To ensure seamless running:

 Monitor the controller display and control panel

indicators regularly when the compressor is running.

 Graphic warning display: This gives graphically the

location of fault.

 Discharge temperature sensor & warning: It is

fixed on the air-oil discharge pipe. It senses the temperature of the discharge air-oil mixture. The compressor will shutdown automatically and the warning light on the controller will glow when the discharge temperature exceeds the preset value of 110 ± 5ºC (230 ± 9ºF).

 Separator element warning: Indicates that the

separator element needs to be replaced. The compressor will not shutdown automatically in this situation.

Operating instructions 5.3

Figure 10. Human machine interface

GRAPHIC WARNING DISPLAY

Please adhere to the safety instructions provided at the section 2.3.2 : Precautions during operations

Running the compressor in the wrong direction for more than 5 seconds will damage compressor parts or even cause total damage.

CLOCKWISE

Page 32

5.11

Installation and operation

 Oil filter warning: Indicates that the oil filter element

needs to be replaced. The compressor will not shutdown automatically in this situation.

 High discharge temperature warning: The

compressor will shutdown automatically and the warning light on the controller will glow when the discharge temperature exceeds the preset value of 110 ± 5ºC (230 ± 9ºF).

 Main motor overload trip: The compressor will

shutdown when the main motor is overloaded and the corresponding warning light will glow.

 Fan motor overload trip: The fan motor has internal

thermal overload protection, which safeguards the fan motor. If the fan motor trips discharge oil temperature will be high and the compressor will trip .

 Reset button: This button must be pressed before

restarting the compressor after it has shutdown with a warning. The machine must be restarted only after taking necessary remedial measures.

 Safety valve: This valve relieves the pressure in the air

-oil separator tank when it exceeds the set pressure. Refer “Technical data”.

 Reverse direction switch: If the motor rotates in the

wrong direction, the reverse direction switch detects and, in turn, trips off the compressor.

 After reaching the maximum cutoff pressure the

pressure sensor senses the pressure and cuts off the solenoid electrical supply.

5.3.6 Stopping

 Press the stop (Red) button in the controller. The

compressor will come to a halt within 10 seconds.

 In case of emergency, to stop the compressor, use the

emergency stop switch. Correct the fault, rotate counterclockwise and unlock the emergency switch. Then press the reset button before the next start.

 Do not use the emergency stop switch for normal

stopping.

 Isolate power to the compressor.

 Close the air discharge valve.

 For water cooled models, close the water inlet valve.

 If there is any possibility of freezing exists, drain the

cooling system completely.

5.3.7 Changing the compressor settings

Change the compressor settings using the tactile keypad and LCD panel on the controller. (Refer to Neuron manual to learn more about the control panel and how to interpret of the message.)

Refer the VFD setting procedure manual for VFD operations.

Model Type

Cutout pressure

bar (psi)

EG 11 EG 45

Standard,

Standard +VFD

Working pressure +

0.5 (7)

EG 55 EG 160

Standard

Working pressure +

1 (15)

Standard +VFD

Working pressure +

0.5 (7)

 Isolate power supply before the discharge ball valve

closes.

 Do not use the emergency stop switch for normal

stopping

Page 33

6.1

Maintenance

Contents Page No.

6.1. Maintenance 6.2

6.1.1 Maintenance intervals 6.2

6.1.2 Maintenance of individual components & systems 6.3

6.1.2.1 Pre filter 6.3

6.1.2.2 Air filter 6.3

6.1.2.3 Air oil Separator 6.3

6.1.2.4 Oil top up and oil changeover 6.4

6.1.2.5 Oil filter 6.6

6.1.2.6 Intake valve 6.6

6.1.2.7 Blow down valve 6.8

6.1.2.8 Minimum pressure valve 6.8

6.1.2.19 Thermal valve 6.9

6.1.2.10 Electrical motor greasing 6.9

6.1.2.11 After and oil coolers 6.9

6.1.2.12 Cooler prefilter accessory 6.10

6.1.2.13 Drive coupling 6.10

6.1.2.14 Moisture separator and auto drain valve 6.10

6.1.3 Use only genuine spare parts 6.12

6.2. Troubleshooting 6.13

6.3. Decommissioning, dismantling & putting out of service 6.18

6.3.1 Waste disposal 6.18

6.3.2 Dismantling the compressor 6.18

6.3.3 Decommissioning the compressor 6.18

6.3.4 Disposal of consumables and replaced parts 6.18

6.4. ELGi services 6.19

6.4.1 ELGi customer care system (ECCS) 6.19

6.4.2 ELGi genuine spare parts 6.19

6.4.3 Air audit 6.19

6.5. Appendix 6.21

6.5.1 Conversion tables 6.21

6.5.2 Torque values 6.22

6.5.3 Service log book 6.23

6.6. Disclaimers 6.24

Maintenance 6.0

Page 34

6.2

Maintenance

6.1.1 Maintenance intervals

Precautions

A. If the compressor is kept idle

 Isolate the power supply.

 Close the main air outlet valve.

 Drain the water from the condensate system.

 Close the inlet and outlet water valve. (applicable only

for water cooled compressors)

B. If the compressor is kept idle for more than 6

months

 Follow the above steps.

 Refer to the section “Preservation for long idle storage”.

Maintenance 6.1

NOTE

The above life time guidelines are applicable only to standard operating and regular maintenance conditions recommended in this manual. In the event of changes in the conditions, consult ELGi.

Table 5. Maintenance intervals

Volume

ELGi Air Lube

UT Synthetic

ELGi Air Lube

5 litres (1.3 gallons) 000998067 000998079

20 litres (5.3 gallons) 000998068 000998078

210 litres (55 gallons) 000998069 000998077

Table 6. Compressor oil

Sl. No. Motor make Grease

1 ELGi ESSO Polyrex EPL

2 SIEMENS Unirex N3 ESSO

3 WEG MOBIL Polyrex EM

Table 7. Electric motor grease

Frequency Part Remarks

Daily

Oil level Check MOS condensate Check Warning / alarms Check Condensate in AOS tank Check

Weekly

Pre filter ( air intake, cooler, control panel) Clean Air filter element Clean *

1000 hours or 3 months #

Pre filter Clean Moisture drain Clean

2000 hours or 6 months #

Oil & after coolers - air cooled (External) Check & Clean Oil filter Replace Oil Sampling ** 50 Hz motor - 2 pole grease Replace

4000 hours or every year

Pre filter ( air intake, cooler, control panel) Replace Air filter element Replace Oil – Air lube XD / Air lube FG Replace Air-oil separator element – Air lube XD / Air lube FG Replace 50 Hz motor ( 4 pole ) grease Replace 60 Hz motor ( > 25HP ) grease Replace Return line sight glass / orifice / NRV Check & Clean Return line strainer Check & Clean

8000 hours or every 2 years

Air-oil separator element - UT Synthetic Replace Oil - UT Synthetic Replace 60 Hz motor ( ≤ 25HP ) grease Replace Electrical connections Check Drive coupling element Replace Pipe coupling element Replace Intake valve kit Replace Actuator kit Replace MPV kit Replace BDV kit Replace Solenoid valve Replace Safety valve Replace MOS-ADV kit Replace Control line filter-ADV kit Check & Replace Hoses and Fittings Kit Replace Blow down adjustment kit Check & Replace Oil & after coolers - water cooled (External) Check & Clean

# - Whichever comes first * - As per air filter clog indicator ** - For USA region only

Page 35

6.3

Maintenance

6.1.2 Maintenance of individual

components and systems

Check all accessories independently to verify that they are functioning as required and replace their components as necessary. After maintenance restart the compressor as mentioned in section “Operating instructions”.

6.1.2.1 Pre filter

Pre work

 Switch off the compressor and disconnect power supply

to the compressor.

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool

for a few minutes.

Requirements

 Compressed air, new pre-filter element (if needed)

Maintenance

 Switch off the machine.

 Refer to the pre-filter cartridge removal & insert

procedure.

 Hold or fix the pre-filter assembly in the cleaning area.

 Clean the pre-filter with compressed air at less than 2.5

bar.g (36.3 psi.g) from the reverse or back side of the pre filter cartridge.

 In case of major dust/dirt accumulation in the pre-filter

element, wash with clean water or light detergent.

 Do not use any acidic/alkaline chemicals for cleaning.

 Repeat this process based on dust

conditions or at regular periodic intervals.

Suction pre-filter cartridge removal procedure

1. Slide Upward

Hold the pre-filter between the louvers and slide upwards slightly until the pre-filter bottom edge is visible

2. Slide Downward

When the pre-filter bottom edge is visible, slant the pre-filter forward and slide it downwards away from the compressor

3. Pull Forward

When the top and bottom edges of the pre-filter are free from the compressor, move the pre-filter forward to remove completely.

Suction pre filter cartridge insert procedure.

For insert sequence procedure from 3-2-1

6.1.2.2 Air filter

If the air filter clog indicator shows a red colour (meaning the blocked condition) then the air filter needs to be cleaned or replaced (if the stipulated life has elapsed).

Pre work

 Switch off the compressor and disconnect power supply

to the compressor.

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool

for a few minutes.

Requirements

 Compressed air, new filter element (if needed).

Maintenance

 Unlock the mounting clips provided on the filter

housing.

 Rotate and remove the filter element carefully.

 Clean the filter using moisture free compressed air at

less than 2.5 bar.g (36.3 psi.g).

 Clean from the inside to outside.

 Remove the dust ejector from the filter housing cap and

clean it carefully.

 Show bright light from inner side of the filter element to

inspect for damage or holes that result in leaks. Light

Disconnect all the power at the source before attempt to perform maintenance or make adjustment.

Fig 11. Pre filter

PRE FILTER ELEMENT

PRE FILTER CATRIDGE

Figure 12. Air filter

FILTER ELEMENT

FILTER HOUSING

Page 36

6.4

Maintenance

will emerge from the holes, indicating their locations. In case of damages replace the filter element

 Inspect all rubber sealing and their contact surfaces of

the housing. Faulty rubber sealing must be replaced immediately.

 Return the dust ejector back in correct (bottom)

position.

 Return the filter element back in position, assemble the

filter housing cap such that the dust ejector settles in bottom position, and lock the assembly using the mounting clips.

 Inspect and tighten all air inlet connections prior to

resuming operation (if necessary).

 Reset the air filter clog indicator.

 If a clean element is to be stored for later use, it must

be stored in a clean container.

6.1.2.3 Air oil separator

Pre work

 Switch off the compressor and disconnect power supply

to the compressor.

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool

for a few minutes.

Requirements

 Strap wrench, new separator element, clean cloth.

Maintenance

 Relieve oil pressure from the air oil tank and all fluid

lines with the help of safety valve

 Disconnect all piping connected to the air oil tank

 Disassemble the separator element by rotating it

counter-clockwise cover to isolate the air oil tank from the return lines, service line, etc.

 Remove the hex head bolt from the top plate.

 Swivel the top plate of the air oil tank.

 Remove the separator element.

 Scrap the old gasket material from cover and flange on

the air oil tank. While doing so, take care not to let the scraps fall into the air oil tank

 Inspect and clean the air oil tank for rust and dirt.

 Stick the new gaskets on to the separator element one

on either side.

 Replace the new separator element into the air oil tank,

taking care not to dent it against the tank opening.

 Reposition the Top plate and assemble it by using

fasteners. Torque: 120 N-m (88.5 lb-ft).

 Reconnect all piping.

 Clean the return oil strainer before restarting the

machine.

6.1.2.4 Oil top up & oil change over

Proper compressor maintenance and operation is crucial for the lubricant to function properly and last till its estimated rated oil hours. The oil product shelf life is of minimum 3 years and maximum 5 years. Products should be kept properly sealed in the original container. Once the seal is broken, the above stated life span of the product is no longer applicable. Products should be stored in proper storage warehouse that is away from direct sunlight and is not exposed to weather elements like rain, typhoon and snow storms. The products should also be stored away from any heat source, high humidity and moisture areas.

The air-oil separator tank is tested according to standards. Regularly have inspections performed in conformity with local regulations.

NOTE

TOP COVER

SCAVENGING LINE TUBE

SEPERATOR ELEMENT

DISCONNECT ALL PIPE LINES/ TUBE LINES

Figure 13. Air oil separator

TOP PLATE

GASKET

SEPERATOR ELEMENT

TANK

Page 37

6.5

Maintenance

If drums are stacked on ground level, they should all be stacked horizontally with the bung openings arranged at the 3 and 9 o’clock position.

ELGi recommends that once the seal is broken, all products be used immediately. ELGi does not encourage reuse or recycling of any leftover fluids due to contamination hazard. ELGi will not warrant the quality of the product once the original seal is broken. Also ensure that the oils are not mixed up between brands and types.

Please refer Material Safety Data Sheet (MSDS) for oil spill handling and disposal procedures.

Pre work

 Switch off the compressor and disconnect power supply

to the compressor.

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool

for a few minutes.

Requirements

 New oil, flushing fluid (if needed)

Maintenance

Step 1: Draining

a. Remove drain plug from the bottom of the separator

tank and drain out all oil. Drain oil while the compressor is warm.

b. Remove the pipe and drain plug from bottom of oil

cooler. Then completely drain.

c. Disconnect all oil pipe work which could trap oil and

drain completely.

d. Drain oil from the airend discharge pipe after

dismantling it.

e. Drain oil from the airend by hand rotation.

Step 2: Flushing (Only for oil change over)

Check the air-oil seperator differential pressure. To flush clean/non-varnished machines, using:

Mineral/PAO/PAG oils

a. Fill the compressor with the ELGi cleaner (use the same

compressor oil fill volume) and run the compressor.

b. After 500 hours of running, drain the cleaner as per

step 1.

c. Refill the compressor with new compressor oil.

d. Send a sample** of the compressor oil to ELGi for oil

analysis after 300 hours.

Step 3: Filling the oil

a. Add fresh oil; fill it up to the oil fill plug. (initial fill)

b. Close the oil fill plug.

c. Pour oil into airend, then restart the compressor.

d. Allow it to run for about 10 minutes.

e. Stop the compressor.

NOTE

 The compressor is originally filled with a particular oil, if

you want to change over to other types of oil, perform steps 1, 2 and 3.

 But if you want to change the oil but continue with the

same kind (same brand & type) perform steps 1 and 3 only.

 Ensure that you drain at least 90% of oil capacity of the

compressor; if not the residual oil can contaminate new oil.

 Ensure no oil spills on anti-vibration mount during

maintenance.

**: Applicable only for USA.

 The cleaner is not recommended to run longer than 500

hours.

 Change the oil filter and oil separator after oil change

over.

NOTE

Figure 14. Air oil separator tank– oil drain

OIL LEVEL SIGHT GLASS

OIL FILL PORT

(OVER FILL CAP)

Figure 15. Cooler oil drain

COOLER

DRAIN PLUG

Page 38

6.6

Maintenance

f. Unscrew the oil filling plug after 5 minutes so that

residual pressure in the tank is vented out through the bleed hole in the oil fill plug.

g. Refill the tank up to the oil fill plug. (second fill)

h. Restart the compressor.

6.1.2.5 Oil filter

The oil filter is fitted between the oil cooler and the airend unit. The components of the oil filter assembly are shown in the figure. This is a full flow filter with a pleated element. To service this filter, order the consumables kit (available with ELGi service personnel) The procedure for complete servicing of this filter is as follows.

Pre work

 Switch off the compressor and disconnect power supply

to the compressor.

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool

for a few minutes.

Requirements

 Strap wrench, new oil filter, O-ring, and clean cloth.

Maintenance

Dismantling method of oil filter:

 Hold the filter shell and & rotate it counter - clockwise

by strap wrench

Assembly of new oil filter:

 Ensure the O-ring of the filter is damaged free.

 Clean the seating surface with clean cloth

 Apply a thin film of oil on the mating surface of the

O-ring.

 Return the filter to its original position and rotate it

clockwise manually. After tightening, rotate it further by hand for one and a half times

 Ensure no oil leaks from the mating surface.

6.1.2.6 Intake valve

Pre work:

 Switch off the compressor and disconnect power supply

to the compressor.

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool

for a 10-minutes.

Requirements :

 Soft cloth, grease, liquid cleaner, Allen keys, screw

driver, spanner, pressure gauge, service kit (if needed).

Procedure :

Disassembly :

 Remove the hoses connected to the intake valve

(Suction hose filter to intake valve pulse line, BDV line)

 Remove the intake valve

 Block the airend intake opening port, to avoid entry of

any foreign particles inside the airend

Servicing of intake valve

 Replace the service kits ( K2,K2/A,K2/B,K3,K2 block) in

case of any failure or damage. Refer exploded view.

Function test :

 Connect the pressurized air to the control block and test

smooth opening and closing of valve for several times

Reassembly of intake valve

 Ensure intake valve mating place (adaptor plate) free

from dust and foreign particles

 Clean if any dust and foreign particles present in intake

valve mating place

 Mount the intake valve on the adaptor plate (refer

intake system)

 Ensure presence of sealing ring at the bottom of intake

valve

 Reconnect the pulse line, BDV line and suction hose

areas must not be damaged.

Valves should not be opened when pressure is applied.

Suspended particulate matter should be less than 150spm to achieve the specified consumable life. Guarantee becomes void if the compressor is operated above its intended pressure.

NOTE

The maintenance of following parts (valves) demands highly skilled authorized personnel. So, it is recommended that an ELGi service engineer does the maintenance.

NOTE

Figure 16. Oil filter

THERMAL VALVE BLOCK

ADAPTOR

OIL FILTER

Page 39

6.7

Maintenance

Service

kit

Part number Description Remark

1 K2 B009405770009 Spare kit block

Refer spare kit detail

table for complete

intake valve kit part

number

B009405770010(30 kW)

Body spare parts kit 2

B009405770011(37 & 45 kW)

3 K2 block B009405770007

Control block unit kit (blowdown block kit)

Figure 17. Intake valve

CONTROL UNIT

ELBOW FOR-

PULSE LINE

CONNECTION

ELBOW FOR-

BLOW DOWN VALVE LINE

CONNECTION

HOUSING

SOLENOID VALVE

Figure 18. Intake valve—Exploded view

Page 40

6.8

Maintenance

 Then reassemble

6.1.2.7 Minimum pressure valve

Pre work

 Switch off the compressor and disconnect power supply

to the compressor.

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool

for a few minutes.

 Release the receiver tank and downstream pressure.

Requirements

 New MPV kit, allen key, grease.

Maintenance

MPV replacement (for 30 & 37kW)

Dismantling

 Isolate MPV from air-oil tank to MPV flange assembly

and MPV to cooler flange assembly

 Remove plastic plug (1) and pull out round-headed pin

(2).

 Unscrew and remove threaded ring (3) and remove

washer (9).

 Take out spring (4) and circlip (10).

 Remove piston (5), check valve (7),spring (6) and O-

ring (11).

Cleaning and Lubrication

 Clean the piston work-surface and sealing seat with a

liquid cleaner.

 Grease the threads, piston work-surface and check

valve work-surfaces with autoltop 2000 (supplied in service Kit).

 Take care not to damage the seat and sealing surfaces

MPV replacement (for 30 & 37kW)

Reassembly

 Put O-ring (11) into lower housing groove. Place check

valve (7) with spring (6) centrally onto valve seat in housing (8).

 Insert piston (5), circlip (10) and spring (4). Lay washer

(9) on spring (4) as shown in drawing.

 Screw in threaded ring (3) to its original position and

secure it with round headed pin(2). Insert plastic plug (1).

MPV replacement (for 45kW)

 Unscrew the head and replace the old parts with new

parts using service kit (K)

Extreme caution should be taken while removing the cap or cover from the body because of the spring.

After completion of intake valve assembly in package, ensure to verify the performance

NOTE

Figure 19. Minimum pressure valve

AUTOL TOP 2000

FLANGE ASSEMBLY—TANK TO MPV

FLANGE ASSEMBLY—MPV TO COOLER

MPV

AUTOL TOP 2000

HEAD

Page 41

6.9

Maintenance

6.1.2.8 Thermal valve

Pre work

 Switch off the compressor and disconnect power supply

to the compressor.

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool

for a few minutes.

Requirements

 Pliers, screw driver, new thermal valve element, new O-

ring.

Procedure

Replacing thermal Valve

 Remove the thermal valve element from the thermal

valve block body

 Inspect and clean seating area in the housing

 Replace with a new thermal valve.

6.1.2.9 Electric motor greasing

Pre work

 Switch off the compressor and disconnect power supply

to the compressor.

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool

for a few minutes.

Requirements

 Recommended grease, cleaning cloth, grease gun.

Procedure

 Stop the motor and lock out the switch.

 Thoroughly clean the grease inlet fitting or plug. If the

motor has a plug, remove the plug and clean the inlet.

 Remove the drain plug and wipe out any hardened

grease.

 Slowly pump the grease into the grease inlet until the

new grease comes out of the drain plug.

 Start the motor and let it run for a minimum of one

hour to expel any excess grease from the drain opening before re-installing the drain plug.

 Stop the motor and lock out the switch.

 Re-install the drain plug.

 Put the motor back in operation.

6.1.2.10 After and oil coolers

Pre work

 Switch off the compressor and disconnect power supply

to the compressor.

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool

for a few minutes.

Requirements

 Pliers, allen keys.

Maintenance

External surfaces:

 Isolate the machine from the service line

 Vent the separator tank pressure before attempting

maintenance

 Open both the LH panel and cooler inspection cover

 Use compressed air below 2.5 bar/36.3 psi maximum to

clean the outer surface of the cooler. Supply a jet of air in the direction opposite to cooling airflow direction

 After cleaning the outer surface of the cooler properly

close the cooler with a cleaning plate and an LH panel.

6.1.2.11 Cooler prefilter accessory (optional)

Cooler prefilter cleaning & maintenance instructions

 Switch off the machine.

 Lift upward & take out the cooler pre filter from the

compressor.

 Hold or fix the prefilter assembly in the cleaning area.

Figure 20. Thermal valve

THERMAL VALVE ELEMENT

THERMAL VALVE BLOCK

Figure 21. Cooler external surface

COMPRESSED AIR JET

COOLER CLEANING PLATE

FASTNERS

LH PANEL

Page 42

6.10

Maintenance

 Clean the pre-filter with compressed air at less than 2.5

bar.g (36.3 psi.g) from the reverse / back side of the cooler prefilter.

 In case of major dust / dirt accumulation in the pre-

filter element, wash with clean water or light detergent. Do not rinse.

 Do not use any acidic / alkaline chemicals for cleaning.

 Repeat the process based on dust conditions or regular

periodic intervals.

6.1.2.12 Drive coupling

Pre work

 Switch off the compressor and disconnect power supply

to the compressor.

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool

for a few minutes.

Requirements

 Spanners, new coupling element.

Maintenance

Replacing the coupling element:

 Open the cooler side panel covers

 Open the coupling guard from the adapter ring .

 Remove the three coupling screws and slide coupling

element on the shaft spline to free the coupling element

 Replace the old coupling element with a new coupling

 element

 Tighten the coupling screws to the specified torque

 Assemble the coupling guard and cooler side panel

cover

 Inspect every three months to ensure screws stay tight.

6.1.2.13 Moisture separator and auto drain valve

Pre work

 Switch off the compressor and disconnect power supply

to the compressor.

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool

for a few minutes.

Requirements

 Spanner, screw driver, player, caustic soda.

COOLER PREFILTER

Figure 22. Cooler prefilter accessory

COOLER PREFILTER

COMPRESSED AIR

COOLER PREFILTER ELEMENT

HANDLE

MOUNTING HOOK

COOLER PREFILTER FRAME

Figure 23. Drive coupling

HUB

ELEMENT

HUB

Page 43

6.11

Maintenance

Dismantling

 Disconnect the pressure sensor line on top of the

moisture separator

 Manually drain the condensate by using the manual

discharge plug located at the bottom of the auto drain assembly.

 Remove the moisture separator from the machine

 Remove the bottom housing from the top housing.

 Remove the auto drain assembly from the bottom housing.

Cleaning and replacement

 Inspect the O-ring and replace it with new one in the

kit, if necessary

 Clean the housing and all other inner parts

 Ensure the mating surfaces of the O-ring are clean and

free from foreign particles

 The auto drain assembly is not serviceable and must be

replaced with new one if not functioning

Reassembly

 The vortex generator cone and the cyclone arrestor

need only to be tightened moderately by hand. Overtightening may lead to failure or damage. ELGi assumes no responsibility for failure or damage resulting from such incorrect installation.

 Reassemble the auto drain assembly with the bottom

housing and the bottom housing with the top housing

 Reassemble the moisture separator in the machine and

connect the all pipe lines, pressure sensing line, and drain line

 Restart the machine and check for any leaks at the

joints. If leaks occur, stop machine and wait for sump pressure to drop to atmospheric pressure.

 Remove the O-ring as described above, and inspect and

clean it

 Ensure that the mating surfaces are clean and refit the

O-ring

Moisture separator may be heavy. Caution should be taken while removing it from the machine.

 Avoid damaging the housing when removing or

tightening the moisture separator. Do not use a pipe wrench. If necessary, use a locking strap clamp/wrench

 Install the separator in a vertical upright position,

observing the correct direction of air

NOTE

Figure 24. Moisture separator and auto drain valve

MANUAL DISCHARGE

INLET FROM COOLER

ARROW DIRECTION

OUTLET

PE WASHER

O-RING (CONE)

CAP SCREW

TOP HOUSING

O-RING HOUSING

VORTEX GENERATOR

-VANE

VORTEX GENERATOR

-CONE

TIE ROD

ARRESTOR

BOTTOM HOUSING

EXTERNAL AUTO DRAIN

Page 44

6.12

Maintenance

6.1.3 Use genuine spare parts

It is very important to use genuine spare parts, to ensures that your compressor work as new for its lifetime. Spurious spares may seem less expensive initially, but they severely compromises on quality. Spurious parts will prove costineffective in the long run, and may even result in total damage of the machine or cause serious accidents. The table includes certain critical spurious parts. It is not an exhaustive list, and you are strongly advised to avoid all other spurious spares that this table does not cover. Be aware of the consequences of using spurious spares including but not limited to the ones described in the table.

Effect Spurious part Remarks

Air oil separator

Due to dense filtration media, it creates in additional pressure drop and so causes additional power consumption. Every1 bar (14.5 psi) of pressure drop results in ~7% additional power consumption.

Higher power consumption

Lubricant

Spurious oil loses its properties soon and may get solidified causing the rotor to malfunction.

Reduced performance

Air oil separator

This imposes 10% additional resistance for air flow and creates more pressure drop and thus additional load on motor. Inadequate separation deteriorates air quality, reduce the performance, and damages downstream components. It also results in huge oil loss (1L / 200hr).

Oil filter

Contaminants are not filtered properly and the contaminated oil affects the critical parts of airend. Thus it reduces performance and life (33% reduction) of the air end, air oil separator etc. Contaminated oil also cause clogging and reduces the cooler performance.

Air filter

Dust carries over to the system and causes the same problems as caused by the spurious oil filter

Safety hazard Air oil separator

Inadequate earthing can cause a separator to collapse (25% risk). Inadequate earthing can also cause fire and destroy the entire machine.

Cost

Higher power consumption means a higher operating cost.

Reduced performance leads to extra functioning and operating cost.

Spurious parts will damage the other components and accelerate maintenance frequency and cost.

Higher consumption of consumables like oil (due to the use of spurious parts) will result in, increased cost.

Page 45

6.13

Maintenance

Troubleshooting 6.2

This guide lists the most likely indications with possible causes. For any problem, follow the diagnosis in sequential order as mentioned in the following charts. Before doing any work in the compressor, be sure that electrical supply has been cut off and the entire compressor is depressurized.

Problem Cause Solution (go sequentially)

Compressor not starting

Power supply not available Restore incoming power supply

Incoming voltage is below limit

(1) Correct the incoming voltage.

(2) Ensure isolator is within 5m (16 ft) from the compressor.

(3) Ensure sufficient power back up

(4) Select and use the correct cable size.

Emergency stop switch in pushed condition

Rotate counterclockwise direction and release

Emergency stop switch malfunction

Clean or replace the emergency switch.

Tighten the wires at terminals

Isolator fuse blown.

(1) Select correct fuse rating from selection chart.

(2) Check and correct the short circuit within the control panel.

(3) Dedicated isolator to be provided to the compressor.

(4) Check and correct the motor winding/ body short after megger test.

Incoming phase-to-phase voltage imbalance of more than 5V

Correct incoming voltage.

Adjust main incoming transformer tapping.

Correct the power factor to less than unity.

Incoming phase to earth voltage imbalance of more than 5V

Correct the incoming voltage.

Control MCB malfunction Replace MCB

Control fuses inside compressor control panel blown

Check for any short circuit or loose connection.

Replace the solenoid valve / control transformer if defective.

Replace the glass fuse (2A for Neuron, 1A for the control circuit).

Control transformer fuse blown

Replace the control transformer if defective.

Replace glass fuse (0.25A for Neuron, 0.5A for the control circuit).

No power supply to Neuron controller.

(1) Replace control transformer fuses.

(2) Ensure tight connection of the 24V power supply connector to Neuron

(3) Replace control transformer (50VA).

No display in Neuron controller

(1) Replace the control transformer (50VA).

(2) Replace the control fuse.

(3) If 24V power supply to Neuron is okay then replace with anew Neuron micro controller.

Page 46

6.14

Maintenance

Problem Cause Solution (go sequentially)

High discharge oil temperature

Oil level is low

(1) Check and refill oil to correct the level. (in stopped condition)

(2) Refer diagnosis procedure for high oil carry over.

(3) Arrest oil leaks

(4) Ensure the correct grade of oil is used.

Room temperature is higher than outside ambient temperature by 30°C (86°F)

Improve ventilation in compressor room

Oil cooler clogged externally

Clean the cooler assembly / cooler pre filter mesh (if available) externally by first using a fibre brush and then blowing compressed air at 2.5 bar.g(36.3 psi.g).

For sticky dust, remove the cooler, close all the cooler ports with dummy plugs and do a water-wash with soap oil.

Install the cooler prefilter mesh.

Cooling fan rotating in wrong direction.

Check and correct the wiring connection to the cooling fan.

Replace with correct fan type.

Check fan motor fuse

Replace the fuse if blown.

Replace with the 2A fuse.

Cooling fan not working. Check and ensure the neutral connection is connected.

Temperature sensor malfunction

Replace the sensor.

Tighten/recrimp the connection with adaptor.

Oil filter clogged

Replace oil filter.

If required replace the oil (based on the condition of oil) and run the compressor.

Thermal valve malfunctioning Replace the thermal valve element.

Oil injection orifice chocked or improper size

Clean the oil injection orifice.

Replace with correct size.

Air filter clogged Clean or replace the air filter

Separator element clogged

Check pressure drop is less than 1bar (14.5 psi).

Replace oil.

Replace separator element.

Poor quality of oil Replace oil.

Oil cooler clogged internally

Check for pressure drop across the oil cooler if less than 1.5 bar (22 psi).

Check and clean the cooler internally with 20L of isopropyl alcohol + toluene mixture in the 1:1 ratio and circulate for 4 hours with external 1 HP pump.

Refit the cleaned cooler and, if required, replace oil (based on condition of the oil) and run the compressor.

Page 47

6.15

Maintenance

Problem Cause Solution (go sequentially)

High oil carry over

High oil level

Drain excess oil and maintain the recommended oil level.

Oil is milky Replace oil and maintain the recommended level.

Scavenge return line non return valve (NRV)/ orifice clogged

1) Remove the return line NRV/orifice and clean it thoroughly.

2) Change/clean the air filter.

Scavenge return line tube clogged

Remove and clean the clogged scavenge return line tube.

Scavenge return line tube gap not maintained (not applicable EG11 to EG22)

Remove the return line tube from the separator and correct it.

The spin-on separator internal pipe thread damaged (applicable to EN series)

Replace the internal pipe.

High discharge oil temperature (DOT) Refer to the diagnosis procedure for high DOT.

Improper grade of oil Use ELGi recommended Air lube oil.

Separator punctured/collapsed (not applicable to EG11 to EG22 units)

Replace with new separator.

Separator element bonding ruptured (not applicable to EG11 to EG22 units)

Replace with new separator.

Compressor runs at lower pressure than normal pressure.

1) Use suitable higher capacity compressor or match demand to compressor capacity.

2) Arrest all line leakages.

Minimum pressure valve (MPV) opening earlier than at the specified opening pressure* 4.5 bar.g (65.26psi.g).

* 3.5 bar.g ( 50.8 psi.g) for compressors with working pressure 4.5 bar.g

Replace MPV kit/assembly.

High tank pressure

Neuron microcontroller pressure settings:

1) Unload pressure set value is above specification.

2) High tank pressure set value is below specification.

Check and correct the unload pressure and high tank pressure values in Neuron micro-controller

Intake valve malfunction

1) Check and replace intake valve kit if required.

2) Check the solenoid valve and clean or replace if required.

3) Check and replace the actuator kit if required.

BDV malfunction Check/replace

Compressor started with air outlet ball valve closed

Open the outlet ball valve.

Solenoid valve malfunction

Check the solenoid valve and clean or replace if required.

Neuron microcontroller malfunction Replace the Neuron microcontroller

Pressure transmitter malfunction Replace the pressure transmitter

MPV stuck up (check with pressure gauge in AOS tank )

Replace the MPV kit.

Separator element choked

Replace the separator element

Page 48

6.16

Maintenance

Problem Cause Solution (go sequentially)

No control air supply to solenoid valve Replace / connect

Loading/unloading Problem

Solenoid valve malfunctioning

1. Replace the solenoid valve assembly

2. Clean the orifice

No electrical supply for energising the solenoid valve

Replace the Neuron microcontroller

Intake valve malfunctioning Check and replace the intake valve kit.

Blow-down valve malfunctioning

1. Clean or change BDV assembly.

2. Clean the orifice.

MPV malfunctioning

1. Check and change the MPV kit.

2. Check and change the MPV assembly

Pressure regulator (applicable only to EG 55 to EG 250) setting lower than working pressure

1. Check and reset the pressure regulator setting to working pressure+0.3 bar (4.35 psi).

2. Change the pressure regulator assembly.

Actuator failure (applicable only to EG 55 to EG 250)

Check and change the actuator / kit / assy.

1. Air requirement is more than compressor capacity

1. Replace the compressor

2. Arrest all pipeline leakages.

2. Working pressure is lower than required application pressure.

3. Excess pressure drop in pipe line.

Pressure transmitter malfunction

1. Tighten the lap cable

2. Replace the lap cable

3. Replace the pressure transmitter

4. Replace the Neuron microcontroller

Malfunction of R04 relay (loading/ unloading relay) in Neuron microcontroller

Replace the Neuron microcontroller

Unload mode enabled in Neuron microcontroller

Disable 'unload mode' in operator settings of the Neuron microcontroller

Page 49

6.17

Maintenance

Problem Cause Solution (go sequentially)

Inlet air pre-filter mat clogged

Clean/change pre-filter mat by following these steps: Switch off the machine. Squeeze and pull out the pre-filter mat from the canopy. Clean pre-filter with compressed air at less than 2.5 bar /36.3 psi Refit the filter after cleaning.

Pressure not built up

Clogged air filter element Clean/change air filter element.

1. Air requirement is more than compressor capacity

1. Replace compressor

2. Arrest all pipeline leakages.

2. Working pressure is lower than required application pressure.

3. Excess pressure drop in pipe line.

No control air supply to solenoid valve. Replace / connect the control line tubes.

Solenoid valve malfunctioning

1. Replace the solenoid valve assembly

2. Clean the orifice

No electrical control supply to solenoid valve Replace the microcontroller

Intake valve malfunctioning Check and replace intake valve kit.

Blow down valve malfunctioning

1. Check and change the BDV assembly.

2. Clean the orifice.

MPV malfunctioning

1. Check and change the MPV kit.

2. Check and change the MPV assembly

Pressure regulator (applicable only to EG 55 to EG 250) setting lower than working pressure

1. Check and reset pressure regulator setting to working pressure+0.3bar (4.35 psi).

2. Change pressure regulator assembly.

Actuator failure (applicable only to EG 55 to EG 250)

Check/change actuator / kit / assembly.

Separator element choked (increase in pressure drop across separator)

Replace separator element. If required, replace the oil (based on condition of the oil) and run the compressor.

Page 50

6.18

Maintenance

If you do not intend to use the compressor or any of its parts, you must dismantle and putting out of service. These tasks must be carried out in compliance with the standards in force of that particular country.

6.3.1 Waste disposal

 Use of compressor generates waste. The residues from

agricultural, industrial, crafts, commercial and service activities must be treated as waste, which needs to be disposed off properly. Deteriorated or obsolete machines are also classified as waste.

 Special attention must be given to active carbon filters

as they cannot be included in urban waste. Observe the waste disposal laws in force where the compressor is used.

 It is mandatory to record loading or unloading of

exhausted oils, obsolete machines and toxic harmful wastes that derive from heavy or light industry processes.

 It is especially important that exhausted oils be

disposed off in compliance with the laws in the countries of use.

6.3.2 Dismantling the compressor

 Dismantle the compressor in accordance with all the

precautions imposed by the laws in force in the country of use.

 Before dismantling, request an inspection by the

relevant authorities. Disconnect the compressor from the electrical system.

 Eliminate any interfaces the compressor may have with

other machines, making sure that interfaces between remaining machines are unaffected.

 Empty the air oil tank containing the lubricating oil and

store in compliance with the laws in force.

 Proceed with the disassembly of the individual

compressor components and group them together according to the materials they are made of: Steel, Stainless Steel, Aluminium and plastic parts.

 Then scrap the machine in compliance with the laws in

force of the country of use.

6.3.3 Decommissioning the compressor

 Remove the foundation for the compressor.

 Unplug the power cable entry to the compressor.

 Drain the oil from the cooler and air oil tank. Dispose of

it properly.

 Make sure all the compressed air is vented out through

ball valves and safety devices residing in the compressor.

 Ensure that all the external supply lines have been

properly disconnected from the compressor before decommissioning.

6.3.4 Disposal of consumables and

replaced parts

 The moisture condensate separated from the

compressed air contains oil particles. Disposal of condensate and filter element is to be done in accordance with the pollution control norms prevailing at the time of compressor installation or use.

 Parts of the compressor that are replaced have metal

and rubber components. These may be recycled and disposed off according to pollution control regulations, respectively.

 Rubber items such as AVMs, coupling elements, and O-

rings should be disposed and replaced before running again.

Decommissioning, dismantling and putting out of service

6.3

The compressor does not give any warnings during short operating times. If it is operated below the dew point and moisture condensate may mix with oil. This will reduce the lubricating quality of the oil and lead to damage of compressor.

ELGi is not responsible for the disposal of old oil or condensate. It is the responsibility of customer to dispose of the foregoing in accordance with local environmental statutory laws.

NOTE

Page 51

6.19

Maintenance

6.4.1 ELGi customer care system (ELGi CCS)

ELGi provides dedicated customer care and after-sales support through the ELGi customer care system (CCS), a computerized system developed in-house. The CCS aims to minimize the time taken to resolve customer complaints.

Service requests/complaints

The CCS toll-free telephone number 1800-425-3544 (accessible within India through BSNL and MTNL lines)

takes the customer’s call to our centralized customer care

center in Coimbatore. Customers can register their service requirements or complaints here.

A unique tracking number is generated for each call logged by the CCS. The customer receives an automatic e-mail acknowledgement with the tracking number and details of the call for reference.

A service engineer is assigned to the call, and the date and

time of the engineer’s visit are communicated to the

customer by e-mail. Every requirement or complaint must be resolved and closed in the CCS within a specified time limit, failing which the complaint is automatically brought to the notice of the manager. If the issue remains unresolved, it will get escalated to the managing director. The CCS ensures that not only the customer complaints are logged but they are also attended to on time, every time.

Enquires

A number of calls received by the CCS relate to customer queries regarding products and spare parts. The details are noted, and basic information on product specifications and usage are provided. The caller is then referred to a salesperson at the head office or the appropriate branch for follow-up.

The CCS database

The CCS also creates a database of customers, adding details of every new customer who calls, thereby building a large pool of installation details. These details are used to provide value-added services to improve customer satisfaction with ELGi products.

CCS-working hours

The ELGi CCS works for six days a week from 08:30 to 21:30 IST (Monday to Saturday).

Multi-lingual capability

The coordinators at the CCS are multi-lingual. They can handle calls in English and all the major regional languages of India.

Coverage: The CCS toll-free number 1800-425-3544 is accessible from the following areas:

 Southern Region: Tamil Nadu, Karnataka, Kerala,

Puducherry, Andhra Pradesh, Telangana, Andaman & Nicobar Islands.

 Western Region: Maharashtra, Gujarat, Madhya

Pradesh, Goa, Lakshadweep Islands.

 Eastern Region: Orissa, Chhattisgarh, Jharkhand,

West Bengal, Bihar and the North-Eastern states.

 Northern Region: Rajasthan, Uttar Pradesh, Delhi,

Haryana, Punjab, Uttaranchal, Himachal and Jammu & Kashmir.

Contact Numbers: You can contact CCS also with the following numbers:

Telephone: 0422-2589206 / 241 / 242 / 243/ 244 / 245 / 97900 21100

Fax: 0422-2589240

Please send the following details to the mail, thus enable us to take immediate action.

1. Name of the customer

2. Compressor model

3. Fab. number

4. Contact person name

5. Phone number

6. Nature of complaint

7. Hour meter reading

You may use the CCS by sending e-mail to: [email protected]

Customer satisfaction survey

If you have used the CCS, you may be contacted for your feedback on our after-sales support. Your response helps ELGi to improve its service.

International customers:

Refer contact information at the end of this manual book.

6.4.2 ELGi genuine spare parts

When ordering spare parts, refer to the lists provided in the parts manual and identify the part number. Specify the part number and quantity, in addition to the name plate details. Global support center of ELGi ensures the supply of the quality spares on time. Ensure that you are using the genuine spare parts so that your Compressor will be working efficiently and effectively. Refer to section 6.1.3 for details on need of using genuine spares.

Please contact our After sales team for any compressor accessory requirements like VFD, Air-Dryer, etc.

6.4.3 Air audit

We extend our proven capabilities in energy efficiency initiatives by carrying out air audits for our customers.

ELGi conducts audits and trains end users in key energy oriented functional areas. The audit reports prepared by

ELGi experts’ team include recommendations on short,

ELGi Services 6.4

Page 52

6.20

Maintenance

medium and long term measures for energy conservation, along with financial estimates and analysis for implementation.

This air audit objective is to provide the customer:

 The framework for systematic collection of data relevant

to the efficient operation of compressed air systems.

 A thorough analysis about the performance of the

compressed air system, identifying potential electricity savings and to provide sound recommendations for implementation of energy efficiency initiatives.

Data analysis will be comprised of the information about different areas such as air leakages, inappropriate use of compressed air, compressed air system network, compressed air system supply including compressor internal maintenance conditions and even more.

The final report issued to the customer end will serve the purpose of assisting concise, consistent and complete presentation of the analysis, findings and recommendations arising from a compressed air system audit.

Depending on the measurement, reporting and cost requirements from the customer end, the intensity in level of audit (base level or investment level) will be decided. Also post implementation monitoring after air audit will be provided if requested from the customer end.

For further information on air audit contact ELGi.

E-Mail: [email protected]

Page 53

6.21

Maintenance

Description From To Multiply by

Length (L)

Inches Millimetres 25.4

Metres Inches 39.37

Feet Millimetres 304.8

Metres Feet 3.281

Inches Thou 1000

Millimetres Micrometres 1000

Area (A)

Square metres Square feet 10.765

Square feet Square inches 144

Square inches Square millimetres 645.16

Volume (V)

Cubic metres Cubic feet 35.315

Cubic feet Cubic inches 1728

Cubic metres Litres 1000

Cubic feet Litres 28.32

US gallons (liq) Litres 3.785

Imperial gallons (liq) Litres 4.546

Volumetric flow (Q)

Cubic feet per minute (cfm) Cubic metres per hour (m3/h) 1.6988

Cubic feet per minute (cfm) lpm 28.32

Cubic metres per hour (m3/h) lpm 16.667

Cubic metres per minute (m3/min) lps 16.667

Mass (M)

Kilograms Pounds 2.205

Kilograms Grams 1000

Kilograms Ounces 35.27

Pressure (P)

kg f/cm2 g psi g 14.223

psi g Pascal 6895

bar g kg f/cm2 g 1.0197

bar g psi g 14.503

psi g kg f/cm2 g 0.0703

Temperature (T)

Degree Celsius (°C) Degree Fahrenheit (°F) °F = 9(°C)/5 +32

Degree Celsius (°C) Kelvin (K) K = °C + 273.15

Degree Fahrenheit (°F) Degree Rankine (°R) °R = °F + 460

Heat (q), Work (W),

Energy (E)

ft-lb f Joules 1.35582

ft-lb f Btu 0.001285

Joules Calories 0.2388

Btu/h Calories/h 252

Kilowatts Btu/h 3411

Metric horsepower Kilowatts 0.7355

Power (P)

Imperial horsepower Kilowatts 0.7457

6.5.1 Conversion tables

Appendix 6.5

Table 8: Conversion table

Page 54

6.22

Maintenance

6.5.2 Torque values

The tightening torque values for bolts and screws used in ELGi Compressors are provided in this section for reference. The tolerance for the torque values is (-) 10% from the given value.

* Property class of 8.8 only

Thread size (inches) Tightening torque (N-m) Tightening torque (lb-ft)

9/16" 149 109.8875

7/8" 579 427.0125

Table 11: UNF threads

Thread size (inches) Tightening torque (N-m) Tightening torque (lb-ft)

¼" 45 33.19

½" 85 62.69

¾" 170 125.38

1" 330 243.39

1¼" 430 317.15

1½" 510 376.15

Table 10: BSP threads

Thread size* Tightening torque (N-m) Tightening torque (lb-ft)

M4 2.9 2.13

M5 5.7 4.20

M6 9.8 7.22

M8 24 17.7

M10 47 34.66

M12 81 59.73

M16 197 145.28

M20 385 283.93

Table 9: Metric hexagonal head bolts and screws

Page 55

6.23

Maintenance

6.5.3 Service log book – record of maintenance

Date From

Till

Total

operated

hours /

day

Line

pressure

System

pressure

Discharge

temperature

Oil level

in AOS

tank

Moisture

removal

from AOS

tank

Pre

Filter

Cleaning

Cooler

cleaning

Trip

record

descrip-

tion

Comments

Operator

sign

Low/

normal/

high/

change

Before

starting

Start/Stop

Time

Page 56

6.24

Maintenance

Please read this document and the warranty terms accompanying the product carefully before using our product. By purchasing our product, you agree that you will assume total responsibility and risk for your use of the product. The warranty terms of the product have been provided separately.

1. ELGi is not liable for failure of the compressor ( hereinafter “compressor” or “product”) to perform its obligations if such

failure is as a result of Acts of God (including but not limited to fire, flood, earthquake, storm, hurricane or other natural disaster), war, invasion, act of foreign enemies, hostilities (regardless of whether war is declared), civil war, rebellion, revolution, insurrection, military or usurped power or confiscation, terrorist activities, nationalization, government sanction, blockage, embargo, labour dispute, strike, lockout or interruption or failure of electricity or telephone service and any other reasons beyond ELGi’s control.

2. ELGi does not take responsibility for any damage or injury resulting from neglecting the safety instructions, warnings,

cautions, precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair of the product, even if not expressly stated, and such instances are specifically disclaimed by ELGi.

3. The entire literature including product description or any other information in this manual exclusively belongs to ELGi and

is subject to copyright. No person has any right to copy, modify, distribute, transmit, display, perform, reproduce, publish, license, create derivative works, transfer or sell any information, or deal with the same in any other manner, without the knowledge and written concurrence of ELGi, violation of which would amount to infringement of rights of ELGi and would necessitate legal action.

4. The information published in this manual may include inaccuracies, or typographical errors. Changes may be periodically

added to the information herein. Any changes/improvements may also be made to the products stated in this manual and ELGi is not liable if the readers are not updated with information.

5. Likewise ELGi is responsible only till the point of first sale to the ultimate customer and not thereafter and only if the

product is purchased from authorized dealers of ELGi. ELGi disowns liability on account of purchase of any second hand product or purchase otherwise from unauthorized dealers. ELGi shall not be liable for any indirect, incidental, punitive, special or consequential losses or damages including any loss of profit, loss of production, loss of income or contract, loss of goodwill, expected savings or business relationships, arising out of or in any way connected with the usage of the product or information in this manual.

6. In no event ELGi shall be liable for any claims or loss having a value higher than the original purchase price of the product

sold by ELGi or its network of authorised dealers.

7. These Disclaimers and the contents of this manual shall be subject to the laws of India and any disputes pertaining to this

manual or anything stated therein or any product stated therein is subject to the exclusive jurisdiction of the courts in Coimbatore, Tamil Nadu, India.

8. No liability in connection with the product will accrue to ELGi,

 If any welding or related operation involving heat is carried out in the compressor. Never weld or modify any parts

including pressure vessels.

 If any damages to the product directly or indirectly arise due to long storage (6 months) of product and subsequent

corrosion of internal parts and which leads to fire or malfunctioning of the product.

 If the compressor package and its accessories are installed in such a way to allow moisture, rain, freezing temperature or

sun damage to affect the safe operation of the unit.

 If the person who operates / maintains the compressor does not adhere to all work related safety practices and regulatory

requirements.

 If unauthorized personnel other than ELGi authorized or trained personnel carries out commissioning, installation,

operation, maintenance and any repair work on the compressor.

 If the compressor and the compressed air are used for unintended use or are misused.

 If the compressor is operated below or in excess of its pressure and temperature limits.

 If the compressor “ON/ OFF” switch is operated through remote control situated away from the compressor location

without giving any adequate notice / alarm before starting the product .

Disclaimers 6.6

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RS 485

13 2

R1R2

X05

46 5

R6 R5

RS 485

X04

RS 485

X06

X03

X07

R10 R9

8 3

X02

9 7

2 10

436

X04

NCNCNC

21436

X02

8710

CONNECTION DETAILS

2143658

91211

X03

123

X08

X01

P N

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