ELGi TS Series, TS15, TS05 Operation And Maintenance Manual
TS Series
TS05 to TS15
Two-Stage
Reciprocating
Air Compressor
OPERATION AND MAINTENANCE MANUAL
2
TS Series
Model Number:
Serial Number:
Date Purchased:
Purchased from:
For further technical assistance, service or replacement parts, please contact:
Elgi Compressors USA, Inc.
3201 South Boulevard
Charlotte, NC 28209
Phone: 704-943-7966
FAX: 704-944-8338
www.elgi.us
Please include the unit serial number located on the control panel with all inquiries.
Elgi reserves the right to make changes and improvements to update products sold previously
without notice or obligation.
Issue Date: August 17, 2017
3
TS Series
Table of Contents
Safety Precautions
1.0 General Information
2.0 Installation
2.1 Inspection Upon Receiving
2.2 Handling
2.3 Location
2.4 Space Requirements
2.5 Wiring
3.0 Control Panel
3.1 Wiring Schematics
4.0 Initial startup
5.0 Maintenance
5.1 Pressure Switch Adjustment
6.0 Trouble Shooting
7.0 Replacement System Parts 5 HP
7.1 Replacement Pump Parts 5 HP
8.0 Replacement System Parts 7.5 HP
8.1 Replacement Pump Parts 7.5 HP
9.0 Replacement System Parts 10 HP
9.1 Replacement Pump Parts 10 HP
10.0 Replacement System Parts 15 HP
10.1 Replacement Pump Parts 15 HP
Notes
4
TS Series
Safety Precautions
Pressurized air from the system may cause personnel injury or property damage if the unit is improperly operated or maintained. The operator should have carefully read and become familiar with the
contents of this manual before installing, wiring, starting, operating, adjusting and maintaining the
system. The operator is expected to use common sense safety precautions, good workmanship
practices and follow any related local safety precautions.
In addition:
• Before starting any installation or maintenance procedures, disconnect all power to the
package.
• All electrical procedures must be in compliance with all national, state and local codes and re-
quirements.
• A certified electrician should connect all wiring.
• Refer to the electrical wiring diagram provided with the unit before starting any installation or
maintenance work.
• Release all pressure from the package before removing, loosening, or servicing any covers,
guards, fittings, connections, or other devices.
• Notify appropriate facility personnel if repairs or maintenance will affect available compressed air
levels.
• This is a high speed, rotating piece of machinery. Do not attempt to service any part while ma-
chine is in operation.
• Do not operate unit without belt guards, shields or screens in place.
• Make sure that all loose articles, packing material, and tools are clear of the package.
• Check all safety devices periodically for proper operation.
• Never operate a compressor with its relief valve not in place. Damage to the compressor may oc-
cur.
• Electrical service must be the same as specified on the control panel nameplate or damage to
the equipment may occur.
• Vibration during shipment can loosen electrical terminals, fuse inserts, and mechanical connec-
tions. Tighten as necessary.
5
TS Series
1.0 General Information
System Configurations
The Reciprocating Air systems are tank mounted units. All consist of at least one compressor, one
motor, integral pre-wired control panel and air receiver. The complete package is pre-wired, prepiped, and assembled.
Compressor Module
The compressor is a continuous duty rated lubricated reciprocating type. The design is two stage
and air cooled with finger type stainless steel valves. An oil splasher is fitted to the connecting rod to
lubricate all moving parts. The connecting rod and crankcase assembly is precision machined and
dynamically balanced. The crankshaft is forged out of carbon steel, hardened, and precision ground.
The crankshaft is provided with steel roller bearings and phosphor bronze bushings. The crankcase
is made of high grade cast iron. It acts as sump for the lubricating oil and is provided with a breather
drain plug and dipstick. The breather maintains a partial vacuum in the crankcase to facilitate better
breathing. The cylinders and cylinder heads are made of high grade cast iron and they have close
deep fins for effective cooling. The hardness of the cylinders is closely controlled to insure high wear
resistance. The pistons are automotive type made out of low expansion aluminum alloy. They are
provide with plain compression rings, stepped compression rings and slotted oil control rings. The
rings are made of special quality close grained cast iron and designed for controlling wear and keeping oil consumption at a minimum. The wrist pins are made of chrome steel case hardened and precision ground. The intercooler is made of aluminum with fins for effective cooling.
Compressor Drive and Motor
The compressor is v-belt driven and protected by an OSHA approved totally enclosed belt guard. A
slotted mounting base allows full adjustment for belt tensioning. The motor is a NEMA rated, open
drip proof, with 1.15 service factor suitable for 208 or 230/460V electrical service.
Intake Filter
Each compressor is fitted with inlet air filters. The inlet filter removes dust from the incoming air
through an element.
Control System The mounted and wired control system is NEMA 1 and U.L. labeled. The . The
control panel also includes full voltage motor starters with overload protection, Off-On selector
switch and a pressure switch.
Air Receiver
The air receiver is ASME Coded, National Board Certified, and rated for a minimum 200 PSIG design pressure. The tank will include a safety relief valve, pressure gauge and manual drain valve.
6
TS Series
2.0 Installation
2.1 Inspection upon Receiving
The Reciprocating Air system should be carefully inspected upon delivery. Any damage by the carrier should be noted on the delivery receipt, especially if the system will not be immediately uncrated
and installed. The system may remain in its shipping container(s) until ready for installation. If the
system is to be stored prior to installation, it must be protected from the elements to prevent rust and
deterioration.
DO NOT REMOVE the protective covers from the inlet and discharge connection ports of the unit
until they are ready for connecting to the distribution system.
2.2 Handling
!!WARNING!!
USE APPROPRIATE LOAD RATED LIFTING EQUIPMENT AND OBSERVE SAFE LIFTING PRO-
CEDURES DURING ALL MOVES.
The compressor package can be moved with either a forklift or dollies. Keep all packing in place during installation to minimize damage. Examine the route the unit must travel and note dimensions of
doorways and low ceilings. Units should be placed to ensure easy access to perform maintenance
and high visibility of indicators and gauges.
2.3 Location
The Air system should be installed indoors in a clean, well-ventilated environment. Areas of excessive dust, dirt or other air-borne particulate should be avoided. Secure the package to a flat, level
surface capable of supporting the weight and forces of the unit. Make sure that the main base is not
bowed, twisted, or uneven. The tank must be securely bolted using all mounting holes provided in
the tank. If a raised concrete pad is used, the tank must not overhang the concrete pad. A method to
drain away moisture is necessary. If a gravity drain is not available, a connection to a drain is necessary. The area should have a maximum ambient temperature of 113oF (45oC). (Note: At tempera-
tures below 32oF condensate can occur which could affect operation.)
2.4 Space Requirements
The Air system should be placed to ensure easy access to perform maintenance and high visibility
of indicators and gauges. It is recommended that a minimum space of 24” be allowed on all sides of
the compressor system for ventilation and maintenance. A minimum space of 36" in front of the con-
trol panel is required by NEC code. A vertical distance of 36” is required above the unit for ventilation
and maintenance.
7
TS Series
2.0 Installation (Continued)
2.5 Wiring
WARNING!
BE SURE TO DISCONNECT ALL ELECTRICAL POWER TO THE COMPRESSOR SYSTEM BE-
FORE PERFORMING ANY ELECTRICAL PROCEDURES.
Refer to the electrical diagram provided with the unit before starting any installation or
maintenance work. Do not operate compressor on a voltage other than the voltage specified
on the compressor nameplate. All customer wiring should be in compliance with the National
Electrical Code and any other applicable state or local codes.
Check the control voltage, phase, and amp ratings before starting the electrical installation, and
make sure the voltage supplied by the customer is the same.
The wire size should be able to handle peak motor amp load of all operating units, refer to the full
load and compressor system amperes on the wiring diagram.
Check all electrical connections within the air system that may have loosened during shipment.
Only qualified electricians should make power connections to the control panel and any interconnecting wiring.
If emergency generator is used for backup make sure the electrical supply is consistent with the air
system’s requirements.
If equipped with an emergency generator the three-phase power supplied must match that of the
normal supply to allow for correct direction of the motor rotation at all times.
If equipped with an emergency generator the three-phase power supplied must match that of the
normal supply to allow for correct direction of the motor rotation at all times.
8
TS Series
3.0 Control Panel
5 HP 208/3/60 230/3/60 460/3/60
Starter 30-03-408 30-03-417 30-03-036
Overload Relay 30-03-207 30-03-206 30-03-204
5 HP 208/1/60 230/1/60
Starter 30-03-410 30-03-420
Overload Relay 30-03-008 30-03-208
Off-On
Switch
54-17-009
Motor
Starter
(see chart)
Motor
Overload
(see chart)
10 HP 208/3/60 230/3/60 460/3/60
Starter 30-03-410 30-03-420 30-03-038
Overload Relay 30-03-208 30-03-208 30-03-206
7.5 HP 208/3/60 230/3/60 460/3/60
Starter 30-03-409 30-03-419 30-03-037
Overload Relay 30-03-208 30-03-207 30-03-205
15 HP 208/3/60 230/3/60 460/3/60
Starter 30-03-412 30-03-422 30-03-040
Overload Relay 30-03-210 30-03-209 30-03-207
9
TS Series
3.0 Control Panel
3.1 Wiring Schematics
Three Phase Compressors
Single Phase Compressors
10
TS Series
4.0 Initial Startup
Check for correct direction of rotation of compressor by momentarily turning the Off-On switch to the
“On” position and observing rotation.
WARNING:
DO NOT RUN THE COMPRESSOR BACKWARDS!
Rotation direction arrows are located on the belt guard (rotation is clockwise, facing the compressor
pulley). Correct the rotation, if required, by switching the motor leads at the starter.
Start compressor by turning the “Off-On” switch to the “On” position. Allow compressor to operate for
a short time (15 to 30 seconds) and check for any unusual noises or vibrations.
If everything appears normal, allow compressor to run in the “On” mode until pressure builds in the
air receiver. The compressor should stop when the pressure reading reaches 125 psig. Check for
any leaks in the piping. Repair leaks, if needed.
5.0 Maintenance
Frequency Maintenance Required
Daily or before
compressor starting
a) Check oil level
b) Drain condensate from air receiver
c) Check belt tension
150 Hours or 10 Days
a) Relieve moisture and dirt from air receiver
b) Carry out first oil change
250 Hours or 20 Days
a) Check for unusual noise or vibration
b) Check bolts for tightness
c) Check for leaks
d) Check pressure settings
e) Check inlet air filter
a) Change Oil
500 Hours or 1 Month
b) Clean breather valve
c) Tighten all wires
d) Clean air filter element
Loading...