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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 2.8

2.4.1 Air circuit 2.8
2.4.2 Oil circuit 2.8
2.4.3 Water circuit 2.8
2.4.4 Drive system 2.8
2.4.5 Control system 2.9
2.4.6 Safety devices 2.9
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 oil free screw
compressor. Before starting the compressor, it is
requested that the manual should be read thoroughly. It
contains vital information about installation,
commissioning, operation and useful tips on maintenance
to keep the compressor as good as new, year after year.
The manual has been prepared with utmost care to help
you understand the various systems of the compressor,
along with descriptions, information and illustrations.
Following chapters are provided to operate the compressor

in its best way.
Safety - safety precautions that must be followed while

using the compressor
Functional description - various systems and their

functions, safety devices
NOTE
Technical data - technical details about the
Note clarifies procedures or conditions which may
compressor
otherwise be misinterpreted or overlooked. Note may also
Installation and operation - site requirements, be used to clarify apparently contradictory or confusing
situations
procedures to be followed while installation,
commissioning, preservation and operation
Operating instructions - to operate the compressor Warning calls attention to dangerous or hazardous
conditions inherent to the operation, cleaning and
Maintenance Maintenance intervals and maintenance maintenance of the compressor which may result in fatal
procedures for compressor accident and personal injury of the operator or other
persons.
Troubleshooting probable failure reasons and
remedies
Decommissioning procedures for decommissioning Caution is to draw attention to a procedure which, if not
and disposal done correctly can lead to compressor damage.
ELGi services services from ELGi: CCS, air audit,

spare parts
Appendix conversion tables, torque values, operation

log book, service log book
Refer to the parts manual to identify the part number of

the required spare. Mention the Fab number, model and
part number while ordering.
This manual must be made available to the

compressor operating and maintenance personnel at
all times.
2.1.1 Definitions and symbols

This information is related to your safety and also to prevent
any problems relevant to the equipments used. In order to
understand the content better, the following symbols have
been used.
All the information, illustrations and specifications in this

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

2.2 Introduction
Welcome to ELGi customer family. ELGi compressors are Silent package for in house operations
the source of compressed air in various segments across Isolated cooling system
the globe.
Robust cooling system
ELGi compressors are known for
Industrial designed canopy
Highest reliability
Compact and occupies less space
Lower maintenance interval
Anti - vibration mounts restricts vibration
Ease of use
Increased life of consumables
Highest safety
Zero leak flanged joints
ELGi screw compressor is designed to give
Doors provided for easy serviceability
High energy efficiency
Class 0 - Oil free air
Low maintenance cost
Advanced programmable logic controller (PLC)
High discharge air quality
Globally certified product - CE / UL and other country
All the above assures a low life cycle cost. specific approvals
Uptime
At ELGi, we are changing the way you look at compressed
about delivering uptime. Our uptime design ensures that

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

Your OF series compressor belongs to a family of rotary
screw compressors from ELGi. With in-house oil-free
technology, the compressors are engineered to deliver
maximum uptime and reliability. ELGi's unique eta-V rotor
design reduces pressure losses and increases stage
efficiencies, leading to an optimised compressed air
system. Rotor and housing are coated with
Polytetrafluoroethylene (PTFE) Perfluoroalkoxy alkane
(PFA) based food grade coating to resist corrosion and
endure high temperature.
The screw compressor technology ensures that there is no

reduction in output capacity even after many years of
operation. It involves a continuous flow of air through
helical cavities in the screw and so the compressed air
delivery is pulsation free. The design of OF series gives
you a compact and self contained compressor. Because it
has no reciprocating parts, it runs quietly and free of
vibrations. And it delivers oil free pure air of CLASS ZERO
(as per ISO 8573-1).
Salient Features
High efficiency air filter
Improved air filter life cycle

2.3 Safety
The operator must follow the safe working practices, The position of the operator should not be near the
instructions, procedures given in this manual for safe intake of the compressor.
operation. The maintenance personnel must be adequately Position the discharge pipe to after cooler in such a way
trained, and have read and thoroughly understood this that it is free to expand under heat and that it is not in
contact with or close to flammable materials.
affixed at specific locations of the compressor and they
Do not exert external force on the air outlet valve and
illustrate very important safety precautions.
keep the connected pipe free of strain.
2.3.1 Precautions during installation Adequate cooling air must be made available for the
Ensure that all loose parts are fastened before lifting. compressor particularly air cooled compressors. Make
Select the appropriate lifting equipment by considering sure that exhausted air is not recirculated to the intake
the local safety regulations, size and weight of the system or cooling system.
compressor. Operate the lifting equipment carefully Make the electrical connections according to the legal
within the safe operating limits. Ensure all necessary standards and earth the compressor suitably. Sufficient
personal protective equipment's (PPEs) during this number of fuses and other protective devices must be
operation. provided to protect the compressor against the short
circuits. It is preferred to have an isolating switch
nearby the compressor.
Manual valves after non-return valves (NRV) must be

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

free of flammable fumes, vapors and particles, since it
can lead to internal fire or explosion.
For remotely controlled compressors and auto-start

compressors, they must bear a clear caution stating:
Remotely controlled machine and will
start without notice

Danger! Compressed air used for breathing or food end will whip and may cause injury. Make sure that a
processing must meet O.S.H.A. 1910.134 or F.D.A. 21 hose is fully de-pressurized before disconnecting it.
C.F.R. 178.3570 regulations. Failure to do so may cause
Release all the pressure in the compressor system
severe injury or death.
before servicing or doing any maintenance activity.
Insulate or use protective guards to cover pipes or other
Do not engage in horseplay with air hoses. Serious
parts that may exceed 80ºC (176ºF) in temperature.
injury or death may result.
High-temperature pipes must be clearly marked as
Do not use air at a pressure greater than 2.5 bar.g (36
potentially dangerous.
psi.g) for cleaning purpose.
Compressor should be placed on level ground.
Open the oil fill cap only when the compressor is not
In case of inclined place, contact ELGi.
running and is not pressurized. Shut down the
Do not allow compressed air to come into contact with
compressor and allow it to cool before removing the
food and related items unless it is treated specifically.
cap.
This air compressor is intended to be used for
Fire and explosion
generating compressed air for industrial use only.
2.3.2 Precautions during operations

When switching on remotely controlled compressors
ensure that no one is checking or working on the
compressor at that time.
Before starting, ensure that no tools or any loose parts Clean up spills of lubricants or other combustible
are kept inside the compressor. substances immediately.
Do not operate the compressor if there is a possibility Shut down the compressor and allow it to cool down
that it could inhale flammable or toxic fumes, vapors or before checking or adding oil. Remove sparks, flames
particles. and other sources of ignition away from the

compressor.
Do not operate the compressor below or above its
operating limits. Do not permit smoking in the vicinity of the compressor.
People working in an environment where the sound Do not use flammable solvents for cleaning purposes.
pressure level reaches or exceeds 90 dB (A) must wear Keep electrical wiring and other terminals in good
ear protectors. condition. Replace any wiring that has cracked, cut,
Keep all the compressor doors shut during operation. abraded or otherwise degraded insulation. Keep all
For carrying out routine checks, the doors should be terminals clean and tight.
opened only for short durations not more than 10 Keep grounded conductive objects such as tools away
minutes. Wear ear protectors when opening a door. from exposed live electrical parts like terminals to avoid
Keep hands, feet, floors, controls and walking surfaces arcing, which might serve as a source.
clean and free of water or other liquids to minimize the Keep oily rags, trash, dry leaves, litter or other
possibility of slips and falls. combustibles out of and away from the compressor.
Pressure release Do not operate the compressor without a proper flow of

cooling water/cooling air or with an inadequate flow of
Annual servicing of the safety valve is necessary.
lubricant or with a degraded lubricant.
It should be checked at the prescribed pressure for
operation. Do not attempt to operate the compressor in a
hazardous environment of any classification unless the
Use correct tools for maintenance and repair work.
compressor has been specially designed and
manufactured for explosive applications.
pressure for pipes, valves, filters and other fittings to
exceed. Moving Parts
It is hazardous to point the compressed air directly Rotating fan blades can cause serious injury. Disconnect
towards any personnel. Keep personnel out of the line power supply before attempting service.
of the discharge air when opening hoses or other points
Keep compressor doors closed except when servicing or
of compressed air discharge.
during maintenance. The sound damping material on
Use only the correct type and size of hose end fittings the inner side of the compressor body should not be
and connections. When blowing through a hose or removed or tampered with.
airline ensure that the open end is held securely. A free

In the event of ingestion of oils, coolants or lubricants
used in the compressor, seek medical treatment
promptly. In case you come in contact with such
substances, wash with soap and water. Use MSDS for
oil to know more on this.
If warm cooling air from the compressor is being used

in air heating systems, e.g. to warm up a work room,
take precautions against air pollution and possible
contamination of the breathing air.
Wear snug-fitting clothing and tie long hair when
working around the compressor, especially when hot or Electric shock
moving parts such as the cooler, the airend, the main
motor or the fan motor are exposed.
Keep hands, arms and clothing away from couplings,

fans and other moving parts.
Keep all parts of the body and any hand held 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.
Before switching on the compressor ensure that proper

Do not attempt to operate the compressor without the earthing is done as per recommendation.
fan guards, coupling guards or other guards removed.
Make all adjustments or repairs with one hand. This
Keep hands, feet, floor, controls and walking surfaces minimizes the risk of creating a current path through
clean and free of fluid, water or other liquids to the heart.
minimize the possibility of slips and falls.
Conduct repairs only in a clean, dry, well lit and
Hot surfaces ventilated area.
Do not leave the compressor unattended with open

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

attempting repairs or adjustments, turning the
compressor manually or handling ungrounded
conductors.
All electrical installation must be in accordance with

Avoid bodily contact with hot oil, hot air and hot
recognized electrical codes and any local health & safety
surfaces like cooler, pipes etc.
codes.
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

Always wear safety equipment while operating the
compressor. Refer OSHA safety standards.

Only authorized and qualified trained personnel should
carry out any electrical work on the compressor.
Regularly check that all electrical connections are tight

and in good condition.
Periodically check whether

All guards are in place and securely fastened.
All hoses and pipes inside the compressor are in good

condition, secure and not rubbing against each other.
Open the oil filler cap only when the compressor is not
There are any leaks. running and is not pressurized. Shut down the
All fasteners are tight. compressor and allow the compressor to cool 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.
2.3.3 Precautions during maintenance

Use safety glasses and incorporate safe working
practices before maintenance work.
Use appropriate tools for all maintenance works.
Use only genuine spare parts. Refer the

in chapter.
Persons switching on remotely controlled compressors

must ensure that nobody is checking or working on the
compressor at that time. A warning sign near the
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.
Ensure that the compressor is cooled down before
maintenance is carried out. Display a maintenance chart near the compressor to
easily identify the maintenance intervals of regular
Springs under tension or compression store energy.
service items.
Uncontrolled release of this energy can cause serious
injury or death. Be cautious while carrying out the
maintenance of components loaded with springs (for
example minimum pressure valve, safety etc.).
A warning sign that says

can be displayed near the
start switch.
Isolate the compressor from the air line (discharge) and

disconnect the power by opening and locking the
isolating switch before maintenance.
Prior to attempting repairs or adjustments, disconnect

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

2.4 Functional description
Figure 1. Oil free two stage water cooled compressor
keeps the oil temperature below 55 ºC (131ºF). Then the

2.4.1 Air circuit
oil line splits up into two where one oil line goes to the
The atmospheric air enters into the first stage airend solenoid valve for actuating the capacity control valve
through the air intake system. The intake filter prevents while the other oil line goes to the MPV which maintains
the entry of foreign particles (such as dust) into the the oil pressure within 1.5 - 2.0 bar.g (22 - 29 psi.g). This
airend. The opening and closing of the capacity control oil is then passed through an oil filter ( 10 micron filter
valve is controlled by the hydraulic line actuated by element) which purifies the oil of impurities. The filtered oil
electrically controlled solenoid valve. enters the oil header in which the oil branches to each
The filtered air enters into the first stage airend. The part. The oil is thus injected into the bearings, gears and
airend consists of two counter rotating intermeshed helical returned to the oil reservoir after lubrication.
screws - the male and the female rotor which are driven If the internal pressure of gear casing rises, the oil will
by electric motor. These screws are provided with invade compression chamber. To prevent this a gear case
Polytetrafluoroethylene (PTFE) + Perfluoroalkoxy alkane breather is provided to vent the air with oil mist from gear
(PFA) coatings on the surface for excellent corrosion and casing. Venting shall be done by supplying external dry air
heat resistance. It protects the rotors against high of 2 bar (29 psi) at 0.14 m 3/min (5 cfm) to the gear case
temperature up to 250ºC (482 ºF) and assures smooth breather.
rotation. The filtered air gets trapped between the rotors
of the airend and gets progressively compressed. 2.4.3 Water circuit
The compressed hot air is cooled in the water cooled The cooling water entering the compressor package splits
intercooler, separated of any moisture content by the up into two - one line goes to the intercooler, while the
moisture separator. The cooled air then passes to the other goes to the oil cooler. The cooling water entering the
second stage airend and is compressed up to the required inter cooler cools the hot compressed air from the first
pressure. The compressed hot air is then passed through stage airend and then goes to the after cooler where it
discharge silencer, discharge check valve (to prevent the cools the hot compressed air from the second stage
back flow from discharge line) and the water cooled after airend. Meanwhile the cooling water entering the oil cooler
cooler. The hot compressed air is cooled in the after cooler cools the lubricating oil and then passes through second
and is separated of any moisture content by the moisture stage and first stage airend cooling jackets sequentially.
separator. The cooled, moisture & oil free air is now The two water lines later joins together and goes out of
discharged to the external receiver, ready to be used. the compressor package.
2.4.2 Oil circuit 2.4.4 Drive system

Oil reservoir is located at the bottom of the gear casing. The airend is powered by an induction motor through a
An oil strainer (150 mesh filter screen) is installed inside coupling. This motor is a totally enclosed fan cooled, pole
the oil reservoir which removes large particles from the oil. flange mounted induction motor. When the compressor is
Oil pumped by the gear pump enters the oil cooler which turned ON, initially the oil pump motor starts, 30 seconds

later the main motor is started in star mode and it takes 5 2.4.6 Safety devices
to 10 seconds to change over to delta mode. During this
The PLC controller continuously monitors the following
period the capacity control valve remains closed and
parameters in the compressed air flow circuit and trips the
motor starts without load. In delta mode the motor speed
compressor whenever the heat and pressure goes beyond
stabilizes, the solenoid valve energized after 10 seconds of
the set values. The below parameters except first stage
change over to reduce the load on motor, the blow down
outlet temperature are displayed in the PLC controller.
valve closes, simultaneously capacity control valve opens
and compressor starts loading. The compressor is equipped with the following safety
devices which will monitor and trip the unit in order to
For compressors with variable frequency drive (VFD), the
protect it against the abnormal running conditions.
speed of the motor gradually increases within 15 to 30
seconds (ramp up time) while capacity control valve will Location Parameter
remain in closed position. This ensures less starting load
Air pressure
and later capacity control valve opens, system starts First stage outlet
building up pressure. Air temperature
The anti vibration mountings (AVMs) are provided below Air pressure
Second stage inlet
the motor, gear housings etc. This will reduce the Air temperature
transmission of vibration to the structure which will help in
Second stage outlet Air temperature
reducing noise as well as ensure the reliability of the parts
mounted on the structure closed position. Discharge outlet Air pressure
Water inlet header Water pressure

2.4.5 Control system
Oil manifold Oil pressure
Depending on the demand for compressed air from
a. Air filter differential pressure switch
application at a particular time, the compressor needs to
respond accordingly to the demand. So to operate This pressure switch is located in the air filter duct. The
compressor based on the demand at a particular time, Low pressure (LP) probe line is taken after the air filter
the compressor operates in either of two modes, the and before the capacity control valve and the High
loading and unloading modes. The primary objective of pressure (HP) probe line is taken from the suction duct
running in these modes is energy saving and reduction of (atmospheric conditions). This switch guarantees against
wear and tear on the machine. The control system air filter clogging or time lapse and sends warning to the
ensures a smooth start without overloading the motor. PLC.
The compressor is started in star mode, during which the
b. Blow off pressure switch
compressed air is vented to the atmosphere and thus
This pressure switch is mounted on the instrument panel
overloading of the motor is avoided. In delta mode the
next to the power panel. The pulse line is taken from the
motor speed stabilizes, the solenoid valve energized after
blow off's downstream side. This switch ensures that the
10 seconds of change over to reduce the load on motor.
second stage pressure during unload condition doesn't
The capacity control valve opens, the blow down stops
exceeds 0.4 bar.g (5.8 psi.g). It signals the PLC controller
simultaneously and the compressor starts loading.
when the pressure exceeds 0.4 bar.g (5.8 psi.g) and trips
When the discharge air line pressure reaches the upper
the system.
set point of discharge pressure transmitter (connected to
c. First stage pressure transmitter
discharge pipe downstream of the after cooler), a signal is
sent by the control system to the solenoid valve. This This pressure transmitter is mounted on the instrument
actuates the capacity control valve, closing it and the panel next to the power panel. The probe is connected at
compressor runs in unloading mode. If the unloading the first stage air end outlet pipe before the intercooler.
mode continues for more than 5 minutes, i.e., there is no This pressure transmitter monitors the high inter stage
consumption of the compressed air and thus no decrease pressure and signals to the PLC controller. The PLC
in pressure, the system stops and goes to a standby controller displays the exceeded values and trips the unit.
mode. When the air line pressure drops to the lower set This ensures the protection of first stage air end and
point of discharge pressure transmitter, the compressor system.
returns to loading mode automatically. Standard factory d. First stage temperature switch
settings for loading and unloading pressures are as
This temperature switch is mounted on the first stage air
follows:
end outlet pipe before inter cooler. It monitors the first
Working pressure 8 8.8 10.0
7 (100) stage air outlet temperatures and signals to the PLC
bar.g (psi.g) (115) (125) (145)
Upper set point 7.2 8.2 9 10.2 controller which trips the system when the values exceed
bar.g (psi.g) (102.9) (117.9) (127.9) (147.9) the recommended temperature limits specified in
Lower set point 6.7 7.7 8.5 9.7 . This ensures the protection of the first
bar.g (psi.g) (95.6) (110.6) (120.6) (140.7)
stage air end and system.
e. Second stage inlet pressure transmitter Technical
. The PLC controller displays the alarm and trips the
This pressure transmitter is mounted on the second stage
air end suction pipe after the inter cooler. This pressure unit. This ensures the protection of cooling and lubrication
system.
transmitter monitors low inter stage pressure and signals
the PLC controller when the values go below the k. Main motor overload relay
Technical
The over load relay is fitted below the K2 contactor in the
. The PLC controller displays the values and trip the power panel. The relay is set to trip the compressor when
compressor. This ensures the protection of second stage
the motor current goes beyond the set limits specified in
air end and system.
. This ensures safety of the motor and
f. Second stage inlet temperature sensor protects the electrical system.
This pressure transmitter is mounted on the second stage l. Oil pump motor overload relay
air end suction pipe after the inter cooler. This
The overload relay is fitted below the K4 contactor (DOL)
temperature sensor monitors the high inter stage
in the power panel. This relay is set to trip the compressor
temperature and signals the PLC controller when the when the motor current goes beyond the set limits
values exceeds the recommended temperature limits . This ensures the safety of
. The PLC controller displays oil pump motor and protects the cooling and lubrication
the values and trips the compressor. This ensures the system.
protection of second stage air end and system.
m. Single phase preventer
g. Second stage discharge temperature sensor
This single phase preventer is mounted inside the power
This temperature sensor is mounted after the second panel. It takes care of the single phasing current, reverse
stage air end and before the after cooler. The probe is direction rotation of the main motor and trips the
connected to the second stage discharge housing silencer. compressor while starting. And it also trips the
This temperature sensor monitors the high discharge compressor while running when voltage imbalance occurs.
temperature and signals the PLC controller when the
n. Safety valve
values exceed the recommended temperature limits
This mechanical safety valve is mounted on the air
. The PLC controller displays
discharge pipe line. The valve is set at working pressure +
the values and trips the compressor. This ensures the
0.7 bar (10 psi). When the discharge pressure exceeds
protection of second stage air end and system.
the safety valve set pressure, it blows off to the
h. Discharge pressure transmitter atmosphere. This protects the entire system.
This pressure transmitter is mounted on the discharge
o. Main motor thermistor
pipe after the after cooler. This pressure transmitter
This is mounted on the main motor body on the top side.
senses line pressure and signals the PLC controller for
It senses the motor winding temperature and signals the
operating in loading and unloading mode. This helps in
PLC controller which trips the compressor if the values
maintaining the discharge pressure and signals the PLC
exceed the set limits. This protects the main motor.
controller when the values exceed the recommended
. The PLC
controller displays the values and trips the compressor.
This ensures the protection of entire system.
i. Water pressure transmitter
This pressure transmitter is mounted on the water inlet

header. This senses the water inlet pressure and signals
the PLC controller to initiate the cooling system. This
monitors the high and low water inlet pressure and
signals the PLC controller when the value falls out of the
. The
PLC controller displays and trips the unit. This ensures the
protection of cooling system.
j. Oil pressure transmitter
This pressure transmitter is mounted on the oil

distribution manifold. It senses the oil injection pressure
and signals the PLC controller to operate the cooling and
lubrication system. It monitors the high and low oil
pressures and signals the PLC controller when values falls

ALL DIMENSIONS ARE IN mm UNLESS OTHERWISE SPECIFIED. MACHINING DEVIATION FOR OPEN DIMNS.IS 2102(Medium) SURFACE FINISH SYMBOLS
All information contained in this document is CONFIDENTIAL OVER - 6 30 120 315 1000 2000
For UNSPECIFIED
and the property of ELGI EQUIPMENTS LIMITED
TOLERANCE Refer 6 30 120 315 2000 4000 N1 N2 N3 N4 N5 N6 N7 N8 N9 N10 N11 N12
Reproduction of these in any form should only be done
with the specific permission of the company. Drg. No. 012392230 ±3
TOLERANCE ± 0.1 ± 0.2 ± 0.3 ± 0.5 ± 0.8 ±1.2 ±2 0.05 0.1 0.2 0.4 0.8 1.6 3.2 6.3 12.5 25 50
1711±10
1850±10
For UNSPECIFIED
TOLERANCE ± 0.1 ± 0.2 ±0.3 ± 0.5 ±0.8 ±1.2 ±2 0.05 0.1 0.2 0.4 0.8 1.6 3.2 6.3 12.5 25 50
noi t at o Rf o noi t c eri D
For UNSPECIFIED
TOLERANCE ± 0.1 ± 0.2 ±0.3 ± 0.5 ± 0.8 ±1.2 ±2 0.05 0.1 0.2 0.4 0.8 1.6 3.2 6.3 12.5 25 50
For UNSPECIFIED
TOLERANCE ± 0.1 ± 0.2 ±0.3 ± 0.5 ± 0.8 ±1.2 ±2 0.05 0.1 0.2 0.4 0.8 1.6 3.2 6.3 12.5 25 50
For UNSPECIFIED
TOLERANCE ± 0.1 ± 0.2 ± 0.3 ± 0.5 ± 0.8 ±1.2 ±2 0.05 0.1 0.2 0.4 0.8 1.6 3.2 6.3 12.5 25 50
Min.Space for
maintenance 2500mm
100
'H'
1850±10
For UNSPECIFIED
TOLERANCE ± 0.1 ± 0.2 ± 0.3 ±0.5 ±0.8 ±1.2 ±2 0.05 0.1 0.2 0.4 0.8 1.6 3.2 6.3 12.5 25 50
270±2
60 206±2
658±10
500±5
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5.0 Technical data
Model - OF 90 OF 110
Working pressure bar.g 7 8 8.8 10 7 8 8.8 10
cfm 575 508 483 403 678 603 568 473
FAD - Free air delivery
m3/min 16.28 14.38 13.68 11.41 19.20 17.07 16.08 13.39
Nominal power supply conditions 415V 50Hz 3Ph
Main motor rating kW 90 110
Main motor speed rpm 2985 2982
Type of motors (main drive) Sq. Cage Induction, TEFC

Insulation & protection of main
Class F, IP55
motor
Frame size/ mounting type 315S and B35
Type of starter for main motor Automatic star delta
Oil pump motor rating kW 1.5
Oil pump motor speed rpm 1432
L 50
Oil tank capacity
gallons 13
lpm 200 233
Cooling water flow
gpm 53 62
Length mm 2955
Dimensions Width mm 1650
Height mm 1850
Weight Kg 4500
7.7 8.7 9.5 10.7 7.7 8.7 9.5 10.7
Safety valve opening bar.g (psi.g)
(110) (125) (135) (152) (110) (125) (135) (152)
OF 90 OF 110
Safety interlocks device setting values
Alarm Trip Alarm Trip
Low oil pressure bar.g (psi.g) 1.3 (18.9) 1.1 (16) 1.3 (18.9) 1.1 (16)
High oil pressure bar.g (psi.g) - 2.8 (40.6) - 2.8 (40.6)
High blow off pressure bar.g (psi.g) 0.3 (4.3) 0.4 (5.8) 0.3 (4.3) 0.4 (5.8)
Low water pressure bar.g (psi.g) 1.2 (17.4) 1.0 (14.5) 1.2 (17.4) 1.0 (14.5)
High water pressure bar.g (psi.g) - 4 (58) - 4 (58)
High interstage pressure bar.g (psi.g) 2.8 (40.6) 3.0 (43.5) 2.8 (40.6) 3.0 (43.5)
Low interstage pressure bar.g (psi.g) 1.6 (23.2) 1.4 (20.3) 1.6 (23.2) 1.4 (20.3)
Air filter pressure bar.g (psi.g) 0.078 (1.13) 0.083 (1.21) 0.078 (1.13) 0.083 (1.21)
Oil filter differential pressure -
bar (psi) 2.0 (29) - 2.0 (29) -
Optional
Low Discharge pressure bar.g (psi.g) - 4.1 (59.5) - 4.1 (59.5)
High first stage outlet
°C (°F) 225 (437) 230 (446) 225 (437) 230 (446)
temperature
High second stage outlet
°C (°F) 225 (437) 230 (446) 225 (437) 230 (446)
temperature
High second stage inlet
°C (°F) 45 (113) 50 (122) 45 (113) 50 (122)
temperature
High oil temperature - Airlube PD °C (°F) 50 (122) 55 (131) 50 (122) 55 (131)
High oil temperature - UT
°C (°F) 70 (158) 75 (167) 70 (158) 75 (167)
Synthetic
Main motor overload 415V, 50Hz A - 104 - 114
Oil pump motor overload 415V,
A - 3.0 - 3.0
50 Hz
NOTE The above values are applicable for standard models and may be changed without prior notice as a part of
product improvement.
Technical data 5.1

6.0 Installation and operation
Contents Page No.

6.1. Installation and commissioning 6.2
6.1.1 Unpacking 6.2
6.1.2 Disposal of packing materials 6.2
6.1.3 Handling 6.2
6.1.3.1 With forklift truck 6.2
6.1.3.2 With shop crane 6.2
6.1.4 Site requirements 6.3
6.1.4.1 Location 6.3
6.1.4.2 Foundation 6.3
6.1.4.3 Ventilation 6.3
6.1.4.4 Electricals 6.4
6.1.4.5 Piping 6.5
6.1.4.6 Cooling water quality 6.6
6.1.5 Commissioning procedure 6.7
6.1.6 Preparation for start up 6.7
6.2. Preservation for long idle storage 6.8

6.2.1 Short term storage 6.8
6.2.2 Long term storage 6.8
6.2.3 Preservation 6.8
6.3. Operating instructions 6.9

6.3.1 Preparation for initial start-up 6.9
6.3.2 Initial start-up checks 6.9
6.3.3 Initial start-up 6.9
6.3.4 Stopping 6.10
6.3.5 Daily operating instructions 6.10
6.3.5.1 Daily start checks 6.10
6.3.5.2 Daily start 6.10
6.3.5.3 During operation 6.10
6.3.5.2 Stopping 6.10
6.3.6 Emergency stop 6.10
6.3.7 Changing the compressor settings 6.11
Installation and operation 6.1

6.1 Installation and commissioning
Before the new OF series compressor is operated for the Ensure padding is used in between compressor and
first time, it needs to be installed at your site according to forklift to prevent damage to compressor's canopy.
ELGi's installation guidelines. Do not attempt to move the compressor by pushing or
6.1.1 Unpacking dragging, as this may cause jerky movements causing

damage to the compressor.
Unpack the compressor from the packing case by
6.1.3.2 With shop crane
removing the nails. Unscrew the bolts, holding the
compressor to the base of the crate. Steel wire ropes and spreader bars shall be used together
to prevent the wire ropes from imposing a force against
Once the packing material is removed, check the contents
the top of the compressor canopy. Be sure to apply pad
against the packing list. The compressor is shipped with
material to the package to prevent any damage to
the following
compressor's canopy. Spreader bars are forwarded in
Key for doors concurrence with the compressor package.
Operation and maintenance manual Ensure the following points while lifting using a
Checklist of parts of the machine crane.
Electrical drawing Prior to lifting, inspect the lifting hooks and points of
attachment for any cracks in hooks and in welds, any
The condition of the compressor shall be carefully
abnormal bends, corrosion of parts, loosening of bolts
inspected after receiving. Any indication of damage due to
or nuts.
carrier shall be noted on the delivery receipt and claims
should be made directly with the carrier. Tools may be
provided on request. If any components are found
missing, contact ELGi immediately.
6.1.2 Disposal of packing material

The wood/cardboard used to make the shipping crates of
the OF series compressors are biodegradable.
The polyethylene covers wrapped around the compressor

and the polystyrene packing provided around the
electrical panels are not recyclable. They must be
disposed off in accordance with prevailing local
environmental laws.
6.1.3 Handling
For lift or crane capacity should be atleast 1.5 times the
Figure 3. Shop Crane
compressor weight (refer technical data 5.1).
Make sure the entire lifting, rigging and supporting
6.1.3.1 With forklift truck
structure has been inspected, is in good condition and
Open the door of container box, draw the compressor has a rated capacity of at least the net weight of the
from container box using a forklift truck. Steel wire ropes compressor. If you are unsure of the weight, then weigh
can be used. the compressor before lifting it.
Make sure the lifting hook has a functional safety latch

CONTAINER
WIRE ROPE or equivalent and is fully engaged and latched on the
COMPRESSOR UNIT
hook.
FORKLIFT TRUCK
Use guide ropes or equivalent to prevent twisting or
swinging of the machine once it has been lifted
completely off the ground.
When the compressor is lifted up by crane, use

cushioning materials at the four points of the bottom for
prevention of damaging the cover. Cushion should be
padded at 4 lifting points for prevention of damages.
Figure 2. Lifting using forklift
If you are using the guide ropes to lift the machine for
Make sure that the forklift is capable of handling the installation, ensure that the rope is not touching the
weight of the compressor and its two arms is fully canopy at the bottom and top to avoid scratches and
engaged with the compressor package. rope marks or any other severe marks on canopy.

Do not attempt to lift the compressor in high winds. If the unit is to be located in the area, where other
Keep all personnel away from the compressor when it is machinery, a vibration dampening material shall be
suspended. placed between the foundation and the bedrock.
Do not lift the compressor higher than the required Leveling and grouting
height. In general, the foundation of screw compressors is
Keep the lift operator in constant attendance whenever made of grout pad liner.
the compressor is suspended. Setting of pad liner shall be finished 3 days before
Set the compressor down only on level surfaces, installing the unit to shorten the working time.
capable of supporting at least its net weight plus an The difference of elevation among the liners shall be
additional 10 per cent allowance. 1 mm (0.04 inch) or less. The level of pad liner shall be
6.1.4 Site requirements 2 mm (0.08 inch) or less in every direction.
6.1.4.1 Location After setting of pad liners various among them, it is

necessary to adjust the height of liner with shim liners.
Locate the compressor in a dry and well ventilated area
with sufficient room (indoor) for proper and safe The purpose of grouting is to solidly fill the space
inspection and maintenance. Compressor shall never be between the base and the foundation and to give a
installed in a damp or heavy or excessive dusty uniform load-bearing surface for the unit.
atmosphere or where corrosive vapours may enter the The use of wedges, shims, or levelling screws for
compressor. It is recommended not to install the permanent installation is not recommended, they are to
compressor unit in an area like chlorine gas, hydrogen be used as a method of levelling and aligning the unit
sulphide gas, sulphur dioxide gas, heavy concentrated prior grouting.
ozone area or any other toxic or flammable gases or any
Prior to grouting, roughen the foundation surface by
other heavy contaminants present. A ventilating fan may
removing approximately 13mm (0.51 inch) deep of the
be provided for the room to keep the room temperature
surface by chipping or other means to provide a good
at 45 C (113 F) or lower. The compressor must be
bonding surface.
protected from freezing and excessive ambient
temperatures. The compressor shall be installed in such a Build a frame around the perimeter of the base.
way that the compressor controller and operating panel is When building the frame, prepare the space for removal
not directly exposed to sunlight. of wedges, shims or other levelling after the grout has
Install the compressor on a smooth, solid level industrial set.
concrete floor capable of bearing the weight of the To obtain a good bond between the foundation and the
compressor. Ensure the unevenness of the surface is grout, the foundation shall be completely clean and free
within 6mm (0.25 inch). of any oil, water or other foreign matters prior to
The recommended minimum distance between the top of pouring grout.
canopy and the ceiling or roof shall be 2.5m (8 ft). Prepare a minimum of 25mm (1 inch) of grout between
Leave minimum 1.5m (5 ft) space around the the base and the foundation. All air pockets and voids
compressor for safe and proper inspection, cleaning and shall be removed from the grout. After grout has set,
maintenance activities. remove the levelling devices. And then tighten the
anchor bolts and fill the void left by the levelling
NOTE devices with the same grouting material.
Operating at ambient temperature above 45ºC (113ºF)
6.1.4.3 Ventilation
may cause compressor shut down or severe damages.
If noise is a problem, avoid installing the compressor in A part of the electric energy to your compressor motor is
an area enclosed with low ceiling and hard walls. converted into heat and this heat must be removed from
the compressor room by suitable ventilation. The
This compressor is designed for indoor application, if it
ventilation requirements could be achieved by the
has to be installed for outdoor application, please contact
following methods.
ELGi for proper installation.
Natural ventilation is sufficient if the temperature rise in
6.1.4.2 Foundation
the compressor room (measured by a thermometer
While the foundation for screw compressors need not be near the air inlet side) is within 2ºC (3.6ºF).
as massive as that for reciprocating machinery, it shall
Forced ventilation with an exhaust fan is necessary if
have a strength sufficient to provide a support for the unit.
the temperature rise inside the room is above 2ºC
Since there are no unbalance forces such as reciprocating
(3.6ºF).
or shock loads, all loads imposed on the foundation may
be considered as static loads. Ventilation with ducts: Ensure hot air exhaust from the

compressor is diverted through the ducts when installed 3. The fuse and cable specifications for 50 Hz and 60 Hz
in an enclosed area. ( Contact ELGi for ducting are listed in tables 2 and 3 respectively.
requirements)
4. Miniature circuit breaker (MCB) is not recommended for
Provide openings on walls/ partitions close to the air this compressor because the selection of contactors is
suction side of the compressor. based on Type-2 co-ordination.
Provide exhaust openings close to the ceiling for hot air 5. Wiring required at the site is the connection of power
exit. supply and grounding. A grounding terminal is provided
in the starter.
If more than four compressors are installed in a room, it
is recommended to have ducting arrangements. This
will avoid hot air recirculation.
Hot air recirculation will affect the compressor

Ensure that only authorized electricians perform
performance.
electrical work. Study the electrical circuit diagram
The air velocity in the supply and exhaust ducts should before starting work.
not exceed 4 m/s (13 ft/s). When making any connection or changes in the wiring of
the compressor, disconnect the main power.
The velocity is ascertained during commissioning using
Be sure that the compressor is adequately grounded.
an anemometer.
Do not connect cool air inlet ducts directly to the

compressor inlet side.
To eliminate transmission of vibrations, provide soft

below connector between the duct and the compressor.
Contact ELGi in case you need to provide a duct

connection or filter fitment on the compressor.
6.1.4.4 Electricals
1. Power should be supplied to the compressor through a

dedicated switch disconnected fuse (SDF) unit of
suitable rating mounted within 5m (16.4ft) of the
compressor. (This gives you possibilities to isolate the
compressor)
2. Use HRC (high rupturing current) fuse instead of a

MCCB (moulded case circuit breaker) to avoid possible
contactor and motor failure.
Incoming Incoming cable size Incoming cable size Earth cable size Power cable gland
Model
fuse rating (Armoured) Copper (Armoured) Aluminium Copper hole diameter
A mm2 mm2 Cu flat mm (inches)
OF 90 250 3 1/2 C x 150 3 1/2 C x 185 30 x 3 50.8 (2.0)
OF 110 250 3 1/2 C x 150 3 1/2 C x 185 35 x 3 57.15 (2.25)
OF 135 315 3 1/2 C x 185 3 1/2 C x 240 50 x 6 69.85 (2.75)
OF 145 400 3 1/2 C x 240 3 1/2 C x 300 50 x 6 76.2 (3.0)
OF 170 400 3 1/2 C x 300 2R x 3 1/2 C x 185 50 x 6 88.9 (3.5)
OF 200 500 2R x 3 1/2 C x 185 2R x 3 1/2 C x 240 50 x 6 88.9 (3.5)
OF 210 500 2R x 3 1/2 C x 185 2R x 3 1/2 C x 240 50 x 6 88.9 (3.5)

OF 250 500 2R x 3 1/2 C x 185 2R x 3 1/2 C x 240 50 x 6 88.9 (3.5)
OF 265 630 2R x 3 1/2 C x 240 2R x 3 1/2 C x 300 50 x 6 88.9 (3.5)
OF 275 630 2R x 3 1/2 C x 240 2R x 3 1/2 C x 300 50 x 6 88.9 (3.5)
OF 300 630 2R x 3 1/2 C x 240 2R x 3 1/2 C x 300 50 x 6 88.9 (3.5)

OF 355 800 2R x 3 1/2 C x 300 2R x 3 1/2 C x 400 50 x 6 88.9 (3.5)
OF 400 1000 2R x 3 1/2 C x 300 2R x 3 1/2 C x 400 50 x 6 88.9 (3.5)
OF 450 1250 2R x 3 1/2 C x 400 2R x 3 1/2 C x 500 75 x 6 88.9 (3.5)
Table 1. Electrical requirements - 50 Hz

Incoming Incoming cable size Incoming cable size Earth cable size Power cable gland
Model
fuse rating (Armoured) Copper (Armoured) Aluminium Copper hole diameter
A mm2 mm2 Cu flat mm (inches)
OF 90 250 3 1/2 x 95 3 1/2 x 120 30 x 3 50.8 (2.0)
OF 110 250 3 1/2 x 120 3 1/2 x 150 35 x 3 57.15 (2.25)
OF 135 400 3 1/2 x 185 3 1/2 x 240 50 x 6 69.85 (2.75)
OF 145 400 3 1/2 x 185 3 1/2 x 240 50 x 6 76.2 (3.0)
OF 170 500 3 1/2 x 240 3 1/2 x 300 50 x 6 88.9 (3.5)

3 1/2 x 300 / 600
OF 200 500 3 1/2 x 400 / 800 kcmil 50 x 6 88.9 (3.5)
kcmil
3 1/2 x 300 / 600
OF 210 500 3 1/2 x 400 / 800 kcmil 50 x 6 88.9 (3.5)
kcmil
3 1/2 x 400 /800
OF 250 600 3 1/2 x 500 / 1000 kcmil 50 x 6 88.9 (3.5)
kcmil
3 1/2 x 400 /800
OF 265 600 3 1/2 x 500 / 1000 kcmil 50 x 6 88.9 (3.5)
kcmil
3 1/2 x 400 /800
OF 275 600 3 1/2 x 500 / 1000 kcmil 50 x 6 88.9 (3.5)
kcmil
3 1/2 x 500 /1000
OF 300 700 3 1/2 x 600 50 x 6 88.9 (3.5)
kcmil
2R x 400 cu cabil
OF 400 1270 - 50 x 6 88.9 (3.5)
2R x 800 kcmil
Table 1. Electrical requirements - 60 Hz
6.1.4.5 Piping If the compressors are operated in parallel, be sure to

provide a stop valve and a drainage opening in each
Discharge air piping
discharge air line. If the compressor is operated in parallel
The size of discharge air line shall be at least as large as
the discharge piping size installed on the unit. It is
recommended to have a flexible connection between
compressor and air receiver or air network pipeline. A
drainage opening and a stop valve shall be installed in the
Service
discharge air line before receiver as much as closer to the line
compressor.
Water condensation has a bad influence upon the

operation of pneumatic devices or tools. The installation
Receiver tank
of air dryers can eliminate this trouble. If the compressors
discharge line is connected with common discharge
header of similar such machines, the discharge line
connections shall be taken from top of the header.
Service
line
Receiver tank
Service
line
Figure 5. Parallel operation
with reciprocating compressor, the discharge air line of

the rotary screw compressor shall be connected
Figure 4. Discharge air piping downstream of the air receiver.
Elevated piping
Parallel operation
If the discharge air line is elevated near the compressor,
be sure to provide drain valve or drip leg to collect the
condensate.

a small volume discharge line. Therefore the receiver
Service capacity (required volume on the discharge line) which
line
determines the switching between the load and unload
operations, must be carefully calculated as follows:
V = 16 x Qs where V is the required capacity for
1 cfm = 0.000472 m3/s 1 m3 = 35.314 ft3
compressor control (m3) and Qs is the flow rate handled
All service piping must be installed so as to exert zero force

of moment on the compressor unit.
Figure 6. Elevated piping
Do not install the check valve between the unit and the air
receiver.
Manifold piping
by the compressor (m3/s).
E.g.: Qs = 20 m3/min = 0.33 m3/s
V = 16 x 0.33 = 5.28 m 3
Thus the receiver capacity (including discharge piping

capacity) is approximately 5 m3.
Condensate drain piping
Condensate is separated from the compressed air by the

moisture (mist) separator installed downstream of the
cooler. The condensate is discharged with a small amount
of compressed air through an automatic drain valve (ADV).
Figure 7. Manifold piping
Ensure that each condensate drain is opened to
Connect the discharge air line to the top of the manifold atmosphere.
piping so that the condensate in piping will not return to Cooling water piping
the compressor when it is standstill.
The take over points of cooling water are provided at the
base of the unit, which consists of one inlet line and one
Service line has to be connected to the top of the header outlet line. Install an ON/ OFF ball valve at the inlet and
line and to be raised above by 300mm minimum to outlet of water line. This ball valve can be used to shut off
avoid entry of condensate the cooling water flow to the compressor when it is not
Compressor ball valve has to be provided at the service running. An automatic motor driven valve in the water
line near to compressor. system can be provided on request to avoid water
Condensate drain valve has to be provided after the ball hammering while closing/ opening the water line into the
valve at the lowest point of the service line to drain the system.
condensate
6.1.4.6 Cooling water quality
Compressor ball valve to be closed when the machine is
not running If the cooling water for the compressor is supplied by a
Drain the condensate by opening the condensate drain cooling tower, corrosion, scale or slime may occur in the
valve before starting the compressor coolers due to :
Compressor ball valve has to be in closed position during 1. High mineral content in water
draining of condensate.
2. Foreign matter like insects
3. Algae or bacterium
Connect the service line to the bottom or center of the
header/manifold line
Position the drain valve between compressor and Ball The lifetime of the cooling water system depends on the
valve water quality. If the water quality is not good, the cooler
tubes can be corroded or scale formation may occur.
External air receiver
In order to prevent corrosion or scaling, sample the
The compressor should not be in unload condition cooling water periodically and test it to check if it meets
frequently. Be very careful when the compressor has only the quality standard, correct if necessary.

compressor is not commissioned for more than 18
Sl.
Parameter Unit Specification months.
No
1 pH at 25ºC * - 6.2 - 8.2 Anti vibration mountings (AVMs) have to be replaced if
2 Conductivity * S/cm < 1500 any abnormal squeezing or damage in rubber part is
observed.
3 Total hardness as CaCO3 ppm < 200
Total alkalinity as Check whether all the screws in the control panel are in
4 ppm < 200
CaCO3* its place and tightened properly.
5 Turbidity NTU <50 Ensure that all red colored transit brackets are removed
6 Calcium Ca+2 ppm < 200
During commissioning
7 TDS * ppm < 1000
Servicing technician carries out a series of checks on the
8 Free Chlorine as Cl2 * ppm <0.5
compressor and the systems to which it is connected, to
9 Silica as SiO2 ppm < 50
ensure that it is in a condition to function safely and as
10 Iron content * ppm <0.1 recommended. Servicing technician will then describe to
the operator of the compressor how the equipment is to be
11 Sulphate as SO4 ppm < 200
operated and maintained. The commissioning of the
12 Ammonia as NH3 ppm < 0.5 compressor ensures that it is installed safely.
13 RSI index - 6.0-7.0
The general operating conditions of the compressor
Use cooling water of good quality as shown in the following including cleanliness of ambient, temperature and
Table 3. Cooling water quality ventilation are checked. Technical details related to your
system such as particulars of your electrical installation
table are noted. The operator of the compressor is familiarized
with all aspects of both its normal running and unusual
*These parameters are critical for corrosion or scale
situations.
formation.
Upon completion of commissioning process, the technician
6.1.5 Commissioning procedure
will fill in the document known as the commissioning
Please make preparations according to the installation report and warranty card provided in the manual. During
section as given, before the compressor is
commissioning any modification suggested by the
commissioned.
technician should be carried out before the compressor is
Ensure that the location meets the requirements of
accessibility, ventilation and safety. put for regular use. Warranty becomes void if not done. In
Provide electric power as recommended in the case of change of operator other than the person trained,
installation section. the new operator should be trained before he is dedicated
Select air pipelines and receivers for your system as for operating the compressor.
recommended in installation section.
Ensure dry compressed air supply to the FRC regulator 6.1.6 Preparation for start up
of gear case breather
Disassembly work (Major components)
Ensure the vacuum pressure range between (-5cm) to
(-10cm) of water column by adjusting the FRC unit After locating the compressor, remove the desiccants
Dry compressed air (after dryer is preferred) need to be hanged in the following locations:
provided (2.0 bar / 29 psi, 5 cfm) from outside package
1. Power panel box
source.
2. Control panel box
Checkpoints before commissioning
3. Main motor starter housing
Replace the following parts in compressor if it is not in use 4. Oil pump motor
more than one year. 5. Gear case
1. Air filter 6. Cover gear case
Remove the packing stickers from the take over flanges
2. Oil filter of discharge air line.
3. Gear case breather ( check and replace) Remove the rectangular packing stickers from top
ventilating duct, blow off duct, air intake duct and
4. Oil motor ventilation duct.
Check for any external / internal damages of package. Remove the stud bolt from the gear casing and plug it.
Remove the plug from the moisture condensate drain
Main motor should be mongered to find the winding
silencer.
insulation conditions if the compressor is not
commissioned for more than one year. Remove the anti vibration mount clamps (red coloured).
Re-greasing of main motor to be carried out if the Remove airend vent plugs (red coloured).

6.2 Storage
6.2.1 Short term storage ensuring the free rotation of the shaft. The rotational
direction is clockwise direction when view from non-
(Post installation)
drive end side of main motor.
If the compressor is going to be stored for: d) Repeat the above action for every 15 days.
More than 8 hours -
e) Purge dry air or Nitrogen for 30 minutes through the
Close the main air outlet valve. provision provided in the package. Repeat this activity
for every 6 months.
Close the inlet and outlet water lines completely.
f) Replace all silica gel packs with new packs. Repeat this
Drain the water completely from the compressor by
activity for every 6 months.
opening the ball valves in water headers.
g) Cover or wrap the compressor to avoid dust, insect and
More than a week - in addition to above activities perform
moisture entry.
the following
Compressor placed at intended location
Rotate the compressor shaft once in 7 days and ensure
free rotation. Also supply dry air at the intercooler dry a) Follow the steps b, c, d, e and f.
air inlet for 30 minutes. b) Check for any external / internal damages of the
6.2.2 Long term storage package. If found any damages contact HO service
personnel.
(Post installation)
Cooler storage
The following procedure is necessary to protect the
compressor against rust if it is going to be stored for a a) Drain both sides of cooler and dry with air.
long period (more than a month). In any case, when post- b) Store the cooler in dry condition.
installation storage is required, contact the nearest ELGi
c) It is recommended to fill the cooler with an inert gas
office.
(Nitrogen) together with a bag of silica gel. Contact
Run the compressor for 5 minutes once in a week. nearest ELGi office for more details.
Mark the unit with a caution sign to declare the storage
NOTE
condition. The sign warns an operator against potential
Ensure that the silica gel bags are removed before putting
hazards or unsafe practices.
the compressor into use.
In addition, there is a dry nitrogen purge method or a
Oil flushing
dry agent method (once in a month) for long term
storage. ELGi will choose which of them is suitable for Oil flushing shall be performed for oil lubrication system, if
the local condition. the induction of oil pressure shows 1.5 bar (21.75 psi) or
less.
6.2.3 Preservation (Pre-Commissioning)
Especially pay attention to the oil pressure before the first
NOTE start-up and any start-ups during commercial operation
when the unit has been put in the following conditions.
This preservation procedure is prepared assuming that the
compressor package is stored as per storage procedure. a) The preserved time (long storage) between the
Scope: The preservation activity should be carried out shipment and the first start- up exceed 3 months from
when the machine is kept under idle condition for more the date of dispatch from factory.
than six months from date of dispatch. This is also b) Every overhaul.
applicable for machines which will be kept idle after
The recommended oil shall be used as flushing oil. It is not
commissioning.
necessary to change the oil after finishing the oil flushing.
Compressor not placed at installation location After the flushing, oil is supplied to the oil reservoir to the
Ensure stability of the packing case of machine, before specified level; the flushing work is performed by the oil
moving the compressor package. pump solo operation. If there is a lot of dirt or rust in the
system, they tend to clog the oil filter and cause a drop of
a) Open the packing case and keep the compressor
oil pressure.
package in dry, leveled surface in weather proof area.
b) Do visual inspection to find if there is any rust formation

on the critical components such as first stage airend
outlet pipe, second stage airend suction pipe, moisture
separators stage gears and timing gears. If rust is found
contact head office service before proceeding further.
c) Rotate the coupling for more than fifty times by hand,

6.3 Operating instructions
Check electrical wiring connections to main motor and

transformers for proper voltage connections.
Please adhere to the safety instructions provided in section Check and remove all the loose items left in and around
2.3.2: precautions during operations the machine during installation.
Before starting the compressor for the first time, an Clean inside the canopy if required.
operator should become familiar with all parts and
Check the oil level in the gear casing and fill the oil with
assemblies.
the recommended grade. The oil fill quantity is
6.3.1 Preparation for initial start up Technical data
Oil is filled in the gear casing from factory before dispatch. Ensure dry air supply to the gear case breather
Check whether the oil is up to the upper line of the oil assembly
level gauge. If not top up the oil. Remove the oil filling cap Make sure the oil level in the gear casing is filled with
and fill the recommended oil to the upper line of the oil sufficient quantity and the level should be above red
level gauge. Ensure dry air supply to the gear case lines of the oil level gauge. Do not over fill. If necessary
breather assembly Refer commissioning procedure to add oil while commissioning, use the same lubricants
(6.1.5) for more details or replace the oil completely with correct grade.
Do not mix multi brand oils. Open the ball valve (provided by the customer outside
Lubrication for the compressor shall be done with the canopy) in the discharge service line before starting
premium quality, highly filtered oil with maximum metal the machine.
wetting ability, rust preventive properties and oxidation
stability. It should contain deforming inhibitors and shall
be free of inorganic acids or alkalis. Oil should not have a
tendency to oxidise or form sludge when mixed with air Main power to the compressor shall be disconnected before
doing any electrical work
and water. Use the following lubrication oil for compressor
lubrication.
Oil Volume Part number

During the first start up of the compressor, raise the
ELGi Air Lube
26 L (6.86 gal) 000998087 pressure step by step.
PD
5 L (1.3 gal) 000998092
ELGi Air Lube
20 L (5.3 gal) 000998090
UT Synthetic
208 L (55 gal) 000998093
Some oil mixtures are incompatible with other, and

result in the formation of varnished shellacs, or lacquers
that trouble, including clogging of the oil filter.
Avoid mixing oil of the same type but different brands. A

brand change is best made at the time of a complete oil
change.
Oil flushing shall be performed if the induction of oil

pressure shows 1.5 bar.g (21.75 psi.g) or less. Refer
Figure 8. Human machine interface
section "Oil flushing" in preservation (6.2.3) for more
details.
6.3.2 Initial start-up checks 6.3.3 Initial start-up
Before starting the compressor, perform the following, Be sure to check the smooth rotation of rotors by
rotating the motor shaft by hand from the motor
Make sure that the unit is provided with adequate
inspection cover.
electrical grounding.
Make sure that the ball valve in the discharge airline
Electrical power should be in off position during
has been completely opened.
pre-start up condition.
Turn on the power supply to the compressor panel.
Make sure the cooling water pump is ON and ensure a
Select the compressor operating mode - Local /Remote/
water pressure of 2 bar.g (29 psi.g) to 4 bar.g (58
DCS (refer PLC manual for more details)
psi.g)
Push the START button (F5) in the PLC controller.

Initially the lube oil pump starts and will run for 30 6.3.4 Stopping
seconds.
Push the STOP button (F6) in the PLC controller.
Make sure that the inlet oil pressure is 1.5 bar.g (21.75
PLC controller signals the solenoid valve which de
psi.g) or more.
energises capacity control valve. Then the butterfly
The main motor will start after 30 seconds from valve is closed and blow off line is opened. Compressor
pressing of START button (F5) in the PLC controller. will run in unload condition.
Check the direction of rotation from the inspection Main motor will stop after 30 seconds of unload.
opening of main motor. Ensure the rotation of main
The lube oil pump stops after 60 seconds of main motor
motor is viewed from the coupling guard and it should
stoppage.
be counter clockwise from motor drive end.
Isolate the power supply to the compressor.
The motor reaches its full speed and compressor starts
running in the unload condition. During unloading stage
the air which is sucked and compressed will be
simultaneously blown off to the atmosphere through the
6.3.5 Daily operating instructions
blow off valve from the second stage outlet. 6.3.5.1 Daily start checks
After 20 seconds the suction valve (CCV) will be Check the oil level in the gear casing. If required top up
opened, blow off valve closes and loading cycle starts. the oil.
Run the compressor on load for 30 minutes with the Open the doors and visually check the compressor for
discharge ball valve completely opened so that the abnormality. Make sure all connections are tight.
compressor runs at the lowest pressure.
Refer section 7.1.1 for daily maintenance activities to be
If the compressor service line is connected with the done.
application line, loading/ unloading will happen based
6.3.5.2 Daily starts
on the air demand in the application side. The loading -
unloading pattern needs to be observed and set the Open the air discharge valve.
load / unload cycle accordingly. The load / unload Turn on the power.
settings can be done in the PLC controller operator
Turn on the cooling water pump.
settings.
Push the START (F5) button on the PLC controller.
Check and confirm that the oil temperature indicates
55ºC (131ºF) or less and the discharge temperature Check whether the lube oil pressure indicated in the PLC
indicates the temperature below the set value. controller after 30 seconds is 1.5 bar.g (21.75 psi.g) or
higher. Normal oil pressure is 1.5 - 2.0 bar.g (21.75 -
When the compressor discharge pressure is lower than the
29 psi.g). This will be displayed in the PLC controller in
rated pressure (if the compressor is tested standalone),
the view menu.
close the discharge ball valve slowly as possible until the
compressor discharge pressure reaches the rated 6.3.5.3 During operation
pressure. Confirm the oil temperature is 55ºC (131ºF) or less.
Check the discharge air temperature.
The unloading cycle time should not be longer than

Running the compressor in the wrong direction for more
than 5 seconds will cause damage to compressor parts or 50% of total duty cycle. It is always better to run the
even total destruction. compressor on load cycle than unload cycle operation.
Confirm that no chattering noise is observed in water

lines, if observed relieve air lock from the water lines by
Do not restart the compressor immediately after shut removing the cap from the air vent.
down. Restart the compressor at least 20 minutes after
6.3.5.4 Stopping
the shut down to prevent overheating of the main
motor. Press the STOP button (F6) on the PLC controller.
To restart the compressor after a protective system shut Make sure that the discharge pressure indicates zero in
down (trip), push the 'reset' button. After the cause for the PLC controller after main motor is stopped.
shut down is corrected, system shall be reset and
6.3.6 Emergency stop
compressor can be started.
In any mode of operation, compressor can be stopped
immediately by pressing the emergency push button.
NOTE
When this push button is pressed, the main motor and oil
For post installation storage refer section 'storage'
pump motor will stop simultaneously. Rotate the

emergency stop switch clockwise, so that the push button
returns to its normal position.
Please do not try to bypass main motor run feedback in

any case. The oil pump will never stop if the main motor
run feedback is present, though the emergency push
button is pressed.
Isolate power supply before the discharge ball valve

closes.
Do not use the emergency stop switch for normal
stopping
6.3.7 Changing the compressor settings

Change the compressor settings using the tactile keypad
and LCD panel on the PLC controller. (Refer to PLC manual
for details of the control panel and interpretation of
messages)

7.0 Maintenance
Contents Page No.

7.1. Maintenance 7.2
7.1.1 Standard maintenance schedule 7.2
7.1.2 Maintenance of individual components and systems 7.3
7.1.2.1 Pre filter - Control panel 7.3
7.1.2.2 Intake air filter 7.3
7.1.2.3 Oil filter 7.3
7.1.2.4 Oil strainer 7.4
7.1.2.5 Oil fill 7.4
7.1.2.6 Oil change 7.5
7.1.2.7 Auto drain valve 7.5
7.1.2.8 Capacity control valve 7.6
7.1.2.9 Blow-off silencer 7.6
7.1.2.10 Coolers 7.6
7.1.2.11 Electric motor 7.9
7.1.2.12 Gear case breather 7.9
7.1.2.13 Minimum pressure valve (MPV) 7.9
7.1.3 Use genuine spare parts 7.9
7.2. Troubleshooting 7.10

7.3. Decommissioning, dismantling & putting out of service 7.14
7.3.1 Waste disposal 7.14
7.3.2 Dismantling the compressor 7.14
7.3.3 Decommissioning the compressor 7.14
7.3.4 Disposal of consumables and replaced parts 7.14
7.4. ELGi services 7.15

7.4.1 ELGi customer care system (ECCS) 7.15
7.4.2 ELGi genuine spare parts 7.15
7.4.3 Air audit 7.15
7.5. Appendix 7.17

7.5.1 Conversion tables 7.17
7.5.2 Torque values 7.18
7.5.3 Operation log book 7.19
7.5.4 Service log book 7.20
7.6. Disclaimers 7.21
Maintenance 7.1
7.1 Maintenance
The actions mentioned in the schedule are repetitive

unless otherwise specified, i.e.; actions at 2000 hours
Before attempting any maintenance activity, carefully interval as an instance shall be carried out again after
read section 'safety'. 4000 hours of operation. Keeping a record is a very good
Isolate the power supply to the compressor before practice for good preventive maintenance. The record also
starting any maintenance activity. enables ELGi to find a potential cause of trouble and
The maintenance schedule is shown in the following Table thereby perform a suitable repair. Use the operation log
4. These maintenance guidelines are applicable only to book provided in the appendix.
standard operating and regular maintenance conditions
7.1.1 Standard maintenance schedule
recommended in this manual. If operated in a harsh
environment, perform the service more frequently. In the Before taking any maintenance actions, read the
event of changes in the conditions, contact ELGi. Carry out concerned section. Time mentioned in the following table
the maintenance work, based on either running hours or is not a performance guarantee period.
calendar time which ever comes first.
Frequency Part Remarks
Oil level Check
Inter cooler auto drain valve (ADV) functionality Check & clean
After cooler auto drain valve (ADV) functionality Check & clean
Daily
Water leakage Check
Oil leakage Clean
Working parameters Check & record
Weekly Pre-filter * Clean
Monthly Auto drain valve (ADV) Clean
As per PLC warnings Intake air filter Clean
2000 hours Main motor (2 pole) Grease #
Intake air filter Replace
Gear case breather Replace
4000 hours
Switches and gauges Calibrate
Main motor (4 pole) Grease #
Pre-filter * Replace
CCV kit / Air piping kit / Lubrication piping kit / Oil cooler kit /
Intercooler & After cooler (gasket & O-rings) kit / Water Replace
piping (O-ring, gasket & pipe coupling elements) kit
Air lube PD Replace
8000 hours or every year Oil filter Replace
Oil strainer Clean
Air and oil coolers Check & clean
Control panel filter Replace
Safety valve Check
Oil pump Check
Solenoid valve Check
Nylon tube Replace
Blow off silencer Replace
16000 hours or every 2 years Oil strainer Replace
Coupling element - Oil pump Replace
MPV kit / Gear case (gaskets) kit Replace
Check valve assembly Replace
Air lube UT Synthetic Replace
30000 hours or every 4 years Machine overhaul Overhaul
#- Electric motor grease details * Applicable to suction pre-filter and control panel pre-filter. Suction pre-filter may not be
available in all models.
Table 4. Maintenance intervals
Maintenance 7.2
Sl. No. Motor make Grease
1 Siemens Unirex N3 ESSO
2 WEG Mobil polyrex EM
Table 5. Electric motor grease details
Refer the section "storage" for storage procedures if the

compressor is kept idle more than 8 hours.
7.1.2 Maintenance of individual

components and systems
7.1.2.1 Pre filter - Control panel
Pre work
Switch off the compressor and disconnect the power

supply to the motor.
FILTER ELEMENT
Close the discharge end ball valve.
Allow the compressor to cool for a few minutes. Figure 3. Intake air filter
Requirements Maintenance
Compressed air, new filter element (if required). Remove the stud and take out the air filter element
from the suction box panel. (Refer air intake system in
Maintenance
parts manual)
Pull out the pre filter frame from the control panel door.
Attach the suction box cover on the suction box panel to
Clean the pre filter element using dry air at less than prevent dust or dirt entering the compressor inlet.
2.5 bar.g / 36.3 psi.g.
Clean the filter using dry air at less than 2.5 bar.g /
The direction of cleaning must be from inside to outside. 36.3 psi.g
In case of major dust/ dirt accumulation in the pre filter The direction of cleaning must be from inside to outside.
element, wash with clean water or light detergent but it
Assemble the filter element and reinstall it in the
shouldn't be rinsed.
suction box panel.
Do not use any acidic/ alkaline chemicals for cleaning.
Replace the pre filter element in the frame and refit the
frame after cleaning. 7.1.2.3 Oil filter
Repeat the procedure based on dust conditions or on The oil filter having 10 micron filter screen is located
regular intervals. between the oil cooler and the airend. This is a full flow
If the pre filter is damaged or torn, replace the pre filter spin-on filter.
element.
Never remove pre filter when the compressor is

running.
A dirty air filter will decrease the suction pressure and will
7.1.2.2 Intake air filter increase the compression ratio. It may cause very high
discharge temperature.
Clean or replace the air filter when alarm pop ups in the
HMI (Human Machine Interface).
Pre work Pre work
Switch off the compressor and disconnect the power Switch off the compressor and disconnect the power
supply to the motor. supply to the motor.
Close the discharge end ball valve. Close the discharge end ball valve.
Allow the compressor to cool for a few minutes. Allow the compressor to cool for a few minutes.
Requirements
Compressed air, new filter element (if required)
Maintenance 7.3
Requirements Pre work
New oil filter, clean cloth, O-ring, Strap wrench Switch off the compressor and disconnect the power
Maintenance
Remove the spin on filter by rotating in counter
clockwise direction. Allow the compressor to cool for a few minutes.
Clean the head assembly thoroughly. Requirements
Check the oil filter mounting hex adapter for tightness. Spanners
Install the new oil filter element. Maintenance

PLUG. HEX-SOCKET Remove the seamless pipe tube which connects the
gear casing with the oil pump.
HEAD
Loosen the bolts of the flange and pull the pipe with the
oil strainer from the gear casing.
Clean the oil strainer.

HEX ADAPTER
After cleaning reassemble the pipe with oil strainer on
the gear casing.
SPIN-ON OIL FILTER
FLANGE
PIPE
OIL STRAINER
Figure 3. Oil filter
Figure 5. Oil strainer with pipe
Figure 4. Location - Oil filter

OIL FILLING PORT
Figure 6. Location-oil filling port

7.1.2.4 Oil strainer
The oil strainer having 150 mesh filter screen is located 7.1.2.5 Oil fill
inside the gear casing. The cleaning of oil strainer shall be
Check the oil level daily. Use recommended oil only and do
made every 8000 hours or every year (whichever comes
not use other brands.
first) at the same period as oil change. The oil strainer can
be removed from the gear casing containing oil and it is Pre work
unnecessary to drain the oil. Switch off the compressor and disconnect the power
Maintenance 7.4
Allow the compressor to cool for a few minutes. 7.1.2.7 Auto drain valve
Requirements DISC RETAINER CAP FILTER
Recommended oil CAP

WASHER
Maintenance DISC CAP
PACKING
DISC
Check the oil level. THREADED
VALVE HOLE
PARTS OF
Open the oil filling port - cap and fill the required THE CAP MAIN BODY
amount of oil.
O-RING
Close the oil filling port - cap.
7.1.2.6 Oil change

Sample the oil from the gear casing every six months.
Change the oil if necessary. WASHER
Pre work
Switch off the compressor and disconnect the power PACKING
supply to the motor. DISC CAP

DISC
Allow the compressor to cool for a few minutes.
Requirements MAIN BODY

THREADED PART
Drain pan, recommended oil (if required) GROOVED SIDE
Maintenance
Place a drain pan under the oil drain opening.
Remove the cap of oil filling port and open the oil drain
valve.
Remove the plugs from the oil cooler and oil filter. Then
drain the oil.
Completely drain off the old oil. Open the inspection RING
covers at both sides of the gear casing, clean and wipe THREADED PART
the bottom of the gear casing with clean cloth.
SCREEN
Attach the inspection cover and close the oil drain
valve. Supply new oil to the upper line of the oil level O-RING BOWL
DRAIN PLUG
gauge. Then operate only the oil pump for one minute
and again top up the oil up to the upper line. Figure 8. Auto drain valve
Attach the cap of the oil filling port

Remove any compressed air from inside the auto drain
valve (ADV) before cleaning / maintenance /
GEAR CASING
inspection.
Pre work

BASE Allow the compressor to cool for a few minutes.
OIL DRAIN OPENING Requirements
Washing brush, air gun, replacement parts (if required)
Maintenance
DRAIN PAN
Close the ball valve in front of ADV, Turn the drain plug
OIL DRAIN VALVE
clockwise to loosen it. Water in bowl and compressed
Figure 7. Oil change air will be removed from ADV.
Disassembly & cleaning of cap:
Maintenance 7.5
Turn the cap counter clockwise to remove it. Remove 7.1.2.9 Blow-off silencer
any foreign matter from the filter with air blow.
Check the blow-off silencer every 16,000 hours or two
Wash the disc and disc cap. Remove any foreign matter years whichever comes first. Replace the sound absorbing
from the valve hole with air blow. Clean the threaded material or the entire blow-off silencer with a new one if
part of the cap and main body. necessary.
Check for damaged parts:
* Worn disc, deformed packing/washer, worn BLOW OFF SILENCER
thread on cap, worn disc cap retainer etc.
Perform the disassembly procedure in reverse order.

When attaching the disc, make sure that the grooved
side is directed downwards.
Attach the packing first and then the washer to the disc
cap.
Wipe the threaded parts of the cap and main body

carefully with a rag and apply grease to them and then
screw them in with hands.
Cleaning of inside of bowl:
Turn the ring counter clockwise to remove it. Remove Figure 10. Blow-off silencer
any foreign matter from the screen with air blow.
Flush the bowl with water and wipe it dry with a clean Pre work
cloth. Do not use any detergent to clean the bowl. This
may result in broken bowl.
Check for damaged parts, in particular the O-ring must Close the discharge end ball valve.
be checked. Damaged O-ring will result in air leakage.
Perform the disassembly procedure in reverse order. If
Requirements
it is hard to screw in the ring, apply grease etc. to the
threaded part and then screw it in with hands. New blow-off silencer (if required)
If air leaks after the cap and ring have been screwed in Maintenance
by hand, the following parts may be worn; replace Remove the top panel from the soundproof cover by
them. loosening the corner bolts.
1. Washer 2. Packing 3. Cap (Disc retainer) Remove the blow-off silencer from the ventilation box.
4. O-ring
Loosen the bolt installed at the top cover of the blow-off
7.1.2.8 Capacity control valve silencer.
Apply grease on the pinion gear and rack of the piston rod After removing the top cover, check it for warping,
every six months. deflection or cracks.
Remove the cartridge of sound absorbing material from

the blow off silencer.
Check the dispersing condition of the sound absorbing

material.
If lot of sound absorbing material is lost, it is necessary

to replace the blow-off silencer with a new one.
Assemble the blow-off silencer in the reverse order.
7.1.2.10 Coolers
PISTON ROD
PINION GEAR Coolers under pressure or hot coolers must not be opened
(screw plugs, caps).
Figure 9. Capacity control valve
Maintenance 7.6
Cleaning intervals Remove the cooler covers by un-tightening the nuts.
Cleaning on the side once in every 2500 hours. (for Also remove the fixation plates and partition plate.
water quality specified in this manual) Remove the outer O-rings from the both tube sheets.
If the water quality can be maintained as per our Drain the shell side circuit, by opening the drain in the
regular norms then it may be extended to 5000 hours lowest point and the vent in the highest point.
also.
Note the position / orientation of tube bundle inside the
Clean the air side once in every two years. cooler housing. After maintenance the tube bundle has
The above intervals are not mandatory and can vary to be installed in the same orientation (flat portion of
tube bundle facing the air flow).
according to the water quality.
Cleaning can be done based on the performance of the Move the tube bundle to one side until the inner O-ring
shows up (do not move the tube bundle further than
coolers.
necessary) and remove the inner O-ring.
Closed water cooling system can be used where de-
mineralised water is used for cooling purposes, which Move the tube bundle to the other side and remove the
inner O-ring on this side as well.
avoids formation of scales. Chemical additives can be used
to prevent scale formation based on water quality. The Carefully pull/ push the tube bundle from the shell.
required concentration of additive varies with water
Support the tube bundle under the fins when lifting it.
quality.
Be sure that the fins are not damaged during this
Preventive maintenance of heat exchanger is an user process (bending or other damage to fins can affect the
responsibility. thermal performance of heat exchanger)
Pre work Cleaning

Switch off the compressor and disconnect the power The air side of the tube bundle can be cleaned using
supply to the motor. compressed air.
Close the discharge end ball valve. Mechanical cleaning of heat exchanger
Allow the compressor to cool for a few minutes. The tubes can be cleaned with a nylon brush. Use the
genuine ELGi brushes only, they have the correct
Requirements
dimensions and are of suitable material. Spurious brushes
Nylon brushes, compressed air, water, chemical
may damage the protective layer present in the tube
cleaning agent (if required), neutralising solution (if
walls.
required), new O-rings (4 No.s)
Chemical cleaning of heat exchanger
The shell as well as the tube side can be cleaned by

Chemical cleaning may damage the heat exchanger. Make
circulating a chemical solution through the heat
sure your cleaning agent supplier verifies and confirms the
compatibility of his product with the materials of heat exchanger. Another possibility is dissembling of the bundle
exchanger. Cleaning of shell side is seldom necessary. and submerging the tube bundle in a tank filled with a
Maintenance chemical solution. There are several international
companies which supply equipment and cleaning fluids for
Disassembly
chemical cleaning of heat exchangers. These companies
Depressurize both circuits. can give you cleaning advice or cleaning service for your
Let both circuits cool down to ambient temperature. heat exchanger.
Drain the tube side circuit, by opening the drain in the Recommended chemicals for chemical cleaning:
lowest point and vent in the highest point. A sample cleaning procedure is given below: (This cleaning
Disassemble the leg supports from the cooler housings. advice is meant for water coolers only) Descalant NF
(inhibited cleaning agent)
Manufacturer Product Submerge the tube bundle in a tank with dissolved

cleaning agent. (time dependant on degree of fouling)
Drew HDE-777
Nalfleet MaxiClean 2 After cleaning neutralize the tube bundle and cleaning
agent with the neutralizing fluid.
Unitor Aquabreak
Flush the tube bundle with fresh water.
NOTE Dry the tube bundle.
specific properties, concentration, duration of cleaning,

temperature, etc.
Maintenance 7.7
Shut down periods Lift the cooler housing (using eye bolt, sling and crane)
and place it over the tube bundle.
(Tube bundle can also be lifted vertically with the help

of thread holes in the tube plates. For horizontal
assembly, bundle should be support under the baffle or
support sheet)
Move the cooler housing down over the tube bundle,

mount the 2 O-rings on the second tube sheet.
Move the tube bundle to its final position.
Mount the partition plate on the tube bundle slot.
Method 1 Mount the fixation plate on the cooler bundle groove,

then assemble the cooler inlet cover on the cooler
housing ( 4 bolts only).
Assemble the leg support on the cooler housing
Mount all connections and start up the heat exchanger

again. Make sure that the cold medium circulation is
established first, followed by gradual introduction of the
hot medium.
Check for any leakages
Tube bundle removal methods
Remarks
Copper fin is a very fragile part and should be handled

Method 2 with caution.
During shut down periods longer than a week the heat Troubleshooting
exchangers has to be drained completely and dries by
Performance too low
means of preheated compressed air. In fact this also has
to be done during short shut down periods (longer than a Check
day) when there is risk of freezing. It also applies when a Whether all connections have been made according to
corrosive medium is used in the heat exchanger. After the drawing.
draining the corrosive medium, heat exchanger has to be
Whether the heat exchanger and the system have been
rinsed with fresh water. Stopping the flows, cooling down
properly vented.
and draining of the heat exchanger has to be done in a
manner to minimize thermal stresses on the heat Whether the flows are according to the specification
exchanger. Never stop any of the fluid flows through heat (check all valves, lines and pumps, as well as flow
exchanger while the other fluid flows (due to risk of directions).
boiling). Whether the shell as well as the tube side have been
cleaned recently (fouling can cause drop in
performance, increased pressure loss)
After disassembling the heat exchanger never use the
old O-rings again. Replace them with genuine ELGi Leaking tubes / tube to tube sheet connection
spares. It is often difficult to determine whether leakage occurs
The O-rings have to be lubricated with a special O-ring because of a leaking tube to tube connection. The shell
lubricant (O-ring silicone paste of Parker O-lube) for side of a heat exchanger can be hydro tested, after
easy assembly and good sealing capacity. lubricants not disassembling the tube side.
suited for O-rings can affect the sealing capacity of the The tubes are roller expanded into the tube sheet. It is
O-ring. Any warranty claim will be rejected when not possible (finned tube bundles) to replace a leaking
unsuitable lubricants are used. tube, but it can be plugged with soft copper plugs
Assembly (other materials are too hard and may cause leakage of
Apply O-ring lubricants on the new O-rings (4 No.s). the adjacent tube to tube sheet connections) in both
tube ends. A maximum of approximately 10% plugged
Mount the 2 O-rings on the first tube sheet.
tubes will not influence the thermal performance of the
Place the tube bundle vertically, in such a way that the heat exchanger too much.
first tube sheet is in down position.
Maintenance 7.8
7.1.2.11 Electric motor Pre work
Pre work Switch off the compressor and disconnect the power
supply to the motor. Close the discharge end ball valve.
Close the discharge end ball valve. Allow the compressor to cool for a few minutes.
Allow the compressor to cool for a few minutes. Requirements
Requirements Spanner / pliers
Recommended grease, cleaning cloth, grease gun Maintenance
Maintenance When the pressure is lower, turn the adjustment screw

clockwise.
Check the insulation of motor winding.
If the oil pressure drops below 1.1 bar.g (15.95 psi.g), the
Remove moisture from the motor.
PLC controller shuts down the compressor automatically.
Check the junction box terminals and cable connectors
for loose connections. NOTE
Thoroughly clean the grease inlet fitting or plug. If the Regularly have inspections carried out in safety valve in
conformity with local regulations. It is the responsibility of
motor has plug, remove the plug and clean the inlet.
compressor owner to have the safety valve properly tested
Remove the drain plug and clean out any hardened at specified intervals.
grease.
7.1.2.14 Disassembly of sound proof
Slowly pump the grease into the grease inlet until the
cover
new grease comes out of the drain plug.
The sound proof cover consists of several panels, doors
Start the motor and allow to run at least one hour to
and shaped steel. They are bolted to each other so that it
expel any excess grease from drain opening before re-
is easy to assemble or disassemble them. To make the
installing the drain plug.
maintenance work easy, it is recommended to remove the
Stop the motor and lock out the switch. concerned panel or door.
Re-install the drain plug.
7.1.3 Use genuine spare parts
Put the motor back in operation.
It is very important to use genuine spare parts, because it
7.1.2.12 Gear case breather ensures that your compressor will work as new for its
lifetime. The spurious spares may be costing less, but it
Pre work
severely compromises on quality. So usage of such parts
Switch off the compressor and disconnect the power will be causing high operating cost, may be even result in
supply to the motor. total destruction of machine or grave danger. Always use
Close the discharge end ball valve. ELGi genuine spare parts.
Requirements
New separator element, strap wrench
Maintenance
Hold the separator outer shell by the strap wrench and

rotate it counter clockwise, until it completely unscrews.
Assemble the new separator to its position and rotate it

clockwise manually. After tightening, rotate it further by
hand or strap wrench for one and a half rotation.
Ensure there is no oil leakage from the mating surface.
7.1.2.13 Minimum pressure valve (MPV)

The minimum pressure valve maintains the oil pressure
adequate for the lubrication system. At the correct setting,
the oil pressure indicates 1.5 - 2.0 bar.g (21.75 - 29 psi.g)
in the PLC controller. If any variations in the standard
setting is found, follow the below procedures.
Maintenance 7.9
7.2 Troubleshooting
As a guide, the most likely problems with possible causes are listed in the following table. Before doing any work on this
unit, be sure the electrical supply has been cut off and the entire compressor system has been vented off all pressure.
marked items of suggested remedy have to be performed by nearest branch.
NOTE
In the case of the shutdown of safety devices, the display shows the fault details. Find the cause of shut down, correct it
and press the reset button.
Do not start the compressor again if the cause of shut down is unknown. Never perform a trial running to find the cause.
Whenever the cause is unknown, contact the nearest ELGi branch. Before starting the compressor again, ensure that
power supply to the motor is isolated, check for smooth rotation of rotors by rotating the motor shaft by hand from the
motor inspection cover. If motor turns free, reconnect power.
Push the reset button and the run button.
Problem Cause Solution (go sequentially)
a. Power failure a. Inspect power source
b. Breaker open b. Reset
c. Low oil pressure c. See condition 5
d. Main motor overload d. See condition 6
e. Main motor failure e. Contact nearest ELGi branch*

1. Compressor not
f. Failure of control circuit f. Check the sequence and replace damaged parts
starting
g. Low cooling water pressure g. See condition 22
h. Compressor in alarm h. Correct the corresponding cause and press reset
i. Low supply voltage i. Check for proper voltage and connections
j. Emergency stop switch pressed j. Release the emergency stop switch
h. Switch / transmitter malfunction h. Replace
a. High altitude a. Contact nearest ELGi branch*
b. Failure of check valve b. Inspect and replace
c. Dirty intake air filter c. Clean or replace
2. High 2nd stage d. Adjust the pre determined value of the unloader pressure
d. High discharge pressure
discharge air transmitter
temperature
e. High oil temperature e. See condition 4
f. High intake air temperature f. Check the ventilation of compressor room
g. Capacity control valve not

g. Contact nearest ELGi branch*
opened fully
a. High cooling water temperature a. Decrease the cooling water temperature

3. High compressor
discharge air b. Fouling of after cooler b. Clean the cooler
temperature
c. Low cooling water pressure / flow c. See condition 22
a. High cooling water temperature a. See condition 3-a
b. Low cooling water pressure / flow b. See condition 22
c. Oil cooler clogged c. Check and clean the cooler

4. High oil
temperature d. Poor quality of oil d. Replace the oil
e. Gear case breather element

e. Replace the element
plugged
f. Switch / transmitter malfunction f. Replace
Maintenance 7.10
a. Oil strainer /and oil filter clogged a. Clean or replace
b. Oil cooler clogged (internal) b. See condition 4-c
c. Low oil level in the reservoir c. Top up the oil

5. Low oil d. Oil pump failure d. Check and replace
pressure
e. Oil leakage e. Retighten the connections
f. Wrong MPV settings f. Re adjust

g. Joint loose connections in pump
g. Re-tight the connections
suction
a. Adjust the pre determined value of the unloader pressure
a. High discharge pressure
transmitter
b. Rotor contact b. Contact nearest ELGi branch*
c. Rotor rusted c. Contact nearest ELGi branch*
d. Main motor failure d. Contact nearest ELGi branch*
e. Unstable/ low source voltage e. Check and correct

nd
6. Main motor f. 2 stage inlet temp too high (dirty
f. Clean intercooler
intercooler)
overload
g. High intercooler pressure
g. Contact nearest ELGi branch*
2nd stage not working properly
h. Low intercooler pressure 1 st stage not
h. Contact nearest ELGi branch*
working properly
i. High cooling water temperature i. See condition 3-a
j. Low cooling water pressure / flow j. See condition 22
k. OLR setting is wrong k. Re adjust
a. Air leak from the discharge line a. Locate and repair
b. Air leak from blow-off silencer b. Check sealing surface and repair it
c. Air leak from safety valve c. Check and repair

7. Low d. Wrong setting of unloader pressure
discharge d. Re adjust
transmitter
pressure
e. Capacity control valve not opened
e. Contact nearest ELGi branch*
fully
f. Airend failure f. Contact nearest ELGi branch*
g. High air consumption g. Contact nearest ELGi branch*
a. Damaged 2 nd stage airend a. Contact nearest ELGi branch*
8. High b. Poor intercooler performance b. Clean* See condition 3-a, 3-c

interstage
pressure c. Dirty intercooler c. Clean the cooler inner fins , tubes and mist separator*
d. Switch / transmitter malfunction d. Replace
a. Dirty intake air filter a. Clean or replace
b. Air leak from interstage line b. Locate and repair
c. Air leak from the intercooler c. Contact nearest ELGi branch*

9. Low suction
pressure of 2nd d. Damaged 1 st stage airend d. Contact nearest ELGi branch*
stage airend
e. Dirty intercooler (internal) e. See condition 8-c
f. Capacity control valve not opened
f. Contact nearest ELGi branch*
fully
g. Switch / transmitter malfunction g. Replace
Maintenance 7.11
a. Damaged 1 st stage airend a. Contact nearest ELGi branch*
10. High 1st b. 2 nd stage not operating properly b. Contact nearest ELGi branch*
stage discharge
air temperature c. High air intake temperature c. Check ventilation of the compressor room
d. Intercooler chocked in air side d. See condition 3-b
a. Low cooling water pressure / flow a. See condition 22

11. High 2nd
stage suction b. High cooling water temperature b. See condition 3-a
air temperature
c. Dirty intercooler c. see condition 8-c
a. Damaged unloader pressure

a. Replace
transmitter
b. Damaged timer relay or power relay b. Replace
c. Low oil pressure c. See condition 5

12. No change
from unload to d. Damaged capacity control valve d. Contact nearest ELGi branch*
load
e. Defective solenoid valve e. Replace
f. Manual unload selected f. Select load option in PLC controller
g. PLC control defects g. Contact nearest ELGi branch*
a. Closed discharge valve a. Open
b. Malfunctioning of check valve which is

installed downstream of compressor unit b. Replace the check valve
(for compressors without aftercooler)
13. Blowing of
safety valve c. Pressure settings too high c. Set load and unload settings to the correct range
d. Damaged unloader pressure

d. Replace
transmitter
e. Safety valve malfunctioning e. Replace
a. Small receiver size a. Size the receiver accordingly
b. Check valve installed downstream of

b. Remove or put receiver between the compressor & the
14. Hunting of compressor unit (for compressors with
check valve*
capacity control aftercooler)
valve
c. Wrong unload pressure settings c. Re adjust
d. Damaged unloader pressure

d. Replace
transmitter
a. Clogged intercooler and/or aftercooler a. Clean*
b. Low source voltage b. Check and correct

15. High source
current
c. Damaged airend c. Contact nearest ELGi branch*
d. Motor failure d. Contact nearest ELGi branch*
a. Gear case breather element clogged a. Replace

16. Discharge
containing oil
b. Damaged shaft seal b. Contact nearest ELGi branch*
Maintenance 7.12
a. Loose joints in oil system a. Re tighten
b. Oil entering discharge line b. See condition 16
17. High oil c. Airend seal damaged c. Contact nearest ELGi branch*
consumption d. Airend joint leakages d. Contact nearest ELGi branch*
e. Airend vent hole plugged e. Contact nearest ELGi branch*
f. Breather filter chocked f. Replace
18. Compressor
back spins on shut a. Defective discharge check valve a. Repair or replace
down
a. Gear case breather element plugged a. Replace breather element

19. Oil leakage b. Oil level too high b. Lower the oil level to the specified level
from air vents on
1st or 2nd stage c. Airend seal damaged c. Contact nearest ELGi branch*
d. High oil pressure d. Re adjust the MPV settings
20. Oil leakage at a. Gear case breather element plugged a. See condition 19-a
main drive shaft
seal b. Shaft seal worn b. Replace shaft seal
a. Air leak from loose joints a. Re tighten
b. Broken blow off silencer b. Replace
c. Open canopy doors c. Close all canopy doors
d. Piping resonance d. Contact nearest ELGi branch*
e. Damaged compressor e. Contact nearest ELGi branch*
f. Damaged motor bearing f. Contact nearest ELGi branch*

21. Noise
g. Gear troubles g. Check tooth contact and correct*
h. Damaged oil pump h. Check and replace
i. Damaged coupling i. Check and correct
j. Oil pump noise due to low oil level j. Top up the oil
k. Oil pump noise due to coupling failure k. Replace
l. CCV troubles l. Check and correct/ replace
a. Failure of water supply a. Check and repair
b. Water stop valve closed b. Open

22. Low cooling
c. Water drain valve open c. Close
water pressure /
flow d. Low water supply pressure d. Check and correct
e. Dirty water line (including air coolers, oil

e. Clean*
coolers, air end jacket)
23. Oil level

a. Water entering the oil system a. Check and repair*
increased
a. Capacity control valve leakage or struck a. Contact nearest ELGi branch*
24. High blow-off b. Check valve leakage b. Contact nearest ELGi branch*
c. Blow-off silencer choke c. Replace blow-off silencer
Maintenance 7.13
7.3 Decommissioning, dismantling and
putting out of service
If you have decided not to use the compressor or any of Ensure that all the external supply lines have been
its parts, you must proceed with its dismantling and properly disconnected from the compressor before
putting out of service. These tasks must be carried out in decommissioning.
compliance with the standards in force of that particular
7.3.4 Disposal of consumables and
country.
replaced parts
7.3.1 Waste disposal
Disposal of the condensate and filter elements is to be
Use of compressor generates waste. The residues from done in accordance with the pollution control norms
agricultural, industrial, crafts, commercial and service prevailing at the time of compressor installation or use.
activities must be treated as waste, which needs to be
Parts of the compressor that are replaced have metal
disposed off properly. Deteriorated or obsolete
and rubber components. These may be recycled and
machines are also classified as waste.
disposed off according to local pollution control
Special attention must be given to active Carbon filters regulations.
as they cannot be included in urban waste. Observe the
Drained off compressor oil to be disposed according to
waste disposal laws in force where the compressor is
environmental regulations.
used.
Dispose all other parts of compressor in accordance
Please note that it is compulsory to record loading or
with local environmental regulations.
unloading of exhausted oils, obsolete machines and
toxic harmful wastes that derive from heavy or light
NOTE
industry processes.
ELGi is not responsible for the disposal of old oil or
It is especially important that exhausted oils be condensate. It is the responsibility of customer to dispose
disposed off in compliance with the laws in the countries the above mentioned in accordance with local
environmental statutory laws.
of use.
7.3.2 Dismantling the compressor

Dismantle the compressor in accordance with all the
precautions imposed by the laws in force in the country
of use.
Before dismantling, request an inspection by the

relevant authorities. Disconnect the compressor from
the electrical system.
Eliminate any interfaces the compressor may have with

other machines, making sure that interfaces between
remaining machines are unaffected.
Empty the gear case 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.
7.3.3 Decommissioning the compressor

Remove the foundation for the compressor.
Unplug the power cable entry to the compressor.
Drain the oil from the cooler and gear case. Dispose it
properly.
Make sure all the compressed air is vented out through

ball valves and safety devices provided in the
compressor.
Maintenance 7.14
7.4 ELGi Services
7.4.1 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)
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
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
7.4.2 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 7.1.3
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 7.4.3 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
Maintenance 7.15
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 7.16
7.5 Appendix
7.5.1 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
Square feet Square inches 144

Area (A)
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
Cubic metres per hour (m3/h) lpm 16.667

Volumetric flow (Q)
3
Cubic metres per minute (m /min) lps 16.667
Kilograms Pounds 2.205
Kilograms Grams 1000

Mass (M)
Kilograms Ounces 35.27
2
kgf/cm g psi g 14.223
psi g Pascal 6895

2
bar g kgf/cm g 1.0197
Pressure (P)
bar g psi g 14.503
psi g kgf/cm2 g 0.0703
Degree Celsius (°C) Degree Fahrenheit (°F) °F = 9(°C)/5 +32
Degree Celsius (°C) Kelvin (K) K = °C + 273.15

Temperature (T)
Degree Fahrenheit (°F) Degree Rankine (°R) °R = °F + 460
ft-lbf Joules 1.35582
ft-lbf Btu 0.001285
Joules Calories 0.2388

Heat (q), Work (W),
Energy (E) Btu/h Calories/h 252
Kilowatts Btu/h 3411
Metric horsepower Kilowatts 0.7355

Power (P)
Imperial horsepower Kilowatts 0.7457
Table 6: Conversion table
Maintenance 7.17
7.5.2 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 7: Metric hexagonal head bolts and screws
Thread size (inches) Tightening torque (N-m) Tightening torque (lb-ft)
¼ 45 33
½ 85 63
¾ 170 125
1 330 243
1¼ 430 317
1½ 510 376
Table 8: BSP threads
Thread size (inches) Tightening torque (N-m) Tightening torque (lb-ft)
9/16" 149 109.8875
7/8" 579 427.0125
Table 9: UNF threads
* Property class of 8.8 only
Maintenance 7.18
7.5.3 Operation log book
Date
Time
Voltage V Limits
Motor Current A
Power kW
#1 Outlet
pressure
bar.g (psi.g)
#2 Inlet
Interstage pressure
bar.g (psi.g)
#2 Inlet
temp.ºC(ºF)
#2 Outlet
temp.ºC(ºF)
Pressure
Discharge [loading]
bar.g (psi.g)
Pressure
[unloading]
bar.g (psi.g)
Ambient temperature
ºC (ºF)
Oil temperature ºC (ºF)
Oil pressure bar.g

(psi.g)
Water pressure bar.g

(psi.g)
Load ratio %
Total operation hours
No. of loadings
Oil added L (gal)
Condensate
Intercooler
drained
Daily Condensate
Aftercooler
control drained
Inspect oil
Oil level
level
(Trips, Parts
Remarks
change etc.)
Maintenance 7.19
7.5.4 Service log book
Sl. No. Date Service performed Serviced by
Maintenance 7.20
7.6 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.
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
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.
without giving any adequate notice / alarm before starting the product .
© Copyright ELGi Equipments Limited, India 2019. All Rights Reserved.
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Contents Page No.

2.1 Using the manual 2.2

2.2 Introduction 2.3

2.3.2 Precautions during operation 2.5

2.3.3 Precautions during maintenance 2.7

2.4 Functional description 2.8

2.4.2 Oil circuit 2.8

2.4.3 Water circuit 2.8

2.4.4 Drive system 2.8

2.4.5 Control system 2.9

2.4.6 Safety devices 2.9

General functional description 2.1

This operation and maintenance manual has been

Following chapters are provided to operate the compressor

Safety - safety precautions that must be followed while

Functional description - various systems and their

ELGi services services from ELGi: CCS, air audit,

Appendix conversion tables, torque values, operation

Refer to the parts manual to identify the part number of

This manual must be made available to the

2.1.1 Definitions and symbols

All the information, illustrations and specifications in this

General functional description 2.2

about delivering uptime. Our uptime design ensures that

Oil free (OF) series

The screw compressor technology ensures that there is no

Improved air filter life cycle

General functional description 2.3

Manual valves after non-return valves (NRV) must be

Do not use frayed, damaged or worn hoses. Distribution

Make sure that the aspirated air by the compressor is

For remotely controlled compressors and auto-start

General functional description 2.4

2.3.2 Precautions during operations

are kept inside the compressor. substances immediately.

particles. and other sources of ignition away from the

Pressure release Do not operate the compressor without a proper flow of

General functional description 2.5

If warm cooling air from the compressor is being used

Keep hands, arms and clothing away from couplings,

Stand on a dry or insulating surface and do not contact

Before switching on the compressor ensure that proper

Do not leave the compressor unattended with open

Disconnect, lock out and tag the power source prior to

All electrical installation must be in accordance with

Keep a first aid kit handy. Seek medical assistance

Toxic and irritating substances

General functional description 2.6

Regularly check that all electrical connections are tight

Periodically check whether

All hoses and pipes inside the compressor are in good

Safety valves and other pressure relief devices are not

Air outlet valve, i.e. pipes, couplings, manifolds, valves,

2.3.3 Precautions during maintenance

Use appropriate tools for all maintenance works.

Use only genuine spare parts. Refer the

Persons switching on remotely controlled compressors

Vent all internal pressure prior to opening any line,