ELGI EQUIPMENTS LIMITED

ELECTRIC POWERED
SCREW AIR COMPRESSOR

E55
S1 PLC, 230V / 460V, 60Hz

OPERATION AND MAINTENANCE MANUAL

PARTS MANUAL
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005

Part / Document No. 01 90 03 430

Print Status
R 00 - March : 2007

Replaces Earlier

Doc. No. : Nil

Date : Nil

* Confidentialness is immensely imperative as this book is controlled document

* This technical document is meant strictly for private (internal) use only by Elgians.

Contact Info :
Rotary Compressor Division
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005, India
Tel : 91 - 422 2574691
Fax : 91 - 422 2591384 (Domestic Business)
Fax : 91 - 422 2576849 (International Business)
e-mail : rocd@elgi.com/ export@elgi.com
Mobile GSM : 91 - 9843 - 057479 / 057369 / 057469
Mobile CDMA :
 SCREW AIR COMPRESSORS

Company Profile

Elgi Equipments Ltd is the technologically innovative company with four decades of expertise in
the manufacture of compressors, based in Coimbatore, India. ELGI is one of the largest manufactures of
compressors and also a leader in Automotive Service Equipment and Diesel Engines.

An ISO 9001 company practicing Six Sigma and TPM, ELGI employs best in class practices and
provides total in-house capabilities to design and manufacture products to meet international standards.

ELGI is driven by the principle of “Extra Engineering”. It means building extra value into everything
we do, right from concept to design, development to manufacturing, marketing, delivery, service and
knowledge sharing.

ELGI manufactures a comprehensive range of products for compressed air applications such as
Reciprocating Air Compressors, Rotary Screw Air Compressors both Oil-flooded and Oil-free and
Centrifugal Air Compressors. ELGI also manufactures the Airmate range of Air Treatment downstream
auxiliary accessories-Refrigeration Air Dryers, combination Air Filters, Air Receivers, Jack Hammers
and more.

ELGI has a committed and technically strong team of 1100 with 325 engineers. ELGI operates
from two state of art manufacturing plants in Coimbatore, India with 30 acres of land and around 350,000
sq. feet of built up factory area. Elgi operating out of an advanced and sophisticated manufacturing
facility with R&D and CAD facilities, a totally integrated machine shop, CNC helical rotor cutting machines,
tool management centers, and Metrology Laboratory.

ELGI has collaborations and technical tie-ups with leading foreign companies, institutions and
consultants that ensure ELGI remains at the cutting edge of manufacturing technology. Axis Airends are
designed and developed by ELGI under joint technology agreement with the Positive Displacement
Compressor Technology Research Centre at City University, London. Also entered joint venture with M/
s. Hitachi Limited, Japan for manufacturing Oil Free Screw Air Compressor & with M/s Samsung Tech
win Company Limited, Korea for producing Centrifugal Air Compressors.

ELGI has a vast network of sales and service outlets manned by well-trained, highly qualified and
motivated engineers worldwide. Elgi is a leading exporter of top blocks of reciprocating air compressors
and Air Ends of Screw Air Compressor for OEM’s and complete compressor packages all over the world.

ELGI truly has a global presence, with over 30 percent of its production reaching end-users and
OEM’s in the USA, Europe, Australia, South East Asia and Middle East.

Based on the firm foundations of reliability, technology, capability and value, Elgi faces the future
with confidence. We are today in a strong position to strike new partnerships for growth, and drive through
mergers and acquisitions, to keep abreast with the latest technology from around the world. As always,
innovation will continue to be our key differentiator. To bring better products and services that put a smile
on the face of our customer.

III
IV
 SCREW AIR COMPRESSORS

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 equipments 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 Operation and Maintenance Manual has been specially designed

keeping you in mind, so that you can get the most out of ELGI
Compressor. Before you start using your compressor, do go through this
manual thoroughly. It contains vital information on operations and useful
tips that will keep your compressor running as good as new, year after
year.

All information, illustrations and specifications 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 has been prepared with utmost care to help the user to
understand various systems involved in the compressor thoroughly
through detailed descriptions, working conditions and illustrations. This
manual must be made available to the compressor operating personnel
at all times.

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

V
VI
 SCREW AIR COMPRESSORS

Table of Contents

Section 1 USER INFORMATION Page No.

1.1 General 1.1
1.2 Guarantee 1.2
1.3 Handling Compressor 1.2
1.4 Compressor Location 1.5
1.5 Ventilation 1.7
1.6 Compressor Installation 1.7
Section 2 SAFETY 2.1
Section 3 DOS AND DON'TS 3.1
Section 4 SPECIFICATIONS & SALIENT
FEATURES
4.1 Technical Specifications 4.1
4.2 Salient Features 4.2
Section 5 COMMISSIONING
5.1 General 5.1
5.2 Instructions for commissioning 5.1
Section 6 WORKING PRINCIPLE 6.1
Section 7 SYSTEM OPERATION 7.1
Section 8 FUNCTIONS OF VARIOUS SYSTEMS
8.1 Air Inlet System 8.1
8.2 Capacity Control System 8.2
8.3 Discharge System 8.3
8.4 Cooling and Lubricating System 8.11
8.5 Control System 8.13
8.6 Air Lube 8.20
Section 9 SAFETY AND INTERLOCKING
DEVICES
9.1 Safety and Interlocking Devices 9.1
Section 10 ELECTRICAL SYSTEM AND
CONTROL ELEMENTS
10.1 Control Panel 10.1
10.2 Annunciation Panel 10.2
10.3 Control Elements 10.3
10.4 Electrical diagram 10.5

VII
Section 11 MAINTENANCE
11.1 General 11.0
11.2 Daily Operation 11.0
11.3 Maintenance after initial
50 hours of running 11.1
11.4 Maintenance after every
500 hours of running 11.1
11.5 Maintenance above
500 hours of running 11.1
11.6 Components Maintenance
and Replacement Procedure 11.3
11.6.1 Oil Filter 11.3
11.6.2 Separator Element 11.4
11.6.3 Air Inlet Filter 11.4
11.6.4 Drive Coupling 11.5
11.6.5 Control System Adjustment 11.5
11.6.6 Minimum Pressure Valve 11.7
11.6.7 Inlet Valve Maintenance 11.9
11.6.8 Blow down Valve 11.11
11.6.9 Moisture Separator 11.13
11.6.10 Thermal valve 11.15
11.7 Trouble Shooting 11.16

Section 12 RECOMMENDED SPARES

12.1 For Horizon E55 models 12.1

Section 13

13.1 Installation data 13.1

Section 14

14.1 Maintenance Log Book 14.1

VIII
 SCREW AIR COMPRESSORS

1. User Information

1.1 General REFER THE DIAGRAMS SHOWN ON PAGE 1.3 & 1.4 FOR
HANDLING COMPRESSOR.
Ensure the Operation Instruction Manual be made available to the
compressor operating personnel at all time.
Please read the instructions carefully and strictly adhere it to the end
as the operating life and the reliability of the Compressor depends to a
large extent on correct operation and maintenance.
While communicating with ELGI Dealer/ Service Centre/ Branch Office
regarding the Compressor you have, ensure all the details on Name-
Plate (format shown below) are given. The name-plate is fitted on the
front side of the Compressor base frame. For ordering spare parts,
refer “Recommended Spare Parts” chapter and provide Part Number
along with quantity in addition to the name plate data of Compressor.

KW

m min
2
kgf cm

1.1
1.2 Guarantee ELGI does not accept any liability for damages in transit and handling
in transport. However this will be settled strictly as per the transit
insurance policy for the equipment. Please inspect the Compressor
immediately after delivery.

In the event of any other complaints, please inform us within six days
after the receipt of consignment. Preserve the Guarantee Certificate
sent along with the Compressor safely.

ELGI cannot accept any guarantee for damages resulting from failure
to observe the operating instructions given in this manual. The guarantee
will also expire if you alter the Compressor yourself in any way, perform
improper repairs or insufficient maintenance. Appropriate repair and
maintenance also involve the exclusive use of ELGI Genuine Spare
Parts and ELGI operating materials.

We reserve the right for modification without notice in the interest of

technology progress.

1.3 Handling Compressor Refer Lifting/ Handling diagrams for general guidance.
l If the compressor is provided with a lifting bail then lift by the bail
provided. If no bail is provided then lift by sling. Compressors to be
air lifted by helicopter must not be supported by the lifting bail, but
by slings instead.
l Prior to lifting, inspect lifting bail and points of attachment for
cracked welds and for cracked, bent, corroded or otherwise degraded
members and for loose bolts and nuts.
l Make sure entire lifting, rigging and supporting structure has been
inspected, is in good condition and has a rated capacity of at least
the net weight of the Compressor plus an additional 10% allowance
for the weight of stored tools and equipment. If you are unsure of
the weight, then weigh Compressor before lifting.
l Make sure lifting hook has a functional safety latch, or equivalent,
and is fully engaged and latched on the bail.
l Use guide ropes or equivalent to prevent twisting or swinging of
the machine once it has been lifted clear off the ground.
l Do not attempt to lift in high winds.

1.2
 SCREW AIR COMPRESSORS

1.3
l Keep all personnel out from under and away from the Compressor
when it is suspended.
l Lift Compressor not higher than necessary.
l Keep lift operator in constant attendance whenever Compressor is
suspended.
l Set Compressor down only on level surfaces capable of supporting
at least its net weight plus an additional 10% allowance for the weight
of stored tools and equipment.

1.4
 SCREW AIR COMPRESSORS

1.4 Compressor Location Please observe the valid Accident Prevention Regulations when
installing this Screw Compressor.

Install the Compressor with adequate accessibility to ensure

obstruction-free operation and maintenance.

The area around Compressor/ Compressor room should be clean, dry,

cool and free of dust. The room temperature for air cooled and oil
lubricated Screw Compressors should be preferably below 45 oC.
Excessively warm intake air affects the compressed air output. When
the discharge temperature of Compressor (temperature at Compression
Unit) exceeds the set value, the Compressor will switch-off. Also the
ambient temperature should not drop below +5 OC. Provide air supply
openings with adjustable louvers to ensure that the minimum
temperature is not dropped below +5 O C in winter. Refer motor
installation standards for details.

Rooms accommodating Compressors with oil lubricated and motor

rating of more than 40 kW must be specially fire protected. Never
store combustible materials within at least 10m radius of Compressor.
The floor around Compressor also must be of non-combustible material.

Compressors may only be installed in working area if the sound

pressure level of their measuring surface does not exceed 85 dB(A).

1.5
A Room ventilation through openings in the outside walls

B Room ventilation support by ventilators

C Room ventilation with hot-air duct into the open.

D Room ventilation with hot-air duct and recirculation flap. Hot air is
mixed with the cold ambient air and prevents the plant freezing up
at temperature under freezing point.

E Room ventilation with hot-air duct. Hot air can be used to heat the
room in the winter; in summer it can be directed in to the open.

1.6
 SCREW AIR COMPRESSORS

1.5 Ventilation l Ensure adequate ventilation in Compressor installation area.

l Provide openings near to the floor level on walls/ partitions close
to air suction side of Compressor for cool air supply to Compressor
l Provide exhaust openings close to ceiling for hot air exit.
l The flow rates in supply and exhaust ducts should not exceed
4m/sec velocity.
l Do not connect cool air inlet ducts directly to the Compressor inlet
side. To eliminate vibration transmission, provide soft bellow
connector between duct and compressor.
l Contact ELGI in case of provision for duct connection/ filter fitment
provision on Compressor.
Refer Figure in Page No. 1.8 for various possibilities of ventilation.

1.6 Compressor l The industrial floor with good surface level is sufficient to install
Installation HORIZON Compressors without foundation.

l While installing the compressors, ensure the following:

1. Forced cool airflow should not be directed towards the Compressor.

2. Compressor to be located such that hot air from other machines

not directed towards the Compressor.

3. Keep the clearance space around the Compressor as shown in

Fig. on next page.

4. Keep the Compressor under cover to protect from rain/ storm.

If you fail to observe the information concerning installation and
ventilation, the discharge temperature of Compressor may increase
or decrease excessively and the Compressor will trip-off at high
discharge temperature conditions. The output of Compressor also
will be affected.

The Compressor will not give warnings during short operating times.
It will operate below dew point and moisture condensate will mix
with oil. This will reduce the lubricating qualities of oil and lead to
damage to the Compressor.

l As per industrial safety regulations, customer must provide a

lockable main switch with pre-connected slow-blow main fuses.

1.7
 Refer table below for fuse ratings for 380/415/ 50Hz/ 3 Ph power
supply conditions.

Recommended Incoming Ventilating

Back up
Model Pre-connected Fuse cable air required
Fuse (A )
Ratings (A) size(sq.mm) ( m3 / hr )
E 55 160 100 3.5 C x120 21780

The moisture condensate separated from compressed air contains oil

particles. The condensate disposal to be done as per Pollution Control
Norms prevailing at the time of Compressor installation or use.

1.8
 SCREW AIR COMPRESSORS

2.0 Safety

ELGI designs and manufactures its products for smooth and safe
operation. However, the responsibility of safe operation rests with those
who use and maintain these products. Following safety precautions
and devices are offered as guide and accessories respectively. These,
when followed will minimise the accidents and failures through out the
useful life of the equipment.
Air Compressor should be operated only by those who have been trained
and delegated to do so, and who have read and understood this
OPERATION AND MAINTENANCE MANUAL. Failure to follow the
instructions, procedures and safety precautions given in the manual
may increase the possibility of accidents and failures.
Never start Air Compressor unless it is safe to do so. Do not attempt
to operate the air compressor with known unsafe condition. Tag
the air compressor and render it inoperative by disconnecting power
supply so others who may not know of unsafe condition will not attempt
to operate it until the condition is corrected.
This ELGI Screw Compressor is not explosive-proof and not to be
operated in explosion area.
Do not modify Compressor except with written factory approval.

Pressure Release 1. Manually pop up the pressure relief valve when the Compressor is
operating, atleast weekly, to make sure the pressure relief valve is
not blocked, closed, obstructed or otherwise inoperative.
2. Do not use tools that are rated below the maximum rating of this
Compressor. Select tools, air hoses, pipes, valves, filters and other
fittings accordingly. Do not exceed manufacturer ’s rated safe
operating pressure for these items.
3. Secure all hose connections by wire, chain or other suitably retaining
devices to prevent tools or hose ends from being accidentally
disconnected.
4. Open oil filter cap only when compressor is not running and is not
pressurised. Shut down the compressor and bleed the receiver tank
to zero internal pressure before removing the cap.
5. Vent all internal pressure prior to opening any line, fitting, hose, valve,
drain plug, connection or other component, such as filters.
6. Keep personnel out of line with and away from the discharge opening
of hoses or tools or other points of compressed air discharge.
7. Do not use air at pressure higher than 2.5 kgf/cm 2 for cleaning
purposes.
8. Do not engage in horseplay with air hoses as death or serious injury
may result.

2.1
Fire and Explosion 1. Clean - up spills of lubricant or other combustible substances
immediately, if such spills occur.
2. Shut - off the air compressor and allow it to cool. Then keep sparks,
flames and other sources of ignition away and do not permit smoking
in the vicinity when checking or adding oil.
3. Do not use flammable solvent for cleaning purposes.
4. Keep electrical wiring and other terminals in good condition. Replace
any wiring that has cracked, cut, abraded or otherwise with degraded
insulation; keep all terminals clean and tight.
5. Keep grounded conductive objects such as tools away from exposed
live electrical parts such as terminals to avoid arcing, which might
serve as a source of ignition.
6. Keep oily rags, trash, dry leaves, litter or other combustibles out of
and away from the Compressor.
7. Do not operate the Compressor without proper flow of cooling air/
cooling water or with inadequate flow of lubricant or with degraded
lubricant.
8. Do not attempt to operate the Compressor in any classification of
hazardous environment unless the Compressor has been specially
designed and manufactured for explosive application.

Moving Parts 1. Keep hands, arms any other parts of the body and also clothing away
from couplings, fans and other moving parts.
2. Do not attempt to operate the Compressor with the fan, coupling or
other guards removed.
3. Wear snug fitting clothing and confine long hair when working around
this Compressor, especially when exposed to hot or moving parts.
4. Keep access doors, if any, closed except when making repairs or
adjustments.
5. Make sure all personnel are out of and/ or clear of the Compressor
prior to attempting to start or operate it.
6. Disconnect and lock out all power at source and verify at the
Compressor that the circuits are de-energised to minimise the
possibility of accidental start-up or operation, prior to attempting
repairs or adjustments. This is especially important when Compressor
is remotely controlled.
7. Keep hand, feet, floors, controls and walking surfaces clean and free
of fluid, water or other liquids to minimise the possibility of slips and
falls.

2.2
 SCREW AIR COMPRESSORS

Hot Surfaces 1. Avoid bodily contact with hot oil, hot coolant, hot surfaces.
2. Keep all parts off the body away from all points of air discharge.
3. Wear personal protective equipment including gloves and head
covering when working in, on or around the Compressor.
4. Keep a first aid kit handy. Seek medical assistance promptly in
case of injury. Don’t ignore small cuts and burns as they may lead
to infection.

Toxic and Irritating 1. Do not use air from this Compressor for respiration (breathing).
Substances 2. Operating the Compressor only in open or well ventilated areas.
3. Oils, coolants and lubricants used in this Compressor are typical of
the industry. Care should be taken to avoid accidental ingestion. In
the event of ingestion, seek medical treatment promptly. Wash with
soap and water in the even of skin contact.

Danger

Death or serious injury may result from

inhaling compressed air without using
proper safety equipment.

Electrical Shock 1. Keep all parts of the body and any hand held tools or other conductive
objects away from exposed live parts of the electrical system.
Maintain dry footing, stand on insulating surfaces and do not contact
any other portion of the compressor when making adjustments or
repair to exposed live parts of the electrical system. Make all such
adjustments or repairs with one hand only so as to minimise the
possibility of creating a current path through heart.

2. Attempt repairs only in clean, dry, well lighted and ventilated area.

3. Do not leave the Compressor unattended with open electrical

enclosures. If necessary to do so, then disconnect. Lock out and take
all power at sources so others will not inadvertently restore power.

4. Disconnect, lock out and tag all power at source prior to attempting
to repairs or adjustments to rotate the machinery and prior to handling
any ungrounded conductors.

2.3
3.0 Dos and Don’ts

Dos l Read the manual in detail and follow the instructions.

l Clean the air compressor package regularly.
l Keep the air filter clean.
l Use only genuine ELGI spares.
l Maintain correct oil level.
l Use proper tools
l Attend immediately to anything unusual with the air compressor.

Don’ts l Neglect the routine attention.

l Allow any leakage in the system.
l Keep any tools or loose items on the compressor/other modules.
l Meddle with any adjustments or settings.
l Use cleaning agents, when changing oil.

3.1
 SCREW AIR COMPRESSORS

4.0 Specifications & Salient Features

4.1 Technical Specifications

Models
No. Description Unit
E55
1. Free Air Delivery at m3/min (cfm)
Working Pressures
7.0 (7.5)* (kgf/cm2) 9.77 (345)
9.5 (10) 8.21 (290)
12.5 (13.0) 6.88 (243)

2. Compressor kW (HP) 55 (75)

drive motor
power

3. Motor rated speed rpm 1475

4. Motor frame size 250 M

5. Fan motor power kW (HP) 1.5 (2)

6. Fan motor rated speed rpm 1410

7. Fan motor frame size 90L

8. Motor type (both) Sq.cage Induction

9. Class of insulation of motor 'F'

10. Degree of protection IP 55

of motor

11. Overall dimensions

LxBxH mm 2000 x 980 x 1715

12. Net Weight kg 1170

* Figures in bracket are Maximum Pressure.

4.1
4.2 Salient Features Less Maintenance
A Screw Compressor has only two moving parts – the rotors do not
touch each other as they are kept apart by means of a thin film of oil
and hence there is no wear and tear. No reciprocating parts like piston,
piston rings, connecting rod and no suction or discharge valves to be
maintained.
Maximum Reliability
Only two moving rotors at conservative speed provide reliability never
before attained in the history of compressor industry.
Low Discharge Temperature
The heat of compression is taken away from the point of origin to the
cooler by the injected oil and hence discharge temperature does not
exceed 90 °C thereby no carbonized oil is formed in the compressor
and in the system.
Small Package
Because of the unique way the screw compresses the air, a complete
air package is provided in small overall dimension with factory tested
and ready to use condition.
Vibration – Free & Low Noise
There is no reciprocating mass. It has only rotating parts that are
dynamically balanced and thus it is guaranteed for quite running and
vibration free operation.
Long Life & No loss in capacity
Since there is no metallic contact between rotors and housing, no wear
or reduction in output capacity/ performance even after many years of
operation.
Pulsation-free Flow
The continuous flow of air through helical cavities in the screw and
continuous compression ensures pulsation-free compressed air delivery.

4.2
 SCREW AIR COMPRESSORS

Optimal Capacity Control

The new generation ‘Varion’ capacity control system provided at the

compressor air inlet side ensures optimum air intake during start up,
normal running and unloading operation.

Air Quality

The unique OSBID Air-Oil separation system ensures efficient separation

of oil particles with minimum pressure drop from compressed air-oil
mixture delivered at compression end. The OSBID system ensures
consistent quality of air during normal running and unloading cycles.
The moisture separator provided at the outlet of After cooler ensures
99% of bulk water seperation from the compressed air.

4.3
5.0 Commissioning

5.1 General The operating instructions given below are for commissioning of standard
version Air cooled HORIZON Series Compressors without additional
equipment. Before commissioning the equipment check for visual
damages of parts. An Electrical circuit diagram is delivered with every
HORIZON Series Compressors (kept inside Electrical control panel) for
electrical wiring reference.

Every Screw Compressor is subjected to test run and set prior to

despatch. Transport damage at a later stage cannot however be
excluded. Therefore, please observe the compressor closely during
commissioning and trial run.

5.2 Instructions for l Remove the transport security bolts / clamps fitted on
commissioning work Compressor/ Parts.

l Connect the Compressor to the air network.

l Check oil level in the receiver tank before starting the Compressor.
The oil level should be upto the top level of the oil sight glass
provided on the receiver tank.

l First oil fill capacity of various models are as below and when
receiver tank is empty.

a) 30 litres for E55

OIL FILL METHOD

l Initially pour 25 litres for model E55

l Run the Unit for 3 minutes and shut down the Unit wait for 2
minutes for oil foaming to settle down

l Pour balance quantity oil as mentioned in the first oil fill capacity

l USE ELGI AIR LUBE for the best performance of Compressor.

l Check and ensure the oil filter cartridge is fitted properly.
l Keep the air outlet line ball valve provided on the rear side of the
compressor in fully open condition before starting the Compressor.
l Connect the moisture outlet line provided on the rear side of the
Compressor to the waste water disposal line.
l The moisture condensate separated from the compressed air
contains oil traces. The condensate disposal to be done as per
Pollution Control Norms prevailing at the time of commissioning or
use.
l Connect earthing line to the point provided on the base frame at
front side.
l Check the total power required on the name plate of the
Compressor before connecting to the electrical lines.

5.1
 SCREW AIR COMPRESSORS

Ensure authorised electricians only carryout the electrical work.

Study electrical circuit diagram before starting work.

l Check the power supply conditions on the name plate and

connect the leads L1, L2, L3 to the terminals inside the Electrical
Control Panel on Compressor.

l Clockwise rotation of motor viewed from fan side must be

created.

l Keep the selector switch on Compressor control panel in ‘HAND’

mode.

l Check the direction of rotation when starting for the first time by
Switch - ON and Switch - OFF immediately. If the direction of rotation
is not correct, isolate the machine from electrical lines and
interchange 2 phases.

Running the compressor in wrong direction for more than 5

seconds will cause damage to Compressor parts or even total
destruction.

l Keep the selector switch on Compressor control panel in ‘AUTO’

mode.

l Switch ON the Compressor after ensuring all above points and run
at rated pressure.

All the settings for, pressure switches, electrical protection

devices, temperature switch etc are set at factory before
despatch.

l In case of problems during the Compressor running, check the LED

glowing on annunciation provided on Control Panel of Compressor
and refer the troubleshooting chart.

In case of abnormal noise observed during running of

Compressor, immediately switch OFF the Compressor and
contact the ELGI Service Engineer for remedy.

All above points to be adhered to during re-installation of

Compressor from one location to the other.

If Compressor is stored for longer period before commissioning,

contact ELGI Service Engineer for installation ancommissioning
services.

5.2
WORKING PRINCIPLE OF SCREW AIR COMPRESSOR

6.0
 SCREW AIR COMPRESSORS

6.0 Working Principle

l Air compression is achieved in Rotary Screw Compressor in

the following manner. Air is admitted at one end of the rotors
where the matching lobe and flute first come into mesh as the
rotors turn. Continued rotation brings the line of mesh past the
air inlet port and then the air in the flute of the female rotor is
confined by the lobe of the male rotor and stator. Compression
now occurs as the rotors turn further. At the time, the far end of
the compression pocket turns towards the discharge port and
air flows out in the system, as shown in Figure on Page No. 6.0,
which depicts one lobe meshing with one flute.
l The flutes of the female rotor and the lobes of male rotor
correspond respectively to the cylinder and piston of Reciprocating
Compressor. Lubricating oil is injected into the compressor unit,
(here to be referred as air end) which in large quantities mixes
directly with the air as the rotors turn compressing the air.
l The lubricating oil has four functions.

a) As a coolant it takes away the heat of compression.

b) Seals the leak paths amongst the rotors and housing.

c) Acts as a lubricating film between the rotors allowing one rotor

to directly drive the other without a metal to metal contact.

d) Also lubricates the bearings and gears.

USE ‘ELGI AIR LUBE’ oil for the best performance.

6.1
7.0 System Operation

2 kgf/cm2 sump pressure during unloading mode

l The air aspirated through the air filter is compressed in the Screw
Compressor driven by an Electric Motor. The injected oil in large
quantities removes the compression heat generated. This internal
cooling make possible very low compression temperatures. The
compression end temperature maintained to approximately 80 – 85
deg C at 30 o ambient temperature.

l The air/oil mixture is delivered to the receiver tank.

l Oil and air are separated by ‘OSBID PROCESS’. ‘OSBID’ process

utilises the impact and difference in density to separate the air &
oil.

l Final filteration is done using a high efficiency separator maintaining

oil carry over levels consistently below 3 ppm.

l The separate oil is re-cooled in the oil cooler and is returned to the
injection point through the oil filter. This oil circulation circuit, operated
solely by the pressure differential, does not require any separate oil
pump.

l The thermal valve provided in the oil circuit ensures discharge

temperature (compression end temperature) maintained for optimum
performance.

l The compressed air liberated from oil separator cartridge, carrying

very small amount of residual oil is passed to the air cooled or water
cooled after cooler through the minimum pressure valve and terminal
check valve and to the service line.

l The minimum pressure valve positioned downstream of the oil

separator maintains minimum pressure for safety supply of oil to the
compressor unit.

l The temperature of the compressed air at the service end is lowered

to few degrees above ambient temperature by the air cooled after
cooler, fitted as a standard element.

l The moisture separator provided at the outlet line of After cooler

ensures 99% of moisture seperation from the cooled compressed
air before delivered to air network.

l Refer Schematic Diagram for various elements used in the system

and their positioning.

l In case of dry air requirements in air network, consult ELGI for the
selection and supply of suitable dryer.

7.1
 SCREW AIR COMPRESSORS

SCHEMATIC DIAGRAM
DURING UNLOADING MODE
Details of Parts in Schematic Diagram
1. Air end 10. Blow down 19. Sump pressure 27. Oil cooler
Silencer gauge
2. Intake Valve 11. Solenoid valve 20. Shut down gauge 28. Fan (Electric motor
pressure switch driven)
3. Air filter element 12. Air-oil seperator
21. Pressure relief 29. Line pressure
4. Indicator air filter 13. Oil sight glass valve gauge
5. Pressure 14. Oil drain hose 22. Moisture drain 30. Line pressure switch
transmitter outlet port
6. Coupling 15. Oil drain gate valve 23. Moisture seperator 31. After cooler (Air)
7. Electric motor 16. Tank receiver
8. Minimum pressure 17. Temperature switch 24. Air outlet ball 32. Oil return line stainer
Valve valve

9. Blow down 18. Discharge line 25. Oil filter 33. Return line oil
Valve temperature gauge sight glass
26. Thermal valve 34. Oil return line orifice

7.2
Air Inlet System For E55

8.0
 SCREW AIR COMPRESSORS

Air Inlet System

Part No. Description Part Code Qty.
Parts List for E55
1. Gasket 01 04 3236 0 1
2. Adapter intake valve 01 04 3214 0 1
3. Gasket 22 04 1200 0 1
4. Intake valve A010105 1
5. Screw socket head M12 x 40 00 09 85 145 4
6. Spring washer Rec.sec. M12 ZYP 00 09 96 112 4
7. Plain washer M12 ZYP 00 09 96 012 4
8. SS T bolt clamp B505302 1
9. Rubber elbow - 4" x 5" B90XX01 1
10. SS T bolt clamp B505309 1
11. Air filter assy B474610 1
12. Indicator air filter 22 04 1313 0 1
13. Bracket air filter mtg 01 04 4501 0 1
14. Hex bolt M8 x 25, 8.8 ZYP 00 09 06 116 2
15. Spring washer Rec. sec. M8 ZYP 00 09 96 108 2
16. Nut hex M8 00 09 48 008 2

8.1
8.2 Capacity Control l The functional description of the Capacity Control System is
described below in 2 distinct phases of operation. This description
System will apply to all control system with an exception to the pressure set
according to your pressure requirements.

l The control system for the set pressures will be in accordance with
a machine having an operating range of pressures.

l A typical control system is illustrated in figure below.

CONTROL SYSTEM FOR E55

WITH 2kgf/cm2 SUMP PRESSURE DURING UNLOADING MODE

8.2
 SCREW AIR COMPRESSORS
8.2.1 Normal Operation l When the unit is switched ON, atmospheric air is drawn through
Mode the intake valve, compressed and discharged to the air-oil receiver.
Now, pressure builds up in the receiver tank and when pressure
rises above 4 kgf/cm 2 , the minimum pressure valve opens and
delivers compressed air to the service line.
8.2.2 Unloading Mode l When a relatively small amount or no air is being used, the service
line pressure rises to the preset cut-out pressure (0.5 kg/cm 2 above
working pressure) of the pressure switch (Blow down). The pressure
switch opens interrupting the electrical power to the solenoid valve
and they get de-energised. As a result, the inlet valve is further
closed and the blow down valve is opened to drop the sump pressure
to 2 kgf/cm2 . The terminal check valve in the air service line prevents
line pressure from returning to the receiver tank.
l When the line pressure drops to the low setting cut-in pressure of
the pressure switch it closes, re-energising the solenoid valves and
as a result, the blow down valve is closed and the inlet valve is
opened. When there is an increase in pressure, once again the
compressor starts unloading.

8.3 Discharge System l The Compressor discharge system is illustrated in Fig on No. 8.8
to 8.18.
l The compressed air/oil mixture from air end enters the specially
designed receiver tank to separate oil particles in 3 stages. The
improved separator element at final stage of air oil separation is the
vital element for getting clean air outlet. The separated oil collects
in the element surface and descends to the bottom of the separator.
l The return line (or scavenge tube ) leads from the bottom of the
separator element to the inlet region of the compressor unit ensures
separated oil is return to the compressor by the pressure differential
between the area surrounding the separator element and the
compressor inlet through orifice and strainer.
l The minimum pressure valve, at the outlet of the receiver tank
ensures a minimum receiver pressure of 3-4 kgf/cm 2 during all
conditions for proper air/oil separation and proper oil circulation to
air end.
l The terminal check valve located downstream of the minimum
pressure valve prevents compressed air in the service line from
bleeding back into the receiver tank on shutdown when the
compressor is being run in parallel with other compressors tied to
air network.
l The unit is also equipped with receiver tank pressure switch
(shutdown) which shutdown the compressor when the pressure
exceeds 2 kg/cm 2 (30 PSI) more than the working pressure. This
prevents the pressure regulator valve from opening under routing
condition, thereby preventing oil loss through the presure regulator
valve.
l The discharge temperature sensor will shutdown the compressor
if the discharge air/oil mixture temperature reaches the preset value
of 110+5 deg C.

Warning
Do not remove caps, plugs, or other components
when compressor is running or pressurised.
Stop compressor and relieve all internal pressure
before doing so.

8.3
8.4
 SCREW AIR COMPRESSORS

Discharge System
Part No. Description Part Code Qty.
Parts List for E55
(AL Cooler) 1. Tank receiver (IS:2825) 01 53 0041 2 1
Tank receiver (ASME) 01 53 0050 9 1
Tank receiver, lloyds certified 01 22 52 040 1
2. Hex bolt M8 X 30 ZYP 00 09 06 177 4
3. Plain washer, M8 ZYP 00 09 96 008 4
4. Spring washer, Rec Sec M8 ZYP 00 09 96 108 4
5. Hex plug 1" NPT A 01 00 18 1
6. Pipe nipple ½" 22 04 76 70F 1
7. Ball valve 1/2" B 31 27 01 1
8. Connector hose 1/2" 00 09 20 002 1
9. Hose 14 X 12 00 09 45 002 1
10. Hex. Plug 1" NPT 22 03 79 05F 1
11. Namp plate Air receiver 00 04 20 930 1
12. Rivet, dia 2.5 x 4.5 00 05 19 520 8
13. Gasket seperator element 01 04 50 460 1
14. Element seperator 01 04 52 250 1
15. Gasket seperator element 01 04 50 460 1
16. Spring washer Rec typ M12 ZYP 00 09 96 112 8
17. Hex Bolet M12 X 40 ZYP 00 09 06 185 8
18. Elbow TMS 1/4" 22 04 76 81B 1
19. Control line tubes 01 03 60 840 1
20. Valve Assy Pressure relief 1" A0 10 107 1
21. Pipe coupling 2 1/2" B 56 XX 05 1
22. discharge Pipe short 01 04 52 950 1
23. Elbow TMS 1/4" 22 04 76 81B 1
24. Strainer Assembly ORL 1/4" NPT A0 10 016 1
25. Hex Nipple 1/4" NPT 22 03 79 03A 1
26. Oil sight glass A0 10 017 1
27. Coupling TMS 1/4" NPT 22 04 76 83A 1
28. Elbow TMS 1/4" 22 04 76 81B 1
29. Control line tubes 01 03 60 840 1
30. Hex Nipple 1 1/4" 22 03 79 03F 1

8.5
Discharge System
Part No. Description Part Code Qty.
Parts List for E55
(AL Cooler) 31. Min. Pressure valve 1 1/4" B009301070007 1
32. Swivel elbow connector 1 1/4" 00 09 59 224 1
33. Pipe MPV to Cooler 01 54 00 384 1
34. TMS,Coupling 1 1/4" 22 04 76 83J 1
35. Pipe air inlet 01 54 00 383 1
36. Cover Receiver Plate 22 04 11 27A 1
37. Bolt Hex M8 X 45 00 09 06 120 4
38. Spring washer M8 00 09 96 108 4
39. Hex Nut M8 00 09 48 008 4
40. Pipe with flange assy 01 04 52 950 1
41. Pipe with flange assy 01 04 34 550 4
42. Moisture seperator MS 365 A0 10 052 1
43. Elbow TMS 1 1/2" 22 04 76 81K 1
44. Pipe MS to Ball valve 01 04 42 230 1
45. TMS Connector 1 1/2" NPT 22 04 76 83K 1
46. Hex Nipple 1 1/2" NPT 22 03 79 03G 1
47. Ball valve 1 1/2" NPT B 31 27 04 1
48. Tube, Nylon dia 6 09 04 45 790 1.5m
49. Coupling TMS 1/4" 22 04 7683A 2

8.6
 SCREW AIR COMPRESSORS

8.4 Cooling and l Refer the figures given in the following pages.
Lubrication System l The cooling and lubrication system consists of:
a) Fan, fan motor, shroud, oil cooler, after cooler, oil filter and
thermal valve and interconnecting tubing in case of Air cooled
models.

l The pressure in the receiver/ sump causes fluid flow from sump to
air end through oil cooler, thermal valve and oil filter.

l The thermal valve is fully closed when the oil temperature is

125oF/155oF. REFER PARTS LIST FOR THE TYPE OF THERMAL
VALVE USED ON THE PARTICULAR MODEL

l As the discharge temperature rises above 125o F/155o F due to the

heat of compressor, the oil temperature rises and the thermal valve
begins to close the oil line from tank to air end through oil filter to
divert the oil through oil cooler. Depending on the oil temperature,
the thermal valve opening position ensures oil inlet temperature to
air end is maintained by,

a) Fully allowing oil from tank to air end

b) Fully allowing oil from cooler to air end
c) Mix of oil from tank and cooler to air end

l A portion of oil flowing to air end is diverted to anti-friction bearings

and gears.

l The oil filter fitted at inlet of Air end is with replaceable element
and integral by-pass valve. The differential pressure switch
provided across the filter line ensures indication in case of pressure
difference across filter is high due to filter clogging.

l Water cooled models are provided with pressure switch to monitor

water inlet pressure and so effective cooling.

8.7
8.8

COOLING SYSTEM FOR E55

 SCREW AIR COMPRESSORS

Cooling System
Part No. Description Part Code Qty.
Parts List for E55
(AL Cooler) 1. Fan, assy 24" A010112 1
2. Fan hub 22 03 7376 0 1
3. Hex bolt, M10 x 20 ZYP 00 09 0614 3 4
4. Spring washer, Rec. Sec. M10 ZYP00 09 9611 0 1
5. Hex bolt, M8 x 25 ZYP 00 09 0611 6 1
6. Hex nut, M8 ZYP 00 09 4800 8 1
7. Oil cooler & after cooler assy (ALU)01 02 4229 0 1
8. Shroud for cooler & fan 01 03 4215 0 1
9. Hex bolt, M8 x 20 ZYP 00 09 0611 5 20
10. Spring washer, Rec. sec. M8 00 09 9610 8 20
11. Hex nut M8 ZYP 00 09 4800 8 20
12. Hex bolt M10 x 30 ZYP 00 09 0614 5 4
13. Spring washer, Rec. sec. M8 00 09 9611 0 4
14. Fan motor 2HP B525803 1
15. Disc end LG01 00 04 1237 0 1
16. Bracket cooler mtg support 01 04 4315 0 2

8.9
8.10

LUBRICATION SYSTEM FOR E55

 SCREW AIR COMPRESSORS

Lubrication
Part No. Description Part Code Qty.
System for E55
(AL Cooler) 1. Nipple pipe 1¼" NPT x 1¼"BSP 01 04 5284 0 1
2. Nipple pipe 1¼" NPT x 1¼" BSP 01 04 5294 0 1
3. Union tee, equal 1¼" NPT 22 04 1705 G 1
4. Bush, reducer, adapter 1½" x 1¼" NPT 22 03 7898 F 1
5. TMS conector 1¼" NPT 22 04 7683 J 2
6. Pipe 1¼" TV to Tank 01 04 5292 0 1
7. Coupling TMS 1¼" x 1¼" NPT 22 04 7683 J 3
8. Housing thermal valve 1¼" NPT 22 03 1079 A 1
9. Element thermal valve 125 F 22 03 1080 0 1
10. Elbow TMS 1¼" x 1¼" NPT 22 04 7681 J 2
11. Pipe 1¼" OC to TV 01 04 4348 0 1
12. Pipe 1¼" TV to BOF 01 04 5293 0 1
13. Pipe 1¼" Tank to Elbow equal 01 04 4347 0 1
14. Oil filter 22 04 4301 0 1
15. Bush reducing adapter 1¼" x 1" NPT 22 03 7897 T 1
16. Elbow TMS 1" x 1" NPT 22 04 7681 I 1
17. Pipe 1" BOF to A/E inlet 01 04 5290 0 1
18. Elbow 1¼" NPT 22 04 7677 F 2

8.11
8.12
 SCREW AIR COMPRESSORS

010464160

8.13
8.14

CANOPY SYSTEM FOR E55

 SCREW AIR COMPRESSORS

Canopy System
Part No. Description Part Code Qty.
Parts List for E55
(AL Cooler) 1. Panel LH & RH 01 03 9230 0 3
2. Panel RH (Oil sight) 01 03 9229 0 1
3. Post center 01 03 9206 0 2
4. Box Elec. Control 01 53 0039 2 1
5. Panel top 01 03 9232 0 1
6. Post cooler mounting, Rear LH 01 03 9226 0 1
7. Post cooler mounting, Rear RH 01 03 9227 0 1
8. Panel rear top 01 03 9228 0 1
9. Panel rear bottom 01 03 9231 0 1
10. Panel front bottom 01 03 9212 0 1
11. Panel front middle 01 03 9213 0 1
12. Electrical box door 01 53 0039 3 1
13. Post corner assembly, Front LH 01 03 9205 A 1
14. Post corner assembly, Front RH 01 03 9205 B 1
15. Hinge 180 - DIRAK
0
00 09 2150 0 2
16. Pocket handle DHP110 00 09 2100 2 12
17. Spring washer sq. sec. M8 ZYP 00 09 9615 8 40
18. Bolt, hex M8 x 16 00 09 0611 3 20
19. Hex. Screw Soc. Head cap M8 x 40 ZYP00 09 8308 7 12
20. Hex. Screw Soc. Head cap M8 x 16 ZYP00 09 8308 1 6
21. Hex. Screw Soc. Head cap M8 x 30 ZYP00 09 8308 5 2
22. Flexible PU foam sheet 00 09 9982 1 4
23. Rubber beeding panel E55 00 89 8608 0 24mt

8.15
8.16

MOTOR BASE ASSEMBLY FOR E55 HORIZON SERIES

 SCREW AIR COMPRESSORS

Motor Assembly
Part No. Description Part Code Qty.
System for E55
1. Ring, Adapter, 1675 22 02 7321 0 1
2. Coupling, B5 4 59 12 1
3. Bracket air end mounting E55 01 04 8209 0 1
4. Guard coupling 01 03 8004 C 1
5. EM75HP 230/460V,60Hz,4P,SF1.15 B005100560065 1

6. Bolt, hex, M10 x 50 ZYP 00 09 06 149 12

7. Bolt, hex, M16 x 65 ZYP 00 09 06 219 8
8. Bolt, hex, M20 x 65 ZYP 00 09 06 246 4
9. Nut, hex, M10 ZYP 00 09 48 010 12
10. Nut, hex, M16 ZYP 00 09 48 016 8
11. Plain Washer M20 ZYP 00 09 96 020 4
12. Spring Washer, Rec. Sec. M10 ZYP00 09 96 110 12
13. Spring Washer, Rec. Sec. M16 ZYP00 09 96 116 8
14. Spring Washer, Rec. Sec. M20 ZYP00 09 96 120 4
15. Bolt hex, M12 x 75 ZYP 00 09 09 192 2
16. Bolt hex, M8 x 25 ZYP 00 09 06 219 2
17. Nut, hex. M10 ZYP 00 09 48 010 6
18. Spring Washer, Rec. Sec. M8 ZYP 00 09 96 108 2
19. Plain washer, M8 ZYP 00 09 96 008 2
20. Screw, soket head, M8 x 20 ZYP 00 09 83 083 2
21. Plain washer, M8 ZYP 00 09 96 008 2
22. Base assembly 01 03 8205 0 1

8.17
INSTRUMENTATION SYSTEM

8.18
 SCREW AIR COMPRESSORS

Instrumentation
Part No. Description Part Code Qty.
System
1. Pressure Gauge B 21 21 10 2
(FOR NON PLC ONLY) 2. Temperature Gauge B 20 21 01 1
3. Nut, Gauge 00 09 59 501 2
4. Ferrule 1/4" 00 09 59 751 2

8.19
8.6 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. For this, a good record of operating
temperature of compressor is essential. Continuous operating of
compressor at high temperature beyond 100 deg C without changing
the oil will lead to varnish formation and will affect life of bearings and
air end.
Proposed Drain Period

Sl. 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.

8.20
 SCREW AIR COMPRESSORS

9.0 Safety and Interlocking Devices

The following safety and interlocking devices have been equipped

with your ELGI PORTABLE ROTARY SCREW AIR COMPRESSOR
for safe and reliable service.

THERMO SWITCH is fitted on the discharge hose to

switch ON the cooling fan of the compressor if the dis-
charge air/oil mixture temperature reaches the preset
temperature

MINIMUM PRESSURE VALVE fitted at the outlet of the

oil separator keeps minimum receiver tank pressure of
about 2.5 to 3 kgf/cm2 during starting which facilitates
proper air and oil separation and oil circulation to air end.
The same valve prevents the compressed air in the ser-
vice line from returning to the receiver tank.

PRESSURE RELIEF VALVE fitted on tank (Air-oil re-

ceiver tank) ensures the pressure is relieved when air
pressure in the tank exceeds 3 kgf/cm2 more than the
working pressure.

OVERLOAD RELAYS FOR MAIN MOTOR & FAN MO-

TOR fitted in Electrical Control Panel ensures the Com-
pressor is switched-off when the power consumption
exceeds the set value.

9.1
10.0 Electrical System and Control Elements

10.1 Control Panel The compressor starter is basically an automatic start delta starter
with safety interlocks. The starter is built in-house..
Complete basic control of compressor in all models (Local, Remote $
DCS) are carried out by means of a dedicated microcontroller called
NEURON. The NEURON comes with 8 digital inputs, 2 Analog in-
puts & 6 relay outputs. Inputs can accept contact closures open &
4.20mA pressure and temperature transducers. Controller is equipped
with 8 tactile pushbuttons, 16 X 2 line alphanumeric LCD for display
of compressor status, various related informations and with 14 LED’s
(Annunciation window) for user interface. If all the inputs are normal
condition then PLC display will show “READY”.

To start the compressor, press the “START” green push button lo-
cated in the front panel of the controller. Controller will switch “ON”
the relay outputs in the order of main and star which I turn will energise
the respective contactors (K1, K2 & K4) LCD will show th related
operation (like Star, Run, Standby & Run load.etc..) Star to delta
changeover time, load delay time will preprogrammed in the controller
itself. Based on that controller output will energise delta contactor &
solenoid valve to run the compressor and to build up pressure. To
stop the compressor press stop (red) push button. Incase of trip due
to fault press reset push button after rectification of fault.

Pre-Programmed timer functions :

· Star Delta delay – decides the star to delta changeover time set for any value
between4 to 8 seconds.

· Delta to run delay (DTR) decides the time delay of solenoid valve to energise
after delta changeover.

· Standby time (Unload monitoring time) stops the compressor if the compressor
runs in unloaded conditions continously for the set time (5-15min) and starts the
compressor automatically on demand
.

Note
Ensure 24V AC powers supply to NEURON controller.
Can modify the timer settings under m/c settings menu
present in the controller.

10.1
 SCREW AIR COMPRESSORS

10.2 Annunciation Panel The different faults are sensed and annunciated in a six point solid state
annunciation system. It lights the following message for immediate
diagnosing of the defects and to proceed for the remedial measures.
(FOR NON PLC ONLY)
1. Separator element - Indication only
2. Bearing oil filter - Indication only
3. Reverse rotation - Indication & shut down
4. Receiver tank pressure - Indication & shut down
5. Discharge temperature - Indication & shut down
6. Main/Fan motor - Indication & shut

Suitable pressure switches and overload relays are used with low voltage
(24V DC input through NC contacts to hold control relay CR).

10.2
10.3 Control Elements
No. Control Indicator Purpose
1. Hour meter Records cumulative hours of compressor
For NON PLC Only operation, useful for planning and logging
service schedule.
2. Line pressure gauge Continuously monitors line air pressure
For NON PLC Only at various loads and unload conditions. It
is located on the dry side of receiver tank
down stream of minimum pressure valve.
3. Sump Pressure gauge Continuously monitors receiver tank
For NON PLC Only pressure at various load and unload
conditions.
4. Discharge temperature gauge Monitors temperature of Air/Oil mixture
For NON PLC Only leaving the compressor unit.
5. Differential pressure switch - An added protective device designed to
reverse rotation shut off the machine when the motor
For NON PLC Only rotates in the reverse direction.
6. Power ON light (Red) Indicates when the starter is receiving
For NON PLC Only power
7. Running light (Green) Indicates when the machine is in
operation.
8. Oil sight glass on tank Helps to keep a visual check on the oil
level in the Receiver Tank. Check oil level
only when machine is shut down. Do not
overfill.
9. Return line oil sight glass Used to indicate oil flow in the return line.
When the compressor is running at full
load, oil flow should be visible in the oil
sight glass. This may be little or noflow
when the compressor is running
unloaded, but a sluggish flow at full load
indicates a need to clean the return line
strainers.

10.3

No. Control Indicator
10. Minimum pressure valve
11. Discharge temperature
switch
For NON PLC Only
12. Receiver tank pressure switch An added protective device designed to
(Shut down)
For NON PLC Only
13. High discharge pressure switch
(Blow down)
For NON PLC Only
14. Thermal valve
15. Pressure relief valve
16. Blow down valve
17. Terminal check valve
18. Air filter clog indicator
19. Temperature Sensor
10.4
SCREW AIR COMPRESSORS
Purpose
Maintains minimum pressure of 3-4 kgf/
cm 2 in the receiver tank. This valve
restricts receiver air discharge from
receiver tank to the service line when
pressure falls below 3-4 kgf/cm2. However
full flow is allowed at normal operating
pressure.
Designed to shut off the machine in case
the discharge air/oil mixture temperature
exceeds the preset value of 110 +/-5 deg C
or 100 +/-5 deg C depending on probe
position.
shut off the machine when the pressure
becomes too high. This switch is set at
2 kgf/cm2 of the working pressure.
Senses service line pressure when the line
pressure reaches pre-set value, pressure
switch signals the solenoid valve to
unload the machine.
It regulates the temperature of oil getting
into the Air End by-passing the oil to
oil cooler in case the temperature of oil
exceeds the preset value.
Set to open receiver tank pressure to
atmosphere if pressure exceeds 3 kgf/cm 2
of the working pressure.
Vents receiver tank pressure to
atmosphere when the unit to shutdown
and during unloading.
Prevents flow of compressed air back into
the receiver tank during no load and shut
off conditions.
Indicates red when inlet air filter
maintenance is required.
Designed to shut off the unit incase the
discharge air.oil temperature exceeds
the preset value of 110+/-5deg.C
10.5

POWER WIRING DIAGRAM

230V,60Hz E55_S1

0 1 8 3 6023 5

10.4 Electrical Diagram

 SCREW AIR COMPRESSORS

1.6. Electrical System

S.No Model Description Part Code Qty

1 E30 Power Contactor K1,K2&K3 008928048 3
2 E37 Power Contactor K1,K2&K3 008928049 3
3 E45 Power Contactor K1,K2&K3 008928066 3
4 E55 Power Contactor K1,K2&K3 008933182 3
5 E30-E55 Fan Motor Contactor K4 008929010 1
6 E30-E45 Universal Transformer 100VA 008937027 1
7 E55 Universal Transformer 200VA 008937029 1
8 E30-E55 Universal Transformer 50VA 008937028 1
9 E30 Main Motor Over Load Relay 008933149 1
10 E37 Main Motor Over Load Relay 008933169 1
11 E45 Main Motor Over Load Relay 008933181 1
12 E55 Main Motor Over Load Relay 008933183 1
13 E30-E55 Fan Motor overload Relay 008933019 1
14 E30-E55 MCB TP 10A Motor Duty 008927039 1
15 E30-E55 S1-PLC Controller 01897701E 1
16 E30-E55 Temperature sensor 00897902C 1
17 E30-E55 Pressure sensor 00897901C 1

10.6
10.7

STARTER CUM CONTROL PANEL

230V,60Hz E55_S1

01 83 6023 5

10.4 Electrical Diagram

10.8

STARTER CUM CONTROL PANEL

230V,60Hz E55_S1

SCREW AIR COMPRESSORS

01 8 3 6023 5
11.0 Maintenance

11.1 General As you proceed in reading this Chapter, it will be easy to see that the
maintenance programme of the unit is quite minimal but important. The
use of the service indicator provided for the suction filter and pressure
switches for separator element, oil filter element, would alert you when
service maintenance is required.
For maintenance requirements of motor, refer to the motor manual for a
detailed description of service instructions.

11.2 Daily Operation Prior to starting the machine, it is necessary to check the oil level in the
receiver tank. Should the level be low, add the necessary amount. If
the addition of oil becomes too frequent, a problem has developed which
is causing this excessive loss. See the trouble shooting section under
excessive coolant consumption for a probable cause and remedy.
After a routine start has been made, observe the instrument gauges
and be sure they monitor the correct readings for that particular phase
of operation. After the machine has warmed up it is recommended that
a general check on the overall machine and instruments be made to
assure that the compressor is running properly.

WARNING
Do not remove caps, plugs or other components when
compressor is running or pressurised. Stop Compressor and
relieve all interval pressure before doing so.

NOTE
Carryout the first oil change after 50 hours of operation and
subsequent oil changes after every 1000 hours of operation.

11. 0
 SCREW AIR COMPRESSORS

11.3 Maintenance after After the initial 50 hours operation of Compressor, some check up is
initial 50 Hours of needed to trace and clean the system of any foreign materials. Carryout
the following maintenance operations so as to prevent the Compressor
Running from giving trouble.

l Clean the return line strainer

l Clean the return line orifice
l Change the oil filter element
l Change the Compressor oil

11.4 Maintenance after l Clean the return line strainer

every 500 Hours of l Change the oil filter element
Running

11.5 Maintenance above l Change the Compressor oil for every 1000 hours of running.
500 Hours of l Change air filter element after every 1500 hours of running.
Running l Change seperator element after 4000 hours of running.
l Clean water cooled heat exchangers after every 1000 hours of
running.

After completion of 2000 hours, in addition to all above, clean the receiver
tank thoroughly. Also check all the accessories independently for its
functions and replace the components as necessary.

NOTE
The Change hours are given as a guideline for normal
operating conditions and may vary depending on site
condition.

11.1
 HEX NUT

HEAD FILTER HEAD

ELEMENT

HEX ADAPTER

SEAL
FILTER ELEMENT
11.2

SPRING WASHER HOUSING

HEX NUT

DRAIN PLUG

OIL FILTER-CATRIDGE TYPE ELEMENT OIL FILTER-SPINON TYPE ELEMENT

 SCREW AIR COMPRESSORS

11.6 Components maintenance

and Replacement Procedure

11.6.1 Oil Filter The oil filter is incorporated in between air cooled or water cooled oil
cooler and the compressor unit. The oil filter exploded view is illustrated
in Figure 11.4. This is a full flow filter with a replaceable pleated element.
For servicing this filter, order the repair kit. The procedure for complete
service of this filter is explained below.
Disassembly
l Disassemble the oil housing by removing the four hex bolts holding
the head assembly to the main body.
l Remove the body seal from the main body.
l Dislodge the element from the head assembly.
l Clean the head assembly and housing thoroughly.
Reassembly
l Lubricate the new body seal and re-position in main housing.
l Replace the new element onto the head assembly.
l Place the head assembly with attached filter back into housing.
l Re-tighten the four hex bolts.
Spin-on type filter element :
Disassembly
l Disassembly the filter element by rotating the filter element in
counter clockwise direction.
l While disassembling the hex adapter should be in tehfilter head.
l Drain the oil present in teh filter element.
l Once the recommended life of hte element is over new element
has to be replaced
Assembly of new filter element
l Ensure that the seal on the filter element is not damaged.
l Clean the seating suffaces.
l Lubricate the filter element.
l Assemble the filter element by rotating the filter element in
clockwise direction tightenin wiht hand is enough.

11.3
11.6.2 Separator Element
The separator element must be changed when the differential pressure
switch indicates pressure drop of 1 kgf/cm 2 or once in a year whichever
is earlier. Order separator element kit. Follow the procedure explained
below for separator replacement.
1. Relieve oil pressure from the receiver tank and all fluid lines.
2. Disconnect all piping connecting to the receiver tank cover to isolate
the receiver tank from return lines, service line etc.
3. Loosen and remove hex head bolt from the cover plate.
4. Lift the cover plate from the receiver tank.
5. Remove the separator element.
6. Scrap the old gasket material from the cover and flange on the
receiver tank. While doing so, care should be taken not to let the
scraps fall in the receiver tank.
7. Inspect and clean the receiver tank for rust, dirt etc.

8. Fix the new gasket.

9. Replace the new separator element into the receiver tank taking
care not to dent it against the tank opening.

10. Clean the underside of the receiver tank and remove any rust. Paint
the surface with an epoxy paint.

11. Replace the cover plate and fasten the cover on the receiver tank.

12. Reconnect all pipings. While doing so, make sure that the return
line tube reaches up to a dimensional clearance of ¼” above the
bottom of the separator element. This will ensure proper oil return
flow to the Compressor.

Clean the return oil strainer before restarting the machine.

11.6.3 Air Inlet Filter Refer Air Inlet System, for details of air inlet filter.

When the air filter clog indicator indicates the blocked condition, remove
the air filter and replace with new air filter.

NEVER CLEAN THE AIR FILTER WITH COMPRESSED AIR.

11.4
 SCREW AIR COMPRESSORS

DURING AIR FILTER REPLACEMENT, DO NOT FORGET TO

REMOVE THE AIR FILTER CLOG INDICATOR FROM THE OLD AIR
FILTER AND FIX IT ON NEW AIR FILTER. ELEMENT INSPECTION

1. Place a bright light inside the element to inspect for damage or

leak holes. Light rays will pass through the element where holes
are present and disclose the same.

2. Inspect all gaskets and gasket contact surfaces of the housing.

Should faulty gaskets be evident, correct the condition immediately.

3. If the clean element is to be stored for later use, it must be stored

in a clean container.

4. After the element has been installed, inspect and tighten if

necessary all air inlet connections prior to resuming operation.

The unit has been provided with flexible coupling, which has the
11.6.4 Drive Coupling following advantages.

1. There is no relative movement between connected parts and hence

there is no wear and tear.
2. The coupling needs no lubrication and maintenance.
3. The flexible element has a very long life and is the only part, which
needs replacement.
4. The coupling is compact and can take large misalignment.
5. The coupling has torsional flexibility and dampening properties to
absorb the torsional vibrations and shock load.

Alignment Check

No alignment check is required. The intermediate housing between

air end and motor is designed and manufactured to ensure correct
alignment of shafts when fitted.

WARNING

Disconnect all power at source before attempting

maintenance or adjustments.

Compressor is preset at factory for maximum and operating pressures

11.6.5 Control System as per our catalogue.
Adjustment
WARNING

If you need reduction in operating pressure to save

power, contact our service engineer.

11.5
MINIMUM PRESSURE VALVE 1 1/2"

11.6
 SCREW AIR COMPRESSORS

11.6.6 Minimum The details of minimum pressure valve inner elements are shown in
Page No. 11.8.
Pressure Valve
Minimum pressure valve maintenance is quite minimal. The only part
which normally requires replacement is the O ring on the piston.

Minimum pressure valve cover is under heavy spring tension. Loosen

the cover bolts alternatively each turn to relieve spring tension.

WARNING
Extreme caution should be taken when removing the cap or
cover from the body because of the spring tension.

1. Evenly remove the cap to relieve the spring tension.

2. Remove the spring.
3. Remove the piston.
4. Remove the O ring and discard.
5. Clean the piston.
6. Replace the O ring.
7. Coat the piston and O ring with grease.
8. Replace the piston.
9. Replace the spring and cap.

11.7
INTAKE VALVE FOR E55

11.8
 SCREW AIR COMPRESSORS

11.6.7 Inlet Valve The inlet valve maintenance usually requires the replacement of the
piston spring, piston ‘O’ ring, seal ring and check valve spring. Follow
Maintenance
the procedure below for proper installation.

1. Remove control lines from fittings on intake valve.

2. Remove the four (4) cap screws that attach the valve body to the
air end and remove valve.
3. Remove snap ring and Teflon ‘O’ ring inside valve body.
4. Lift and remove check valve assembly and spring from the inlet
body flange.
5. Remove piston cap, piston spring and piston.
6. Clean valve body as needed, making sure all air passages are
clear and old seal ring is removed from the inlet body flange.
7. Reassemble the inlet valve using the new parts supplied in the
repair kit.

8. Install ‘O’ ring on piston, lightly oil piston, and install in valve body.

9. Install new piston spring and replace piston cap.

10. Place new check valve spring into piston and install check valve
assembly.

11. Position the Teflon ‘O’ ring in valve body and install snap ring.

12. Clean air end/ intake valve flanges before installing new flange
seal ring.

13. Install valve on air end and torque cap screws to 45 – 50 ft-lb.

14. Install control lines and air inlet elbow.

15. Start Compressor and check for proper operation of intake valve.

11.9
BLOW DOWN VALVE

11.10
 SCREW AIR COMPRESSORS

11.6.8 Blow Down Blow down valve maintenance is limited to replacement of the cover
gasket and internal ring and seat.
Valve
Using repair kit, follow the instructions given below for proper installation.

1. Remove the four screws on the top cover which hold the assembly
together.

2. Pull the top cover away from the body.

3. Remove the old gasket and replace with the new ones.

4. Align the top cover with the body, replace the four screws and tighten.

5. To replace the valve seat, loosen and remove the two socket head
screws in bottom cover.

6. Pull the bottom cover from the main body.

7. Remove the cover ring, spring, seat cup and seat. Discard the seat
and ring, replace with the new ones in the kit.

8. Re-assemble the bottom cover.

11.11
MOISTURE SEPARATOR

11.12
 SCREW AIR COMPRESSORS

11.6.9 Moisture Separator The water separators will operate indefinitely under normal working
conditions. However, at some time, it may be necessary to replace
seals which should the housing leak.

1. Isolate housing from air supply

2. Fully depressurizes using vent valve at bottom of bowl.

3. Unscrew bowl (3) and remove. If pressure has not been completely
released from the housing, air will escape from the warning hole
giving an audible alarm. Screw back bowl and repeat instruction 2
before attempting again. Should resistance to unscrewing be
experienced, provision is made for a ‘C’ spanner to fit onto the ribs
of the bowl.

4. Check conditions of O ring and replace if necessary. Clean screw

threads.

5. The auto drain assembly is not serviceable and must be replaced if

faulty.

6. Check the autodrain seal and replace if worn. NOTE WHEN

REPLACING AUTODRAIN, TAKE THE OPPORTUNITY TO
GENERALLY CLEAN THE INSIDE OF THE BOWL AND THE
SCREW THREADS.

7. Replace vent valve or if faulty or leaking.

8. Refit bowl (3) with ‘O’ ring seal (5).

9. A sight glass (monitors the function of the automatic drain and in

adverse conditions can become contaminated. Dismantle as per
details ‘A’ and clean. A replacement kit is available.

10.Repressurise and check for leaks. If leaks do occur they will most
probably be from the bowl ‘O’ ring. Depressurize housing and remove
‘O’ ring as stated above and inspect and clean. Ensure that mating
surfaces are clean and then refit ‘O’ ring and repressurise.

11.13
THERMAL VALVE ASSY

11.14
 SCREW AIR COMPRESSORS

11.6.10 Thermal Valve l Disassemble the thermal valve and the temperature cools down to
room temperature.

2 Remove the thermal valve element with suitable spanner rotating

in counter-clockwise direction.

3 Check and clean seating surface area in the housing.

4 Replace withe new element (Refer Parts List for particular model)

5 Assemble the element by rotating in counter clockwise direction

with spanner.

11.15
11.7 Trouble Shooting
Problem Causes Remedies

Machine will 1. Main disconnect Close switch.

not start switch open.
2. Line fuse blown. Replace fuse.
3. Control transformer Replace fuse.
fuse blown.
4. Motor starter overload Reset. If trouble persists,
tripped. check whether motor
starter contacts are
functioning properly.
5. Low incoming Check voltage. If voltage
line voltage. low, consult local electricity
board office.

Machine 1. Loss of control voltage. Reset. If trouble persists,

shuts down check that line pressure
with air does not exceed maximum
demand operating pressure of the
present machine (specified on the
name pates).
2. Low incoming voltage. Consult electricity board
office.
Machine shuts 3. Excess operating
down with air pressure
demand a) Defect in pressure Check pressure at which
present switch contact points open, reset
for required pressure.
Change the pressure
switch if defective.
b) Separator element Check and replace.
clogging.
c) Receiver tank Re-adjust to 135% of
pressure switch is working pressure.
adjusted too low.

11.16
 SCREW AIR COMPRESSORS

Problem Causes Remedies

d) Defective solenoid Check and replace.

valve.
e) Defective blow down
valve Check and replace.
4) Discharge temperature
switch opens
a) Cooling air flow Clean cooler and check
restricted. for proper ventilation.
b) Cooler plugged. Clean the cooler tubes
(Watercooled machine).
c) Ambient temperature Provide sufficient
is too high. ventilation.
d) Low oil level. Add oil to correct level.
e) Clogged oil filter. Check, clean and replace/
change the oil filter
element.
f) Defective discharge Check and replace.
temperature switch.
g) Defective water Check and replace.
regulating valve
(Watercooled machine)

Machine will 1. Air demand is too much. Check for service line
not build up leaks or open valves.
full discharge
pressure 2. Dirty air filter. Check indicator air filter
maintenance and change
or clean element if
required.

11.17
 Problem Causes
Line pressure 1. Defective pressure
rises above cut switch.
out pressure
setting on high
Disc pressure 2. Defective solenoid
switch (blow valve.
down)
3. Defective blowdown
valve
4. Receiver tank switch
is defective or
adjustment is incorrect.
5. Clogged moisture filter.
Excessive oil 1. Clogged return line
in service line strainer or orifice.
2. Separator element
damaged or not
functioning properly.
3. Leak in lubrication
system.
4. Excess oil foaming.
5. Oil level too high.
Oil thro’ suction 1. Intake valve
side when the malfunctioning
unit is shut off.
Pressure relief 1. Receiver tank pressure
valve opens. switch (shut down) is
defective or out of
adjustment.
2. Defective pressure
relief valve.
11.18
Remedies
Check the diaphragm and
contacts of the pressure
switch. Replace if found
defective.
Check and replace
Check the receiver
tank pressure is
exhausted to the
atmosphere when the
pressure switch
contacts open. Replace
or repair if necessary.
Readjust or replace.
Check and replace.
Clean strainer and
orifice.
Change separator
element.
Check all pipe connections
for leakage.
Drain and change the oil.
Drain to correct level.
Check and replace.
Re-adjust to 135% of
working pressure or
replace the pressure
switch.
Replace pressure
relief valve.
 SCREW AIR COMPRESSORS

12. Recommended Spares

12.1 For Horizon Series

E55 Models

Kit of spares up to 2500

K 01 05 H08
hours of running, contains
Air filter 22 04 1964 9 1 No.
Oil filter kit 01 04 4022 9 5 Nos.
Element separator 01 04 5225 0 1 No.

Insurance Kit for (7.5,10 & 13 kgf/

015400437
cm2 )

110V AC Solenoid valve 1 No.

Minimum pressure valve kit 22 02 1037 9 1 No.
Gasket, Pipe coupling 01 04 5127 0 1 No.
Valve blow downe kit 22 03 7108 9 1 No.
Coupling element 01 24 3761 0 1 No.
Intake valve kit 01 03 3109 9 1 No.
Auto drain assy. 01 04 4225 0 1 No.

12.1
12.2 For Horizon Series
E55 Models (380 V) Kit of spares up to 2500
K 01 05 H08
hours of running, contains
Air filter 22 04 1964 9 1 No.
Oil filter kit 01 04 4022 9 5 Nos.
Element separator 01 04 5225 0 1 No.

Insurance Kit for (7.5,10 & 13 kgf/

015400437
cm 2 )

110V AC Solenoid valve 1 No.

Minimum pressure valve kit 22 02 1037 9 1 No.
Gasket, Pipe coupling 01 04 5127 0 1 No.
Valve blow downe kit 22 03 7108 9 1 No.
Coupling element 01 24 3761 0 1 No.
Intake valve kit 01 03 3109 9 1 No.
Auto drain assy. 01 04 4225 0 1 No.

12.3 Recommended Oil

PART No. 000998043

12.2
 SCREW AIR COMPRESSORS

13.1 Installation Data

13.1
 Please record the maintenance work performed in the individual columns
Suction Oil Oil Oil
Operating Line System Temperature filter separat. Cooler Motor
Date filter level Comments
hours pressure pressure change change cleaning mainten
* **

14.1
14.1 Maintenance Log Book

* Cl = Cleaning ** Co = Control
Ch = Change Ch = Change