ELGi EG Series Operation, Maintenance And Parts Manual
  1. Manuals
  2. Brands
  3. ELGi Manuals
  4. Air Compressor
  5. EG Series
  6. Operation, maintenance and parts manual
ELGi EG Series Operation, Maintenance And Parts Manual

ELGi EG Series Operation, Maintenance And Parts Manual

Screw air compressor
Hide thumbs Also See for EG Series:
Table of Contents

Advertisement

Quick Links

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the EG Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for ELGi EG Series

Summary of Contents for ELGi EG Series

  • Page 3 Product Manual EG Series Electric Powered Screw Air Compressor EG 18 – 100.0, 125.0 Air - Cooled, Standard + VFD 460V, 3Ph, 60Hz...
  • Page 4 © ELGI EQUIPMENTS LIMITED Coimbatore, TN - 641 005 Part / Document No. 019000383 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 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 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: Table Of Contents

    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

    Introduction The design of the EG Series gives you a compact and self- Welcome to ELGi customer family. ELGi compressors are contained compressor. Because it contains no the source of compressed air in various segments across reciprocating parts, it runs quietly and free of vibrations.

  • 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 mountings reside below the air end and the motor. This 2.4.5 For retro-fitment of Standalone VFD configuration reduces the transmission of vibration from with Compressor (C) version in field airend and motor to the structure, reducing noise and ensuring reliability of mounted parts on the structure.
  • Page 21 Technical data Standard, Standard + VFD Model EG 11 EG 15 EG 18 EG 22 Working pressure psi.g 100 FAD - Free air Delivery 1.98 1.76 1.56 1.39 2.58 2.38 2.18 1.95 3.28 3.03 2.58 2.27 3.96 3.74 3.17 2.69 Unloading pressure psi.g 107 Nominal power supply...
  • Page 22 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 procedure 5.2.

  • Page 23: 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 STIFF SPREADER BAR ROPE ELGi's installation guidelines. ROPE 5.1.1 Unpacking Unpack the compressor from the packing case by removing the nails.

  • Page 24: 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 25: Electricals

    Table 1. Global series – Ventilation requirements  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 connection or filter fitment on the compressor. 5.1.5 Electricals Ensure that only authorized service technicians perform electrical work.

  • Page 26: 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 27 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 28: 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 29: Oil Fill Procedure

    for operating the compressor. Fill oil in the oil tank up to over fill cap 5.1.10 Oil fill procedure Initial oil fill procedure Initial fill Close the oil filling plug Check whether your compressor comes with oil filled. This can be checked through the oil sight glass on the air oil separator.

  • Page 30: 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 31: Operating Instructions

     Machines with an automatic star-delta starter will have  For water cooled compressors, ensure that the water 6 seconds changeover time from star to delta and quality is maintained as specified by ELGi. another 10-seconds delta-to-run delay. 5.3.2 Initial start-up 5.3.5 During running...

  • Page 32: Stopping

     Oil filter warning: Indicates that the oil filter element 5.3.7 Changing the compressor settings needs to be replaced. The compressor will not Change the compressor settings using the tactile keypad shutdown automatically in this situation. and LCD panel on the controller. (Refer to Neuron manual ...
  • Page 33 6.3.2 Dismantling the compressor 6.18 6.3.3 Decommissioning the compressor 6.18 6.3.4 Disposal of consumables and replaced parts 6.18 6.4. ELGi services 6.19 6.4.1 ELGi customer care system (ECCS) 6.19 6.4.2 ELGi genuine spare parts 6.19 6.4.3 Air audit 6.19 6.5. Appendix 6.21 6.5.1 Conversion tables...

  • Page 34: 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 ELGi Air Lube ELGi Air Lube Volume A.

  • Page 35: Maintenance Of Individual Components & Systems

    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 36: Air Oil Separator

    3 and 9 o’clock position. wrench and rotate it counter clockwise, until it completely unscrews. ELGi recommends that once the seal is broken, all products be used immediately. ELGi does not encourage  Ensure the hex adapter stays in the separator head reuse or recycling of any leftover fluids due to during disassembly.

  • Page 37: Oil Filter

    BALL step 1. VALVE c. Refill the compressor with new compressor oil. d. Send a sample** of the compressor oil to ELGi for oil analysis after 300 hours. DRAIN PLUG **: Applicable only for USA. Figure 15. Cooler oil drain NOTE ...

  • Page 38: Intake Valve

    (9) with the liquid highly skilled authorized personnel. So, it is recommended cleaner and soft cloth. Grease the screw drive of the rod that an ELGi service engineer does the maintenance. (12) and piston working area with AUTOL TOP 2000. Maintenance...
  • Page 39 HAKG 3 CONTROL DISC POSITION DURING ASSEMBLY DETAIL: ROTARY DRIVE UNIT Figure 17. Intake valve The flattened medium part of the rod and the thread (grey) must point away from the housing in the must be absolutely free of grease. Seat and sealing direction to the second steel disc (14).

  • Page 40: Blow Down Valve

     Work areas and sealing areas of the housing and their NOTE threads must be cleaned with the liquid cleaner and any After completion of intake valve assembly in package, residual Loctite removed. ensure to verify the performance  Piston work areas have to be greased by any means. 6.1.2.7 Blow down valve Seat and sealing areas must not be damaged.

  • Page 41: Electrical Motor Greasing

    to the compressor.  Put the motor back in operation.  Close the discharge end ball valve. 6.1.2.11 After and oil coolers  Release air oil tank pressure and allow the tank to cool Pre work for a few minutes. ...

  • Page 42: Drive Coupling

     Do not use any acidic / alkaline chemicals for cleaning. 6.1.2.13 Drive coupling  Repeat the process based on dust conditions or regular periodic intervals. ELEMENT Figure 23. Drive coupling Pre work COOLER PREFILTER COOLER PREFILTER  Switch off the compressor and disconnect power supply to the compressor.
  • Page 43 Reassembly  The vortex generator cone and the cyclone arrestor need only to be tightened moderately by hand. Over- tightening may lead to failure or damage. ELGi assumes no responsibility for failure or damage resulting from such incorrect installation.  Reassemble the auto drain assembly with the bottom housing and the bottom housing with the top housing ...

  • Page 44: Use Only Genuine Spare Parts

    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. 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 45: Troubleshooting

    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 46 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 47 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 48 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 49 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 50: Decommissioning, Dismantling & Putting Out Of Service

     It is mandatory to record loading or unloading of NOTE exhausted oils, obsolete machines and toxic harmful ELGi is not responsible for the disposal of old oil or wastes that derive from heavy or light industry condensate. It is the responsibility of customer to dispose processes.

  • Page 51: 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 52 (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 6.20...

  • Page 53: 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 54: Torque Values

    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 55: Service Log Book

    6.5.3 Service log book – record of maintenance Maintenance 6.23...

  • Page 56: Disclaimers

    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 58 RS 485 RS 485...

This manual is also suitable for:

Eg18Eg 11Eg 15Eg 22Eg 30Eg 37 ... Show all

Table of Contents

Save PDF