Eg - Series Elgi
Eg - Series Elgi
Eg - Series Elgi
EG Series
Electric Powered Screw Air Compressor
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
Machine Identification and Sale Record
Model : ………………………………………………………………………………………………………
………………………………………………………………………………………………………
………………………………………………………………………………………………………
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
Table of Contents
1.6
1.0 About ELGi
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.
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
2.0 General functional description
2.4.5 For retro-fitment of Standalone VFD with Compressor (C) version in field 2.10
Welcome to ELGi customer family. ELGi compressors are Salient Features of EG Series
the source of compressed air in various segments across
Three-stage inlet air filtration ensure
the globe. reliability
ELGi compressors are known for high UPTIME, high
Low noise and vibration ensures user
efficiency, Low maintenance cost , resulting in low comfort and machine reliability
lifecycle cost, They comply to global statutory and
regulatory requirement and ensure high safety during Efficient air-oil separation by OSBIC (Oil
usage. Separation By Impact and Centrifugal
action) ensures high air quality and low oil
Technology consumption.
Compressor and sub systems are optimally designed to Robust cooling system suitable for all
meet the installation, performance and reliability environmental conditions
requirements. Better aesthetics and user friendliness
Airend is the key element in a screw compressor. ELGi’s
Flanged joints ensures leak free.
airend are designed and manufactured with the state of
art in-house facilities. Integrated VFD (Variable Frequency Drive)
and dryer*.
The rotors in the airend are employed with a specially
designed Eta-V profile which is the latest and the most Increased life of consumable ensures low life
energy efficient profile in the compressor industry cycle cost.
EG Series
Your EG Series compressor belongs to a family of rotary
screw compressors from ELGi.
The operator must follow the safe working practices, Ensure the operator is located far away from the intake
instructions, procedures that this manual describes for of the compressor.
safe operation. The maintenance personnel must be Position the after-cooler discharge pipe in a way that it
adequately trained, and have read and thoroughly is free to expand under heat and is not in contact with
understood this ‘Operation and maintenance manual’. or close to flammable materials.
Decals are affixed at specific locations of the compressor
Do not exert external force on the air outlet valve and
and they illustrate very important safety precautions.
keep the connected pipe always free of strain.
2.3.1 Precautions during installation Make available adequate cooling air must be made
Ensure that you fasten all loose parts before lifting. Select available for the compressor particularly air cooled
the appropriate lifting equipment by considering the local compressors. Make sure that exhausted air does not
safety regulations, size and weight of the compressor. circulate back to the intake or cooling system.
Operate the lifting equipment carefully within the safe Make the electrical connections according to the legal
operating limits. Ensure all necessary personal protective standards and earth the compressor suitably. Provide a
equipment's (PPEs) is close at hand during this operation. 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.
Know that annual servicing of the safety valve is Keep grounded conductive objects such as tools away
necessary. It should be checked at the prescribed from exposed live electrical parts like terminals to avoid
pressure for operation. arcing, which might serve as a source.
Use correct tools for maintenance and repair work. Keep oily rags, trash, dry leaves, litter or other
Do not allow the manufacturers’ rated safe operating combustibles out of and away from the compressor.
pressure to exceed for pipes, valves, filters and other Do not operate the compressor without a proper flow of
fittings. cooling air or with an inadequate flow of lubricant or
It is hazardous to point the compressed air directly with a degraded lubricant.
towards any personnel. Keep personnel out of the line Do not attempt to operate the compressor in a
of the discharge air when opening hoses or other points hazardous environment of any classification unless the
of compressed air discharge. compressor has been specially designed and
Use only the correct type and size of hose end fittings manufactured for explosive applications.
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
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.
Make all adjustments or repairs with one hand. This Ensure that the compressor is cooled down before
minimizes the risk of creating a current path through maintenance is performed.
the heart.
2.4.4 Control system 2. Turndown only upto 50% for conversion models
(considering the motor speed) i.e. motor frequency range
Load - Unload is 50 - 25 Hz for 50Hz variant and 60 - 30Hz for 60Hz
variant. No pressure turndown is applicable
Depending on the demand for compressed air from the
application at a particular time, the compressor needs to 3. Run the compressor in the VFD operating range (50 to
respond accordingly. The compressor, therefore operates 25Hz) and skip the frequency in VFD controller (within +/-
in either loading or unloading mode to meet this 1Hz) if abnormal noise / vibration is observed
requirement. The primary objective of these modes is to 4. Change the thermal element from 65°C to 75°C
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.
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.
10 " 11 "
FAN1
10 11
16
15 9
8 3 C
13
7
12
1 14
6
2.36 " 2
CABLE ENTRY
I D
. NM
EARTHING POINT 2 2 A 3 3 3
3 3 3 3 3 3 3
SIZE : M10 10.83 " 7.87 " 26.57 " 2 7.87 " B
10.33" 7.28" 6.89" 7.28"
7.28 " 6.89 " 7.28 " 10.33 " 5
12.30 " 39.37 "
Z OIL DRAIN PORT
X
0.79 " 40.55 " DETAIL A MOISTURE DRAIN
67 ±0.39 " DIA 0.47" X 0.39"
43.74 ±0.39 "
Sl.No. DESCRIPTION Qty. DRAWING No. Rev. REMARKS
CH ECKED SCALE
DRG.No. 01 53 17 5 2 6
REV. NO. ECO.No. DATE DESCRIPTION ALT. BY CHKD. BY APPRO VED
NTS DRG.SHEET OF REVISION
1 3 R 0 2
6 5 4 3 2 DO NOT SCALE T HIS DRG. IF IN DOUBT , ASK ENGG. DEPT .
6 5 4 3 2 1
CC - CRITICAL CHARACTERISTIC (SAFETY/REGULATORY)
To Controller
CHOKE
101 INDICATOR 104 AIREND
AIR FILTER 102 PRESSURE SENSOR
To Controller
PS01
MINIMUM PRESSURE
S U CTION TH R OTTLE (N C) VALVE
M 107 MINIMUM PRESSURE
107
IN T A K E V A LVE (N C) VALVE
FAN WITH M OTOR CONDENSATE DRAIN
103
104
A IR E ND
M 109 SAFETY VALVE
MOTOR
THERMAL VALVE 110 THERMAL VALVE
110 T E MP E RA T U RE
S E NS O R
T S 01 111 OIL COOLER
T o C ontroller
C
I D
. NM 116 SOLENOID VALVE (NC)
O IL DR A IN V A LV E
IN STR UM ENTS TAG N o: DESCR IPTION
114
B
TS01 TEM PERATU RE SENSOR
Air Oil Line 2 inch CAD SBH 17.02.18 REF.DRG.No. NEXT ASSY.
CH ECKED
SCALE
DRG.No. 01 53 17 5 2 6
NTS
REV. NO. ECO.No. DATE DESCRIPTION ALT. BY CHKD. BY APPRO VED DRG.SHEET OF REVISION
2 3 R 0 2
6 5 4 3 2 DO NOT SCALE T HIS DRG. IF IN DOUBT , ASK ENGG. DEPT .
6 5 4 3 2 1
CC - CRITICAL CHARACTERISTIC (SAFETY/REGULATORY)
DUCT MOUNTING DIMENSION DETAILS :
SC - SIGNIFICANT CHARACTERISTIC (FIT/FORM/FUNCTION/FINISH)
I D
. NM
WEIGH T :
GA DRAWING
2018 NAME DATE A
12.30 " 39.37 "
CONTROL PANEL SIDE 63.98 " CAD SBH 17.02.18 REF.DRG.No. NEXT ASSY.
CH ECKED
SCALE
DRG.No. 01 53 17 5 2 6
NTS
REV. NO. ECO.No. DATE DESCRIPTION ALT. BY CHKD. BY APPRO VED DRG.SHEET OF REVISION
3 3 R 0 2
6 5 4 3 2 DO NOT SCALE T HIS DRG. IF IN DOUBT , ASK ENGG. DEPT .
4.0 Technical data
Standard
Model - EG 22P EG 26
Standard + VFD
Model - EG 22P EG 26
Standard
Model - EG 30 EG 37 EG 45
1 Working Pressure psi.g 66 100 125 150 175 66 100 125 150 175 66 100 125 150 175
cfm 204 203 178 153 136 254 248 212 203 172 309 302 267 230 210
FAD - Free Air
2
Delivery
m3/min 5.78 5.75 5.04 4.33 3.85 7.19 7.02 6.0 5.75 4.87 8.75 8.55 7.56 6.51 5.95
3 Unloading pressure psi.g 72 115 140 165 190 72 115 140 165 190 72 115 140 165 190
Standard + VFD
Model - EG 30 EG 37 EG 45
1 Working Pressure psi.g 66 100 125 150 175 66 100 125 150 175 66 100 125 150 175
cfm 204 203 178 153 136 254 248 212 203 172 309 302 267 230 210
FAD - Free Air
2
Delivery
m3/min 5.78 5.75 5.04 4.33 3.85 7.19 7.02 6.0 5.75 4.87 8.75 8.55 7.56 6.51 5.95
3 Unloading pressure psi.g 72 115 140 165 190 72 115 140 165 190 72 115 140 165 190
Electrical drawing
MINIMUM CLEARANCE, X=1 m (3.5 ft) Provide openings on walls/partitions close to the air
suction side of the compressor.
Figure 5. Horizontal clearance around the Provide exhaust openings close to the ceiling for hot air
compressor exit.
If the floor is splashed frequently with water while If more than four compressors are installed in a room,
cleaning, then place your compressor on a raised good practice is to provide ducting arrangements. This
concrete plinth 100 to 150 mm (4 to 6 inches) high. will avoid hot air recirculation.
Ensure the compressor base makes 100% contact Be aware hot air recirculation in the enclosed area will
directly with the floor. affect the compressor performance.
Know that an industrial floor with level surface capable Ensure the air velocity in the supply and exhaust ducts
of supporting the weight if the compressor is sufficient does not exceed 4 m/s (13 ft/s).
Minimum Minimum
ventilation ventilation
Model
requirement requirement
(ft3/h ) (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 22P 247,202 7,000 Figure 6. Forced ventilation with exhaust fan
EG 26 247,202 7,000
EG 30 247,202 7,000
EG 37 300,175 8,500
EG 45 372,923 10,560
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 Figure 7. Ventilation with ducts
EG 110-P 1,218,356 34,500
EG 132-P 1,218,356 34,500
EG 160-P 1,218,356 34,500
Incoming Incoming cable size Incoming cable size Earth cable Power cable
Compressor fuse (Armored) (Armored) size gland hole
model rating Copper Aluminum Copper diameter
A Sq.mm Sq.mm mm (inches)
EG 11 32 4C x 6 4C x 10 2.5 Gauge 25 (0.984)
EG 15 50 4C x 6 4C x 10 4 Gauge 28 (1.102)
EG 18 50 4C x 10 4C x 16 4 Gauge 28 (1.102)
EG 22 63 4C x 10 4C x 25 4 Gauge 32 (1.259)
EG 30 100 4C x 25 3 ½ C x 35 6 Gauge 32 (1.259)
EG 37 100 3 ½ C x 35 3 ½ C x 50 6 Gauge 35 (1.377)
EG 45 125 3 ½ C x 50 3 ½ C x 70 8 Gauge 50 (1.968)
EG 55 200 3 ½ C x 95 3 ½ C x 120 12 Gauge 38.1 (1.50)
EG 75 200 3 ½ C x 95 3 ½ C x 120 25 x 3 flat 44.45 (1.75)
EG 90, EG 90-P 250 3 ½ C x 120 3 ½ C x 150 30 x 3 flat 50.8 (2.00)
EG 110, EG 110-P 315 3 ½ C x 150 3 ½ C x 185 35 x 3 flat 57.15 (2.25)
EG 132, EG 132-P 400 3 ½ C x 185 3 ½ C x 240 50 x 6 flat 69.85 (2.75)
EG 160, EG 160-P 500 3 ½ C x 240 3 ½ C x 300 50 x 6 flat 76.2 (3.00)
EG 200 500 2R x 3 ½ C x 185 2R x 3 ½ C x 240 50 x 6 flat 88.9 (3.50)
EG 250 630 2R x 3 ½ C x 240 2R x 3 ½ C x 300 50 x 6 flat 88.9 (3.50)
Table 2. Global series – Electrical requirements
1. Use the pipe sizes (as in Table 3) for the delivery pipe
NOTE
that connects to ball valve of the compressor.
The above table shows the pressure drops in 100m length
schedule 40 steel pipe at 7 bar (abs) 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.
Receiver
Compressed capacity
applications
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
5.1.10 Oil fill and Oil level checking How to read oil level?
Oil fill procedure When level indication is
The oil level can be checked through the oil float gauge on in start of red zone as
the air oil separator tank. shown in figure start filling
of oil (Oil less alarm
region)
Fill the oil up to this black line (black line in the region)
(Oil Fill limit region)
Initial fill
Close the oil filling plug
EG 22P, EG 26
1 20 19
EG 30-45
If your compressor is going to remain unused for six Check the air-oil separator tank.
months or longer, special measures must be undertaken to Replace the oil filter element similarly.
ensure the protection of the following components
Flush the tank, airend with compressor oil and replace
Airend the separator element before using the compressor
Motors again.
Block the discharge port completely. Use after representative samples are
subjected to proof, impulse, and burst
Remove the inlet rubber duct connected to the intake 5 to 8 years
pressure tests and cold bend and
valve of the air filter assembly.
electrical tests.
Turn the intake valve flap and pour rust preventive oil
Over 8 years Scrap
(use Castrol DWX 32 or an equivalent grade) into the
airend through the intake valve.
5.2.2 Motor
To prepare the motor for 1-year storage:
Check the insulation of the motor winding.
5.3.1 Initial start-up checks Machines with an automatic star-delta starter will have
6 seconds changeover time from star to delta and
Check whether the oil level in the tank is up to the
another 10-seconds delta-to-run delay.
specified level. If not, top up oil as per the oil fill
procedure given in the maintenance section. 5.3.5 During running
Open all doors and visually check the compressor for To ensure seamless running:
abnormality. Make sure all connections are tight.
Monitor the controller display and control panel
Open the electrical panel door of the compressor and indicators regularly when the compressor is running.
check that the three phases and earth cables are
Graphic warning display: This gives graphically the
connected securely. (L1, L2, L3, and PE wires)
location of fault.
Check the necessary earthing line in the panel/
compressor base.
Check whether the oil level in the tank is up to the Figure 10. Human machine interface
specified level. If not, top up oil as per the oil fill
Discharge temperature sensor & warning: It is
procedure given in the maintenance section.
fixed on the air-oil discharge pipe. It senses the
Open all doors and visually check the compressor for temperature of the discharge air-oil mixture. The
abnormality. Make sure all connections are tight. compressor will shutdown automatically and the
Refer section 6.1.1 for how to perform daily warning light on the controller will glow when the
maintenance activities. discharge temperature exceeds the preset value of 110
± 5ºC (230 ± 9ºF).
5.3.4 Starting
Separator element warning: Indicates that the
To prepare to start the system, perform these tasks: separator element needs to be replaced. The
Open the air discharge valve. compressor will not shutdown automatically in this
situation.
Turn on power.
Cutout pressure
Model Type
bar (psi)
EG 11 - Standard, Working pressure +
EG 45 Standard +VFD 0.5 (7)
Working pressure +
Standard
EG 55 - 1 (15)
EG 250 Working pressure +
Standard +VFD
0.5 (7)
5.3.6 Stopping
Press the stop (Red) button in the controller. The
compressor will come to a halt within 10 seconds.
Maintenance 6.1
6.1 Maintenance
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.
Maintenance 6.2
and slide upwards slightly until the pre-filter bottom edge
is visible
Disconnect all the power at the source before attempt to
perform maintenance or make adjustment. 2. Slide Downward
Release air oil tank pressure and allow the tank to cool
for a few minutes. AIR FILTER COVER
Requirements
Compressed air, new pre-filter element (if needed)
Figure 12. Air filter
Maintenance
Refer to the pre-filter cartridge removal & insert Switch off the compressor and disconnect power supply
procedure. to the compressor.
Hold or fix the pre-filter assembly in the cleaning area. Close the discharge end ball valve.
Clean the pre-filter with compressed air at less than 2.5 Release air oil tank pressure and allow the tank to cool
bar.g (36.3 psi.g) from the reverse or back side of the for a few minutes.
pre filter cartridge. Requirements
In case of major dust/dirt accumulation in the pre-filter Compressed air, new air filter element (if needed).
element, wash with clean water or light detergent.
Maintenance
Do not use any acidic/alkaline chemicals for cleaning.
Turn the knob counter clockwise to open the air filter
Repeat this process based on dust conditions or at door.
regular periodic intervals.
Remove the air filter cover.
Suction pre-filter cartridge removal
Loosen and remove the wing nut.
procedure
Remove the air filter element.
1. Slide Upward
Hold the pre-filter between the louvers Clean the air filter element by blowing compressed air
Maintenance 6.3
<2.5 bar from inner side of air filter element to outside.
Close the discharge end ball valve. Figure 13. Air oil separator
Release air oil tank pressure and allow the tank to cool
for a few minutes. Inspect and clean the air oil tank for rust and dirt.
Maintenance 6.4
contamination hazard. ELGi will not warrant the quality of After 300hours running, drain and send the oil sample**
the product once the original seal is broken. Also ensure to ELGi for oil analysis.
that the oils are not mixed up between brands and types.
Please refer Material Safety Data Sheet (MSDS) for oil spill **: Applicable only for USA/CANADA.
handling and disposal procedures.
Pre work
NOTE
The cleaner is not recommended to run longer than 500
Switch off the compressor and disconnect power supply hours.
to the compressor. Change the oil filter and oil separator after oil change
over.
Close the discharge end ball valve.
Step 3: Filling the oil
Release air oil tank pressure and allow the tank to cool
for a few minutes. Add fresh oil through oil fill port with recommended
Requirements level.
New oil, flushing fluid (if needed) Close the oil fill plug.
Step 1: Draining
a. Fill the compressor with the ELGi cleaner (use the same
compressor oil fill volume) and run the compressor.
c. Drain the cleaner and refill with compressor oil as per Figure 15. Cooler oil drain
recommendation.
Maintenance 6.5
Ensure the O-ring seating in groove.
Release air oil tank pressure and allow the tank to cool
for a ten minutes.
Figure 16. Oil filter element assy.
Requirements :
Maintenance Pressure gauge, Soft cloth, Grease, Liquid cleaner.
Dismantling method of oil filter: Refer periodic maintenance kit
Loosen the oil filter assembly by rotating it in clockwise
Intake valve kit EIV 159, BDV Assembly kit EIV
direction (use strap wrench).
159, Tamper Cap kit EIV 159 , Actutator Kit EIV
Unscrew the oil filter assembly by hand. 159, Tube and Fittings Kit .
Remove the oil filter assembly. Disassembly procedure:
Loosen all the allen bolts (use 5 mm allen key). Remove the connections of intake valve
Remove the old oil filter element from housing. Pulse line & blow down line connection
Clean inside of the filter housing with clean cloth. Power supply to solenoid
Assembly of new oil filter: Suction elbow from air filter
Take O-rings from kit. Remove the Top Housing(03) from Bottom housing(01).
Fix the new O-ring on the new oil filter element flange Remove the Plunger(05) and Spring(04) from Bottom
bottom side (apply with grease). housing(01).
Ensure the O-ring seating in the flange. Maintenance
Assemble the new oil filter element in the housing. Clean Bottom housing(01) bore dia, Plunger(5) sliding
Fix all the allen bolts and tighten it (use 5 mm allen area with liquid cleaner.
key). Clean the pivot hole of Top housing (03) in which
Fix the new O-ring on the top flange of the filter flange throttle shaft rotates.
and apply grease.
Maintenance 6.6
Figure 17. Intake valve
Sl.
Description Part number Qty Sl. no Description Part number Qty
no
2 O-RING ID122.0 X 3.6 415400655 1 32 NUT HEX M10 X 1 ZBP 000948013 1
4 SPRING CHECK VALVE IV159 970400040 1 34 SUPPORT ACTUATOR IV159 970400060 1
5 PLUNGER CHECK VALVE 970300690 1 35 FLOW CONTROL VALVE B013406760001 1
6 O-RING ID94.8 X 3.5 220410750 1 36 TUBINGS 6MM 000920620 1
7 BUSH THROTTLE SHAFT 970400030 2 39 O RING 190 ID X 3.55 970400010 1
13 SCR SOC HD CAP M6x35 12.9 000983067 1 42 SLEEVE 159 970400270 2
14 BALL JOINT MACHINED M5X0.8 B004900520003 1 43 NUT NYLOC M6 000948307 1
15 ACTUATOR PNEU. B011406760002 1 45 O RING ID 12.5X1 970400400 1
16 SCR SOC HD CAP M5x16 12.9 000983044 2 47 TAMPER CAP MPV 970300510 1
17 BLOWDOWN BLOCK 970300170 1 48 QUICK FITTINGS CONN 000920509 1
19 QF ELBOW 1/4BSP-DIA 6 000920624 1 49 QUICK FITTINGS ELBOW 000920609 1
26 SOLENOID VALVE NC,24V50/60HZ B007300990017 1 50 SILENCER SLIT TYPE 970300750 1
27 O-RING ID11.6 X 1.8 990402410 1 51 NYLON TYBE 10x8MM BLUE 000919244 0.12
28 SCR SOC HD CAP M5x40 12.9 000983050 2 52 UNION ELBOW DIA 10 B010501880007 1
Maintenance 6.7
After cleaning replace all parts as per the kit drawing. Adjustment procedures as follows,
with screw(11) and spring washer(10). Ensure the Apply Loctite & Assemble the new tamper cap(47).
engraving ”TOP” in throttle plate is facing the top side.
NOTE
Fasten the Actuator block(34) and corresponding
actuator kit parts to Bottom housing(01) . After completion of intake valve assembly in package,
ensure to verify the performance as per the product
Connect throttle shaft (08) and ball joint(14) with the specifications. Also ensure that there is no leak in control
help of shaft connector(12). Press the throttle plate system tubings and pipelines in the package.
against the housing (03) and fasten shaft connector(12)
with bolt (13).
6.1.2.7 Minimum pressure valve
Measure the no load sump pressure with the aid of Switch off the compressor and disconnect power supply
pressure gauge mounted on the tank and verify to the compressor.
whether it is within specification limit (refer package Close the discharge end ball valve.
specifications).
Release air oil tank pressure and allow the tank to cool
If no load sump pressure is out of specifications, use for a few minutes.
the below steps to adjust the settings
Requirements
Maintenance 6.8
Figure 18b. Minimum pressure valve
Sl.No. Description Part number Qty Sl.No. Description Part number Qty
1 Valve housing 970300240 1 10 Spring - 38mm 970400110 1
2 Screw socket head 000976060 1 11 Spring spacer 970400100 1
3 Plain washer M6 000997006 1 12 O-ring 970400130 1
4 O-ring Stopper 970400390 1 13 Cap 970300260 1
5 O'-ring 970400150 1 14 Punched washer M10 000996059 1
6 Split Plunger 970400380 1 15 Spring washer M10 000996110 1
7 Spring 970400120 1 16 Hex nut M10 000948013 1
8 O-ring 970400140 1 Socket head crub screw
17 970400160 1
M10
9 Piston 970300250 1
18 Tamper cap 970300510 1
MPV Disassembly Assemble new O- ring (5) and fasten O ring Stopper (4)
Remove the protective cap (18) to Split Plunger (6) by applying a torque of 2 Nm on
screw socket head M6X12 (2) . Thread sealant 262 to
Loosen hex nut M10 X 1 (16) and unscrew the threaded
be applied in first 2 threads of screw socket head
stud M10 hex grub screw (17) using 6mm Allen key
M6X12 (2).
Hold housing (1) and slowly unscrew and remove the
Assemble the new O-ring (8) in cylinder (3) groove.
cap (13) (spanner size : 49 mm) (Attention : Spring in
Reassemble split plunger assembly (6,4,5) spring-
compressed state inside the housing)
13mm (7), piston assembly (9,8), spring - 38mm (10)
Remove O-ring (12) from cap (13) and spring spacer (11) fasten the cap (13) to the
housing (1) slowly with the specified torque.
Remove spring spacer (11) and spring - 38mm (10)
Insert threaded stud (17) to the housing (1) and tighten
Remove piston (9) and o ring(8) from piston
it using Allen wrench.
Unfasten the screw socket head M6X12 (2) to
Tighten the hex nut M10 X 1 (16) to the threaded stud
disassemble O-ring (5).
(17)
Cleaning and Lubrication
Functional testing:
Clean piston sliding-surface and sealing seat with a
After service valve functioning to be tested on compressor
liquid cleaner.
in running condition
Lubricate the piston sliding surface with compressor oil
Adjust the threaded stud (1) such that 4.5±0.5 bar
Take care not to damage the valve seat and sealing pressure is achieved in sump
surfaces
6.1.2.8 Thermal valve
Take care not to damage the piston seating surface and
sealing surfaces Pre work
Maintenance 6.9
THERMAL VALVE 6.1.2.10 Cooler cleaning
BLOCK
THERMAL VALVE Cooler surface might be hot caution should be taken while
ELEMENT cleaning. Fan should not run while cleaning the cooler.
Pre work
Figure 19. Thermal valve Release air oil tank pressure and allow the tank to cool
for a few minutes.
Close the discharge end ball valve.
CLEANING
Release air oil tank pressure and allow the tank to cool AIR FLOW
DIRECTION
for a few minutes.
Requirements
Procedure COOLER
ASSEMBLY
Replacing thermal Valve SHROUD
COOLER
COOLER CLEANING
Remove the thermal valve element from the thermal DOOR-I
CLEANING
valve block body DOOR-II
Maintenance 6.10
Pre work
Release air oil tank pressure and allow the tank to cool
ELEMENT for a few minutes.
Requirements
HUB
Spanner, screw driver, player, caustic soda.
Maintenance
Figure 21. Drive coupling
Maintenance Dismantling
Replacing the coupling element: Disconnect the pressure sensor line on top of the
moisture separator
Open the cooler side panel covers
Manually drain the condensate by using the manual
Open the coupling guard from the adapter ring .
discharge plug located at the bottom of the auto drain
Remove the three coupling screws and slide coupling assembly.
element on the shaft spline to free the coupling element
Remove the moisture separator from the machine
Replace the old coupling element with a new coupling
Remove the bottom housing from the top housing.
element
Remove the auto drain assembly from the bottom housing.
Tighten the coupling screws & assemble the coupling
guard with adaptor ring. NOTE
Avoid damaging the housing when removing or
Reassemble the cooler side panel cover
tightening the moisture separator. Do not use a pipe
Inspect every three months to ensure screws stay tight. wrench. If necessary, use a locking strap clamp/wrench
Install the separator in a vertical upright position,
6.1.2.12 Moisture separator and auto observing the correct direction of air
drain valve
Cleaning and replacement
CAP SCREW
PE WASHER
TOP HOUSING
O-RING HOUSING
VORTEX GENERATOR
O-RING (CONE) -VANE
VORTEX GENERATOR
-CONE
TIE ROD
MANUAL DISCHARGE
ARRESTOR
ARROW
DIRECTION
EXTERNAL AUTO
DRAIN
Maintenance 6.11
EYE BOLT
FASTENERS (TOP ROOF TO CANOPY)
The auto drain assembly is not serviceable and must be Isolate the machine from the service line and vent the
replaced with new one if not functioning air-oil sump pressure to atmospheric pressure
Reassembly Remove the Air outlet pipe connected with cooler outlet
need only to be tightened moderately by hand. Over- Ensure machine is disconnected from power supply
tightening may lead to failure or damage. ELGi assumes
Isolate machine from exhaust duct mounting.
no responsibility for failure or damage resulting from
such incorrect installation. Requirements
Spanners, safety gloves
Reassemble the auto drain assembly with the bottom
housing and the bottom housing with the top housing Cooler Disassembly
Reassemble the moisture separator in the machine and Remove top panel from canopy (Use M8 eyebolt into
connect the all pipe lines, pressure sensing line, and roof panels for lifting purpose)
drain line
Loosen fasteners between cooler and shroud mounting
Restart the machine and check for any leaks at the location (M8 Hex bolt, M8 Plain & spring washer -Qty 5)
joints. If leaks occur, stop machine and wait for sump Insert lifting hook into lifting pad provision in cooler
pressure to drop to atmospheric pressure.
Remove the cooler from package
Remove the O-ring as described above, and inspect and
clean it Cooler Reassembly
6.1.2.13 Cooler Maintenance Reassemble fasteners (M8 Hex bolt, M8 Plain & spring
washer - Qty 5) assembled with shroud
Switch of the compressor & disconnect power supply to
compressor Reconnect the Air outlet pipe with cooler outlet flange
Maintenance 6.13
6.1.2.16 Cooler and motor suction prefilter
prefilter cleaning & maintenance instructions
Lift upward & take out the cooler pre-filter assembly from the compressor.
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 prefilter.
In case of major dust / dirt accumulation in the pre-filter mesh, wash with clean water.
COMPRESSED AIR
PRE FILTER
PREFILTER SS WIRE MESH SS WIRE MESH
Maintenance 6.14
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 and life of compressor. Spurious parts
will prove cost-ineffective in the long run, and may even result in total damage of the machine or cause serious accidents.
The table includes certain some critical spurious parts with its effects 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.
Due to dense filtration media, it creates in additional pressure drop and so causes
Air oil separator Higher power additional power consumption. Every1 bar (14.5 psi) of pressure drop results in
consumption ~7% additional power consumption.
Spurious oil loses its properties soon and may get solidified causing the rotor to
Lubricant
malfunction.
This imposes 10% additional resistance for air flow and creates more pressure
drop and thus additional load on motor. Inadequate separation deteriorates air
Air oil separator quality, reduce the performance, and damages downstream components. It also
results in huge oil loss (1L / 200hr).
Reduced
performance 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
Oil filter
end, air oil separator etc. Contaminated oil also cause clogging and reduces the
cooler performance.
Dust carries over to the system and causes the same problems as caused by the
Air filter
spurious oil filter
Maintenance 6.15
6.2 Troubleshooting
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.
(2) Check and correct the short circuit within the control
panel.
Isolator fuse blown.
(3) Dedicated isolator to be provided to the compressor.
(4) Check and correct the motor winding/ body short after
megger test.
Control fuses inside compressor Replace the solenoid valve / control transformer if defective.
control panel blown
Replace the glass fuse (2A for Neuron, 1A for the control
circuit).
No power supply to Neuron (2) Ensure tight connection of the 24V power supply connector
controller. to Neuron
Maintenance 6.16
Problem Cause Solution (go sequentially)
(1) Check and refill oil to correct the level. (in stopped
condition)
Cooling fan not working. Check and ensure the neutral connection is connected.
High discharge
oil temperature Replace the sensor.
Temperature sensor malfunction
Tighten/recrimp the connection with adaptor.
Check for pressure drop across the oil cooler if less than 1.5
bar (22 psi).
Maintenance 6.17
Problem Cause Solution (go sequentially)
Scavenge return line tube gap not Remove the return line tube from
maintained (not applicable EG11 to EG22) the separator and correct it.
High oil carry over High discharge oil temperature (DOT) Refer to the diagnosis procedure for high DOT.
Maintenance 6.18
Problem Cause Solution (go sequentially)
Intake valve malfunctioning Check and replace the intake valve kit.
Unload mode enabled in Neuron Disable 'unload mode' in operator settings of the
microcontroller Neuron microcontroller
Maintenance 6.19
Problem Cause Solution (go sequentially)
No control air supply to solenoid valve. Replace / connect the control line tubes.
Maintenance 6.20
6.3 Decommissioning, dismantling and
putting out of service
Empty the air oil tank containing the lubricating oil and
store in compliance with the laws in force.
Maintenance 6.21
6.4 ELGi Services
6.4.1 ELGi customer care system (ELGi Southern Region: Tamil Nadu, Karnataka, Kerala,
Puducherry, Andhra Pradesh, Telangana, Andaman &
CCS)
Nicobar Islands.
ELGi provides dedicated customer care and after-sales
Western Region: Maharashtra, Gujarat, Madhya
support through the ELGi customer care system (CCS), a
Pradesh, Goa, Lakshadweep Islands.
computerized system developed in-house. The CCS aims
to minimize the time taken to resolve customer Eastern Region: Orissa, Chhattisgarh, Jharkhand,
complaints. West Bengal, Bihar and the North-Eastern states.
be resolved and closed in the CCS within a specified time 3. Fab. number
limit, failing which the complaint is automatically brought
4. Contact person name
to the notice of the manager. If the issue remains
unresolved, it will get escalated to the managing director. 5. Phone number
The CCS ensures that not only the customer complaints 6. Nature of complaint
are logged but they are also attended to on time, every 7. Hour meter reading
time.
You may use the CCS by sending e-mail to: [email protected]
Enquires
Customer satisfaction survey
A number of calls received by the CCS relate to customer
If you have used the CCS, you may be contacted for your
queries regarding products and spare parts. The details
feedback on our after-sales support. Your response helps
are noted, and basic information on product specifications
ELGi to improve its service.
and usage are provided. The caller is then referred to a
salesperson at the head office or the appropriate branch International customers:
for follow-up. Refer contact information at the end of this manual book.
The CCS database
6.4.2 ELGi genuine spare parts
The CCS also creates a database of customers, adding
When ordering spare parts, refer to the lists provided in
details of every new customer who calls, thereby building
the parts manual and identify the part number. Specify the
a large pool of installation details. These details are used
part number and quantity, in addition to the name plate
to provide value-added services to improve customer
details. Global support center of ELGi ensures the supply
satisfaction with ELGi products.
of the quality spares on time. Ensure that you are using
CCS-working hours the genuine spare parts so that your Compressor will be
The ELGi CCS works for six days a week from 08:30 to working efficiently and effectively. Refer to section 6.1.3
21:30 IST (Monday to Saturday). for details on need of using genuine spares.
Multi-lingual capability Please contact our After sales team for any compressor
accessory requirements like VFD, Air-Dryer, etc.
The coordinators at the CCS are multi-lingual. They can
handle calls in English and all the major regional 6.4.3 Air audit
languages of India.
We extend our proven capabilities in energy efficiency
Coverage: The CCS toll-free number 1800-425-3544 is initiatives by carrying out air audits for our customers.
accessible from the following areas:
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,
Maintenance 6.22
medium and long term measures for energy conservation,
along with financial estimates and analysis for
implementation.
Maintenance 6.23
6.5 Appendix
Maintenance 6.24
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.
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
¼" 45 33.19
½" 85 62.69
Maintenance 6.25
Total Moisture Trip
Oil level Pre
operated Line System Discharge removal Cooler record Operator
Date From Till in AOS Filter Comments
hours / pressure pressure temperature from AOS cleaning descrip- sign
tank Cleaning
day tank tion
Maintenance
Low/
Start/Stop normal/ Before
Time high/ starting
change
6.5.3 Service log book – record of maintenance
6.26
Total Moisture Trip
Oil level Pre
operated Line System Discharge removal Cooler record Operator
Date From Till in AOS Filter Comments
hours / pressure pressure temperature from AOS cleaning descrip- sign
tank Cleaning
day tank tion
Maintenance
Low/
Start/Stop normal/ Before
Time high/ starting
change
6.27
6.6 Disclaimers
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.
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 .
Maintenance 6.28
Controller Manual
Neuron III
Version 3.6
July 2020
Contents Page No.
Abbreviations used 7.4
7.1. Technical specification 7.5
7.2. Installation instruction 7.7
7.2.1 Equipment’s safety 7.7
Temp Temperature
AF Air filter
OF Oil filter
Min Minimum
Max Maximum
AO Analog output
UL Unload
En Enable
Dis Disable
L Load
St Stop
F Fault
R Run
Sby Standby
DD Date
MM Month
YY Year
Pr Pressure
Tr Temperature
PR Pressure
OL Overload
NC Not connected
PS Pressure schedule
REM Remote
Software : Embedded C
3 Phase detection : Phase loss / reverse at the time of pressing START key
Keypad : 11 key (Usage: up, down, right, left, enter, TAB, INFO, Esc, start, stop & reset) 11
LED (status, warnings and fault indication)
Certification : CE, UL
Digital inputs:
Number of channel : 8 Ports
Usage
: Emergency stop, motor overload, cooler over load, motor reverse rotation, DPOF,
Digital outputs:
Number of channel : 8 Ports
Usage : 6 Pre-programmed (Main, star, delta, load/unload, ADV, fan motor), 2 by default
programmed for trip and warn. programmable for warn, load, service, standby, trip,
remote, ready and dryer if enabled.
Analog inputs:
Number of channel : 4
2 x 4-20mA inputs:
2 x PT1000:
Usage : Discharge temperature, dew point /motor winding temperature software selectable
Analog outputs:
Number of channel : 2
Range : 1 to 5V DC
Resolution : 1 mV
Accuracy : ±25 mV
Communication ports:
Port 2 : RS485, MODBUS RTU (for VFD parameter reading, analog input module)
This equipment is sensitive to electrostatic discharge, Since the electronic circuits must not be subjected to
which can cause internal damage and affect normal uncontrolled temperatures, place the cabinet in shade.
operation. Follow these guidelines when you handle this Protection from rain
equipment:
Partial tightening of screws or doors allows water to enter
Touch a grounded object to discharge potential static.
the enclosure and cause irreparable damage to the
Wear an approved grounding wrist-strap. circuitry. Provide canopy to avoid such damages.
Do not touch connectors or pins on component boards. Do not install equipment on structures subject to
continuous vibration
Do not touch circuit components inside the equipment.
Partially tightened wires or components in the cabinet
Store the equipment in appropriate static-safe
disconnect during vibrations and cause irreparable damage
packaging when not in use.
to circuitry.
7.2.1.2. Assembly
The place of assembly has to correspond to the class of
protection. The ambient temperature in the installation
position may not exceed the admissible temperature for
the nominal use, specified in the data sheet. Not to use in
wet condition.
LED Description
Continuous glow - to indicate the machine in auto power recovery mode.
Auto
LED blink - when the machine is going to start irrespective of any start mode.
Glows when
Air oil separator 1. Air oil separator service is due - based on service hours
2. Pressure drop in separator is more than set value (if sensor is fixed).
Main motor overload Glows when the main motor overload digital input is open.
Reverse rotation Glows when the reverse rotation digital input is closed.
1&3 24V DC discharge pressure 24V DC PR1 4 - 20mA 0 to 16 bar (0 to 232 psi)
2&4 24V DC sump pressure 24V DC PR2 4 - 20mA 0 to 16 bar (0 to 232 psi)
5&7 Discharge temperature T1-1 T1-2 PT1000 -10 to 150°C (14 to 302oF)
1 NC
3 NC
5 NC
7 NC
*If Dryer and VFD is enabled, AI module add-on will be used for dryer dew point
** If Dew point sensor and Winding temperature are used, Winding temperature shall be connected here
\
Controller Manual 7.10
7.5.5 X05: Main motor relays
1 R Phase L1
3 B Phase L3
The home screen will show discharge pressure , discharge Live sump pressure (displays only if sump pressure enabled)
oil temperature ,VFD speed % (if VFD enabled), Live Pt1000 temperature (displays only if DRYER ON
compressor status, warn messages, compressor mode
enabled)
selection details and date & time
"UP" - Set analog values
Status Description
Ready Ready for start
During the start, if the discharge temperature is lower than the set inhibit temperature value,
Temperature inhibit ±XX you will see this message. ±XX denotes the live discharge temperature value. The compressor
starts only if the discharge temperature value goes above the set value.
If sump pressure is not used (disabled) then the controller will ensure minimum 60 seconds
Start inhibit "seconds"
delay between the stop and the start. Count stops if "STOP" key is pressed
If compressor is in auto mode, the controller will ensure minimum delay (user set, e.g. 60 sec)
Auto restart "seconds"
between stop and start. count stops if "STOP" key is pressed
This message is displayed after a fault is cleared and waiting for user acknowledgement. By
Start ack wait…
pressing "RESET" key user can acknowledge.
Sump pr. probe failure Sump pressure sensor probe failure, if sump pressure is enabled
HSP (AD) If discharge pressure exceeds the set high sump pressure value.
Trip temperature If the discharge temperature exceeds the set trip temperature value.
Sump Pressure After the Start, The sump pressure should be at least 0.3 bar/4psi after star delay expires. If
Not Developing this is NOT achieved this Fault occurs , if sump pressure is enabled.
Power failure If the mains supply is interrupted for more than 20 msec
If the mains supply voltage is less than the 75% of rated voltage.
Low voltage Compressor is tripped & All controller operation is halted until the mains supply Comes back to
normal (at least 85% of the rated)
Dis. pressure After the Load, The discharge pressure should be at least 0.5 bar/7psi in 5mins. If this is NOT
Not developing achieved this fault occurs
Dryer IP trip If dryer is enabled with trip, if dryer trip occurs, this fault message will be shown
Dryer low DP trip When dew point temperature is less than set value.
Temperature not If the discharge temperature not raised above the inhibit temperature before the set inhibit
developing temperature time.
If CV20 variant selected or winding temperature enabled, it will trip the compressor based on
Winding temp. high
SET value of MOTOR WINDING temperature
If CV20 variant selected or winding temperature enabled, it will trip the compressor if sensor
Winding temp. fail
open
Dryer Off - Low DP warn When Ch-4 Dew point temp. is less than Set value
High Dew Point When Ch-4 Dew point temp. is greater than Set Value
When the difference between Sump. Pressure and Discharge Pressure exceeds the Set
High Differential Pressure
Pressure. ( Only in Sump Pr. Enabled condition)
Warn Temperature W he n Discharg e te mp . e x ce e d s the se t warn temperature (Default is 105Deg C/Deg F)
Change Oil Filter When service remaining Hr. reaches 0000 Hrs
Change Air Filter When service remaining Hr. reaches 0000 Hrs
Change Valve kit When service remaining Hr. reaches 0000 Hrs
Dryer Off - IP Warn If Dryer Digital Input is Open and dryer warn is selected in the input
If CV20 variant selected or winding temperature enabled and if the temperature exceeds [SET
Winding temp Exceeded
value-10] of MOTOR WINDING temperature
If this is enabled, the compressor operates automatically 12. High dew Point
after a power outage and resumes based on the previous The system will warn if the dew point temperature is
condition. The default delay is 30* sec. Warn RST delay higher than the set value (if the dryer is enabled).
delays the compressor start if power resumes and Auto
13. Load/Unload Source
Restart Mode is ON.
Local: Load/Unload pressure is based on load/unload
*If compressor recover from standby, restart delay is 10
settings in the controller.
sec.
Remote: Selection from digital input– remote load/unload
4. Load / Unload pressure
can be operated from remote through a wired switch.
The compressor operates between load pressure and
DCS: Load/Unload can be operated from DCS (load/unload
unload pressure based on compressed air utilization. You
command should be given continuously in the interval ≤ 3
can set load/unload pressure based on the requirement
sec) Ensure master control bit in enabled condition.
within the operating pressure band zone.
Press any one of the following keys and to enter main menu
7.7.1 Main Menu
Dis. Pr : 0.0 bar / 0 psi
Dis. Tr : 25°C / 77°F
Status :
View
Operator
Service
Factory
Customer care
Admin
7.7.1.1 View
In the view menu, you can view the set parameters, but you cannot edit any of them - no password required.
View Operator
Fault report
Day report
Service time
Cumulative time
VFD
Rental hours
7.7.1.2 Operator
LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4
View Operator Mode Control mode Local / Remote / DCS
Auto restart On/ Off
Pressure unit Bar/psi
Temperature unit Fahren / centi
Pressure Unload pressure X X . X b or p (bar or psi)
Load pressure X X . X b or p
Pr. schedule ON/ OFF
Delay Warn RST delay X X X s (second)
Star delay XXs
DTR delay XXs
RTS delay XXs
Standby time X X m (minute)
St/Sp PH XX
DCS port Type Modbus
ID XX
Baud 9600/19200
Parity None / Even / Odd
Length 8/7
Stop bit 2/1
Temperature Trip temperature X X X C or F
Warn temp X X X C or F
Fan temp X X X C or F
Rating XXXXXXXXXX
Fab No. XXXXXXXXXX
Date : DD/MM/YY
Time : HH:MM:SS
Dis.Pr : X X .X
Dis.Tr : X X X
STC:X X X LDC:X X X X X
L- Load, St - Stop, UL - Unload, F- Fault, R- Run, Sby- Standby, STC - Start Count, LDC - Load Count
Utilisation XX%
RPM
7.7.2 Operator
Status of the VFD
This option requires a password to adjust operator settings
Run hours based on VFD speed % within the set limits.
Mode
Pressure
Based on
5 Unload pressure ≥ load pressure ≤ max unload pressure - bar/psi
compressor
pressure
6 Load pressure 4.0bar(58psi) ≤ unload pressure - - bar/psi
rating
Set Delay
8 Star 6 20 - 6 second
9 DTR 10 60 - 3 second
10 RTS 5 30 - 5 second
DCS Port
12 Type - - Modbus -
13 ID 01 99 - 01 -
16 Length - - 8/7 8 -
19 On time 1 15 - 5 Second
Contrast adjust
3 Time HH 00 23 - 00 Hour
4 Time MM 00 59 - 00 Minute
(one schedule should be in Sunday (first day of the week) 00:00 Hrs) Then Press "Enter" to set the following
1 AF changed - - no/yes no -
2 OF changed - - no/yes no -
3 OS changed - - no/yes no -
5 Re-grease - - no/yes no -
# Item
1 English
2 Portuguese
3 Francais
4 Italiano
5 Spanish
I-Time 1 200 20
accumulated errors from the past, it can cause the present read and write between VFD and Neuron III.
value to overshoot the set point value
View the VFD RPM range in the factory AO scaling menu
Effect of change in Kp( Proportional value ) & Ki ( Integral to ensure MODBUS communication exists between VFD
value ) listed below. and Neuron III. Current VFD RPM appears here, if
I-Gain - Range: 1-5000. This gain occurs over a full To reset the rental hour, select “rental off” and then
A lower setting enables the system to be tolerant to the updates with the current date. You can then view it in the
error. A value of 50 for I-Gain will enable the system to customer care menu.
correct the error only if the pressure difference between Spares replaced - If you select yes, the last spares
set and actual pressure exceeds 0.020 bar / 0.3 psi. replaced updates with the current date. You can then view
The higher the setting, the more sensitive the system it in the customer care menu.
becomes to very small changes. Regular service - If you select yes, the Regular service
E.g. A value of 1000 for I-Gain makes the system updates with the current date. You can then view it in the
sensitive to a 0.001 bar / 0.01 psi difference. A very high customer care menu.
value and sensitive system (low receiver capacity) will 7.7.3 Service
drive the system into a completely unstable state. Always
Password required.
try to set lower values for I-Gain.
The setting changes should be made by ELGi authorized
Setting I-Time
service technicians only. Any attempt to change service
I-time - Range: 1-200. This indirectly counts the scan settings by unauthorized people may lead to compressor
time. The recommended value is 15-20. malfunction and the warranty becoming void.
The higher the value, the more delay will be on the Service Sensor Offset
application of correction calculated based on I-Gain and Relay
the reverse is true.
Temperature
Min speed: The compressor remains in min speed up to Maintenance
the start "Run Load" condition during start. If demand is Clock
very little, the compressor will run at minimum speed. Self-Test
Unload speed: The compressor runs at set unload speed Password
during unload. This is irrespective of all unload modes like Digital Input
Remote, DCS and local unload. Dryer Input
Pre-checks that must be performed before starting Unload Mode
the compressor under VFD control Lat /Lon
7.7.3.2 Programmable relay You used to register the filter replacement in operator->
Maintenance by choosing Yes/No option. Once you choose
Select programmable relay 1 or 2 using the ∆ and ∇ keys.
Yes in operator then filter life time will be updated.
Then press “Enter” to assign any one of the following
functionalities to the relay. # Item Min Max Option Default Unit
2 Time format 12 hr 24 hr
# Item Min Max Option Default Unit
3 Day light savings 0 2
1 Fan temp On 95oC Off - - C/F
7.7.3.8 Latitude/Longitude
This option involves deg, min, and sec with NE, NW, SE,
and SW format.
7.7.3.9 VFD_model
A list of VFD models appears here for you to select a
pressure-based speed, based on customer requirement.
URL : www.elgi.com
E-mail : [email protected]
Analog output
DCS Port
NOTE
If analog input probe failure occurs, analog output
becomes 0V by default.
S.
Failure symptoms Possible causes Remedies
NO
No display in LCD Screen & Please check the controller input voltage at connector
1 Transformer failure.
Backlight was not glown X08. Voltage should be 24V ± 15% VAC.
Key not responding Check any key stuck / Flat. If any change Controller
Key not functioning
2
Note: Controller keys
Key struck / Flat Change the controller.
Plastic enclosures
C1 C1 C1
7b/333cfm 7b/333cfm 7b/333cfm
Air Receiver
1000 cfm
Weekly utilization
Air demand: 100% Air demand: 75% Air demand: 50% Air demand:25%
Comp -> C1 C2 C3 C1 C2 C3 C1 C2 C3 C1 C2 C3
The scheduler reduces power consumption since compressors are only utilized based on demand.
Step-4 enable
During the start, if the sump pressure is higher than the set start sump pressure value, you
Start inhibit xx.x will see this message. XX.X denotes the live sump pressure value. The compressor starts only
if the sump pressure value goes below the set value.
During the start, if the discharge temperature is lower than the set inhibit temperature value,
Temperature inhibit ±XX you will see this message. ±XX denotes the live discharge temperature value. The compressor
starts only if the discharge temperature value goes above the set value.
If sump pressure is not used (disabled) then the controller will ensure minimum 60 seconds
Start inhibit "seconds"
delay between the stop and the start. Count stops if "STOP" key is pressed
If compressor is in auto mode, the controller will ensure minimum delay (user set, e.g. 60 sec)
Auto restart "seconds"
between stop and start. count stops if "STOP" key is pressed
This message is displayed after a fault is cleared and waiting for user acknowledgement. By
Start ack wait…
pressing "RESET" key user can acknowledge.
Warning Description
Dryer Off - Low DP warn When Ch-4 Dew point temp. is less than Set value
High Dew Point When Ch-4 Dew point temp. is greater than Set Value
When the difference between Sump. Pressure and Discharge Pressure exceeds the Set
High Differential Pressure
Pressure. ( Only in Sump Pr. Enabled condition)
Change Oil Filter When service remaining Hr. reaches 0000 Hrs
Change Air Filter When service remaining Hr. reaches 0000 Hrs
Change Valve kit When service remaining Hr. reaches 0000 Hrs
Dryer Off - IP Warn If Dryer Digital Input is Open and dryer warn is selected in the input
Sump pr. probe failure Sump pressure sensor probe failure, if sump pressure is enabled
HSP (AD) If discharge pressure exceeds the set high sump pressure value.
Main motor overload/ IF the MMOL digital input opens due to main motor
VFD error over load. VFD error if VFD control is enabled.
Rev rot / Ph fail If the rev rot input closes when motor running due to motor reverse rotation or Phase failure.
Trip temperature If the discharge temperature exceeds the set trip temperature value.
Sump Pressure After the Start, The sump pressure should be at least 0.3 bar/4psi after star delay expires. If
Not Developing this is NOT achieved this Fault occurs , if sump pressure is enabled.
Power failure If the mains supply is interrupted for more than 20 msec
If the mains supply voltage is less than the 75% of rated voltage.
Low voltage Compressor is tripped & All controller operation is halted until the mains supply Comes back to
normal (at least 85% of the rated)
Dis. pressure After the Load, The discharge pressure should be at least 0.5 bar/7psi in 5mins. If this is NOT
Not developing achieved this fault occurs
Dryer IP trip If dryer is enabled with trip, if dryer trip occurs, this fault message will be shown
Dryer low DP trip When dew point temperature is less than set value.
Temperature not If the discharge temperature not raised above the inhibit temperature before the set inhibit
developing temperature time.
Winding temp. high/fail It will trip the compressor based on SET value of MOTOR WINDING temperature/ sensor open
Sl.
Description Qty. Part Number
No.
20 WING NUT 1 -
S.
Description Qty. Part number
No
1 MOTOR 1 B005106400028
4 AVM 6 B001406190007
S.
Description Qty. Part number
No
1 MOTOR 1 B005106400028
4 AVM 6 B001406190007
Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.
3 MPV TO COOLER HOSE ASSY 1 015321139 38 1/4 BSP BONDED WASHER 3 000959385
7 OIL FILL PLUG - 1INCH BSP 1 015402651 42 TUBINGS 6mm 2.4 m 000920620
ADJUSTABLE ELBOW
22 1 B010506780014 57 RECEIVER TANK 1 015318382
1/4”G-1/4”G
26 HEX BOLT M12 X 25 5 000906182 61 1/4” BSP X 6mm ST. FITTING 1 B009606780009
34 O-RING 1 220412320
Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.
3 MPV TO COOLER HOSE ASSY 1 015321139 38 1/4 BSP BONDED WASHER 3 000959385
7 OIL FILL PLUG - 1INCH BSP 1 015402651 42 TUBINGS 6mm 2.4 m 000920620
ADJUSTABLE ELBOW
22 1 B010506780014 57 RECEIVER TANK 1 015318382
1/4”G-1/4”G
26 HEX BOLT M12 X 25 5 000906182 61 1/4” BSP X 6mm ST. FITTING 1 B009606780009
34 O-RING 1 220412320
Sl.
Description Qty. Part Number
No.
S.N
Description Qty Part number
o
12 PISTON 1 015403621
Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.
4 PILLAR - SERVICE DOOR ASSY 1 015317438 41 QUICK FITTINGS 1/2” BSP-12 2 000920512
18 LOCK 12 B15204790005
Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.
4 PILLAR - SERVICE DOOR ASSY 1 015317438 41 QUICK FITTINGS 1/2” BSP-12 2 000920512
18 LOCK 12 B15204790005
9) Safety Valve
S. No Description Part Number Qty.
1 Safety valve B012805340028 1
Oil Cooler Out to 2.1 TVB to Oil Cooler In hose assy 015321123 1
2 012465169
TVB hose kit 2.2 O-Ring 015402685 2
TVB to Oil Cooler 3.1 Oil Cooler Out to TVB hose assy 015317427 1
3 012485069
In hose kit 3.2 O-Ring 015402685 2
F) Other Spares
*Parts and quantity required for Cooler to Shroud sealing
S. No Description Part Number Qty.
1 After cooler EG 22P - 30 015317409 1
2 Oil cooler EG 22P - 30 015317408 1
3 After cooler EG 37 - 45 015317467 1
*** VFD Retro fitment kit is applicable for US/CANADA variant only
Models
EG 26 &
EG 22P EG 45
Insurance kit details EG 30 EG 37 (C)
(C) (C)
( C)
Kit No
Calibration must be carried out if any sensors are replaced. For doing so please contact ELGi dealer/Service engineer
C - Standard, CV - Standard + VFD
EG 26 &
EG 37
Insurance kit details EG 30 EG 45 ( CV)
( CV)
( CV )
Kit No
S.No Description Part Number 012485009 012484999 012485019
Calibration must be carried out if any sensors are replaced. For doing so please contact ELGi dealer/Service engineer
C - Standard, CV - Standard + VFD
01 83 6365 5
1 4
3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1
Re10 Re9 Re8 Re7 Re6 Re5 Re4 Re3 Re2 Re1
X08
X02 X03
1B
2B
1A
2A
2 4 6 8 10 2 4 6 8
2 4 6 8 10 12
X01 1 3 5 7 9 1 3 5 7 9 11
1 3 5 7
P N
PE
CN
CN
CN
CN
X04
NC A1
1
2
RS 485
NC B1
3
4
NC A2
5
6
RS 485
NC B2
7
8
CONNECTION DETAILS
X02
X03
1
2
1
2
3
4
3
4
5
6
5
6
7
8
7
8
9
10
9
10
11
12
01 83 6365 5
2 4
CNTRL PANEL EG26-EG45
(BOM)
01 83 6365 5
3 4
K4 K2 CR1
TR.1 TR.2
PE
01 83 6365 5
4 4
16.0 VFD setting procedure
series compressor Based on the compressor rating, VFD parameters are pre-
programmed in the Setup 1 location and in the compressor
In VFD model compressors, the Variable Frequency Drive controller. The setting details are available in Annexure 1.
(VFD) is integrated with the compressor. Simply put, the
During installation and commissioning, you can tune the PI
main motor is controlled through VFD instead of the star
at your own site to ensure smooth speed control according
delta starter.
to your requirements. Except for PI settings in the
Hardware (wiring) details
controller, no other setting is required to change. Similarly
The figure illustrates the wiring integrations with the VFD
and control panel/controller. The following section
describes the purpose of each connection in this
architecture.
2. Motor connection
For more details about VFD parameters and If the machine runs in unload for more than the stand
troubleshooting, refer to the VFD manual that shipped by time set in the controller, the compressor stops and
along with the compressor. goes to standby mode. It waits till pressure reaches the
Operation set load point in the controller and then starts as per
the start sequence.
The Start command enables the compressor motor to start
and rotate in the required direction. It is issued from the If the drive does not respond to quick pressure changes
controller to VFD. (drop in set pressure) or responds very fast to pressure
changes (continuous increase and decrease in speed to
After receiving the Start command, VFD accelerates the
maintain set pressure), then adjust P and I settings in the
compressor motor to 40% speed (minimum speed setting
NII controller**.
in the controller). After ensuring the run feedback signal
from VFD and reaching 40% speed, the controller actuates ** One-time fine tuning is recommended during
the solenoid valve to start the loading process. Only then installation by an expert.
does VFD increase motor speed from 40% to 100% (max If you do not opt for speed change with respect to
speed setting in the controller). pressure, and instead opt to operate in fixed speed, then
Until the Target pressure is reached, the VFD delivers choose the optimum speed enable option in the operator
100% speed. Once the Target pressure is reached and the setting. The compressor then operates at optimum speed
demand becomes low, the speed reduces and stabilizes to during load and at unload speed during unload.
maintain the set pressure. The speed limit varies from
40% to 100% speed based on the demand and pressure NOTE
range. Max speed, min speed, optimum speed, and unload speed
Even when speed reaches 40% of the rating and the are all factory settings. Do not attempt to change these
settings. You can view set speed details in the operator
demand is still low, pressure increases and reaches load menu
pressure of +7 psi. At this point, the compressor switches
to unload mode and starts running at unload speed.
Trouble shooting
The motor speed changes The PI setting is too short. It continuously gives feedback to change motor speed
2 frequently and makes noise and produces very high response to pressure variation. In this case, PI values must
(acceleration and deceleration) be increased to have smooth speed changeover.
The motor runs at low speed The compressor runs in unload mode.
3
continuously (30Hz) Air demand is less and the standby time set is more than 3 minutes.
Ensure VFD processes the start command and VFD display shows Ramping or
Running.
Check for any Trip Message in the VFD.
5 Motor not starting Verify that the ON status LED in the VFD glows. If not, press the Auto on button in
the VFD and ensure the ON LED glows.
Check the pressure is more than load pressure and the compressor is in standby
mode.
1 Language English
614 Terminal 53 Low Ref./Feedb. Value *** (Edit from NII Controller)
615 Terminal 53 High Ref./Feedb. Value *** (Edit from NII Controller)
NOTE
#Make ramp-up time (341) and ramp-down time (342) settings as follows:
11 KW to 45 KW 25sec 15 sec
I-Time 0 200 10 -
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DIVISION
PRESSURE VESSEL DIVISION
1473 - Trichy Road, Coimbatore - 641 018,
Tel: +91-422-2589777,
Email: [email protected].