ELECTRIC POWERED SCREW AIR COMPRESSOR

PARTS MANUAL

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 SCREW AIR COMPRESSOR

Coimbatore – 641 005, INDIA

Document Ref. No. : 01 90 03 440

Revision Status: R00 dt :March 2007

First print:

Printed in India

Price: INR

Compiled by
 SCREW AIR COMPRESSOR

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 SCREW AIR COMPRESSOR

Introduction

ELGI EQUIPMENTS LIMITED is a leading Indian manufacturer of

Rotary Screw Air Compressors. ELGI Rotary Screw Air Compressors are
widely used in India and other parts of the world. The equipment are
known for their reliability, maintenance, friendliness and safety. Every
Screw Type Air Compressor is designed keeping in mind three key quality
consideration viz.,

1. Energy Efficiency
2. Air Quality
3. Maintenance

We are confident, the equipment you have purchased will give you
satisfactory service for its life.

We thank you for giving us an opportunity to serve you with our

Compressor.

This Parts Manual has been specially designed keeping you in mind, so that
you can get the most out of ELGI Compressor. This Manual contains
schematic views and parts lists for various sub-assemblies of the
compressor.

All information and illustrations in this manual are based on the latest
product development available at the time of supply. We reserve the right
to make changes in the product at any time without notice. We assure you
of the best service in maintaining uptime of the compressor through prompt
service and supply of spare parts as per your requirements.

This manual must be made available to the maintenance personnel at all

times.

Please read the instructions very carefully given in the Operation and
Maintenance Manual, right to the end, as the operating life and reliability of
the compressor depends to a large extent on correct operation and
maintenance.

Contact ELGI dealer / representative for any assistance. Always indicate

the Model and Fabrication number in your communication.
 SCREW AIR COMPRESSOR

Table of Contents

Section 1 PART LIST OF VARIOUS SYSTEMS Page

No.

1.1 Air Inlet System 2

1.2 Discharge System 4

1.3 Cooling System 8

1.4 Lubrication System 10

1.5 Control System 12

1.6 Canopy system 14

1.7 Motor and Base system 16

1.8 Electrical System parts list 17

1.9 Layout dimension 20

Section 2 RECOMMENDED SPARES

2.1 Horizon series 21

2.2 Recommended Oil 22

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 SCREW AIR COMPRESSOR

1.1 AIR INLET SYSTEM PARTS LIST

Part No. Description Part Code Qty.

1. Bolt, hex, M12 x 25 00 09 06 182 4

2. Washer Spring M12 00 09 96 112 4

3. Washer, plain, M10 00 09 96 010 2

4. Intake valve B988701 1

5. Gasket , intake valve 01 04 3039 0 1

6. Rubber pipe bend B906701 1

7. SS T-Bolt clamp B505307 2

8. Air filter B476701 1

9. Dust indicator B896701 1

10. Bracket filter mtg 01 04 3074 0 1

11. Washer spring M8 00 09 96 108 2

12. Bolt hex M8x20 00 09 06 115 2

13. Nut hex M8 00 09 4800 8 2

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1.2 DISCHARGE SYSTEM

Part No. Description Part Code Qty.

1. O ring 01 04 5150 0 2
2. Pipe with flange DCV Line 01 53 0034 5 1
3. Pressure relief valve 1/2" NPT A01 0019 1
4. Hex. bolt M8 x 25 00 09 06 116 4
5. Spring washer M8 00 09 96 108 4
6. Plain washer M8 00 09 96 008 4
7. Nylon Hose 1/2 ID 00 09 45 002 0.3Mt
8. Pipe Coupling style 12 - 1 ½” B 56 XX 07 1
9. Connector, PVC hose 1/2" 00 09 20 002 1
10. Ball valve, 1/2" NPT B312701 1
11. Hex Nipple ½” 22 03 7903 C 1
12. Tank ,receiver ASME 01 53 00 445 1
13. Oil sight glass 1 1/2" NPT A01 0018 1
14. Plug hex. 1" NPT 22 03 7905 F 1
15. Name plate, receiver tank 00 04 2093 0 1
16. Rivet dia 2.5 x 6.5 00 05 1953 0 4
17. Gasket, separator element 01 04 5046 0 2
18. Element seperator 01 03 5006 0 1
19. Cover, receiver tank 22 04 1127 A 1
20. Spring washer, M12 00 09 96 112 12
21. Hex. bolt M12 x 40 00 09 06 185 8
22. Hex. nipple 1 1/4" NPT 22 03 7903 F 1
23. Minimum pressure valve 1 1/4" NPT 22 02 1052 A 1
24. Bush adaptor reducer 1 1/4" M x 1" F 22 03 7897 T 1
25. TMS Elbow 1"NPTxM36x2 000959296 2
26. Hose MPV to Cooler 015400319 1
27. Pipe 1" AC to MS - E11 01 54 00 317 1
- E15-E22 01 04 4337 C 1
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Part No. Description Part Code Qty.

28. Moisture separator * See Below 1
29. Pipe 1" - MS to Ball valve 01 04 4337 A 1
30. Hex. nipple 1" NPT 22 03 7903 E 1
31. Ball valve 1" NPT B312703 1
Parallel MSC ½”BSPxM36x2 - E11-E15 0009 59 262 1
32.
Parallel MSC ¾”BSPxM36x2 - E18-E22 0009 59 263 1
33. Nylon tube / 1/4" OD 09 45 45 790 0.75Mt
34. Plastic male conn 1/8”BSPx6mm OD B010501240002 1
35. Plain washer M12 0009 06 012 4
36. TMS elbow 1/4"NPTx1/4”BSP 0009 59 270 2
37. Tube 1/4" OD –Return line 01 53 00 355 1
38. Hex. bolt M12 x 35 00 09 06 184 4
39. Coupling TMS ¼” x1/4” NPT 22 04 7683 A 1
40. Plastic male conn 1/4”BSPx6mm OD B010501240004 1
41. Swivel elbow con.1”NPT x M36x2 00 09 59 260 1
42. Swivel elbow con.1”NPT x M36x2 00 09 59 260 1
43 TMS elbow 1/8" x 1/4"BSP 0009 59 269 1
SE con.1/2”BSP x M36x2x ¼”Tap-E11-E15 0009 59 XXX 1
44.
SE con.3/4”BSP x M36x2x ¼”Tap-E18-E22 0009 59 294 1
45. Adapter Temperature Sensor 01 04 6103 0 1
46. Thermal Switch B172201 1
47. Cover Thermal switch 01 54 00 514 1

* NOTE :.

For E11 t o E15 - A010102

For E18 to E22 - A010103

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1.3 Cooling System

Part No. Description Part Code Qty.

1. Oil Cooler & After cooler assembly * See Below 1

2. Plate cooler support ** See Below 2
3. Washer, spring, M8 00 09 96 108 16
4. Bolt, hex, M8 x 25 00 09 06 116 12
5. Shroud, cooling, *** See Below 1
6. Fan motor 230 V /460V **** See Below 1
7. Washer, spring, M10 00 09 96 110 4
8. Bolt, hex, M10 x 30 00 09 96 145 4
9. Fan ***** See Below 1
10. Fan hub , E22 01 04 4359 0 1
11. Bolt, hex, M8 x 20 00 09 06 115 4
12. Nut, hex, M8 00 09 48 008 1
13. Bolt, hex, M8 x 20 00 09 06 115 1
14. Nut ,hex,M8 00 09 48 008 12

NOTE :.

* For E11 – B007700690001

* For E15 – E22 – B007700690004

** For E11 – 015300950

** For E15 – E22 – NIL

*** For E11 – 01 03 4170 0

*** For E15 – E22 – 01 03 4078 0

**** For E11 – 1Hp, 60 Hz – B007600580001

**** For E15 – E22 -1.5Hp – B525802

***** For E11 – B810103

***** For E15 – E22 – B810102

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1.4 LUBRICATION SYSTEM

Part No. Description Part Code Qty.

1. TMS Elbow 3/4" NPT x M27x1.5 0009 59 267 4
Pipe Elbow tank to cooler No.1 – E11 01 54 00 316 1
2.
Pipe Elbow tank to cooler No.1 – E15-E22 01 04 4337 E 1
3. Pipe Elbow tank to cooler No.2 – E11 01 54 00 315 1
Pipe Elbow tank to cooler No.2 – E15-E22 01 04 4337 F 1
4. Pipe Cooler to MOF – E11 01 54 00 318 1
Pipe Cooler to MOF – E15-E22 01 04 4337 G 1
5. Spin on filter assembly A010113 1
6. Pipe MOF to Airend – E11 01 54 00 322 1
Pipe MOF to Airend – E15-E22 01 04 4337 D 1
7. Elbow Union M27x1.5 NPT 0009 59 297 1
8. SE connector 3/4”BSP x M27x1.5 0009 59 265 1
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1.5 Control System Parts List for E11 - E22 With two kgf/cm2
sump pressure during unloading

Part No. Description Part Code Qty.

1. Bush reducing adapter ½”Mx1/4”F 22 03 7897 E 1
2. TMS Elbow ¼”NPT 22 04 7681 B 5
3. Control line tubes 01 53 0 1053 1
4. TMS Coupling ¼” x ¼” NPT(Pressure transmitter) 22 04 7683 A 2
5. Tee pipe ¼” NPT (Pressure transmitter to solenoid) 22 04 7680 A 1
6. TMS Elbow ½”NPT 22 04 7681 F 1
7. Hose ¼”x M10 00 09 19 242 1m
8. Quick fitting connector ¼” BSP x M10 00 09 20 506 4
9. Pipe ½” Tank to BDV 01 04 6097 0 1
10. TMS Coupling ½” NPT 22 04 7683 E 1
11. Blow down valve assy – 3/8” B 98 87 04 1
12. Bush reducing adapter 3/8”Mx1/4”F 22 03 7897 C 1
13. Tee pipe ¼” NPT 22 04 7680 A 1
14. Non-Return valve assy ¼” B 44 17 01 1
15. Socket ¼” NPT (Both side thread) 22 04 7685 A 1
16. Hose ¼”x M10 00 09 19 242 0.5m
17 Quick fitting connector ¼” BSP x M6 00 09 20 504 2
18. Hose ¼”x M6 00 09 19 226 0.25m
19. Manifold ¼” NPT 01 54 00 442 1
20. TMS Coupling ½” x ¼” NPT 22 04 7683 N 1
21. Orifice 20S 22 04 1069 C 1
22. Solenoid valve 110 V 01 04 6416 0 1
23. TMS Coupling ¼” x ¼” NPT 22 04 7683 A 4
24. TMS Coupling ¼” x 1/8” NPT 22 04 7683 P 1
23. Branch Tee ¼” NPT 22 04 7682 A 1
24. TMS ELBOW ¼” x 1/8” NPT 22 04 7681 A 1
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1.6 CANOPY SYSTEM

Part No. Description Part Code Qty.

1 Panel LH & RH 01 02 9006 0 3
2 Panel LH – Tank side 01 03 9099 0 1
3 Post center 01 03 9003 0 2
4 Box Electrical control 01 53 0036 0 1
5 Panel top 01 03 9097 0 1
6 Support cooler mounting LH 01 53 00 924 1
7 Support cooler mounting RH 01 53 00 925 1
8 Panel rear bottom 01 03 9007 0 1
9 Panel rear top 01 03 9094 0 1
10 Panel front bottom 01 03 9002 0 1
11 Door Electrical Box 01 53 0034 4 1
12 Post corner front LH 01 53 0034 6 1
13 Post corner front RH 01 53 0034 7 1
14 Post corner rear RH 01 03 9096 0 1
15 Post corner rear LH 01 03 9603 0 1
16 M8 Spring washer 00 09 96 108 21
17 Bolt hex head cap M8x20 00 09 06 115 21
18 Screw hex socket head cap M8x40 00 09 83 087 6
19 Screw hex socket head cap M8x16 00 09 83 081 4
20 Screw hex socket head cap M8x30 00 09 83 083 2
21. Screw hex socket head cap M8x20 00 09 83 079 8
22. Screw hex socket head cap M6x12 - Hinge 00 09 83 062 2
23. Plain washer M6 - Hinge 00 09 96 008 2
* 24. Fire Retardant foam ------- 1 Set

* - Not shown in Figure

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1.7 MOTOR & BASE ASSEMBLY

Part No. Description Part Code Qty.

1. Base assembly for E11-E22 01 03 8038 0 1
2. Main motor * see below 1
3. Washer punched M12 00 09 96 012 4
4. Washer spring M12 00 09 96 112 4
5. Bolt, hex, M12 x 45 00 09 06 186 4
6. Coupling, flexible * see below 1
7. Ring adapter 22 02 1203 0 1
8. Bolt hex, M16 x 60 00 09 06 218 4
9. Washer spring M16 00 09 96 116 4
10. Nut hex M16 00 09 48 016 4
11. Bolt, hex M10 x 50 00 09 06 149 8
12. Washer spring M10 00 09 96 110 8
13. Nut, hex, M10 00 09 48 010 8
Bracket airend – E11-E15 01 04 8022 A 1
14.
Bracket airend – E18-E22 01 04 8022 B 1
15. Bolt hex M8 x 20 00 09 06 115 3
16. Washer spring M8 00 09 96 108 2
17. Washer plain M8 00 09 96 008 3
18. Guard, coupling 01 03 8004 A 1
19. Bolt, M8 x20 00 09 06 115 4
20. Washer plain M8 00 09 96 0108 4
21. Name plate 01 04 6422 0 1
22. Rivet dia 2.5 x 4.5 00 05 1952 0 4

Main Motor :. Coupling Flexible :.

For E11 - B515812 E11 & E15 - B545901

For E15 - B515807 E18 & E22 - B545902
For E18 - B515808
For E22 - B515809
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1.8 ELECTRICAL SYSTEM PARTS LIST FOR

E11-E55 LAC (230 V_60Hz)
Sl. No. Description Part Code Qty.
1. Power contactor (K1, K2 & K3) 3
1.1 E11, 37A 00892827P
1.2 E15, 43A 00892828P
1.3 E18, 60A 00892830P
1.4 E22, 60A 00892830P
1.5 E30, 85A 00892831P
1.6 E37, 95A 00892832P
1.7 E45, 140A 00892833P
1.8 E55 180A 00892834P
2 Fan motor contactor (K4) 16A 00892826P 1
3. Main motor overload relay (e1) 1
3.1 E11 18-30A 00893323P
3.2 E15, 30-45A 00893324P
3.3 E18, 30-45A 00893325P
3.4 E22, 45-60A 00893326P
3.5 E30 60-75A 00893327P
3.6 E37 70-90A 00893328P
3.7 E45 57-180A 00893329P
3.8 E55 57-180A 00893329P
4. Fan motor overload relay (e2)
4.1 E11 2.4-4A 00893321P 1
4.2 E15-E22 4-6A 00893322P
4.3 E30-E55 6-10A 00893330P
5. Control relay (CR)
5.1 E11 – E55 24-240V AC/DC 00893612 1 1
6. EM.Stop PB 008940017 1
7. Manual Unload PB 008940016 1
8. Universal Transformer 200VA 008937045 1
9. Universal Transformer 50VA 008937028 1
10 Miniature Circuit Breaker 10A,TP 008927039 1
POWER WIRING DIAGRAM
230V,60Hz E11_S1

01 8 3 6022 0
SCREW AIR COMPRESSOR
STARTER CUM CONTROL PANEL
230V,60Hz E11_S1

0 1 8 3 6022 0
SCREW AIR COMPRESSOR
STARTER CUM CONTROL PANEL
230V,60Hz E11_S1

0 1 8 3 6022 0
SCREW AIR COMPRESSOR
POWER WIRING DIAGRAM
230V,60Hz E15_S1

0 1 8 3 6022 2
SCREW AIR COMPRESSOR
STARTER CUM CONTROL PANEL
230V,60Hz E15_S1

0 1 8 3 6022 2
SCREW AIR COMPRESSOR
STARTER CUM CONTROL PANEL
230V,60Hz E15_S1

0 1 8 3 6022 2
SCREW AIR COMPRESSOR
POWER WIRING DIAGRAM
230V,60Hz E18_S1

0 1 8 3 6022 4
SCREW AIR COMPRESSOR
STARTER CUM CONTROL PANEL
230V,60Hz E18_S1

01 8 3 6022 4
SCREW AIR COMPRESSOR
STARTER CUM CONTROL PANEL
230V,60Hz E18_S1

0 1 8 3 6022 4
SCREW AIR COMPRESSOR
POWER WIRING DIAGRAM
230V,60Hz E22_S1

0 1 8 3 6022 6
SCREW AIR COMPRESSOR
STARTER CUM CONTROL PANEL
230V,60Hz E22_S1

01 8 3 6022 6
SCREW AIR COMPRESSOR
STARTER CUM CONTROL PANEL
230V,60Hz E22_S1

0 1 8 3 6022 6
SCREW AIR COMPRESSOR
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 SCREW AIR COMPRESSOR

2. RECOMMENDED SPARES
2.1 FOR HORIZON SERIES

Kit of spares up to 2500 hours of running, contains K 01 03 H1 8

Air filter element B574603 1 No.

Oil filter kit 01 03 40480 3 Nos.

Element separator 01 03 5006 0 1 No.

Insurance kit E11 – E22 ELGI S1 PLC

Minimum pressure valve kit 22 02 1052 9 1 No.
110V AC Solenoid valve 010464160 1 No.
Pipe Coupling style 12 - 1 ½” B56XX07 1 No.
`O’ Ring 01 04 5150 0 2 Nos
Blow down valve kit 22 03 7108 9 1 No.
Coupling element ,Rotex 48 01 24 3752 0 1 No.
Intake valve kit 01 03 3120 9 1 No.
Auto drain assy 01 04 4225 0 1 No.
Pressure Transmitter 00 89 7901 C 1 No
Temperature Sensor 00 89 7902 C 1 No
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2.2 RECOMMENDED OIL

Elgi Air Lube
• Oil performs a very critical function in the oil flooded screw type air compressor. This takes away
major part of the heat of the compression, seals all the areas and lubricates bearings and gears. The
major criteria in a good quality lubricant for screw compressor are

a) Viscosity
b) Wear Characteristic
c) Demalcibility
d) Heat resistance
e) Thermal stability

• Elgi Airlube is blended using heavy-duty hydraulic based oil with proper amount of additives and strict
quality control check of every batch footprint ensures satisfactory compressor performance.

Life of mineral oil is covered by operating temperature for every 10 deg C of temperature beyond 95
deg C. Life of oil goes down by almost 30-40%. (It is recommended that oil change frequency could
be vary between summer months and winter months to get best out of the mineral oil and compressor)
Hece operating temperature of compressor oil is essential. Continuous operating of compressor at high
temperature beyond 95 deg C and without changing the oil will lead to varnish formation and will
affect life of bearings of airend and compressor parts.

Proposed Drain Period for AIR LUB

S.No. Description Drain Period

1. Normal industrial application operating temperature 95 deg C 1000 hours
2. Dusty environment 750 hours

• All the above figures are guidelines based on extensive trials in the field. However, our Service
Engineers can help you to optimise the oil drain interval for your application based on the operating
temperature, pressure and the environment condition.

PART NO. 000998043

 SCREW AIR COMPRESSOR

Proposed Drain Period for AIR LUB+

S.No. Description Drain Period

1. Normal industrial application operating temperature 95 deg C 2000 hours
2. Dusty environment 1500 hours

• All the above figures are guidelines based on extensive trials in the field. However, our Service
Engineers can help you to optimise the oil drain interval for your application based on the operating
temperature, pressure and the environment condition.

PART NO. 00099805*

PART No.
00099805A Air lube plus long life oil 20Ltr
00099805B Air lube plus long life oil 50Ltr
00099805C Air lube plus long life oil 210Ltr

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