Eg - Series Elgi

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Product Manual

EG Series
Electric Powered Screw Air Compressor

EG 37 - 100.0, 125.0, 150.0, 175.0


Air - Cooled, Standard + VFD
460V, 3Ph, 60Hz
©
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005

Part / Document No. 019000959

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

Owner’s name / : ………………………………………………………………………………………………………


Company name
………………………………………………………………………………………………………

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

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

E-Mail address/ : ………………………………………………………………………………………………………


Phone number
………………………………………………………………………………………………………

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

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

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

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

Capacity : ……………………………………………………………………………………m3/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
Table of Contents

Chapter Page No.


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

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.

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
2.0 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 2.1


2.1 Using the manual

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. 2.1.1 Definitions and symbols
Following chapters are provided to help operate the
This information is related to your safety and also to prevent
compressor in its best way.
any problems relevant to the equipments used. To help
 Safety - safety precautions that must be followed while recognize this information better, the symbols are illustrated
using the compressor. in section “safety”.
 Technical specifications - technical details about the All the information, illustrations and specifications in this
compressor. manual are based on the latest product information at the
 Installation and commissioning - all site time of preparation of the manual. Product improvement is a
requirements, procedures to be followed during continuous process in ELGi. The details in this manual are
installation, commissioning, preservation etc. likely to change without notice and ELGi reserves the right to
incorporate such changes.
 Functional description – parts, their function and
working.
NOTE
 Operating instructions – to operate the compressor
Note clarifies procedures or conditions which may otherwise
properly.
be misinterpreted or overlooked. Note may also be used to
 Maintenance – how to do the maintenance for the clarify apparently contradictory or confusing situations.
compressor and their intervals.

 Troubleshooting – identification and solving the


problems. Warning calls attention to dangerous or hazardous condi-
 Decommissioning – how to decommission the tions inherent to the operation, cleaning and maintenance
of the compressor which may result in fatal accident and
compressor, its disposal etc.
personal injury of the operator or other staff
 ELGi services – services from ELGi: CCS, air audit,
spare parts

 Appendix – conversion tables, torque values, service


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

General functional description 2.2


2.2 Introduction

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.

Uptime  Neuron III controller ensures safe machine


operation
For ELGi it is no longer just about delivering air, It’s about
delivering uptime.  Energy efficient motor.

Our uptime design ensures that the compressor would run


cooler, cleaner and longer with longer service intervals. * For selected models.
The uptime components are best 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 centers 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.

General functional description 2.3


2.3 Safety

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.

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


isolate each compressor in multi-compressor systems.
 Maintain a cool and clean ambient for the compressor Do not rely on NRV for isolating pressure systems.
and ensure that the air inlet is not obstructed. Make
 Do not bypass, remove or adjust the safety devices or
arrangements to reduce the moisture entry through the
other attachments residing on the compressor. Every
incoming air.
installed pressure vessel or auxiliary outside the
 Remove protection such as caps, plugs, desiccant bags compressor should have pressure relieving device or
before connecting the air line pipes. devices, as required.
 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

 Danger! Be aware that compressed air used for


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

General functional description 2.4


1910.134 or F.D.A. 21 C.F.R. 178.3570 regulations. depressurize a hose fully before disconnecting it.
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


 Release all the pressure in the compressor system
inclined surface, contact ELGi.
before servicing or performing any maintenance
 Do not allow compressed air to come in contact with activity.
food and related items unless they are compressed air-
 Do not engage in horseplay with air hoses. Serious
treated specifically.
injury or death may result.
 Be aware that this air compressor is intended for
 Do not use air at a pressure greater than 2.5 bar.g (36
generating only industrial-use compressed air.
psi.g) for cleaning purpose.
2.3.2 Precautions during operations
 Open the oil fill cap only when the compressor is not
 When switching on remotely controlled compressors running and is not pressurized. Shut down the
ensure that no one is checking or working on the compressor and bleed the receiver tank to zero internal
compressor at that time. pressure before removing the cap.
 Before starting, ensure that no tools or any loose parts Fire and explosion
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.  Clean up spills of lubricants or other combustible
substances immediately.
 Wear ear protectors if you work in an environment
where the sound pressure level reaches or exceeds 90  Shut down the compressor and allow it to cool down
dB (A). before checking or adding oil. Remove sparks, flames
and other sources of ignition away from the
 Keep all the compressor doors shut during operation.
compressor.
For carrying out routine checks, the doors should open
only for short durations not more than 10 minutes.  Do not permit smoking in the vicinity of the compressor.
Wear ear protectors when opening a door.  Do not use flammable solvents for cleaning purposes.
 Keep hands, feet, floors, controls and walking surfaces  Keep electrical wiring and other terminals in good
clean and free of water or other liquid to minimize the
condition. Replace any wiring that has cracked, cut,
possibility of slips and falls. abraded or otherwise degraded insulation. Keep all
Pressure release terminals clean and tight.

 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

General functional description 2.5


Moving Parts  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.
 Rotating fan blades can cause serious injury. Disconnect  Always wear safety equipment while operating the
power supply before attempting service. compressor. Refer OSHA safety standards.
 Keep compressor doors closed except when servicing or  Do not allow compressed air to come into contact with
during maintenance. The sound damping material on any edible items.
the inner side of the compressor body should not be
 In the event of ingestion of oils, coolants or lubricants
removed or tampered with.
used in the compressor, seek medical treatment
 Wear snug-fitting clothing and tie long hair when promptly. In case you come in contact with such
working around the compressor, especially when hot or substances, wash with soap and water. Use MSDS for
moving parts such as the cooler, the airend, the thermal oil to know more on this.
valve, the main motor or the fan motor are exposed.
 If warm cooling air from the compressor is being used
 Keep hands, arms and clothing away from couplings, in air heating systems, e.g. to warm up a work room,
fans/belts and other moving parts. take precautions against air pollution and possible
 Do not attempt to operate the compressor with the fan contamination of the breathing air.
guards, coupling guards/belt guards or other guards Electric shock
removed.
 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.

General functional description 2.6


 Use only genuine spare parts. Refer the section “Use
genuine spare parts” in “Maintenance” chapter.

 Before switching on the compressor ensure that proper


earthing is done as per recommendation.

 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.

 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
 Springs under tension or compression store energy.
compressor manually or handling ungrounded
Uncontrolled release of this energy can cause serious
conductors.
injury or death. Be cautious while performing the
 All electrical installation must be in accordance with maintenance of components loaded with springs (for
recognized electrical codes and any local health & safety example minimum pressure valve, safety valve etc.).
codes.
 Display a warning sign that says “Maintenance under
 Recognize that only authorized and qualified trained progress, don’t switch on” near the start switch.
personnel should carry out any electrical work on the
 Isolate the compressor from the air line (discharge) and
compressor.
disconnect the power by opening and locking the
 Regularly check that all electrical connections are tight isolating switch before maintenance.
and in good condition.
 Prior to attempting repairs or adjustments, disconnect
Periodically check whether the power at the source and verify at the compressor
that the circuits have de-energized. This minimizes the
 All guards are in place and securely fastened.
possibility of accidental start-up or operation, especially
 All hoses and pipes inside the compressor are in good when the compressor is remotely controlled.
condition, secure and not rubbing against each other.
 Open the oil filler cap only when the compressor is not
 Any leaks exists. running and is not pressurized. Shut down the
 All fasteners are tight. compressor and bleed the receiver tank to zero internal
pressure before removing the cap.
 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.

General functional description 2.7


 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.

General functional description 2.8


2.4 Functional description

Figure 1. Screw compressor systems - Schematic diagram

2.4.1 Air circuit separated of any moisture content by the moisture


separator. The cooled and moisture free compressed air is
The atmospheric air enters into the airend through the air now discharged to the external receiver, ready to be used.
intake system. The intake filters (pre filter and air filter)
prevents the entry of foreign particles (such as dust) into 2.4.2 Oil circuit
the airend. The intake valve regulates the amount of air The oil in the air-oil separation tank after being separated
sucked into the airend. The opening and closing of the is fed into the airend. The oil either gets diverted to the oil
intake valve are controlled by the pneumatic pulse line cooler or oil filter or both depending upon the
actuated by an electrically controlled solenoid valve. The temperature. The thermal valve governs and controls the
clog indicator fitted in the air filter turns red when the oil flow path. The oil before being injected into the airend
filter is clogged. is filtered. An orifice is provided in oil flow path towards
The filtered air enters into the airend where it mixes with the airend to control the oil flow. The whole oil circulation
the injected oil. The injected oil acts as a coolant to circuit in the compressor is operated solely by the
maintain optimum temperature. It also seals the leaks differential pressure maintained by the minimum pressure
between the rotors and the housing and lubricates the valve (MPV) and doesn't require any additional pump.
bearings and gears. The airend consists of two counter- 2.4.3 Drive system
rotating intermeshed helical screws - the male and the
female rotors - which are driven by electric motor. The air The airend transmission is powered by an electric
-oil mixture is trapped between the rotors of the airend induction motor through a coupling. When the compressor
and is progressively compressed. is turned ON, the motor is started in star mode and takes
6 to 9 seconds to change over to delta mode. During this
After being compressed, the air-oil mixture enters with
period the intake valve remains closed and thus the motor
high velocity into the air-oil separator tank where it
starts without load. In delta mode, the motor speed
undergoes a unique 3 stage separation process which
stabilizes, the solenoid valve energizes after 10 seconds of
removes maximum oil content. This highly efficient 3 stage
change-over to reduce load on the motor, the blow down
separation process uses the impact velocity of air-oil
valve is closes, intake valve opens and the compressor
mixture along with centrifugal action, which makes the
starts loading. For compressors with variable frequency
mixture very lean. The final stage of this separation
drive (VFD), speed of the motor gradually increases within
consists of passing the lean mixture through the air-oil
30 seconds (ramp-up time) while the intake valve remains
separator element which leaves the air with an oil content
in the closed position. This ensures very little starting load.
of < 1 ppm.
Next, the intake valve opens and the system starts
The oil separated and collected in this element is then building up pressure. An adaptor ring connects the airend
returned to the airend through the oil return line. The air and the motor. It also helps in maintaining the coupling
passes through a minimum pressure valve (MPV). It alignment. The coupling element acts as a safety interlock
maintains a minimum differential pressure which is and it is the first one to fail when coupling elements
required for circulation of oil within the compressor unit. become over loaded. This architecture saves the whole
The compressed hot air is cooled in the after cooler and is drive system from failure. Malfunctioning of the coupling

General functional description 2.9


element will result in noise and vibration. Anti-vibration 2.4.5 For retro-fitment of Standalone VFD
mountings reside below the air end and the motor. This
with Compressor (C) version in field
configuration reduces the transmission of vibration from
airend and motor to the structure, reducing noise and 1. Change the bearings to insulated type for motors
ensuring reliability of mounted parts on the structure. >=90kw at Non Drive End side of Motor

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.

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.

General functional description 2.10


6 5 4 3 2 1
16 MOISTURE SEPARATOR WITH ADV 1 63.98 " 4.64 " CC - CRITICAL CHARACTERISTIC (SAFETY/REGULATORY)
15 CONTROL PANEL ASSEMBLY 1 42.34 "
1 5.51 " 1
1 1 SC - SIGNIFICANT CHARACTERISTIC (FIT/FORM/FUNCTION/FINISH)
14 VARIABLE FREQUENCY DRIVE # 1 10X M8 S.NO MODEL COOLING AIR FLOW, ft3/hr
9.45 " 1 19.69 " 8.07 "
13 THERMAL VALVE ELEMENT 1 1 EG30 2,47,202
12 OIL FILTER 2 2 EG37 3,00,175
11 OIL AND AFTER COOLER 1 3 EG45 3,72,923 E
10 COOLING FAN 3
9 MINIMUM PRESSURE VALVE 1 1 1 1/2" NPT
8 SAFETY VALVE 1
7 SEPARATOR ELEMENT 1 PACKAGE WEIGHT (APPROX) +/- 55 lbs
6 AIR OIL SEPARATOR TANK 1 1
S.NO MODEL EG22 P EG26 & EG30 EG37 EG45
5 DRIVE COUPLING 1 1
1 COMPRESSOR 2254 2401 2447 2453
4 INTAKE VALVE 1
2 COMPRESSOR + VFD - 2501 2547 2553
3 AIR FILTER 1
2 AIR END 1 NOTES :
1 ELECTRIC MOTOR 1 1 .INDICATES DUCTING INTERFACE DIMENSIONS
2 .INDICATES FORK LIFT ACCESS POINTS
S.NO DESCRIPTION QTY
3 .INDICATES FORK/PALLET TRUCK ACCESS POINTS
4 .ALL DIMENSIONS WITHOUT TOLERANCES FOR REFERENCE ONLY
5 .MINIMUM DISTANCE REQUIRED AROUND THE COMPRESSOR IS 1m AT ALL SIDES
CG DETAILS (in inch, APPROX) AND 2m AT TOP (INSTALLATION REQUIREMENTS)
S.NO X Y Z 6 .# FOR CV MODELS ONLY D
1 36.7 24.2 23.7 7. FOR EG22P,26,30 NO OF FAN QTY WILL BE 2 No's

10 " 11 "

HO T AIR OU TLET (FR OM CO OLER)

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

MO DEL. : EG22P - EG45 60Hz


ELGI EQUIPMENTS LTD.,
MATER IAL : - COIMBATORE - INDIA.

WEIGH T : REFER TABLE


GA DRAWING
2018 NAME DATE A

CAD SBH 17.02.18 REF.DRG.No. NEXT ASSY.

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)

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


P & I DRAWING
LEGEND :
101 AIR FILTER E
BLOW DOWN VALVE
115 102 CHOKE INDICATOR

103 INTAKE VALVE (NC)

To Controller
CHOKE
101 INDICATOR 104 AIREND
AIR FILTER 102 PRESSURE SENSOR
To Controller
PS01

AFTER COOLER MOISTURE SEPARATER 105


AIR OIL SEPERATOR
(AUTO DRAIN) TANK
SOLENOID
108 113 A IR O UT LE T
VALVE (NC)
116 D
106 AIR OIL SEPERATOR

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

108 AFTER COOLER

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

SCAVENG ING L INE O RIFICE 112 OIL FILTER


112

OIL FILTER S A FE T Y V A LV E 113 MOISTURE SEPARATOR


(AUTO DRAIN)
109
AIR OIL SEPERATOR
106 114 OIL DRAIN VALVE
M
O IL LEV E L IN DICA T O R 115 BLOW DOW N VALVE (NO)
AIR OIL SEPARATOR
TANK 105

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

PS01 PRESSUR E SENSOR

Sl.No. DESCRIPTION Qty. DRAWING No. Rev. REMARKS


LEGEND PIPE SIZE
MO DEL. : EG22P - EG45 60Hz
Envelope line
ELGI EQUIPMENTS LTD.,
- COIMBATORE - INDIA.
MATER IAL : -
Air Line 1-1/2 inch
WEIGH T :
Pulse Line 6 mm GA DRAWING
Oil Line 1 inch 2018 NAME DATE A

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)

2.87 " 40.47 "

5.51 " 9.45 " 19.69 " 8.07 " E


0.31 "

PACKAGE MOUNTING DETAILS (BASE) :


4X 0.71
12.30 " 39.37 "

I D
. NM

Sl.No. DESCRIPTION Qty. DRAWING No. Rev. REMARKS

MO DEL. : EG22P - EG45 60Hz


ELGI EQUIPMENTS LTD.,
MATER IAL : - COIMBATORE - INDIA.

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

1 Working Pressure psi.g 66 100 125 66 100 125 150 175

cfm 136 133 132 177 171 133 140 126


2 FAD - Free Air Delivery
m3/min 3.85 3.77 3.74 5.01 4.84 3.77 3.96 3.57

3 Unloading pressure psi.g 72 115 140 72 115 140 165 190

Nominal power supply


4 208-230 / 460V (+/-10%), 60Hz (+/-5%), 3 Phase
conditions

5 Main motor rating Hp(kW) 30(22) 40(30)

Type of motors (main drive &


6 Squirrel cage induction motor - TEFC & Cooling fan with integrated motor
fan drive)

Insulation and protection of


7 Class F & IP 55
main motor

8 Frame size / mounting type 286T / B35T 324T / B35T

Type of starter for main


9 Automatic Star Delta
motor
Maximum fan motor rating
10 Hp(kW) 0.19 X 2
per fan X no. of fans

11 Rated speed of fan motor rpm 1390

12 Safety valve set pressure psi.g 205

Standard + VFD

Model - EG 22P EG 26

1 Working Pressure psi.g 66 100 125 66 100 125 150 175

cfm 136 133 132 177 171 133 140 126


2 FAD - Free Air Delivery
m3/min 3.85 3.77 3.74 5.01 4.84 3.77 3.96 3.57

3 Unloading pressure psi.g 72 115 140 72 115 140 165 190

Nominal power supply


4 208-230 / 460V (+/-10%), 60Hz (+/-5%), 3 Phase
conditions

5 Main motor rating Hp(kW) 30(22) 40(30)

Type of motors (main drive &


6 Squirrel cage induction motor - TEFC & Cooling fan with integrated motor
fan drive)
Insulation and protection of
7 Class F & IP 55
main motor

8 Frame size / mounting type 286T / B35T 324T / B35T

Type of starter for main


9 Variable frequency drive
motor

Maximum fan motor rating


10 Hp(kW) 0.19 X 2
per fan X no. of fans

11 Rated speed of fan motor rpm 1390

12 Safety valve set pressure psi.g 205

Technical data 4.1


4.0 Technical data

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

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


4 208-230 / 460V (+/-10%), 60Hz (+/-5%), 3 Phase
conditions (+/-5%), 3 Phase

5 Main motor rating Hp(kW) 40(30) 50(37) 60(45)

Type of motors (main


6 Squirrel cage induction motor - TEFC & Cooling fan with integrated motor
drive & fan drive)
Insulation and
7 protection of Class F & IP 55
main motor
Frame size /
8 324T / B35T 326TD / B35T 364/5T/ B35R
mounting type
Type of starter for
9 Automatic Star Delta
main motor
Maximum fan motor
10 rating per fan X no. Hp(kW) 0.4(03) X 2 2.07(1.55) X 1
of fans
Rated speed of fan
11 rpm 1630 1420
motor
Safety valve set
12 psi.g 205
pressure

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

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


4 208-230 / 460V (+/-10%), 60Hz (+/-5%), 3 Phase
conditions (+/-5%), 3 Phase

5 Main motor rating Hp(kW) 40(30) 50(37) 60(45)

Type of motors (main


6 Squirrel cage induction motor - TEFC & Cooling fan with integrated motor
drive & fan drive)
Insulation and
7 protection of Class F & IP 55
main motor
Frame size /
8 324T / B35T 326TD / B35T 364/5T/ B35R
mounting type
Type of starter for
9 Variable frequency drive
main motor
Maximum fan motor
10 rating per fan X no. Hp(kW) 0.4(03) X 2 2.07(1.55) X 1
of fans
Rated speed of fan
11 rpm 1630 1420
motor
Safety valve set
12 psi.g 205
pressure

Technical data 4.2


5.0 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 and Oil level checking 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 5.1


5.1 Installation and commissioning

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.
ROPE / SLING
5.1.1 Unpacking
STIFF SPREADER
BAR
Unpack the compressor from the packing case by
removing the nails. Unscrew the bolts, holding the
compressor to the base of the crate.

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 Figure 3. Lifting using crane

The wood/cardboard used to make the shipping crates of


NOTE
the EG series compressors are biodegradable.
Removal of transit brackets:
The polyethylene covers wrapped around the compressor
Once you have placed the compressor in its final position,
and the polystyrene packing provided around the electrical remove the red painted transit brackets and store for
panels are not recyclable. They must be disposed off in future use.
accordance with prevailing local environmental laws. Locations:
5.1.3 Handling  Bracket in between the base and airend support
 Bracket in between the base and motor
1. Lift compressors using either a forklift/pallet truck
 Bracket in between the shroud and control panel box
(Fig.2) or a crane (Fig.3).

2. When using a forklift, ensure padding is used in 5.1.4 Site requirements


between the compressor and forklift (as shown in Fig.2)
 Install the air compressor in a clean, dry, cool and dust
to prevent damage to the compressor’s canopy.
free room as extreme temperatures (hot or cold),
3. When using a crane, please ensure stiff spreader bars moisture, air borne contaminants can significantly affect
are used (as shown in Fig.3) to prevent rope slings from compressor performance, durability and compressed air
damaging the compressor’s canopy. quality.
4. Do not drop the compressor.  Be aware the entrance to the compressor room should
5. Do not attempt to move the compressor by pushing or be high enough and wide enough to carry the
dragging it as this may cause jerky movements causing compressor in and out.
damage to the compressor.  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
PADDING motor.

 Neither install the machine in a location where flame is


used nor place any inflammable objects near the
Figure 2. Lifting using forklift compressor.

Installation and operation 5.2


 Ensure the room temperature is within 50ºC (122ºF) as for installing your compressor. No special foundation or
high ambient temperatures can reduced oil life due to anchoring is necessary for rotary screw compressors.
higher discharge oil temperature (DOT). It also results  Do not store toxic, volatile, or corrosive agents near the
in high approach temperatures affecting cooling and
compressor.
condensation efficiency in the after-cooler and in air
 Isolate the compressor from corrosive agents like
treatment equipment like air dryers.
ammonia, chlorine, salt spray, and other chemicals as
 Ensure the hot medium of other utility equipments like
these may erode the internal components and also
genset/dryer/ boilers, etc., not sucked by compressor contaminate the oil and filters.
inlet or ensure that in any way room temperature does
 Do not allow hot air from additional equipment to blow
not rise to prevent high discharge oil temperature.
towards the compressor.
 Ensure the ambient temperature does not drop below
 If you operate in high dust applications like rice mills,
0ºC (32ºF). Provide air supply openings and adjustable
cement, flour mills, etc., it would be necessary to clean
louvers to ensure that the minimum temperature does
and replace the filters more often.
not drop down below 0ºC (32ºF).
 Good practice is to have overhead lifting in the
 Ensure unevenness of the surface is within 6mm
compressor room to facilitate any major overhaul. If an
(0.25").
overhead hoist is not available, you should be able to
use a mobile crane or forklift truck in your compressor
room at a minimum.
MINIMUM 2 m (6.6 ft) CLEARANCE
5.1.4.1 Ventilation
CEILING  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.
ELGi SCREW AIR
COMPRESSOR  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


Figure 4. Vertical clearance around the
compressor 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
ELGi SCREW AIR above 5ºC (9ºF) .
COMPRESSOR
 Ventilation with ducts: Ensure hot air exhaust from the
WALLS OR
OTHER compressor is diverted through the ducts when installed
EQUIPMENTS in an enclosed area. (contact ELGi for ducting
requirements)

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).

 Know air velocity is ascertained during commissioning

Installation and operation 5.3


using an anemometer.

 Do not connect cool air inlet ducts directly to the


compressor inlet side.

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

Table 1. Global series – Ventilation requirements


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

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

Installation and operation 5.4


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 co-
ordination.

5. Connect the earthling line to the point provided on the


base frame at the side of the compressor and motor.
Power cable entry
Earthing point

Figure 8. Earthing line of compressor


5.1.6 Air pipe dimensions
NPS Pipe size/ Inside diameter (mm)
Volume Flow FAD 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

Installation and operation 5.5


NPS Pipe size/ Inside diameter (mm)
Volume Flow FAD 1 1/2 2 2 1/2 3 4
40.89 52.50 62.71 77.93 102.26
(m3/
(cfm) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi)
min)
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
Table 3. Global series – Air pipeline dimensions

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.

Installation and operation 5.6


5.1.7 Receivers for compressed air
systems

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

Table 4. Global series—Receivers specifications

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


5.1.8 Possible mistakes
commissioned for more than 1- ½ years (18 months)
1. The compressor is installed on the wooden pallet of the
b. Replace the AVMs if you detect any abnormal squeezing
packing case.
or damage in the rubber part.
2. The compressor base is not making 100% contact with
e. Check whether all the screws in the control panel are in
the floor.
place and tightened properly.
3. The compressor is mounted on anti-vibration mounts.
f. Check the oil cooler and after-cooler for any external fin
4. The isolator is more than 5m (16.40ft) away from the blockage and clear the blockage if necessary
compressor.
g. Ensure that all the transit brackets are removed.
5.1.9 Commissioning procedure
During commissioning
1. Please make preparations according to the installation
The servicing technician performs a series of checks on the
section as given, before the compressor is
machine and on the systems to which it connects, to
commissioned.
ensure that it is in a condition to function safely and as
2. Ensure that the location meets the requirements of recommended. The servicing technician will then explain to
accessibility, ventilation and safety. operate and maintain the equipment. This procedure is
3. Provide electrical power as recommended in the referred to as the commissioning process.
installation section. The commissioning of the compressor ensures that it is
4. Select air pipe lines and receivers for your system installed safely.
according to the tables provided in the installation The general operating conditions of the equipment
section. including the cleanliness of the atmosphere, the
Checkpoints before commissioning temperature and the ventilation are checked. Technical
details relating to your system such as particulars of your
Replace the parts in compressor if it had been in storage
electrical installation are noted. The operator of the
for more than one year.
compressor is familiarized with all aspects of both its
1. Air filter normal running and dealing with unusual situations.
2. Oil filter Upon completion of the commissioning process, the
3. Air oil separator (check and replace) technician will fill in the document known as the
commissioning report and the warranty card provided in
4. Oil
this manual.
a. Check for any external / internal damages of the
During commissioning any modification suggested by the
package.
technician should be performed before the compressor is
b. Megger the main motor and fan motor should be ready for regular use. Else, warranty becomes void. In
meggered to find the winding insulation conditions if the case of change of operator other than the person trained,
compressor is not commissioned for more than 1 year the new operator should be trained before he is dedicated

Installation and operation 5.7


for operating the compressor.

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)

When to read oil level?


OIL FILL PORT Following sequence to be followed before reading the oil
(OVER FILL CAP)
level in separator tank

a) Switch off the machine in load condition

b) Wait for 3 mins to allow the oil drain back to separator


tank
OIL FLOAT GUAGE c) Read the oil level as mentioned above

OIL DRAIN PORT

Figure 9. Oil filling and oil float gauge location on


air oil seperator tank

Fill oil in the oil tank up to over fill cap

Initial fill
Close the oil filling plug

Run the compressor for 10 minutes,


until the thermostatic valve opens

Stop the compressor

Sl. Model Volume Initial fill


No. of oil required (litres)
(litres)

EG 22P, EG 26
1 20 19
EG 30-45

Installation and operation 5.8


5.2 Preservation for long idle storage

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.

 Air–oil separator tank 5.2.4 Rubber Hoses


 Rubber hoses
Test Recommendations for
5.2.1 Airend Rubber Hoses

To prepare the airend for 6-month storage: Age Recommendations

 Remove the airend discharge hose/pipe coupling. Up to 3


Use without further testing
years
 Rotate the drive coupling three times so that the oil
present inside the airend comes out through the Use after representative samples are
3 to 5 years
discharge port. subjected to proof-pressure test

 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.

 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.

Installation and operation 5.9


5.3 Operating instructions

 If all the inputs from contact switches, pressure and


temperature transducers are normal, the display will
Please adhere to the safety instructions provided at the indicate "READY''.
section 2.3.2 : Precautions during operations
 Press the ''START'' (green) button on the controller.

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.

 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
CLOCKWISE
rotation. If not, stop the compressor by pressing the stop
button (Red) on the control panel. Open the isolating GRAPHIC WARNING DISPLAY

switch and reverse the appropriate lines.

Running the compressor in the wrong direction for more


than 5 seconds will damage compressor parts or even
cause total damage.

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 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.

Installation and operation 5.10


 Oil filter warning: Indicates that the oil filter element  If there is any possibility of freezing exists, drain the
needs to be replaced. The compressor will not cooling system completely.
shutdown automatically in this situation.

 High discharge temperature warning: The


compressor will shutdown automatically and the  Isolate power supply before the discharge ball valve
warning light on the controller will glow when the closes.
discharge temperature exceeds the preset value of 110  Do not use the emergency stop switch for normal
stopping
± 5ºC (230 ± 9ºF).

 Main motor overload trip: The compressor will


5.3.7 Changing the compressor settings
shutdown when the main motor is overloaded and the
corresponding warning light will glow. Change the compressor settings using the tactile keypad
and LCD panel on the controller. (Refer to Neuron manual
 Fan motor overload trip: The fan motor has internal
to learn more about the control panel and how to interpret
thermal overload protection, which safeguards the fan
of the message.)
motor. If the fan motor trips discharge oil temperature
will be high and the compressor will trip . Refer the VFD setting procedure manual for VFD
operations.
 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.

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.

 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.

Installation and operation 5.11


6.0 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 6.4

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 Minimum pressure valve 6.8

6.1.2.8 Thermal valve 6.9

6.1.2.9 Electrical motor greasing 6.10

6.1.2.10 Cooler cleaning 6.10

6.1.2.11 Drive coupling 6.10

6.1.2.12 Moisture separator and auto drain valve 6.11

6.1.2.13 Cooler maintenance 6.12

6.1.2.14 Fan maintenance 6.13

6.1.2.15 Anti vibration mount 6.13

6.1.2.16 Cooler and motor suction prefilter 6.14

6.1.3 Use only genuine spare parts 6.15

6.2. Troubleshooting 6.16


6.3. Decommissioning, dismantling & putting out of service 6.21
6.3.1 Decommissioning the compressor 6.21

6.3.2 Dismantling the compressor 6.21

6.3.3 Waste disposal 6.21

6.4. ELGi services 6.22


6.4.1 ELGi customer care system (ECCS) 6.22

6.4.2 ELGi genuine spare parts 6.22

6.4.3 Air audit 6.22

6.5. Appendix 6.24


6.5.1 Conversion tables 6.24

6.5.2 Torque values 6.25

6.5.3 Service log book 6.26

6.6. Disclaimers 6.28

Maintenance 6.1
6.1 Maintenance

6.1.1 Maintenance intervals


Frequency Part Remarks
Oil level Check
MOS condensate Check
Daily
Warning / alarms Check
Condensate in AOS tank Check
Pre filter ( air intake, cooler, control panel) Clean
Weekly
Air filter element Clean *
Oil & after coolers - air cooled (External) Check & Clean
2000 hours or 6 months # Oil Sampling **
50 Hz motor - 2 pole grease Replace
Pre filter ( air intake, cooler, control panel) Replace
Oil filter Replace
Air filter element Replace
50 Hz motor ( 4 pole ) grease Replace
4000 hours or every year # 60 Hz motor ( > 25HP ) grease Replace
Return line / orifice / NRV Check & Clean
Return line strainer Check & Clean
Oil-Air lube XD/Air lube FG Replace
Air-oil separator element - Air lube XD/Air lube FG Replace
Air-oil separator element - UT Synthetic Replace
Oil - UT Synthetic Replace
60 Hz motor ( ≤ 25HP ) grease Replace
Drive coupling element Replace
Pipe coupling element Replace
Intake valve kit Replace
Actuator kit Replace
MPV kit Replace
8000 hours or every 2 years # BDV kit Replace
Solenoid valve Replace
Safety valve Replace
MOS-ADV kit Replace
Thermal valve kit Check & Replace
Tube and Fittings Kit Replace
Blow down adjustment kit Check & Replace
Oil & after coolers - water cooled (External) Check & Clean
Electrical connections Check
# - Whichever comes first
* - As per air filter clog indicator
** - For USA/CANADA region only

Table 5. Maintenance intervals

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.

Precautions Sl. No. Motor make Grease Part Number


A. If the compressor is kept idle 1 ELGi
EM UNIREX N3 015404151
2 SIEMENS
 Isolate the power supply.
3 WEG EM POLYREX N2 015404152
 Close the main air outlet valve.
Table 6. Electric motor grease
 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 6.2
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

When the pre-filter bottom edge is


6.1.2 Maintenance of individual visible, slant the pre-filter forward and
components and systems slide it downwards away from the
compressor
Check all accessories independently to verify that they are
functioning as required and replace their components as 3. Pull Forward
necessary. After maintenance restart the compressor When the top and bottom edges of the
as mentioned in section “Operating instructions”. pre-filter are free from the compressor,
6.1.2.1 Pre filter 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 FILTER CATRIDGE PRE FILTER ELEMENT

Fig 11. Pre filter


Pre work AIR FILTER ELEMENT
WASHER
 Switch off the compressor and disconnect power supply
WING NUT
to the compressor.

 Close the discharge end ball valve.

 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

 Switch off the machine. Pre work

 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.

 Check the air filter mounting bracket and ensure there


is no damage. TOP PLATE

 Inspect rubber seal in air filter element and their GASKET

contact surface and ensure there is no damage.


SEPERATOR ELEMENT
 Replace new air filter element/assemble cleaned air
filter element.

 Fix and tighten the wing nut.

 Assemble the air filter cover.

 Turn the knob clockwise to lock the air filter cover.

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. 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.

Requirements  Stick the new gaskets on to the separator element one


on either side.
 Spanners, new separator element, clean cloth.
 Replace the new separator element into the air oil tank,
Maintenance
taking care not to dent it against the tank opening.
 Ensure pressure is relieved from the air oil tank
 Reposition the Top plate and assemble it by using
 Disconnect all MPV, control lines & all other piping fasteners. Torque: 120 N-m (88.5 lb-ft).
connected to the air oil tank
 Reconnect all piping.
 Isolate the air oil seperator tank from the return lines,
 Clean the return oil strainer before restarting the
service line, etc.
machine.
 Remove the top plate after loosening the M12 hex bolt

 Remove the separator element. NOTE


 Scrap the old gasket material from cover and flange on The air-oil separator tank is tested according to standards.
the air oil tank. While doing so, take care not to let the Regularly have inspections performed in conformity with
local regulations.
scraps fall into the air oil tank

TOP 6.1.2.4 Oil top up & oil change over


COVER
Proper compressor maintenance and operation is crucial
SCAVENGING
LINE TUBE 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
SEPERATOR be kept properly sealed in the original container. Once the
ELEMENT
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
DISCONNECT ALL PIPE LINES/
snow storms. The products should also be stored away
TUBE LINES from any heat source, high humidity and moisture areas.
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

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.

 Restart the compressor and allow it to run for about 10


Maintenance
minutes.

NOTE  Stop the compressor.


 The compressor is originally filled with a particular oil, if  Unscrew the oil filling plug after 5 minutes so that
you want to change over to other types of oil, perform
residual pressure in the tank is vented out through the
steps 1, 2 and 3.
 But if you want to change the oil but continue with the bleed hole in the oil fill plug.
same kind (same brand & type) perform steps 1 and 3
 Refill the tank with recommended level (if required)
only.
 Ensure that you drain at least 90% of oil capacity of the  Restart the compressor.
compressor; if not the residual oil can contaminate new
oil.
 Ensure no oil spills on anti-vibration mount during
maintenance.

Step 1: Draining

a. Switch off the compressor and disconnect the power


supply to the motor.
OIL FILL PORT
b. Close the discharge end ball valve. Release the air oil
tank pressure and allow the tank cool for few minutes.

c. Remove drain plug from the bottom of the separator


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

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


cooler. Then drain completely. OIL DRAIN
PORT
e. Disconnect all oil pipe work to the prevent oil from
being trapped. Then, drain completely. Figure 14. Air oil separator tank– oil drain

f. Drain oil from the airend discharge pipe after


dismantling it

g. Drain oil from the airend by hand rotation. OIL LINES

Step 2: Flushing (if under the following conditions) :

Oil change from one type to other recommended type of


oil.

Machine run with oil for more than recommended hours.

a. Fill the compressor with the ELGi cleaner (use the same
compressor oil fill volume) and run the compressor.

b. Run the compressor with cleaner for 500 hours.

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.

 Clean the seating surface with clean cloth.


6.1.2.5 Oil filter
 Assemble the oil filter assembly with the thermal valve
The oil filter is fitted between the oil cooler and the airend
block by rotating it in counter clock wise direction.
unit. The components of the oil filter assembly are shown
in the figure. This is a full flow filter with a pleated  Tighten firmly by hand.
element. To service this filter, order the consumables kit
(available with ELGi service personnel) The procedure for NOTE
complete servicing of this filter is as follows.
Check the oil filter assembly if any leakage during
 Switch off the compressor and disconnect power supply compressor operation.
to the compressor. NOTE
 Close the discharge end ball valve. Suspended particulate matter should be less than 150spm
to achieve the specified consumable life. Guarantee
 Release air oil tank pressure and allow it to cool for a
becomes void if the compressor is operated above its
few minutes. intended pressure.
Requirements
6.1.2.6 Intake valve
 Allen key, strap wrench, new oil filter element, O-rings
( top and bottom)
O-RING
Valves should not be opened when pressure is applied.
OIL
FILTER NOTE
ELEMENT
ALLEN O-RING The maintenance of following parts (valves) demands
BOLT OIL FILTER highly skilled authorized personnel. So, it is recommended
ASSEMBLY
that an ELGi service engineer does the maintenance.
FILTER Pre work:
HOUSING FLANGE
Switch off the compressor and disconnect power supply to
THERMAL
VALVE the compressor.
BLOCK
 Close the discharge end ball valve.

 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

Figure 17. Intake valve/BDV/Actuator kit

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

31 M10 HEX SOCKET GRUB SCREW 970400160 1


Table 7. Intake valve/BDV/Actuator kit

Maintenance 6.7
After cleaning replace all parts as per the kit drawing. Adjustment procedures as follows,

 Break & Remove the Tamper cap.


NOTE
Refer GA drawing (EIV 159 - 970300430,) for required  Loosen Nut (32) .
torque values.  Adjust Blow down adjustment screw (31) to achieve no
load sump pressure as specified in product
Assemble the intake valve in the following specifications. Use pressure gauge to measure the
sequence: pressure in the sump.
 Insert the Spring(04) and Plunger(05) in the Bottom  Turn the screw clockwise to increase the no load
housing(01). sump pressure
 Assemble the Top Housing(03) and Bottom housing  Turn the screw anticlockwise to decrease the no
(01). load sump pressure
 Insert the Bush(8) and Sleeve (42) in top housing (03).  Fasten the Nut (32), after attainment of desired no load
 Assemble the Throttle plate (09) and Throttle shaft (08) sump pressure

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

 Assemble O rings (27) & (45).

 Assemble the BDV assembly kit to Top Housing(03) with


screw(28).

 Assemble quick fittings (19),(49),(52) & hoses (36)


(51A),(51 B).
PISTON SLIDING
 Assemble the hex nipple(37) & Solenoid valve (26) . SURFACE

 Assemble the intake valve on Air end.

 Connect the below mentioned parts to intake valve

 Pulse line & BDV tube connection

 Power supply to solenoid

 Duct from air filter

No Load sump pressure adjustment:

No Load sump pressure adjustment should be carried out


by skilled ELGi service person only. PISTON SEATING
SURFACE
 Assemble the pressure gauge to the air oil separator
tank by removing the plug.
Figure 18a. Minimum pressure valve
 Start the compressor , run in unload mode and ensure
no load sump pressure reaches a stabilised value. Pre work

 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

 New MPV kit, allen key, spanner, grease, gloves.

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

Maintenance MPV Assembly

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

 Switch off the compressor and disconnect power supply


to the compressor.

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

 Switch off the compressor and disconnect power supply


to the compressor.

 Close the discharge end ball valve.

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

 Pliers, screw driver, new thermal valve element & Oring

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

 Inspect and clean seating area in the housing

 Replace with a new thermal valve.

6.1.2.9 Electric motor greasing


Requirements
Pre work
 Pliers, allen keys. compressed air, safety gloves,
 Switch off the compressor and disconnect power supply cleaning cloth.
to the compressor.
Maintenance
 Close the discharge end ball valve.
External surfaces:
 Release air oil tank pressure and allow the tank to cool
 Remove the exhaust duct connected to top roof panel
for a few minutes.
 Use compressed air 2.5 bar/ 36.3 psi maximum to clean
Requirements
the outer surface of the cooler. Supply a jet of air in the
 Recommended grease, cleaning cloth, grease gun. direction opposite to cooling airflow direction
Procedure  Open the side panel (LH side) and rear panel.
 Stop the motor and lock out the switch.  Open cooler cleaning door-I & II, apply compressed air
 Thoroughly clean the grease inlet fitting or plug. If the through the opening provided in the shroud.
motor has a plug, remove the plug and clean the inlet.  Remove the dust deposited inside the shroud box.
 Remove the drain plug and wipe out any hardened
6.1.2.11 Drive coupling
grease.
Pre work
 Slowly pump the grease into the grease inlet until the
new grease comes out of the drain plug.  Switch off the compressor and disconnect power supply
to the compressor.
 Start the motor and let it run for a minimum of one
hour to expel any excess grease from the drain opening  Close the discharge end ball valve.
before re-installing the drain plug.  Release air oil tank pressure and allow the tank to cool
 Stop the motor and lock out the switch. for a few minutes.

 Re-install the drain plug. Requirements

 Put the motor back in operation.  Spanners, new coupling element.

Maintenance 6.10
Pre work

 Switch off the compressor and disconnect power supply


to the compressor.
HUB
 Close the discharge end ball valve.

 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

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


Moisture separator may be heavy. Caution should be taken kit, if necessary
while removing it from the machine.  Clean the housing and all other inner parts

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


free from foreign particles

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

INLET FROM COOLER OUTLET


BOTTOM HOUSING

EXTERNAL AUTO
DRAIN

Figure 22. Moisture separator and auto drain valve

Maintenance 6.11
EYE BOLT
FASTENERS (TOP ROOF TO CANOPY)

TOP ROOF PANEL FASTENERS (COOLER TO SHROUD)

COOLER LIFTING PAD COOLER ASSEMBLY

FASTENERS (COOLER TO SHROUD)


SHROUD BOX

Figure 23 . Cooler service

 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

 The vortex generator cone and the cyclone arrestor flange

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

 Insert eyebolt (M8) into lifting pad provision in cooler


 Ensure that the mating surfaces are clean and refit the
O-ring  Locate cooler on shroud box

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

 Reassemble the roof panel with canopy


Maintenance 6.12
 Reassemble exhaust duct with top roof.  Remove the fan 2 from shroud box

6.1.2.14 Fan Maintenance


 Isolate the machine from power supply and ensure safe
message is placed in front of machine before servicing
the fan

 Wear proper safety accessories like gloves, shoes for


handling

 Ensure that the Rotor must be standing still SHROUD


FAN 1
Requirements
FASTENERS
 Spanners, Safety gloves
FAN 2
Fan Disassembly for EG 37 and EG 45

 Disconnect the electrical wires connected to fan

Figure 25 . Fan maintenance– EG 22P, EG 26 & EG30


SHROUD
Fan reassembly for EG 22P, EG 26 and EG 30
FASTNERS
 Locate fan 1 with shroud box and reassemble fasteners
COOLING
FAN (M8 Hex bolt, M8 spring washer Qty 4) with shroud

 Locate fan 2 with shroud box and reassemble fasteners


(M8 Hex bolt, M8 spring washer - Qty 4) assembled
with shroud

 Connect the electrical wires to fan terminal boxes and


tie the electrical cable with fan guards using wire tie

 Ensure fan 1 and fan 2 is rotating right direction by


Figure 24 . Fan maintenance—EG 37 & EG 45 switching ON.

6.1.2.15 Anti Vibration Mount


terminal box
Anti Vibration Mount should be replaced during major
 Loosen fasteners (M8 Hex bolt, M8 spring washer - Qty overhaul of airend or motor. If no such situation, replace
4) assembled with shroud AVM every 5 years
 Remove the fan from shroud box

Fan reassembly for EG 37 and EG 45

 Locate the fan with shroud box and Reassemble


fasteners (M8 Hex bolt, M8spring washer - Qty 4)
assembled with shroud

 Connect the electrical wires to fan terminal box and tie


the electrical cable with fan guard using wire tie

 Ensure fan is rotating right direction by switching ON.

Fan Disassembly for EG 22P, EG 26 and EG 30

 Disconnect the electrical wires connected to fan 1 and


fan 2 terminal boxes

 Loosen fasteners of fan 1 (M8 Hex bolt, M8 spring


washer - Qty 4) with shroud

 Remove the fan 1 from shroud box

 Loosen fasteners of fan 2 (M8 Hex bolt, M8spring


washer - Qty 4) with shroud

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.

 Hold 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 / back side of the prefilter.

 In case of major dust / dirt accumulation in the pre-filter mesh, wash with clean water.

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

 Repeat the process based on dust conditions or at regular periodic intervals.

PREFILTER SS WIRE MESH PREFILTER SS WIRE MESH

COMPRESSED AIR

PRE FILTER
PREFILTER SS WIRE MESH SS WIRE MESH

Figure 26. Pre filter –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.

Spurious part Effect Remarks

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

Inadequate earthing can cause a separator to collapse (25% risk). Inadequate


Air oil separator Safety hazard
earthing can also cause fire and destroy the entire machine.

Higher power consumption means a higher operating cost.


Reduced performance leads to extra functioning and operating cost.
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.

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.

Problem Cause Solution (go sequentially)

Power supply not available Restore incoming power supply

(1) Correct the incoming voltage.

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


Incoming voltage is below limit
(3) Ensure sufficient power back up

(4) Select and use the correct cable size.

Emergency stop switch in pushed


Rotate counterclockwise direction and release
condition

Clean or replace the emergency switch.


Emergency stop switch malfunction
Tighten the wires at terminals

(1) Select correct fuse rating from selection chart.

(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.

Correct incoming voltage.


Incoming phase-to-phase voltage
Adjust main incoming transformer tapping.
imbalance of more than 5V
Compressor not
Correct the power factor to less than unity.
starting
Incoming phase to earth voltage
Correct the incoming voltage.
imbalance of more than 5V

Control MCB malfunction Replace MCB

Check for any short circuit or loose connection.

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).

Replace the control transformer if defective.


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

(1) Replace control transformer fuses.

No power supply to Neuron (2) Ensure tight connection of the 24V power supply connector
controller. to Neuron

(3) Replace control transformer (50VA).

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

(2) Replace the control fuse.


No display in Neuron controller
(3) If 24V power supply to Neuron is okay then replace with
anew Neuron micro controller.

Maintenance 6.16
Problem Cause Solution (go sequentially)

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

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


Oil level is low
(3) Arrest oil leaks

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

Room temperature is higher than


outside ambient temperature by Improve ventilation in compressor room
30°C (86°F)

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).

Oil cooler clogged externally


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.

Check and correct the wiring connection to the cooling fan.


Cooling fan rotating in wrong
direction.
Replace with correct fan type.

Replace the fuse if blown.


Check fan motor fuse
Replace with the 2A fuse.

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.

Replace oil filter.


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

Thermal valve malfunctioning Replace the thermal valve element.

Clean the oil injection orifice.


Oil injection orifice chocked or
improper size
Replace with correct size.

Air filter clogged Clean or replace the air filter

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

Separator element clogged Replace oil.

Replace separator element.

Poor quality of oil Replace oil.

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


Oil cooler clogged internally 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.

Maintenance 6.17
Problem Cause Solution (go sequentially)

Drain excess oil and maintain the recommended oil


High oil level
level.

Oil is milky Replace oil and maintain the recommended level.

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


Scavenge return line non return valve thoroughly.
(NRV)/ orifice clogged
2) Change/clean the air filter.

Remove and clean the clogged scavenge return line


Scavenge return line tube clogged
tube.

Scavenge return line tube gap not Remove the return line tube from
maintained (not applicable EG11 to EG22) the separator and correct it.

The spin-on separator internal pipe thread


Replace the internal pipe.
damaged (applicable to EN series)

High oil carry over 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


Replace with new separator.
applicable to EG11 to EG22 units)

Separator element bonding ruptured


Replace with new separator.
(not applicable to EG11 to EG22 units)

1) Use suitable higher capacity compressor or match


Compressor runs at lower pressure than demand to compressor capacity.
normal pressure.
2) Arrest all line leakages.

Minimum pressure valve (MPV) opening


earlier than at the specified opening
pressure* 4.5 bar.g (65.26psi.g). Replace MPV kit/assembly.
* 3.5 bar.g ( 50.8 psi.g) for compressors
with working pressure 4.5 bar.g
Neuron microcontroller pressure settings:
1) Unload pressure set value is above
Check and correct the unload pressure and high tank
specification.
pressure values in Neuron micro-controller
2) High tank pressure set value is below
specification.

1) Check and replace intake valve kit if required.

2) Check the solenoid valve and clean or replace if


Intake valve malfunction
required.

3) Check and replace the actuator kit if required.

BDV malfunction Check/replace


High tank pressure
Compressor started with air outlet ball
Open the outlet ball valve.
valve closed

Check the solenoid valve and clean or replace if


Solenoid valve malfunction
required.

Neuron microcontroller malfunction Replace the Neuron microcontroller

Pressure transmitter malfunction Replace the pressure transmitter

MPV stuck up (check with pressure gauge in


Replace the MPV kit.
AOS tank )

Separator element choked Replace the separator element

Maintenance 6.18
Problem Cause Solution (go sequentially)

No control air supply to solenoid valve Replace / connect

1. Replace the solenoid valve assembly


Solenoid valve malfunctioning
2. Clean the orifice

No electrical supply for energising the


Replace the Neuron microcontroller
solenoid valve

Intake valve malfunctioning Check and replace the intake valve kit.

1. Clean or change BDV assembly.


Blow-down valve malfunctioning
2. Clean the orifice.

1. Check and change the MPV kit.


MPV malfunctioning
2. Check and change the MPV assembly

1. Check and reset the pressure regulator setting to


Pressure regulator (applicable only to EG 55
working pressure+0.3 bar (4.35 psi).
to EG 250) setting lower than working
pressure
2. Change the pressure regulator assembly.
Loading/unloading
Problem
Actuator failure (applicable only to EG 55 to
Check and change the actuator / kit / assy.
EG 250)

1. Air requirement is more than compressor


capacity

2. Working pressure is lower than required 1. Replace the compressor


application pressure. 2. Arrest all pipeline leakages.

3. Excess pressure drop in pipe line.

1. Tighten the lap cable

2. Replace the lap cable


Pressure transmitter malfunction
3. Replace the pressure transmitter

4. Replace the Neuron microcontroller

Malfunction of R04 relay (loading/ unloading


Replace the Neuron microcontroller
relay) in Neuron microcontroller

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

Maintenance 6.19
Problem Cause Solution (go sequentially)

Clean/change pre-filter mat by following these steps:


Switch off the machine.
Squeeze and pull out the pre-filter mat from the
Inlet air pre-filter mat clogged
canopy.
Clean pre-filter with compressed air at less than 2.5
bar /36.3 psi Refit the filter after cleaning.

Clogged air filter element Clean/change air filter element.

1. Air requirement is more than compressor


capacity

2. Working pressure is lower than required 1. Replace compressor


application pressure. 2. Arrest all pipeline leakages.

3. Excess pressure drop in pipe line.

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

1. Replace the solenoid valve assembly


Solenoid valve malfunctioning

2. Clean the orifice


Pressure not built
up
No electrical control supply to solenoid valve Replace the microcontroller

Intake valve malfunctioning Check and replace intake valve kit.

1. Check and change the BDV assembly.


Blow down valve malfunctioning
2. Clean the orifice.

1. Check and change the MPV kit.


MPV malfunctioning
2. Check and change the MPV assembly

1. Check and reset pressure regulator setting


Pressure regulator (applicable only to EG 55
to working pressure+0.3bar (4.35 psi).
to EG 250) setting lower than working
pressure 2. Change pressure regulator assembly.

Actuator failure (applicable only to EG 55 to


Check/change actuator / kit / assembly.
EG 250)

Replace separator element. If required, replace the


Separator element choked (increase in
oil (based on condition of the oil) and run the
pressure drop across separator)
compressor.

Maintenance 6.20
6.3 Decommissioning, dismantling and
putting out of service

6.3.1 Decommissioning the compressor condensate and filter element is to be done in


accordance with local pollution control norms
Decommissioning is necessary under the
 Parts of the compressor that are replaced have metal
following conditions, and rubber components. These may be recycled and
 The compressor is not needed temporarily disposed according to pollution control regulations
 The compressor is to be relocated respectively
 The compressor is to be scrapped  Rubber items such as AVMs, coupling elements, and O-
 Unplug the power cable entry to the compressor rings should be disposed and replaced before running
 Depressurize the air oil tank again.
 Drain the oil from the cooler and air oil tank. Dispose of
it properly
NOTE
 Ensure that all the external supply lines have been ELGi is not responsible for any the disposal of waste, It is
properly disconnected from the compressor before the responsibility of customer to dispose the waste in
decommissioning accordance with local environmental statutory laws.

 Make sure all the compressed air is vented out through


ball valves and safety devices residing in the
compressor The compressor does not give any warnings during short
operating times. If it is operated below the dew point and
 Remove the compressor from the foundation moisture condensate may mix with oil. This will reduce the
6.3.2 Dismantling the compressor lubricating quality of the oil and lead to damage of
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 and following decommissioning
procedure

 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 Waste disposal


 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. Follow 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 drive 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
 The moisture condensate separated from the
compressed air contains oil particles. Disposal of

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.

Service requests/complaints  Northern Region: Rajasthan, Uttar Pradesh, Delhi,


Haryana, Punjab, Uttaranchal, Himachal and Jammu &
The CCS toll-free telephone number 1800-425-3544
Kashmir.
(accessible within India through BSNL and MTNL lines)
takes the customer’s call to our centralized customer care Contact Numbers: You can contact CCS also with the
center in Coimbatore. Customers can register their service following numbers:
requirements or complaints here. Telephone: 0422-2589206 / 241 / 242 / 243/ 244 / 245 /
A unique tracking number is generated for each call logged 97900 21100
by the CCS. The customer receives an automatic e-mail Fax: 0422-2589240
acknowledgement with the tracking number and details of
Please send the following details to the mail, thus enable
the call for reference.
us to take immediate action.
A service engineer is assigned to the call, and the date and
1. Name of the customer
time of the engineer’s visit are communicated to the
customer by e-mail. Every requirement or complaint must 2. Compressor model

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.

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]

Maintenance 6.23
6.5 Appendix

6.5.1 Conversion tables


Description From To Multiply by

Inches Millimetres 25.4

Metres Inches 39.37

Feet Millimetres 304.8


Length (L)
Metres Feet 3.281

Inches Thou 1000

Millimetres Micrometres 1000

Square metres Square feet 10.765

Area (A) Square feet Square inches 144

Square inches Square millimetres 645.16

Cubic metres Cubic feet 35.315

Cubic feet Cubic inches 1728

Cubic metres Litres 1000


Volume (V)
Cubic feet Litres 28.32

US gallons (liq) Litres 3.785

Imperial gallons (liq) Litres 4.546


3
Cubic feet per minute (cfm) Cubic metres per hour (m /h) 1.6988

Cubic feet per minute (cfm) lpm 28.32


Volumetric flow (Q)
Cubic metres per hour (m3/h) lpm 16.667
3
Cubic metres per minute (m /min) lps 16.667

Kilograms Pounds 2.205

Kilograms Grams 1000


Mass (M)
Kilograms Ounces 35.27
2
kg f/cm g psi g 14.223

psi g Pascal 6895


2
Pressure (P) bar g kg f/cm g 1.0197

bar g psi g 14.503

psi g kg f/cm2 g 0.0703

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

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

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

ft-lb f Joules 1.35582

ft-lb f Btu 0.001285


Heat (q), Work (W),
Joules Calories 0.2388
Energy (E)
Btu/h Calories/h 252

Kilowatts Btu/h 3411

Metric horsepower Kilowatts 0.7355


Power (P)
Imperial horsepower Kilowatts 0.7457

Table 8: Conversion table

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.

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

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

9/16" 149 109.8875

7/8" 579 427.0125

Table 11: UNF threads

* Property class of 8.8 only

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.

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 .

© Copyright ELGi Equipments Limited, India 2018. All Rights Reserved.

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

7.2.1.1 Static discharge warning 7.7

7.2.1.2 Assembly 7.7

7.2.1.3 Electrical connection 7.7

7.2.1.4 Power supply 7.7

7.2.2 General instruction 7.7

7.3. Display & terminal details 7.8


7.3.1 Terminal connection 7.8

7.4. Neuron-III salient features 7.9


7.4.1 Home screen display 7.9

7.4.2 Records (view-> day report and fault report) 7.9

7.4.3 Remote function (both MODBUS as well as digital input) 7.9

7.4.4 Lead and lag – pressure schedule (operator-> schedule) 7.9

7.4.5 Other interfaces and communication 7.9

7.4.6 Safeguard 7.9

7.4.7 Mimic LED for fault indicators 7.9

7.5. Input output description 7.10


7.5.1 X01: Power supply 7.10

7.5.2 X02: Digital inputs 7.10

7.5.3 X03: Analog input/output 7.10

7.5.4 X04: RS 485 communication 7.10

7.5.5 X05: Main motor relays 7.11

7.5.6 X06: Relays 7.11

7.5.7 X07: Relays 7.11

7.5.8 X08: 3 Phase input 7.11

7.6. Home screen 7.12


7.6.1 Important machine settings for users 7.14

7.7. Menu structure 7.16


7.7.1 Main menu 7.16

7.7.1.1 View 7.16

7.7.1.2 Operation 7.16

7.7.1.3 Fault report 7.17

7.7.1.4 Day report 7.17

Controller Manual 7.2


Contents Page No.
7.7.1.5 View service time 7.17

7.7.1.6 View cumulative time 7.17

7.7.1.7 VFD 7.18

7.7.1.8 Rental hours 7.18

7.7.2 Operator 7.18

7.7.2.1 Machine 7.18

7.7.2.2 Operator scheduler 7.19

7.7.2.3 Operator maintenance 7.19

7.7.2.4 Language 7.20

7.7.2.5 VFD control 7.20

7.7.2.6 VFD speed control 7.20

7.7.3 Service 7.21

7.7.3.1 Calibration (offset) 7.22

7.7.3.2 Programmable relay 7.22

7.7.3.3 Temperature 7.22

7.7.3.4 Maintenance 7.22

7.7.3.5 Clock 7.22

7.7.3.6 Digital input 7.22

7.7.3.7 Dryer input 7.23

7.7.3.8 Latitude/Longitude 7.23

7.7.3.9 VFD model 7.23

7.7.4 Customer care 7.23

7.8. Data interface 7.24


7.8.1 Analog output 7.24

7.8.2 DCS port 7.24

7.9. Troubleshooting 7.25


7.10. Construction 7.26
7.10.1 Dimension drawing 7.26

7.11. Example – scheduler setting 7.27


7.12. Revision details 7.28
7.13. Neuron III quick reference 7.29

Controller Manual 7.3


Abbreviations Used

Dis. Pressure Discharge pressure

Dis. Temperature Discharge temperature

HSP High sump pressure

Temp Temperature

DPAF Differential pressure air filter

DPOF Differential pressure oil filter

AF Air filter

OF Oil filter

Min Minimum

Max Maximum

VFD Variable frequency drive

AO Analog output

UL Unload

En Enable

Dis Disable

L Load

St Stop

F Fault

R Run

Sby Standby

STC Start count

LDC Load count

DD Date

MM Month

YY Year

Ph Fail Phase failure

Pr Pressure

Tr Temperature

DCS Distributed control system

PR Pressure

MMOL Main motor overload

OL Overload

NC Not connected

PS Pressure schedule

RST Restart time

DTR Delta to run

RTS Run to stop

I/O Input / Output

REM Remote

RTU Remote terminal unit

Controller Manual 7.4


7.1 Technical specification

Definition : Pre-programmed logic controller

Function : Compressor control system & I/O monitoring

Part number : 018362618

Software : Embedded C

Rated voltage : 24VAC + 15% -20%

Power consumption : 10W (Max)

Ride through : 30ms

Graphic display : 2.9" Mono chrome graphics display

Display contrast : Adjustable using software

Protections : Low voltage

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)

Language : English, French, Portuguese, Italian, Spanish

Enclosure material : ABS PC - Plastic

Dimensions : 280 X 190 X 90 mm

Mounting : Locking knob for panel tightening

Protection class : IP55 from front panel only

Operating temp : - 10°C ~ 50°C (14oF ~ 122oF)

Storage temp : -10 to 70°C (14oF ~ 158oF)

Relative humidity : <95% @ 50°C (122 oF) without condensation

Certification : CE, UL

For Technical support/assistance contact ELGI Customer Care


E-mail: [email protected]

Digital inputs:
Number of channel : 8 Ports

Rated voltage : 24VDC

Usage
: Emergency stop, motor overload, cooler over load, motor reverse rotation, DPOF,

Digital outputs:
Number of channel : 8 Ports

Rated voltage : 24VDC / 250VAC

Rated load : 10A @ 250VAC

Controller Manual 7.5


Coil rated current : 21mA

Coil voltage : 24VDC

Contact resistance : max 100milliohms

Insulation resistance : min 1000Megohms @ 500VDC

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:

Range : 0 to16 bar (0 to 232 psi)

Resolution : 0.1bar (1 psi)

Accuracy : ± 0.1bar (1 psi)

Usage : Discharge pressure and sump pressure

2 x PT1000:

Range : -10 to150° C (14 to 302oF)for 1st channel

-10 to 200o C (14 to 392 oF)for 2nd channel

Resolution : 1°C (2°F)

Accuracy : ±1°C (2°F)

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

Usage : Discharge pressure and discharge temperature

Communication ports:

Port 1 : RS485, MODBUS RTU (for DCS interface)

Port 2 : RS485, MODBUS RTU (for VFD parameter reading, analog input module)

Controller Manual 7.6


7.2 Installation instruction

indicates damage, so that safe operation is not possible,


7.2.1. Equipment safety
then the device may be removed from operation.
The device, before delivery, was checked according to the
Carefully unpack the system. Open the doors and inspect
prescribed tests of the inspection scheme. In order to
the cabinet, door, printed circuit board, and other
maintain this status through shipment and secure a safe
components for the possibility of shipping damage. It is
operation, consider the notes and warning notes this
recommended that the cabinet be stored in a clean dry
instruction manual covers. The device should be operated
area until mounting takes place.
by only trained personnel. Maintenance and repair should
be performed only by trained, technical personnel, familiar The signal cables and power cable should be separately
with the associated dangers. The device can be operated routed.
without compromising its security within the certified The protective earth connection in the panel must be
environment condition. connected to field earth only.
7.2.1.1. Static discharge warning Protection from direct sunlight

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.

The devices should be installed only outside of explosion


hazardous areas!

7.2.1.3. Electrical connection


External connections are to be performed according to the
respective national rules. Switch off the device before
doing any wiring work. Do not connect or disconnect any
wire when the device is powered on and operating.

7.2.1.4. Power supply


It is to be ensured that supply voltage corresponds with
the specification on the type sign. If the device is switched
on with other devices and/or mechanisms, then the effects
have to be considered before switching and appropriate
precautions taken. Do not connect welding or such high
noise sources to the same line of controller supply.

7.2.2. General instruction


The following procedures and instructions should be
followed closely to avoid damage to the control panel and
its associated equipment. Reliability of the system depends
upon proper installation and maintenance.

The device is to be examined with feed and storage to rule


out damage from inappropriate handling. If the device

Controller Manual 7.7


7.3 Display & terminal details

1 128x64 Graphical display


2 Navigation keys
3 Enter key
4 Start key
LED (green - start , red -
5
stop/fault )
6 Stop key
7 Reset key
Oil filter change indication
8
LED
Air oil separator change
9
indication LED
10 Cooler fault LED
Auto mode enabled
11
indication LED
12 High pressure fault LED
13 Main motor fault LED
14 Reverse rotation fault LED
Air filter change indication
15
LED
High discharge temperature
16
fault LED
17 Escape key
18 Tab key
19 Info key

7.3.1. Terminal connection


X01 - Power supply

X02 - Digital input (8 Channel)

X03 - Analog input (4 Channel) / output (2 Channel)

X04 - Communication ports (2 Ports)

X05 - Relay outputs (main, star, delta)

X06 - Relay outputs (3 Nos)

X07 - Relay outputs (2 Nos)

X08 - Phase monitoring

Controller Manual 7.8


7.4 Neuron-III salient features

 PC interface through MODBUS - To download reports


7.4.1. Home screen display
and setting parameters
 Easy user interface 8 line graphical display and intuitive
 70 + Modbus parameters for DCS controls
menu navigation keys
 Dryer integration
7.4.2. Records (view -> day report and
 High, Low dew point warnings
fault report)
 30 day reports (load hours, unload hours, run hours,
7.4.6. Safeguard
stop hours, fault hours, standby hours, start count, load  The 'Smart Logic' of NEURON III automatically decides
count) the start delay required to ensure minimum wait time
 99 fault reports between successive starts of the compressor and dryer
thereby increasing their lifetime.
 Faults with date and time stamp, status of the machine
 Start Inhibit till sump pressure is within safe limits to
at the time of fault etc.
enhance the life of the compressor
7.4.3. Remote function (both from
 Low voltage & Short time Power interrupts detection to
MODBUS as well as digital input) enhance the life of the contactors
 Remote loading and unloading  Low temperature start inhibit to avoid start-up overloads
 Remote start and stop
7.4.7. Mimic LED for fault indications
7.4.4. Lead and Lag - Pressure
schedule (Operator -> schedule)
 32 pressure program (one schedule should be in
Sunday (first day of the week) 00:00 Hrs)

 Setting hours considered as 24hr format irrespective of


time format setting.

 Important parameters to customize - Day, On Time,


OFF Time, Load Pr, Unload Pr

7.4.5. Other interfaces and


communication
 VFD interface through MODBUS

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.

Cooler O/L Glows when the cooler digital input is open


Glows when
1. Analog pressure input is open (probe failure)
Pressure
2. Discharge pressure is higher than set HSP
3. Sump. pressure is higher than set HSP (If sump pressure sensor is fixed)
Glows when the
Temperature 1. Analog Temperature Input is Open (Probe Failure)
2. Dis. Temperature is higher than set Trip temp.
Glows when the
Differential Pressure
1. DPOF Digital input is open & DPOF is enabled
oil Filter (DPOF)
2. Oil filter service is due - based on service hours
Glows when the
Differential pressure
1. DPAF digital input is open & DPAF is enabled
air filter (DPAF)
2. Air filter Service is due - based on service hours
1. Glows in red when machine is stopped / idle
Start & Stop
2. Glows in green when machine is running

Controller Manual 7.9


7.5 Input output description

7.5.1 X01: Power supply

Pin Function Id Active state

1 24V AC Phase 24 VAC P -

2 24V AC Neutral 24 VAC N -

3 24V Earth Earth -

7.5.2 X02: Digital inputs

Pin Function Id Active state

1 Digital Inputs common - 24VDC 24VDC -

2 Emergency stop Emergency Fault if open

3 Differential pressure oil filter DPOF Warn if open

4 Reverse rotation Rev. Rot Fault if closed

5 DPAF/REM load and unload DPAF/REM L/UL Warn or unload if open

6 Remote start stop control Remote Start /Stop Stop if open

7 Dryer warn/trip Dryer Warn/Trip Warn/Fault if open

8 Cooler motor overload Cooler OL Fault if open

9 Main motor overload MMOL Fault if open

7.5.3 X03: Analog input/output

Pin Function Id Type Range

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)

** Dew point temperature / Ambient


6&8 T2-1 T2-2 PT1000 -10 to 200°C (14 to 392oF)
temperature/winding temperature

Dis. pressure output (0 to 16 bar/0 to


9 & 11 DAC1 GND Voltage 1~5V
232 psi) common ground

Dis. Temperature (-10 to 150oC / 14


10 & 12 DAC2 GND Voltage 1~5V
to 302oF) common ground

7.5.4 X04 : RS 485 Communication

Pin Function Id Active state

2 DCS interface A1 RS485 A Modbus RTU protocol

4 DCS interface B1 RS485 B

6 * VFD interface /AI module A2 RS485 A Modbus RTU protocol

8 * VFD interface /AI module B2 RS485 B

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

Pin Function Id Active state

1 Common for main, star and delta contactors Common -

2 Main contactor Main Energized

3 Star contactor Star Energized

4 Delta contactor Delta Energized

7.5.6 X06 : Relays

Pin Function Id Active state

1 Common - load relay Common


Load when energized
2 Load relay L/UL

3 Common - fan relay Common


FAN ON when energized
4 Fan relay NO

5 Common - auto drain valve relay Common


ADV ON when energized
6 Auto drain valve relay NO

7.5.7 X07 : Relays

Pin Function Id Active state

1 Common - Programmable relay Common


Energized
2 Programmable relay NO

3 Common - Programmable relay Common


Energized
4 Programmable relay NO

7.5.8 X08: 3 Phase input

Pin Function Id Type Range

1 R Phase L1

2 Y Phase L2 AC Voltage 150 to 550 V AC

3 B Phase L3

Controller Manual 7.11


7.6 Home screen

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

 Set load pressure

 Set unload pressure

 Set start sump pressure (displays only if sump Pressure


enabled)

 Max differential pressure (displays only if sump Pressure

Compressor mode selection details: enabled)

1. PS - Pressure schedule enabled , "DOWN" - Today report

UL - unload mode enabled,  Load and stop hours


PS & UL disabled the space will be shown as empty
 Unload and fault hours
2. L or R or D - compressor start from - Local or remote
 Run and standby hours
or DCS,
 Start count and load count
3. A or M - Auto restart enabled or auto restart disabled.
For more details refer machine settings in operator menu. TAB Key - For changing the language

Shortcut key usage HELP Key - For contrast adjustments

When the controller is in home screen, you can access


below listed parameters using the shortcut keys.

"RIGHT" - Live analog values

 Live differential pressure (displays only if sump pressure


enabled)

Message 1 - Compressor status message

Status Description
Ready Ready for start

Star Motor running in star


Run Motor running in delta

Run load Compressor in load

Run unload Compressor in unload


Stop busy Stop sequence in progress

Emergency stop Emergency stop push switch is ON


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.

Standby Compressor in standby

Controller Manual 7.12


Message 2 - Compressor fault message
Fault Description
Pr. Probe failure Discharge pressure sensor probe failure

Tr. Probe failure Temperature sensor probe failure

Sump pr. probe failure Sump pressure sensor probe failure, if sump pressure is enabled

HSP (AS) Case 1: sump pressure is enabled

If sump pressure exceeds the set high sump pressure value.

HSP (AD) If discharge pressure exceeds the set high sump pressure value.

Cooler If the cooler digital Input opens due to Cooler fault


Main motor overload/ IF the MMOL digital input opens due to main motor over load. VFD error if VFD control is
VFD error 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.
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

Message 3 - Compressor warning message


Warning Description

DPAF If DPAF Digital Input is Open and DPAF ON in factory setting

DPOF If DPOF Digital Input is Open and DPOF ON in factory

Dryer Probe Failure When Ch-4 analog sensor input fails

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 Oil When service remaining Hr. reaches 0000 Hrs

Change Grease When service remaining Hr. reaches 0000 Hrs

Change Separator 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

Calibration error When there is error in sensor calibration

If CV20 variant selected or winding temperature enabled and if the temperature exceeds [SET
Winding temp Exceeded
value-10] of MOTOR WINDING temperature

Controller Manual 7.13


immediately. This feature helps save the energy if very
7.6.1 Important user machine settings
little compressed air is used.
1. Control mode
NOTE
Local - Users can start and stop the compressor by using
If the compressor is started more than the specified
local start/stop key number of cycles per hour through the Standby sequence,
Remote - Users can start and stop the compressor by then the system does not enter into the Standby stop
sequence until the existing hour is completed. Next, the
using potential free digital input. (refer digital input Standby override will appear on the screen.
connector - X04).
9. Start/Stop per hour
DCS - Users can start and stop the compressor by using
The system will warn if the compressor is started more
RS485 modbus communication port ( refer connector - X07 ).
than the specified number of cycles per hour. The default
timeframe is 5 per hours.
NOTE
10. Auto drain valve
In remote and DCS mode, the start/stop button in the
controller is inactive. In case of emergency, stop the The auto drain valve is a special feature to prevent water
compressor using the "emergency stop push" button from entering into compressed air delivery. This function
available in the front panel. This is applicable across all
types of control mode. resets the drain valve to ON and OFF based on the time
specified in the menu. The default setting is 5 Sec ON in 4-
2. Unload mode min intervals. You can adjust the ON and OFF time based
on the requirement.
If this is enabled, the compressor operates only in unload
mode and never in load mode. (This mode is used for 11. Low dew point
service and maintenance purposes.) The system will warn/trip if the dew point temperature is
3. Auto restart less than the set value (if the dryer is enabled).

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.

5. Star delay NOTE


Star to delta change over delay time. Default 6 sec delay The compressor starts working in local load and unload
mode if communication is lost in DCS mode.
given in the factory.

6. DTR delay 14. VFD Function


From delta change over to load delay time. Default 3 sec VFD speed percentage will appear in the HOME screen
delay given in the factory. once VFD mode is enabled in the factory setting.
7. RTS delay You can also view the below VFD parameters by accessing
The normal stop of the compressor will unload and wait for the view->VFD menu:
this delay time to stop the compressor. The default delay  Voltage in V
is 5 sec.
 Current in A
8. Standby time
 Frequency in Hz
The compressor will switch to standby if unloading exceeds
 Power in KW
the specified time. The default delay is 5 mins.
 RPM
Standby resume - If the actual pressure is less than the
load pressure, then the compressor will restart  Status of the VFD
automatically after 10 sec delay. If demand from the
standby stop comes after 10 sec, the compressor will start

Controller Manual 7.14


VFD Mechanism

 The machine operates at the set minimum speed till it


reaches the RUN LOAD condition at start-up.

 The machine will run at the set unload speed when it is


in unload, which may be remote or DCS unload or when
discharge pressure is > unload pressure.

 The machine will run at optimum speed when optimum


is ON. This works only under the load condition. Under
the unload condition, it follows the unload speed.

 The machine will run at calculated speed between


minimum and maximum speed based on machine usage
and when the machine is under load with optimum OFF.

Controller Manual 7.15


7.7 Menu structure

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

Controller Manual 7.16


7.7.1.3 Fault Report
Use ∆ and ∇ to select the fault record number (1 to 99). The latest fault will be displayed in the first position. For fault
message details refer the “Fault Message” table.

LEVEL 1 LEVEL 2 LEVEL 3

View Fault report Fault message

Date : DD/MM/YY

Time : HH:MM:SS

Dis.Pr : X X .X

Dis.Tr : X X X

Status : RDY/ACK/STAR etc.,

7.7.1.4 Day Report


The day report explains the usage pattern of the compressor day wise for last 30 days. Use ∆ and ∇ to select the record
number (1 to 30). The latest report will be displayed in record 1.
LEVEL 1 LEVEL 2 LEVEL 3

View Day report Date: DD/MM/YY

L:X X Hours St: X X Hours

UL:X X Hours F:X X Hours

R:X X Hours Sby: X X Hours

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

7.7.1.5 View Service Time


For consumable parts, the remaining life will appear in the view menu. Every run hour, the count will decrements by one
hour. Once it reaches zero, an alarm message will pop up and the counter will show negative hours.

LEVEL 1 LEVEL 2 LEVEL 3

View Service time Remaining AFCT: X X X X X hours

Remaining OFCT: X X X X X hours

Remaining OSCT: X X X X X hours

Remaining OCT: X X X X X hours

Remaining RGT: X X X X X hours

Remaining valve kit: X X X X X hours

7.7.1.6 View Cumulative Time


From the compressor commissioning to till date , the run hours and utilization pattern will be displayed in the menu.

LEVEL 1 LEVEL 2 LEVEL 3

View Cumulative time Load X X X X X X hrs: X X Min

Unload X X X X X X hrs: X X Min

Run X X X X X X hrs: X X Min

Stop X X X X X X hrs: X X Min

Fault X X X X X X hrs: X X Min

Standby X X X X X X hrs: X X Min

Start count XXXXXX

Load count XXXXXXXXX

Utilisation XX%

Controller Manual 7.17


To reset the rental hours, you have to choose “rental off”
7.7.1.7 VFD
and then “rental on” in operator menu.
If VFD is enabled in the controller and VFD communication
port is connected, you can view the following VFD Load X X X X X X hrs: X X Min
parameters in Neuron III. Unload X X X X X X hrs: X X Min
Run X X X X X X hrs: X X Min
 Voltage in V Stop X X X X X X hrs: X X Min
 Current in A Fault X X X X X X hrs: X X Min
Standby X X X X X X hrs: X X Min
 Frequency in Hz Start count XXXXXX
Load count XXXXXXXXX
 Power in KW

 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.

< 40% speed XXXX hours Operator Machine


40~50% speed XXXX hours Scheduler
51~60% speed XXXX hours Maintenance
61-70% speed XXXX hours Language
71-80% speed XXXX hours Change password
81~90% speed XXXX hours VFD control
91~100% speed XXXX hours Rented hrs setting
Last serviced

7.7.1.8 Rental hours 7.7.2.1 Machine


If you select rental hours in the operator menu, you can The machine settings available are listed in the below
view the run hours and the utilization pattern of the table.
compressor in the view menu.

# Item Min Max Option Default Unit

Mode

1 Control mode - - loc/rem/dcs loc -

2 Auto restart - - on / off off -

3 Pr unit - - bar / psi bar/psi -

4 Tr unit - - cen / far cen -

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

7 Warn RST 30 250 - 30 second

8 Star 6 20 - 6 second

9 DTR 10 60 - 3 second

10 RTS 5 30 - 5 second

11 Standby 1(VFD),3(Non-VFD) 99 - 3 minute

DCS Port

12 Type - - Modbus -

13 ID 01 99 - 01 -

14 Baud - - 9600/19200 9600 bps

Controller Manual 7.18


# Item Min Max Option Default Unit

14 Baud - - 9600/19200 9600 bps

15 Parity - - None/Even/ Odd None

16 Length - - 8/7 8 -

17 Stop bit - - 2/1 1 -

Auto Drain Valve

18 Off time 1 180 - 4 minute

19 On time 1 15 - 5 Second

Load / Unload Source

20 LD / UL Source - - Loc / Rem/ DCS Loc -

Set dew point

21 Low dew point -6oC(21oF) 2oC(36oF) -2oC(28oF) Cen

22 High dew point 6oC(43oF) 12oC(54oF) 8oC(46oF) Cen

Contrast adjust

24 Contrast adjust 10 100 50 %

7.7.2.2 Operator - Scheduler


If you enable the pressure scheduler, then you can view and access the below table in edit mode. Use ∆ and ∇ to select the
pressure scheduler number (1 to 32). For details, refer to “Example - scheduler setting”.
# Item Min Max Option Default Unit

Sun to Sat / (---


1 Day - - --- -
means no schedule)

2 Action - - on / off off -

3 Time HH 00 23 - 00 Hour

4 Time MM 00 59 - 00 Minute

Unload  Load pressure + 7.5bar


5 ≤Max unload pressure - bar/psi
Pressure 0.5bar(7psi) (109psi)

6 Load pressure 4.0 bar(58psi) ≤Unload pressure - - 5.5bar bar/psi

(one schedule should be in Sunday (first day of the week) 00:00 Hrs) Then Press "Enter" to set the following

7.7.2.3 Operator - Maintenance


If you modify the settings for the below consumables, you can select the yes option to restart the service counter from the default

# Item Min Max Option Default Unit

1 AF changed - - no/yes no -

2 OF changed - - no/yes no -

3 OS changed - - no/yes no -

4 Oil changed - - no/yes no -

5 Re-grease - - no/yes no -

6 Valve kit - - No/yes No -

Controller Manual 7.19


7.7.2.4 Language
Default is English. You can choose any one of the given languages.

# Item
1 English
2 Portuguese
3 Francais
4 Italiano
5 Spanish

7.7.2.5 VFD Control


Item Min Max Default Unit

Optimum Speed on/off on/off off

P-Gain 1 50000 250

I-Gain 1 5000 500

I-Time 1 200 20

Max. Speed RPM

Min. Speed RPM

Optimum Speed RPM


Factory settings can be viewed here
UL Speed RPM

High (5v) RPM

Low (1v) RPM


contrast, a small gain results in a small output response to
7.7.2.6 VFD Speed Control
a large input error, and a less responsive or less sensitive
Optimum speed: The compressor runs at optimum speed controller. If the proportional gain is too low, the control
under load with optimum ON (Operator menu). action may be too small when responding to system
PI speed control: In the "Run Load" condition, the disturbances.
compressor operates at calculated speed between Min and Effect of Integral Value
Max speed depending on air utilization/usage.
The contribution from the integral term is proportional to
Setting the P value both the magnitude of the error and the duration of the
P-Gain - Range: 1-50000. This gain occurs over a full error.The integral term accelerates the movement of the
range. The recommended setting is 20-1000. process towards set point and eliminates the residual
steady-state error that occurs with a pure proportional
A proportional–integral controller (PI controller) is
controller. However, since the integral term responds to
a control loop feedback mechanism used in
industrial control systems and a variety of other
applications requiring continuously modulated control.

Proportional-Integral controller results from the


combination of the proportional and the integral mode.
This mode is also called as the proportional plus reset
action controller

Effect of Proportional Value

The proportional term produces an output value that is


proportional to the current error value. The proportional
response can be adjusted by multiplying the error by a
constant Kp, called the proportional gain constant.

A high proportional gain results in a large change in the


output for a given change in the error. If the proportional
gain is too high, the system can become unstable. In

Controller Manual 7.20


Parameter Rise time Overshoot Settling time Steady-state error Stability
Kp Decrease Increase Small change Decrease Degrade
Ki Decrease Increase Increase Eliminate Degrade

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

Example: communication no longer exists.

Sample 1:  Ensure min reference of AO scaling > VFD Parameters 3


-02 and 4-11 and max reference of AO scaling < VFD
If P-Gain=20 and the difference between set pressure and
parameters 3-03 and 4-13.
actual pressure ≥ 5 bar (73 psi), then the PI loop
activates. NOTE
The VFD factory settings in the controller are synchronized
Sample 2:
with VFD. It is not recommended to adjust the settings in
If P-Gain=1000 and the difference between set pressure VFD.
actual pressure ≥ 0.1 bar (1 psi), then the PI loop Rental hrs settings
activates.
Rental-ON: If selected, then a separate timer is recorded
Set a higher P-Gain value if receiver capacity is high and for rental hrs of load, unload, run, stop, fault, and
the reverse holds true. standby/STC/LDC. It can be viewed in the view menu only
Setting the I-Gain value when the rental hour is on.

I-Gain - Range: 1-5000. This gain occurs over a full To reset the rental hour, select “rental off” and then

range. The recommended setting is 50- 1000. “rental on”.

The recommended value is 125 to 250 in our case. Last serviced


Anything less than 125 will be more stable. AMC service - If you select yes, the last AMC serviced

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

 VFD should be enabled in Factory -> VFD settings to VFD_model

Controller Manual 7.21


7.7.3.1 Calibration (offset) 7.7.3.4 Maintenance
If any deviation occurs in the pressure and temperature Here you can feed the filter lift time. This timeframe will
between that displayed in the controller and that in the vary depending on the model and filter. Contact Elgi for
master gauge, approach the ELGi service engineer. more information.

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

1 Set AFCT 0000 30000 - 2000H Hour


# Item
1 Warn 2 Set OFCT 0000 30000 - 2000H Hour
2 Load 3 Set OSCT 0000 30000 - 4000H Hour
3 Service
4 Set OCT 0000 30000 - 2000H Hour
4 Stand by
5 Trip 5 Set RGT 0000 30000 - 2000H Hour
6 Remote
Set Valve
7 Ready 6 0000 30000 - 2000H Hour
Kit

Default 7.7.3.5 Clock


Relay 1 = Warn Here the real time clock settings can be done. 24 hrs
Relay 2 = Trip format will be applicable for all menus and features related
to clock settings, Whereas 12 hrs time format is applicable
for the home screen only.
NOTE
If Dryer is enabled, then programmable relay 2 is not user
# Item Min Max
programmable. It is used for automatic dryer control.
1 Hour 00 23
7.7.3.3 Temperature 2 Minute 00 59
Fan Temperature - Fan relay will energize if discharge 3 Second 00 59
temperature reaches the set value. It will de-energize
4 Date 01 31
when the temperature comes below 75°C from the set
value. Alternatively, fan start/stop is allowed for 15 times/ 5 Month 01 12
per hour. Beyond 15 times, the fan will not switch off. 6 Year 00 99
The above logic will work only if the fan input connected to Sun/Mon/Tue/Wed/Thu/
relay output of the controller (Ref:7.5.6 X06: Relay in 7 Day
Fri/Sat
page No:7.11).

Inhibit temperature – If you enable this setting and Daylight saving


Temperature inhibit is already enabled in factory settings, Daylight saving settings will add 1 or 2 hours from the
the compressor will start when the discharge temperature current GMT time. If you choose daylight option as off, the
is higher than the set value. clock will revert back to GMT time.
Temperature inhibit time - The compressor will wait for
this specified time to reach the inhibit temperature. If not, # Item Min Max

it trips as temperature is not building. . 1 Date format DD/MM/YY MM/DD/YY

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

Inhibit -5oC 5oC 0oC 7.7.3.6 Digital input


2 o o
- o
C/F
temp (23 F) (41 F) (32 F) Configuration of DI-4 (DPAF or Remote Load/Unload) can
Tr_ intial be viewed from this menu. (if the load/unload source is
3 5 90 - 5 min
time selected as remote in operator -> machine settings). Then
the digital Input will configure for remote Load/Unload.

Controller Manual 7.22


7.7.3.7 Dryer input
Dryer digital input DI-6 can be configured for warn or
trip. This input will be effective if the dryer is ON in
factory -> dryer.

7.7.3.8 Latitude/Longitude
This option involves deg, min, and sec with NE, NW, SE,
and SW format.

The Latitude/Longitude entry helps ElGi to determine the


location of the compressor on which air alert is equipped.

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.

7.7.4 Customer care

Dis. Pr : 6.0 bar/ 87psi

Dis. Tr : 32°C (90°F)

Status : S/W Version

URL : www.elgi.com

E-mail : [email protected]

Controller Manual 7.23


7.8 Data interface

Neuron III supports two types of data interface

 Analog output

 DCS Port

7.8.1 Analog output


Two channels are available as analog output.

Channel -1 for discharge pressure values 0.0 to 16.0


bar / 0 to 232 psi converted into 1 to 5V.

Channel -2 for discharge temperature values from -10 to


150°C / 14 to 302°F converted into 1 to 5V.

NOTE
If analog input probe failure occurs, analog output
becomes 0V by default.

7.8.2 DCS port


The DCS port is a Modbus RTU type to interface to the
generic DCS system.

You can set the device ID in the "Operator/ Machine/ DCS


Port" menu. Also the baud rate, parity, data length, and
stop bit are user settable.

Controller Manual 7.24


7.9 Troubleshooting

S.
Failure symptoms Possible causes Remedies
NO

No input supply Check incoming AC input

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.

Controller failure. Change the controller.

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.

Until will start functioning, once input voltage


"Low voltage" message in Controller Input voltage less recovered
3
display. than 18VAC to nominal or with in specification
( 415 V +10% - 15 %)
Loose connection in connector
Check the loose connection at both end - Controller
position (X03 - 1, 3) &
and pressure sensor side.
(X03 - 2, 4) .
"Pr. probe failure"
4 Pressure sensor failure. Change the Pressure sensor.
message in display
Check the voltage across (X03 - 3) & (X03-4) with
Controller failure Gnd, voltage should be b/w 0.4 to 2VDC. If it is
different change the controller.

Loose connection in connector


Check the loose connection at both end - Controller
position (X03 - 5, 7) &
and Temp sensor side.
(X03 - 6, 8)
"Tr. probe failure"
5 Temperature sensor failure. Change the Temperature sensor.
message in display
Check the voltage across (X03 - 7) & (X03-8) with
Controller failure Gnd, voltage should be 3.3 VDC. If it is different
change the controller.

Loose connection in connector


"Emergency stop" Check the loose connection at controller end.
position X02 - 1 to 9).
"MMOL"
"Cooler OL" Check either the external switches got sturck / Fault
6 Switch got struck
"Dryer trip" not cleared
"Rev rot/Ph fail"
message in display Controller failure Change the controller.

Disconnect the X05, X06 & X07 connector,


Check the relay working by switching on the start key
7 Motor not driving Controller failure (X05 -1) with (X05- 2, 3 & 4) & (X06 -1) with (X06-
2).
Note: Ckeck in the continuity mode.

Loose connection in connector


Check the loose connection at controller end.
"Phase loss/ Reverse" position X08 - 1, 2 & 3.
8
message in display Check for the X05 connection X08(1- R, 2-Y, 3 -B),
Controller failure
Still the same error change the controller

Controller Manual 7.25


7.10 Construction

 Plastic enclosures

 IP55 polyethylene front keypad

 Inputs and Outputs through terminal block

 Enclosure dimensions 280 X 190 X 90 mm

7.10.1 Dimension drawing

Controller Manual 7.26


7.11 Example – scheduler setting

Scheduler settings are considered when:


1. End customer usage is 6 bar (87 psi)
2. Pressure variation in the air pipe is less than 0.1bar (1 psi)
3. All 3 compressors connect to a single/common header or a common
receiver
4. All 3 compressors connect to a common header or a common receiver

Pressure schedule settings in Neuron III

Comp-1 Comp-2 Comp-3

Load U/L Load U/L Load U/L


ON OFF bar bar ON OFF bar bar ON OFF bar bar
(psi) (psi) (psi) (psi) (psi) (psi)

Monday Lead Lag Lag

7 7.5 6.6 7.2 6 6.8


8:00 18:00 8:00 18:00 8:00 18:00
(102) (109) (96) (104) (87) (99)

Tuesday Lag Lead Lag

6 6.8 7 7.5 6.6 7.2


8:00 18:00 8:00 18:00 8:00 18:00
(87) (99) (102) (109) (96) (104)

Wednesday Lag Lag Lead

6.6 7.2 6 6.8 7 7.5


8:00 18:00 8:00 18:00 8:00 18:00
(96) (104) (87) (99) (102) (109)

Thursday Lead Lag Lag

7 7.5 6.6 7.2 6 6.8


8:00 18:00 8:00 18:00 8:00 18:00
(102) (109) (96) (104) (87) (99)

Friday Lag Lead Lag

6 6.8 7 7.5 6.6 7.2


8:00 18:00 8:00 18:00 8:00 18:00
(87) (99) (102) (109) (96) (104)

Saturday Lag Lag Lead

6.6 7.2 6 6.8 7 7.5


8:00 18:00 8:00 18:00 8:00 18:00
(96) (104) (87) (99) (102) (109)

Sunday 00:00hrs As required ON/Off has to be set. This is mandatory setting.

C1 C1 C1
7b/333cfm 7b/333cfm 7b/333cfm

Air Receiver
1000 cfm

Controller Manual 7.27


Example - scheduler setting

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

Day-1 100 100 100 100 100 25 100 50 0 75 0 0

Day-2 100 100 100 25 100 100 0 100 50 0 75 0

Day-3 100 100 100 100 25 100 50 0 100 0 0 75

Day-4 100 100 100 100 100 25 100 50 0 75 0 0

Day-5 100 100 100 25 100 100 0 100 50 0 75 0

Day-6 100 100 100 100 25 100 50 0 100 0 0 75

Avg. Utl% 100 100 100 75 75 75 50 50 50 25 25 25


Conclusion

Equal utilization of all the 3 compressor based on pressure demand

The scheduler reduces power consumption since compressors are only utilized based on demand.

Neuron III Pressure schedule setup

Step-1 Go to operator menu

Step-2 Enter password "4545"

Step-3 operator -> schedule

Step-4 enable

Step-5 set ON TIME

Step-6 set OFF TIME

Step-7 set load Pr.

Step-8 set unload Pr.

7.12 Revision Details


Version Date Changes
1.0 25/02/15 Release
2.0 09/05/15 Updated corrections
3.0 30/06/17 Software features & CE/UL updated
3.1 01/03/18 Software version 2.07
3.2 01/12/18 Software version 2.08
3.3 11/03/19 Software version 2.09
3.4 05/07/19 Software version 2.09a
3.5 10/02/20 Software version 2.09b
3.6 10/07/20 Software version 2.09c

Controller Manual 7.28


7.13 Neuron III quick reference

1 128x64 Graphical display


2 Navigation keys
3 Enter key
4 Start key
LED (green - start , red -
5
stop/fault )
6 Stop key
7 Reset key
Oil filter change indication
8
LED
Air oil separator change
9
indication LED
10 Cooler fault LED
Auto mode enabled
11
indication LED
12 High pressure fault LED
13 Main motor fault LED
14 Reverse rotation fault LED
Air filter change indication
15
LED
High discharge temperature
16
fault LED
17 Escape key
18 Tab key
19 Info key

MAIN SCREEN DISPLAY


▲ “UP” – Set Analog Values
 Package Discharge Pressure
1. Current Load Pressure
 Discharge Temperature
2. Current Unload Pressure
 VFD Speed % on screen (if applicable)
3. Current Start Sump Pressure (Displays only if Sump
 Machine Status like Run, Load, Unload, Standby etc.
Pressure enabled)
 Warning Messages
4. Current Differential Pressure (Displays only if Sump
 Date & Time Pressure enabled)
 Mode Information (see below) ▼ “DOWN” – Today Report
Mode Information – 1, 2, 3 1. Load and Stop Hours
1. PS – Pressure Schedule Enabled / UL – Unload Mode 2. Unload and Fault Hours
Enabled
3. Run and Standby Hours
2. L – Local / R – Remote / D – DCS

MAIN SCREEN SHORTCUTS

Pressing the navigation keys while on the main


menu allows user to read common settings.

►“RIGHT” ‐ Live Analog Values

1. Live Differential Pressure (Displays only if Sump


Pressure enabled)

2. Live Sump Pressure (Displays only if Sump Pressure


enabled)

3. Live Pt1000 Temperature (Displays only if Dryer ON


enabled)

Controller Manual 7.29


Compressor Status messages
Status Description

Ready Ready for start


Star Motor running in star

Run Motor running in delta

Run load Compressor in load


Run unload Compressor in unload

Stop busy Stop sequence in progress


Emergency stop Emergency stop push switch is ON

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.

Standby Compressor in standby

Compressor Warning messages

Warning Description

DPAF If DPAF Digital Input is Open and DPAF ON in factory setting

DPOF If DPOF Digital Input is Open and DPOF ON in factory

Dryer Probe Failure When Ch-4 analog sensor input fails

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 Oil When service remaining Hr. reaches 0000 Hrs

Change Grease When service remaining Hr. reaches 0000 Hrs

Change Separator 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

Calibration error When there is error in sensor calibration

Controller Manual 7.30


Compressor Fault messages
Fault Description

Pr. Probe failure Discharge pressure sensor probe failure

Tr. Probe failure Temperature sensor probe failure

Sump pr. probe failure Sump pressure sensor probe failure, if sump pressure is enabled

HSP (AS) Case 1: sump pressure is enabled

If sump pressure exceeds the set high sump pressure value.

HSP (AD) If discharge pressure exceeds the set high sump pressure value.

Cooler If the cooler digital Input opens due to Cooler fault

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

Controller Manual 7.31


Menu Structure

Controller Manual 7.32


PARTS MANUAL
EG SERIES

ELECTRIC POWERED SCREW AIR COMPRESSOR


EG 22P - EG 45
8.0 Air inlet and control system
[ Ref : 015317512—X017195 ] EG 22P - EG 45

Parts Manual 8.2


8.0 Air inlet and control system
[ Ref : 015317512—X017195 ] EG 22P - EG 45

Sl.
Description Qty. Part Number
No.

1 INTAKE VALVE 1 A970012

2 RUBBER ELBOW 1 015318798

3 CLOG INDICATOR 1 B012400770001

ERMETO 1/8" - 1/8" STRAIGHT


4 1 020403100
ADAPTOR

5 SS WORM CLAMP 2 B005000530005

1/8 BSP BONDED SEAL


6 2 000959381
WASHER

7 BDV HOSE 1 015320086

8 AIR FILTER 1 B004700770039

9 PUNCHED WASHER M16 4 000996061

10 HEX BOLT M16X35 4 000906213

11 SPRING WASHER REC SEC M16 4 000996116

12 ELBOW 1/2" X 3/8" 1 B010506720015

13 CONNECTOR 1/2" X 1/2" 1 B010506720014

14 SUCTION DUCT 1 015318344

15 HEX BOLT M8 X 25 4 000906116

16 SPRING WASHER REC SEC M8 4 000996108

17 PLAIN WASHER M8 4 000996008

1/2 BSP BONDED SEAL


18 1 000959387
WASHER

19 PRE FILTER 1 015400889

20 WING NUT 1 -

Parts Manual 8.3


9.0 Drive system
[ Ref : 015319304-X017686] EG 37

Parts Manual 9.1


9.0 Drive system
[ Ref : 015319304-X017686]

S.
Description Qty. Part number
No

1 MOTOR 1 B005106400028

2 ADAPTOR RING 1 015306748

3 DRIVE COUPLING 1 B005405550050

4 AVM 6 B001406190007

5 HEX BOLT M12X75 4 000906192

6 SPRING WASHER REC SEC M12 6 000996112

7 PLAIN WASHER M12 6 000996012

8 HEX BOLT M12X35 2 000906184

9 PUNCHED WASHER M10 12 000996059

10 SPRING WASHER REC SEC M10 24 000996110

11 HEX BOLT M10X25 12 000906144

12 HEX BOLT M10X45 12 000906148

13 HEX NUT M10 12 000948010

14 AIREND MOUNTING BRACKET 1 015304359

15 HEX BOLT M20 X 65 4 000906246

16 SPRING WASHER REC SEC M20 4 000996120

17 HEX NUT M20 4 000948020

18 BUSH MOTOR MOUNTING 4 015402753

19 SPRING WASHER REC SEC M16 2 000996116

20 HEX BOLT M16X30 2 000906212

21 PUNCHED WASHER M16 2 000996061

22 AIREND ASSEMBLY - 150 psi 1 X990703

AIREND ASSEMBLY - 175 psi 1 X990704

23 MOTOR DUCT 1 015315971

24 HEX BOLT M8 X 16 4 000906113

25 PLAIN WASHER M8 ZYP 4 000996008

26 SPRING WASHER REC SEC M8 4 000996108

27 AXIAL FAN 1 B005100950131

28 FAN GRILL 1 018362844

29 PUNCHED WASHER M5 4 000996056

30 SPRING WASHER REC SEC M5 4 000996105

SOCKET HEAD CAP SCREW M5


31 4 000983058
X 90

32 DUCT WIRE GUIDE 1 015318364

33 HEX BOLT M6 X 20 4 000906086

34 SPRING WASHER REC SEC M6 4 000996106

35 PUNCHED WASHER M6 4 000996057

Parts Manual 9.2


9.0 Drive system
[ Ref : 015319304-X017686] EG 37

Parts Manual 9.3


9.0 Drive system
[ Ref : 015319304-X017686]

S.
Description Qty. Part number
No

1 MOTOR 1 B005106400028

2 ADAPTOR RING 1 015306748

3 DRIVE COUPLING 1 B005405550050

4 AVM 6 B001406190007

5 HEX BOLT M12X75 4 000906192

6 SPRING WASHER REC SEC M12 6 000996112

7 PLAIN WASHER M12 6 000996012

8 HEX BOLT M12X35 2 000906184

9 PUNCHED WASHER M10 12 000996059

10 SPRING WASHER REC SEC M10 24 000996110

11 HEX BOLT M10X25 12 000906144

12 HEX BOLT M10X45 12 000906148

13 HEX NUT M10 12 000948010

14 AIREND MOUNTING BRACKET 1 015304359

15 HEX BOLT M20 X 65 4 000906246

16 SPRING WASHER REC SEC M20 4 000996120

17 HEX NUT M20 4 000948020

18 BUSH MOTOR MOUNTING 4 015402753

19 SPRING WASHER REC SEC M16 2 000996116

20 HEX BOLT M16X30 2 000906212

21 PUNCHED WASHER M16 2 000996061

22 AIREND ASSEMBLY - 150 psi 1 X990703

AIREND ASSEMBLY - 175 psi 1 X990704

23 MOTOR DUCT 1 015315971

24 HEX BOLT M8 X 16 4 000906113

25 PLAIN WASHER M8 ZYP 4 000996008

26 SPRING WASHER REC SEC M8 4 000996108

27 AXIAL FAN 1 B005100950131

28 FAN GRILL 1 018362844

29 PUNCHED WASHER M5 4 000996056

30 SPRING WASHER REC SEC M5 4 000996105

SOCKET HEAD CAP SCREW M5


31 4 000983058
X 90

32 DUCT WIRE GUIDE 1 015318364

33 HEX BOLT M6 X 20 4 000906086

34 SPRING WASHER REC SEC M6 4 000996106

35 PUNCHED WASHER M6 4 000996057

Parts Manual 9.4


10.0 Discharge system
[ Ref : 015322522—X018619 ]

Parts Manual 10.1


10.0 Discharge system
[ Ref : 015322525—X018619]

Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.

1 AVM 3 B001401300003 36 ELBOW G 1/8” ORIFICE DIA 1.5 1 B010506780015

2 MPV 1 970300230 37 HEX NUT M12 2 000948012

3 MPV TO COOLER HOSE ASSY 1 015321139 38 1/4 BSP BONDED WASHER 3 000959385

4 SCAVENGING LINE 1 015321140 39 PLUG G 1/4 2 020498750

5 1/4"STRAINER ASSEMBLY 1 B008806100002 40 O-RING 1 035400187

6 AIR OUTLET PIPE 1 015317420 41 PUNCHED WASHER M10 2 000996059

7 OIL FILL PLUG - 1INCH BSP 1 015402651 42 TUBINGS 6mm 2.4 m 000920620

8 1” BSP BONDED SEAL WASHER 1 000959439 43 CLOSURE PLUG G1/8 1 B010506360009

9 BULK HEAD CONNECTOR 2 B010500170002 44 RETURN LINE TUBE 1 015321124

10 O RING 3 015400891 45 PULSE LINE TUBE 1 015321124

11 RUBBER COVER 1 015317433 46 1/4X1/8 BSP HEX REDUCER 1 B009606780003

12 CONNECTOR-MOS OUT 2 015305936 47 NYLON TUBE 12 X 10 mm 1.3 m B010301610005

13 QUICK FITTINGS ELBOW1/2BSP 1 000920612 48 O-RING 1 015402871

14 QUICK FITTINGS CONN 1/2BSP 2 000920512 49 NRV- 1/8" 1 B004100170001

15 O RING 2 010453920 50 HEX BOLT M8 X 25 2 000906116

16 PIPE COUPLING 2 IN STY12 1 B005602930001 51 SPRING WASHER M8 2 000996108

17 BALL VALVE ASSY 3/4" BSP 1 011409580 52 PLAIN WASHER M8 2 000996008

18 OIL DRAIN PLUG - 3/4" 1 015402654 53 ST.ELBOW 1/4 BSP X 6 mm 1 B009606780010

19 LOCK NUT 3/4 INCH 1 020499840 54 HEX NUT M10 2 000948010

20 WATER SEPARATOR 1 B000306040012 55 ST FITTING 1/8 TO 6mm OD 1 000959913

21 1 1/2 BSP BONDED WASHER 3 000959391 56 DISCHARGE PIPE ASSY 1 015320747

ADJUSTABLE ELBOW
22 1 B010506780014 57 RECEIVER TANK 1 015318382
1/4”G-1/4”G

23 ELEMENT SEPARATOR 1 B006700770013 58 QUICK FITTING ELBOW 1/8 1 B010500170001

24 SAFETY VALVE 1 B012805340028 59 DISCHARGE FLANGE ASSY 1 015320671

25 3/4BSP BONDED SEAL WASHER 3 000959438 60 WASHER 4 015404366

26 HEX BOLT M12 X 25 5 000906182 61 1/4” BSP X 6mm ST. FITTING 1 B009606780009

1/4" MALE X 1/4" FEMALE BALL


27 SPRING WASHER REC SEC M12 21 000996112 62 1 B003105390005
VALVE

28 HEX BOLT M12 X 35 10 000906184 63 TUBINGS 6mm BLUE 1.35m 000919226

29 HEX BOLT M10 X 25 2 000906144 64 CONNECTOR 1 1/2 BSP 1 015309867

30 SPRING WASHER REC SEC M10 2 000996110

31 PLAIN WASHER M12 3 000996012

32 OIL FLOAT GUAGE 1 B010706790001

33 REDUCER 1-1/2 BSP -3/4 BSP 1 035400662

34 O-RING 1 220412320

35 HEX BOLT M12 x 50 6 000906187

Parts Manual 10.2


10.0 Discharge system
[ Ref : 015322525—X018619 ]

Parts Manual 10.3


10.0 Discharge system
[ Ref : 015322525—X018619 ]

Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.

1 AVM 3 B001401300003 36 ELBOW G 1/8” ORIFICE DIA 1.5 1 B010506780015

2 MPV 1 970300230 37 HEX NUT M12 2 000948012

3 MPV TO COOLER HOSE ASSY 1 015321139 38 1/4 BSP BONDED WASHER 3 000959385

4 SCAVENGING LINE 1 015321140 39 PLUG G 1/4 2 020498750

5 1/4"STRAINER ASSEMBLY 1 B008806100002 40 O-RING 1 035400187

6 AIR OUTLET PIPE 1 015317420 41 PUNCHED WASHER M10 2 000996059

7 OIL FILL PLUG - 1INCH BSP 1 015402651 42 TUBINGS 6mm 2.4 m 000920620

8 1” BSP BONDED SEAL WASHER 1 000959439 43 CLOSURE PLUG G1/8 1 B010506360009

9 BULK HEAD CONNECTOR 2 B010500170002 44 RETURN LINE TUBE 1 015321124

10 O RING 3 015400891 45 PULSE LINE TUBE 1 015321124

11 RUBBER COVER 1 015317433 46 1/4X1/8 BSP HEX REDUCER 1 B009606780003

12 CONNECTOR-MOS OUT 2 015305936 47 NYLON TUBE 12 X 10 mm 1.3 m B010301610005

13 QUICK FITTINGS ELBOW1/2BSP 1 000920612 48 O-RING 1 015402871

14 QUICK FITTINGS CONN 1/2BSP 2 000920512 49 NRV- 1/8" 1 B004100170001

15 O RING 2 010453920 50 HEX BOLT M8 X 25 2 000906116

16 PIPE COUPLING 2 IN STY12 1 B005602930001 51 SPRING WASHER M8 2 000996108

17 BALL VALVE ASSY 3/4" BSP 1 011409580 52 PLAIN WASHER M8 2 000996008

18 OIL DRAIN PLUG - 3/4" 1 015402654 53 ST.ELBOW 1/4 BSP X 6 mm 1 B009606780010

19 LOCK NUT 3/4 INCH 1 020499840 54 HEX NUT M10 2 000948010

20 WATER SEPARATOR 1 B000306040012 55 ST FITTING 1/8 TO 6mm OD 1 000959913

21 1 1/2 BSP BONDED WASHER 3 000959391 56 DISCHARGE PIPE ASSY 1 015320747

ADJUSTABLE ELBOW
22 1 B010506780014 57 RECEIVER TANK 1 015318382
1/4”G-1/4”G

23 ELEMENT SEPARATOR 1 B006700770013 58 QUICK FITTING ELBOW 1/8 1 B010500170001

24 SAFETY VALVE 1 B012805340028 59 DISCHARGE FLANGE ASSY 1 015320671

25 3/4BSP BONDED SEAL WASHER 3 000959438 60 WASHER 4 015404366

26 HEX BOLT M12 X 25 5 000906182 61 1/4” BSP X 6mm ST. FITTING 1 B009606780009

1/4" MALE X 1/4" FEMALE BALL


27 SPRING WASHER REC SEC M12 21 000996112 62 1 B003105390005
VALVE

28 HEX BOLT M12 X 35 10 000906184 63 TUBINGS 6mm BLUE 1.35m 000919226

29 HEX BOLT M10 X 25 2 000906144 64 CONNECTOR 1 1/2 BSP 1 015309867

30 SPRING WASHER REC SEC M10 2 000996110

31 PLAIN WASHER M12 3 000996012

32 OIL FLOAT GUAGE 1 B010706790001

33 REDUCER 1-1/2 BSP -3/4 BSP 1 035400662

34 O-RING 1 220412320

35 HEX BOLT M12 x 50 6 000906187

Parts Manual 10.4


11.0 Cooling system
[ Ref : 015317505—X017193 ] EG 37 - EG 45

Parts Manual 11.1


11.0 Cooling system
[ Ref : 015317505—X017193 ] EG 37 - EG 45

Sl.
Description Qty. Part Number
No.

1 SHROUD ASSEMBLY 1 015317478

2 OIL AND AFTER COOLER 1 015317465

3 AXIAL FAN Ø560 PUSHER 1 018400046

4 HEX BOLT M8x25 18 000906116

5 SPRING WASHER REC SEC M8 18 000996108

6 PLAIN WASHER M8 14 000996008

Parts Manual 11.2


12.0 Lubrication system
[ Ref : 015317625-X017232]

Parts Manual 12.1


12.0 Lubrication system
[ Ref : 015317625-X017232]

S.N
Description Qty Part number
o

1 FLANGE ASSY-OIL INJ 1 015316015

2 O RING ID 32.9 X 3.5 7 015402685

3 OIL FILTER ELEMENT 1 X017485

4 TANK TO TVB PIPE ASSY 1 015320085

5 NC THERMAL VALVE BLOCK 1 015318384

6 OIL COOLER OUT TO TVB IN 1 015321123

7 TVB TO OIL COOLER IN 1 015317427

8 CIRCLIP INTERNAL B37 1 000917237

9 THERMOSTATIC VALVE PLUG 1 015403622

10 TVB TO A/E INJECTION HOSE 1 015320673

11 THERMAL ELEMENT 65 Deg 1 B008706030003

12 PISTON 1 015403621

13 SPRING THERMAL 1 015401073

14 O RING ID 27.6 X 2.4 1 015400890

15 PUNCHED WASHER M8 4 000996058

16 HEX BOLT M8 X 35 12 000906118

17 SPRING WASHER M8 16 000996108

18 1/4" PLUG 1 020498750

19 O RING ID 37.69 X 3.53 1 015402283

20 O RING ID 19.18 2.46 1 015402046

21 HEX BOLT M8 X 30 4 000906117

1/4 BSP BONDED SEAL


22 1 000959385
WASHER

1/2 BSP BONDED SEAL


23 4 000959387
WASHER

24 G1/2-G1/2 HOSE CONNECTOR 3 015402065

G 1/2 STRAIGHT SWIVEL


25 1 B010506360042
ADAPTER

26 SOLENOID VALVE 1 B007306590004

27 OIL BYPASS HOSE 1 015404075

28 OIL SAMPLING VALVE 1 B013206660001

Parts Manual 12.2


13.0 Base & canopy system
[ Ref : 015318414—X017456] EG 22P - EG 45

Parts Manual 13.1


13.0 Base & canopy system
[ Ref : 015318414—X017456] EG 22P - EG 45

Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.

1 BASE ASSEMBLY 1 015317481 38 SPRING WASHER M10 8 000996110

2 DISCHARGE PILLAR ASSY 1 015317436 39 PLASTIC PLUG - M8 10 -

3 PILLAR ASSY-COOLER SIDE LH 1 015317437 40 SPRING WASHER M8 12 000996108

4 PILLAR - SERVICE DOOR ASSY 1 015317438 41 QUICK FITTINGS 1/2” BSP-12 2 000920512

5 PILLAR FRONT PANEL 1 015317439 42 GROMMET ID -31 MM 2 01531068D

6 CONTROL PANEL ASSY 1 015317440 43 PREFILTER 1 015400889

7 SIDE PANEL ASSY - LH 1 015318375 44 VFD MOUNTING BRACKET 1 015312240

8 SIDE PANEL ASSY - RH 1 015317442 45 CONNECTING MEMBER - REAR 1 015319614

9 DOOR ASSY - SERVICE SIDE 1 015317443 46 SOCKET HEAD SCREW M8 X 16 4 000906113

10 DOOR ASSY - CONTROL PANEL 1 015317444 47 PLASTIC BUSH 4 015403244

11 PANEL FRONT 1 015317445 48 PREFILTER MESH - LH 1 015320855

12 PANEL ROOF ASSEMBLY 1 015317446 49 PREFILTER MESH - REAR 2 015320856

13 SUPPORT MEMBER-DISCHARGE 1 015317447

14 SUPPORT MEMBER- SERVICE 1 015317448

15 REAR PANEL ASSEMBLY 1 015317449

16 CONNECTING MEMBER 1 015317454

17 SHROUD LEG 2 015317455

18 LOCK 12 B15204790005

19 GUIDE PIN 6 015404034

20 HEX BOLT M8 X 20 34 000906115

21 KEY HOLDER 1 015403237

22 SLOTTED CHEESE SCREW - 1 000983485

23 HINGE MALE 6 B015104790001

24 SOCKET HEAD SCREW M8 X 50 10 000983089

25 PUNCHED WASHER M8 26 000996058

26 PLAIN WASHER M10 8 000996010

27 SOCKET HEAD SCREW M8 X 16 4 000906113

28 HEX BOLT M10 X 25 8 000906144

29 COUNTER SUNK SCREW M6X16 12 -

30 PAN HEAD SCREW M6 X 16 12 -

31 HINGE FEMALE 6 B015104790001

32 HEX NUT M6 12 000948007

33 CONNECTOR ASSEMBLY 1 015312759

34 CABLE GLAND 13 008985060

35 PLAIN WASHER M8 4 000996008

36 CONNECTING MEMBER - DRIER 1 015318362

37 CATRIDGE - PRE FILTER 1 015314902

Parts Manual 13.2


13.0 Base & canopy system
[ Ref : 015318414—X017456] EG 22P - EG 45

Parts Manual 13.3


13.0 Base & canopy system
[ Ref : 015318414—X017456] EG 22P - EG 45

Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.

1 BASE ASSEMBLY 1 015317481 38 SPRING WASHER M10 8 000996110

2 DISCHARGE PILLAR ASSY 1 015317436 39 PLASTIC PLUG - M8 10 -

3 PILLAR ASSY-COOLER SIDE LH 1 015317437 40 SPRING WASHER M8 12 000996108

4 PILLAR - SERVICE DOOR ASSY 1 015317438 41 QUICK FITTINGS 1/2” BSP-12 2 000920512

5 PILLAR FRONT PANEL 1 015317439 42 GROMMET ID -31 MM 2 01531068D

6 CONTROL PANEL ASSY 1 015317440 43 PREFILTER 1 015400889

7 SIDE PANEL ASSY - LH 1 015318375 44 VFD MOUNTING BRACKET 1 015312240

8 SIDE PANEL ASSY - RH 1 015317442 45 CONNECTING MEMBER - REAR 1 015319614

9 DOOR ASSY - SERVICE SIDE 1 015317443 46 SOCKET HEAD SCREW M8 X 16 4 000906113

10 DOOR ASSY - CONTROL PANEL 1 015317444 47 PLASTIC BUSH 4 015403244

11 PANEL FRONT 1 015317445 48 PREFILTER MESH - LH 1 015320855

12 PANEL ROOF ASSEMBLY 1 015317446 49 PREFILTER MESH - REAR 2 015320856

13 SUPPORT MEMBER-DISCHARGE 1 015317447

14 SUPPORT MEMBER- SERVICE 1 015317448

15 REAR PANEL ASSEMBLY 1 015317449

16 CONNECTING MEMBER 1 015317454

17 SHROUD LEG 2 015317455

18 LOCK 12 B15204790005

19 GUIDE PIN 6 015404034

20 HEX BOLT M8 X 20 34 000906115

21 KEY HOLDER 1 015403237

22 SLOTTED CHEESE SCREW - 1 000983485

23 HINGE MALE 6 B015104790001

24 SOCKET HEAD SCREW M8 X 50 10 000983089

25 PUNCHED WASHER M8 26 000996058

26 PLAIN WASHER M10 8 000996010

27 SOCKET HEAD SCREW M8 X 16 4 000906113

28 HEX BOLT M10 X 25 8 000906144

29 COUNTER SUNK SCREW M6X16 12 -

30 PAN HEAD SCREW M6 X 16 12 -

31 HINGE FEMALE 6 B015104790001

32 HEX NUT M6 12 000948007

33 CONNECTOR ASSEMBLY 1 015312759

34 CABLE GLAND 13 008985060

35 PLAIN WASHER M8 4 000996008

36 CONNECTING MEMBER - DRIER 1 015318362

37 CATRIDGE - PRE FILTER 1 015314902

Parts Manual 13.4


RECOMMENDED SPARES
A) PERIODIC MAINTENANCE KITS
1) Consumables Kit upto 8000 Hours - 012484839*
S. No Description Part Number Qty.

1 Air filter element B004700770039 2


2 Oil filter element X017485 2
3 Air oil separator B006700770013 1
4 Suction Prefilter 015400889 2

* Consists of all consumables required upto 8000 hours of operation


2) Lubricant - ELGi Air Lube Synthetic
S. No Description Part Number

1 ELGi Air Lube UT Synthetic 5 litres (1.3 gallons) 000998092


2 ELGi Air Lube UT Synthetic 20 litres (5.3 gallons) 000998090
3 ELGi Air Lube UT Synthetic 208 litres (55 gallons) 000998093

3) Lubricant - ELGi Air Lube FG


S. No Description Part Number

1 ELGi Air Lube FG 5 litres (1.3 gallons) 000998077

2 ELGi Air Lube FG 20 litres (5.3 gallons) 000998078

3 ELGi Air Lube FG 210 litres (55 gallons) 000998079

4) Valve Kit (C version) - 012485149


S. No Description Part Number Qty.
1 Intake valve EIV 159 KIT 972300090 1

2 Minimum Pressure Valve Kit 972400030 1

3 Blow down valve assembly 972300030 1

4 Solenoid Valve NC,24V,50HZ/60Hz B007300990017 1


5 Auto drain valve F3 B000306040013 1

6 Actuator kit 972300070 1

5) Valve Kit (CV version) - 012486809

S. No Description Part Number Qty.

1 Intake valve EIV 159 KIT 972300090 1

2 Minimum Pressure Valve Kit 972400030 1

3 Blow down valve assembly 972300030 1

4 Solenoid Valve NC,24V,50HZ/60Hz B007300990017 1

5 Auto drain valve F3 B000306040013 1

6 Actuator kit 972300070 1

7 Solenoid valve (for 20% turndown) B007306590004 1

Kit Details 14.1


6) Blow down adjustment kit EIV 159 - 972300100
S. No Description Part Number Qty.

1 Tamper cap MPV 970300510 1

2 Hex socket grub screw - M10 970400160 1


3 Hex nut M10 000948013 1

7) Tube and Fittings kit- 012484879

S. No Description Part Number Qty.

1 Quick fitting elbow 1/8" - 6mm OD B010500170001 1

2 Quick fitting conn 1/4 BSP-6 000920504 1

3 Tubings 6mm 000920620 1.85 m

4 Quick fitting elbow 1/2 BSP-12 000920612 1

5 Nylon tube 12X10 mm blue B010301610005 1.3 m

6 Quick fittings conn 1/2 BSP-12 000920512 2

7 Flow control valve B013406760001 1

8 QF elbow 1/4 BSP - dia 6 000920624 1

9 Quick fittings conn 3/8 BSP-10 000920509 1

10 Quick fittings elbow 3/8 BSP-10 000920609 1

11 Tubings 10 mm 000919244 0.5 m

8) Drive Coupling Element


S. No Description Part Number Qty.

1 Drive coupling element - EG 22P, EG 26, EG 30 & EG 37 B011201170002 1

2 Drive coupling element - EG 45 B011200830003 1

9) Safety Valve
S. No Description Part Number Qty.
1 Safety valve B012805340028 1

10) Anti Vibration Mount

S. No Description Part Number Qty.

1 Anti vibration mount B001406190007 6

11) Thermal Valve Kit - 012484859 (C & CV Version)

S. No Description Part Number Qty.


1 Spring thermal 015401073 1
2 Thermal element 65 Deg B008706030003 1
3 O-Ring ID 27.6 x 2.4 015400890 1
4 Circlip internal 000917237 1

Kit Details 14.2


B) OTHER MAINTENANCE KITS
O-Ring Kit - 012484899 (C & CV)
S. No Description Part Number Qty.
1 O-Ring ID190 x 3.55 970400010 1
2 1/8 BSP bonded seal washer 000959381 5
3 1/4 BSP bonded seal washer 000959385 6
4 1/2 BSP bonded seal washer 000959387 8

5 3/4BSP bonded seal washer 000959438 3


6 1 BSP bonded seal washer 000959439 1
7 1 1/2 BSP bonded seal washer 000959391 3
8 O-Ring ID69.4 x 3.5 010453920 2
9 O-Ring ID30.0 x 2.6 220412320 1

10 O-Ring ID56.7 x 3.5 035400187 1


11 O-Ring ID47.2 x 3.5 015400891 3
12 O-Ring ID27.6 x 2.4 015400890 1
13 O-Ring ID37.7 x 3.5 015402283 1
14 O-Ring ID32.9 x 3.5 015402685 9
15 O-Ring ID19.2 x 2.5 015402046 1
16 O-Ring ID80 x 3.0 015402871 1

C) SS tube and fittings kit - 012485889 - C Version

S. No Description Part Number Qty.

1 Return line tube (OD 6 X ID 4) 015321124 1

2 ST fitting 1/8 to 6mm OD 000959913 1

3 Adjustable Elbow 1/8’’G B010506780015 1

D) SS tube and fittings kit - 012486149 - CV Version

S. No Description Part Number Qty.


1 Return line tube (OD 6 X ID 4) 015321484 1
2 ST fitting 1/8 to 6mm OD 000959913 3
3 Adjustable Elbow 1/8’’G B010506780015 1

Kit Details 14.3


E) HOSE KITS

S. No Description Part Number S. No Description Part Number Qty.


1.1 MPV to Cooler hose assy 015321139 1
MPV to cooler
1 012485889 1.2 O-Ring (Cooler side) 015400891 1
hose kit
1.3 O-Ring (MPV side) 035400187 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

TVB to airend 4.1 TVB to Airend Hose assy 015321121 1


4 012485909
hose kit - C 4.2 O-Ring 015402685 2
5.1 TVB to Airend hose assy 015320673 1
TVB to airend
5 012485459 5.2 O-Ring 015402685 2
hose kit - CV
5.3 Bypass Hose 015404075 1

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

4 Oil cooler EG 37 - 45 015317466 1

5 Clip on gasket 1* 015311825 1.2m

6 Clip on gasket 2* 010491260 0.7m

7 Sealing strip* 41041X223 1.2m

8 Pre Filter -SS wire mesh –Motor 015320855 1

9 Pre Filter -SS wire mesh –Cooler 015320856 2

Kit Details 14.4


VFD RETROFITMENT KITS ***
1) VFD retro kit C TO CV 26 & 30 kW - 012485159

S. No Description Part Number Qty.

1 VFD 30kW B012000510050 1


2 VFD Mounting plate 015312240 1

3 Hex bolt M8 X 20 000906115 8


4 Punched washer M8 000996108 8

5 Spring washer M8 000996008 8

6 Control harness EG 22-30 CV 018363876 1

7 Control panel EG 45 CV 460V 60HZ NIII 018363655 1


8 Caution sticker F3-F4 VFD 018362571 1
9 Field sticker- EG 30 460V 60HZ-CV 445400151 1

10 Fuse sticker EG 30-45 CV NIII 445400720 1


11 Hose gland PG36-UL 018900038 1

2) VFD retro kit C TO CV 37 kW - 012485209


S. No Description Part Number Qty.

1 VFD 37kW B012000510051 1

2 VFD Mounting plate 015312240 1

3 Hex bolt M8 X 20 000906115 8

4 Punched washer M8 000996108 8

5 Spring washer M8 000996008 8

6 Control panel EG 45 CV 460V 60HZ NIII 018363655 1

7 Caution sticker F3-F4 VFD 018362571 1

8 Field sticker- EG 37 460V 60HZ-CV 445400147 1

9 Fuse sticker EG 30-45 CV NIII 445400720 1

10 Hose gland PG36-UL 018900038 1

3) VFD retro kit C TO CV 45 kW - 012485219

S. No Description Part Number Qty.

1 VFD 45kW B012000510048 1

2 VFD Mounting plate 015312240 1

3 Hex bolt M8X 20 000906115 8

4 Punched washer M8 000996108 8

5 Spring washer M8 000996008 8

6 Control panel EG 45 CV 460V 60HZ NIII 018363655 1

7 Caution sticker F3-F4 VFD 018362571 1

8 Field sticker- EG 45 460V 60HZ-CV 445400111 1

9 Fuse sticker EG 30-45 CV NIII 445400720 1

*** VFD Retro fitment kit is applicable for US/CANADA variant only

Kit Details 14.5


Insurance kit details

Models

EG 26 &
EG 22P EG 45
Insurance kit details EG 30 EG 37 (C)
(C) (C)
( C)

Kit No

S.No Description Part Number 012484939 012484949 012484969 012484959

1 Intake valve kit, 972300090    


2 Blowdown valve kit 972300030    
3 Actuator kit 972300070    
4 MPV kit 972400030    
Drive coupling element - 22, 26, 30
5
& 37kW
B011201170002    -
6 Drive coupling element - 45kW B011200830003 - - - 
7 Solenoid valve ( 24V) - Intake valve B007300990017    
8 Auto drain valve - F3 B000306040013    
9 Separator element gasket B013604620001    
10 Shaft seal 013436254    
11 Inner Ring 013436256    
12 Spacer - Inner ring 013436255    
13 Oil level float glass B010706790001    
14 O -rings kit - C & CV 012484899    
15 Tube and fittings kit 012484879    
16 Temperature sensor 018400077    
17 Pressure sensor 00897902N    
Pipe coupling element - 2"(Rubber
18
Gasket)
B005604150001    
19 Thermal valve kit - C 012484859    
20 Thermal valve kit - CV 012484919 - - - -

Calibration must be carried out if any sensors are replaced. For doing so please contact ELGi dealer/Service engineer
C - Standard, CV - Standard + VFD

Kit Details 14.6


Models

EG 26 &
EG 37
Insurance kit details EG 30 EG 45 ( CV)
( CV)
( CV )

Kit No
S.No Description Part Number 012485009 012484999 012485019

1 Intake valve kit, 972300090   


2 Blowdown valve kit 972300030   
3 Actuator kit 972300070   
4 MPV kit 972400030   
Drive coupling element - 22, 26, 30
5
& 37kW
B011201170002   -
6 Drive coupling element - 45kW B011200830003 - - 
7 Solenoid valve ( 24V) - Intake valve B007300990017   
8 Auto drain valve - F3 B000306040013   
9 Separator element gasket B013604620001   
10 Shaft seal 013436254   
11 Inner Ring 013436256   
12 Spacer - Inner ring 013436255   
13 Oil level float glass B010706790001   
14 O -rings kit - C & CV 012484899   
15 Tube and fittings kit 012484879   
16 Temperature sensor 018400077   
17 Pressure sensor 00897902N   
Pipe coupling element - 2"(Rubber
18
Gasket)
B005604150001   
19 Thermal valve kit - C 012484859 - - -
20 Thermal valve kit - CV 012484919   

Calibration must be carried out if any sensors are replaced. For doing so please contact ELGi dealer/Service engineer
C - Standard, CV - Standard + VFD

Kit Details 14.7


CNTRL PANEL EG26-EG45
(POWER CIRCUIT)

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

X07 X06 X05


X04 RS 485 RS 485

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

CNTRL PANEL EG26-EG45


(CONTROL CIRCUIT)

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

CNTRL PANEL EG26-EG45


(PANEL LAY OUT)

01 83 6365 5
4 4
16.0 VFD setting procedure

Brief introduction to VFD in the global Software details (programming details)

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.

1. 3 Phase connection to VFD

The input side phase sequence is critical for the fan


direction of rotation. During installation, the fan direction
needs to be checked and, if required, change the phase
sequence. However, the motor phase sequence is
controlled by VFD.

2. Motor connection

It is wired for the required phase sequence with respect to


your compressor requirements. Do not change the
configuration.

3. Start command to VFD

The Start/Stop command that flows to the VFD from the


controller rotates/stops the main motor.

4. Run feedback signal


in VFD, all settings are pre–programmed, so you need not
After reaching 40% of speed, VFD sends a run feedback
change any of the settings. During operation, you can
signal to the controller to switch on the solenoid valve to
change the load pressure set point according to your
the start loading process.
requirements. .
5. Trip command from VFD
The following parameters are important for the
During any abnormalities in the VFD drive, a trip signal correct drive operation
flows to the controller to stop the compressor. (To
 Right analog output feedback from the controller to
troubleshoot, refer to the VFD manual.)
VFD. (1V corresponds to AO scaling low reference and
6. Pressure feedback signal 5V corresponds to AO scaling high reference.)
The delivery pressure feedback signal propagates from the  The AO high and low reference scaling settings are
controller (analogue output CH1) to VFD to control motor configured in the factory setting menu in the Neuron II
speed. The feedback is an analogue voltage signal with a controller. You can view these parameters in the NII
range 1-5 V. controller. The corresponding low ref and high ref
7. RS485 communication settings must be verified in drive parameters 614 and
615, respectively.
An RS485 communication medium occurs between the
VFD and controller to read/write parameters such as  Ensure the dip switch in VFD (right behind the display)
voltage, current, power, frequency, and the analog scale is set in voltage mode.
setting.  Enter motor nameplate details in VSD settings (such as
All the above connections are factory wired and you only voltage, current (I max value-SF current), power,
need to connect the incoming supply to the compressor frequency, and RPM).
with the right wire size and incoming protection fuse (as  You need to adjust PI parameters at your site for
per the compressor manual). effective tuning to ensure smooth speed control to meet
your exact requirements.
NOTE
 You can edit the parameters 614 and 615 in the VFD
Ensure the dip switch in VFD (right behind the display) is
set in voltage mode. through the controller. Ensure this value matches the

VFD Settings 16.1


AO scaling in the controller. Good practice is to not If pressure reduces and reaches the load point of the
attempt to change these settings on your own. Instead controller, then the compressor starts loading and the
contact ELGi . speed increases from 40% to maintain the set pressure.

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

Fault Description Details to be checked


The PI settings in the controller to be reduced to have the speed respond to
pressure variation.
The compressor does not develop the required pressure (under-rating of the
The motor runs at full speed or
compressor) and always runs at max speed of the motor.
1 low speed (no speed change
Check the controller A/O scaling value (viewed in the operator menu) with respect
with respect to pressure)
to the VFD parameter 614,615.
Ensure unload is enabled in the controller.
Ensure optimum speed setting is enabled.

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.

The compressor minimum and


maximum speed is not as per Check AO scaling values in the controller (operator menu view).
4
minimum and maximum speed Ensure VFD parameters 614 and 615 are the same.
limits set in the controller

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.

VFD Settings 16.2


Fault Description Details to be checked

Check the run feedback signal from VFD.


Compressor does not switch to
6 Verify that the controller issues the load command.
load mode
Ensure that the solenoid valve receives supply and energizes.
Verify if the motor consumes more power than the nameplate value.
Ensure that the VFD parameter is correct.
Compressor trips from VFD and
7 Check the VFD trip history/details of the trip and make the required corrections as
the controller displays VFD fault
per
VFD troubleshooting guidelines.

FAQ What is the significance of max and min speed


settings in the controller?
What is target pressure?
This imposes limitation on Max/Min speed for selected
It is a set load pressure that VFD needs to maintain by compressor models. This limitation will change between
varying compressor motor speed. If demand is low, speed compressor models. This setting must not exceed the AO
reduces and pressure remains constant. If demand scaling range.
continues to be low, pressure increases and reaches load
What is the significance of the optimum speed
pressure
setting in the controller?
 Of 7 psi. When this occurs, the compressor switches to
If the compressor needs to operate in fixed speed, then
unload mode and starts operating at unload speed.
optimum speed must be enabled in the operator setting, If
What is the significance of P&I settings in the optimum speed is enabled, the compressor will operate at
controller? optimum speed during load and at unload speed during
The change in pressure with respect to time is not linear in unload. This feature affords flexibility to customers if the
all the cases, but the rate of change in pressure depends compressed air circuit has more than one VFD machine
on receiver and pipeline capacity of a particular customer. and one machine for speed control. Typically, one machine
The higher the storage capacity, the greater is the time is enough.
available for speed correction and for producing a The optimum speed setting lies between the range of min
response to pressure requirement, and the reverse is also and max speed settings.
true. In such a case, the P & I setting must be adjusted at
What is the significance of the unload speed setting
the site for smooth speed change-over. One-time fine
in the controller?
tuning is required at the site and the settings can be
adjusted through the controller. Unload speed is nothing but the speed at which the
compressor must operate during unload. This setting must
Why must be the direction of rotation verified in VFD
be in the range of min speed and max speed and less than
output?
optimum speed.
VFD output always causes clockwise rotation irrespective
of the input connection to the VFD. In case the compressor
needs to operate counterclockwise, the motor connection
from VFD output must be reversed. (Refer to the circuit
right direction of rotation.)

What is the meaning of main motor overload trip in


the controller?

The VFD trip is connected to the controller for main motor


trip display in the controller. Refer to VFD trip information,
verify the type of trip, and make corrections as per the
manual.

What is the significance of the AO scale setting in


the controller?
AO scaling with respect to 1V corresponds to min speed
and 5V corresponds to max speed. Based on this scaling
range and analogue input reference, VFD calculates the
required speed/frequency at which the compressor motor
must operate. AO scaling values in the controller settings
and in the drive parameters 614 and 615 need to be the
same.

VFD Settings 16.3


Annexure 1
ID Name Setup 1

1 Language English

2 Motor Speed Unit RPM

10 Active Set-up Set-up 1

20 Display Line 1.1 Small Motor Voltage

21 Display Line 1.2 Small Motor current

22 Display Line 1.3 Small Speed [RPM]

23 Display Line 2 Large Analog Input 53

24 Display Line 3 Large Frequency

40 [Hand on] Key on LCP Disabled

41 [Off] Key on LCP Disabled

42 [Auto on] Key on LCP Enabled

43 [Reset] Key on LCP Enabled

100 Configuration Mode Speed open loop

101 Motor Control Principle VVC+

104 Overload Mode Normal torque

106 Clockwise Direction Normal

120 Motor Power [kW] Motor name plate

122 Motor Voltage Motor name plate

123 Motor Frequency Motor name plate

124 Motor Current Motor name plate * SF

125 Motor Nominal Speed Motor name plate

139 Motor Poles Motor name plate

190 Motor Thermal Protection ETR Trip1

191 Motor External Fan Yes

300 Reference Range Min - Max

301 Reference/Feedback Unit RPM

302 Minimum Reference 900

303 Maximum Reference 2400

304 Reference Function Sum

310-[0] Preset Reference 0

313 Reference Site Remote

315 Reference Resource 1 Analog Input 53

316 Reference Resource 2 No Function

317 Reference Resource 3 No Function

340 Ramp 1 Type Linear

341 Ramp 1 Ramp Up Time

342 Ramp 1 Ramp Down Time

VFD Settings 16.4


ID Name Setup 1

410 Motor Speed Direction Clockwise

411 Motor Speed Low Limit [RPM] 900

413 Motor Speed High Limit [RPM] 2400

419 Max Output Frequency 80

512 Terminal 27 Digital Input Coast inverse

540 Relay->Option relay 7-> Function relay Running

540 Relay->Option relay 8-> Function relay Alarm

610 Terminal 53 Low Voltage 1

611 Terminal 53 High Voltage 5

614 Terminal 53 Low Ref./Feedb. Value *** (Edit from NII Controller)

615 Terminal 53 High Ref./Feedb. Value *** (Edit from NII Controller)

830 Protocol Modbus RTU

832 FC Port Baud rate 9600

833 Parity/Stop bits No Parity,1 Stop bit

843-[0] PCD read Configuration (1603) – Status word

844-[1] PCD read Configuration (1605) – Main Actual Value ...

845-[2] PCD read Configuration (1612) – Motor Voltage

846-[3] PCD read Configuration (1613) – Frequency

847-[4] PCD read Configuration (1614) – Motor Current

848-[5] PCD read Configuration (1614) – Motor Current

849-[6] PCD read Configuration (1610) – Power KW

850-[7] PCD read Configuration (1610) – Power KW

851-[8] PCD read Configuration (1502) – Kwh Counter

852-[9] PCD read Configuration (1502) – Kwh Counter

853-[10] PCD read Configuration (1501) – Running Hours

854-[11] PCD read Configuration (1501) – Running Hours

855-[12] PCD read Configuration (1601) – Reference [Unit]

856-[13] PCD read Configuration (1601) – Reference [Unit]

857-[14] PCD read Configuration (1617) – Speed [RPM]

858-[15] PCD read Configuration (1617) – Speed [RPM]

859-[16] PCD read Configuration (1615) – Frequency [%]

NOTE
#Make ramp-up time (341) and ramp-down time (342) settings as follows:

Motor kW Ramp up time Ramp down time

11 KW to 45 KW 25sec 15 sec

55 KW and 75 KW 30 sec 20 sec

160 KW 30 sec 30 sec

VFD Settings 16.5


Compressor controller setting in Operator menu VFD
settings.

Min Default Unit

Optimum speed on/off on/off off -

P-Gain 0 50000 100 -

I-Gain 0 5000 100 -

I-Time 0 200 10 -

Max. speed RPM

Min. speed RPM

Optimum speed RPM


Factory setting can be viewed
UL speed RPM

High (5V) RPM

Low (1V) RPM

This information is for reference only. The settings are all


made at the factory. You need not perform these settings
at your site. However, P, I, and integral time settings need
to be configured during installation.

VFD Settings 16.6


Branch offices

"ELGI HOUSE" 2, Mill Officer's Colony, Behind La-Gajjar Chambers, (Old Reserve Bank), Opp. Times of India, Ashram
AHMEDABAD Road, Ahmedabad - 380 009, Tel: +961-79- 26583736, 26581274, 26587683, Fax: 91-79-6587683,
E-mail: [email protected]

BANGALORE 15,16 Richmond Road, Bangalore - 560 025, Tel: +91-80-22537208, Fax: 91-080-22293274, E-mail: [email protected]

S4-II Floor, Apollo Dubai Plaza, No-100, Mahalingapuram Main Road, Nungambakkam, Chennai - 600 034,
CHENNAI
Tel: +91-44-28172599, 28179500, Fax: 91-44-28174699, E-mail: [email protected]

1st Floor, No.622-A, Near ELGi industrial Complex, Trichy Road, Singanallur, Coimbatore - 641 005,
COIMBATORE
Tel: +91-422-2589555, Fax: 91-422-2573697, E-mail: [email protected]

H.NO: 12-13-188, II nd Floor, Street No. 2, Taranaka, Hyderabad - 500 017,


HYDERABAD
Tel: +91-40-27000435, 27000437, 27000439, 27000431, Fax: 91-40-27000438, E-mail: [email protected]

602, 6th Floor, Diamond Tower, Purani Chungi, Ajmer Road, Jaipur - 302 021,
JAIPUR
Tel: +91-141-2970120, 2970121, E-mail: [email protected]

1st Floor, Asset Summit Suites, National Highway 47, Near SCMS, Kalamassery, Kochi – 683106.
KOCHI
Tel: +91-484 -2360155, 2351904, E-mail: [email protected]

Space No. 502, Block - C, 5th Floor, Axis Mall, Action Area - 1C, New Town, Premises No. CF - 9, Kolkata - 700 156,
KOLKATA
Tel: +91-33-2324-4270, 2324-4271, Fax: 91-33-2324-4272, E-mail: [email protected]

Marol Co-op Industrial Estate Ltd. Plot No.48, Mathurdas Vassanji Road, Near Sakinaka, Andheri (East), Mumbai-400 059,
MUMBAI
Tel: +91-22-42161000, Fax: 91-22-28591601, E-mail: [email protected]

23, Shivaji Marg, Near Karampura, Opp.DCM, New Delhi - 110 015,
NEW DELHI
Tel: +91-11-25928095, 25153644, 25175018, Fax: 91-11-25459375, E-mail: [email protected]

White House, Ground Floor, 388/A-1/2240, Mumbai - Pune Road, Opp. Sandvik(Asia), Dapodi, Pune - 411 012,
PUNE
Tel: +91- 20-30635457, Fax: 91-20-4073759, E-mail: [email protected]

Om1, 1st Floor, Ashoka Milllennium, Ring Road No.1, Raipur - 492 003, Chhattisgargh,
RAIPUR
Tel: +91-97520 93008, Fax: 91-771-4073759, E-mail: [email protected]

4/2, Nandhini Complex, 1st Floor, Velur Road, Tiruchengode - 637 211,
TIRUCHENGODE
Tel: +91-4288-257137, Fax: 91-4288-257693, E-mail: [email protected]

ELGI EQUIPMENTS LIMITED, No. 2A-4-6, Jalan Jubli Perak, 22/1, Section 22, 40400, Shah Alam, Selangor, Malaysia,
MALAYSIA
Tel: +60 355693544 Web: www.elgi.com.my

ELGI EQUIPMENTS LIMITED, 223/66, 14th Floor, Building A, Country Complex, Sanphawut Road, Bang Na, Bangkok,
THAILAND Thailand - 10260, Tel: +6627455160, Local Use: 02-7455160,
E-mail: [email protected], Web: www.elgi.co.th

Overseas offices

ELGI EQUIPMENTS PTY LTD., Unit 1, 33 Kingsbury Street, Brendale Queensland - 4500. Australia,
AUSTRALIA Tel: +61 7 3106 0589, Fax: +61-7 3106 0537, Email: [email protected],
Web: www.elgi.com.au

ELGI COMPRESSORES DO BRASIL LTD, Av. Emílio Chechinatto, 4195 – Bairro São Roque da Chave,
BRAZIL
CEP:13.295-000, Itupeva – São PauloBrasil, Tel: +55-11-4496 5519, 4496 6611, E-mail: [email protected]

ELGI EQUIPMENTS (ZHEJIANG) LIMITED, West of 1st Floor, Building 2, No. 232, Yunhai Road, Jiaxing 314033 P.R. China,
Tel: +86-573-82079100, Hotline: 400-826-3585 E-mail: [email protected], Web: elgi.cn
CHINA
ELGI COMPRESSORS TRADING (SHANGHAI) CO.,LTD. Rm 912-913, No. 8-9, Lane 1500, South Lianhua Road, Shanghai
201108 P.R. China, Tel: +86-21-33581191, Hotline: 400-826-3585, E-mail: [email protected], Web: elgi.cn

PT ELGI EQUIPMENTS INDONESIA, Kawasan Pergudangan, Bizpark Commercial Estate, Pulogadung Jl, Raya Bekai Km.
INDONESIA 21, 5 Block A3 No. 12, Kel. Rawa Terate, Kec. Cakung, Pulogadung Jakarta Timur 13920,
Tel: +62-21- 46822216, 46827388, E mail: [email protected], Web: www.elgi.co.id

ROTAIR Spa, Via Bernezzo-67, 12023, Caraglio (CN), Italy, Tel: +39 0171619676, Fax: +39-0171619677,
ITALY
E-mail: [email protected], Web: www.rotairspa.com

ELGI GULF FZE, PO Box: 120695, P6-27, SAIF Zone, Sharjah, U.A.E. Tel: +971 6 557 9970, +971 50 457 6470,
MIDDLE EAST
Fax: +971 6 557 9980, E-mail: [email protected], Web: www.elgigulf.com

ELGI COMPRESSORS USA, INC. 1500 Suite N Continental Blvd, Charlotte, NC 28273, USA. Tel: +1-704-943-7966,
USA
E-mail: [email protected]
Overseas fellow subsidiaries

FACTORY & REGISTERED OFFICE


ELGI EQUIPMENTS LIMITED
Singanallur, Coimbatore - 641 005,
India (CIN:L29120TZ1960PLC000351).
Tel: +91-422-2589555
Fax: +91-422-2573697, +91-422-2589401
E-mail: [email protected], Web: www.elgi.com
ELGI EQUIPMENTS LIMITED (FOUNDRY DIVISION)
SF No: 212/1A, 213/1, KodangipalayamVillage,
Nallatipalayam Road, Singarampalayam Post, Kinathukkadavu,
Kinathukkadavu Taluk,
Coimbatore - 642 109, India.
Tel : +91-422-2587631, 620
GLOBAL SUPPORT CENTRE
SF NO 221, 221/2 & 221/3, Kothavadi Road,
Kodangipalayam Village, Singarampalayam(PO),
Kinathukkadavu Taluk,
Coimbatore - 642 109, India.
Tel : +91-422-2587000.
ELGI EQUIPMENTS LIMITED (AIR COMPRESSOR PLANT)
SF NO 221/1 to 3 - 229/B1, B2, B3, 232/B1,B2, 234/B1, 264/B1 and 264/B2.
KothavadiRoad, Kodangipalayam Village,
Singarampalayam (PO) Kinathukkadavu
Taluk, Coimbatore - 642 109, India.
Tel : +91-422-2587000.

FELLOW SUBSIDIARIES (DOMESTIC)


ATS ELGI LIMITED,
Kurichy Private Industrial Estate, Kurichy,
Coimbatore - 641 021, India,
Tel: +91-422-2589999, 2672201-3,
Fax: +91-422-2675446,
E-mail: [email protected],
Web: www.ats-elgi.com
ADISONS PRECISION INSTRUMENTS MFG.CO.LIMITED
Elgi Indusrial Complex, Singanallur,
Coimbatore - 641 005
Tel: +91-422-2589555
ERGO DESIGN PVT LTD,
150, 2nd Main, 2nd Cross, Chelekare, Kalyan Nagar,
Bengaluru, Karnataka 560043,
Tel: +91-80-42436000

JOINT VENTURE
ELGI SAUER COMPRESSORS LIMITED,
Elgi Industrial Complex III, Singanallur,
Coimbatore - 641 005, India,
Tel: +91-422-2589555, 2589634, 2589510,
Fax: +91-422-2573697,
E-mail: [email protected], Web: www.elgisauer.com
INDUSTRIAL AIR SOLUTIONS LLP,
1, R R Industrial Estate, Opposite Shanthi Gears Regd Office, Singanallur,
Coimbatore, Tamil Nadu 641005,
Tel: 0422 227 1862.

DIVISION
PRESSURE VESSEL DIVISION
1473 - Trichy Road, Coimbatore - 641 018,
Tel: +91-422-2589777,
Email: [email protected].

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