GLOBAL SERIES ELECTRIC POWERED

SCREW AIR COMPRESSOR

11 Kw to 22 Kw STD
11 Kw to 22 Kw STD + Dryer
11 Kw to 22 Kw STD + Dryer + VFD
220V/380V, 3Ph, 60Hz

OPERATION AND MAINTENANCE MANUAL

NEURON+ MANUAL
PARTS MANUAL
DRYER MANUAL
VFD MANUAL
©
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005

Part / Document No. 01 90 15 57 0

Print Status
R00- August- 2009
R00- October- 2009
R00- November- 2009- Reprint
R00- December- 2009- Reprint
R01- January- 2010
R02- February-2010

Replaces Earlier

Doc. No. : Nil

Date : Nil

Price: INR 500

Contact Info :
Rotary Compressor Division
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005, India
Tel : 91 - 422 2589555
Fax : 91 - 422 2591384 (Domestic Business)
Fax : 91 - 422 2576849 (International Business)
E-mail : info@elgi.com
www.elgi.com
List of Contents

CHAPTER-I
OPERATION AND MAINTENANCE MANUAL
Introduction 1.0
Customer Care System 2.0

Commissioning process 3.0

Using the Manual 4.0

Definitions and symbols 5.0

Safety 6.0

Technical specifications 7.0

Decals Diagram 8.0

Installation 9.0

Disposal of packing 10.0

Functional description 11.0

Operating precautions 12.0

Schematic Diagram 13.0

Operation 14.0

Maintenance 15.0

Disposal of consumables and replaced parts 16.0

Troubleshooting 17.0

iii
CHAPTER-II
NEURON+ MANUAL
General information 18.0
User interface 19.0
Basic software menus and functions 20.0
Hardware 21.0
Installation and Connections 22.0
Technical Specification 23.0
Mechanical Dimensions 24.0
Maintenance & Trouble shooting 25.0
Trouble Shooting 26.0
Appendix A (Examples) 27.0
Appendix B (Abbreviation) 27.2
Appendix C (Drawings) 27.6
Appendix D (Identification Sticker) 27.7
CHAPTER-III
PARTS MANUAL
Drive Sub Assy 28.0
Intake Sub Assy 29.0
Tank Sub Assy 30.0
Cooler Box Sub Assy 31.0
Cooler Sub Assy 32.0
Moisture Separator Sub Assy 33.0
Base and Canopy Assy 34.0
VFD Retrofitment kit 35.0

iv
Machine Identification and Sale
Record
Owner’s name : ________________________________________

Address : ________________________________________

Model : ________________________________________

FAB No. : ________________________________________

Year of manufacture : ________________________________________

Motor : ________________kW_____________________

Capacity : _____________________m3/ min_____________

Rated Pressure : _______________________psi (g)____________

Date of Delivery : ________________________________________

Date of Commissioning : ________________________________________

Dealer’s name/code : ________________________________________

Dealer’s signature and stamp

Note: The warranty on this compressor is valid only if all the details
above are filled and the dealer stamps and signs this page

v
Message from the Managing Director

Dear ELGI customer,

It gives me great pleasure to welcome you to the family of users of Global

Series compressors from ELGI, among the most sophisticated rotary screw air
compressors available in the world today

ELGI has designed your Global Series compressor to be reliable, safe, easy to
maintain and friendly to use in meeting your compressed air requirements. This
user manual will enable you to use the Global series compressor optimally.
Please familiarise yourself with all the information it contains

I look forward to your continued satisfaction as a Global series user. ELGI is

honoured to be your choice for all your compressed air needs

Yours sincerely,

Jairam Varadaraj
Managing Director

vi
About ELGI

ELGI Equipments Limited, an ISO 9001 company, is the flagship of the ELGI
group. It has grown spectacularly over the last 50 years into a multi-market,
multi-product enterprise, transforming itself to meet the challenges of
globalization. ELGI is Asia’s largest and most integrated manufacturer of air
compressors. It is also a leader in automotive service equipment, with a
comprehensive range of products. The company has a strong presence in the
global market. It is one of the leading exporters in India, with more than 30
percent of its production reaching end-users and OEMs in 63 countries across
the world

ELGI operates out of two advanced and sophisticated manufacturing facilities

with R&D and CAD facilities, a totally integrated machine shop, CNC helical
rotor cutting machines, tool management centres, and a metrology laboratory.
ELGI’s dedication to after-sales service and support through its country-wide
system of branches and its global network of distributors and dealers has earned
it an excellent reputation. Driven by the philosophy of Think Long Run, ELGI
believes in forging long running partnerships with its customers and partners
world-wide guided by reliability, technology, capability and values and fuelled
by constant innovation

vii
Introduction

Your Global Series compressor belongs to a family of rotary screw compressors

from ELGI. Overall, the features of your Global Series translate to convenience
for you. The compressor has only two moving parts—the rotors—which are
separated by a thin film of oil, so that there is no wear. This also means that the
reliability of the compressor is unsurpassed

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 the Global Series gives you a compact and self-contained
compressor. Because it has no reciprocating parts, it runs quietly and free of
vibrations. The discharge temperature of the coolant oil is low, less than 90°C,
and therefore carbonized oil is not formed in the compressor

The Global Series compressors feature a Varion capacity control system at the
air inlet side and a three stage separation system including a unique OSBIC
air–oil separation system. The capacity control system ensures optimum air
intake during start-up, normal running and unloading. The three - stage separation
system and the moisture separator at the outlet ensure that oil and water are
separated from the compressed air

Please read the instructions in this manual carefully and follow them at all
times. The operating life and reliability of the compressor depend to a large
extent on correct operation and maintenance

When calling your ELGI branch office, dealer or service centre regarding your
compressor, keep at hand the details present on the name plate of the
compressor and entered in the inside front cover of this manual

When ordering spare parts, refer to the lists provided in Appendix B of this
manual and identify the part number. Specify the part number and quantity in
addition to the name plate details

1.0
ELGI’s Customer Care System (CCS)

ELGI provides dedicated customer care and after-sales support through the
CCS, a computerized system developed in-house. The CCS aims to minimize
the time taken to resolve complaints

Service Requests/Complaints

At the heart of the CCS is the toll-free telephone number 1800-425-3544 (with in
india BSNL MTNL lines) at the centralized customer care center in Coimbatore.
Customers can register their service requirements or complaints with coordinators
here

A unique tracking number is generated for each call logged by the CCS. The
customer is sent an automatic e-mail acknowledgement with the tracking number
and details of the call for reference

A service engineer is assigned to the call, and the date and time of the engineer’s
visit are communicated to the customer by e-mail. Every requirement or
complaint must be resolved and closed in the CCS within a specified time limit,
failing which the call is brought automatically to the notice of the manager
higher in the hierarchy, up to the level of the Managing Director. Thus the CCS
ensures that not only are customer complaints logged, they are also attended
on time every time

Enquiries

A number of calls received by the CCS relate to customers’ queries regarding

products and spare parts. The details are noted, and basic information on product
specifications and usage are provided. The caller is informed whom to contact
for further discussions. The enquiry is passed on to a salesperson at the Head
Office or the appropriate branch for follow-up

The CCS Database

The CCS also creates a database of customers, adding every new customer
calling and thereby building a large pool of installation details. These details are
used to provide value-added services to improve customer satisfaction with
ELGI products

2.0
CCS—Working Hours

The CCS at ELGI works for six days a week from 08:30 to 21:30 IST
(Monday to Saturday)

Multi-lingual Capability

The coordinators at the CCS are multi-lingual. They can handle calls in all the
major regional languages of India

Coverage

The toll-free number of the CCS is accessible from the following areas:

Southern Region : Tamilnadu, Karnataka, Kerala, Pondicherry, Andhra Pradesh,

Andaman & Nicobar islands

Western Region : Maharashtra, Gujarat, Madhya Pradesh, Goa, Lakshadweep

Islands

Eastern Region : Orissa, Chattisgarh, Jharkhand, West Bengal, Bihar and the
North-Eastern states

Northern Region : Rajasthan, Uttar Pradesh, Delhi, Haryana, Punjab,

Uttaranchal, Himachal and Jammu & Kashmir

Other Contact Numbers

The CCS can also be availed through the following numbers:

Telephone : 0422-2589 206/2589 241/2589 242/2589 243
2589 244/2589 245/ 97900 21100
Fax : 0422-2589 240

You may use the CCS by sending e-mail to:

ccs@elgi.com

Customer Satisfaction Survey

If you have used the CCS, you may be contacted and your feedback sought on
the after-sales support received by you. Your response helps ELGI to improve
this service

2.1
Commissioning Process

Before the new Global Series compressor is operated for the first time, it needs
to be installed at your site according to ELGI’s specifications. ELGI’s
commissioning engineer carries out a series of checks on the machine and the
systems to which it is connected to ensure that it is in a condition to function
safely and as desired. The engineer will then describe to the operator of your
compressor how the equipment is to be operated and maintained. This procedure
is referred to as the commissioning process

The commissioning of your compressor ensures that it is installed safely: the

general operating conditions of the equipment including the cleanliness of the
atmosphere, the temperature and the ventilation are checked. Technical details
relating to your system such as particulars of your electrical installation are
noted. The operator of your compressor is familiarised with all aspects of both
its normal running and dealing with unusual situations. The commissioning
process provides to ELGI data that will help understand your requirements
better

Please make preparations according to the instructions provided in the Installation

section for your Global Series compressor to be commissioned. Ensure that
the location chosen meets the requirements of accessibility, ventilation and
safety. Provide electrical power as recommended in the Installation section, in
discussion with ELGI’s commissioning engineer. Select air pipe lines and
receivers for your system according to the tables provided in the same section

Upon completion of the commissioning process the commissioning engineer

will fill in the document known as the commissioning Report. Please verify the
information filled in and attest the certificate of completion of commissioning.
The commissioning engineer will also sign the report. Kindly hand over the
commissioning report to the commissioning engineer. Please fill in also the
Warranty Card that comes along with the compressor and hand it over to the
engineer. The engineer will send the report and the card to ELGI’s Service
Department — Compressor Division, Head Office

3.0
Using the Manual

This operation and maintenance manual has been specially designed keeping
you in mind so that you can get the most out of your ELGI Global Series
compressor. Before you start using your compressor, go through this manual
thoroughly. It contains vital information on operation as well as useful tips that
will help you keep your compressing running as good as new year after year. It
is essential to maintain the compressor as recommended in the Maintenance
section

The manual has been prepared with utmost care to help you understand the
various systems of the compressor thoroughly through descriptions, information
and illustrations. Use the parts lists in Appendix B when ordering replacement
parts for your compressor

All the information, illustrations and specifications in this manual are based on
the latest product information at the time of preparation of the manual. ELGI
reserves the right to make changes in the product at any time without notice

The manual must be available at all times to the personnel operating the
compressor

4.0
Definitions and symbols

This information relates to protecting your safety and preventing equipment

problems. To help you recognize this information, we use the following symbols

NOTE:

A Note clarifies procedures or conditions which may otherwise be misinterpreted

or overlooked. A Note may also be used to clarify apparently contradictory or
confusing situations

CAUTION:

A Caution is to draw attention to a procedure which, if not done correctly, can

lead to equipment damage

WARNING:

A Warning calls attention to dangerous or hazardous conditions inherent to the

operation, cleaning and maintenance of the equipment which may result in
personal injury or death of the operator or other persons
SYMBOLS:

CAUTION DO NOT OPERATE

WARNING DE-ENERGISE

OPERATION
DO NOT ATTEMPT
REPAIRS
ENERGISED
(POWER ON)
DO NOT INHALE

CAN CARRY OUT REPAIRS

OR ADJUSTMENT

KEEP ACCESS DOORS CLOSED

5.0
Safety

General Information
The operator should follow the instructions, procedures and decals given in this
manual for safe operation

The maintenance personnel should be adequately trained, and have read and
completely understood this operation anhd maintenance manual

Compressed air and electricity can be dangerous. To prevent injury before

attempting any maintenance, be sure to disconnect the power at the source
and the compressor is relieved of all pressure

Ensure that all the protective covers are in place and that the canopy/doors are
closed during operation

All electrical installation must be in accordance with recogonised electrical codes

and any local health & safety codes

Remove red coloured brackets at the airend and motor while commissioning
the compressor

Death or serious injury may occur from inhaling compressed air. Always wear
safety equipment while operating the compressor. Refer OSHA safety standards

Do not allow compressed air to come into contact with food

Rotating fan blades can cause serious injury. Disconnect power before attempting
service

Read the safety guidelines before installation and operation

WA RNING

6.0
Technical Specifications

E11 E15 E18 E22

Free air delivery (cfm)
@ 100 psi (g) working pressure 71 96 115 136
@ 125 psi (g) working pressure 65 88 110 132
@ 150 psi (g) working pressure 58 80 98 114
@ 175 psi (g) working pressure 49 69 80 95
Compressor main - motor kW(HP) 11(15) 15(20) 18.5(25) 22(30)
Motor type (main motor) Totally enclosed fan cooled
Class of insulation of motor Class F
Degree of protection of motor IP 55
Overall dimensions
LXBXH (mmxmmxmm) 1425x720x1490

Models Pressure Weight

Comp. With dryer With dryer+ vfd
psi (g) Kg Kg Kg
E11 – 7.5 100 534 605 612
E11 – 8.5 125 534 605 612
E11 – 10 150 534 605 612
E11 – 13 175 534 605 612
E15 – 7.5 100 565 636 643
E15 – 8.5 125 565 636 643
E15– 10 150 565 636 643
E15 – 13 175 565 636 643
E18 – 7.5 100 680 788 806
E18 – 8.5 125 680 788 806
E18– 10 150 600 709 728
E18 – 13 175 600 709 728
E22 – 7.5 100 700 810 828
E22 – 8.5 125 700 810 828
E22– 10 150 700 810 828
E22 – 13 175 630 740 758

7.0
 DAILY CHECKS
l Hour meter condition
l Discharge temperature
l Load & unload pressure
l Air filter clog indicator
l Moisture outlet while running
l Oil level indication

Decals Diagram

8.0
Decals Diagram

Direction of Rotation
Gear Driven - C.W
Direct Driven - C.C.W
From Motor Cowl Side

8.1
Decals Diagram

8.2
Decals Diagram

8.3
Installation

9.0
Installation

q If the compressor is provided with a lifting bail then lift using the bail. If no
bail is provided, lift it using slings. Compressors to be air lifted by helicopter
must not be supported by the lifting bail but by slings

q Prior to lifting, inspect the lifting bails and points of attachment for cracked
welds and for cracked, bent, corroded or otherwise degraded members and
for loose bolts and nuts

q Make sure the 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. If you are unsure of the weight, then weigh the
compressor before lifting it

q Make sure the lifting hook has a functional safety latch, or equivalent, and
is fully engaged and latched on the bail

q Use guide ropes or equivalent to prevent twisting or swinging of the machine

once it has been lifted clear of the ground

q Do not attempt to lift the compressor in high winds

q Keep all personnel away from the compressor when it is suspended

q Lift the compressor no higher than necessary

q Keep the lift operator in constant attendance whenever the compressor is

suspended

q Set the compressor down only on level surfaces capable of supporting at

least its net weight plus an additional 10 per cent allowance

9.1
Installation

Unpacking
Unpack the compressor from the packing case by removing the nails. Unscrew
the bolts holding the compressor to the base of the crate

Once all the packing material is removed, check the contents against the packing
list. The compressor is shipped with the following:

q Key for doors

q Operation and Maintenance Manual

q Checklist of parts of the machine

q Electrical drawing

Tools may be provided on request. If any components are found missing, contact
WA R NING
ELGI immediately

Compressor Location – Space around Compressor

Please observe all accident prevention regulations when installing

this compressor

Install the compressor with adequate accessibility to ensure obstruction-free

operation and maintenance. Maintain a clearance around the compressor as
shown in the figure below on Page 9.4

9.2
Installation

Compressor Location – General Requirements

The compressor room or the area around the compressor should be clean,
dry,cool and free of dust. The room temperature for the compressor should
preferably be below 45ºC. Excessively warm intake air affects the compressed
air output.When the discharge temperature of the compressor (temperature at
compression unit) exceeds the factory-set value of 110ºC, the compressor will
trip off.Also, the ambient temperature should not drop below +5ºC. Provide air
supply openings with adjustable louvres to ensure that the minimum temperature
does not drop below +5ºC in winter

Never store combustible materials within a 10 m radius of the compressor. The

room housing the compressor must be equipped with fire fighting equipment.
The floor around the compressor must be of non-combustible material

Compressors may only be installed in a working area where the ambient noise
level does not exceed 80 dB(A)

9.3
 Control panel for
Standard Model Cooling Air Out

VFD for VFD Electrical Connection

integrated models Remote Management

Control panel for

VFD integrated
NOTE
model

Installation
A minimum of 1m clearance is required
on all sides of compressor and 2m
clearance above the unit

Electrical Connection
Remote Monitoring

Lift slot
fork lift

Cooling air inlet

9.4
G1-1/4”
Air
Discharge

Cooling air inlet

for Electric motor
G1-1/4” drain for
condenser line
Installation

Ventilation and Exhausting Hot Air

Ensure adequate ventilation in the compressor installation area. Your compressor

has a ventilating air requirement of 7000 m3/h. The figure provided indicates
different ways in which this could be achieved

If your compressor is fitted with ducts as shown in the figure, the ventilating air
requirement is only a third of the value specified herein

NOTE

• Suspended particulate matter should be less than 150 spm to achieve

the specified consumable life
• No guarantee shall be given if the compressor is operated above
its intended pressure

I Possibility II Possibility
III Possibility

B
B

A A

Natural Forced Force & above 5 C

NOTE :
A = Intake air aperture with louvres
B = Exhaust air inlet area, should V Possibility Summer Option

match the cooler area

Air pressure considered 1 bar.
absolute
C
Pressure drop in conduit should not
IV Possibility be more than 30 Pa B

Winter Option

Stores
A

Force & above 0 C

9.5
Installation

Follow the guidelines herein for providing ventilation for the compressor:

l Provide openings close to the floor level on walls/partitions close to the

air suction side of the compressor

l Provide exhaust openings close to the ceiling for hot air exit

l The air velocity in the supply and exhaust ducts should not exceed 4 m/s.
The velocity is ascertained during commissioning using an anemometer

l Do not connect cool air inlet ducts directly to the compressor inlet side

l To eliminate transmission of vibrations, provide a soft bellows connector

between the duct and the compressor

l Contact ELGI in case you need to provide a duct connection or filter

fitment on the compressor

l A forced flow of cool air should not be directed towards the compressor
WAR NING
l The compressor is to be located such that the hot air from other machines
is not directed towards it

Failure to observe the instructions regarding installation and

ventilation may result in an excessive increase or decrease
of the discharge temperature of the compressor, and the
compressor will trip under high discharge temperature
conditions. The output of the compressor will also be affected

Foundation

An industrial floor with a level surface capable of supporting the weight of the
compressor (refer to the technical specifications) is sufficient for installing a
Global Series compressor. A foundation is not necessary

9.6
Installation

Electricals
You must provide a lockable main switch with pre-connected slow-blow main
fuses as per industrial safety regulations.The power supply should be 220/380
Volts 3 phase with Neutrol
The fuse and cable specifications for 220 V or 380 V, 60 Hz/3 Ph power supplies
are listed in the table below

Recommended Incoming Copper

Incoming Copper
Models pre-connected fuse cable size Al(mm2)
cable size Cu(mm2)
rating (A)
220V 380V 220V 380V 220V 380V
E11 63 32 4Cx16 3½Cx10 4Cx25 3½Cx16
E15 80 50 3½Cx25 3½Cx16 3½Cx35 3½Cx25
E18 100 50 3½Cx35 3½Cx16 3½Cx50 3½Cx25
E22 160 63 3½Cx50 3½Cx25 3½Cx70 3½Cx35

NOTE : Power should be supplied to the compressor through a fuse switch

unit of suitable rating mounted within 5m of the compressor

Air Pipe-lines
Use the table below as guidance for selecting pipes for your system

Free Nominal pipe diameter

air ½ inch ¾ inch 1 inch 1¼ inch 1½ inch
(cfm)
80 lb 100 lb 125 lb 80 lb 100 lb 125 lb 80 lb 100 lb 125 lb 80 lb 100 lb 125 lb 80lb 100 lb 125 lb
10 0.45 0.38 0.31 0.11 0.09 0.08 0.04 0.03 0.02 0.0086 0.0071 0.0058
20 1.74 1.42 1.17 0.41 0.34 0.28 0.13 0.1 0.08 0.032 0.026 0.021 .014 .0 12 .010
30 3.84 3.13 2.54 0.9 0.74 0.6 0.28 0.23 0.19 0.068 0.056 0.046 .031 .026 .021
40 6.93 5.55 4.53 1.55 1.28 1.05 0.46 0.38 0.31 0.116 0.096 0.079 .053 .044 .036
50 10.7 8.65 7.01 2.42 2 1.62 0.73 0.6 0.49 0.18 0.046 0.12 .081 .067 .055
60 3.47 2.84 2.33 1.02 0.84 0.69 0.25 0.21 0.17 .12 .095 .078
70 4.73 3.85 3.14 1.36 1.12 0.92 0.34 0.28 0.23 .16 .13 .10
80 6.14 5.01 4.08 1.76 1.44 1.18 0.44 0.36 0.3 .20 .16 .14
90 7.75 6.4 5.17 2.23 1.85 1.49 0.55 0.45 0.37 .25 .20 .17
100 9.62 7.8 6.33 2.69 2.21 1.81 0.066 0.55 0.45 .30 .25 .20
125 15.5 12.4 9.8 4.18 3.41 2.79 1.03 0.85 0.69 .46 .38 .32
150 23 18.1 14.4 5.75 4.19 3.99 1.47 1.2 0.99 .65 .54 .44
175 1.81 6.8 5.45 2 1.64 1.32 .90 .73 .60
200 10.9 8.79 7.11 2.58 2.12 1.73 1.15 .95 .78
250 1.82 1.48 1.20
300 2.55 2.10 1.72
350 3.53 2.86 2.35
400 4.53 3.70 3.03
450 5.80 4.65 3.80
500 7.12 5.79 4.71

9.7
Installation

Receivers for Compressed Air Systems

The table below is given for your guidance in selecting an appropriate air receiver
for your system

Receiver specifications Compressed capacity

Volume Modulation
Height Diameter Weight On/Off
control
(mm) (mm) (kg) control (cfm)
(ft3) (m3) (cfm)

0.25 8.83 1740 655 115 Up to 40 Up to 60

0.5 17.66 2100 780 210 41–85 61–120
1 35.32 2785 1000 344 86–140 121–235
1.5 52.97 2500 1250 783 141–225 236–355
2 70.63 3175 1250 954 226–310 356–470
3 105.95 2805 1565 1308 311–445 471–710
4 141.26 3580 1595 1564 446–570 711–945
5 176.58 3535 1780 2129 571–700 946–1180
6 211.89 4185 1780 2343 701–850 1181–1415
7 247.21 3640 2100 2885 851–990 1416–1650
8 282.52 3985 2100 3115 990–1130 1651-1885

Commissioning

Before the new Global Series compressor is operated for the first time, it must
be installed at your site by ELGI’s commissioning engineer. The following
instructions and specifications are given only for your reference. They are
applicable to standard air-cooled Global Series compressors without additional
equipment (receivers, Driers etc). For identification of parts, refer to the Functional
Description section of this manual

Before commissioning, check the equipment for visual damage of parts. An

electrical circuit diagram is delivered with every Global Series compressor (kept
inside the electrical control panel) for electrical wiring reference

Every ELGI screw compressor is subjected to a test run prior to despatch.

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

9.8
Installation

Check the total power supply requirements from the name plate before connecting
the compressor to the electrical lines

Connect the earthing line to the point provided on the base frame at the side of
the compressor

Control panel

Earthing point
Detail-A
Power cable entry

9.9
Installation

Connect the leads L1, L2, L3 and N to the terminals inside the electrical control
panel of the compressor

Ensure that only authorised electricians carry out the electrical

work. Study the electrical circuit diagram before starting work

Transformer tappings & OLR settings need to be adjusted

according to voltage conditions (220V/380V) at site

l Connect the compressor to the air network

l Fill the oil as per the oil fill procedure

l Use ELGI recommended Air Lube oil (Airlube XD) for optimum
performance of the compressor
WARNING

9.10
Installation

Removal of the AVM arresting bracket

Locking Clamps and Locking Bolts

For Motor and Airend (to be removed after the compressor is installed)

9.11
Installation

Oil Fill Procedure

Oil Filling Port Oil Filling

Port

Oil Level For Model 22 kW Oil Level For Model 11kW, 15kW
and 30 kW Models and 18.5 kW Models

NOTE

• Suspended particulate matter should be less than 150 spm to achieve the specified
consumable life
• No guarantee shall be given if the compressor is operated above its intended
pressure

9.12
 Installation

Procedure for filling oil in newly Procedure for changing oil in

assembled machine compressors on-site

l Fill oil in the oil tank up to the
maximum level indicated in the
drawing
l Close the oil filling plug
l Run the compressor for 10 minutes,
until the thermostatic valve opens
l Stop the compressor
l Open the oil filling plug after 5
minutes
l Refill the oil tank, it can be filled upto
the maximum level as indicated on
the drawing
l Restart the compressor
l Shut off the compressor
l Drain oil from the oil tank through
the drain ball valve
l Drain oil from the cooler through the
drain plug
l Drain oil from the discharge pipe after
dismantling it
l Drain oil from the airend by hand
rotating
l Add new oil . Fill it upto the maximum
level as indicated on the drawing
l Close the oil fill plug
l Restart the compressor and allow it
to run for about 10 minutes, until the
thermostatic valve opens
l Stop the compressor
l Open the oil fill plug after 5 minutes
l Refill the oil tank to the maximum level
indicated on the drawing
l Restart the compressor

NOTE
1. Prior to starting the machine, ensure all the plugs and ports are closed. Check if all the
dismantled components are assembled properly
2. Do not remove plugs or ports when the compressor is running or pressurized. Stop the
compresor and relieve all internal pressure before doing so
3. Do not check the oil level when the compressor is running

9.13
Installation

Keep the air outlet line ball valve provided at the rear of the compressor in fully
open condition before starting the compressor

Open

Connect the moisture outlet line provided at the rear of the compressor to the
waste water disposal line

9.14
Installation

Check the power supply requirements from the name plate and connect the
leads L1, L2, L3 and Neutral to the terminals inside the electrical control panel
on the compressor

Ensure that only authorised electricians carry out the electrical

work. Study the electrical circuit diagram before starting work

Change transformer tappings & OLR setting according to voltage

conditions (220V/380V) at site

Check the direction of rotation of the main motor and the fan motor when starting
for the first time by switching on the compressor (pressing the green Start
button) and switching off (pressing the red mushroom Stop button) immediately.
The motor must rotate in the clockwise direction when viewed from the front
side (non-drivingside). WIfAthe
R NI NG
direction of rotation is not correct, isolate the machine
from the electrical lines and interchange any two phases. Re-start the compressor
and ensure that the direction of rotation of the main motor and the fan motor is
clockwise

The direction of rotation of motor for

gear driven Airend is clockwise(C.W.)
where as in case of direct driven Airend
the direction of rotation is counter
clockwise(C.C.W.) , from motor cowling
side

Gear Models : E11- all pressures

E15- all pressures
E18 - 150,175
E22 - 175

9.15
Installation

Switch on the compressor after ensuring all the above points and run at the
rated speed

CAUTION
Running the compressor in the wrong direction for more than 5 s
will cause damage to compressor parts or even total destruction

NOTE
All the settings for pressure, temperature , electrical protection devices,
etc. are set at factory before dispatch

In case of problems during the running of the compressor, check which

CAUTION
warningLEDs are illuminated on the control panel of the compressor and refer
to the Functional Description and Operation sections of this manual

If any abnormal noise is heard when the compressor is run, switch it off
immediately and contact the ELGI service engineer for remedy

All the points listed in the foregoing are to be followed when the compressor is
re-installed at a different location

If the compressor has been stored for an extended period before commissioning,
contact the ELGI service engineer

Extended storage

If your compressor is expected not to be used for a prolonged period, special

measures must be undertaken to ensure the protection of the following
components:
The airend
The motors
The sump or air–oil separator tank

9.16
Installation

Airend

l Remove the airend discharge hose/pipe coupling fitted to the air receiver

l Rotate the coupling three times so that the oil present inside the airend
comes out through the discharge port

l Block the discharge port completely

l Remove the inlet rubber duct connected to the intake valve of the air filter
assembly

l Press the puppet intake valve and pour rust-preventive oil (use Castrol
DWX 32 or an equivalent grade) into the airend through the intake valve

l Rotate the coupling five times by hand so that the rust preventive oil
spreads all over the bearings, seals and other parts of the airend

l Drain the rust-preventive oil by opening the discharge port plug fully

l Refit the hose/pipe coupling on the discharge port

l Take care to ensure that all the openings are plugged always to avoid dust
entry

l This procedure protects the airend for up to six months storage. It must
be repeated every six months during storage

Motors
l Check the insulation of the motor winding
l Remove moisture if any in the motor
l Check the junction box terminals for tightness of the wires
l Grease the motor
l This procedure will protect the motor for up to one year storage
l Air–oil separator tank
l Replace the oil filter element
l Replace the air filter element

9.17
Installation

The sump or air–oil separator tank

l Remove the entire tank from the compressor after

disconnecting it from all hoses, the tank top lid, the minimum
pressure valve outlet line, control pulse lines and control
switches

l Clean the tank using DW X 32 oil

The separator tank may now be stored for up to two years. Replace
the separator element before using the compressor again

9.18
Disposal of Packing

The wood used to make the shipping crates of the Global Series compressors
is biodegradable

The polyethylene covers wrapped around the compressor and the polystyrene
packing provided around the electrical panels are not recyclable. They must be
disposed of in accordance with prevailing environmental laws

10.0
Functional Description

BLEED 159 - Direct Drive airends

This product is part of an ELGI initiative to extend the range of existing Direct
Drive airends in Electric Powered Screw Compressors. Currently, these base
models cater to only specific capacities (FAD). A Direct Drive airend has the
obvious advantage that it rotates at the prime mover speed, owing to direct
coupling, without the use of an intermediate belt or gear drive. Compared to
small gear-driven airends, the direct-drive airends provide cost savings, no-
loss power transmission and gain in operating efficiency

BLEED is a capacity reduction concept that enables operation of airends at the

same Direct Driven speed for capacities upto 23% lower than the Base capacity.
Bleed can thus substitute for gears for airends upto 23% Capacity reduction

Direct Drive

In this case, capacity is reduced not by speed reduction (as with gears & belt
drives), but by removing air early in the compression cycle and recirculating it
to suction. This effectively reduces the length/lobe volume enclosed by the
rotors for further compression, improving the capacity. The provisions for BLEEDs
in the rotor housing of these airends make them visibly different from their gear
& belt driven counterparts, though rotors & other components are same.
Implemented with Axis 159 lubricated airends, BLEED 159 offers advantages
like improved mechanical efficiency, elimination of the gear box, reduced noise

11.0
Functional Description

profile & longer bearing life than the equivalent 102 Gear Driven models. Another
bonus is that a few of these BLEED airends can be scaled up to a higher
operating pressure without changing the Motor or Airend. This enables
compressor paackage modifications to be done on-site

11.1
Functional Description

Compression in a Global Series compressor

At the heart of the Global Series compressor is the compressor unit or airend,
driven by an electrical motor. There are two counter-rotating, intermeshed helical
screw elements in the airend, the male rotor and the female rotor

Gear Drive

The rotors mesh with each other as they turn. Air is trapped between the flutes
and lobes of the rotors, getting progressively compressed as the rotors turn.
The compressed air flows out towards the discharge port. One pocket of trapped
air getting compressed progressively is illustrated (next page)

11.2
Functional Description

Compression in a screw compressor

In practice, oil is injected in large quantities into the air. It acts as a coolant,
removing the heat of compression. It also serves to seal leaks between the
rotors and the housing, and lubricates the rotors and the bearings and gears.
The oil is separated from the discharge stream, cooled, filtered and then recycled

Internal cooling using oil permits the temperature at the compression end to be
maintained at approximately 80–85°C at an ambient temperature of 30°C

11.3
Functional Description

Air Intake System

Air is provided to the airend by the air intake system

Air Filter Clog

Indicator

Air Filter

Intake Valve
Air Filter
Bracket

NOTE:
• Suspended particulate matter should be less than 150 spm
to achieve the specified consumable life
• No guarantee shall be given if the compressor is operated
above its intended pressure

The air filter prevents foreign particles like dust from entering the airend. Air get
filtered in two stages by two different filters primary and secondary air filters.
The air inlet valve controls the amount of air taken into the airend. The indicator
on the filter turns red when the filter is to be cleaned or replaced. Normally,
when compressed air is being delivered in the service line, the intake valve is
open. When very little or no air is being supplied, the intake valve is closed

11.4
Functional Description

III Stage separation

by
Air Oil Separator

I Stage Separation

II Stage Separation

Discharge system

Much of the oil is removed from the air–oil mixture by the advance three stage
separation techniques, but some oil still remains in the air. To bring the oil
content to within the desirable limits below 1ppm, the lean mixture is passed
through a highly efficient separator element. The oil separated thus is returned
to the lubricating system through the scavenge line. The air passes through a
minimum pressure valve. The minimum pressure valve is positioned downstream
of the oil separator. It maintains a minimum pressure for safe supply of oil to the
compressor unit. The air temperature at this stage is still higher than the desired
temperature at the receiver. So it is cooled in an after-cooler to a few degrees
above the ambient temperature. Before the air is discharged to the external
receiver, moisture is removed from it using a moisture separator

NOTE
Consult ELGI for the selection and supply of a suitable dryer for your
requirements of dry air

11.5
Functional Description

Cooling and lubrication system

The oil separated from the air-oil mixture is cooled in the oil cooler. A thermal
element controls the flow of oil to the cooler, depending on the temperature of
the oil. The cooler is bypassed by the oil if the temperature is low enough, such
as in the initial flow when the compressor is started. The oil is passed through
an oil filter which removes dust and other impurities before it is returned to the
airend. The oil circulation circuit is operated solely by the pressure differential
and does not require any separate oil pump

As stated previously, the oil has a critical function in the compressor. It removes
the major part of the heat of compression, seals all the areas in the airend and
lubricates the bearings and gears. The properties of an oil that determine its
suitability for use in the compressor include its viscosity, wear characteristics,
demulsibility, heat resistance and thermal stability

Cooling
Fan
&
Fasteners

Shroud Assembly

Cooler Cooler Box

&
Fasteners

11.6
Functional Description

ELGI Air Lube, blended using heavy-duty hydraulic based oil with the right
amounts of additives under strict quality control checks, ensures satisfactory
compressor performance

The life of any mineral oil decreases by almost 30–40% for every 10°C above
90°C. It is recommended that the oil change frequency is varied in summer and
winter months for optimum benefits. A good record of the operating temperature
of the compressor is essential for this. Continuous operation of the compressor
at a temperature above 100°C without changing the oil will lead to varnish
formation and will affect the life of the bearings and the airend

Drain Period(Hrs)
DOT Status
Air Lube Plus Air Lube XD
(00099805’A’) (000998053)
DOT<90ºC 2000 4000

DOT
OT 90ºC to 100ºC 1500 3000

DOT above 100ºC Consult Nearest Elgi Dealer

The above figures are guidelines based on extensive trials in the field. However,
ELGI’s Service Engineers can help you optimize the oil drain interval for your
application based on the operating temperature and pressure and the
environmental conditions

NOTE:
• Suspended particulate matter should be less than 150 spm
to achieve the specified consumable life
• No guarantee shall be given if the compressor is operated
above its intended pressure

11.7
Functional Description

Transmission system

Drivecoupling

Airend Adapter Ring Main Motor

Electrical system and controls

The compressor starter is an automatic star–delta starter with safety interlocks.

If no fault is detected in the controller, Ready message is displayed. If any
fault is detected, trip warning is displayed

The fault warnings are displayed as described in the following section

NOTE
Power should be supplied to the compressor through a fuse switch
unit of suitable rating mounted within 5 m of the compressor

ELGI offers Variable Frequency Drive(VFD) instead of star delta starter. If your
compressor is with VFD, please refer the VFD manual for more detailed
operations

11.8
Functional Description

Electrical System

The compressor starter is an automatic star–delta starter with safety interlocks

The compressor can be controlled in all modes (Local, Remote and DCS) by
the Neuron+, a dedicated microcontroller. Neuron+ has eight digital inputs, three
analogue inputs and eight relay outputs. The inputs are provided by contact
switches, pressure and temperature transducers. Neuron+ control panel has
eight tactile push-buttons, a 16x2 line alphanumeric LCD for display of
compressor status and related information, and 14 LEDs (Annunciation Window)
for user interface. If all the inputs are normal, the display indicates “READY”

To start the compressor, press the “START” (green) push-button located on the
controller. The controller will switch on the relays in the correct order, and these
in turn will energise the delta contactor and the solenoid valve. The LCD display
will show the current status of the compressor. The compressor runs and builds
up pressure

To stop the compressor, press the STOP (red) push-button. If the machine trips
due to a fault, press the Reset button after rectification of the fault

Preprogrammed timer functions:

l Star-delta delay-determines the star-to-delta changeover time; set at
any value between 6 and 10 sec
l Delta-to-run (DTR) delay-decides the delay between the delta change over
and energising of the solenoid valve
l Standby time (unload monitoring time)-stops the compressor if it is running
in unloaded condition for a set time (5 min) and starts the compressor
automatically on demand

11.9
Functional Description

NOTE
Ensure 24 V AC power supply to Neuron+ controller. Modify the timer
settings under m/c settings menu present in the controller according
to requirement. Before starting the compressor, check the following
electrically

Separator element warning

Indicates that the separator element needs to be replaced. The compressor

does not shut down automatically in this situation

Oil filter warning

Indicates that the oil filter element needs to be replaced. The compressor does
not shut down automatically in this situation

High discharge temperature trip

The compressor shuts down automatically and this warning light goes on when
the discharge temperature exceeds the preset value of 110±5ºC

Main motor overload trip

This warning lights up and the compressor shuts down when the main motor is
overloaded

Fan motor overload trip

The fan motor has internal thermal over load protection which safe gaurds the
fan motor . If the fan motor trips then DOT will be high and tripped the compressor
as high temperature

Graphic warning display

This gives graphically the location of a fault (condition requiring a warning)

Reset button

This button must be pressed before restarting the compressor after it has shut
down with a warning and remedial measures have been taken

11.10
Functional Description

Safety system and interlocking devices

Your Global Series compressor is equipped with the following devices for reliability
and safety:

Discharge temperature sensor

This is provided to shut down the compressor if the discharge air– oil mixture
temperature reaches a preset value of 110 ± 5ºC. The temperature probe is
fitted on the airend outlet cover or receiver tank

Minimum pressure valve

This valve is fitted at the outlet of the oil separator and maintains a minimum
receiver tank pressure of about 4 bar g. This facilitates proper air and oil
separation and oil circulation to the airend

Pressure relief valve

The pressure relief valve relieves the pressure in the air–oil receiver tank when
it exceeds 140% of the working pressure

Thermo switch is fitted on the discharge hose to switch on the cooling fan of
the compressor if the discharge air/oil mixture temperature reaches the preset
temperature

Overload relays for main motor and fan motor

These relays are fitted on the electrical control panel. They ensure the
compressor is switched off when the power consumption exceeds a set value

11.11
Functional Description

ELGI designs and manufactures its products for smooth and safe operation.
However, the responsibility for safe operation rests with those who use and
maintain these products. The following precautions are offered as guidance.
When followed regularly, they will minimise accidents and failures throughout
the useful life of your Global Series compressor

The compressor should be operated only by those who have been trained and
delegated to do so and have read and understood this operation and
maintenance manual. Failure to follow the instructions, procedures and
precautions given in this manual may increase the possibility of accidents and
failures

Never start the compressor unless you know it is safe to do so.

Do not attempt to operate the compressor when it is known to be
!
WARNING
in an unsafe condition. Examples of unsafe conditions include
improper earthing of the machine and reverse rotation of the motors

Electrical arcing from compressor components can ignite

flammable liquids and vapours which can result in serious injury.
!
WARNING
Never operate the compressor near flammable liquids or vapours.
If the compressor is used to spray flammable materials, keep it at
least 6 m away from the spray area

When you know the compressor to be in an unsafe condition, tag it as unsafe

and render it inoperative by disconnecting the power supply so that others who
many not know of this unsafe condition will not attempt to operate it until the
condition is corrected. Do not modify your Global Series compressor except
with written approval from ELGI

11.12
Operating Precautions

Pressure release

l Annual servicing of safety valve and the kit is necessary. The kit should
be checked at stndard pressure

l Use only the correct tools for maintenance and repair work. Do not allow
the manufacturers’ rated safe operating pressure for pipes, valves, filters
and other fittings to be exceeded

l Open the oil filter cap only when the compressor is not running and is not
pressurized. Shut down the compressor and bleed the receiver tank to
zero internal pressure before removing the cap

l Vent all internal pressure prior to opening any line, fitting, valve, drain
plug, connection or other components such as a filters. Vent pressure by
popping up the pressure relief valve

12.0
Operating Precautions

l Keep personnel out of the line of the discharged air when opening hoses
or other points of compressed air discharge

l Do not use air at a pressure greater than 2.5 kgf/cm2 for cleaning purposes

Do not engage in horseplay with air hoses: serious injury or death

WA R NI NG
may result

Fire and explosion

l Clean up spills of lubricant or other combustible substances immediately

l Shut down the compressor and allow it to cool down. Move sparks, flames
and other sources of ignition away.Do not permit smoking in the vicinity
when checking or adding oil

l Do not use flammable solvents for cleaning purposes

l Keep grounded conductive objects such as tools away from exposed live
electrical parts like terminals to avoid arcing, which might serve as a
source of ignition. Keep all terminals clean and tight

l Keep electrical wiring and other terminals in good condition. Replace any
wiring that has cracked, cut, abraded or otherwise degraded insulation

12.1
Operating Precautions

l Keep oily rags, trash, dry leaves, litter or other combustibles out of and
away from the compressor

l Do not operate the compressor without a proper flow of cooling air or with
an inadequate flow of lubricant or with a degraded lubricant

l Do not attempt to operate the compressor in a hazardous environment of

any classification unless the compressor has been specially designed
and manufactured for explosive applications

Moving parts

l Keep hands, arms and clothing away from couplings, fans and other moving
parts

l Do not attempt to operate the compressor with the fan guards, coupling
guards or other guards removed

l Keep access doors closed except when making repairs or adjustments

l Wear snug-fitting clothing and confine long hair when working around the
compressor, especially when hot or moving parts such as the cooler, the
airend, the thermal valve, the main motor or the fan motor are exposed

l Prior to attempting to start the compressor or operate it, make sure that all
personnel are clear of the compressor

l Prior to attempting repairs or adjustment, disconnect the power at the

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

12.2
Operating Precautions

l Keep hands, feet, floors, controls and walking surfaces clean and free of
fluid, water or other liquids to minimize the possibility of slips and falls
Hot surfaces
l Avoid bodily contact with hot oil, hot coolant and hot surfaces
l Keep all parts of the body away from all points of air discharge
l Keep a first aid kit handy. Seek medical assistance promptly in case of
injury. Do not ignore small cuts and burns as they may lead to infection
Toxic and irritating substances
l Do not use air from the compressor for respiration

12.3
Operating Precautions

l In the event of ingestion of oils, coolants and lubricants used in the

compressor, seek medical treatment promptly. Wash with soap and water
in the event of skin contact

Electrical shock

l Keep all parts of the body and any handheld tools or other conductive
objects away from exposed live parts of the electrical system. Stand on a
dry or insulating surface and do not contact any other part of the compressor
when making adjustments or repairs to exposed live parts of the electrical
system. Make all such adjustments or repairs with one hand. This
minimizes the possibility of creating a current path through the heart

l Attempt repairs only in a clean, dry, well lit and ventilated area

l Do not leave the compressor unattended with open electrical enclosures.

If it is necessary to do so, disconnect the power to the compressor at the
source and lock it out so that power is not inadvertently restored

l Disconnect, lock out and tag the power source prior to attempting repairs
or adjustments, turning the machinery manually or handling ungrounded
conductors

12.4
Schematic Diagram

SCHEMATIC DIAGRAM
P AND I - OFF MODE

1. Air Filter 15. 3/2 Solenoid Valve NC

2. Choke Indicator 16. Blow Down Valve No
3. Intake Valve with Check Valve NC 17. Minimum Pressure Valve with check valve
4. Airend 19. Moisture Drain Automatic
5. Motor 20. Ball Valve
6. Temperature Sensor 21. Auto Drain Valve
7. Air Oil Separator Tank 22. Pressure Transmitter
8. Oil Drain 23. Outlet Valve
9. Safety Valve 24. Fan with Motor
10. Air Oil Separator Element
11. Orifice
12. Thermostatic Valve
13 & 18. Oil and Air cooler
14. Oil Filter
13.0
Operation

Checks before starting the compressor

l Fill oil in the oil tank as per the oil filling procedure

l Fill oil up to the half level of the oil sight glass. Tighten the oil filling plug
using a spanner

l Open all doors and visually check that the machine for suitability for
operation

l Open the door of the electrical panel at the front of the compressor and
check whether the three phases and neutral phase are connected securely
(red, yellow, blue and black wires)

l Check the nessary earthing line in the panel / compressor base

Starting the equipment

Press the start button (green) and check that the main motor turns clockwise
or counter clock wise (when viewed from the front of the compressor).
Stop the compressor by pressing the stop button (red) on the control panel.
Ensure correct direction of rotation for the specified compressor model

Starting and normal operation mode

When the machine is switched on the motor runs in the star mode and
switches to delta mode, during this period the inlet valve remains closed.
After switching to delta mode the solenoid valve energizes and releases
the inlet valve and stops blow down valve. Thus the machine is started
with reduced load on the motor. Now the pressure in the system goes up
and the minimum pressure valve opens the pressurized air to the discharge

Unloading mode

After reaching the maximum cut out pressure,the pressure sensor senses
the pressure and cuts off the solenoid electrical supply. The solenoid valve
becomes NC. The pulse goes to the intake valve and the blow-down valve
stops, which releases the sump pressure to atmospheric pressure and
the intake valve closes. The compressor runs, maintaining the minimum
sump pressure. The blowdown line is connected to the air filter element
for auto cleaning. During every unloading process the blow-down valve
releases air, which is routed to the air filter element for cleaning it. This
reduces the cleaning requirements of the air filter

14.0
Operation

Monitoring the running of the compressor

l Monitor the indicators on the control panel regularly when the compressor
is running. Under the following conditions, the corresponding warning light
on the control panel lights up and the compressor stops automatically:

l High discharge temperature

l Main motor overload

l Fan motor overload

Stopping

Press the stop button (red) on the control panel to stop the compressor

Changing the compressor settings

Change the compressor settings using the tactile keypad and the LCD on
the Neuron+controller. panel. (Refer to Appendix A for details of the control
panel and interpretation of the messages)

14.1
Maintenance

The maintenance of Global Series compressors is minimal but important. The

indicators on the control panel of the compressor give warnings when servicing
of the suction filter or oil filter element is necessary

Maintenance schedule

Daily : Prior to starting the machine, it is necessary to check the oil level in the
receiver tank (see Starting the compressor in the Operation section No.10.1)
Should the level be low add the necessary amount. If the addition of oil becomes
very frequent, a problem has developed which is causing this excessive loss.
Refer to the section on excessive coolant consumption in the Troubleshooting
section 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 ensure that the compressor is
running properly

After initial 100h of running :

Do not remove caps, plugs or other components when the

compressor is running or pressurised. Stop the compressor and
WA R N I NG relieve all internalpressure before doing so

A check-up is necessary to detect and clean the system of any foreign materials.
Carry out the following operations

l Clean the return line orifice

l Change the oil filter element

15.0
Maintenance
Air Oil Separator Element (Spin-on Type)
NOTE
The number of hours of running after which the filter and separator elements
and oil are to be replaced are given as a guideline for normal operating
conditions. They may vary depending on actual operating conditions

Disassembly of existing Separator:

l Switch off and isolate the machine from service line
l Vent the separator tank pressure and allow it to cool for few minutes
l Hold the separator outer shell by the removed strap belt & rotate it counter
clockwise , until it completely unscrews
l The helix adapter should be in the Separator headduring disassembly
l Check the recommended life of oil separator. Once the recommemded life
is over, it has to be replaced with a new element

Assembly of new Separator:

l Ensure gasket of the separator is not damaged
l Clean the gasket-seating surface with a clean cloth
l Apply a thin film of oil on the mating surface of the gasket
l Return the separator to its original position & handrotate it in clockwise
direction
l Ensure there are no oil leaks from the mating surface. In case of leakage,
check the gasket
l After tightening by hand, rotate it further

ELGI ELGI

15.1
Maintenance
Oil Filter (Spin -on Type)

NOTE
The number of hours of running after which the filter and separator elements
and oil are to be replaced are given as a guideline for normal operating
conditions. They may vary depending on actual operating conditions

Dismantling method of existing Oil Filter :

l Isolate the machine from the service line, vent the Separator tank pressure
and allow if to cool for few minutes
l Hold the filter shell and & rotate it counter - clockwise by hand
Assembly of new Oil Filter :
l Ensure the gasket of the filter is not damaged
l Clean the seating surface with a clean cotton
l Apply this film of oil on the mating surface of the gasket
l Return the filter to its original position & rotate it clockwise manually. After
tightening, rotate it further by hand for one and half rotation
l Ensure there are no oil leaks from the mating surface

NOTE

• Suspended particulate matter should be less than 150 spm to achieve

the specified consumable life
• No guarantee shall be given if the compressor is operated above
its intended pressure

15.2
Maintenance

Air Filter: Spin-on Type

For details refer Airinlet System
Caution:
l When the air filter log indicates a blocked condition, remove the air filter
and replace it with a new one. Do not forget to remove the air filter log
indicator from the old air filter and fix it on the new filter
l Clean the air filter element using moisture free compressed air at less
than 2.5 bar g. Supply the compressed air from inside to outside of the
filter element
Inspection of filter element:
l Shine a bright light from inside the filter element to inspect for damage or
holes that will cause leaks. The light will emerge from the holes, indicating
their location
Dismantling Air Filter:
l Shut down the compressor
l Release the three clips of Air filter end cover by hand
l Pull the Air filter end cover away from the filter housing
l Take it out axially giving it a mild shake
l Bring the indicator back to normal position
Assembly of New Air Filter:
l Ensure the seal of filter element is not damaged
l Clean the filter element housing with cotton
l Insert the filter element axially into the filter housing by hand, free of oil &
dirt
l Place the End cover on the filter housing and firmly clamping it with
stretching clips

Clips

Air Filter End

Cover

15.3
Maintenance

Oil Cooler

Handle toluene and isopropanol with care. These solvents are

harmful and hazardous to humans

Cleaning the internal surfaces of Oil

l For aluminum coolers, use a 5% by volume mixture of caustic soda in
water. Circulate this mixture at 600C in the cooler for 5 hrs. The duration
of circulation can be increased based on requirement
Cleaning of external surfaces of Oil Cooler
l Isolate the machine from the service line
l Vent the separator tank pressure before attempting maintenance
l Open both the LH panel & cooler inspection cover
l Use compressed air at less than 7 bar g to clean the outer surface of
the cooler. Supply the jet of air in opposite direction of cooling airflow
WA RNING

direction, through the cut out shown in figure below

l Close the cooler inspection cover & LH panel

Do not get rid of the cotton in the cooler fins by burning it. This may
lead to deformation of the cooler. It may also lead to expansion of
the cooler joints, resulting in leakage

Compressed Air Jet

15.4
Maintenance
Pre- Filter

Cleaning pre-filter

l Switch off the machine

l Squeeze and take out the filter from the panel board

l Clean pre-filter with compressed air at less than 7 bar g

l Refit the filters after cleaning

l Repeat this process every 100 hrs, for increased life of separator and Air
filter elements

Pre-filter Housing

Pre-Filter Element
Squeeze
&
Take out

NOTE:

Suspended particulate matter should be less than 100 spm to achieve
the specified consumable life

No guarantee shall be given if the compressor is operated above its
intended pressure

15.5
Maintenance
Drive Coupling Element

l Coupling element provides flexible coupling between the motor & the airend

l Malfunctioning of coupling element results in sound & vibratin

Replacement method of Coupling Element:

Disconnect all power at the source before attempting

maintenance or adjustments

l Isolate the machine from the service line

l Before attempting maintenance, release the separator tank pressure and

allow if to cool for few minutes

l W Asupply
Disconnect power R NI NG to the motor

l Open the cooler side panel covers

l Open the Coupling guard by using spanner

l Remove the three coupling screws & slid coupling element it on the shaft
spline to free the coupling element

l Replace the old coupling element with a new coupling element

l Tighten the coupling screws to the specified torque

l Assemble the coupling guard and cooler side panel cover

l Perio dic inspection of tightening of screws be done every three months

NOTE
l The inspection interval for Coupling hub screw is three months.
l The inspection interval for Coupling element screen is three months.

15.6
Maintenance
Minimum Pressure Valve (MPV)

MPV Replacement:

l Isolate the machine from the service line vent the Separator tank pressure
& allow if to cool for few minutes

l Release the receiver tank and downstream pressure

l Unscrew the four bolts

l Remove the old MPV kit and replace it with a new one

l Grease the new MPV kit

l Assemble the MPV kit, and then reinstall the spring and the cap

l Tighten the bolts

WA R N I NG
l Adjust stud protrusion (6mm) to achieve a minimum pressure of 4.5 bar g

Extreme caution should be taken while removing the cap or

cover from the body because of the spring tension

MPV Separator
Body Block

Screw

15.7
Maintenance
Thermal Valve

Replacing thermal Valve

l Isolate the machine from the service line vent the Separator tank pressure
and allow the system to cool for few minutes

l Release the receiver tank and the downstream pressure

l Remove the circlip using plier

l Take out the thermal valve from the separator body

l Inspect and clean seating area in the housing

l Replace with a new thermal Valve

l Assemble the valve in its place & lock it by circlips

l Remove the plug using a M6 screw

Separator Body Block

Circlip

Plug
O-ring
Thermal Element
Piston

15.8
Maintenance
Electric Motor

Frequent Checks:

l Check the insulation of the motor winding

l Remove moisture from the motor

l Check the junction box terminals and cable connectors

l Grease the motor

Greasing Intervals:

l Grease the 2 Pole motors after every 2000h of running

l Grease the 4 Pole motors after every 4000h of running

Recommended Greases are:

l Use only a lithium based high temperature grease ESSO UNIREX N3 or

any Equivalent brand of Lithium soap based Grease

NOTE
l If the compressor is lying idle for more than a year, fresh grease should
be applied after removing the old grease

l The compressor Motor IR (Insulation Resistance) value should be

verified before starting

15.9
Maintenance
Intake Valve

Attention ! Always depressurize valves before opening it !

Function of NRV-flaps
Dismantling:
l He valve must be completely dismantled from the compressor. Then remove
the bearing bolts (4) and take out pin (5). Take out NRV-flap
Cleaning:
l Clean interior of housing with liquid cleaner. Free thread of possible
remainders of Loctite.Seat and sealing areas must by no means be
damaged!
Reassembly:
l Wet a bearing bolt with Loctite 242 and screw it into the thread, Install
NRV-flap/ NRV-flap and counterweight in the housing according to drawing.
Press the pin (4) through the bearing bores into the pre-assembled bearing
bolt. Wet the second screw with Loctite 242 and screw it in. Lock both
screws with 50 N-m
Function testing:
l Check easy moving of NRV-flap manually. It must have slight axial play
and must not touch the housing
1. Rotary drive unit
l He valve must be completely dismantled from the compressor.( Additionally
the control discs has to be moved to closed position by pressure airsignal
before)
l Turn out Tensilock screws (10) and take out control disc (1) (with magnet).
( take off pressurized air. )
l Take off plastic plug (11). Turn out MHT-nut (15) and remove the 2 rings
(13+14) below. Attention: When screwing off cover (8). Spring (6) is pre-
tensioned, therefore press by Hand onto the cover when turning out! Take
out sealing ring (7), piston unit (9), spring(6), rod (12) and the remaining 2
rings (16+17)

15.10
Maintenance
Intake Valve

Cleaning:
l Clear rod (12) of Loctite remainders. Clean working area of the piston unit
(9) with liquid cleaner and soft cloth. Grease screw drive of rod (12) and
piston working area with AUTOL TOP 2000. The flattened medium part of
the rod and the thread must be absolutely free of grease. Seat and sealing
areas must by no means be damaged.
Reassembly:
1. Insert two discs (16+17) into housing according to drawing. The sinter
area of the first disc (17) (grey) has to point off the housing in direction to
the second steel disc (16). Turn piston unit (9) on rod (12) until stop. Hold
rod in a way that the flattened part looks upward. Then turn piston unit
back until for the first time a guiding area is parallel with the flattened part
of the rod.
2. HAKG: Insert together with spring (6) according to drawing into the
housing against the spring pressure, in a way that flattened part points to
the counterweight section of the housing.
3. Block rod (12). Install two discs (13+14) acc. to drawing. The sinter
area of the first disc (13) (grey) has to point away from the housing in
direction to the second steel disc (14). Wet MHT-nut (15) with Loctite 270,
lock it and then loosen it again by 1/6 turn. Insert sealing ring (7) in groove
provided in the cover (8). Put cover (8) on top and fix it by turning. Connection
E must look downward. Loosen blocking of rod.
4. Install control disc (1) according to drawing. The bore for idle operation
must always Point at the counterweight section of the housing. Wet
Tensilock bolts (9) with Loctite 270 and lock them. Lock with 9 N-m. Install
plastic plug according to drawing.
Function testing:
Connect to pressurized air (see data sheet HAK: control air lower pressure
range!) and test smooth opening/closing for several times, Adjust by turning
MHT-nut (15) in either direction if needed. Pay attention to Loctite (see Lo
Loctite – description). If the time is too long, clean Loctite off the nut and
wet again.

15.11
Maintenance
Intake Valve

Service kits:
l HAK50 90-663868

3 control disc position

During assembly

16
17
Detail: Rotary drive unit
Note: Schematic diagrams only!

15.12
Maintenance
Blow-down Valve

Complete Service and Dismantling

Dismantle valve completely from the

compressor. Unscrew outlocking screw
(2) (SW(10). Take out piston unit (4).
Remove O-ring (1) from locking screw (2)

Cleaning

Work and sealing areas of the housing

and its threads have to be cleaned with
liquid cleaner and possible Loctite
remainders have to be removed. Piston
work areas have to be greased with Autol
Top 2000 (in the service kit, pos.30).
The thread and the area of the slide
bushing (3) (piston) must be greased
by any means. Seat and sealing areas
must not be damaged

Reassembly
Insert piston unit (4) into housing. Cover housing thread with Loctite 222.
Assemble O-ring(1) onto locking screw (2). Screw locking screw (2) in until the
upper edge of the locking screw (2) is on an even level with the upper edge of
teh housing. VVF. Additionally insert O-ring (5) into housing
Function testing
Test valve function after each service or inspection at the running compressor
Inspection
Dismantle valve and check componenet for wear. Work and sealing areas
of the housing and its threads have to be cleaned with liquid cleaner and
possible Loctite remainders have to be removed. Piston work areas have to be
greased with Autol Top 2000 (in the service kit, pos.30) The thread and the
area of the slide bushing (3) (piston) must be greased by any means. Seat and
sealing areas must not be damaged. Then reassemble valve as described
above and test for its functioning

15.13
Disposal of Consumables and
Replaced Parts
The moisture condensate separated from compressed air contains oil particles.
Disposal of the condensate and of filter elements is to be done in accordance
with the pollution control norms prevailing at the time of compressor installation
or use

The compressor does not give warnings during short operating

times. It will operate below the dew point and moisture
condensate may mix with the oil. This will reduce the lubricating
WA R N I NG
qualities of the oil and lead to damage to the compressor

Parts of the compressor that are replaced have metal and rubber components.
These may be recycled and disposed of according to pollution control
regulations, respectively

16.0
Troubleshooting
Problem: Machine not starting

Check Remedy

Main disconnect
switch Close switch
open

Line fuse blown Replace fuse

Replace fuse
fuse blown

Reset. If trouble is
Motor starter
overload tripped

Low incoming Do alternate

voltage arrangement

Wire loose Check wires for

connection loose connection

Emergency
Replace emergency
push button
push button/replace
locked/malfunction

Due for consumables

Change if
change (see warning
accordingly
message)

Incoming R YB Change if
phase connection accordingly

17.0
 Troubleshooting

Problem: Machine status down with the air demand present

Check Remedy

Low incoming Do alternate

voltage arrangement

Loss of control Check for tappings of

voltage control voltage

Low pressure Set to correct

setting in controller working pressure

Stand by time
10 minutes Reset
(6 times start & stop accordingly
allowed.)in 1 Hr

17.1
Troubleshooting
Problem : High discharge temperature
Check Remedy
in Make arrangement
for proper
exhaust and inlet Ventilation
Provide required
Insufficient space
space around the
around compressor compressor

Cooling air flow Clean cooler and

check for proper
restricted ventilation

Clean the cooler

Cooler plugged
tubes

Ambient Temperature Provide sufficient

is too high forced air ventilation

Fill oil to correct

Low oil level
the level

Replace the filter

Clogged oil filter
element

Poor quality oil Check and change

Cooling fan Check wiring

rotation regularly

emperature
T sensor
in ambient Calibrate it

Check neutral Connect/ensure

connect given Neutral

Check fan Replace if

motor fuse blown

17.2
Troubleshooting

Problem: Excessive oil in service line / consumption

Check Remedy

Line pressure if less Do proper compressor

than 5 bar selection

Loading/Unloading
Do proper compressor
pattern, if unloading is
selection
more than loading

Clogged lone Clean strainer and

strainer or orifice orifice

Separator element Change separator

damage or not
element
functioning

Check all pipe

Leek in
connection for
lubrication system
leaks

Excess oil Drain and

Foaming change the oil

Oil level
too high Drain the oil to
(off condition) correct level

17.3
Troubleshooting

Problem: Pressure relief valve opens

Check Remedy

Replace pressure
Defective pressure
relief valve
relief valve

Replace separator
Defective separator
element
element

Minimum pressure Replace valve kit

valve struck

Wrong stud length Adjust accordingly

in MPV (6mm)

Set according to
Working pressure intended working
set in controller pressure

Check and clean

Blockage in intake the intake valve
valve actuation line actuation line

Replace the
High pressure separator element/
in the sump Clean the cooler

17.4
Troubleshooting

Problem: Machine fails to build up full discharge pressure

Check Remedy

Too much Check for service line

air demand leaks or open valve

Dirty air filter Change element

Intake valve Check and

malfunction replace kit

Solenoid valve
malfunction Check and replace

Pressure sensor in Calibrate

ambient accordingly
(should be zero)

Check for internal Tight and arrest

piping leaks the leaks

17.5
Troubleshooting

Problem : Excessive operation pressure

Check Remedy

Defect in pressure
Check and replace
transmitter

Defective solenoid
Check and replace
valve

Defective BDV Check and replace

Defective intake valve Check and replace

Check the loading and

unloading relay of the
Controller defect controller Check the
pressure sensor in the
controller

17.6