Product Manual

EG Series
Electric Powered Screw Air Compressor

EG 11 - 125.0
Air - Cooled, Standard
460V, 3Ph, 60Hz
©
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005

Part / Document No. 019000665

Contact Info:
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005, India
Tel : 91 - 422 2589555
Fax : 91 - 422 2573697 (Domestic Business)
Fax : 91 - 422 2589401 (International Business)
E-mail : [email protected]
Website : www.elgi.com
 Machine Identification and Sale Record

Owner’s name / : ………………………………………………………………………………………………………

Company name
………………………………………………………………………………………………………

Phone number : ………………………………………………………………………………………………………

Contact person : ………………………………………………………………………………………………………

E-Mail address/ : ………………………………………………………………………………………………………

Phone number
………………………………………………………………………………………………………

Model : ………………………………………………………………………………………………………

Fab. No. : ………………………………………………………………………………………………………

Year of manufacture : ………………………………………………………………………………………………………

Motor : ……………………………………………………………………………………………kW (HP)

Capacity : ……………………………………………………………………………………m3/min (cfm)

Rated pressure : ………………………………………………………………………………………bar.g (psi.g)

Date of delivery : ………………………………………………………………………………………………………

Date of commissioning : ………………………………………………………………………………………………………

Dealer name/address : ………………………………………………………………………………………………………

………………………………………………………………………………………………………

………………………………………………………………………………………………………

Dealer’s signature : ………………………………………………………………………………………………………

NOTE 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.

1.5
Table of Contents

Chapter Page No.

1.0 About ELGi 1.7

2.0 General functional description 2.1

3.0 GA drawing, P&I diagram 3.1

4.0 Technical data 4.1

5.0 Installation and operation 5.1

6.0 Maintenance 6.1

7.0 Controller 7.1

8.0 Air inlet and control system 8.2

9.0 Drive system 9.1

10.0 Discharge system 10.1

11.0 Cooling system 11.1

12.0 Lubrication system 12.1

13.0 Base and canopy system 13.1

14.0 Spare kit details 14.1

15.0 Electrical drawings 15.1

1.6
 1.0 About ELGi

ELGi, established in 1960, designs and manufactures a wide range of air compressors. The company has gained its
reputation for design and manufacture of screw compressors through strategic partnerships and continuous research and
development. Over the years, it has emerged as a multi-product, multi-market enterprise providing total compressed air
solutions to all segments. ELGi’s design capabilities translated into a wide range of products ranging from oil-lubricated and
oil-free rotary screw compressors, reciprocating compressors and centrifugal compressors.

ELGi is one of the few companies in the world capable of manufacturing wide range of airends and compressor packages.
ELGi has most modern manufacturing facilities with high precision grinding machines, turning centres, CNC horizontal and
vertical machining centres and also the latest self measurement technology to maintain precise, aerospace manufacturing
tolerances. ELGi’s manufacturing plants are ISO and EOHS certified.

Over two million ELGi compressors are powering business in 70+ countries worldwide. The company offers a strong sales
and service network with a well-knit distribution network of dealers and distribution, worldwide. ELGi has its own
manufacturing operations in India, Italy and USA with subsidiary offices in Australia, Bangladesh, Brazil, China, Indonesia,
Italy, Malaysia, Middle East, Sri Lanka and Thailand. The company is fast expanding its global footprint, attracting
distributors and customers with its new generation products.

Need help…?

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.

Toll free : 1800 425 3544

E-Mail : [email protected]
Website : www.elgi.com

Before making service request for your compressor, keep ready the details printed on the name plate of the compressor and
machine identification and sale record of this manual. When ordering spare parts, refer to the lists provided in the parts
manual and identify the part number. Specify the part number and quantity, in addition to the name plate details.

Refer “ELGi services” for more details about ECCS under chapter “Maintenance”.

1.7
 2.0 General functional description

Contents Page No.

2.1 Using the manual 2.2

2.1.1. Definitions and symbols 2.2

2.2 Introduction 2.3

2.3 Safety 2.4
2.3.1 Precautions during installation 2.4

2.3.2 Precautions during operation 2.5

2.3.3 Precautions during maintenance 2.7

2.4 Functional description 2.9

2.4.1 Air circuit 2.9

2.4.2 Oil circuit 2.9

2.4.3 Drive system 2.9

2.4.4 Control system 2.10

2.4.5 For retro-fitment of Standalone VFD with Compressor (C) version in field 2.10

General functional description 2.1

 2.1 Using the manual

This operation and maintenance manual has been

specially designed keeping the customer in mind so that
the person can get the most out of this EG compressor.
Before starting the compressor, it is requested that the
manual should be read thoroughly. It contains vital
information about installation, commissioning, operation
and useful tips on maintenance to keep the compressor
as good as new, year after year. The manual has been
prepared with utmost care to help you understand the
various systems of the compressor, along with
descriptions, information and illustrations. 2.1.1 Definitions and symbols
Following chapters are provided to help operate the
This information is related to your safety and also to prevent
compressor in its best way.
any problems relevant to the equipments used. To help
 Safety - safety precautions that must be followed while recognize this information better, the symbols are illustrated
using the compressor. in section “safety”.
 Technical specifications - technical details about the All the information, illustrations and specifications in this
compressor. manual are based on the latest product information at the
 Installation and commissioning - all site time of preparation of the manual. Product improvement is a
requirements, procedures to be followed during continuous process in ELGi. The details in this manual are
installation, commissioning, preservation etc. likely to change without notice and ELGi reserves the right to
incorporate such changes.
 Functional description – parts, their function and
working.
NOTE
 Operating instructions – to operate the compressor
Note clarifies procedures or conditions which may otherwise
properly.
be misinterpreted or overlooked. Note may also be used to
 Maintenance – how to do the maintenance for the clarify apparently contradictory or confusing situations.
compressor and their intervals.

 Troubleshooting – identification and solving the

problems. Warning calls attention to dangerous or hazardous condi-
 Decommissioning – how to decommission the tions inherent to the operation, cleaning and maintenance
of the compressor which may result in fatal accident and
compressor, its disposal etc.
personal injury of the operator or other staff
 ELGi services – services from ELGi: CCS, air audit,
spare parts

 Appendix – conversion tables, torque values, service

Caution is to draw attention to a procedure which, if not
log book done correctly can lead to compressor damage.
Refer to the parts manual to identify the part number of
the required spare. Mention the Fab number, model and
part number while ordering.

This manual must be made available to the

compressor operating and maintenance personnel at
all times.

General functional description 2.2

 2.2 Introduction

Welcome to ELGi customer family. ELGi compressors are The design of the EG Series gives you a compact and self-
the source of compressed air in various segments across contained compressor. Because it contains no
the globe. reciprocating parts, it runs quietly and free of vibrations.
The discharge temperature of the coolant oil is low, less
ELGi compressors are known for
than 90oC (195oF), under normal conditions and therefore
 Greatest reliability prevents carbonized oil from forming in the compressor.
 Fewer maintenance interval Salient Features
 Ease of use
 Three-stage air filtration
 Highest safety
 Improved air filter life cycle
ELGi screw compressor is designed to give
 Noise-free package suitable for in-house operations
 High energy efficiency
 Variable capacity control system*
 Low maintenance cost
 High volumetric efficiency
 High discharge air quality
 Efficient air-oil separation by OSBIC (Oil Separation By
All the above assures a low life-cycle cost. Impact and Centrifugal action)
The rotors incorporate a specially designed eta-v profile  Reliable fan that works even at high temperature
– ELGi patented profile-which emphasizes on improving
 Isolated cooling system
reliability, performance and efficiency. Eta-v profile is the
latest and the most energy efficient profile in the industry  Robust cooling system
globally, assuring consistent performance during entire life  Industrial designed canopy
of the compressor. ELGi screw air compressors have a
 Compact and hardly space-intensive
compact design and compressor run with low noise or
vibrations. The capacity control system ensures optimum  Split type oil & after coolers for easy serviceability
air intake during start up, normal running and unloading  Flush type panels for easy handling
stages, minimizing power consumption. The oil separation
 Anti-vibration mounts for restricted vibration
system ensures that maximum oil is separated from the
compressed air, ensuring the best air quality with very  Increased life of consumables
little oil carry-over.  Integrated VFD (Variable Frequency Drive) and dryer*.

Uptime  Zero-leak flanged joints.

At ELGi, we are changing the way you look at compressed  Oil carry over < 1 ppm
air systems. It’s no longer just about delivering air. It’s  Advanced Neuron controller
about delivering uptime. Our uptime design ensures that
 Globally certified product - CE / UL and other country
the compressors would run cooler, cleaner and longer with
specific approvals.
longer service intervals. The uptime components are bests
in quality keeps your compressor to run smoothly, * For selected models.
efficiently and profitably. With uptime assurance we back
our pledge, with industry-leading warranties, parts
availability, loaner compressors and call centres staffed by
experts. We thank you for purchasing ELGi compressor
and assure you the best service during entire life of
compressor.

EG Series
Your EG Series compressor belongs to a family of rotary
screw compressors from ELGi. The compressor has only
two moving parts: the two rotors. A thin film of oil
separates the rotors to prevent wear. This also means that
the reliability of the compressor is unsurpassed.

The screw compressor technology ensures that output

capacity never diminishes even after many years of
operation. It involves a continuous flow of air through
helical cavities in the screw, ensuring pulsation-free
compressed air delivery.

General functional description 2.3

 2.3 Safety

The operator must follow the safe working practices,  Ensure the operator is located far away from the intake
instructions, procedures that this manual describes for of the compressor.
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’. or close to flammable materials.
Decals are affixed at specific locations of the compressor
 Do not exert external force on the air outlet valve and
and they illustrate very important safety precautions.
keep the connected pipe always free of strain.
2.3.1 Precautions during installation  Make available adequate cooling air must be made
 Ensure that you fasten all loose parts before lifting. Select available for the compressor particularly air cooled
the appropriate lifting equipment by considering the local compressors. Make sure that exhausted air does not
safety regulations, size and weight of the compressor. circulate back to the intake or cooling system.
Operate the lifting equipment carefully within the safe  Make the electrical connections according to the legal
operating limits. Ensure all necessary personal protective standards and earth the compressor suitably. Provide a
equipment's (PPEs) is close at hand during this operation. sufficient number of fuses and other protective devices
to protect the compressor against short circuits. Good
practice is to provide an isolating switch nearby the
compressor.

 Install manual valves behind non-return valves (NRV) to

isolate each compressor in multi-compressor systems.
 Maintain a cool and clean ambient for the compressor Do not rely on NRV for isolating pressure systems.
and ensure that the air inlet is not obstructed. Make
 Do not bypass, remove or adjust the safety devices or
arrangements to reduce the moisture entry through the
other attachments residing on the compressor. Every
incoming air.
installed pressure vessel or auxiliary outside the
 Remove protection such as caps, plugs, desiccant bags compressor should have pressure relieving device or
before connecting the air line pipes. devices, as required.
 Remove the red colored protective clamps from the
airend and motor while commissioning the compressor.

 Do not use frayed, damaged or worn hoses. Distribution

pipes and connections must be of the correct size and
suitable for working pressure.
 Make sure that the aspirated air by the compressor is
free of flammable fumes, vapors and particles, to
prevent internal fire or explosion.

 For remotely controlled compressors and auto-start

compressors, provide a clear caution stating:
“DANGER” – Remotely controlled machine and will
start without notice

 Danger! Be aware that compressed air used for

breathing or food processing must meet O.S.H.A.

General functional description 2.4

 1910.134 or F.D.A. 21 C.F.R. 178.3570 regulations. depressurize a hose fully before disconnecting it.
Failure to do so may cause severe injury or death.

 Insulate or use protective guards to cover pipes or other

parts that may exceed 80ºC (176ºF). High-temperature
pipes must have a clear marking as potentially
dangerous.

 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.
food and related items unless they are compressed air-
 Do not engage in horseplay with air hoses. Serious
treated specifically.
injury or death may result.
 Be aware that this air compressor is intended for
 Do not use air at a pressure greater than 2.5 bar.g (36
generating only industrial-use compressed air.
psi.g) for cleaning purpose.
2.3.2 Precautions during operations
 Open the oil fill cap only when the compressor is not
 When switching on remotely controlled compressors running and is not pressurized. Shut down the
ensure that no one is checking or working on the compressor and bleed the receiver tank to zero internal
compressor at that time. pressure before removing the cap.
 Before starting, ensure that no tools or any loose parts Fire and explosion
remain inside the compressor.

 Do not operate the compressor if a possibility exists

that it could inhale flammable or toxic fumes, vapors or
particles.

 Do not operate the compressor below or above its

operating limits.  Clean up spills of lubricants or other combustible
substances immediately.
 Wear ear protectors if you work in an environment
where the sound pressure level reaches or exceeds 90  Shut down the compressor and allow it to cool down
dB (A). before checking or adding oil. Remove sparks, flames
and other sources of ignition away from the
 Keep all the compressor doors shut during operation.
compressor.
For carrying out routine checks, the doors should open
only for short durations not more than 10 minutes.  Do not permit smoking in the vicinity of the compressor.
Wear ear protectors when opening a door.  Do not use flammable solvents for cleaning purposes.
 Keep hands, feet, floors, controls and walking surfaces  Keep electrical wiring and other terminals in good
clean and free of water or other liquid to minimize the
condition. Replace any wiring that has cracked, cut,
possibility of slips and falls. abraded or otherwise degraded insulation. Keep all
Pressure release terminals clean and tight.

 Know that annual servicing of the safety valve is  Keep grounded conductive objects such as tools away
necessary. It should be checked at the prescribed from exposed live electrical parts like terminals to avoid
pressure for operation. arcing, which might serve as a source.

 Use correct tools for maintenance and repair work.  Keep oily rags, trash, dry leaves, litter or other
Do not allow the manufacturers’ rated safe operating combustibles out of and away from the compressor.
pressure to exceed for pipes, valves, filters and other  Do not operate the compressor without a proper flow of
fittings. cooling air or with an inadequate flow of lubricant or
 It is hazardous to point the compressed air directly with a degraded lubricant.
towards any personnel. Keep personnel out of the line  Do not attempt to operate the compressor in a
of the discharge air when opening hoses or other points hazardous environment of any classification unless the
of compressed air discharge. compressor has been specially designed and
 Use only the correct type and size of hose end fittings manufactured for explosive applications.
and connections. When blowing through a hose or
airline ensure that the open end stays securely. A free
end will whip and may cause injury. Make sure to

General functional description 2.5

 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.

 Keep all parts of the body away from all points of air
discharge.

 Keep a first aid kit handy. Seek medical assistance

promptly in case of injury. Do not ignore small cuts and
burns.

Toxic and irritating substances

 Do not use air from the compressor for breathing.
 Rotating fan blades can cause serious injury. Disconnect  Always wear safety equipment while operating the
power supply before attempting service. compressor. Refer OSHA safety standards.
 Keep compressor doors closed except when servicing or  Do not allow compressed air to come into contact with
during maintenance. The sound damping material on any edible items.
the inner side of the compressor body should not be
 In the event of ingestion of oils, coolants or lubricants
removed or tampered with.
used in the compressor, seek medical treatment
 Wear snug-fitting clothing and tie long hair when promptly. In case you come in contact with such
working around the compressor, especially when hot or substances, wash with soap and water. Use MSDS for
moving parts such as the cooler, the airend, the thermal oil to know more on this.
valve, the main motor or the fan motor are exposed.
 If warm cooling air from the compressor is being used
 Keep hands, arms and clothing away from couplings, in air heating systems, e.g. to warm up a work room,
fans/belts and other moving parts. take precautions against air pollution and possible
 Do not attempt to operate the compressor with the fan contamination of the breathing air.
guards, coupling guards/belt guards or other guards Electric shock
removed.
 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.

General functional description 2.6

  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  Ensure that the compressor is cooled down before
minimizes the risk of creating a current path through maintenance is performed.
the heart.

 Conduct repairs only in a clean, dry, well-lit and

ventilated area.

 Do not leave the compressor unattended with open

electrical enclosures. If necessary to do so, disconnect
the power to the compressor at the source and lock it
out so that power is not in advertently restored.

 Disconnect, lock out, and tag the power source prior to

attempting repairs or adjustments, turning the
 Springs under tension or compression store energy.
compressor manually or handling ungrounded
Uncontrolled release of this energy can cause serious
conductors.
injury or death. Be cautious while performing the
 All electrical installation must be in accordance with maintenance of components loaded with springs (for
recognized electrical codes and any local health & safety example minimum pressure valve, safety valve etc.).
codes.
 Display a warning sign that says “Maintenance under
 Recognize that only authorized and qualified trained progress, don’t switch on” near the start switch.
personnel should carry out any electrical work on the
 Isolate the compressor from the air line (discharge) and
compressor.
disconnect the power by opening and locking the
 Regularly check that all electrical connections are tight isolating switch before maintenance.
and in good condition.
 Prior to attempting repairs or adjustments, disconnect
Periodically check whether the power at the source and verify at the compressor
that the circuits have de-energized. This minimizes the
 All guards are in place and securely fastened.
possibility of accidental start-up or operation, especially
 All hoses and pipes inside the compressor are in good when the compressor is remotely controlled.
condition, secure and not rubbing against each other.
 Open the oil filler cap only when the compressor is not
 Any leaks exists. running and is not pressurized. Shut down the
 All fasteners are tight. compressor and bleed the receiver tank to zero internal
pressure before removing the cap.
 All electrical leads are secure and in good order.

 Safety valves and other pressure relief devices are not

obstructed by dirt or paint.

 Air outlet valve, i.e. pipes, couplings, manifolds, valves,

hoses, etc. are in good repair, free of wear or abuse.

 The air-oil tank is properly grounded.

2.3.3 Precautions during maintenance

 Use safety glasses and incorporate safe working
practices before maintenance work.

 Use appropriate tools for all maintenance works.

General functional description 2.7

 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.

 Vent all internal pressure prior to opening any line,

fitting, valve, drain plug, connection or other
components such as filters. Vent pressure by popping
up the safety valve.

 Display a maintenance chart near the compressor to

easily identify the maintenance intervals of regular
service items.

General functional description 2.8

 2.4 Functional description

Figure 1. Screw compressor systems - Schematic diagram

2.4.1 Air circuit separated of any moisture content by the moisture

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.
intake system. The intake filters (pre filter and air filter)
prevents the entry of foreign particles (such as dust) into 2.4.2 Oil circuit
the airend. The intake valve regulates the amount of air The oil in the air-oil separation tank after being separated
sucked into the airend. The opening and closing of the is fed into the airend. The oil either gets diverted to the oil
intake valve are controlled by the pneumatic pulse line cooler or oil filter or both depending upon the
actuated by an electrically controlled solenoid valve. The temperature. The thermal valve governs and controls the
clog indicator fitted in the air filter turns red when the oil flow path. The oil before being injected into the airend
filter is clogged. is filtered. An orifice is provided in oil flow path towards
The filtered air enters into the airend where it mixes with the airend to control the oil flow. The whole oil circulation
the injected oil. The injected oil acts as a coolant to circuit in the compressor is operated solely by the
maintain optimum temperature. It also seals the leaks differential pressure maintained by the minimum pressure
between the rotors and the housing and lubricates the valve (MPV) and doesn't require any additional pump.
bearings and gears. The airend consists of two counter- 2.4.3 Drive system
rotating intermeshed helical screws - the male and the
female rotors - which are driven by electric motor. The air The airend transmission is powered by an electric
-oil mixture is trapped between the rotors of the airend induction motor through a coupling. When the compressor
and is progressively compressed. is turned ON, the motor is started in star mode and takes
6 to 9 seconds to change over to delta mode. During this
After being compressed, the air-oil mixture enters with
period the intake valve remains closed and thus the motor
high velocity into the air-oil separator tank where it
starts without load. In delta mode, the motor speed
undergoes a unique 3 stage separation process which
stabilizes, the solenoid valve energizes after 10 seconds of
removes maximum oil content. This highly efficient 3 stage
change-over to reduce load on the motor, the blow down
separation process uses the impact velocity of air-oil
valve is closes, intake valve opens and the compressor
mixture along with centrifugal action, which makes the
starts loading. For compressors with variable frequency
mixture very lean. The final stage of this separation
drive (VFD), speed of the motor gradually increases within
consists of passing the lean mixture through the air-oil
30 seconds (ramp-up time) while the intake valve remains
separator element which leaves the air with an oil content
in the closed position. This ensures very little starting load.
of < 1 ppm.
Next, the intake valve opens and the system starts
The oil separated and collected in this element is then building up pressure. An adaptor ring connects the airend
returned to the airend through the oil return line. The air and the motor. It also helps in maintaining the coupling
passes through a minimum pressure valve (MPV). It alignment. The coupling element acts as a safety interlock
maintains a minimum differential pressure which is and it is the first one to fail when coupling elements
required for circulation of oil within the compressor unit. become over loaded. This architecture saves the whole
The compressed hot air is cooled in the after cooler and is drive system from failure. Malfunctioning of the coupling

General functional description 2.9

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
airend and motor to the structure, reducing noise and with Compressor (C) version in field
ensuring reliability of mounted parts on the structure. 1. Change the bearings to insulated type for motors
2.4.4 Control system >=90kw at Non Drive End side of Motor

2. Turndown only upto 50% for conversion models

Load - Unload
(considering the motor speed) i.e. motor frequency range
Depending on the demand for compressed air from the is 50 - 25 Hz for 50Hz variant and 60 - 30Hz for 60Hz
application at a particular time, the compressor needs to variant. No pressure turndown is applicable
respond accordingly. The compressor, therefore operates
3. Run the compressor in the VFD operating range (50 to
in either loading or unloading mode to meet this
25Hz) and skip the frequency in VFD controller (within +/-
requirement. The primary objective of these modes is to
1Hz) if abnormal noise / vibration is observed
save energy and reduce wear and tear on the machine.
The control system ensures a smooth start without 4. Change the thermal element from 65°C to 75°C
overloading the motor. The compressor is started in star
mode, during which most of the compressed air is vented
to the atmosphere. This mechanism helps prevent
overloading the motor. In delta mode the motor speed
stabilizes, the solenoid valve energizes after 10 seconds of
change-over to reduce load on the motor, the blow-down
valve is closes, and the compressor starts loading.

When the receiver pressure reaches the maximum limit, a

signal arrives the solenoid valve from the control system.
Next, the inlet valve actuates and closes, and the
compressor runs in unloading mode. If unloading mode
continues for more than 5 minutes, i.e., compressed air is
consumed and thus no decrease in pressure occurs, the
system stops and switches to standby mode. If a drop in
pressure occurs in the receiver, the compressor returns to
loading mode automatically.

Suction modulation
When you operate a compressor without VFD, capacity
control occurs via a pressure regulator (for selected
models). When the consumption of air is less than the FAD
of the compressor, the line pressure will start increasing.
Whenever the line pressure goes up constantly beyond the
set pressure, the pressure regulator bleeds the excess air
to the atmosphere thereby reducing the amount of flow
into the actuator. The actuator is spring loaded, which, in
turn, closes the intake valve slightly and enables capacity
control. Similarly when the consumption of air is more
than the FAD, the line pressure starts decreasing and the
actuator progressively opens the intake valve. This
regulation is called intake modulation by throttling.

VFD modulation
VFD is an efficient way of controlling capacity as per
demand. In a compressor with VFD the power of
compressor varies proportionally with capacity reduction.
The VFD tunes the frequency, thereby adjusting the speed
based on the change in line pressure. The incoming flow
will automatically reduce because of reduced speed of the
motor. Conversely speed increases when line pressure
goes down below working pressure.

General functional description 2.10

 4.0 Technical data

Standard, Standard + VFD

Model - EG 11 EG 15 EG 18 EG 22

Working pressure psi.g 100 125 150 175 100 125 150 175 100 125 150 175 100 125 150 175

FAD - Free air cfm 71 62 55 49 94 85 77 65 117 110 92 82 143 134 116 96

3
m /
Delivery 2.01 1.76 1.56 1.39 2.66 2.41 2.18 1.84 3.31 3.11 2.61 2.32 4.05 3.79 3.28 2.72
min

Unloading pressure psi.g 107 132 157 182 107 132 157 182 107 132 157 182 107 132 157 182

Nominal power supply

- 208-230V / 460V (+/-10%), 60Hz(+/-5%),3phase
conditions

Main motor rating hp 15 20 25 30

Type of motors (main

- Squirrel Cage Induction-TEFC & Cooling Fan Integrated Motor
drive & fan drive)

Insulation and
- Class F & IP55
protection of main motor

Frame size / mounting

- 254T/L / B35 256T / B35 284T / B35 286T / B35
type

STD Automatic Star Delta

Type of starter
-
for main motor STD +
Through Variable Frequency Drive
VFD
Maximum fan motor
rating per fan X no. of hp 0.38 (208-230V) / 0.40 (460V) X 1 Fan 0.38 (208-230V) / 0.40 (460V) X 2 Fans
fans
Rated speed of fan
rpm 1560 (208V-230V) / 1630 (460V)
motor
Safety valve set
psi.g 205
pressure

Technical data 4.1

 5.0 Installation and operation

Contents Page No.

5.1. Installation and commissioning 5.2
5.1.1 Unpacking 5.2

5.1.2 Disposal of packing materials 5.2

5.1.3 Handling the compressor 5.2

5.1.4 Site requirements 5.2

5.1.4.1 Ventilation 5.3

5.1.5 Electricals 5.4

5.1.6 Air pipe dimensions 5.5

5.1.7 Receivers for compressed air systems 5.7

5.1.8 Possible mistakes 5.7

5.1.9 Commissioning procedure 5.7

5.1.10 Oil fill procedure 5.8

5.2. Preservation for long idle storage 5.9

5.2.1 Airend 5.9

5.2.2 Motor 5.9

5.2.3 Air-oil separator tank 5.9

5.2.4 Rubber hoses 5.9

5.3. Operating instructions 5.10

5.3.1 Initial start-up checks 5.10

5.3.2 Initial start-up 5.10

5.3.3 Pre-start checks 5.10

5.3.4 Starting 5.10

5.3.5 During running 5.10

5.3.6 Stopping 5.11

5.3.7 Changing the compressor settings 5.11

Installation and operation 5.1

 5.1 Installation and commissioning

Before the new EG series compressor is operated for the  Lifted compressors using either a forklift /pallet truck
first time, it needs to be installed at your site according to (Fig.12) or a crane (Fig.13).
ELGi's installation guidelines  When using a forklift, ensure padding is used in
between the compressor and forklift (as shown in
5.1.1 Unpacking Fig.12) to prevent damage to the compressor’s canopy.
Unpack the compressor from the packing case by  When using a crane, please ensure stiff spreader bars
removing the nails. Unscrew the bolts, holding the are used (as shown in Fig.13) to prevent rope slings
compressor to the base of the crate from damaging the compressor’s canopy.
Once the packing material is removed, check the contents  Do not drop the compressor.
against the packing list. The compressor is shipped with  Do not attempt to move the compressor by pushing or
the following dragging it as this may cause jerky movements causing
 Key for doors. damage to the compressor.

 Operation and maintenance manual NOTE

 Checklist of parts of the machine Removal of transit brackets:
 Electrical drawing Once you have placed the compressor in its final position,
remove the red painted transit brackets and store for
5.1.2 Disposal of packing material future use.
Locations:
The wood/cardboard used to make the shipping crates of
 Bracket in between the base and airend support
the EG series compressors are biodegradable.
 Bracket in between the base and motor
The polyethylene covers wrapped around the compressor
 Bracket in between the shroud and control panel box
and the polystyrene packing provided around the electrical
panels are not recyclable. They must be disposed off in 5.1.4 Site requirements
accordance with prevailing local environmental laws.  Install the air compressor in a clean, dry, cool and dust
free room as extreme temperatures (hot or cold),
5.1.3 Handling
moisture, and air borne contaminants can significantly
affect compressor performance, durability and
compressed air quality.
 Be aware the entrance to the compressor room should
be high enough and wide enough to carry the
compressor in and out.
 Leave a minimum of 1m (3.28ft) space around the
compressor for safe and proper inspection, cleaning,
and maintenance activities.
 Leave a minimum of 2m (6.56ft) space above the
compressor for hot air to flow away from the
compressor.
PADDING
 Ensure the compressor is protected against direct
Figure 2. Lifting using forklift sunlight and rain.
 Avoid exposing the compressor to excessive moisture
STIFF BAR ROPE/SLING
(from rain, dryer vent etc.) as moisture can affect
ROPE/SLING airend lubrication, promote rust formation on the
compressor and lead to electrical problems of the
motor.
 Neither install the machine in a location where flame is
used or place any inflammable objects near the
compressor.
 Ensure the room temperature is within 50ºC (122ºF) as
high ambient temperatures can reduce oil life due to
higher discharge oil temperature (DOT). It also results
in high approach temperatures affecting cooling and
condensation efficiency in the after- cooler and in air
treatment equipment like air dryers.
Figure 3. Lifting using crane

Installation and operation 5.2

 Ensure the hot and medium of other utility equipment  If you operate in high dust applications like rice mills,
like gensets/dryers/ boilers, etc., is not sucked by the cement, flour mills etc., clean and replace the filters
compressor inlet or in any way the room temperature more often.
does not rise to prevent high discharge oil temperature.  Good practice is to have overhead lifting in the
 Ensure the ambient temperature does not drop below compressor room to facilitate any major overhaul. If an
0ºC (32ºF). Provide air supply openings and adjustable overhead hoist is not available, you should be able to
louvers to ensure that the minimum temperature does use a mobile crane or forklift truck in your compressor
not drop down below 0ºC (32ºF). room at a minimum.
 Install the compressor on a smooth, solid, level 5.1.4.1 Ventilation
industrial concrete floor capable of bearing the weight of
 A part of electric energy to your compressor motor is
the compressor.
converted into heat and this heat must be removed
 Ensure unevenness of the surface is within 6mm (0.25")
from the compressor room by suitable ventilation.
 If the floor is splashed frequently with water while
 The ventilation requirements of the compressor are
cleaning, then place your compressor on a raised
listed in Table 1.
concrete plinth 100 to 150 mm (4 to 6 inches) high.
 The ventilation requirements could be achieved by the
following methods.
 Natural ventilation is sufficient if the temperature rise in
MINIMUM 2 m (6.6 ft) CLEARANCE
the compressor room (measured by a thermometer
CEILING near the air inlet pre-filter) is within 5ºC (9ºF) when
compared with outside temperature.
ELGi SCREW AIR  Forced ventilation with an exhaust fan is necessary if
COMPRESSOR the temperature rise inside the room (measured by a
thermometer near the air inlet pre-filter mesh) rises
above 5ºC (9ºF) .
 Ventilation with ducts: Ensure hot air exhaust from the
Figure 4. Vertical clearance around the compressor is diverted through the ducts when installed
compressor
in an enclosed area. (contact ELGi for ducting
requirements)
 Provide openings on walls/partitions close to the air
suction side of the compressor.
 Provide exhaust openings close to the ceiling for hot air
ELGi SCREW AIR
COMPRESSOR exit.
WALLS OR  If more than four compressors are installed in a room,
OTHER
good practice is to ducting arrangements. This will avoid
hot air recirculation.
MINIMUM CLEARANCE, X=1 m (3.5 ft)  Be aware hot air recirculation in the enclosed area will
affect the compressor performance.
Figure 5. Horizontal clearance around the
compressor  Ensure the air velocity in the supply and exhaust ducts
does not exceed 4 m/s (13 ft/s).
 Ensure the compressor base makes 100% contact
directly with the floor.  Know air velocity is ascertained during commissioning
using an anemometer.
 Know that an industrial floor with a level surface
capable of supporting the weight if the compressor is
sufficient for installing your compressor. No special
foundation or anchoring is necessary for rotary screw
compressors.
 Do not store toxic, volatile, or corrosive agents near the
compressor.
 Isolate the compressor from corrosive agents like
ammonia, chlorine, salt spray, and other chemicals as
these may erode the internal components and also
contaminate the oil and filters.
 Do not allow hot air from additional equipment to blow
towards the compressor. Figure 6. Forced ventilation with exhaust fan

Installation and operation 5.3

 Do not connect cool air inlet ducts directly to the  Contact ELGi in case you need to provide a duct
compressor inlet side. connection or filter fitment on the compressor.
 To eliminate transmission of vibrations, provide a soft 5.1.5 Electricals
bellows connector between the duct and the
compressor.
Ensure that only authorized service technicians carry out
Minimum the electrical work. Study the electrical circuit diagram
Minimum before starting the work.
ventilation
ventilation
Model require-
requirement
3 ment (m3/ 1. Supply power to the compressor through a dedicated
(ft /h )
h)
switch disconnected fuse (SDF) unit of suitable a rating
EG 11 94,537 2,677
mounted within 5 m (16.4ft) of the compressor. (This
EG 15 128,086 3,627
EG 18 157,185 4,451 architecture lets you isolate the compressor).
EG 22 204,154 5,781 2. Use an HRC (high rupturing current) fuse instead of an
EG 30 242,576 6,869 MCCB (moulded case circuit breaker) to avoid possible
EG 37 299,185 8,472
contactor and motor failure.
EG 45 363,847 10,303
EG 55 464,246 13,146 3. Refer to table 2 for fuse and cable specifications for
EG 75 631,708 17,888 380/400/415 V, 50Hz,3-Ph power supplies.
EG 90 705,481 19,977
4. Do not use an MCB (miniature circuit breaker) because
EG 110 864,821 24,489
the selection of contactors depends on Type-2 co-
EG 132 1,033,801 29,274
EG 160 1,273,482 36,061 ordination.
EG 200 1,718,976 48, 676 5. Connect the earthling line to the point provided on the
EG 250 1,718,976 48, 676 base frame at the side of the compressor and motor.
Table 1. Global series – Ventilation
requirements

Figure 7. Ventilation with ducts

Incoming cable Incoming cable size Earth cable Power cable

Compressor Incoming size (Armored) (Armored) size gland hole
model fuse rating Copper Aluminum Copper diameter
A Sq.mm Sq.mm mm (inches)
EG 11 32 4C x 6 4C x 6 2.5 Gauge 25 (0.984)
EG 15 50 4C x 6 4C x 10 4 Gauge 28 (1.102)
EG 18 50 4C x 10 4C x 16 4 Gauge 28 (1.102)
EG 22 63 4C x 10 4C x 25 4 Gauge 32 (1.259)
EG 30 80 4C x 25 3 ½ C x 35 6 Gauge 32 (1.259)
EG 37 125 3 ½ C x 35 3 ½ C x 50 6 Gauge 35 (1.377)
EG 45 160 3 ½ C x 50 3 ½ C x 70 8 Gauge 50 (1.968)
EG 55 200 3 ½ C x 95 3 ½ C x 120 12 Gauge 38.1 (1.50)
EG 75 220 3 ½ C x 95 3 ½ C x 120 25 x 3 flat 44.45 (1.75)
EG 90 220 3 ½ C x 120 3 ½ C x 150 30 x 3 flat 50.8 (2.00)
EG 110 250 3 ½ C x 120 3 ½ C x 150 35 x 3 flat 57.15 (2.25)
EG 132 315 3 ½ C x 150 3 ½ C x 185 50 x 6 flat 69.85 (2.75)
EG 160 400 3 ½ C x 185 2R x 3 ½ C x 240 50 x 6 flat 76.2 (3.00)
EG 200 500 2R x 3 ½ C x 185 2R x 3 ½ C x 240 50 x 6 flat 88.9 (3.50)
EG 250 630 2R x 3 ½ C x 240 2R x 3 ½ C x 300 50 x 6 flat 88.9 (3.50)
Table 2. Global series – Electrical requirements

Installation and operation 5.4

 POWER CABLE ENTRY

EARTHING POINT

Figure 8. Earthing line of compressor

5.1.6 Air pipe dimensions

NPS Pipe size/ Inside diameter (mm)
Volume Flow FAD 1/2 3/4 1 1 1/4 1 1/2
15.80 20.93 26.65 35.05 40.89
(m3/min) (cfm) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi)
0.1 4 0.02 0.22
0.2 7 0.06 0.80 0.01 0.20
0.3 11 0.12 1.69 0.03 0.41 0.01 0.12
0.4 14 0.20 2.88 0.05 0.71 0.01 0.21
0.5 18 0.30 4.35 0.07 1.07 0.01 0.32 0.01 0.08
0.6 21 0.43 6.09 0.10 1.49 0.03 0.45 0.01 0.11
0.7 25 0.57 8.10 0.14 1.99 0.04 0.59 0.01 0.15
0.8 28 0.73 10.38 0.18 2.54 0.05 0.76 0.01 0.19 0.01 0.09
0.9 32 0.90 12.90 0.22 3.16 0.07 0.95 0.02 0.24 0.01 0.11
1.0 35 1.10 15.68 0.27 3.84 0.08 1.15 0.02 0.29 0.01 0.13
1.2 42 0.38 5.38 0.11 1.61 0.03 0.41 0.01 0.19
1.4 49 0.50 7.16 0.15 2.14 0.04 0.54 0.02 0.25
1.6 56 0.64 9.16 0.19 2.74 0.05 0.70 0.02 0.32
1.8 64 0.80 11.40 0.24 3.41 0.06 0.87 0.03 0.40
2.0 71 0.97 13.85 0.29 4.14 0.07 1.05 0.03 0.49
2.2 78 1.16 16.52 0.35 4.94 0.09 1.25 0.04 0.58
2.4 85 1.36 19.40 0.41 5.80 0.10 1.47 0.05 0.68
2.6 92 0.47 6.73 0.12 1.71 0.06 0.79
2.8 99 0.54 7.72 0.14 1.96 0.06 0.91
3.0 106 0.61 8.77 0.16 2.23 0.07 1.03
3.5 124 0.82 11.66 0.21 2.96 0.10 1.37
4.0 141 1.05 14.93 0.27 3.79 0.12 1.75
4.5 159 1.30 18.57 0.33 4.71 0.15 2.18
5.0 177 0.40 5.73 0.19 2.65
5.5 194 0.48 6.83 0.22 3.16
6.0 212 0.56 8.02 0.26 3.71
6.5 229 0.65 9.30 0.30 4.30
7.0 247 0.75 10.67 0.35 4.94
7.5 265 0.85 12.12 0.39 5.61
8.0 282 0.96 13.66 0.44 6.32
8.5 300 1.07 15.28 0.50 7.07
9.0 318 1.19 16.99 0.55 7.86
9.5 335 1.32 18.477 0.61 8.69
10.0 353 1.45 20.64 0.67 9.55
15.0 530 1.42 20.22

Installation and operation 5.5

 NPS Pipe size/ Inside diameter (mm)
Volume Flow FAD 1 1/2 2 2 1/2 3 4
40.89 52.50 62.71 77.93 102.26
(m3/
(cfm) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi)
min)
0.8 28 0.01 0.09
0.9 32 0.01 0.11
1.0 35 0.01 0.13
1.2 42 0.01 0.19
1.4 49 0.02 0.25 0.01 0.07
1.6 56 0.02 0.32 0.01 0.09
1.8 64 0.03 0.40 0.01 0.11
2.0 71 0.03 0.49 0.01 0.14
2.2 78 0.04 0.58 0.01 0.17
2.4 85 0.05 0.68 0.01 0.20 0.01 0.08
2.6 92 0.06 0.79 0.02 0.23 0.01 0.09
2.8 99 0.06 0.91 0.02 0.26 0.01 0.11
3.0 106 0.07 1.03 0.02 0.30 0.01 0.12
3.5 124 0.10 1.37 0.03 0.39 0.01 0.16
4.0 141 0.12 1.75 0.04 0.50 0.01 0.21
4.5 159 0.15 2.18 0.04 0.63 0.02 0.26 0.01 0.09
5.0 177 0.19 2.65 0.05 0.76 0.02 0.31 0.01 0.11
5.5 194 0.22 3.16 0.06 0.91 0.03 0.37 0.01 0.13
6.0 212 0.26 3.71 0.07 1.06 0.03 0.44 0.01 0.15
6.5 229 0.30 4.30 0.09 1.23 0.04 0.51 0.01 0.17
7.0 247 0.35 4.94 0.10 1.42 0.04 0.58 0.01 0.20
7.5 265 0.39 5.61 0.11 1.61 0.05 0.66 0.02 0.22
8.0 282 0.44 6.32 0.13 1.81 0.05 0.75 0.02 0.25
8.5 300 0.50 7.07 0.14 2.03 0.06 0.83 0.02 0.28 0.01 0.07
9.0 318 0.55 7.86 0.16 2.25 0.06 0.93 0.02 0.31 0.01 0.08
9.5 335 0.61 8.69 0.17 2.49 0.07 1.02 0.02 0.35 0.01 0.09
10.0 353 0.67 9.55 0.19 2.74 0.08 1.13 0.03 0.38 0.01 0.10
15.0 530 1.42 20.22 0.41 5.80 0.17 2.38 0.06 0.80 0.01 0.21
20.0 706 0.69 9.87 0.28 4.06 0.10 1.37 0.02 0.35
25.0 883 1.05 14.92 0.43 6.13 0.15 2.07 0.04 0.53
30.0 1059 1.46 20.90 0.60 8.59 0.20 2.90 0.05 0.75
35.0 1236 0.80 11.43 0.27 3.86 0.07 0.99
40.0 1412 1.03 14.63 0.35 4.94 0.09 1.27
45.0 1589 1.28 18.20 0.43 6.14 0.11 1.58
50.0 1765 0.52 7.46 0.13 1.92
55.0 1942 0.62 8.90 0.16 2.29
60.0 2118 0.73 10.46 0.19 2.69
65.0 2295 0.85 12.13 0.22 3.12
70.0 2471 0.97 13.91 0.25 3.57
75.0 2648 1.11 15.80 0.28 4.06
80.0 2824 1.25 17.81 0.32 4.58
85.0 3001 1.40 19.92 0.36 5.12
90.0 3177 0.40 5.69
95.0 3354 0.44 6.29
100.0 3530 0.48 6.92
150.0 5295 1.03 14.64
Table 3. Global series – Air pipeline dimensions

NOTE 1. Use the pipe sizes (as in Table 3) for the delivery pipe
that connects to the ball valve of the compressor.
The above table shows the pressure drops in 100m length
schedule 40 steel pipe at 7 bar (abs) 2. In case the main delivery pipe is more than 100 m (300
feet) long, use a pipe diameter that is one size bigger
than shown in the table.

Installation and operation 5.6

5.1.7 Receivers for compressed air
systems
Receiver
Compressed capacity
applications
Volume On/Off control Modulation control
m3 ft3 m3/min cfm m3/min cfm
0.3 10.59 Up to 1.13 Up to 40 Up to 1.7 Up to 60
0.5 17.66 1.14 - 2.4 41 - 85 1.7 - 3.4 61-120
1 35.32 2.4 - 4.0 86 - 140 3.4 - 6.7 121-235
1.5 52.97 4.0 - 6.4 141 - 225 6.7 - 10.0 236-355
2 70.63 6.4 - 8.8 226 - 310 10.0 - 13.0 356-470
3 106.0 8.8 - 12.6 311 - 445 13.0 - 20.1 471-710
4 141.3 12.6 - 16.1 446 - 570 20.1 - 26.7 711-945
5 176.6 16.1 - 19.8 571 - 700 26.7 - 33.4 946-1180
6 211.9 19.8 - 24.0 701 - 850 33.4 - 40.0 1181-1415
7 247.2 24.0 - 28.0 851 - 990 40.0 - 46.7 1416-1650
8 282.5 28.0 - 32.0 990 - 1130 46.7 - 53.3 1651-1885
Table 4. Global series—Receivers specifications

5.1.8 Possible mistakes d. Replace the AVMs if you detected any abnormal
1. The compressor is installed on the wooden pallet of the squeezing or damage in the rubber part.
packing case.
e. Check whether all the screws in the control panel are in
2. The compressor base is not making 100% contact with place and tightened properly.
the floor.
f. Check the oil cooler and after-cooler for any external fin
3. The compressor is mounted on anti-vibration mounts. blockage and clear the blockage if necessary.
4. The isolator is more than 5m (16.40ft) away from the g. Ensure that all the transit brackets are removed.
compressor.
During commissioning
5.1.9 Commissioning procedure The Servicing technician performs a series of checks on
1. Please make preparations according to the installation the machine and on the systems to which it connects, to
section as given, before the compressor is ensure that it is in a condition to function safely and as
commissioned. recommended. The Servicing technician will then explain
2. Ensure that the location meets the requirements of how to operated and maintain the equipment. This
accessibility, ventilation and safety. procedure is referred to as the commissioning process.

3. Provide electrical power as recommended in the The commissioning of the compressor ensures that it is
installation section. installed safely.

4. Select air pipe lines and receivers for your system The general operating conditions of the equipment
according to the tables provided in the installation including the cleanliness of the atmosphere, the
section. temperature and the ventilation are checked. Technical
details relating to your system such as particulars of your
Checkpoints before commissioning
electrical installation are noted. The operator of the
Replace the parts in compressor if it had been in storage
compressor is familiarized with all aspects of both its
for more than one year.
normal running and dealing with unusual situations.
1. Air filter
Upon completion of the commissioning process, the
2. Oil filter
technician will fill in the document known as the
3. Air oil separator (check and replace) commissioning report and the warranty card provided in
4. Oil this manual.

a. Check for any external / internal damages of the During commissioning any modification suggested by the
package. technician should be performed before the compressor is
ready for regular use. Else, Warranty become void if not
b. Monger the main motor and fan motor should be
done. In case of change of operator other than the person
mongered to find the winding insulation conditions if the
trained, the new operator should be trained before he is
compressor is not commissioned for more than 1 year
dedicated for operating the compressor.
c. Re-grease the main motor to be carried out if the
compressor is not commissioned for more than 1- ½
years (18 Months)

Installation and operation 5.7

5.1.10 Oil fill procedure Fill oil in the oil tank up to over fill cap
Initial oil fill procedure
Check whether your compressor comes with the oil filled.
Close the oil filling plug

Run the compressor for 10 minutes,

until the thermostatic valve opens

OIL FILLING PORT Stop the compressor

OIL LEVEL INDICATOR

Unscrew the oil fill plug by 3 turns only

so that any entrapped air inside the
tank will bleed out it. By doing this the
sump pressure drops to atmospheric
pressure before opening the oil fill plug

Figure 9. Oil filling and oil level indicator location on

air oil seperator tank

This can be checked through the oil sight float gauge on If required fill the oil by reading the oil
float gauge
the air oil separator tank. If not, follow the oil filling
procedure given below.

How to read oil level?

Close the oil fill plug
 When level
indication is in start
of red zone as shown Start the compressor
in figure start filling
of oil (Oil less alarm
Sl. Volume
region) Model
No. of oil required (gal)
 Fill the oil up to this black line (black line in the green
region) (Oil Fill limit region) 1 Airend 102 2.4

When to read oil level?

2 Airend 159 /159S 2.6
Following sequence to be followed before reading the oil
level in separator tank
NOTE
a) Switch off the machine in load condition
Refill oil in the tank if the level falls below the minimum
b) Wait for 3 mins to allow the oil drain back to separator level.
tank

c) Read the oil level as mentioned above

Oil level check

 The float gauge indication should be shown as “green”
after fumes settle down after shutdown.

Installation and operation 5.8

 5.2 Preservation for long idle storage

If your compressor is going to remain unused for six  Remove the entire tank from the compressor after
months or longer, special measures must be undertaken to disconnecting it from all hoses, the tank top plate, the
ensure the protection of the following components: minimum pressure valve outlet line, and control pulse
lines and control switches.
 Airend
 Clean the tank using ELGi compressor clean flushing oil.
 Motors
 Check the air-oil separator tank.
 Air–oil separator tank
 Replace the oil filter element before you use the com-
 Rubber hoses
pressor.
5.2.1 Airend  Replace the air filter element similarly.
To prepare the airend for 6-month storage:  Flush the tank, airend with compressor oil and replace
 Remove the airend discharge hose/pipe coupling. the separator element before using the compressor
again.
 Rotate the drive coupling three times so that the oil
present inside the airend comes out through the 5.2.4 Rubber hoses
discharge port.

 Block the discharge port completely. Test recommendations for rubber hoses

 Remove the inlet rubber duct connected to the intake Age Recommendations
valve of the air filter assembly.
Up to 3
Use without further testing.
 Turn the intake valve flap and pour rust preventive oil years
(use Castrol DWX 32 or an equivalent grade) into the
Use after representative samples are
airend through the intake valve. 3 to 5 years
subjected to proof-pressure test.
 Rotate the coupling five times by hand so that the rust
Use after representative samples are
preventive oil spreads all over the bearings, seals and subjected to proof, impulse, and burst
5 to 8 years
other parts of the airend. pressure tests, and cold bend and
electrical tests.
 Drain the rust-preventive oil by opening the discharge
port plug fully. Over 8 years Scrap.
 Refit the hose/pipe coupling on the discharge port.

 Take care to ensure that all the openings are plugged

always to avoid dust entry.

 Rotate the compressor shaft once in 7 days and ensure

free rotation.

 This procedure protects the airend for up to six months

storage. It must be repeated every six months during
storage.

 For more details contact ELGi office or ELGi’s distributer

network.

5.2.2 Motor
 To prepare the motor for 1-year storage: Check the
insulation of the motor winding.

 Remove any moisture in the motor.

 Check junction box terminals for tightness of wires.

 Apply grease on the motor bearings.

 This procedure will protect the motor for up to one year

storage.

5.2.3 Air-oil separator tank

To prepare the airend for 2-year storage:

 Drain the oil from the seperator tank.

Installation and operation 5.9

 5.3 Operating instructions

5.3.3 Daily start checks

Please adhere to the safety instructions provided at the Before using the compressor every day, you must prepare
section 2.3.2 : precautions during operations it by performing these tasks:

 Check whether the oil level in the tank is up to the

5.3.1 Initial start-up checks
specified level. If not, top up oil as per the oil fill
 Check whether the oil level in the tank is up to the
procedure given in the maintenance section.
specified level. If not, top up oil as per the oil fill
procedure given in the maintenance section.  Open all doors and visually check the compressor for
abnormality. Make sure all connections are tight.
 Open all doors and visually check the compressor for
abnormality. Make sure all connections are tight.  Refer to section 6.1.1 for how to perform daily
maintenance activities.
 Open the electrical panel door of the compressor and
check that the three phases and earth cables are 5.3.4 Starting
connected securely. (L1, L2, L3, and PE wires.) To prepare to start the system, perform these tasks:
 Check the necessary earthing line in the panel/  Turn on power.
compressor base.  If all inputs from contact switches, pressure and
 Ensure that all condensate drains are connected temperature transducers are normal, the display will
properly. indicate "READY''.

 For water cooled compressors, ensure that the water  Open the air discharge valve.
inlet and outlet valves are opened. Also make sure that  Press the ''START'' (green) button on the controller.
the inlet and outlet water drain valves are closed.
 Machines with an automatic star-delta starter will have
5.3.2 Initial start-up 6 seconds changeover time from star to delta and
Turn on power, open the air outlet ball valve and press the another 10-seconds delta-to-run delay.
start button (Green). The direction of rotation of motor for
5.3.5 During running
gear driven airend is clockwise (C.W.) whereas in case of
 To ensure seamless running:
direct driven airend direction of rotation is counter
clockwise (C.C.W.) from motor cowling side (non-driving  Monitor the controller display and control panel
side). The correct direction of rotation is also shown on the indicators regularly when the compressor is running.
motor. Ensure correct direction of rotation. if not, stop the  Graphic warning display: This gives graphically the
compressor by pressing the stop button (Red) on the location of fault.
control panel. Open the isolating switch and reverse the
 Discharge temperature sensor & warning: It is fixed on
appropriate lines.
the air-oil discharge pipe. It senses the temperature of
the discharge air-oil mixture. The compressor will
shutdown automatically and the warning light on the
Running the compressor in the wrong direction for more
than 5 seconds will cause damage to compressor parts or controller will glows when the discharge temperature
even cause total damage. exceeds the preset value of 110 ± 5ºC (230 ± 9ºF).
Graphic
warning
display

C.W
C.C.W

Gear models Figure 20 Human machine interface

11kW - All pressures
15kW - 10,13 bar  Separator element warning: Indicates that the
18.5kW - 13 bar separator element needs to be replaced. The
22kW - 13 bar

Installation and operation 5.10

 compressor will not shutdown automatically in this  If any possibility of freezing exists, drain the cooling
situation. system completely.
 Oil filter warning: Indicates that the oil filter element
needs to be replaced. The compressor will not
 Isolate the power supply before the discharge ball valve
shutdown automatically in this situation.
closes.
 High discharge temperature warning: The compressor  Do not use the emergency stop switch for normal stop-
will shutdown automatically and the warning light on ping.
the controller will glows when discharge temperature
exceeds the preset value of 110 ± 5ºC (230 ± 9ºF). 5.3.7 Changing the compressor
 Main motor overload trip: The compressor will settings
shutdown when the main motor is overloaded and the Change the compressor settings using the tactile keypad
corresponding warning light will glow. and LCD panel on the controller. (Refer to Neuron manual
to learn more about control panel and how interpret the
 Fan motor overload trip: The fan motor has internal
message.)
thermal overload protection, which safeguards the fan
motor. If the fan motor trips, discharge oil temperature Refer the VFD setting procedure manual for VFD
will be high and the compressor will trip. operations.

 Reset button: This button must be pressed before

restarting the compressor after it has shutdown with a
warning. The machine must be restarted only after
taking necessary remedial measures.

 Pressure relief valve: This valve relieves the pressure

in the air-oil separator tank when it exceeds 14.5 bar.
g (210 psi.g)

 Reverse direction switch: If the motor rotates in the

wrong direction, the reverse direction switch detects
and, in turn, trips off the compressor.

 After reaching the maximum cutoff pressure the

pressure sensor senses the pressure and cuts off the
solenoid electrical supply.

Cutout pressure
Model Type
bar
Standard, Working pressure +
EG 11 - EG 45
Standard +VFD 0.5
Standard, Working pressure +
EG 55 - EG 75
Standard +VFD 1
Working pressure +
Standard
1
EG 90 - EG 160
Working pressure +
Standard +VFD
0.5

5.3.6 Stopping
 Press the stop (Red) button in the controller. The
compressor will come to a halt within 10 seconds.

 In case of emergency, to stop the compressor use the

emergency stop switch. Correct the fault, rotate
counter clockwise, and unlock the emergency switch.
Then press the reset button before the next start.

 Do not use the emergency stop switch for normal

stopping.

 Close the air discharge valve.

 For water cooled models, close the water inlet valve.

Installation and operation 5.11

 6.0 Maintenance

Contents Page No.

6.1. Maintenance 6.2
6.1.1 Maintenance intervals 6.2

6.1.2 Maintenance of individual components & systems 6.3

6.1.2.1 Pre filter 6.3

6.1.2.2 Air filter 6.3

6.1.2.3 Air oil Separator 6.4

6.1.2.4 Oil top up and oil changeover 6.4

6.1.2.5 Oil filter 6.6

6.1.2.6 Intake valve 6.6

6.1.2.7 Minimum pressure valve 6.9

6.1.2.8 Thermal valve 6.10

6.1.2.9 Electrical motor greasing 6.10

6.1.2.10 After and oil coolers 6.10

6.1.2.11 Cooler and motor suction prefilter 6.11

6.1.2.12 Drive coupling 6.11

6.1.2.13 Moisture separator and auto drain valve 6.12

6.1.2.14 Oil strainer 6.13

6.1.2.15 Anti Vibration Mount 6.13

6.1.3 Use only genuine spare parts 6.13

6.2. Troubleshooting 6.14

6.3. Decommissioning, dismantling & putting out of service 6.19
6.3.1 Waste disposal 6.19

6.3.2 Dismantling the compressor 6.19

6.3.3 Decommissioning the compressor 6.19

6.3.4 Disposal of consumables and replaced parts 6.19

6.4. ELGi services 6.20

6.4.1 ELGi customer care system (ECCS) 6.20

6.4.2 ELGi genuine spare parts 6.20

6.4.3 Air audit 6.20

6.5. Appendix 6.22

6.5.1 Conversion tables 6.22

6.5.2 Torque values 6.23

6.5.3 Service log book 6.24

6.6. Disclaimers 6.26

Maintenance 6.1
 6.1 Maintenance

6.1.1 Maintenance intervals

Frequency Part Remarks
Oil level Check
MOS condensate Check
Daily
Warning / alarms Check
Condensate in AOS tank Check
Pre filter ( air intake, cooler, control panel) Clean
Weekly
Air filter element Clean *
Pre filter Clean
1000 hours or 3 months #
Moisture drain Clean
Oil & after coolers - air cooled (External) Check & Clean
Oil filter Replace
2000 hours or 6 months #
Oil Sampling **
50 Hz motor - 2 pole grease Replace
Pre filter (air intake, control panel) Replace
Air filter element Replace
Oil – Air lube XD / Air lube FG Replace
# Air-oil separator element – Air lube XD / Air lube FG Replace
4000 hours or every year
50 Hz motor ( 4 pole ) grease Replace
60 Hz motor ( > 25HP ) grease Replace
Return line sight glass / orifice / NRV Check & Clean
Return line strainer Check & Clean
Air-oil separator element - UT Synthetic Replace
Oil - UT Synthetic Replace
60 Hz motor ( ≤ 25HP ) grease Replace
Electrical connections Check
Drive coupling element Replace
Pipe coupling element Replace
Intake valve kit Replace
Actuator kit Replace
8000 hours or every 2 years # MPV kit Replace
BDV kit Replace
Solenoid valve Replace
Safety valve Replace
MOS-ADV kit Replace
Thermal Valve Kit Check & Replace
Tubes and Fittings Kit Replace
Blow down adjustment kit Check & Replace
Oil & after coolers - water cooled (External) Check & Clean
# - Whichever comes first * - As per air filter clog indicator ** - For USA/CANADA region only

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
Sl. No. Motor make Grease Part Number
Precautions 1 ELGi
EM UNIREX N3 015404151
2 SIEMENS
A. If the compressor is kept idle
3 WEG EM POLYREX N2 015404152
 Close the main air outlet valve.
Table 7. Electric motor grease
 Drain the water from the condensate system.

 Close the inlet and outlet water valve. (applicable only

for water cooled compressors)

B. If the compressor is kept idle for more than 6

months

 Follow the above steps.

 Refer to the section “Preservation for long idle storage”.

Maintenance 6.2
 Suction pre-filter cartridge removal procedure

1. Slide Upward
Disconnect all the power at the source before you attempt
to perform the maintenance or adjustment. Hold the pre-filter between the
louvers and slide upwards slightly
6.1.2 Maintenance of individual until the pre-filter bottom edge is
components and systems visible

Check all accessories independently to verify that they are 2. Slide Downward
functioning as required and replace their components as When the pre-filter bottom edge is
necessary. visible, slant the pre-filter forward and
slide it downwards away from the
6.1.2.1 Pre filter
compressor.

3. Pull Forward

When the top and bottom edges of

the pre-filter are free from the main

unit, move the pre-filter forward to

PRE FILTER ELEMENT
remove completely.
PRE FILTER HOUSING
Suction pre filter cartridge insert
procedure.

For insert sequence procedure from 3-2-1

SLIDE UP AND
PULL FORWARD 6.1.2.2 Air filter
WORM CLAMP

AIR FILTER ASSY

Fig 11. Pre filter

Pre work

 Switch off the compressor and disconnect power supply

to the motor. AIR FILTER MOUNTING CLAMP

 Close the discharge end ball valve.

AIR FILTER MOUNTING BRACKET
 Release the air oil tank pressure and allow the tank to
cool for a few minutes.
Figure 12. Air filter
Requirements
If the air filter clog indicator shows a red color (meaning
 Compressed air, new pre-filter element (if needed) the blocked condition), then the air filter needs to be
Maintenance cleaned or replaced (if the stipulated life has elapsed).

 Switch off the machine Pre work

 Refer to the pre-filter cartridge removal & insert  Switch off the compressor and disconnect power supply
procedure. to the motor.

 Hold or fix the pre-filter assembly in the cleaning area.  Close the discharge end ball valve.

 Clean the pre-filter with compressed air at less than 2.5  Release the air oil tank pressure and allow it to cool for
bar.g (36.3 psi.g) from the reverse or back side of the few minutes.
pre filter cartridge. Requirements
 In case of major dust/dirt accumulation in the pre-filter  Compressed air, new filter element (if needed).
element, wash with clean water or light detergent.
Maintenance
 Do not use any acidic/alkaline chemicals for cleaning.
 Unlock the mounting clips provided on the filter
 Repeat this process based on dust conditions or at housing.
regular periodic intervals.
 Rotate and remove the filter element and remove it
carefully.
Maintenance 6.3
 Clean from the filter using moisture free compressed air wrench and rotate it counter clockwise, until it
at less than 2.5 bar.g (36.3 psi.g). completely unscrews

 Clean from the inside to outside.  Ensure the hex adapter stays in the separator head
during disassembly
 Remove the dust ejector from the filter housing cap and
clean it carefully.  Once the recommended life is over, replace it with a
new element.
 Show bright light from inner side of the filter element to
inspect for damage or holes that result in leaks. Light Assembly of new Separator
will emerge from the holes, indicating their locations. In  Ensure O-ring of the separator is damaged free.
case of damages replace the filter element.
 Clean the O-ring-seating surface with a clean cloth
 Inspect all rubber seals and their contact surfaces of the
 Apply a thin film of compressor oil on the mating
housing. Faulty rubber sealing must be replaced
surface of the O-ring.
immediately.
 Return the separator to its original position and rotate it
 Return the dust ejector back in correct (bottom)
by hand clockwise.
position.
 Ensure no oil leaks from the mating surface. In case of
 Return the filter element back in position, assemble the
leakage, check the O-ring.
filter housing cap such that the dust ejector settles in
bottom position, and lock the assembly using the  After tightening by hand, rotate it further for one and a
mounting clips. half times

 Inspect and tighten all air inlet connections prior to

NOTE
resuming operation (if necessary).
The air-oil separator tank is tested according to standards.
 Reset the air filter clog indicator. Regularly have inspections performed in conformity with
 If a clean element is to be stored for later use, it must local regulations.
be stored in a clean container.
6.1.2.4 Oil top up & oil change over
6.1.2.3 Air oil separator
Proper compressor maintenance and operation is crucial
REMOVE for the lubricant to function properly and last till its
estimated rated oil hours. The oil product shelf life is of
minimum 3 years and maximum 5 years. Products should
be kept properly sealed in the original container. Once the
AIR OIL SEPERATOR
seal is broken, the above stated life span of the product is
no longer applicable. Products should be stored in proper
storage warehouse that is away from direct sunlight and is
not exposed to weather elements like rain, typhoon and
snow storms. The products should also be stored away
from any heat source, high humidity, and moisture areas.
If drums are stacked on ground level, they should all be
stacked horizontally with the bung openings arranged at
the 3 and 9 o’clock position.

Figure 13. Air oil separator ELGi recommends that once the seal is broken, all
products be used immediately. ELGi does not encourage
Pre work reuse or recycling of any of these leftover fluids due to
 Switch off the compressor and disconnect power supply contamination hazard. ELGi will not warrant the quality of
to the motor. the product once the original seal is broken. Also ensure
that the oils are not mixed up between brands and types.
 Close the discharge end ball valve.
Please refer Material Safety Data Sheet (MSDS) for oil spill
 Release the air oil tank pressure and allow it to cool for
handling and disposal procedures.
few minutes.
Pre work
Requirements
 Switch off the compressor and disconnect the power
 Strap wrench, new separator element, clean cloth.
supply to the motor.
Maintenance
 Close the discharge end ball valve.
Disassembly of existing separator
 Release the air oil tank pressure and allow the tank
 Hold the separator outer shell by the removed strap cool for few minutes.

Maintenance 6.4
Requirements b. After 300 hours, send a sample** to ELGi for analysis.

 New oil, flushing fluid (if needed) c. It may take more than one charge of cleaner to
properly clean the system.
NOTE
 The compressor is filled with a particular oil, if you want **: Applicable only for USA/CANADA.
to change over to other types of oil, perform steps 1, 2
and 3. Step 3: Filling the oil
 If you want to change the oil but continue with the same
kind (same brand & type) perform steps 1 and 3 only. a. Add fresh oil; fill it up to the oil fill plug. (initial fill)
 Ensure that you drain at least 90% of oil capacity of the
compressor; if not the residual oil can contaminate new b. Close the oil fill plug
oil. c. Pour oil into airend through the intake valve after
 Ensure no oil spills on anti-vibration mount during
removing the air filter hose. Then restart the
maintenance.
compressor.

Maintenance d. Allow it to run for about 10 minutes.

Step 1: Draining e. Stop the compressor.

a. Remove drain plug from the bottom of the separator f. Unscrew the oil filling plug after 5 minutes so that
tank and drain out all oil. Drain oil while the compressor residual pressure in the tank is vented out through the
is warm. bleed hole in the oil fill plug.

b. Remove the pipe and drain plug from bottom of oil g. Refill the tank up to the oil fill plug. (second fill)
cooler. Then drain completely . h. Restart the compressor.
c. Disconnect all oil pipe work to the prevent oil from
being trapped. Then, drain completely.

d. Drain oil from the airend discharge pipe after

dismantling it.

e. Drain oil from the airend by hand rotation.

Step 2: Flushing (Only for oil change over)

For flushing clean/non-varnished machines, using

Mineral/PAO oils

a. Fill the compressor with the ELGi cleaner (use the same
compressor oil fill volume) and run the compressor. OIL FILLING PORT

b. After 500 hours of running, drain the cleaner.

OIL LEVEL INDICATOR
c. Send a sample** of the compressor oil to ELGi for oil
analysis after 300 hours. LOCK NUT

OR BONDED SEAL WASHER

BALL VALVE
a. Fill the compressor with new compressor oil through the
oil filling plug and run the machine as normal operation. DRAIN PLUG

New oil may not be able to run till its stated hours in
this case, depending upon the conditions.

b. Sample** the oil and send it to ELGi after 300 hours. Figure 14. Air oil separator tank– oil drain

NOTE
 The cleaner is not recommended to run longer than 500
hours.
 Change the oil filter and oil separator after oil change
over.

Polyglycols (PAG) and for varnished machines using

mineral oils, PAO or PAG or Dieter
OIL COOLER
a. Fill the compressor with ELGi cleaner (use the same
compressor oil fill volume) and run the machine for no OIL COOLER DRAIN PLUG
longer than 500 hours.
Figure 15. Cooler oil drain

Maintenance 6.5
6.1.2.5 Oil filter 6.1.2.6 Intake valve
The oil filter is fitted between the oil cooler and the airend
unit. The components of the oil filter assembly are shown
Valves should not be opened without releasing the
in the figure 15. This is a full flow filter with a pleated
pressure is applied.
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.
The maintenance of following parts (valves) demands
Pre work highly skilled authorized personnel. So, it is recommended
that an ELGi service engineer does the maintenance.
 Switch off the compressor and disconnect power supply
to the motor. Pre work:

 Close the discharge end ball valve.  Switch off the compressor and disconnect the power
supply to compressor.
 Release the air oil tank pressure and allow it to cool for
a few minutes.  Close the discharge end ball valve.

Requirements  Release the air pressure in separator tank and allow the
tank to cool for 10 mins.
 Strap wrench, new oil filter, and clean cloth, O-ring.
Requirements :
Maintenance
 Pressure gauge, Soft cloth, Grease, Liquid cleaner.
Disassembly of the existing oil filter :
 Refer periodic maintenance kit
 Isolate the machine from the service line, vent
separator tank pressure, and allow the tank to cool for  EIV 159:Intake valve kit EIV 159, BDV
few minutes. Assembly kit EIV 159, Tamper Cap kit EIV 159 ,
Actutator Kit EIV 159, Hoses and Fittings Kit .
 Hold the filter shell and rotate it counter clockwise using
the strap wrench.  EIV 102:Intake valve kit EIV 102, BDV
Assembly kit EIV 102, Tamper Cap kit EIV 102 ,
Actutator Kit EIV 102,Hoses and Fittings Kit.
REMOVE
Disassembly procedure:
 Remove the connections of intake valve

 Pulse line & blow down line connection

 Power supply to solenoid

OIL FILTER  Duct from air filter

NOTE
Below mentioned numbering procedure is documented for
EIV 159. Same procedure to be followed for EIV 102.
Ignore numberings that are unavailable in part list of EIV
Figure 16. Oil filter

Assembly of new oil filter :  Remove the intake valve from Air end.

 Ensure the O-ring of the filter is damage free.  Remove the Solenoid valve (26) & Hex nipple (37).

 Clean the seating surface with clean cotton  Remove quick fittings (19),(49),(52) & hoses (36)
(51A),(51 B).
 Apply a thin film of compressor oil on the mating
surface of the O-ring  Remove the Silencer (50).

 Return the filter to its original position and rotate it  Remove the BDV assembly from Top Housing(03).
clockwise manually. After tightening, rotate it further by  Remove O rings (27) & (45).
hand for one a half rotation
 Remove the Actuator block(34) from Bottom housing
 Ensure no oil leaks from the mating surface. (01).

NOTE  Remove the Throttle plate (09) from Throttle shaft (08)
Suspended particulate matter should be less than 150spm by disassembling screw(11) and spring washer(10)
to achieve the specified consumable life. Guarantee  Remove the Bush(8) and Sleeve (42) from top housing
become void compressor is operated above its intended
(03).
pressure.

Maintenance 6.6
 Figure 17. EIV 102 - 970300390-A970008

Sl. Sl.
Description Part number Qty Description Part number Qty
no no
2 O-RING ID74.0 X 2.0 991401220 1 27 O-RING ID11.6 X 1.8 990402410 1
4 SPRING CHECK VALVE IV102 970400050 1 28 SCR SOC HD CAP M5x40 000983050 2
5 PLUNGER IV102 970300100 1 31 SCREW GRUB M8X40 970400370 1
6 O RING 54.02 X 3.53 970400220 1 32 NUT;HEX;M8; ZYP 000948008 1
7 BUSH THROTTLE SHAFT 970400030 2 34 SUPPORT ACTUATOR IV102 970400070 1
13 SCR SOC HD CAP M6x35 000983067 1 35 FLOW CONTROL VALVE B013406760001 1
14 BALL JOINT MACHINED M5X0.8 B004900520003 1 36 TUBINGS 6MM 000920620 0.3
15 ACTUATOR PNEU. B011406760001 1 39 O-RING ID110.7 X 3.5 415400814 1
16 SCR SOC HD CAP M5x16 12.9 000983044 2 42 SLEEVE 102 970400280 2
17 BLOWDOWN BLOCK 970300170 1 43 NUT NYLOC M6 000948307 1
19 QF ELBOW 1/4BSP-DIA 6 000920624 1 45 O RING ID 12.5X1 970400400 1
26 SOL VALVE NC,24V50/60HZ B007300990017 1 47 TAMPER CAP EIV 970300680 1
Table 8. EIV 102 - 970300390

Maintenance 6.7
 Figure 18. EIV 159 - 970300430 -A970012

Sl.
Description Part number Qty Sl. no Description Part number Qty
no
2 O-RING ID122.0 X 3.6 415400655 1 32 NUT HEX M10 X 1 ZBP 000948013 1
4 SPRING CHECK VALVE IV159 970400040 1 34 SUPPORT ACTUATOR IV159 970400060 1
5 PLUNGER CHECK VALVE 970300690 1 35 FLOW CONTROL VALVE B013406760001 1
6 O-RING ID94.8 X 3.5 220410750 1 36 TUBINGS 6MM 000920620 1
7 BUSH THROTTLE SHAFT 970400030 2 39 O RING 190 ID X 3.55 970400010 1
13 SCR SOC HD CAP M6x35 12.9 000983067 1 42 SLEEVE 159 970400270 2
14 BALL JOINT MACHINED M5X0.8 B004900520003 1 43 NUT NYLOC M6 000948307 1
15 ACTUATOR PNEU. B011406760002 1 45 O RING ID 12.5X1 970400400 1
16 SCR SOC HD CAP M5x16 12.9 000983044 2 47 TAMPER CAP MPV 970300510 1
17 BLOWDOWN BLOCK 970300170 1 48 QUICK FITTINGS CONN 000920509 1
19 QF ELBOW 1/4BSP-DIA 6 000920624 1 49 QUICK FITTINGS ELBOW 000920609 1
26 SOLENOID VALVE NC,24V50/60HZ B007300990017 1 50 SILENCER SLIT TYPE 970300750 1
27 O-RING ID11.6 X 1.8 990402410 1 51 NYLON TYBE 10x8MM BLUE 000919244 0.12

28 SCR SOC HD CAP M5x40 12.9 000983050 2 52 UNION ELBOW DIA 10 B010501880007 1

31 M10 HEX SOCKET GRUB SCREW 970400160 1

Table 9. EIV 159 - 970300430-A970012

Maintenance 6.8
 Remove the Top Housing(03) from Bottom housing(01).  Start the compressor , run in unload mode and check
no load sump pressure is in the range of 1.2 to 1.6
 Remove the Plunger(05) and Spring(04) from Bottom
bar.g / 17.4 - 23.2 psi.g.
housing(01).
 If no load sump pressure is out of specification, follow
Maintenance
the below steps to adjust the no load sump pressure.
 Clean Bottom housing(01) bore dia, Plunger(5) sliding
area with liquid cleaner. Adjustment procedures as follows,

 Break & Remove the Tamper cap (47).

 Clean the pivot hole of Top housing (03) in which
throttle shaft rotates.  Loosen Nut (32) .

After cleaning replace all parts as per the kit drawing.  Adjust Blow down adjustment screw (31) to achieve no
load sump pressure.
NOTE
 Turn the screw clockwise to increase the no load
Refer GA drawing (EIV 102 - 970300390& EIV 159 - sump pressure
970300430,) for required torque values.
 Turn the screw anticlockwise to decrease the no
load sump pressure
Assemble the intake valve in the following
sequence:  Fasten the Nut (32), after attainment of desired no load
sump pressure
 Insert the Spring(04) and Plunger(05) in the Bottom
housing(01).  Apply Loctite & Assemble the new tamper cap(47).

 Assemble the Top Housing(03) and Bottom housing NOTE

(01).
After completion of intake valve assembly in package,
 Insert the Bush(8) and Sleeve (42) in top housing (03). ensure to verify the performance as per the product
specifications. Also ensure that there is no leak in control
 Assemble the Throttle plate (09) and Throttle shaft (08) system tubings and pipelines in the package.
with screw(11) and spring washer(10). Ensure the
engraving ”TOP” in throttle plate is facing the top side.
6.1.2.7 Minimum pressure valve
 Fasten the Actuator block(34) and corresponding
Pre work
actuator kit parts to Bottom housing(01) .
 Switch off the compressor and disconnect power supply
 Connect throttle shaft (08) and ball joint(14) with the
to the motor.
help of shaft connector(12). Press the throttle plate
against the housing (03) and fasten shaft connector(12)  Close the discharge end ball valve.
with bolt (13).  Release air oil tank pressure and allow the system to
 Assemble O rings (27) & (45). cool for a few minutes.

 Assemble the BDV assembly kit to Top Housing(03) with  Release the receiver tank and downstream pressure.
screw(28).

 Assemble quick fittings (19),(49),(52) & hoses (36)

(51A),(51 B). MPV

 Assemble the hex nipple(37) & Solenoid valve (26) .

 Assemble the intake valve on Air end. SEPERATOR BODY BLOCK

 Connect the below mentioned parts to intake valve

 Pulse line & BDV tube connection

 Power supply to solenoid

 Duct from air filter

No Load sump pressure adjustment:

Figure 19. Minimum pressure valve

No Load sump pressure adjustment should be carried out
by skilled ELGi service person only.
Requirements
 Assemble the pressure gauge to the air oil separator  New MPV kit, allen key, grease.
tank by removing the plug.

Maintenance 6.9
 6.1.2.9 Electric motor greasing
Pre work
 Extreme caution should be taken while removing the cap
or cover from the body because of the spring.  Switch off the compressor and disconnect power supply
to the motor.
 Over and under setting of the MPV can upset machine
performance  Close the discharge end ball valve.

 Release air oil tank pressure and allow the system to

Maintenance
cool for a few minutes.
MPV Replacement
Requirements
 Unscrew the four screws
 Recommended grease (refer table 7), cleaning cloth,
 Remove and replace the old MPV kit with a new one. grease gun.
 Grease the O-ring groove in the new MPV kit Procedure
 Assemble the MPV kit and reinstall the spring and cap.  Thoroughly clean the grease inlet fitting or plug. If the
 Tighten the bolts motor has a plug, remove the plug and clean the inlet.

 Adjust stud protrusion (6mm/0.236 inch) to achieve a  Remove the drain plug and wipe out any hardened
minimum pressure of 4.5 bar.g (65 psi.g) grease.

6.1.2.8 Thermal valve  Slowly pump the grease into the grease inlet until the
new grease comes out of the drain plug.
Pre work
 Start the motor and let it run for a minimum of one
 Switch off the compressor and disconnect power supply
hour to expel any excess grease from the drain opening
to the motor.
before re-installing the drain plug.
 Close the discharge end ball valve.
 Stop the motor and lock out the switch.
 Release air oil tank pressure and allow the tank to cool
 Re-install the drain plug.
for few minutes.
 Put the motor back in operation.

CIRCLIP 6.1.2.10 After and oil coolers

SEPARATOR BODY
BLOCK
PLUG Pre work

 Switch off the compressor and disconnect power supply

to the motor.
O-RING  Close the discharge end ball valve.
THERMAL VALVE ELEMENT  Release the air oil tank pressure and allow the system
PISTON
to cool for a few minutes.
SPRING
AFTER COOLER
Figure 20. Thermal valve

Requirements

 Pliers, screw driver, new thermal valve element, new O-

ring.

Procedure

Replacing thermal Valve

 Remove the circlip using a plier OIL COOLER

 Remove the thermal valve from the separator body OIL COOLER DRAIN PLUG

 Inspect and clean seating area in the housing Figure 21. Cooler external surface
 Fix a new thermal valve
Requirements
 Assemble the valve in its place and lock it by circlips.
 Pliers, allen keys.
 Remove the plug using an M6 screw.

Maintenance 6.10
PRE-FILTER ASSEMBLED CONDITION PRE-FILTER DISMANDLED CONDITION

PREFILTER
PREFILTER SS WIRE MESH
SS WIRE MESH

COMPRESSED AIR
PREFILTER SS WIRE MESH
PRE FILTER
SS WIRE MESH

Figure 22. Pre filter –SS Wire-mesh

 Repeat the process based on dust conditions or at
Maintenance
regular periodic intervals.
External surfaces
6.1.2.12 Drive coupling
 Open both the LH panel and cooler inspection cover.
Malfunctioning of the coupling element results in abnormal
 Use compressed air below 2.5 bar.g(36.3 psi.g) to
sound and excessive vibration.
clean the outer surface of the cooler.
Pre work
 Supply a jet of air in direction opposite to the cooling
airflow direction  Switch off the compressor and disconnect power supply
to the motor.
 After cleaning the outer surface of the cooler, properly
close the cooler with a cleaning plate and an LH panel.  Close the discharge end ball valve.

 Release the air oil tank pressure and allow the system
6.1.2.11 Cooler and motor suction
to cool for few minutes
prefilter
prefilter cleaning & maintenance instructions

 Lift upward & take out the cooler pre-filter assembly

from the compressor. HUB

 Hold the pre-filter assembly in the cleaning area.

ELEMENT
 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
HUB
prefilter.

 In case of major dust / dirt accumulation in the pre- Figure 23. Drive coupling
filter mesh, wash with clean water.
Requirements
 Do not use any acidic / alkaline chemicals for cleaning.
 Spanners, new coupling element.

Maintenance 6.11
Maintenance  Disconnect the pressure sensor line on top of the

Replacing the Coupling Element moisture separator

 Open the cooler side panel covers  Manually drain the condensate by using the manual
discharge plug located at the bottom of the auto drain
 Open the coupling guard from the adapter ring
assembly.
 Remove the three coupling screws and slid the coupling
 Remove the moisture separator from the machine
element on the shaft spline to free the coupling element
 Remove the bottom housing from the top housing.
 Replace the old coupling element with a new coupling
element  Remove the auto drain assembly from the bottom
housing.
 Tighten the coupling screws to the specified torque
Cleaning and replacement
 Assemble the coupling guard and cooler side panel
 Inspect the O-ring and replace it with new one in the
cover
kit, if necessary
 Inspect every three month to ensure screw stay tight.
 Clean the housing and all other inner parts
6.1.2.13 Moisture separator and auto
 Ensure the mating surfaces of the O-ring are clean and
drain valve free from foreign particles

 The auto drain assembly is not serviceable and must be

replaced with new one if not functioning
Moisture separator may be heavy. Caution should be taken
while removing it from the machine. Reassembly

 The vortex generator cone and the cyclone arrestor

Pre work need only to be tightened moderately by hand. Over-
 Switch off the machine and disconnect power supply to tightening may lead to failure or damage, ELGi assumes
the motor. no responsibility for failure or damage resulting from
such incorrect installation.
 Close the discharge end ball valve.
 Reassemble the auto drain assembly with the bottom
 Release the air oil tank pressure and allow the system
housing and the bottom housing with the top housing.
to cool for a few minutes.
 Reassemble the moisture separator in the machine and
Requirements
connect the pipe lines, pressure sensing line, and drain
 Spanner, screw driver, player, caustic soda. line
Maintenance  Restart the machine and check for any leaks at the
Dismantling joints. If leaks occur, stop machine and wait for sump
pressure to drop to atmospheric pressure.

CAP SCREW
PE WASHER

TOP HOUSING

O-RING HOUSING
VORTEX GENERATOR
O-RING (CONE) -VANE

VORTEX GENERATOR
-CONE

TIE ROD

MANUAL DISCHARGE
ARRESTOR
ARROW
DIRECTION

INLET FROM COOLER OUTLET

BOTTOM HOUSING

EXTERNAL AUTO
DRAIN

Figure 24. Moisture separator and auto drain valve

Maintenance 6.12
 Remove the O-ring as described above, and inspect and  Clean the filter using compressed air at less than 2.5
clean it bar (36.3 psi). The direction of cleaning must be from
outside to inside.
 Ensure that the mating surfaces are clean and refit the
O-ring  Assemble the strainer in separator body block.

6.1.2.14 Oil Strainer  Assemble the bonded seal washer to separator block

Pre work body.

 Close the discharge end ball valve.  Assemble the plug strainer and tighten.

 Switch off the machine and disconnect the power supply 6.1.2.15 Anti Vibration Mount
to the motor. Anti Vibration Mount should be replaced during major
 Release the air oil tank pressure and allow it to cool for overhaul of airend or motor. If no such situation, replace
few minutes. AVM every 5 years

NOTE 6.1.3 Use genuine spare parts

 Avoid damaging the housing when removing or It is very important to use genuine spare parts, to ensures
tightening the moisture separator. Do not use a pipe
that your compressor work as new for its lifetime.
wrench. If necessary, use a locking strap clamp/wrench
Spurious spares may seem less expensive initially, but
 Install the separator in a vertical upright position,
observing the correct direction of air they severely compromises on quality. Spurious parts will
prove cost-ineffective in the long run, and may even result
Requirements
in total damage of the machine or cause serious accidents.
 Spanner / adjustable wrench The table includes certain critical spurious parts. It is not
Maintenance an exhaustive list, and you are strongly advised to avoid
 Dismantle the plug strainer using the spanner. all other spurious spares that this table does not cover. Be
aware of the consequences of using spurious spares
 Remove the bonded seal washer from separator block
including but not limited to the ones described in the table.
body

 Take out the strainer mesh from the separator block

body.

Effect Spurious part Remarks

Due to dense filtration media, it creates in additional pressure drop and so causes
Higher power Air oil separator additional power consumption. Every1 bar (14.5 psi) of pressure drop results in ~7%
consumption additional power consumption.
Spurious oil loses its properties soon and may get solidified causing the rotor to
Lubricant
malfunction.
This imposes 10% additional resistance for air flow and creates more pressure drop
and thus additional load on motor. Inadequate separation deteriorates air quality,
Air oil separator
reduce the performance, and damages downstream components. It also results in
huge oil loss (1L / 200hr).
Reduced
performance Contaminants are not filtered properly and the contaminated oil affects the critical
parts of airend. Thus it reduces performance and life (33% reduction) of the air end,
Oil filter
air oil separator etc. Contaminated oil also cause clogging and reduces the cooler
performance.
Dust carries over to the system and causes the same problems as caused by the
Air filter
spurious oil filter
Inadequate earthing can cause a separator to collapse (25% risk). Inadequate
Safety hazard Air oil separator
earthing can also cause fire and destroy the entire machine.
Higher power consumption means a higher operating cost.

Reduced performance leads to extra functioning and operating cost.

Cost Spurious parts will damage the other components and accelerate maintenance
frequency and cost.
Higher consumption of consumables like oil (due to the use of spurious parts) will
result in, increased cost.

Maintenance 6.13
 6.2 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.

Problem Cause Solution (go sequentially)

Power supply not available Restore incoming power supply

(1) Correct the incoming voltage.

(2) Ensure isolator is within 5m (16 ft) from the compressor.

Incoming voltage is below limit
(3) Ensure sufficient power back up

(4) Select and use the correct cable size.

Emergency stop switch in pushed

Rotate counterclockwise direction and release
condition

Clean or replace the emergency switch.

Emergency stop switch malfunction
Tighten the wires at terminals

(1) Select correct fuse rating from selection chart.

(2) Check and correct the short circuit within the control
panel.
Isolator fuse blown.
(3) Dedicated isolator to be provided to the compressor.

(4) Check and correct the motor winding/ body short after
megger test.

Correct incoming voltage.

Incoming phase-to-phase voltage
Adjust main incoming transformer tapping.
imbalance of more than 5V
Compressor not
Correct the power factor to less than unity.
starting
Incoming phase to earth voltage
Correct the incoming voltage.
imbalance of more than 5V

Control MCB malfunction Replace MCB

Check for any short circuit or loose connection.

Control fuses inside compressor Replace the solenoid valve / control transformer if defective.
control panel blown
Replace the glass fuse as per the drawing (for Neuron, for the
control circuit).

Replace the control transformer if defective.

Control transformer fuse blown Replace glass fuse as per the drawing (for Neuron, for the
control circuit).

(1) Replace control transformer fuses.

No power supply to Neuron (2) Ensure tight connection of the 24V power supply connector
controller. to Neuron

(3) Replace control transformer.

(1) Replace the control transformer.

(2) Replace the control fuse.

No display in Neuron controller
(3) If 24V power supply to Neuron is okay then replace with
anew Neuron micro controller.

Maintenance 6.14
 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
30°C (86°F)

Clean the cooler assembly / cooler pre filter mesh (if

available) externally by first using a fibre brush and then
blowing compressed air at 2.5 bar.g(36.3 psi.g).
Oil cooler clogged externally
For sticky dust, remove the cooler, close all the cooler ports

Install the cooler prefilter mesh.

Check and correct the wiring connection to the cooling fan.

Cooling fan rotating in wrong
direction.
Replace with correct fan type.

Replace the fuse if blown.

Check fan motor fuse
Replace with the 2A fuse.

Cooling fan not working. Check and ensure the neutral connection is connected.

High discharge Replace the sensor.

oil temperature Temperature sensor malfunction
Tighten/recrimp the connection with adaptor.

Replace oil filter.

Oil filter clogged
If required replace the oil (based on the condition of oil) and

Thermal valve malfunctioning Replace the thermal valve element.

Clean the oil injection orifice.

Oil injection orifice chocked or
improper size
Replace with correct size.

Air filter clogged Clean or replace the air filter

Check pressure drop is less than 1bar (14.5 psi).

Separator element clogged Replace oil.

Replace separator element.

Poor quality of oil Replace oil.

Check for pressure drop across the oil cooler if less than 1.5

Check and clean the cooler internally with 20L of isopropyl

Oil cooler clogged internally alcohol + toluene mixture in the 1:1 ratio and circulate for 4
hours with external 1 HP pump.

Refit the cleaned cooler and, if required, replace oil (based on

Maintenance 6.15
 Problem Cause Solution (go sequentially)

Drain excess oil and maintain the recommended oil

High oil level
level.

Oil is milky Replace oil and maintain the recommended level.

1) Remove the return line NRV/orifice and clean it

Scavenge return line non return valve thoroughly.
(NRV)/ orifice clogged
2) Change/clean the air filter.

Remove and clean the clogged scavenge return line

Scavenge return line tube clogged
tube.

Scavenge return line tube gap not Remove the return line tube from
maintained (not applicable EG11 to EG22) the separator and correct it.

The spin-on separator internal pipe thread

Replace the internal pipe.
damaged (applicable to EN series)

High oil carry over High discharge oil temperature (DOT) Refer to the diagnosis procedure for high DOT.

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.
(not applicable to EG11 to EG22 units)

1) Use suitable higher capacity compressor or match

Compressor runs at lower pressure than demand to compressor capacity.
normal pressure.
2) Arrest all line leakages.

Minimum pressure valve (MPV) opening

earlier than at the specified opening
pressure* 4.5 bar.g (65.26psi.g). Replace MPV kit/assembly.
* 3.5 bar.g ( 50.8 psi.g) for compressors
with working pressure 4.5 bar.g

Neuron microcontroller pressure settings:

1) Unload pressure set value is above Check and correct the unload pressure and high tank
specification. pressure values in Neuron micro-controller
2) High tank pressure set value is below

1) Check and replace intake valve kit if required.

2) Check the solenoid valve and clean or replace if

Intake valve malfunction
required.

3) Check and replace the actuator kit if required.

BDV malfunction Check/replace

High tank pressure
Compressor started with air outlet ball
Open the outlet ball valve.
valve closed

Solenoid valve malfunction Check the solenoid valve and clean or replace if

Neuron microcontroller malfunction Replace the Neuron microcontroller

Pressure transmitter malfunction Replace the pressure transmitter

MPV stuck up (check with pressure gauge in

Replace the MPV kit.
AOS tank )

Separator element choked Replace the separator element

Maintenance 6.16
 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.

1. Clean or change BDV assembly.

Blow-down valve malfunctioning
2. Clean the orifice.

1. Check and change the MPV kit.

MPV malfunctioning
2. Check and change the MPV assembly

1. Check and reset the pressure regulator setting to

Pressure regulator (applicable only to EG 55
working pressure+0.3 bar (4.35 psi).
to EG 250) setting lower than working

Loading/unloading pressure 2. Change the pressure regulator assembly.

Problem
Actuator failure Check and change the actuator / kit / assy.

1. Air requirement is more than compressor

capacity

2. Working pressure is lower than required 1. Replace the compressor

application pressure. 2. Arrest all pipeline leakages.

3. Excess pressure drop in pipe line.

1. Tighten the lap cable

2. Replace the lap cable

Pressure transmitter malfunction
3. Replace the pressure transmitter

4. Replace the Neuron microcontroller

Malfunction of R04 relay (loading/ unloading

Replace the Neuron microcontroller
relay) in Neuron microcontroller

Unload mode enabled in Neuron Disable 'unload mode' in operator settings of the
microcontroller Neuron microcontroller

Maintenance 6.17
 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.

Clogged air filter element Clean/change air filter element.

1. Air requirement is more than compressor

capacity

2. Working pressure is lower than required 1. Replace compressor

application pressure. 2. Arrest all pipeline leakages.

3. Excess pressure drop in pipe line.

No control air supply to solenoid valve. Replace / connect the control line tubes.

1. Replace the solenoid valve assembly

Solenoid valve malfunctioning
2. Clean the orifice
Pressure not built
up No electrical control supply to solenoid valve Replace the microcontroller

Intake valve malfunctioning Check and replace intake valve kit.

1. Check and change the BDV assembly.

Blow down valve malfunctioning
2. Clean the orifice.

1. Check and change the MPV kit.

MPV malfunctioning
2. Check and change the MPV assembly

1. Check and reset pressure regulator setting

Pressure regulator (applicable only to EG 55
to working pressure+0.3bar (4.35 psi).
to EG 250) setting lower than working
pressure 2. Change pressure regulator assembly.

Actuator failure Check/change actuator / kit / assembly.

Replace separator element. If required, replace the

Separator element choked (increase in
oil (based on condition of the oil) and run the
pressure drop across separator)
compressor.

Maintenance 6.18
 6.3 Decommissioning, dismantling and
putting out of service

If you do not intend to use the compressor or any of its 6.3.4 Disposal of consumables and
parts, you must dismantle and putting out of service. replaced parts
These tasks must be carried out in compliance with the
standards in force of that particular country.  The moisture condensate separated from the
compressed air contains oil particles. Disposal of
6.3.1 Waste disposal condensate and filter element is to be done in
 Use of compressor generates waste. The residues from accordance with the pollution control norms prevailing
agricultural, industrial, crafts, commercial and service at the time of compressor installation or use.
activities must be treated as waste, which needs to be  Parts of the compressor that are replaced have metal
disposed off properly. Deteriorated or obsolete and rubber components. These may be recycled and
machines are also classified as waste. disposed of according to pollution control regulations,
 Special attention must be given to active carbon filters respectively.
as they cannot be included in urban waste. Observe the  Rubber items such as AVMs, coupling elements, and O-
waste disposal laws in force where the compressor is rings should be disposed and replaced before running
used. again.
 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. of the foregoing in accordance with local environmental
statutory laws.
 It is especially important that exhausted oils be
disposed off in compliance with the laws in the countries
of use.
The compressor does not give any warnings during short
operating times. If it is operated below the dew point and
6.3.2 Dismantling the compressor
moisture condensate may mix with oil. This will reduce the
 Dismantle the compressor in accordance with all the lubricating quality of the oil and lead to damage of
compressor.
precautions imposed by the laws in force in the country
of use.

 Before dismantling, request an inspection by the

relevant authorities. Disconnect the compressor from
the electrical system.

 Eliminate any interfaces the compressor may have with

other machines, making sure that interfaces between
remaining machines are unaffected.

 Empty the air oil tank containing the lubricating oil and
store in compliance with the laws in force.

 Proceed with the disassembly of the individual

compressor components and group them together
according to the materials they are made of: Steel,
Stainless Steel, Aluminium and plastic parts.

 Then scrap the machine in compliance with the laws in

force of the country of use.

6.3.3 Decommissioning the compressor

 Remove the foundation for the compressor.

 Unplug the power cable entry to the compressor.

 Drain the oil from the cooler and air oil tank. Dispose of
it properly.

 Make sure all the compressed air is vented out through

ball valves and safety devices residing in the
compressor.

 Ensure that all the external supply lines have been

properly disconnected from the compressor before
decommissioning.

Maintenance 6.19
 6.4 ELGi Services

6.4.1 ELGi customer care system (ELGi  Southern Region: Tamil Nadu, Karnataka, Kerala,
Puducherry, Andhra Pradesh, Telangana, Andaman &
CCS)
Nicobar Islands.
ELGi provides dedicated customer care and after-sales
 Western Region: Maharashtra, Gujarat, Madhya
support through the ELGi customer care system (CCS), a
Pradesh, Goa, Lakshadweep Islands.
computerized system developed in-house. The CCS aims
to minimize the time taken to resolve customer  Eastern Region: Orissa, Chhattisgarh, Jharkhand,
complaints. West Bengal, Bihar and the North-Eastern states.

Service requests/complaints  Northern Region: Rajasthan, Uttar Pradesh, Delhi,

Haryana, Punjab, Uttaranchal, Himachal and Jammu &
The CCS toll-free telephone number 1800-425-3544
Kashmir.
(accessible within India through BSNL and MTNL lines)
patches the customer’s call to our centralized customer Contact Numbers: You can contact CCS also with the
care center in Coimbatore. Customers can register their following numbers:
service requirements or complaints here. Telephone: 0422-2589206 / 241 / 242 / 243/ 244 / 245 /
A unique tracking number is generated for each call logged 97900 21100
by the CCS. The customer receives an automatic e-mail Fax: 0422-2589240
acknowledgement with the tracking number and details of
Please send the following details to the mail, thus enable
the call for reference.
us to take immediate action.
A service engineer is assigned to the call, and the date and
1. Name of the customer
time of the engineer’s visit are communicated to the
customer by e-mail. Every requirement or complaint must 2. Compressor model

be resolved and closed in the CCS within a specified time 3. Fab. number
limit, failing which the complaint is automatically brought
4. Contact person name
to the notice of the manager. If the issue remains
unresolved, it will get escalated to the managing director. 5. Phone number

The CCS ensures that not only the customer complaints 6. Nature of complaint
are logged but they are also attended to on time, every 7. Hour meter reading
time.
You may use the CCS by sending e-mail to: [email protected]
Enquiries
Customer satisfaction survey
A number of calls received by the CCS relate to customer
If you have used the CCS, you may be contacted for your
queries regarding products and spare parts. The details
feedback on our after-sales support. Your response helps
are noted, and basic information on product specifications
ELGi to improve.
and usage is provided. The caller is then referred to a
salesperson at the head office or the appropriate branch International customers:
for follow-up. Refer contact information at the end of this manual book.
The CCS database
6.4.2 ELGi genuine spare parts
The CCS also creates a database of customers, adding
When ordering spare parts, refer to the lists provided in
details of every new customer who calls, thereby building
the parts manual and identify the part number. Specify the
a large pool of installation details. These details are used
part number and quantity, in addition to the name plate
to provide value-added services to improve customer
details. Global support center of ELGi ensures the supply
satisfaction with ELGi products.
of the quality spares on time. Ensure that you are using
CCS-working hours the genuine spare parts so that your Compressor will be
The ELGi CCS works for six days a week from 08:30 to working efficiently and effectively. Refer to section 6.1.3
21:30 IST (Monday to Saturday). for details on need of using genuine spares.

Multi-lingual capability Please contact our After sales team for any compressor
accessory requirements like VFD, Air-Dryer, etc.
The coordinators at the CCS are multi-lingual. They can
handle calls in English and all the major regional 6.4.3 Air audit
languages of India.
We extend our proven capabilities in energy efficiency
Coverage: The CCS toll-free number 1800-425-3544 is initiatives by carrying out air audits for our customers.
accessible from the following areas:
ELGi conducts audits and trains end users in key energy
oriented functional areas. The audit reports prepared by
ELGi experts’ team include recommendations on short,

Maintenance 6.20
medium and long term measures for energy conservation,
along with financial estimates and analysis for
implementation.

This air audit objective is to provide the customer with :

 The framework for systematic collection of data relevant

to the efficient operation of compressed air systems.

 A thorough analysis about the performance of the

compressed air system, identifying potential electricity
savings and to provide sound recommendations for
implementation of energy efficiency initiatives.

Data analysis will be comprised of the information about

different areas such as air leakages, inappropriate use of
compressed air, compressed air system network,
compressed air system supply including compressor
internal maintenance conditions and even more.

The final report issued to the customer end will serve

the purpose of assisting concise, consistent and complete
presentation of the analysis, findings and recommendations
arising from a compressed air system audit.

Depending on the measurement, reporting and cost

requirements from the customer end, the intensity in level
of audit (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: [email protected]

Maintenance 6.21
 6.5 Appendix

6.5.1 Conversion tables

Description From To 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

Area (A) Square feet Square inches 144

Square inches Square millimetres 645.16

Cubic metres Cubic feet 35.315

Cubic feet Cubic inches 1728

Cubic metres Litres 1000

Volume (V)
Cubic feet Litres 28.32

US gallons (liq) Litres 3.785

Imperial gallons (liq) Litres 4.546

3
Cubic feet per minute (cfm) Cubic metres per hour (m /h) 1.6988

Cubic feet per minute (cfm) lpm 28.32

Volumetric flow (Q)
Cubic metres per hour (m3/h) lpm 16.667
3
Cubic metres per minute (m /min) lps 16.667

Kilograms Pounds 2.205

Kilograms Grams 1000

Mass (M)
Kilograms Ounces 35.27
2
kg f/cm g psi g 14.223

psi g Pascal 6895

Pressure (P) bar g kg f/cm2 g 1.0197

bar g psi g 14.503

psi g kg f/cm2 g 0.0703

Degree Celsius (°C) Degree Fahrenheit (°F) °F = 9(°C)/5 +32

Temperature (T) Degree Celsius (°C) Kelvin (K) K = °C + 273.15

Degree Fahrenheit (°F) Degree Rankine (°R) °R = °F + 460

ft-lb f Joules 1.35582

ft-lb f Btu 0.001285

Heat (q), Work (W),
Joules Calories 0.2388
Energy (E)
Btu/h Calories/h 252

Kilowatts Btu/h 3411

Metric horsepower Kilowatts 0.7355

Power (P)
Imperial horsepower Kilowatts 0.7457

Table 8: Conversion table

Maintenance 6.22
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)

M4 2.9 2.13

M5 5.7 4.20

M6 9.8 7.22

M8 24 17.7

M10 47 34.66

M12 81 59.73

M16 197 145.28

M20 385 283.93

Table 9: Metric hexagonal head bolts and screws

Thread size (inches) Tightening torque (N-m) Tightening torque (lb-ft)

¼" 45 33.19

½" 85 62.69

¾" 170 125.38

1" 330 243.39

1¼" 430 317.15

1½" 510 376.15

Table 10: BSP threads

Thread size (inches) Tightening torque (N-m) Tightening torque (lb-ft)

9/16" 149 109.8875

7/8" 579 427.0125

Table 11: UNF threads

* Property class of 8.8 only

Maintenance 6.23
 Total Moisture Trip
Oil level Pre
operated Line System Discharge removal Cooler record Operator
Date From Till in AOS Filter Comments
hours / pressure pressure temperature from AOS cleaning descrip- sign
tank Cleaning
day tank tion

Maintenance
Low/
Start/Stop normal/ Before
Time high/ starting
change
6.5.3 Service log book – record of maintenance

6.24
 Total Moisture Trip
Oil level Pre
operated Line System Discharge removal Cooler record Operator
Date From Till in AOS Filter Comments
hours / pressure pressure temperature from AOS cleaning descrip- sign
tank Cleaning
day tank tion

Maintenance
Low/
Start/Stop normal/ Before
Time high/ starting
change

6.25
 6.6 Disclaimers

Please read this document and the warranty terms accompanying the product carefully before using our product.
By purchasing our product, you agree that you will assume total responsibility and risk for your use of the product.
The warranty terms of the product have been provided separately.

1. ELGi is not liable for failure of the compressor ( hereinafter “compressor” or “product”) to perform its obligations if such
failure is as a result of Acts of God (including but not limited to fire, flood, earthquake, storm, hurricane or other natural
disaster), war, invasion, act of foreign enemies, hostilities (regardless of whether war is declared), civil war, rebellion,
revolution, insurrection, military or usurped power or confiscation, terrorist activities, nationalization, government
sanction, blockage, embargo, labour dispute, strike, lockout or interruption or failure of electricity or telephone service
and any other reasons beyond ELGi’s control.

2. ELGi does not take responsibility for any damage or injury resulting from neglecting the safety instructions, warnings,
cautions, precautions, or non-observance of the normal caution and care required for installation, operation, maintenance
and repair of the product, even if not expressly stated, and such instances are specifically disclaimed by ELGi.

3. The entire literature including product description or any other information in this manual exclusively belongs to ELGi and
is subject to copyright. No person has any right to copy, modify, distribute, transmit, display, perform, reproduce, publish,
license, create derivative works, transfer or sell any information, or deal with the same in any other manner, without the
knowledge and written concurrence of ELGi, violation of which would amount to infringement of rights of ELGi and would
necessitate legal action.

4. The information published in this manual may include inaccuracies, or typographical errors. Changes may be periodically
added to the information herein. Any changes/improvements may also be made to the products stated in this manual and
ELGi is not liable if the readers are not updated with information.

5. Likewise ELGi is responsible only till the point of first sale to the ultimate customer and not thereafter and only if the
product is purchased from authorized dealers of ELGi. ELGi disowns liability on account of purchase of any second hand
product or purchase otherwise from unauthorized dealers. ELGi shall not be liable for any indirect, incidental, punitive,
special or consequential losses or damages including any loss of profit, loss of production, loss of income or contract, loss
of goodwill, expected savings or business relationships, arising out of or in any way connected with the usage of the
product or information in this manual.

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.

7. These Disclaimers and the contents of this manual shall be subject to the laws of India and any disputes pertaining to this
manual or anything stated therein or any product stated therein is subject to the exclusive jurisdiction of the courts in
Coimbatore, Tamil Nadu, India.

8. No liability in connection with the product will accrue to ELGi,

 If any welding or related operation involving heat is carried out in the compressor. Never weld or modify any parts
including pressure vessels.

 If any damages to the product directly or indirectly arise due to long storage (6 months) of product and subsequent
corrosion of internal parts and which leads to fire or malfunctioning of the product.

 If the compressor package and its accessories are installed in such a way to allow moisture, rain, freezing temperature or
sun damage to affect the safe operation of the unit.

 If the person who operates / maintains the compressor does not adhere to all work related safety practices and regulatory
requirements.

 If unauthorized personnel other than ELGi authorized or trained personnel carries out commissioning, installation,
operation, maintenance and any repair work on the compressor.

 If the compressor and the compressed air are used for unintended use or are misused.

 If the compressor is operated below or in excess of its pressure and temperature limits.

 If the compressor “ON/ OFF” switch is operated through remote control situated away from the compressor location
without giving any adequate notice / alarm before starting the product .

© Copyright ELGi Equipments Limited, India 2018. All Rights Reserved.

Maintenance 6.26
Controller Manual
Neuron III

Version 3.4
July 2019
 Contents Page No.
Abbreviations used 7.4
7.1. Technical specification 7.5
7.2. Installation instruction 7.7
7.2.1 Equipment’s safety 7.7

7.2.1.1 Static discharge warning 7.7

7.2.1.2 Assembly 7.7

7.2.1.3 Electrical connection 7.7

7.2.1.4 Power supply 7.7

7.2.2 General instruction 7.7

7.3. Display & terminal details 7.8

7.3.1 Terminal connection 7.8

7.4. Neuron-III salient features 7.9

7.4.1 Home screen display 7.9

7.4.2 Records (view-> day report and fault report) 7.9

7.4.3 Remote function (both MODBUS as well as digital input) 7.9

7.4.4 Lead and lag – pressure schedule (operator-> schedule) 7.9

7.4.5 Other interfaces and communication 7.9

7.4.6 Safeguard 7.9

7.4.7 Mimic LED for fault indicators 7.9

7.5. Input output description 7.10

7.5.1 X01: Power supply 7.10

7.5.2 X02: Digital inputs 7.10

7.5.3 X03: Analog input/output 7.10

7.5.4 X04: RS 485 communication 7.10

7.5.5 X05: Main motor relays 7.11

7.5.6 X06: Relays 7.11

7.5.7 X07: Relays 7.11

7.5.8 X08: 3 Phase input 7.11

7.6. Home screen 7.12

7.6.1 Important machine settings for users 7.14

7.7. Menu structure 7.16

7.7.1 Main menu 7.16

7.7.1.1 View 7.16

7.7.1.2 Operation 7.16

7.7.1.3 Fault report 7.17

7.7.1.4 Day report 7.17

Controller Manual 7.2

 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

7.7.3 Service 7.21

7.7.3.1 Calibration (offset) 7.22

7.7.3.2 Programmable relay 7.22

7.7.3.3 Temperature 7.22

7.7.3.4 Maintenance 7.22

7.7.3.5 Clock 7.22

7.7.3.6 Digital input 7.22

7.7.3.7 Dryer input 7.23

7.7.3.8 Latitude/Longitude 7.23

7.7.3.9 VFD model 7.23

7.7.4 Customer care 7.23

7.8. Data interface 7.24

7.8.1 Analog output 7.24

7.8.2 DCS port 7.24

7.9. Troubleshooting 7.25

7.10. Construction 7.26
7.10.1 Dimension drawing 7.26

7.11. Example – scheduler setting 7.27

7.12. Revision details 7.28
7.13. Neuron III quick reference 7.29

Controller Manual 7.3

 Abbreviations Used

Dis. Pressure Discharge pressure

Dis. Temperature Discharge temperature

HSP High sump pressure

Temp Temperature

DPAF Differential pressure air filter

DPOF Differential pressure oil filter

AF Air filter

OF Oil filter

Min Minimum

Max Maximum

VFD Variable frequency drive

AO Analog output

UL Unload

En Enable

Dis Disable

L Load

St Stop

F Fault

R Run

Sby Standby

STC Start count

LDC Load count

DD Date

MM Month

YY Year

Ph Fail Phase failure

Pr Pressure

Tr Temperature

DCS Distributed control system

PR Pressure

MMOL Main motor overload

OL Overload

NC Not connected

PS Pressure schedule

RST Restart time

DTR Delta to run

RTS Run to stop

I/O Input / Output

REM Remote

RTU Remote terminal unit

Controller Manual 7.4

 7.1 Technical specification

Definition : Pre-programmed logic controller

Function : Compressor control system & I/O monitoring

Part number : 018362618

Software : Embedded C

Rated voltage : 24VAC + 15% -20%

Power consumption : 10W (Max)

Ride through : 30ms

Graphic display : 2.9" Mono chrome graphics display

Display contrast : Adjustable using software

Protections : Low voltage

3 Phase detection : Phase loss / reverse at the time of pressing START key

Keypad : 11 key (Usage: up, down, right, left, enter, TAB, INFO, Esc, start, stop & reset) 11
LED (status, warnings and fault indication)

Language : English, French, Portuguese, Italian, Spanish

Enclosure material : ABS PC - Plastic

Dimensions : 280 X 190 X 90 mm

Mounting : Locking knob for panel tightening

Protection class : IP55 from front panel only

Operating temp : - 10°C ~ 50°C (14oF ~ 122oF)

Storage temp : -10 to 70°C (14oF ~ 158oF)

Relative humidity : <95% @ 50°C (122oF) without condensation

Certification : CE, UL

For Technical support/assistance contact ELGI Customer Care

E-mail: [email protected]

Digital inputs:
Number of channel : 8 Ports

Rated voltage : 24VDC

Usage Emergency stop, motor overload, cooler over load, motor reverse rotation, DPOF,
:
dryer warn/trip, remote start/stop, programmable DPAF/remote load/unload

Digital outputs:
Number of channel : 8 Ports

Rated voltage : 24VDC / 250VAC

Rated load : 10A @ 250VAC

Controller Manual 7.5

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.

Analog inputs:

Number of channel : 4

2 x 4-20mA inputs:

Range : 0 to16 bar (0 to 232 psi)

Resolution : 0.1bar (1 psi)

Accuracy : ± 0.1bar (1 psi)

Usage : Discharge pressure and sump pressure

2 x PT1000:

Range : -10 to150° C (14 to 302oF)for 1st channel

-10 to 200o C (14 to 392oF)for 2nd channel

Resolution : 1°C (2°F)

Accuracy : ±1°C (2°F)

Usage : Discharge temperature, dew point /motor winding temperature software selectable

Analog outputs:

Number of channel : 2

Range : 1 to 5V DC

Resolution : 1 mV

Accuracy : ±25 mV

Usage : Discharge pressure and discharge temperature

Communication ports:

Port 1 : RS485, MODBUS RTU (for DCS interface)

Port 2 : RS485, MODBUS RTU (for VFD parameter reading, analog input module)

Controller Manual 7.6

 7.2 Installation instruction

7.2.1. Equipment safety indicates damage, so that safe operation is not possible,
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. In order to
the cabinet, door, printed circuit board, and other
maintain this status through shipment and secure a safe
components for the possibility of shipping damage. It is
operation, consider the notes and warning notes this
recommended that the cabinet be stored in a clean dry
instruction manual covers. The device should be operated
area until mounting takes place.
by only trained personnel. Maintenance and repair should
be performed only by trained, technical personnel, familiar The signal cables and power cable should be separately
with the associated dangers. The device can be operated routed.
without compromising its security within the certified The protective earth connection in the panel must be
environment condition. connected to field earth only.
7.2.1.1. Static discharge warning Protection from direct sunlight

This equipment is sensitive to electrostatic discharge, Since the electronic circuits must not be subjected to
which can cause internal damage and affect normal uncontrolled temperatures, place the cabinet in shade.
operation. Follow these guidelines when you handle this Protection from rain
equipment:
Partial tightening of screws or doors allows water to enter
 Touch a grounded object to discharge potential static. the enclosure and cause irreparable damage to the
 Wear an approved grounding wrist-strap. circuitry. Provide canopy to avoid such damages.

 Do not touch connectors or pins on component boards. Do not install equipment on structures subject to
continuous vibration
 Do not touch circuit components inside the equipment.
Partially tightened wires or components in the cabinet
 Store the equipment in appropriate static-safe
disconnect during vibrations and cause irreparable damage
packaging when not in use.
to circuitry.
7.2.1.2. Assembly
The place of assembly has to correspond to the class of
protection. The ambient temperature in the installation
position may not exceed the admissible temperature for
the nominal use, specified in the data sheet. Not to use in
wet condition.

The devices should be installed only outside of explosion

hazardous areas!

7.2.1.3. Electrical connection

External connections are to be performed according to the
respective national rules. Switch off the device before
doing any wiring work. Do not connect or disconnect any
wire when the device is powered on and operating.

7.2.1.4. Power supply

It is to be ensured that supply voltage corresponds with
the specification on the type sign. If the device is switched
on with other devices and/or mechanisms, then the effects
have to be considered before switching and appropriate
precautions taken. Do not connect welding or such high
noise sources to the same line of controller supply.

7.2.2. General instruction

The following procedures and instructions should be
followed closely to avoid damage to the control panel and
its associated equipment. Reliability of the system depends
upon proper installation and maintenance.

The device is to be examined with feed and storage to rule

out damage from inappropriate handling. If the device

Controller Manual 7.7

 7.3 Display & terminal details

1 128x64 Graphical display

2 Navigation keys
3 Enter key
4 Start key
LED (green - start , red -
5
stop/fault )
6 Stop key
7 Reset key
Oil filter change indication
8
LED
Air oil separator change
9
indication LED
10 Cooler fault LED
Auto mode enabled
11
indication LED
12 High pressure fault LED
13 Main motor fault LED
14 Reverse rotation fault LED
Air filter change indication
15
LED
High discharge temperature
16
fault LED
17 Escape key
18 Tab key
19 Info key

7.3.1. Terminal connection

X01 - Power supply

X02 - Digital input (8 Channel)

X03 - Analog input (4 Channel) / output (2 Channel)

X04 - Communication ports (2 Ports)

X05 - Relay outputs (main, star, delta)

X06 - Relay outputs (3 Nos)

X07 - Relay outputs (2 Nos)

X08 - Phase monitoring

Controller Manual 7.8

 7.4 Neuron-III salient features

7.4.1. Home screen display  PC interface through MODBUS - To download reports

and setting parameters
 Easy user interface 8 line graphical display and intuitive
 70 + Modbus parameters for DCS controls
menu navigation keys
 Dryer integration
7.4.2. Records (view -> day report and
 High, Low dew point warnings
fault report)
 30 day reports (load hours, unload hours, run hours,
7.4.6. Safeguard
stop hours, fault hours, standby hours, start count, load  The 'Smart Logic' of NEURON III automatically decides
count) the start delay required to ensure minimum wait time

 99 fault reports between successive starts of the compressor and dryer

thereby increasing their lifetime.
 Faults with date and time stamp, status of the machine
at the time of fault etc.  Start Inhibit till sump pressure is within safe limits to
enhance the life of the compressor
7.4.3. Remote function (both from
 Low voltage & Short time Power interrupts detection to
MODBUS as well as digital input) enhance the life of the contactors
 Remote loading and unloading  Low temperature start inhibit to avoid start-up overloads
 Remote start and stop
7.4.7. Mimic LED for fault indications
7.4.4. Lead and Lag - Pressure
schedule (Operator -> schedule)
 32 pressure program (one schedule should be in
Sunday (first day of the week) 00:00 Hrs)

 Setting hours considered as 24hr format irrespective of

time format setting.

 Important parameters to customize - Day, On Time,

OFF Time, Load Pr, Unload Pr

7.4.5. Other interfaces and

communication
 VFD interface through MODBUS

LED Description
Continuous glow - to indicate the machine in auto power recovery mode.
Auto
LED blink - when the machine is going to start irrespective of any start mode.
Glows when
Air oil separator 1. Air oil separator service is due - based on service hours
2. Pressure drop in separator is more than set value (if sensor is fixed).
Main motor overload Glows when the main motor overload digital input is open.

rotation Glows when the reverse rotation digital input is closed.

Cooler O/L Glows when the cooler digital input is open

Glows when
1. Analog pressure input is open (probe failure)
Pressure
2. Discharge pressure is higher than set HSP
3. Sump. pressure is higher than set HSP (If sump pressure sensor is fixed)
Glows when the
Temperature 1. Analog Input is Open (Probe Failure)
2. Dis. Temperature is higher than set Trip temp.
Glows when the
Pressure
1. DPOF Digital input is open & DPOF is enabled
oil Filter (DPOF)
2. Oil filter service is due - based on service hours
Glows when the
pressure
1. DPAF digital input is open & DPAF is enabled
air filter (DPAF)
2. Air filter Service is due - based on service hours
1. Glows in red when machine is stopped / idle
Start & Stop
2. Glows in green when machine is running

Controller Manual 7.9

 7.5 Input output description

7.5.1 X01: Power supply

Pin Function Id state

1 24V AC Phase 24 VAC -

2 24V AC Neutral 24 VAC N -

3 24V Earth Earth -

7.5.2 X02: Digital inputs

Pin Function Id state

1 Digital Inputs common - 24VDC 24VDC -

2 Emergency stop Emergency Fault if open

3 Differential pressure oil filter DPOF Warn if open

4 Reverse rotation Rev. Rot Fault if closed

5 DPAF/REM load and unload DPAF/REM L/UL Warn or unload if open

6 Remote start stop control Remote Start /Stop Stop if open

7 Dryer warn/trip Dryer Warn/Trip Warn/Fault if open

8 Cooler motor overload Cooler OL Fault if open

9 Main motor overload MMOL Fault if open

7.5.3 X03: Analog input/output

Pin Function Id Range

1&3 24V DC discharge pressure 24V DC PR1 4 - 20mA 0 to 16 bar (0 to 232 psi)

2&4 24V DC sump pressure 24V DC PR2 4 - 20mA 0 to 16 bar (0 to 232 psi)

5&7 Discharge temperature T1-1 T1-2 PT1000 -10 to 150°C (14 to 302oF)

Dew point temperature / Ambient

6&8 T2-1 T2-2 PT1000 -10 to 200°C (14 to 392oF)
temperature/winding temperature

Dis. pressure output (0 to 16 bar/0 to

9 & 11 DAC1 GND Voltage 1~5V
232 psi) common ground

Dis. Temperature (-10 to 150oC / 14

10 & 12 DAC2 GND Voltage 1~5V
to 302oF) common ground

7.5.4 X04 : RS 485 Communication

Pin Function Id state

2 DCS interface A1 RS485 A Modbus RTU protocol

4 DCS interface B1 RS485 B

6 * VFD interface /AI module A2 RS485 A Modbus RTU protocol

8 * VFD interface /AI module B2 RS485 B

1 NC

3 NC

5 NC

7 NC

*If Dryer and VFD is enabled, AI module add-on will be used for dryer dew point

Controller Manual 7.10

7.5.5 X05: Main motor relays

Pin Function Id state

1 Common for main, star and delta contactors Common -

2 Main contactor Main Energized

3 Star contactor Star Energized

4 Delta contactor Delta Energized

7.5.6 X06 : Relays

Pin Function Id state

1 Common - load relay Common

Load when energized
2 Load relay L/UL

3 Common - fan relay Common

FAN ON when energized
4 Fan relay NO

5 Common - auto drain valve relay Common

ADV ON when energized
6 Auto drain valve relay NO

7.5.7 X07 : Relays

Pin Function Id state

1 Common - Programmable relay Common

Energized
2 Programmable relay NO

3 Common - Programmable relay Common

Energized
4 Programmable relay NO

7.5.8 X08: 3 Phase input

Pin Function Id Type Range

1 R Phase L1

2 Y Phase L2 AC Voltage 150 to 550 V AC

3 B Phase L3

Controller Manual 7.11

 7.6 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 & time
"UP" - Set analog values

 Set load pressure

 Set unload pressure

 Set start sump pressure (displays only if sump Pressure

enabled)

 Max differential pressure (displays only if sump Pressure

Compressor mode selection details: enabled)

1. PS - Pressure schedule enabled , "DOWN" - Today report

UL - unload mode enabled,  Load and stop hours
PS & UL disabled the space will be shown as empty
 Unload and fault hours
2. L or R or D - compressor start from - Local or remote
 Run and standby hours
or DCS,
 Start count and load count
3. A or M - Auto restart enabled or auto restart disabled.
For more details refer machine settings in operator menu. TAB Key - For changing the language

Shortcut key usage HELP Key - For contrast adjustments

When the controller is in home screen, you can access

below listed parameters using the shortcut keys.

"RIGHT" - Live analog values

 Live differential pressure (displays only if sump pressure
enabled)

Message 1 - Compressor status message

Status Description
Ready Ready for start
Star Motor running in star
Run 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. XX.X denotes the live sump pressure value. The compressor starts only
if the sump pressure value goes below the set value.

During the start, if the discharge temperature is lower than the set inhibit temperature value,
Temperature inhibit ±XX you will see this message. ±XX denotes the live discharge temperature value. The compressor
starts only if the discharge temperature value goes above the set value.

If sump pressure is not used (disabled) then the controller will ensure minimum 60 seconds
Start inhibit "seconds"
delay between the stop and the start. Count stops if "STOP" key is pressed

If compressor is in auto mode, the controller will ensure minimum delay (user set, e.g. 60 sec)
Auto restart "seconds"
between stop and start. count stops if "STOP" key is pressed
This message is displayed after a fault is cleared and waiting for user acknowledgement. By
Start ack wait…
pressing "RESET" key user can acknowledge.

Standby Compressor in standby

Controller Manual 7.12

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.

HSP (AD) If discharge pressure exceeds the set high sump pressure value.

Cooler If the cooler digital Input opens due to Cooler fault

Main motor overload/ IF the MMOL digital input opens due to main motor over load. VFD error if VFD control is
VFD error enabled.
Rev rot / Ph fail If the rev rot input closes when motor running due to motor reverse rotation or Phase failure.

Trip temperature If the discharge temperature exceeds the set trip temperature value.
Sump Pressure After the Start, The sump pressure should be at least 0.3 bar/4psi after star delay expires. If
Not Developing this is NOT achieved this Fault occurs , if sump pressure is enabled.
Power failure If the mains supply is interrupted for more than 20 msec
If the mains supply voltage is less than the 75% of rated voltage.
Low voltage Compressor is tripped & All controller operation is halted until the mains supply Comes back to
normal (at least 85% of the rated)
Dis. pressure After the Load, The discharge pressure should be at least 0.5 bar/7psi in 5mins. If this is NOT
Not developing achieved this fault occurs
Dryer IP trip If dryer is enabled with trip, if dryer trip occurs, this fault message will be shown

Dryer low DP trip When dew point temperature is less than set value.
Temperature not If the discharge temperature not raised above the inhibit temperature before the set inhibit
developing temperature time.
If motor fan external enabled, it will trip the compressor based on SET value of MOTOR
Winding temp. high
WINDING temperature

Winding temp. fail If motor fan external enabled, it will trip the compressor if sensor open

Message 3 - Compressor warning message

Warning Description
DPAF If DPAF Digital Input is Open and DPAF ON in factory setting

DPOF If DPOF Digital Input is Open and DPOF ON in factory

Dryer Probe Failure When Ch-4 analog sensor input fails

Dryer Off - Low DP warn When Ch-4 Dew point temp. is less than Set value

High Dew Point When Ch-4 Dew point temp. is greater than Set Value

When the difference between Sump. Pressure and Discharge Pressure exceeds the Set
High Pressure
Pressure. ( Only in Sump Pr. Enabled condition)

Warn Temperature When Discharge temp. exceeds the set warn (Default is 105Deg C/Deg F)

Change Oil Filter When service remaining Hr. reaches 0000 Hrs

Change Air Filter When service remaining Hr. reaches 0000 Hrs

Change Oil When service remaining Hr. reaches 0000 Hrs

Change Grease When service remaining Hr. reaches 0000 Hrs

Separator When service remaining Hr. reaches 0000 Hrs

Change Valve kit When service remaining Hr. reaches 0000 Hrs

Dryer Off - IP Warn If Dryer Digital Input is Open and dryer warn is selected in the input

Calibration error When there is error in sensor calibration

Controller Manual 7.13

7.6.1 Important user machine settings immediately. This feature helps save the energy if very
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,
Remote - Users can start and stop the compressor by then the system does not enter into the Standby stop
sequence until the existing hour is completed. Next, the
using potential free digital input. (refer digital input Standby override will appear on the screen.
connector - X04).
9. Start/Stop per hour
DCS - Users can start and stop the compressor by using
The system will warn if the compressor is started more
RS485 modbus communication port ( refer connector - X07 ).
than the specified number of cycles per hour. The default
timeframe is 5 per hours.
NOTE
10. Auto drain valve
In remote and DCS mode, the start/stop button in the
controller is inactive. In case of emergency, stop the The auto drain valve is a special feature to prevent water
compressor using the "emergency stop push" button from entering into compressed air delivery. This function
available in the front panel. This is applicable across all
types of control mode. resets the drain valve to ON and OFF based on the time
specified in the menu. The default setting is 5 Sec ON in 4-
2. Unload mode min intervals. You can adjust the ON and OFF time based
on the requirement.
If this is enabled, the compressor operates only in unload
mode and never in load mode. (This mode is used for 11. Low dew point
service and maintenance purposes.) The system will warn/trip if the dew point temperature is
3. Auto restart less than the set value (if the dryer is enabled).

If this is enabled, the compressor operates automatically 12. High dew Point
after a power outage and resumes based on the previous The system will warn if the dew point temperature is
condition. The default delay is 30* sec. Warn RST delay higher than the set value (if the dryer is enabled).
delays the compressor start if power resumes and Auto
13. Load/Unload Source
Restart Mode is ON.
Local: Load/Unload pressure is based on load/unload
*If compressor recover from standby, restart delay is 10
settings in the controller.
sec.
Remote: Selection from digital input– remote load/unload
4. Load / Unload pressure
can be operated from remote through a wired switch.
The compressor operates between load pressure and
DCS: Load/Unload can be operated from DCS (load/unload
unload pressure based on compressed air utilization. You
command should be given continuously in the interval ≤ 3
can set load/unload pressure based on the requirement
sec) Ensure master control bit in enabled condition.
within the operating pressure band zone.

5. Star delay NOTE

Star to delta change over delay time. Default 6 sec delay The compressor starts working in local load and unload
mode if communication is lost in DCS mode.
given in the factory.

6. DTR delay 14. VFD Function

From delta change over to load delay time. Default 3 sec VFD speed percentage will appear in the HOME screen
delay given in the factory. once VFD mode is enabled in the factory setting.
7. RTS delay You can also view the below VFD parameters by accessing
The normal stop of the compressor will unload and wait for the view->VFD menu:
this delay time to stop the compressor. The default delay  Voltage in V
is 5 sec.
 Current in A
8. Standby time
 Frequency in Hz
The compressor will switch to standby if unloading exceeds
 Power in KW
the specified time. The default delay is 5 mins.
 RPM
Standby resume - If the actual pressure is less than the
load pressure, then the compressor will restart  Status of the VFD
automatically after 10 sec delay. If demand from the
standby stop comes after 10 sec, the compressor will start

Controller Manual 7.14

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 > unload pressure.

 The machine will run at optimum speed when optimum

is ON. This works only under the load condition. Under
the unload condition, it follows the unload speed.

 The machine will run at calculated speed between

minimum and maximum speed based on machine usage
and when the machine is under load with optimum OFF.

Controller Manual 7.15

 7.7 Menu structure

Press any one of the following keys  and  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.

View Operator
Fault report
Day report
Service time
Cumulative time
VFD
Rental hours

7.7.1.2 Operator
LEVEL 1 LEVEL 2 LEVEL 3 LEVEL
View Operator Mode Control mode Local / Remote / DCS
Auto restart On/ Off
Pressure unit Bar/psi
Temperature unit Fahren / centi
Pressure Unload pressure X X . X b or p (bar or psi)
Load pressure X X . X b or p
Pr. schedule ON/ OFF
Delay Warn RST delay X X X s (second)
Star delay XXs
DTR delay XXs
RTS delay XXs
Standby time X X m (minute)
St/Sp PH XX
DCS port Type Modbus
ID XX
Baud 9600/19200
Parity None / Even / Odd
Length 8/7
Stop bit 2/1
Temperature Trip temperature X X X C or F
Warn temp X X X C or F
Fan temp X X X C or F
Rating XXXXXXXXXX
Fab No. XXXXXXXXXX

Controller Manual 7.16

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

View Fault report Fault message

Date : DD/MM/YY

Time : HH:MM:SS

Dis.Pr : X X .X

Dis.Tr : X X X

Status : RDY/ACK/STAR etc.,

7.7.1.4 Day Report

The day report explains the usage pattern of the compressor day wise for last 30 days. Use ∆ and ∇ to select the record
number (1 to 30). The latest report will be displayed in record 1.
LEVEL 1 LEVEL 2 LEVEL 3

View Day report Date: DD/MM/YY

L:X X Hours St: X X Hours

UL:X X Hours F:X X Hours

R:X X Hours Sby: X X Hours

STC:X X X LDC:X X X X X

L- Load, St - Stop, UL - Unload, F- Fault, R- Run, Sby- Standby, STC - Start Count, LDC - Load Count
7.7.1.5 View Service Time
For consumable parts, the remaining life will appear in the view menu. Every run hour, the count will decrements by one
hour. Once it reaches zero, an alarm message will pop up and the counter will show negative hours.

LEVEL 1 LEVEL 2 LEVEL

View Service time Remaining AFCT: X X X X X hours

Remaining OFCT: X X X X X hours

Remaining OSCT: X X X X X hours

Remaining OCT: X X X X X hours

Remaining RGT: X X X X X hours

Remaining valve kit: X X X X X hours

7.7.1.6 View Cumulative Time

From the compressor commissioning to till date , the run hours and utilization pattern will be displayed in the menu.

LEVEL 1 LEVEL 2 LEVEL

View Cumulative time Load X X X X X X hrs: X X Min

Unload X X X X X X hrs: X X Min

Run X X X X X X hrs: X X Min

Stop X X X X X X hrs: X X Min

Fault X X X X X X hrs: X X Min

Standby X X X X X X hrs: X X Min

Start count XXXXXX

Load count XXXXXXXXX

Utilisation XX%

Controller Manual 7.17

7.7.1.7 VFD To reset the rental hours, you have to choose “rental off”
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
parameters in Neuron III. Unload X X X X X X hrs: X X Min
Run X X X X X X hrs: X X Min
 Voltage in V Stop X X X X X X hrs: X X Min
 Current in A Fault X X X X X X hrs: X X Min
Standby X X X X X X hrs: X X Min
 Frequency in Hz Start count XXXXXX
Load count XXXXXXXXX
 Power in KW

 RPM
7.7.2 Operator
 Status of the VFD
This option requires a password to adjust operator settings
 Run hours based on VFD speed % within the set limits.

< 40% speed XXXX hours Operator Machine

40~50% speed XXXX hours Scheduler
51~60% speed XXXX hours Maintenance
61-70% speed XXXX hours Language
71-80% speed XXXX hours Change password
81~90% speed XXXX hours VFD control
91~100% speed XXXX hours Rented hrs setting
Last serviced

7.7.1.8 Rental hours 7.7.2.1 Machine

If you select rental hours in the operator menu, you can The machine settings available are listed in the below
view the run hours and the utilization pattern of the table.
compressor in the view menu.

Min Option Default Unit

Mode

1 Control mode - - loc/rem/dcs loc -

2 Auto restart - - on / off o -

3 Pr unit - - bar / psi bar/psi -

4 Tr unit - - cen / far cen -

Based on
5 Unload pressure load pressure max unload pressure - bar/psi
compressor
pressure
6 Load pressure 4.0bar(58psi) unload pressure - - bar/psi
rating

Set

7 Warn RST 30 250 - 30 second

8 Star 6 20 - 6 second

9 DTR 10 60 - 3 second

10 RTS 5 30 - 5 second

11 Standby 1(VFD),3(Non-VFD) 99 - 3 minute

DCS Port

12 Type - - Modbus -

13 ID 01 99 - 01 -

14 Baud - - 9600/19200 9600 bps

Controller Manual 7.18

 Min Option Default Unit

14 Baud - - 9600/19200 9600 bps

15 Parity - - None/Even/ Odd None

16 Length - - 8/7 8 -

17 Stop bit - - 2/1 1 -

Auto Drain

18 Off time 1 180 - 4 minute

19 On time 1 15 - 5 Second

Load / Unload

20 LD / UL Source - - Loc / Rem/ DCS Loc -

Set dew point

21 Low dew point -6oC(21oF) 2oC(36oF) -2oC(28oF) Cen

o o o o o o
22 High dew point 6 C(43 F) 12 C(54 F) 8 C(46 F) Cen

Contrast adjust

24 Contrast adjust 10 100 50 %

7.7.2.2 Operator - Scheduler

If you enable the pressure scheduler, then you can view and access the below table in edit mode. Use ∆ and ∇ to select the
pressure scheduler number (1 to 32). For details, refer to “Example - scheduler setting”.
Min Option Default Unit

Sun to Sat / (---

Day - - --- -
means no schedule)

Action - - on / off ff -

Time HH - Hour

Time MM - Minute

Unload  pressure 7.5bar

≤Max - bar/psi
Pressure 0.5 (109psi)

Load pressure 4.0 bar(58psi) pressure - - 5.5bar bar/psi

(one schedule should be in Sunday (first day of the week) 00:00 Hrs) Then Press "Enter" to set the following

7.7.2.3 Operator - Maintenance

If you modify the settings for the below consumables, you can select the yes option to restart the service counter from the default

Min Option Default Unit

1 AF changed - - no/yes no -

2 OF changed - - no/yes no -

3 OS changed - - no/yes no -

4 Oil changed - - no/yes no -

5 Re-grease - - no/yes no -

6 Valve kit - - No/yes No -

Controller Manual 7.19

7.7.2.4 Language
Default is English. You can choose any one of the given languages.

# Item
1 English
2 Portuguese
3 Francais
4 Italiano
5 Spanish

7.7.2.5 VFD Control

Min Default Unit

Optimum Speed on/off on/off off

P-Gain 1 50000 250

I-Gain 1 5000 500

I-Time 1 200 20

Max. Speed RPM

Min. Speed RPM

Optimum Speed RPM

Factory settings can be viewed here
UL Speed RPM

High (5v) RPM

Low (1v) RPM

7.7.2.6 VFD Speed Control contrast, a small gain results in a small output response to
a large input error, and a less responsive or less sensitive
Optimum speed: The compressor runs at optimum speed controller. If the proportional gain is too low, the control
under load with optimum ON (Operator menu). action may be too small when responding to system
PI speed control: In the "Run Load" condition, the disturbances.
compressor operates at calculated speed between Min and Effect of Integral Value
Max speed depending on air utilization/usage.
The contribution from the integral term is proportional to
Setting the P value both the magnitude of the error and the duration of the
P-Gain - Range: 1-50000. This gain occurs over a full error.The integral term accelerates the movement of the
range. The recommended setting is 20-1000. process towards set point and eliminates the residual
steady-state error that occurs with a pure proportional
A proportional–integral controller (PI controller) is
controller. However, since the integral term responds to
a control loop feedback mechanism used in
industrial control systems and a variety of other
applications requiring continuously modulated control.

Proportional-Integral controller results from the

combination of the proportional and the integral mode.
This mode is also called as the proportional plus reset
action controller

Effect of Proportional Value

The proportional term produces an output value that is

proportional to the current error value. The proportional
response can be adjusted by multiplying the error by a
constant Kp, called the proportional gain constant.

A high proportional gain results in a large change in the

output for a given change in the error. If the proportional
gain is too high, the system can become unstable. In

Controller Manual 7.20

 Parameter Rise time Overshoot Settling time Steady-state error Stability
Kp Decrease Increase Small change Decrease Degrade
Ki Decrease Increase Increase Eliminate Degrade
accumulated errors from the past, it can cause the present read and write between VFD and Neuron III.
value to overshoot the set point value
 View the VFD RPM range in the factory AO scaling menu
Effect of change in Kp( Proportional value ) & Ki ( Integral to ensure MODBUS communication exists between VFD
value ) listed below. and Neuron III. Current VFD RPM appears here, if

Example: communication no longer exists.

Sample 1:  Ensure min reference of AO scaling > VFD Parameters 3

-02 and 4-11 and max reference of AO scaling < VFD
If P-Gain=20 and the difference between set pressure and
parameters 3-03 and 4-13.
actual pressure ≥ 5 bar (73 psi), then the PI loop
activates.
NOTE
The VFD factory settings in the controller are synchronized
Sample 2:
with VFD. It is not recommended to adjust the settings in
If P-Gain=1000 and the difference between set pressure VFD.
actual pressure ≥ 0.1 bar (1 psi), then the PI loop Rental hrs settings
activates.
Rental-ON: If selected, then a separate timer is recorded
Set a higher P-Gain value if receiver capacity is high and for rental hrs of load, unload, run, stop, fault, and
the reverse holds true. standby/STC/LDC. It can be viewed in the view menu only
Setting the I-Gain value when the rental hour is on.

I-Gain - Range: 1-5000. This gain occurs over a full To reset the rental hour, select “rental off” and then
range. The recommended setting is 50- 1000. “rental on”.

The recommended value is 125 to 250 in our case. Last serviced

Anything less than 125 will be more stable. AMC service - If you select yes, the last AMC serviced
A lower setting enables the system to be tolerant to the updates with the current date. You can then view it in the
error. A value of 50 for I-Gain will enable the system to customer care menu.
correct the error only if the pressure difference between Spares replaced - If you select yes, the last spares
set and actual pressure exceeds 0.020 bar / 0.3 psi. replaced updates with the current date. You can then view
The higher the setting, the more sensitive the system it in the customer care menu.
becomes to very small changes. Regular service - If you select yes, the Regular service
E.g. A value of 1000 for I-Gain makes the system updates with the current date. You can then view it in the
sensitive to a 0.001 bar / 0.01 psi difference. A very high customer care menu.
value and sensitive system (low receiver capacity) will 7.7.3 Service
drive the system into a completely unstable state. 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. The recommended value is 15-20. malfunction and the warranty becoming void.
The higher the value, the more delay will be on the Service Sensor Offset
application of correction calculated based on I-Gain and Relay
the reverse is true.
Temperature
Min speed: The compressor remains in min speed up to Maintenance
the start "Run Load" condition during start. If demand is Clock
very little, the compressor will run at minimum speed. Self-Test
Unload speed: The compressor runs at set unload speed Password
during unload. This is irrespective of all unload modes like Digital Input
Remote, DCS and local unload. Dryer Input
Pre-checks that must be performed before starting Unload Mode
the compressor under VFD control Lat /Lon
VFD_model
 VFD should be enabled in Factory -> VFD settings to

Controller Manual 7.21

7.7.3.1 Calibration (offset) 7.7.3.4 Maintenance
If any deviation occurs in the pressure and temperature 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.

7.7.3.2 Programmable relay You used to register the filter replacement in operator->
Maintenance by choosing Yes/No option. Once you choose
Select programmable relay 1 or 2 using the ∆ and ∇ keys.
Yes in operator then filter life time will be updated.
Then press “Enter” to assign any one of the following
functionalities to the relay. Item Min Option Default Unit
1 Set AFCT 0000 30000 - 2000H Hour
#
1 arn 2 Set OFCT 0000 30000 - 2000H Hour
2 Load 3 Set OSCT 0000 30000 - 4000H Hour
3 Service
4 Set OCT 0000 30000 - 2000H Hour
4 Stand by
5 Trip 5 Set RGT 0000 30000 - 2000H Hour
6 Remote
Set Valve
7 Ready 6 0000 30000 - 2000H Hour
Kit

Default 7.7.3.5 Clock

Relay 1 = Warn Here the real time clock settings can be done. 24 hrs
Relay 2 = Trip format will be applicable for all menus and features related
to clock settings, Whereas 12 hrs time format is applicable
for the home screen only.
NOTE
If Dryer is enabled, then programmable relay 2 is not user
Item Min
programmable. It is used for automatic dryer control.
1 Hour 23
7.7.3.3 Temperature 2 Minute 59
Fan Temperature - Fan relay will energize if discharge 3 Second 59
temperature reaches the set value. It will de-energize
4 Date 31
when the temperature decreases to 15°C from the set
value. Alternatively, fan start/stop is allowed for 15 times/ 5 Month 12
per hour. Beyond 15 times, the fan will not switch off. 6 Year 99
The above logic will work only if the fan input connected to Sun/Mon/Tue/Wed/Thu/
relay output of the controller (Ref:7.5.6 X06: Relay in 7 Day
Fri/Sat
page No:7.11).
Inhibit temperature – If you enable this setting and Daylight saving
Temperature inhibit is already enabled in factory settings, Daylight saving settings will add 1 or 2 hours from the
the compressor will start when the discharge temperature current GMT time. If you choose daylight option as off, the
is higher than the set value. clock will revert back to GMT time.
Temperature inhibit time - The compressor will wait for
this specified time to reach the inhibit temperature. If not, Item Min
it trips as temperature is not building. . 1 Date format DD/MM/YY MM/DD/YY
2 Time format 12 hr 24 hr
Item Min Option Default Unit
3 Day light savings
60oC 90oC 85oC
1 Fan temp - C/F
(140oF) (185oF) (185oF)

Inhibit -5oC 5oC 0oC 7.7.3.6 Digital input

2 o o - o C/F
temp (23 F) (41 F) (32 F) Configuration of DI-4 (DPAF or Remote Load/Unload) can
Tr_ intial be viewed from this menu. (if the load/unload source is
3 5 90 - 5 min
time selected as remote in operator -> machine settings). Then
the digital Input will configure for remote Load/Unload.

Controller Manual 7.22

7.7.3.7 Dryer input
Dryer digital input DI-6 can be configured for warn or
trip. This input will be effective if the dryer is ON in
factory -> dryer.

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.

7.7.4 Customer care

Dis. Pr : 6.0 bar/ 87psi

Dis. Tr : 32°C (90°F)

Status : S/W Version

URL : www.elgi.com

E-mail : [email protected]

Controller Manual 7.23

 7.8 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.

NOTE
If analog input probe failure occurs, analog output
becomes 0V by default.

7.8.2 DCS port

The DCS port is a Modbus RTU type to interface to the
generic DCS system.

You can set the device ID in the "Operator/ Machine/ DCS

Port" menu. Also the baud rate, parity, data length, and
stop bit are user settable.

Controller Manual 7.24

 7.9 Troubleshooting

S.
Failure symptoms Possible causes Remedies
NO

No input supply Check incoming AC input

No display in LCD Screen & Please check the controller input voltage at connector
1 Transformer failure.
Backlight was not glown X08. Voltage should be 24V ± 15% VAC.

Controller failure. Change the controller.

Key not responding Check any key stuck / Flat. If any change Controller
Key not functioning
2
Note: Controller keys
Key struck / Flat Change the controller.

Until will start functioning, once input voltage

"Low voltage" message in Controller Input voltage less recovered
3
display. than 18VAC to nominal or with in specification
( 415 V +10% - 15 %)
Loose connection in connector
Check the loose connection at both end - Controller
position (X03 - 1, 3) &
and pressure sensor side.
(X03 - 2, 4) .
"Pr. probe failure"
4 Pressure sensor failure. Change the Pressure sensor.
message in display
Check the voltage across (X03 - 3) & (X03-4) with
Controller failure Gnd, voltage should be b/w 0.4 to 2VDC. If it is
different change the controller.
Loose connection in connector
Check the loose connection at both end - Controller
position (X03 - 5, 7) &
and Temp sensor side.
(X03 - 6, 8)
"Tr. probe failure"
5 Temperature sensor failure. Change the Temperature sensor.
message in display
Check the voltage across (X03 - 7) & (X03-8) with
Controller failure Gnd, voltage should be 3.3 VDC. If it is different
change the controller.
Loose connection in connector
"Emergency stop" Check the loose connection at controller end.
position X02 - 1 to 9).
"MMOL"
"Cooler OL" Check either the external switches got sturck / Fault
6 Switch got struck
"Dryer trip" not cleared
"Rev rot/Ph fail"
message in display Controller failure Change the controller.

Disconnect the X05, X06 & X07 connector,

Check the relay working by switching on the start key
7 Motor not driving Controller failure (X05 -1) with (X05- 2, 3 & 4) & (X06 -1) with (X06-
2).
Note: Ckeck in the continuity mode.

Loose connection in connector

Check the loose connection at controller end.
"Phase loss/ Reverse" position X08 - 1, 2 & 3.
8
message in display Check for the X05 connection X08(1- R, 2-Y, 3 -B),
Controller failure
Still the same error change the controller

Controller Manual 7.25

 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

 7.11 Example – scheduler setting

Scheduler settings are considered when:

1. End customer usage is 6 bar (87 psi)
2. Pressure variation in the air pipe is less than 0.1bar (1 psi)
3. All 3 compressors connect to a single/common header or a common
receiver
4. All 3 compressors connect to a common header or a common receiver

Pressure schedule settings in Neuron III

Comp-1 Comp-2 Comp-3

Load U/L Load U/L Load U/L

ON OFF bar bar ON OFF bar bar ON OFF bar bar
(psi) (psi) (psi) (psi) (psi) (psi)

Monday Lead Lag Lag

7 7.5 6.6 7.2 6 6.8

8:00 18:00 8:00 18:00 8:00 18:00
(102) (109) (96) (104) (87) (99)

Tuesday Lag Lead Lag

6 6.8 7 7.5 6.6 7.2

8:00 18:00 8:00 18:00 8:00 18:00
(87) (99) (102) (109) (96) (104)

Wednesday Lag Lag Lead

6.6 7.2 6 6.8 7 7.5

8:00 18:00 8:00 18:00 8:00 18:00
(96) (104) (87) (99) (102) (109)

Thursday Lead Lag Lag

7 7.5 6.6 7.2 6 6.8

8:00 18:00 8:00 18:00 8:00 18:00
(102) (109) (96) (104) (87) (99)

Friday Lag Lead Lag

6 6.8 7 7.5 6.6 7.2

8:00 18:00 8:00 18:00 8:00 18:00
(87) (99) (102) (109) (96) (104)

Saturday Lag Lag Lead

6.6 7.2 6 6.8 7 7.5

8:00 18:00 8:00 18:00 8:00 18:00
(96) (104) (87) (99) (102) (109)

Sunday 00:00hrs As required ON/Off has to be set. This is mandatory setting.

C1 C1 C1
7b/333cfm 7b/333cfm 7b/333cfm

Air Receiver
1000 cfm

Controller Manual 7.27

Example - scheduler setting

Weekly utilization
Air demand: 100% Air demand: 75% Air demand: 50% Air demand:25%

Comp -> C1 C2 C3 C1 C2 C3 C1 C2 C3 C1 C2 C3
Day-1 100 100 100 100 100 25 100 50 0 75 0 0

Day-2 100 100 100 25 100 100 0 100 50 0 75 0

Day-3 100 100 100 100 25 100 50 0 100 0 0 75
Day-4 100 100 100 100 100 25 100 50 0 75 0 0
Day-5 100 100 100 25 100 100 0 100 50 0 75 0
Day-6 100 100 100 100 25 100 50 0 100 0 0 75

Avg. Utl% 100 100 100 75 75 75 50 50 50 25 25 25

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 Goto operator menu

Step-2 Enter password "4545"

Step-3 operator -> schedule

Step-4 enable

Step-5 set ON TIME

Step-6 set OFF TIME

Step-7 set load Pr.

Step-8 set unload Pr.

7.12 Revision Details

Version Date Changes
1.0 25/02/15 Release
2.0 09/05/15 Updated corrections
3.0 30/06/17 Software features & CE/UL updated
3.1 01/03/18 Software version 2.07
3.2 01/12/18 Software version 2.08
3.3 11/03/19 Software version 2.09
3.4 05/07/19 Software version 2.09a

Controller Manual 7.28

 7.13 Neuron III quick reference

1 128x64 Graphical display

2 Navigation keys
3 Enter key
4 Start key
LED (green - start , red -
5
stop/fault )
6 Stop key
7 Reset key
Oil filter change indication
8
LED
Air oil separator change
9
indication LED
10 Cooler fault LED
Auto mode enabled
11
indication LED
12 High pressure fault LED
13 Main motor fault LED
14 Reverse rotation fault LED
Air filter change indication
15
LED
High discharge temperature
16
fault LED
17 Escape key
18 Tab key
19 Info key

MAIN SCREEN DISPLAY

 Package Discharge Pressure ▲ “UP” – Set Analog Values
1. Current Load Pressure
 Discharge Temperature
2. Current Unload Pressure
 VFD Speed % on screen (if applicable)
3. Current Start Sump Pressure (Displays only if Sump
 Machine Status like Run, Load, Unload, Standby etc.
Pressure enabled)
 Warning Messages
4. Current Differential Pressure (Displays only if Sump
 Date & Time Pressure enabled)
 Mode Information (see below) ▼ “DOWN” – Today Report
Mode Information – 1, 2, 3 1. Load and Stop Hours
1. PS – Pressure Schedule Enabled / UL – Unload Mode 2. Unload and Fault Hours
Enabled
3. Run and Standby Hours
2. L – Local / R – Remote / D – DCS
MAIN SCREEN SHORTCUTS

Pressing the navigation keys while on the main

menu allows user to read common settings.

►“RIGHT” ‐ Live Analog Values

1. Live Differential Pressure (Displays only if Sump

Pressure enabled)

2. Live Sump Pressure (Displays only if Sump Pressure

enabled)

3. Live Pt1000 Temperature (Displays only if Dryer ON

enabled)

Controller Manual 7.29

Compressor Status messages
Status Description
Ready Ready for start
Star Motor running in star

Run 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. XX.X denotes the live sump pressure value. The compressor starts only
if the sump pressure value goes below the set value.
During the start, if the discharge temperature is lower than the set inhibit temperature value,
Temperature inhibit ±XX you will see this message. ±XX denotes the live discharge temperature value. The compressor
starts only if the discharge temperature value goes above the set value.

If sump pressure is not used (disabled) then the controller will ensure minimum 60 seconds
Start inhibit "seconds"
delay between the stop and the start. Count stops if "STOP" key is pressed

If compressor is in auto mode, the controller will ensure minimum delay (user set, e.g. 60 sec)
Auto restart "seconds"
between stop and start. count stops if "STOP" key is pressed
This message is displayed after a fault is cleared and waiting for user acknowledgement. By
Start ack wait…
pressing "RESET" key user can acknowledge.
Standby Compressor in standby

Compressor Warning messages

Warning Description

DPAF If DPAF Digital Input is Open and DPAF ON in factory setting

DPOF If DPOF Digital Input is Open and DPOF ON in factory

Dryer Probe Failure When Ch-4 analog sensor input fails

Dryer Off - Low DP warn When Ch-4 Dew point temp. is less than Set value
High Dew Point When Ch-4 Dew point temp. is greater than Set Value
When the difference between Sump. Pressure and Discharge Pressure exceeds the Set
High Pressure
Pressure. ( Only in Sump Pr. Enabled condition)

Warn Temperature When Discharge temp. exceeds the set warn (Default is 105Deg C/Deg F)

Change Oil Filter When service remaining Hr. reaches 0000 Hrs
Change Air Filter When service remaining Hr. reaches 0000 Hrs
Change Oil When service remaining Hr. reaches 0000 Hrs

Change Grease When service remaining Hr. reaches 0000 Hrs

Separator When service remaining Hr. reaches 0000 Hrs

Change Valve kit When service remaining Hr. reaches 0000 Hrs

Dryer Off - IP Warn If Dryer Digital Input is Open and dryer warn is selected in the input
Calibration error When there is error in sensor calibration

Controller Manual 7.30

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.

HSP (AD) If discharge pressure exceeds the set high sump pressure value.
Cooler If the cooler digital Input opens due to Cooler fault
Main motor overload/ IF the MMOL digital input opens due to main motor
VFD error over load. VFD error if VFD control is enabled.

Rev rot / Ph fail If the rev rot input closes when motor running due to motor reverse rotation or Phase failure.

Trip temperature If the discharge temperature exceeds the set trip temperature value.
Sump Pressure After the Start, The sump pressure should be at least 0.3 bar/4psi after star delay expires. If
Not Developing this is NOT achieved this Fault occurs , if sump pressure is enabled.
Power failure If the mains supply is interrupted for more than 20 msec
If the mains supply voltage is less than the 75% of rated voltage.
Low voltage Compressor is tripped & All controller operation is halted until the mains supply Comes back to
normal (at least 85% of the rated)
Dis. pressure After the Load, The discharge pressure should be at least 0.5 bar/7psi in 5mins. If this is NOT
Not developing achieved this fault occurs
Dryer IP trip If dryer is enabled with trip, if dryer trip occurs, this fault message will be shown

Dryer low DP trip When dew point temperature is less than set value.
If the discharge temperature not raised above the inhibit temperature before the set inhibit
Temperature not developing
temperature time.
If motor fan external enabled, it will trip the compressor based on SET value of MOTOR
Winding temp. high/fail
WINDING temperature/ sensor open

Controller Manual 7.31

Menu Structure

Controller Manual 7.32

PARTS MANUAL
EG SERIES

ELECTRIC POWERED SCREW AIR COMPRESSOR

EG 11– EG 22
8.0 Air Inlet system
[ Ref : 015316779—X017012] EG 11, EG 11 V, EG 15, EG 15 V - 100.0, 125.0, 150.0, 175.0 psi.g; EG 18, EG 18 V - 150.0,
175.0 psi.g; EG 22, EG 22 V - 175.0 psi.g

Parts Manual 8.2

8.0 Air Inlet system
[ Ref : 015316779—X017012]

Sl.
Description Qty. Part Number
No.

1 PRE FILTER 1 015400889

2 AIR FILTER ADAPTOR 1 015318044

3 RUBBER REDUCER 1 015317378

4 SS WORM CLAMP 3 B005000530003

5 AIR FILTER ASSY 1 B004700770005

6 RUBBER DUCT 1 015404122

7 INTAKE VALVE 1 A970008

8 SERVICE INDICATOR 1 B004700770017

9 TUBINGS 6MM 1.8 000920620

10 SS WORM CLAMP 2 B005000530002

11 QF ELBOW 1 000920624

12 SCR SOC HD M12X25 4 000983142

13 WASHER SPRING M12 4 000996112

14 BOLT HEX M8X25 3 000906116

15 WASHER SPRING M8 5 000996108

16 WASHER;PLATE M8 7 000996058

17 NUT;HEX;M8 2 000948008

18 BOLT HEX M8X40 2 000906119

19 RUBBER DUCT 1 015403827

20 BULK HEAD CONNECTOR 1 B010500170002

21 NON RETURN VALVE 1 B004100170001

22 ADJ. SS ELBOW 1/4 BSP 2 B010506720006

23.1 BLOWDOWN PIPE 1 015318156

23.2 SCAVENGING PIPE 1 015318153

23.3 PULS LINE PIPE 1 015320493

24 CONNECTOR 1/4 BSP 2 B009606780009

25 1/8 BONDED SEAL WASHER 3 000959381

26 ORIFICE G1-8 DIA-1 M-F 1 015403984

27 ST FITTING 2 015403616

28 ST ADAPTOR 1/8-1/8 BSP MALE 1 B010506360057

29 PLASTIC TUBE(BLUE) 1 000919226

Parts Manual 8.3

8.0 Air Inlet system
[ Ref : 015316779—X017012] EG 11, EG 11 V, EG 15, EG 15 V - 100.0, 125.0, 150.0, 175.0 psi.g; EG 18, EG 18 V - 150.0,
175.0 psi.g; EG 22, EG 22 V - 175.0 psi.g

Parts Manual 8.4

8.0 Air Inlet system
[ Ref : 015316779—X017012]

Sl.
Description Qty. Part Number
No.

1 PRE FILTER 1 015400889

2 AIR FILTER ADAPTOR 1 015318044

3 RUBBER REDUCER 1 015317378

4 SS WORM CLAMP 3 B005000530003

5 AIR FILTER ASSY 1 B004700770005

6 RUBBER DUCT 1 015404122

7 INTAKE VALVE 1 A970008

8 SERVICE INDICATOR 1 B004700770017

9 TUBINGS 6MM 1.8 000920620

10 SS WORM CLAMP 2 B005000530002

11 QF ELBOW 1 000920624

12 SCR SOC HD M12X25 4 000983142

13 WASHER SPRING M12 4 000996112

14 BOLT HEX M8X25 3 000906116

15 WASHER SPRING M8 5 000996108

16 WASHER;PLATE M8 7 000996058

17 NUT;HEX;M8 2 000948008

18 BOLT HEX M8X40 2 000906119

19 RUBBER DUCT 1 015403827

20 BULK HEAD CONNECTOR 1 B010500170002

21 NON RETURN VALVE 1 B004100170001

22 ADJ. SS ELBOW 1/4 BSP 2 B010506720006

23.1 BLOWDOWN PIPE 1 015318156

23.2 SCAVENGING PIPE 1 015318153

23.3 PULS LINE PIPE 1 015320493

24 CONNECTOR 1/4 BSP 2 B009606780009

25 1/8 BONDED SEAL WASHER 3 000959381

26 ORIFICE G1-8 DIA-1 M-F 1 015403984

27 ST FITTING 2 015403616

28 ST ADAPTOR 1/8-1/8 BSP MALE 1 B010506360057

29 PLASTIC TUBE(BLUE) 1 000919226

Parts Manual 8.5

9.0 Drive system
[ Ref : 015316742—X016995]

Parts Manual 9.1

9.0 Drive system
[ Ref : 015316742—X016995]

Sl.
Description Qty. Part Number
No.

1 AIREND 100 psi 1 X990643

AIREND 125 psi 1 X990644

AIREND 150 psi 1 X990645

AIREND 175 psi 1 X990646

2 AIREND MOUNTING BRKT 1 015315665

3 ANTI VIBRATION MOUNT 1 B001401300003

4 ADAPTOR RING 1 015305729

5 DRIVE COUPLING 1 B005405550016

6 MOTOR 1 B005106400005

7 MOTOR MOUNTING PLATE 2 015402509

8 BOLT HEX M12X30 4 000906183

9 WASHER SPRING M12 2 000996112

10 WASHER PLAIN M12 4 000996012

11 BOLT HEX M16X60 4 000906218

12 WASHER SPRING M16 4 000996116

13 NUT;HEX; M16 4 000948016

14 SCR SOC HD M12X25 4 000983142

15 BOLT HEX M10X45 8 000906148

16 NUT HEX M10 8 000948010

17 WASHER SPRING M10 8 000996110

18 BOLT HEX M12X20 3 000906181

19 WASHER;PLATE;M12 1 000996060

20 ANTI VIBRATION MOUNT 4 B001401300022

Parts Manual 9.2

10.0 Discharge system
[ Ref : 015316750—X017003] EG 11; EG 15; EG 18 - 150.0, 175.0 psi.g; EG 22 - 175.0 psi.g

Parts Manual 10.1

10.0 Discharge system
[ Ref : 015316750—X017003]

Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.

1 AOS TANK 1 015318047 36 COVER OUTLET 1 015404310

2 1'' BONDED SEAL WASHER 1 000959439 37 O-RING ID69.4 X 3.5 1 010453920

3 OIL FILL PLUG 1 015402651 38 DISCHARGE HOSE ASSY 1 015318050

4 OIL SIGHT - FLOT TYPE 1 B010706790001 39 O-RING ID56.7 X 3.5 1 035400187

5 1 1/2"BONDED SEAL WASHER 1 000959391 40 BOLT HEX M8X30 4 000906117

6 LOCK NUT 1/2 BSP 1 020496120 41 WASHER SPRING M8 8 000996108

7 1/2 BONDED SEAL WASHER 1 000959387 42 WASHER PLAIN M8 2 000996008

8 VALVE ASSY BALL 1/2” 1 B312717 43 WASHER 4 015404399

9 CLOSURE PLUG G1/2 1 B010506360004 44 WASHER SPRING M10 4 000996110

10 OIL SAMPLING VALVE 1/4” 1 B013206660001 45 BOLT HEX M10X30 4 000906145

11 DOUBLE FITTING 1 015404147 46 WASHER;PLATE;M12 7 000996060

12 SEPARATOR TUBE 1 990404840 47 WASHER SPRING M12 7 000996112

13 AIR OIL SEPERATOR SPINON 1 B006700770010 48 BOLT HEX M12X35 4 000906184

MALE ST CONNECTOR 1/2" X

14 O-RING ID122.0 X 3.6 1 415400655 49 1 B009605390004
6MM

15 SEPARATOR BLOCK BODY 1 015315681 50 BOLT HEX M12X30 3 000906183

16 SAFETY VALVE 1 B012805340024 52 PLASTIC TUBING DIA.6x1 1 000919226

17 STRAINER MESH 1 B008806100003 53 QF ELBOW 1/4BSP-DIA 6 1 000920624

18 M22 BONDED SEAL WASHER 1 000959436 54 1 INCH CONNECTOR 1 015317270

19 PLUG STRAINER 1 015404020 55 REDUCER 1-1/2 TO 3/4 1 035400662

20 MPV HOUSING 1 990402630 56 CLOSER PLUG G1/4 1 B010506360010

21 MPV SUB ASSY 1 A990223 57 QF 1/4BSP-DIA 6 1 000920503

22 O-RING ID62.0 X 2.0 1 990402960 58 1/2 BONDED SEAL WASHER 1 000959387

23 ADAPTOR 1 - 1/4 1 B010506720007 59 AUTO DRAIN VALVE 1 B000306040013

24 BOLT HEX M8X25 6 000906116 62 BOLT HEX M8x30 4 000906117

25 WASHER SPRING M8 6 000996108 66 PLASTIC TUBING DIA 6x1 1.3mt 000919226

26 SCR SOC HD M10X35 6 000983116 67 BULK HEAD CONNECTOR 1 B010500170002

27 WASHER SPRING M10 6 000996110 68 1/4 BONDED SEAL WASHER 1 000959385

28 1/2 BONDED SEAL WASHER 1 000959387 69 1/4” MALEX1/4” FEMALE VALVE 1 B003105390005

29 O-RING M42 1 990404850

30 O-RING ID32.8 X 2.3 1 990403438

31 PLUG HEX 1/2" 1 340401400

32 O-RING ID32.9 X 3.5 3 015402685

33 PIPE COOLER TO MOS 1 015315687

34 MOISTURE SEPARATOR 1 B000306040014

35 PIPE OUTLET 1 015321577

Parts Manual 10.2

10.0 Discharge system
[ Ref : 015316750—X017003] EG 11; EG 15; EG 18 - 150.0, 175.0 psi.g;
EG 22 - 175.0 psi.g

Parts Manual 10.3

10.0 Discharge system
[ Ref : 015316750—X017003]

Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.

1 AOS TANK 1 015318047 36 COVER OUTLET 1 015404310

2 1'' BONDED SEAL WASHER 1 000959439 37 O-RING ID69.4 X 3.5 1 010453920

3 OIL FILL PLUG 1 015402651 38 DISCHARGE HOSE ASSY 1 015318050

4 OIL SIGHT - FLOT TYPE 1 B010706790001 39 O-RING ID56.7 X 3.5 1 035400187

5 1 1/2"BONDED SEAL WASHER 1 000959391 40 BOLT HEX M8X30 4 000906117

6 LOCK NUT 1/2 BSP 1 020496120 41 WASHER SPRING M8 8 000996108

7 1/2 BONDED SEAL WASHER 1 000959387 42 WASHER PLAIN M8 2 000996008

8 VALVE ASSY BALL 1/2” 1 B312717 43 WASHER 4 015404399

9 CLOSURE PLUG G1/2 1 B010506360004 44 WASHER SPRING M10 4 000996110

10 OIL SAMPLING VALVE 1/4” 1 B013206660001 45 BOLT HEX M10X30 4 000906145

11 DOUBLE FITTING 1 015404147 46 WASHER;PLATE;M12 7 000996060

12 SEPARATOR TUBE 1 990404840 47 WASHER SPRING M12 7 000996112

13 AIR OIL SEPERATOR SPINON 1 B006700770010 48 BOLT HEX M12X35 4 000906184

MALE ST CONNECTOR 1/2" X

14 O-RING ID122.0 X 3.6 1 415400655 49 1 B009605390004
6MM

15 SEPARATOR BLOCK BODY 1 015315681 50 BOLT HEX M12X30 3 000906183

16 SAFETY VALVE 1 B012805340024 52 PLASTIC TUBING DIA.6x1 1 000919226

17 STRAINER MESH 1 B008806100003 53 QF ELBOW 1/4BSP-DIA 6 1 000920624

18 M22 BONDED SEAL WASHER 1 000959436 54 1 INCH CONNECTOR 1 015317270

19 PLUG STRAINER 1 015404020 55 REDUCER 1-1/2 TO 3/4 1 035400662

20 MPV HOUSING 1 990402630 56 CLOSER PLUG G1/4 1 B010506360010

21 MPV SUB ASSY 1 A990223 57 QF 1/4BSP-DIA 6 1 000920503

22 O-RING ID62.0 X 2.0 1 990402960 58 1/2 BONDED SEAL WASHER 1 000959387

23 ADAPTOR 1 - 1/4 1 B010506720007 59 AUTO DRAIN VALVE 1 B000306040013

24 BOLT HEX M8X25 6 000906116 62 BOLT HEX M8x30 4 000906117

25 WASHER SPRING M8 6 000996108 66 PLASTIC TUBING DIA 6x1 1.3mt 000919226

26 SCR SOC HD M10X35 6 000983116 67 BULK HEAD CONNECTOR 1 B010500170002

27 WASHER SPRING M10 6 000996110 68 1/4 BONDED SEAL WASHER 1 000959385

28 1/2 BONDED SEAL WASHER 1 000959387 69 1/4” MALEX1/4” FEMALE VALVE 1 B003105390005

29 O-RING M42 1 990404850

30 O-RING ID32.8 X 2.3 1 990403438

31 PLUG HEX 1/2" 1 340401400

32 O-RING ID32.9 X 3.5 3 015402685

33 PIPE COOLER TO MOS 1 015315687

34 MOISTURE SEPARATOR 1 B000306040014

35 PIPE OUTLET 1 015321577

Parts Manual 10.4

11.0 Cooling system
[ Ref : 015319655 —X017772] EG 11

Parts Manual 11.1

11.0 Cooling system
[ Ref : 015319655 —X017772]

Sl.
Description Qty. Part Number
No.

1 OIL AND AFTER COOLER EG-15 1 015315679

COOLER SHROUD ASSY EG-15

2.1 1 015318042
60HZ

2.2 COVER PLATE EG-15 1 015318210

3 PUSHER FAN 350DIA,60HZ 1 B008106910003

4 BOLT HEX M8X25 8.8 ZYP 5-8M 10 000906116

5 WASHER SPRING M8 RECT ZYP 10 000996108

6 WASHER PLAIN M8 ZYP 10 000996008

7 SCR SOC HD M6X12 3 000983060

8 WASHER SPRING REC SEC M6 3 000996106

9 MASKING PLATE 1 015319549

10 M5 X 16 BOLT 2 000906054

Parts Manual 11.2

12.0 Lubrication system
[ Ref : 015315855—X016704] EG 11 (50Hz);
EG 11 & EG 15 - 125.0 psi.g (60Hz)

Parts Manual 12.1

12.0 Lubrication system
[ Ref : 015315855—X016704]

Sl.
Description Qty. Part Number
No.

1 PIPE ORIFICE 1 015315698

2 O-RING ID19.2 X 2.5 2 015402046

3 O-RING ID25.0 X 3.5 6 015403001

4 HOSE OIL INJECTION EG-11 1 015318014

5.1 HOSE TVB TO OC 1 015318017

5.2 HOSE OC TO TVB 1 015318016

5.3 HOSE MPV TO COOLER 1 015318018

6 PIPE OIL SUCTION EG-22 1 015315690

7 OIL FILTER ELEMENT-75 LPM 1 B004800770001

8 HEX ADAPTOR 1"UNFXM24 1 010440500

9 SPRING THERMAL 1 015401073

10 PISTON TVB EG22 1 015404024

11 THERMAL ELEMENT 65 Deg 1 B008706030003

12 O-RING ID27.6 X 2.4 1 015400890

13 THERMOSTATIC VALVE PLUG 1 015400874

14 CIRCLIP INTERNAL B37 1 000917237

15 BOLT HEX M8X25 8.8 ZYP 5-8M 4 000906116

16 WASHER SPRING M8 RECT ZYP 16 000996108

17 STUD M8 8 015404066

18 NUT;HEX;M8; ZYP 8 000948008

19 O-RING ID32.9 X 3.5 2 015402685

20 BOLT HEX M8X30 8.8 ZYP 5-8M 4 000906117

Parts Manual 12.2

13.0 Base & canopy system
[ Ref : 015316856—X017033] EG 22

Parts Manual 13.1

13.0 Base & canopy system
[ Ref : 015316856—X017033]

Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.

1 BASE ASSEMBLY 1 015316783 39 REAR PANEL ASSEMBLY 1 015319130

2 TANK SIDE PILLAR ASSEMBLY 1 015315661 40 SCR SOC HD M8X16 10.9 ZYP 4 000983081

3 TOP ROOF PANEL ASSEMBLY 1 015318188 41 PLASTIC BUSH 4 015403244

4 MOTOR SIDE PILLAR ASSEMBLY 1 015315663 42 PRE FILTER –SS WIRE MESH 3 015320855

5 CONTROL PANEL ASSEMBLY 1 015315664

6 CONTROL PANEL DOOR ASSY 1 015315675

7 SERVICE DOOR ASSEMBLY 1 015315676

8 PANEL ASSY LH 1 015315667

9 PANEL ASSY RH 1 015315668

DISCHARGE SIDE PILLAR

10 1 015318189
ASSEMBLY

11 REAR PANEL FIXED 1 015319131

12 COOLER SUPPORT MEMBER 1 015315671

13 CROSS-MEMBER FRONT 1 015318190

14 FRONT PANEL ASSEMBLY 1 015316784

15 AIR-FILTER BRACKET ASSY. 1 015318191

16 CATRIDGE - PRE FILTER 2 015314902

17 CONNECTOR ASSEMBLY - G¼ 1 015312907

18 HINGE MALE 6 B011604790005

19 LOCK 12 B15204790005

20 KEY 1 B15204790004

21 WIRE GUIDE 12 008985060

22 GROMMET DIA 20 20 01531068B

23 GROMMET DIA 51 2 01531068F

24 COUNTER SUNK SCREW M6X16 12 -

25 HEX BOLT M8X20 19 -

26 M8 PLASTIC PLUG 4 -

27 GROMMET DIA 41 1 01531068E

28 KEY HOLDER 1 015403237

29 HEX NUT - M4 1 -

SLOTTED CHEESE SCREW - M4

30 1 -
X 16

31 GROMMET ID -31 MM 1 01531068D

32 WASHER SPRING M8 19

33 GUIDE PIN 9 015404034

34 BOLT HEX SOC.HEAD M8 x 50 7 -

35 NYLOC NUT - M6 12 -

36 M8 PLAIN WASHER 2 -

37 PRE FILTER 2 015400889

38 GROMMET DIA 17 1 -

Parts Manual 13.2

13.0 Base & canopy system
[ Ref : 015316856—X017033] EG 22

Parts Manual 13.3

13.0 Base & canopy system
[ Ref : 015316856—X017033]

Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.

1 BASE ASSEMBLY 1 015316783 39 REAR PANEL ASSEMBLY 1 015319130

2 TANK SIDE PILLAR ASSEMBLY 1 015315661 40 SCR SOC HD M8X16 10.9 ZYP 4 000983081

3 TOP ROOF PANEL ASSEMBLY 1 015318188 41 PLASTIC BUSH 4 015403244

4 MOTOR SIDE PILLAR ASSEMBLY 1 015315663 42 PRE FILTER –SS WIRE MESH 3 015320855

5 CONTROL PANEL ASSEMBLY 1 015315664

6 CONTROL PANEL DOOR ASSY 1 015315675

7 SERVICE DOOR ASSEMBLY 1 015315676

8 PANEL ASSY LH 1 015315667

9 PANEL ASSY RH 1 015315668

DISCHARGE SIDE PILLAR

10 1 015318189
ASSEMBLY

11 REAR PANEL FIXED 1 015319131

12 COOLER SUPPORT MEMBER 1 015315671

13 CROSS-MEMBER FRONT 1 015318190

14 FRONT PANEL ASSEMBLY 1 015316784

15 AIR-FILTER BRACKET ASSY. 1 015318191

16 CATRIDGE - PRE FILTER 2 015314902

17 CONNECTOR ASSEMBLY - G¼ 1 015312907

18 HINGE MALE 6 B011604790005

19 LOCK 12 B15204790005

20 KEY 1 B15204790004

21 WIRE GUIDE 12 008985060

22 GROMMET DIA 20 20 01531068B

23 GROMMET DIA 51 2 01531068F

24 COUNTER SUNK SCREW M6X16 12 -

25 HEX BOLT M8X20 19 -

26 M8 PLASTIC PLUG 4 -

27 GROMMET DIA 41 1 01531068E

28 KEY HOLDER 1 015403237

29 HEX NUT - M4 1 -

SLOTTED CHEESE SCREW - M4

30 1 -
X 16

31 GROMMET ID -31 MM 1 01531068D

32 WASHER SPRING M8 19

33 GUIDE PIN 9 015404034

34 BOLT HEX SOC.HEAD M8 x 50 7 -

35 NYLOC NUT - M6 12 -

36 M8 PLAIN WASHER 2 -

37 PRE FILTER 2 015400889

38 GROMMET DIA 17 1 -

Parts Manual 13.4

13.0 Base & canopy system
[ Ref : 015316856—X017033] EG 22

Parts Manual 13.5

13.0 Base & canopy system
[ Ref : 015316856—X017033]

Sl. Sl.
Description Qty. Part Number Description Qty. Part Number
No. No.

1 BASE ASSEMBLY 1 015316783 39 REAR PANEL ASSEMBLY 1 015319130

2 TANK SIDE PILLAR ASSEMBLY 1 015315661 40 SCR SOC HD M8X16 10.9 ZYP 4 000983081

3 TOP ROOF PANEL ASSEMBLY 1 015318188 41 PLASTIC BUSH 4 015403244

4 MOTOR SIDE PILLAR ASSEMBLY 1 015315663 42 PRE FILTER –SS WIRE MESH 3 015320855

5 CONTROL PANEL ASSEMBLY 1 015315664

6 CONTROL PANEL DOOR ASSY 1 015315675

7 SERVICE DOOR ASSEMBLY 1 015315676

8 PANEL ASSY LH 1 015315667

9 PANEL ASSY RH 1 015315668

DISCHARGE SIDE PILLAR

10 1 015318189
ASSEMBLY

11 REAR PANEL FIXED 1 015319131

12 COOLER SUPPORT MEMBER 1 015315671

13 CROSS-MEMBER FRONT 1 015318190

14 FRONT PANEL ASSEMBLY 1 015316784

15 AIR-FILTER BRACKET ASSY. 1 015318191

16 CATRIDGE - PRE FILTER 2 015314902

17 CONNECTOR ASSEMBLY - G¼ 1 015312907

18 HINGE MALE 6 B011604790005

19 LOCK 12 B15204790005

20 KEY 1 B15204790004

21 WIRE GUIDE 12 008985060

22 GROMMET DIA 20 20 01531068B

23 GROMMET DIA 51 2 01531068F

24 COUNTER SUNK SCREW M6X16 12 -

25 HEX BOLT M8X20 19 -

26 M8 PLASTIC PLUG 4 -

27 GROMMET DIA 41 1 01531068E

28 KEY HOLDER 1 015403237

29 HEX NUT - M4 1 -

SLOTTED CHEESE SCREW - M4

30 1 -
X 16

31 GROMMET ID -31 MM 1 01531068D

32 WASHER SPRING M8 19

33 GUIDE PIN 9 015404034

34 BOLT HEX SOC.HEAD M8 x 50 7 -

35 NYLOC NUT - M6 12 -

36 M8 PLAIN WASHER 2 -

37 PRE FILTER 2 015400889

38 GROMMET DIA 17 1 -

Parts Manual 13.6

RECOMMENDED SPARES
50Hz models
EG 11 - 7, EG 11 - 8, EG 11 - 9.5, EG 11 - 12.5; EG 15 - 9.5, EG 15 - 12.5; EG 18 - 12.5; EG 22 - 12.5
60Hz models
EG 11 - 100, EG 11 - 125, EG 11 - 150, EG 11 - 175; EG 15 - 100, EG 15 - 125, EG 15 - 150, EG 15 - 175; EG 18 - 150,
EG 18 - 175; EG 22 - 175
A) PERIODIC MAINTENANCE KITS
1) Consumables Kit upto 8000 Hours - * Part Number 012475679
S. No Description Part Number Qty.

1 Air filter element B005700770004 2

2 Oil filter element-75 LPM B004800770001 4
3 Air oil separator spin on B006700770010 1
4 Suction pre filter 015400889 2

* Consists of all consumables required from commissioning upto 8000 hours of operation for machines with UT synthetic oil
2) 8000 Hours Service Kit - ** Part Number 012485144

S. No Description Part Number Qty.

1 Air filter element B005700770004 1
2 Oil filter element-75 LPM B004800770001 1
3 Air oil separator spin on B006700770010 1
4 Suction pre filter 015400889 1
** One time service kit consisting of all consumables required at 8000 hours (UT synthetic oil) / 4000 hours (ELGi Airlube XD)

3) Valve Kit - Part number 012485146

S. No Description Part Number Qty.
1 Intake valve kit EIV 102 972300040 1
2 BDV valve assembly EIV 102 972300080 1
3 Solenoid valve NC,24V,50/60Hz B007300990017 1

4 Minimum pressure valve kit - EN102 A990293 1

5 Actuator kit EIV 102 972300060 1

6 Auto drain valve B000306040013 1

4) Tube and Fittings Kit - Part number 012485143

S. No Description Part Number Qty.

1 Quick fittings CONN 1/4BSP-6 000920504 2
2 Tubing DIA.6x1 000919226 1m
3 QF elbow 1/4BSP-DIA 6 000920624 4
4 Tubings 6MM 000920620 2.15 m

5) Blow down adjustment kit EIV102 972300110

S. No Description Part Number Qty.
1 Tamper cap EIV 970300680 1
2 Screw grub hex soc head M8X40 970400370 1
3 Nut hex M8 ZYP 000948008 1

Kit Details 14.1

6) Drive Coupling Element

S. No Description Part Number Qty.

1 Drive coupling element B011201170003 1

7) Safety Valve
S. No Description Part Number Qty.
1 Safety valve B008401880003 1

8) Anti Vibration Mount

S. No Description Part Number Qty.
1 Anti vibration mount B001401300022 4
2 Anti vibration mount B001401300003 1
9) Thermal Valve Kit

S. No Description Part Number Qty.

1 Thermal valve kit 65 deg C (C & CD) 012485140

1.1 Spring thermal 015401073 1
1.2 Thermal element 65 Deg B008706030003 1
1.3 O-Ring ID27.6 X 2.4 015400890 1

1.4 Circlip internal B37 000917237 1

2 Thermal valve kit 75 deg C (CV & CDV) 012485141
2.1 Spring thermal 015401073 1
2.2 Thermal element 75 Deg B008706030008 1
2.3 O-Ring ID27.6 X 2.4 015400890 1
2.4 Circlip internal B37 000917237 1

B) OTHER MAINTENANCE KITS

S. No Description Part Number Qty.

1 O-Ring Kit 012479659
1.1 1/8 BSP Bonded seal washer 000959381 3
1.2 1/2 BSP Bonded seal washer 000959387 3
1.3 M22 Bonded seal washer 000959436 1
1.4 3/4BSP Bonded seal washer 000959438 1
1.5 O-Ring ID27.6 X 2.4 015400890 1
1.6 O-Ring ID19.2 X 2.5 015402046 2

1.7 O-Ring ID32.9 X 3.5 015402685 5

1.8 O-Ring ID25.0 X 3.5 015403001 6

1.9 O-Ring ID37.5 X 3.0 035400026 3
1.10 O-Ring ID122.0 X 3.6 415400655 1

1.11 O-Ring ID62.0 X 2.0 990402960 1

1.12 O-Ring ID56.7 X 3.5 035400187 1
1.13 O-Ring ID60.0 X 3.6 415400685 1
1.14 O-Ring ID32.8 X 2.3 990403438 1
1.15 O-Ring_M42 ISO 990404850 1

Kit Details 14.2

 S. No Description Part Number Qty.

2 SS Tube and fittings kit 012400662

2.1 Pipe set EG-15 015320509 1
2.2 PMS coupling 1/4 BSP X 6MM B009606780009 2
2.3 ST Fitting 1/8 TO 6MM OD 015403616 2

2.4 ADJ. SS Elbow 1/4 BSP X 8 MM B010506720006 2

C) Hose kits

S. No Description Part Number Qty.

1 MPV to cooler Hose kit 012479599

1.1 Hose MPV TO AC EG-22 015318018 1

1.2 O-Ring ID32.9 X 3.5 015402685 2

2 Hose oil injection kit-11KW 012479609

2.1 Hose Oil injection EG-11 015318014 1

2.2 O-Ring ID25.0 X 3.5 015403001 2

3 Hose tank to cooler kit 012479629

3.1 Hose TVB TO OC EG-22 015318017 1

3.2 O-Ring ID25.0 X 3.5 015403001 2

4 Hose cooler to tank kit 012479639

4.1 Hose OC TO TVB EG-22 015318016 1

4.2 O-Ring ID25.0 X 3.5 015403001 2

D) 8000 hours kit - Part Number 012400672

S. No Description Part Number Qty.

1 One time consumable kit 012485144 1

2 8000 hrs valve kit 012485146 1

3 Drive coupling element B011201170003 1

4 NRV B004100170001 1

5 Safety valve B008401880003 1

6 Strainer, return line B008806100003 1

7 Tube and fittings kit 012485143 1

Kit Details 14.3

50Hz models
EG 15 - 7, EG 15 - 8; EG 18 - 7, EG 18 - 8, EG 18 - 9.5; EG 22 - 7, EG 22 - 8, EG 22 - 9.5
60Hz models
EG 18 - 100, EG 18 - 125; EG 22 - 100, EG 22 - 125, EG 22 - 150
A) PERIODIC MAINTENANCE KITS
1) Consumables Kit upto 8000 Hours 159 -* Part Number 012475689
S. No Description Part Number Qty.
1 Air filter element B005700770005 2

2 Oil filter element-75 LPM B004800770001 4

3 Air oil separator spin on B006700770010 1
4 Suction pre filter 015400889 2

* Consists of all consumables required from commissioning upto 8000 hours of operation for machines with UT synthetic oil
2) 8000 Hours Service Kit 159 - ** Part Number 012485145
S. No Description Part Number Qty.
1 Air filter element B005700770005 1
2 Oil filter element-75 LPM B004800770001 1
3 Air oil separator spin on B006700770010 1
4 Suction pre filter 015400889 1

** One time service kit consisting of all consumables required at 8000 hours (UT synthetic oil) / 4000 hours (ELGi Airlube XD)
3) Valve Kit 159 - Part number - 012400646
S. No Description Part Number Qty.
1 Intake valve kit EIV 159 972300090 1
2 BDV assembly kit EIV159 972300030 1
3 Solenoid valve NC,24V,50/60Hz B007300990017 1
4 Minimum pressure valve kit - EN102 A990293 1
5 Actuator kit EIV 159 972300070 1

6 Auto drain valve B000306040013 1

7 Plug auto drain valve B010501880008 1

4) Tube and Fittings Kit - Part number 012485142
S. No Description Part Number Qty.
1 Quick fittings CONN 1/4BSP-6 000920504 2
2 Tubing DIA.6x1 000919226 1m
3 QF elbow 1/4BSP-DIA 6 000920624 4
4 Tubings 6MM 000920620 2.15m
5 Union Elbow Dia 10 B010501880007 1

6 Tubings 10 MM 000919244 0.12 m

7 Quick fittings CONN 3/8 BSP 10 000920509 1

8 Quick fittings elbow 3/8 BSP 10 000920609 1

5) Blow down adjustment kit EIV159 - 972300100

S. No Description Part Number Qty.
1 Tamper cap MPV 970300510 1
2 M10 hex socket grub screw 970400160 1
3 Nut Hex M10 X 1 ZBP 000948013 1

Kit Details 14.4

6) Drive Coupling Element
S. No Description Part Number Qty.

1 Drive coupling element B011201170002 1

7) Safety Valve
S. No Description Part Number Qty.
1 Safety valve B008401880003 1

8) Anti Vibration Mount

S. No Description Part Number Qty.
1 Anti vibration mount B001401300022 4
2 Anti vibration mount B001401300003 1
9) Thermal Valve Kit
S. No Description Part Number Qty.
1 Thermal valve kit 65 deg C (C & CD) 012485140
1.1 Spring thermal 015401073 1
1.2 Thermal element 65 Deg B008706030003 1

1.3 O-Ring ID27.6 X 2.4 015400890 1

1.4 Circlip internal B37 000917237 1

2 Thermal valve kit 75 deg C (CV & CDV) 012485141
2.1 Spring thermal 015401073 1
2.2 Thermal element 75 Deg B008706030008 1

2.3 O-Ring ID27.6 X 2.4 015400890 1

2.4 Circlip internal B37 000917237 1
B) OTHER MAINTENANCE KITS
S. No Description Part Number Qty.

1 O-Ring Kit 012479649

1.1 1/8 BSP Bonded seal washer 000959381 3

1.2 1/2 BSP Bonded seal washer 000959387 3

1.3 M22 Bonded seal washer 000959436 1

1.4 3/4BSP Bonded seal washer VITO 000959438 1

1.5 O-Ring ID27.6 X 2.4 015400890 1

1.6 O-Ring ID19.2 X 2.5 015402046 2

1.7 O-Ring ID32.9 X 3.5 015402685 5

1.8 O-Ring ID25.0 X 3.5 015403001 6

1.9 O-Ring ID37.5 X 3.0 035400026 3

1.10 O-Ring ID103.0 X 3.6 415400654 1

1.11 O-Ring ID122.0 X 3.6 415400655 1

1.12 O-Ring ID62.0 X 2.0 990402960 1

1.13 O-Ring ID32.8 X 2.3 990403438 1

1.14 O-Ring_M42 ISO 990404850 1

2 SS Tube and fittings kit 012400663 1

2.1 Tube pulse line EG-22 015320491 1
2.2 PMS coupling 1/4 BSP X 6MM B009606780009 2

Kit Details 14.5

 S. No Description Part Number Qty.

2.3 1/8" BSP- DIA 6MM - Elbow fitting B010505390017 1

2.4 ST Fitting 1/8 TO 6MM OD 015403616 1

2.5 Tube scavenging EG-22 015320490 1

C) Hose kits

S. No Description Part Number Qty.

1 MPV to cooler Hose kit 012479599
1.1 Hose MPV TO AC EG-22 015318018 1
1.2 O-Ring ID32.9 X 3.5 015402685 2
2 Hose oil injection kit-22KW 012479619

2.1 Hose Oil injection EG-22 015318015 1

2.2 O-Ring ID25.0 X 3.5 015403001 2
3 Hose tank to cooler kit 012479629
3.1 Hose TVB TO OC EG-22 015318017 1
3.2 O-Ring ID25.0 X 3.5 015403001 2
4 Hose cooler to tank kit 012479639

4.1 Hose OC TO TVB EG-22 015318016 1

4.2 O-Ring ID25.0 X 3.5 015403001 2

D) 8000 hours kit - Part Number 012400673

S. No Description Part Number Qty.

1 One time consumable kit 012485145 1

2 8000 hrs valve kit 012400646 1

3 Drive coupling element B011201170002 1

4 NRV B004100170001 1

5 Safety valve B008401880003 1

6 Strainer B008806100003 1
7 Tube and fittings kit 012485142 1

Lubricant - ELGi Air Lube UT Synthetic

S. No Description Part Number

1 ELGi Air Lube UT Synthetic 5 litres (1.3 gallons) 000998092

2 ELGi Air Lube UT Synthetic 20 litres (5.3 gallons) 000998090
3 ELGi Air Lube UT Synthetic 208 litres (55 gallons) 000998093

Lubricant - ELGi Air Lube XD

S. No Description Part Number

1 ELGi Air Lube XD 5 litres (1.3 gallons) 000998066

2 ELGi Air Lube XD 20 litres (5.3 gallons) 000998053
3 ELGi Air Lube XD 210 litres (55 gallons) 000998055

Kit Details 14.6

Lubricant - ELGi Air Lube FG
S. No Description Part Number

1 ELGi Air Lube FG 5 litres (1.3 gallons) 000998077

2 ELGi Air Lube FG 20 litres (5.3 gallons) 000998078

3 ELGi Air Lube FG 210 litres (55 gallons) 000998079

Other Spares
*Parts and quantity required for Cooler to Shroud sealing
S. No Description Part Number Qty

1 OIL COOLER (EG11 & 15) 015315703 1

2 AFTER COOLER (EG11 & 15) 015315704 1

3 OIL COOLER (EG18 & 22) 015315701 1

4 AFTER COOLER (EG18 & 22) 015315702 1

5 PRE FILTER -SS WIRE MESH 015320855 3

6 CLIP ON GASKET 015312471 0.5m

7 SEALING STRIP 41041X223 1.6m

Kit Details 14.7

VFD RETROFITMENT KITS ***

1) VFD retro kit C TO CV 11 KW–012486849

S. No Description Part Number Qty.

1 VFD,575V,60HZ,FC-302P11KT6E20,FRAME-B3 B012000510121 1

2 VFD Mounting plate 015311410 1

3 Hex bolt M8 X 16 000906113 4

4 Hex bolt M6 X 16 000906084 2
5 Plain washer M8 000996008 4

6 Spring washer M8 RECT ZYP 000996108 4

7 Spring washer REC SEC M6 000996106 2

8 Control panel EG11-22V 575V 60HZA 018364106 1

9 FIELD STICKER- EG 15HP 575V 60HZ-CV 445400958 1

10 FUSE STICKER EG15-30HP 575V 60HZ-C/CV 445400929 1
11 EMI FILTER 575V,60H-FN 258HV-30-33 B012700510003 1

2) VFD retro kit C TO CV 15 KW–012486859

S. No Description Part Number Qty.

1 VFD,575V,60HZ,FC-302P15KT6E20,FRAME-B3 B012000510122 1

2 VFD Mounting plate 015311410 1

3 Hex bolt M8 X 16 000906113 4

4 Hex bolt M6 X 16 000906084 2

5 Plain washer M8 000996008 4

6 Spring washer M8 RECT ZYP 000996108 4
7 Spring washer REC SEC M6 000996106 2

8 Control panel EG11-22V 575V 60HZA 018364106 1

9 FIELD STICKER- EG 20HP 575V 60HZ-CV 445400959 1

10 FUSE STICKER EG15-30HP 575V 60HZ-C/CV 445400929 1

11 EMI FILTER 575V,60H-FN 258HV-30-33 B012700510003 1

3) VFD retro kit C TO CV 18 KW–012486869

S. No Description Part Number Qty.

1 VFD,575V,60HZ,FC-302P18KT6E20,FRAME-B4 B012000510123 1

2 VFD Mounting plate 015311410 1

3 Hex bolt M8 X 16 000906113 1
4 Hex bolt M6 X 16 000906084 1

5 Plain washer M8 000996008 1

6 Spring washer M8 RECT ZYP 000996108 1

Kit Details 14.8

 S. No Description Part Number Qty.
7 Spring washer REC SEC M6 000996106 1

8 Control panel EG11-22V 575V 60HZA 018364106 1

9 FIELD STICKER- EG 25HP 575V 60HZ-CV 445400960 1

10 FUSE STICKER EG15-30HP 575V 60HZ-C/CV 445400929 1

11 EMI FILTER 575V,60H-FN 258HV-30-33 B012700510003 1

4) VFD retro kit C TO CV 22 KW–012486879

S. No Description Part Number Qty.

1 VFD,575V,60HZ,FC-302P22KT6E20,FRAME-B4 B012000510124 1

2 VFD Mounting plate 015311410 1

3 Hex bolt M8 X 16 000906113 4

4 Hex bolt M6 X 16 000906084 2

5 Plain washer M8 000996008 4

6 Spring washer M8 RECT ZYP 000996108 4
7 Spring washer REC SEC M6 000996106 2

8 Control panel EG11-22V 575V 60HZA 018364106 1

9 FIELD STICKER- EG 30HP 575V 60HZ-CV 445400926 1
10 FUSE STICKER EG15-30HP 575V 60HZ-C/CV 445400929 1
11 EMI FILTER 575V,60H-FN 258HV-42-33 B012700510004 1

*** VFD Retro fitment kit is applicable for US/CANADA variant only

Kit Details 14.9

INSURANCE KIT DETAILS - 50Hz

Models

15CD,V 18C -
11CD,V 15C - 15C - 15CD,V
Insurance kit details 11C all - 7.5,8.5,
all 7.5,8.5 10,13 -10,13
7.5,8.5 10

Kit No

S. 01247968 01240066 01240064 01247971 01240066 01240066 01240064

Description Part Number 9 4 7 9 5 4 9
No
INTAKE VALVE KIT (FOR EIV
1
159 A970012)
972300090 - -  -  - 
INTAKE VALVE KIT (FOR EIV
2
102 A970008)
972300040   -  -  -
BLOW DOWN VALVE KIT (102) 972300080   -  -  -
3
BLOW DOWN VALVE KIT (159) 972300030 - -  -  - 
DRIVE COUPLING ELEMENT
4
18kW TO 22kW
B011201170002 - - - - - - 
DRIVE COUPLING ELEMENT
5
11kW TO 15kW
B011201170003       -
6 O-RING AND GASKET KIT 012479649 - -  -  - 
7 O-RING AND GASKET KIT 012479659   -  -  -
PULSE LINE, RETURN LINE,
OIL LEVEL
8
TUBES,CORRESPONDING FER-
012479669   -  -  -
RULE AND SLEEVE KIT
PULSE LINE, RETURN LINE,
OIL LEVEL
9
TUBES,CORRESPONDING FER-
012479679 - -  -  - 
RULE AND SLEEVE KIT
SOLENOID VALVE NC,24V,
10
50/60Hz
B007300990017       
MINIMUM PRESSURE VALVE
11
KIT
A990293       
12 HOSE OIL INJECTION KIT 012479609   -  -  -
13 HOSE OIL INJECTION KIT 012479619 - -  -  - 
14 HOSE MPV TO COOLER KIT 012479599       
15 HOSE TANK TO COOLER KIT 012479629       
16 HOSE COOLER TO TANK KIT 012479639       
HOSE MOS OUT TO DRYER
17
KIT
012400671 -  - -   -
HOSE DRYER TO BALL VALVE
18
KIT
012475749 -  - -   -
19 SUCTION DUCT 015404122       
C : Standard version CV : Standard + Variable frequency drive D : Dryer version

Kit Details 14.10

 Models

18CD,V 22CD,V
22C -
- 18CD,V - 22CD,V
Insurance kit details 18C -13 7.5,8.5, 22C-13
7.5,8.5, -13 7.5,8.5, -13
10
10 10

Kit No

S. 01247974 01240066 01240066 01240065 01247555 01240066 01240067

Description Part Number 9 7 8 1 9 9 0
No
INTAKE VALVE KIT (FOR EIV
1
159 A970012)
972300090 -  -  -  -
INTAKE VALVE KIT (FOR EIV
2
102 A970008)
972300040  -  -  - 
BLOW DOWN VALVE KIT (102) 972300080  -  -  - 
3
BLOW DOWN VALVE KIT (159) 972300030 -  -  -  -
DRIVE COUPLING ELEMENT
4
18kW TO 22kW
B011201170002       
DRIVE COUPLING ELEMENT
5
11kW TO 15kW
B011201170003 - - - - - - -
6 O-RING AND GASKET KIT 012479649 -  -  -  -
7 O-RING AND GASKET KIT 012479659  -  -  - 
PULSE LINE, RETURN LINE,
OIL LEVEL
8
TUBES,CORRESPONDING FER-
012479669  -  -  - 
RULE AND SLEEVE KIT

PULSE LINE, RETURN LINE,

OIL LEVEL
9
TUBES,CORRESPONDING FER-
012479679 -  -  -  -
RULE AND SLEEVE KIT

SOLENOID VALVE NC,24V,

10
50/60Hz
B007300990017       
MINIMUM PRESSURE VALVE
11
KIT
A990293       
12 HOSE OIL INJECTION KIT 012479609  -  -  - 
13 HOSE OIL INJECTION KIT 012479619 -  -  -  -
14 HOSE MPV TO COOLER KIT 012479599       
15 HOSE TANK TO COOLER KIT 012479629       
16 HOSE COOLER TO TANK KIT 012479639       
17 HOSE MOS TO DRYER KIT 012400671 -   - -  
HOSE DRYER TO BALL VALVE
18
KIT
012475749 -   - -  
19 SUCTION DUCT 015404122       
C : Standard version CV : Standard + Variable frequency drive D : Dryer version
NOTE
 * * Parts not included in insurance kit
 Calibration must be carried out if any sensors are replaced. For doing so please contact ELGi dealer/ service engineer.
Kit Details 14.11
INSURANCE KIT DETAILS - 60Hz

Models

11CD,V 15CD,V 18C – 18C -

Insurance kit details 11C all 15C all
all all 100,125 150,175

Kit No

S. 01247968 01240066 01247971 01240066 01247974

Description Part Number 9 4 9 4
012400649
9
No

INTAKE VALVE KIT (FOR EIV 159

1
A970012)
972300090 - - - -  -
INTAKE VALVE KIT (FOR EIV 102
2
A970008)
972300040     - 
BLOW DOWN VALVE KIT (102) 972300080     - 
3
BLOW DOWN VALVE KIT (159) 972300030 - - - -  -
DRIVE COUPLING ELEMENT
4
18kW TO 22kW
B011201170002 - - - -  
DRIVE COUPLING ELEMENT
5
11kW TO 15kW
B011201170003     - -
6 O-RING AND GASKET KIT 012479649 - - - -  -
7 O-RING AND GASKET KIT 012479659     - 
PULSE LINE, RETURN LINE, OIL
8 LEVEL TUBES,CORRESPONDING 012479669     - 
FERRULE AND SLEEVE KIT
PULSE LINE, RETURN LINE, OIL
9 LEVEL TUBES,CORRESPONDING 012479679 - - - -  -
FERRULE AND SLEEVE KIT

SOLENOID VALVE NC,24V,

10
50/60Hz
B007300990017      
11 MINIMUM PRESSURE VALVE KIT A990293      
12 HOSE OIL INJECTION KIT 012479609     - 
13 HOSE OIL INJECTION KIT 012479619 - - - -  -
14 HOSE MPV TO COOLER KIT 012479599      
15 HOSE TANK TO COOLER KIT 012479629      
16 HOSE COOLER TO TANK KIT 012479639      
17 HOSE MOS OUT TO DRYER KIT 012400671 -  -  - -
18 HOSE DRYER TO BALL VALVE KIT 012475749 -  -  - -
19 SUCTION DUCT 015404122      
C : Standard version CV : Standard + Variable frequency drive D : Dryer version

Kit Details 14.12

 Models

22CD,V
18CD,V 18CD,V 22C –
– 22CD,V
Insurance kit details – - 100,125 22C-175
100,125 -175
100,125 150,175 ,150
,150

Kit No

S. 01240066 01240066 01240065 01247555 01240066 01240067

Description Part Number 7 8 1 9 9 0
No
INTAKE VALVE KIT (FOR EIV 159
1
A970012)
972300090  -  -  -
INTAKE VALVE KIT (FOR EIV 102
2
A970008)
972300040 -  -  - 
BLOW DOWN VALVE KIT (102) 972300080 -  -  - 
3
BLOW DOWN VALVE KIT (159) 972300030  -  -  -
DRIVE COUPLING ELEMENT
4
18kW TO 22kW
B011201170002      
DRIVE COUPLING ELEMENT
5
11kW TO 15kW
B011201170003 - - - - - -
6 O-RING AND GASKET KIT 012479649  -  -  -
7 O-RING AND GASKET KIT 012479659 -  -  - 
PULSE LINE, RETURN LINE, OIL
8 LEVEL TUBES,CORRESPONDING 012479669 -  -  - 
FERRULE AND SLEEVE KIT
PULSE LINE, RETURN LINE, OIL
9 LEVEL TUBES,CORRESPONDING 012479679  -  -  -
FERRULE AND SLEEVE KIT
SOLENOID VALVE NC,24V,
10
50/60Hz
B007300990017      
11 MINIMUM PRESSURE VALVE KIT A990293      
12 HOSE OIL INJECTION KIT 012479609 -  -  - 
13 HOSE OIL INJECTION KIT 012479619  -  -  -
14 HOSE MPV TO COOLER KIT 012479599      
15 HOSE TANK TO COOLER KIT 012479629      
16 HOSE COOLER TO TANK KIT 012479639      
17 HOSE MOS TO DRYER KIT 012400671   - -  
18 HOSE DRYER TO BALL VALVE KIT 012475749   - -  
19 SUCTION DUCT 015404122      
C : Standard version CV : Standard + Variable frequency drive D : Dryer version
NOTE
 * * Parts not included in insurance kit
 Calibration must be carried out if any sensors are replaced. For doing so please contact ELGi dealer/ service engineer.
Kit Details 14.13
CONTROL PANEL 3PH,208-230V AC 60Hz N-III

CS 30.11.16
STARTER CUM CONTROL PANEL
MANOJ 30.11.16

01 83 6352 0
NTS 1 4 R 0 3
 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1

Re10 Re9 Re8 Re7 Re6 Re5 Re4 Re3 Re2 Re1
X08

X07 X06 X05

X02 X03
X04
RS 485 RS 485
2B

1B
2A

1A

2 4 6 8 10 2 4 6 8
2 4 6 8 10 12
X01 1 3 5 7 9 1 3 5 7 9 11
1 3 5 7

P N
PE
CN

CN

CN
CN

CONNECTION DETAILS

X02
X03

1
2
1
2

3
4
3
4

5
6
5
6

7
8
7
8

9
10
9
10

11
12

CONTROL PANEL 3PH,208-230V AC 60Hz N-III

CS 30.11.16
CONTROLLER CIRCUIT
MANOJ 30.11.16

01 83 6352 0
NTS 2 4 R 0 3
CONTROL PANEL 3PH,208-230V AC 60Hz N-III

CS 30.11.16
BILL OF MATERIALS
MANOJ 30.11.16

01 83 6352 0
NTS 3 4 R 0 3
CONTROL PANEL 3PH,208-230V AC 60Hz N-III

CS 30.11.16
PANEL LAY OUT
MANOJ 30.11.16

01 83 6352 0
NTS 4 4 R 0 3
CONTROL PANEL EG11,460V,60HZ,NIII

CS 30.11.16
STARTER CUM CONTROL PANEL
MANOJ 30.11.16

01 83 6352 0
NTS 1 4 R 0 3
 3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1

Re10 Re9 Re8 Re7 Re6 Re5 Re4 Re3 Re2 Re1
X08

X07 X06 X05

X02 X03
X04
RS 485 RS 485
2B

1B
2A

1A

2 4 6 8 10 2 4 6 8
2 4 6 8 10 12
X01 1 3 5 7 9 1 3 5 7 9 11
1 3 5 7

P N
PE
CN

CN

CN
CN

CONNECTION DETAILS

X02
X03

1
2
1
2

3
4
3
4

5
6
5
6

7
8
7
8

9
10
9
10

11
12

CONTROL PANEL EG11,460V,60HZ,NIII

CS 30.11.16
CONTROLLER CIRCUIT
MANOJ 30.11.16

01 83 6352 0
NTS 2 4 R 0 3
CONTROL PANEL EG11,460V,60HZ,NIII

CS 30.11.16
BILL OF MATERIALS
MANOJ 30.11.16

01 83 6352 0
NTS 3 4 R 0 3
CONTROL PANEL EG11,460V,60HZ,NIII

CS 30.11.16
PANEL LAY OUT
MANOJ 30.11.16

01 83 6352 0
NTS 4 4 R 0 3
Branch offices

"ELGI HOUSE" 2, Mill Officer's Colony, Behind La-Gajjar Chambers, (Old Reserve Bank), Opp. Times of India, Ashram
AHMEDABAD Road, Ahmedabad - 380 009, Tel: +961-79- 26583736, 26581274, 26587683, Fax: 91-79-6587683,
E-mail: [email protected]

BANGALORE 15,16 Richmond Road, Bangalore - 560 025, Tel: +91-80-22537208, Fax: 91-080-22293274, E-mail: [email protected]

S4-II Floor, Apollo Dubai Plaza, No-100, Mahalingapuram Main Road, Nungambakkam, Chennai - 600 034,
CHENNAI
Tel: +91-44-28172599, 28179500, Fax: 91-44-28174699, E-mail: [email protected]

1st Floor, No.622-A, Near ELGi industrial Complex, Trichy Road, Singanallur, Coimbatore - 641 005,
COIMBATORE
Tel: +91-422-2589555, Fax: 91-422-2573697, E-mail: [email protected]

H.NO: 12-13-188, II nd Floor, Street No. 2, Taranaka, Hyderabad - 500 017,

HYDERABAD
Tel: +91-40-27000435, 27000437, 27000439, 27000431, Fax: 91-40-27000438, E-mail: [email protected]

602, 6th Floor, Diamond Tower, Purani Chungi, Ajmer Road, Jaipur - 302 021,
JAIPUR
Tel: +91-141-2970120, 2970121, E-mail: [email protected]

1st Floor, Asset Summit Suites, National Highway 47, Near SCMS, Kalamassery, Kochi – 683106.
KOCHI
Tel: +91-484 -2360155, 2351904, E-mail: [email protected]

Space No. 502, Block - C, 5th Floor, Axis Mall, Action Area - 1C, New Town, Premises No. CF - 9, Kolkata - 700 156,
KOLKATA
Tel: +91-33-2324-4270, 2324-4271, Fax: 91-33-2324-4272, E-mail: [email protected]

Marol Co-op Industrial Estate Ltd. Plot No.48, Mathurdas Vassanji Road, Near Sakinaka, Andheri (East), Mumbai-400 059,
MUMBAI
Tel: +91-22-42161000, Fax: 91-22-28591601, E-mail: [email protected]

23, Shivaji Marg, Near Karampura, Opp.DCM, New Delhi - 110 015,
NEW DELHI
Tel: +91-11-25928095, 25153644, 25175018, Fax: 91-11-25459375, E-mail: [email protected]

White House, Ground Floor, 388/A-1/2240, Mumbai - Pune Road, Opp. Sandvik(Asia), Dapodi, Pune - 411 012,
PUNE
Tel: +91- 20-30635457, Fax: 91-20-4073759, E-mail: [email protected]

Om1, 1st Floor, Ashoka Milllennium, Ring Road No.1, Raipur - 492 003, Chhattisgargh,
RAIPUR
Tel: +91-97520 93008, Fax: 91-771-4073759, E-mail: [email protected]

4/2, Nandhini Complex, 1st Floor, Velur Road, Tiruchengode - 637 211,
TIRUCHENGODE
Tel: +91-4288-257137, Fax: 91-4288-257693, E-mail: [email protected]

Overseas offices

ELGI EQUIPMENTS LIMITED, No. 2A-4-6, Jalan Jubli Perak, 22/1, Section 22, 40400, Shah Alam, Selangor, Malaysia,
MALAYSIA
Tel: +60 355693544 Web: www.elgi.com.my

ELGI EQUIPMENTS LIMITED, 223/66, 14th Floor, Building A, Country Complex, Sanphawut Road, Bang Na, Bangkok,
THAILAND Thailand - 10260, Tel: +6627455160, Local Use: 02-7455160,
E-mail: [email protected], Web: www.elgi.co.th

Overseas fellow subsidiaries

ELGI EQUIPMENTS PTY LTD., 7/66 Pritchard Road, Virginia, Queensland - 4014, Australia,
AUSTRALIA Tel: +61 7 3106 0589, Fax: +61-7 3106 0537, Email: [email protected],
Web: www.elgi.com.au

ELGI COMPRESSORES DO BRASIL LTD, Av. Emílio Chechinatto, 4195 – Bairro São Roque da Chave,
BRAZIL
CEP:13.295-000, Itupeva – São PauloBrasil, Tel: +55-11-4496 5519, 4496 6611, E-mail: [email protected]

ELGI EQUIPMENTS (ZHEJIANG) LIMITED, West of 1st Floor, Building 2, No. 232, Yunhai Road, Jiaxing 314033 P.R. China,
Tel: +86-573-82079100, Hotline: 400-826-3585 E-mail: [email protected], Web: elgi.cn
CHINA
ELGI COMPRESSORS TRADING (SHANGHAI) CO.,LTD. Rm 912-913, No. 8-9, Lane 1500, South Lianhua Road, Shanghai
201108 P.R. China, Tel: +86-21-33581191, Hotline: 400-826-3585, E-mail: [email protected], Web: elgi.cn

PT ELGI EQUIPMENTS INDONESIA, Kawasan Pergudangan, Bizpark Commercial Estate, Pulogadung Jl, Raya Bekai Km.
INDONESIA 21, 5 Block A3 No. 12, Kel. Rawa Terate, Kec. Cakung, Pulogadung Jakarta Timur 13920,
Tel: +62-21- 46822216, 46827388, E mail: [email protected], Web: www.elgi.co.id

ROTAIR Spa, Via Bernezzo-67, 12023, Caraglio (CN), Italy, Tel: +39 0171619676, Fax: +39-0171619677,
ITALY
E-mail: [email protected], 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: [email protected], Web: www.elgigulf.com

ELGI COMPRESSORS USA, INC. 1500 Suite N Continental Blvd, Charlotte, NC 28273, USA. Tel: +1-704-943-7966,
USA
E-mail: [email protected]
FACTORY & REGISTERED OFFICE
ELGI EQUIPMENTS LIMITED
Singanallur, Coimbatore - 641 005,
India (CIN:L29120TZ1960PLC000351).
Tel: +91-422-2589555
Fax: +91-422-2573697, +91-422-2589401
E-mail: [email protected], Web: www.elgi.com

ELGI EQUIPMENTS LIMITED (FOUNDRY DIVISION)

SF No: 212/1A, 213/1, KodangipalayamVillage,
Nallatipalayam Road, Singarampalayam Post, Kinathukkadavu,
Kinathukkadavu Taluk,
Coimbatore - 642 109, India.
Tel : +91-422-2587631, 620

GLOBAL SUPPORT CENTRE

SF NO 221, 221/2 & 221/3, Kothavadi Road,
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.
Tel : +91-422-2587000.

FELLOW SUBSIDIARIES (DOMESTIC)

ATS ELGI LIMITED,
Kurichy Private Industrial Estate, Kurichy,
Coimbatore - 641 021, India,
Tel: +91-422-2589999, 2672201-3,
Fax: +91-422-2675446,
E-mail: [email protected],
Web: www.ats-elgi.com

ADISONS PRECISION INSTRUMENTS MFG.CO.LIMITED

Elgi Indusrial Complex, Singanallur,
Coimbatore - 641 005
Tel: +91-422-2589555

ERGO DESIGN PVT LTD,

150, 2nd Main, 2nd Cross, Chelekare, Kalyan Nagar,
Bengaluru, Karnataka 560043,
Tel: +91-80-42436000

JOINT VENTURE
ELGI SAUER COMPRESSORS LIMITED,
Elgi Industrial Complex III, Singanallur,
Coimbatore - 641 005, India,
Tel: +91-422-2589555, 2589634, 2589510,
Fax: +91-422-2573697,
E-mail: [email protected], Web: www.elgisauer.com

INDUSTRIAL AIR SOLUTIONS LLP,

1, R R Industrial Estate, Opposite Shanthi Gears Regd Office, Singanallur,
Coimbatore, Tamil Nadu 641005,
Tel: 0422 227 1862.

DIVISION
PRESSURE VESSEL DIVISION
1473 - Trichy Road, Coimbatore - 641 018,
Tel: +91-422-2589777,
Email: [email protected].


 2
2
1
0
3
0
S

ELGI EQUIPMENTS LIMITED

C

Trichy Road, Singanallur, Coimbatore - 641005, India

T

T +91 422 2589555, E [email protected], W www.elgi.com

Toll-free No. 1800 425 3544
M

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