ELGi EG Series Operation, Maintenance And Parts Manual
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ELGi EG Series Operation, Maintenance And Parts Manual

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Summary of Contents for ELGi EG Series

  • Page 3 Product Manual EG Series Electric Powered Screw Air Compressor EG 37 - 100.0, 125.0, 150.0, 175.0 Air - Cooled, Standard + VFD 460V, 3Ph, 60Hz...
  • Page 4 © ELGI EQUIPMENTS LIMITED Coimbatore, TN - 641 005 Part / Document No. 019000959 Contact Info: ELGI EQUIPMENTS LIMITED Coimbatore, TN - 641 005, India : 91 - 422 2589555 : 91 - 422 2573697 (Domestic Business) : 91 - 422 2589401 (International Business) E-mail : enquiry@elgi.com...
  • Page 5 The warranty on the compressor is valid only if all the details above are filled in and the dealer stamps and signs this page. This report must reach the Regional Office/Head Office of ELGi within seven days of commissioning date.

  • Page 6: Table Of Contents

    Table of Contents Chapter Page No. About ELGi General functional description GA drawing, P&I diagram Technical data Installation and operation Maintenance Controller Air inlet and control system Drive system 10.0 Discharge system 10.1 11.0 Cooling system 11.1 12.0 Lubrication system 12.1...

  • Page 7: About Elgi

    In India You can contact ELGi customer care system (ECCS) to take care of customer complaints. The ELGi CCS works for six days a week from 08:30 to 21:30 IST (Monday to Saturday). The complaints can be logged by calling any of the following toll free numbers or by e–mail.

  • Page 9: General Functional Description

    General functional description Contents Page No. 2.1 Using the manual 2.1.1. Definitions and symbols 2.2 Introduction 2.3 Safety 2.3.1 Precautions during installation 2.3.2 Precautions during operation 2.3.3 Precautions during maintenance 2.4 Functional description 2.4.1 Air circuit 2.4.2 Oil circuit 2.4.3 Drive system 2.4.4 Control system 2.10 2.4.5 For retro-fitment of Standalone VFD with Compressor (C) version in field...

  • Page 10: Using The Manual

     Installation and commissioning - all site continuous process in ELGi. The details in this manual are requirements, procedures to be followed during likely to change without notice and ELGi reserves the right to installation, commissioning, preservation etc. incorporate such changes.

  • Page 11: Introduction

    Uptime  Neuron III controller ensures safe machine operation For ELGi it is no longer just about delivering air, It’s about  Energy efficient motor. delivering uptime. Our uptime design ensures that the compressor would run * For selected models.

  • Page 12: Safety

    Safety  Ensure the operator is located far away from the intake The operator must follow the safe working practices, of the compressor. instructions, procedures that this manual describes for safe operation. The maintenance personnel must be  Position the after-cooler discharge pipe in a way that it adequately trained, and have read and thoroughly is free to expand under heat and is not in contact with understood this ‘Operation and maintenance manual’.

  • Page 13: Precautions During Operation

     Position the compressor on level surface. In case of  Release all the pressure in the compressor system inclined surface, contact ELGi. before servicing or performing any maintenance  Do not allow compressed air to come in contact with activity.
  • Page 14 Moving Parts  Keep hands, feet, floor, controls and walking surfaces clean and free of fluid, water or other liquids to minimize the possibility of slips and falls. Hot surfaces  Avoid bodily contact with hot oil and hot surfaces like cooler, pipes etc.

  • Page 15: Precautions During Maintenance

     Use only genuine spare parts. Refer the section “Use genuine spare parts” in “Maintenance” chapter.  Before switching on the compressor ensure that proper earthing is done as per recommendation.  Make all adjustments or repairs with one hand. This ...
  • Page 16  If you are going to switch on remotely controlled compressors must ensure that nobody is checking or working on the compressor at that time. A warning sign near the equipment’s start button is mandatory.  Wait up to five minutes to ensure that the air in the air- oil separator tank is released to start routing maintenance.

  • Page 17: Functional Description

    Functional description Figure 1. Screw compressor systems - Schematic diagram separated of any moisture content by the moisture 2.4.1 Air circuit separator. The cooled and moisture free compressed air is The atmospheric air enters into the airend through the air now discharged to the external receiver, ready to be used.

  • Page 18: Control System

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

  • Page 22: Technical Data

    Technical data Standard Model EG 22P EG 26 Working Pressure psi.g FAD - Free Air Delivery /min 3.85 3.77 3.74 5.01 4.84 3.77 3.96 3.57 Unloading pressure psi.g Nominal power supply 208-230 / 460V (+/-10%), 60Hz (+/-5%), 3 Phase conditions Main motor rating Hp(kW) 30(22)
  • Page 23 Technical data Standard Model EG 30 EG 37 EG 45 1 Working Pressure psi.g FAD - Free Air Delivery /min 5.78 5.75 5.04 4.33 3.85 7.19 7.02 5.75 4.87 8.75 8.55 7.56 6.51 5.95 3 Unloading pressure psi.g Nominal power supply 460V (+/-10%), 60Hz 208-230 / 460V (+/-10%), 60Hz (+/-5%), 3 Phase conditions...

  • Page 24: Installation And Operation

    Installation and operation Contents Page No. 5.1. Installation and commissioning 5.1.1 Unpacking 5.1.2 Disposal of packing materials 5.1.3 Handling the compressor 5.1.4 Site requirements 5.1.4.1 Ventilation 5.1.5 Electricals 5.1.6 Air pipe dimensions 5.1.7 Receivers for compressed air systems 5.1.8 Possible mistakes 5.1.9 Commissioning procedure 5.1.10 Oil fill and Oil level checking 5.2.

  • Page 25: Installation And Commissioning

    Installation and commissioning Before the new EG series compressor is operated for the first time, it needs to be installed at your site according to ELGi's installation guidelines. ROPE / SLING 5.1.1 Unpacking STIFF SPREADER Unpack the compressor from the packing case by removing the nails.

  • Page 26: Ventilation

    WALLS OR compressor is diverted through the ducts when installed OTHER EQUIPMENTS in an enclosed area. (contact ELGi for ducting requirements)  Provide openings on walls/partitions close to the air MINIMUM CLEARANCE, X=1 m (3.5 ft) suction side of the compressor.

  • Page 27: Electricals

     To eliminate transmission of vibrations, provide a soft bellows connector between the duct and the compressor.  Contact ELGi in case you need to provide a duct Ensure that only authorized service technicians perform connection or filter fitment on the compressor.

  • Page 28: Air Pipe Dimensions

    1. Supply power to the compressor through a dedicated switch disconnected fuse (SDF) unit of a suitable rating mounted within 5 m (16.4ft) of the compressor. (This architecture lets you isolate the compressor). 2. Use HRC (high rupturing current) fuse instead of an MCCB (moulded case circuit breaker) to avoid possible contactor and motor failure.
  • Page 29 NPS Pipe size/ Inside diameter (mm) 1 1/2 2 1/2 Volume Flow FAD 40.89 52.50 62.71 77.93 102.26 (cfm) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi) min) 0.01 0.09 0.01 0.11 0.01 0.13 0.01 0.19 0.02 0.25 0.01 0.07 0.02...

  • Page 30: Receivers For Compressed Air Systems

    5.1.7 Receivers for compressed air systems Receiver Compressed capacity applications Volume On/Off control Modulation control 10.59 Up to 1.13 Up to 40 Up to 1.7 Up to 60 17.66 1.14 - 2.4 41 - 85 1.7 - 3.4 61 - 120 35.32 2.4 - 4.0 86 - 140...

  • Page 31: Oil Fill And Oil Level Checking

    for operating the compressor. 5.1.10 Oil fill and Oil level checking How to read oil level? Oil fill procedure  When level indication is in start of red zone as The oil level can be checked through the oil float gauge on shown in figure start filling the air oil separator tank.

  • Page 32: Preservation For Long Idle Storage

     Remove the entire tank from the compressor after disconnecting it from all hoses, the tank top plate, the minimum pressure valve outlet line, and control pulse lines and control switches.  Clean the tank using ELGi compressor clean flushing oil. Installation and operation...

  • Page 33: Operating Instructions

    Also make sure that the inlet and outlet water drain valves are closed.  For water cooled compressors, ensure that the water quality is maintained as specified by ELGi. 5.3.2 Initial start-up Open the air outlet ball valve, turn on power, and press the start button (Green).

  • Page 34: Stopping

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

  • Page 35: Maintenance

    6.3.1 Decommissioning the compressor 6.21 6.3.2 Dismantling the compressor 6.21 6.3.3 Waste disposal 6.21 6.4. ELGi services 6.22 6.4.1 ELGi customer care system (ECCS) 6.22 6.4.2 ELGi genuine spare parts 6.22 6.4.3 Air audit 6.22 6.5. Appendix 6.24 6.5.1 Conversion tables 6.24...

  • Page 36: Maintenance

    Table 5. Maintenance intervals NOTE The above life time guidelines are applicable only to standard operating and regular maintenance conditions recommended in this manual. In the event of changes in the conditions, consult ELGi. Precautions Sl. No. Motor make Grease...

  • Page 37: Maintenance Of Individual Components & Systems

    and slide upwards slightly until the pre-filter bottom edge is visible Disconnect all the power at the source before attempt to 2. Slide Downward perform maintenance or make adjustment. When the pre-filter bottom edge is 6.1.2 Maintenance of individual visible, slant the pre-filter forward and components and systems slide it downwards away from the compressor...

  • Page 38: Air Oil Separator

    3 and 9 o’clock position. ELGi recommends that once the seal is broken, all products be used immediately. ELGi does not encourage reuse or recycling of any leftover fluids due to...
  • Page 39 Oil change from one type to other recommended type of oil. Machine run with oil for more than recommended hours. a. Fill the compressor with the ELGi cleaner (use the same compressor oil fill volume) and run the compressor. b. Run the compressor with cleaner for 500 hours.

  • Page 40: Oil Filter

     Tighten firmly by hand. in the figure. This is a full flow filter with a pleated element. To service this filter, order the consumables kit (available with ELGi service personnel) The procedure for NOTE complete servicing of this filter is as follows.
  • Page 41 Figure 17. Intake valve Figure 17. Intake valve/BDV/Actuator kit Description Part number Sl. no Description Part number O-RING ID122.0 X 3.6 415400655 NUT HEX M10 X 1 ZBP 000948013 SPRING CHECK VALVE IV159 970400040 SUPPORT ACTUATOR IV159 970400060 PLUNGER CHECK VALVE 970300690 FLOW CONTROL VALVE B013406760001...

  • Page 42: Minimum Pressure Valve

     Power supply to solenoid  Duct from air filter No Load sump pressure adjustment: No Load sump pressure adjustment should be carried out by skilled ELGi service person only. PISTON SEATING SURFACE  Assemble the pressure gauge to the air oil separator tank by removing the plug.

  • Page 43: Thermal Valve

    Figure 18b. Minimum pressure valve Description Part number Sl.No. Description Part number Sl.No. Valve housing 970300240 Spring - 38mm 970400110 Screw socket head 000976060 Spring spacer 970400100 Plain washer M6 000997006 O-ring 970400130 O-ring Stopper 970400390 970300260 O'-ring 970400150 Punched washer M10 000996059 Split Plunger 970400380...

  • Page 44: Electrical Motor Greasing

    6.1.2.10 Cooler cleaning THERMAL VALVE BLOCK Cooler surface might be hot caution should be taken while THERMAL VALVE cleaning. Fan should not run while cleaning the cooler. ELEMENT Pre work  Switch off the compressor and disconnect power supply to the compressor. ...

  • Page 45: Moisture Separator And Auto Drain Valve

    Pre work  Switch off the compressor and disconnect power supply to the compressor.  Close the discharge end ball valve.  Release air oil tank pressure and allow the tank to cool for a few minutes. ELEMENT Requirements  Spanner, screw driver, player, caustic soda. Maintenance Figure 21.

  • Page 46: Cooler Maintenance

    Over-  Ensure machine is disconnected from power supply tightening may lead to failure or damage. ELGi assumes  Isolate machine from exhaust duct mounting. no responsibility for failure or damage resulting from Requirements such incorrect installation.

  • Page 47: Fan Maintenance

     Reassemble exhaust duct with top roof.  Remove the fan 2 from shroud box 6.1.2.14 Fan Maintenance  Isolate the machine from power supply and ensure safe message is placed in front of machine before servicing the fan  Wear proper safety accessories like gloves, shoes for handling ...

  • Page 48: Cooler And Motor Suction Prefilter

    6.1.2.16 Cooler and motor suction prefilter prefilter cleaning & maintenance instructions  Lift upward & take out the cooler pre-filter assembly from the compressor.  Hold the pre-filter assembly in the cleaning area.  Clean the pre-filter with compressed air at less than 2.5 bar.g(36.3 psi.g) from the reverse / back side of the prefilter. ...
  • Page 49 6.1.3 Use genuine spare parts It is very important to use genuine spare parts, to ensures that your compressor work as new for its lifetime. Spurious spares may seem less expensive initially, but they severely compromises on quality and life of compressor. Spurious parts will prove cost-ineffective in the long run, and may even result in total damage of the machine or cause serious accidents.

  • Page 50: Controller

    Troubleshooting This guide lists the most likely indications with possible causes. For any problem, follow the diagnosis in sequential order as mentioned in the following charts. Before doing any work in the compressor, be sure that electrical supply has been cut off and the entire compressor is depressurized.
  • Page 51 Problem Cause Solution (go sequentially) (1) Check and refill oil to correct the level. (in stopped condition) (2) Refer diagnosis procedure for high oil carry over. Oil level is low (3) Arrest oil leaks (4) Ensure the correct grade of oil is used. Room temperature is higher than outside ambient temperature by Improve ventilation in compressor room...
  • Page 52 High discharge oil temperature (DOT) Refer to the diagnosis procedure for high DOT. High oil carry over Improper grade of oil Use ELGi recommended Air lube oil. Separator punctured/collapsed (not Replace with new separator. applicable to EG11 to EG22 units) Separator element bonding ruptured Replace with new separator.
  • Page 53 Problem Cause Solution (go sequentially) No control air supply to solenoid valve Replace / connect 1. Replace the solenoid valve assembly Solenoid valve malfunctioning 2. Clean the orifice No electrical supply for energising the Replace the Neuron microcontroller solenoid valve Intake valve malfunctioning Check and replace the intake valve kit.
  • Page 54 Problem Cause Solution (go sequentially) Clean/change pre-filter mat by following these steps: Switch off the machine. Squeeze and pull out the pre-filter mat from the Inlet air pre-filter mat clogged canopy. Clean pre-filter with compressed air at less than 2.5 bar /36.3 psi Refit the filter after cleaning.

  • Page 55: Decommissioning The Compressor

    NOTE  Ensure that all the external supply lines have been ELGi is not responsible for any the disposal of waste, It is properly disconnected from the compressor before the responsibility of customer to dispose the waste in accordance with local environmental statutory laws.

  • Page 56: Elgi Services

    Compressor will be working efficiently and effectively. Refer to section 6.1.3 The ELGi CCS works for six days a week from 08:30 to for details on need of using genuine spares. 21:30 IST (Monday to Saturday).
  • Page 57 (base level or investment level) will be decided. Also post implementation monitoring after air audit will be provided if requested from the customer end. For further information on air audit contact ELGi. E-Mail: ccs@elgi.com Maintenance 6.23...

  • Page 58: Appendix

    Appendix 6.5.1 Conversion tables Description From Multiply by Inches Millimetres 25.4 Metres Inches 39.37 Feet Millimetres 304.8 Length (L) Metres Feet 3.281 Inches Thou 1000 Millimetres Micrometres 1000 Square metres Square feet 10.765 Square feet Square inches Area (A) Square inches Square millimetres 645.16 Cubic metres...
  • Page 59 6.5.2 Torque values The tightening torque values for bolts and screws used in ELGi Compressors are provided in this section for reference. The tolerance for the torque values is (-) 10% from the given value. Thread size* Tightening torque (N-m) Tightening torque (lb-ft) 2.13...
  • Page 60 6.5.3 Service log book – record of maintenance Maintenance 6.26...
  • Page 61 Maintenance 6.27...
  • Page 62 6. In no event ELGi shall be liable for any claims or loss having a value higher than the original purchase price of the product sold by ELGi or its network of authorised dealers.
  • Page 63 Controller Manual Neuron III Version 3.6 July 2020...
  • Page 64 Contents Page No. Abbreviations used 7.1. Technical specification 7.2. Installation instruction 7.2.1 Equipment’s safety 7.2.1.1 Static discharge warning 7.2.1.2 Assembly 7.2.1.3 Electrical connection 7.2.1.4 Power supply 7.2.2 General instruction 7.3. Display & terminal details 7.3.1 Terminal connection 7.4. Neuron-III salient features 7.4.1 Home screen display 7.4.2 Records (view->...
  • Page 65 Contents Page No. 7.7.1.5 View service time 7.17 7.7.1.6 View cumulative time 7.17 7.7.1.7 VFD 7.18 7.7.1.8 Rental hours 7.18 7.7.2 Operator 7.18 7.7.2.1 Machine 7.18 7.7.2.2 Operator scheduler 7.19 7.7.2.3 Operator maintenance 7.19 7.7.2.4 Language 7.20 7.7.2.5 VFD control 7.20 7.7.2.6 VFD speed control 7.20...

  • Page 66: Abbreviations Used

    Abbreviations Used Dis. Pressure Discharge pressure Dis. Temperature Discharge temperature High sump pressure Temp Temperature DPAF Differential pressure air filter DPOF Differential pressure oil filter Air filter Oil filter Minimum Maximum Variable frequency drive Analog output Unload Enable Disable Load Stop Fault Standby...

  • Page 67: Technical Specification

    : -10 to 70°C (14 F ~ 158 Relative humidity : <95% @ 50°C (122 F) without condensation Certification : CE, UL For Technical support/assistance contact ELGI Customer Care E-mail: ccs@elgi.com Digital inputs: Number of channel : 8 Ports Rated voltage : 24VDC...
  • Page 68 Coil rated current : 21mA Coil voltage : 24VDC Contact resistance : max 100milliohms Insulation resistance : min 1000Megohms @ 500VDC Usage : 6 Pre-programmed (Main, star, delta, load/unload, ADV, fan motor), 2 by default programmed for trip and warn. programmable for warn, load, service, standby, trip, remote, ready and dryer if enabled.

  • Page 69: Installation Instruction

    Installation instruction indicates damage, so that safe operation is not possible, 7.2.1. Equipment safety then the device may be removed from operation. The device, before delivery, was checked according to the Carefully unpack the system. Open the doors and inspect prescribed tests of the inspection scheme.

  • Page 70: Display & Terminal Details

    Display & terminal details 1 128x64 Graphical display 2 Navigation keys 3 Enter key 4 Start key LED (green - start , red - stop/fault ) 6 Stop key 7 Reset key Oil filter change indication Air oil separator change indication LED 10 Cooler fault LED Auto mode enabled...

  • Page 71: Neuron-Iii Salient Features

    Neuron-III salient features  PC interface through MODBUS - To download reports 7.4.1. Home screen display and setting parameters  Easy user interface 8 line graphical display and intuitive  70 + Modbus parameters for DCS controls menu navigation keys ...

  • Page 72: Input Output Description

    Input output description 7.5.1 X01: Power supply Function Active state 24 VAC P 24V AC Phase 24V AC Neutral 24 VAC N 24V Earth Earth 7.5.2 X02: Digital inputs Function Active state Digital Inputs common - 24VDC 24VDC Emergency stop Emergency Fault if open Differential pressure oil filter...

  • Page 73: X05: Main Motor Relays

    7.5.5 X05: Main motor relays Function Active state Common for main, star and delta contactors Common Main contactor Main Energized Star contactor Star Energized Delta contactor Delta Energized 7.5.6 X06 : Relays Function Active state - load relay Common Common Load when energized Load relay L/UL...

  • Page 74: Home Screen

    Home screen The home screen will show discharge pressure , discharge  Live sump pressure (displays only if sump pressure enabled) oil temperature ,VFD speed % (if VFD enabled),  Live Pt1000 temperature (displays only if DRYER ON compressor status, warn messages, compressor mode enabled) selection details and date &...
  • Page 75 Message 2 - Compressor fault message Fault Description Pr. Probe failure Discharge pressure sensor probe failure Tr. Probe failure Temperature sensor probe failure Sump pr. probe failure Sump pressure sensor probe failure, if sump pressure is enabled HSP (AS) Case 1: sump pressure is enabled If sump pressure exceeds the set high sump pressure value.
  • Page 76 immediately. This feature helps save the energy if very 7.6.1 Important user machine settings little compressed air is used. 1. Control mode NOTE Local - Users can start and stop the compressor by using If the compressor is started more than the specified local start/stop key number of cycles per hour through the Standby sequence, then the system does not enter into the Standby stop...
  • Page 77 VFD Mechanism  The machine operates at the set minimum speed till it reaches the RUN LOAD condition at start-up.  The machine will run at the set unload speed when it is in unload, which may be remote or DCS unload or when discharge pressure is >...

  • Page 78: Menu Structure

    Menu structure   Press any one of the following keys to enter main menu 7.7.1 Main Menu Dis. Pr : 0.0 bar / 0 psi Dis. Tr : 25°C / 77°F Status View Operator Service Factory Customer care Admin 7.7.1.1 View In the view menu, you can view the set parameters, but you cannot edit any of them - no password required.

  • Page 79: Fault Report

    7.7.1.3 Fault Report Use ∆ and ∇ to select the fault record number (1 to 99). The latest fault will be displayed in the first position. For fault message details refer the “Fault Message” table. LEVEL 1 LEVEL 2 LEVEL 3 View Fault report Fault message...

  • Page 80: Vfd

    To reset the rental hours, you have to choose “rental off” 7.7.1.7 VFD and then “rental on” in operator menu. If VFD is enabled in the controller and VFD communication port is connected, you can view the following VFD Load X X X X X X hrs: X X Min Unload X X X X X X hrs: X X Min...

  • Page 81: Operator Scheduler

    Item Option Default Unit Baud 9600/19200 9600 Parity None/Even/ Odd None Length 8 / 7 Stop bit 2 / 1 Auto Drain Valve Off time minute On time Second Load / Unload Source LD / UL Source Loc / Rem/ DCS Set dew point Low dew point C(21...

  • Page 82: Language

    7.7.2.4 Language Default is English. You can choose any one of the given languages. Item English Portuguese Francais Italiano Spanish 7.7.2.5 VFD Control Item Default Unit Optimum Speed on/off on/off P-Gain 50000 I-Gain 5000 I-Time Max. Speed Min. Speed Optimum Speed Factory settings can be viewed here UL Speed High (5v)

  • Page 83: Service

    Always Password required. try to set lower values for I-Gain. The setting changes should be made by ELGi authorized Setting I-Time service technicians only. Any attempt to change service I-time - Range: 1-200. This indirectly counts the scan settings by unauthorized people may lead to compressor time.

  • Page 84: Calibration (Offset)

    Here you can feed the filter lift time. This timeframe will between that displayed in the controller and that in the vary depending on the model and filter. Contact Elgi for master gauge, approach the ELGi service engineer. more information.

  • Page 85: Dryer Input

    7.7.3.8 Latitude/Longitude This option involves deg, min, and sec with NE, NW, SE, and SW format. The Latitude/Longitude entry helps ElGi to determine the location of the compressor on which air alert is equipped. 7.7.3.9 VFD_model A list of VFD models appears here for you to select a pressure-based speed, based on customer requirement.

  • Page 86: Data Interface

    Data interface Neuron III supports two types of data interface  Analog output  DCS Port 7.8.1 Analog output Two channels are available as analog output. Channel -1 for discharge pressure values 0.0 to 16.0 bar / 0 to 232 psi converted into 1 to 5V. Channel -2 for discharge temperature values from -10 to 150°C / 14 to 302°F converted into 1 to 5V.

  • Page 87: Troubleshooting

    Troubleshooting Failure symptoms Possible causes Remedies No input supply Check incoming AC input Please check the controller input voltage at connector No display in LCD Screen & Transformer failure. Backlight was not glown X08. Voltage should be 24V ± 15% VAC. Controller failure.

  • Page 88: Construction

    7.10 Construction  Plastic enclosures  IP55 polyethylene front keypad  Inputs and Outputs through terminal block  Enclosure dimensions 280 X 190 X 90 mm 7.10.1 Dimension drawing Controller Manual 7.26...

  • Page 89: Example - Scheduler Setting

    7.11 Example – scheduler setting Scheduler settings are considered when: End customer usage is 6 bar (87 psi) Pressure variation in the air pipe is less than 0.1bar (1 psi) All 3 compressors connect to a single/common header or a common receiver All 3 compressors connect to a common header or a common receiver Pressure schedule settings in Neuron III...
  • Page 90 Example - scheduler setting Weekly utilization Air demand: 100% Air demand: 75% Air demand: 50% Air demand:25% Comp -> Day-1 Day-2 Day-3 Day-4 Day-5 Day-6 Avg. Utl% Conclusion Equal utilization of all the 3 compressor based on pressure demand The scheduler reduces power consumption since compressors are only utilized based on demand. Neuron III Pressure schedule setup Step-1 Go to operator menu Step-2 Enter password "4545"...

  • Page 91: Neuron Iii Quick Reference

    7.13 Neuron III quick reference 1 128x64 Graphical display 2 Navigation keys 3 Enter key 4 Start key LED (green - start , red - stop/fault ) 6 Stop key 7 Reset key Oil filter change indication Air oil separator change indication LED 10 Cooler fault LED Auto mode enabled...
  • Page 92 Compressor Status messages Status Description Ready Ready for start Star Motor running in star Motor running in delta Run load Compressor in load Run unload Compressor in unload Stop busy Stop sequence in progress Emergency stop Emergency stop push switch is ON During the start, if the sump pressure is higher than the set start sump pressure value, you Start inhibit xx.x will see this message.
  • Page 93 Compressor Fault messages Fault Description Pr. Probe failure Discharge pressure sensor probe failure Tr. Probe failure Temperature sensor probe failure Sump pr. probe failure Sump pressure sensor probe failure, if sump pressure is enabled HSP (AS) Case 1: sump pressure is enabled If sump pressure exceeds the set high sump pressure value.
  • Page 94 Menu Structure Controller Manual 7.32...
  • Page 95 PARTS MANUAL EG SERIES ELECTRIC POWERED SCREW AIR COMPRESSOR EG 22P - EG 45...

  • Page 96: Air Inlet And Control System

    8.0 Air inlet and control system [ Ref : 015317512—X017195 ] EG 22P - EG 45 Parts Manual...
  • Page 97 8.0 Air inlet and control system [ Ref : 015317512—X017195 ] EG 22P - EG 45 Description Qty. Part Number INTAKE VALVE A970012 RUBBER ELBOW 015318798 CLOG INDICATOR B012400770001 ERMETO 1/8" - 1/8" STRAIGHT 020403100 ADAPTOR SS WORM CLAMP B005000530005 1/8 BSP BONDED SEAL 000959381 WASHER...

  • Page 98: Drive System

    9.0 Drive system [ Ref : 015319304-X017686] EG 37 Parts Manual...
  • Page 99 9.0 Drive system [ Ref : 015319304-X017686] Description Qty. Part number MOTOR B005106400028 ADAPTOR RING 015306748 DRIVE COUPLING B005405550050 B001406190007 HEX BOLT M12X75 000906192 SPRING WASHER REC SEC M12 000996112 PLAIN WASHER M12 000996012 HEX BOLT M12X35 000906184 PUNCHED WASHER M10 000996059 SPRING WASHER REC SEC M10 000996110...
  • Page 100 9.0 Drive system [ Ref : 015319304-X017686] EG 37 Parts Manual...
  • Page 101 9.0 Drive system [ Ref : 015319304-X017686] Description Qty. Part number MOTOR B005106400028 ADAPTOR RING 015306748 DRIVE COUPLING B005405550050 B001406190007 HEX BOLT M12X75 000906192 SPRING WASHER REC SEC M12 000996112 PLAIN WASHER M12 000996012 HEX BOLT M12X35 000906184 PUNCHED WASHER M10 000996059 SPRING WASHER REC SEC M10 000996110...

  • Page 102: Discharge System

    10.0 Discharge system [ Ref : 015322522—X018619 ] Parts Manual 10.1...
  • Page 103 10.0 Discharge system [ Ref : 015322525—X018619] Description Qty. Part Number Description Qty. Part Number B001401300003 ELBOW G 1/8” ORIFICE DIA 1.5 B010506780015 970300230 HEX NUT M12 000948012 MPV TO COOLER HOSE ASSY 015321139 1/4 BSP BONDED WASHER 000959385 SCAVENGING LINE 015321140 PLUG G 1/4 020498750...
  • Page 104 10.0 Discharge system [ Ref : 015322525—X018619 ] Parts Manual 10.3...
  • Page 105 10.0 Discharge system [ Ref : 015322525—X018619 ] Description Qty. Part Number Description Qty. Part Number B001401300003 ELBOW G 1/8” ORIFICE DIA 1.5 B010506780015 970300230 HEX NUT M12 000948012 MPV TO COOLER HOSE ASSY 015321139 1/4 BSP BONDED WASHER 000959385 SCAVENGING LINE 015321140 PLUG G 1/4...

  • Page 106: Cooling System

    11.0 Cooling system [ Ref : 015317505—X017193 ] EG 37 - EG 45 Parts Manual 11.1...
  • Page 107 11.0 Cooling system [ Ref : 015317505—X017193 ] EG 37 - EG 45 Description Qty. Part Number SHROUD ASSEMBLY 015317478 OIL AND AFTER COOLER 015317465 AXIAL FAN Ø560 PUSHER 018400046 HEX BOLT M8x25 000906116 SPRING WASHER REC SEC M8 000996108 PLAIN WASHER M8 000996008 Parts Manual...

  • Page 108: Lubrication System

    12.0 Lubrication system [ Ref : 015317625-X017232] Parts Manual 12.1...
  • Page 109 12.0 Lubrication system [ Ref : 015317625-X017232] Description Part number FLANGE ASSY-OIL INJ 015316015 O RING ID 32.9 X 3.5 015402685 OIL FILTER ELEMENT X017485 TANK TO TVB PIPE ASSY 015320085 NC THERMAL VALVE BLOCK 015318384 OIL COOLER OUT TO TVB IN 015321123 TVB TO OIL COOLER IN 015317427...

  • Page 110: Base And Canopy System

    13.0 Base & canopy system [ Ref : 015318414—X017456] EG 22P - EG 45 Parts Manual 13.1...
  • Page 111 13.0 Base & canopy system [ Ref : 015318414—X017456] EG 22P - EG 45 Description Qty. Part Number Description Qty. Part Number BASE ASSEMBLY 015317481 SPRING WASHER M10 000996110 DISCHARGE PILLAR ASSY 015317436 PLASTIC PLUG - M8 PILLAR ASSY-COOLER SIDE LH 015317437 SPRING WASHER M8 000996108...
  • Page 112 13.0 Base & canopy system [ Ref : 015318414—X017456] EG 22P - EG 45 Parts Manual 13.3...
  • Page 113 13.0 Base & canopy system [ Ref : 015318414—X017456] EG 22P - EG 45 Description Qty. Part Number Description Qty. Part Number BASE ASSEMBLY 015317481 SPRING WASHER M10 000996110 DISCHARGE PILLAR ASSY 015317436 PLASTIC PLUG - M8 PILLAR ASSY-COOLER SIDE LH 015317437 SPRING WASHER M8 000996108...
  • Page 114 2) Lubricant - ELGi Air Lube Synthetic S. No Description Part Number ELGi Air Lube UT Synthetic 5 litres (1.3 gallons) 000998092 ELGi Air Lube UT Synthetic 20 litres (5.3 gallons) 000998090 ELGi Air Lube UT Synthetic 208 litres (55 gallons)
  • Page 115 Blow down adjustment kit EIV 159 - 972300100 S. No Description Part Number Qty. Tamper cap MPV 970300510 Hex socket grub screw - M10 970400160 Hex nut M10 000948013 7) Tube and Fittings kit- 012484879 S. No Description Part Number Qty.
  • Page 116 B) OTHER MAINTENANCE KITS O-Ring Kit - 012484899 (C & CV) S. No Description Part Number Qty. O-Ring ID190 x 3.55 970400010 1/8 BSP bonded seal washer 000959381 1/4 BSP bonded seal washer 000959385 1/2 BSP bonded seal washer 000959387 3/4BSP bonded seal washer 000959438 1 BSP bonded seal washer...
  • Page 117 E) HOSE KITS S. No Description Part Number S. No Description Part Number Qty. MPV to Cooler hose assy 015321139 MPV to cooler 012485889 O-Ring (Cooler side) 015400891 hose kit O-Ring (MPV side) 035400187 TVB to Oil Cooler In hose assy 015321123 Oil Cooler Out to 012465169...
  • Page 118 VFD RETROFITMENT KITS *** VFD retro kit C TO CV 26 & 30 kW - 012485159 S. No Description Part Number Qty. VFD 30kW B012000510050 VFD Mounting plate 015312240 Hex bolt M8 X 20 000906115 Punched washer M8 000996108 Spring washer M8 000996008 Control harness EG 22-30 CV 018363876...
  • Page 119 Thermal valve kit - C 012484859 Thermal valve kit - CV 012484919 Calibration must be carried out if any sensors are replaced. For doing so please contact ELGi dealer/Service engineer C - Standard, CV - Standard + VFD Kit Details 14.6...
  • Page 120 Thermal valve kit - C 012484859    Thermal valve kit - CV 012484919 Calibration must be carried out if any sensors are replaced. For doing so please contact ELGi dealer/Service engineer C - Standard, CV - Standard + VFD Kit Details 14.7...
  • Page 122 RS 485 RS 485...
  • Page 125 16.0 VFD setting procedure Software details (programming details) Brief introduction to VFD in the global Based on the compressor rating, VFD parameters are pre- series compressor programmed in the Setup 1 location and in the compressor In VFD model compressors, the Variable Frequency Drive controller.
  • Page 126 If pressure reduces and reaches the load point of the attempt to change these settings on your own. Instead controller, then the compressor starts loading and the contact ELGi . speed increases from 40% to maintain the set pressure. For more details about VFD parameters and ...
  • Page 127 Fault Description Details to be checked Check the run feedback signal from VFD. Compressor does not switch to Verify that the controller issues the load command. load mode Ensure that the solenoid valve receives supply and energizes. Verify if the motor consumes more power than the nameplate value. Ensure that the VFD parameter is correct.
  • Page 128 Annexure 1 Name Setup 1 Language English Motor Speed Unit Active Set-up Set-up 1 Display Line 1.1 Small Motor Voltage Display Line 1.2 Small Motor current Display Line 1.3 Small Speed [RPM] Display Line 2 Large Analog Input 53 Display Line 3 Large Frequency [Hand on] Key on LCP Disabled...
  • Page 129 Name Setup 1 Motor Speed Direction Clockwise Motor Speed Low Limit [RPM] Motor Speed High Limit [RPM] 2400 Max Output Frequency Terminal 27 Digital Input Coast inverse Relay->Option relay 7-> Function relay Running Relay->Option relay 8-> Function relay Alarm Terminal 53 Low Voltage Terminal 53 High Voltage Terminal 53 Low Ref./Feedb.
  • Page 130 Compressor controller setting in Operator menu VFD settings. Default Unit Optimum speed on/off on/off P-Gain 50000 I-Gain 5000 I-Time Max. speed Min. speed Optimum speed Factory setting can be viewed UL speed High (5V) Low (1V) This information is for reference only. The settings are all made at the factory.
  • Page 131 ROTAIR Spa, Via Bernezzo-67, 12023, Caraglio (CN), Italy, Tel: +39 0171619676, Fax: +39-0171619677, ITALY E-mail: info@rotairspa.com, Web: www.rotairspa.com ELGI GULF FZE, PO Box: 120695, P6-27, SAIF Zone, Sharjah, U.A.E. Tel: +971 6 557 9970, +971 50 457 6470, MIDDLE EAST Fax: +971 6 557 9980, E-mail: gulfenquiry@elgi.com, Web: www.elgigulf.com ELGI COMPRESSORS USA, INC.
  • Page 132 Kodangipalayam Village, Singarampalayam(PO), Kinathukkadavu Taluk, Coimbatore - 642 109, India. Tel : +91-422-2587000. ELGI EQUIPMENTS LIMITED (AIR COMPRESSOR PLANT) SF NO 221/1 to 3 - 229/B1, B2, B3, 232/B1,B2, 234/B1, 264/B1 and 264/B2. KothavadiRoad, Kodangipalayam Village, Singarampalayam (PO) Kinathukkadavu Taluk, Coimbatore - 642 109, India.
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