Product Manual

EG Series
Electric Powered Screw Air Compressor

EG 110 - 150.0
Air - Cooled, Standard + VFD
460V, 3Ph, 60Hz
©
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005

Part / Document No. 019000051

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

16.0 VFD setting 16.1

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

 9''

OIL POUR

82.7"±0.2"
72"±0.2"

84.1"±0.2" (WITH FAN)

OIL SIGHT

Y
GLASS
20.7''

VFD DISPLAY OIL DRAIN 9.8''

7.9" 40.2" 7.9''

3"
PANEL SIZE G 34'
108"
117"
120"±0.4''
 101

102

103

104

105

Compressed Air
Discharge

106

107

108

DPOF 109

110

111

112

113

114

115

116

117
INSTRUMENT
TAG No
DESCRIPTION LOCATION RANGE
TEMPERATURE After Air end 0-150°C
TS01
SENSOR
PS01 PRESSURE SENSOR After Aftercooler 0 - 16 bar

PS02 PRESSURE SENSOR on Air oil seperator tank 0 - 16 bar

DPOF PRESSURE SENSOR Oil Filter 0 - 16 bar

 4.0 Technical data

Standard
Model - EG 90 EG 110 EG 160

Working pressure psi.g 100 115 125 150 100 115 125 150 100 115 125 150

cfm 604 546 536 478 720 650 630 570 975 887 850 778
FAD - Free air delivery 3
m /
17.10 15.46 15.18 13.54 20.39 18.40 17.84 16.14 27.61 25.11 24.07 22.03
min

Unloading pressure psi.g 115.0 130.0 140.0 165.0 115.0 130.0 140.0 169.6 115.0 130.0 140.0 165.0
Nominal power supply
- 460V (+/-10%), 60Hz(+/-5%), 3 Phase
conditions

Main motor rating hp 125 150 200

Type of motors (main drive & Squirrel cage induction ,TEFC & Cooling fan integrated
-
fan drive) motor
Insulation and protection of
- Class F / IP55
main motor
Frame size / mounting type - 444/5T / B35T 445/7T / B35T

Type of starter for main motor - Automatic star delta

Maximum fan motor rating per

hp 2.1 X 1 Fan 2.1 X 2 Fans
fan X no. of fans
Rated speed of fan motor rpm 1070

Safety valve set pressure psi.g 205

Standard + VFD

Model - EG 90 EG 110 EG 160

Working pressure psi.g 100 115 125 150 100 115 125 150 100 115 125 150

cfm 604 546 536 478 720 650 630 570 975 887 850 778
FAD - Free air delivery 3
m /
17.10 15.46 15.18 13.54 20.39 18.40 17.84 16.14 27.61 25.11 24.07 22.03
min
Unloading pressure psi.g 107.0 130.0 132.0 157.0 107.0 130.0 132.0 157.0 107.0 130.0 132.0 157.0
Nominal power supply
- 460V (+/-10%), 60Hz(+/-5%), 3 Phase
conditions

Main motor rating hp 125 150 200

Type of motors (main drive & Squirrel cage induction ,TEFC & Cooling fan integrated
-
fan drive) motor
Insulation and protection of
- Class F / IP55
main motor

Frame size / mounting type - 444/5T / B35T 445/7T / B35T

Type of starter for main motor - Through Variable Frequency Drive

Maximum fan motor rating per

hp 2.1 X 1 Fan 2.1 X 2 Fans
fan X no. of fans
Rated speed of fan motor rpm 1070

Safety valve set pressure psi.g 205

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

first time, it needs to be installed at your site according to
ELGi's installation guidelines.
ROPE / SLING
5.1.1 Unpacking
STIFF SPREADER
Unpack the compressor from the packing case by BAR
removing the nails. Unscrew the bolts, holding the
compressor to the base of the crate.

Once the packing material is removed, check the contents

against the packing list. The compressor is shipped with
the following

 Key for doors

 Operation and maintenance manual

 Checklist of parts of the machine

 Electrical drawing

5.1.2 Disposal of packing material Figure 3. Lifting using crane

The wood/cardboard used to make the shipping crates of
the EG series compressors are biodegradable. NOTE
Removal of transit brackets:
The polyethylene covers wrapped around the compressor
and the polystyrene packing provided around the electrical Once you have placed the compressor in its final position,
remove the red painted transit brackets and store for
panels are not recyclable. They must be disposed off in
future use.
accordance with prevailing local environmental laws.
Locations:
5.1.3 Handling  Bracket in between the base and airend support

1. Lift compressors using either a forklift/pallet truck  Bracket in between the base and motor
(Fig.2) or a crane (Fig.3).  Bracket in between the shroud and control panel box

2. When using a forklift, ensure padding is used in 5.1.4 Site requirements

between the compressor and forklift (as shown in Fig.2)
 Install the air compressor in a clean, dry, cool and dust
to prevent damage to the compressor’s canopy.
free room as extreme temperatures (hot or cold),
3. When using a crane, please ensure stiff spreader bars moisture, air borne contaminants can significantly affect
are used (as shown in Fig.3) to prevent rope slings from compressor performance, durability and compressed air
damaging the compressor’s canopy. quality.
4. Do not drop the compressor.  Be aware the entrance to the compressor room should
5. Do not attempt to move the compressor by pushing or be high enough and wide enough to carry the
dragging it as this may cause jerky movements causing compressor in and out.
damage to the compressor.  Leave a minimum of 1m (3.28ft) space around the
compressor for safe and proper inspection, cleaning,
and maintenance activities.

 Leave minimum of 2m (6.56ft) space above the

compressor for hot air to flow away from the
compressor.

 Ensure the compressor is protected against direct

sunlight and rain.

 Avoid exposing the compressor to excessive moisture

(from rain, dryer vent, etc.) as moisture can affect
airend lubrication, promote rust formation on the
compressor and lead to electrical problems of the
motor.
PADDING
 Neither install the machine in a location where flame is
used nor place any inflammable objects near the
Figure 2. Lifting using forklift
compressor.

Installation and operation 5.2

 Ensure the room temperature is within 50ºC (122ºF) as  Do not store toxic, volatile, or corrosive agents near the
high ambient temperatures can reduced oil life due to compressor.
higher discharge oil temperature (DOT). It also results
 Isolate the compressor from corrosive agents like
in high approach temperatures affecting cooling and
ammonia, chlorine, salt spray, and other chemicals as
condensation efficiency in the after-cooler and in air
these may erode the internal components and also
treatment equipment like air dryers.
contaminate the oil and filters.
 Ensure the hot medium of other utility equipments like
 Do not allow hot air from additional equipment to blow
genset/dryer/ boilers, etc., hot medium not sucked by
towards the compressor.
compressor inlet or that in any way room temperature
does not rise to prevent high discharge oil temperature.  If you operate in high dust applications like rice mills,
cement, flour mills, etc., it would be necessary to clean
 Ensure the ambient temperature does not drop below
and replace the filters more often.
0ºC (32ºF). Provide air supply openings and adjustable
 Good practice is to have overhead lifting in the
louvers to ensure that the minimum temperature does
not drop down below 0ºC (32ºF). compressor room to facilitate any major overhaul. If an
overhead hoist is not available, you should be able to
 Ensure unevenness of the surface is within 6mm
use a mobile crane or forklift truck in your compressor
(0.25").
room at a minimum.

5.1.4.1 Ventilation
 A part of electric energy to your compressor motor is
MINIMUM 2 m (6.6 ft) CLEARANCE
converted into heat and this heat must be removed
from the compressor room by suitable ventilation.
CEILING
 The ventilation requirements of the compressor are
listed in Table 1.
ELGi SCREW AIR
 The ventilation requirements could be achieved by the
COMPRESSOR
following methods.

 Natural ventilation is sufficient if the temperature rise in

the compressor room (measured by a thermometer
near the air inlet pre-filter) is within 5ºC (9ºF) when
Figure 4. Vertical clearance around the compared with outside temperature
compressor
 Forced ventilation with an exhaust fan is necessary if
the temperature rise inside the room (measured by a
thermometer near the air inlet pre-filter mesh) is rises
above 5ºC (9ºF) .

 Ventilation with ducts: Ensure hot air exhaust from the

ELGi SCREW AIR
COMPRESSOR compressor is diverted through the ducts when installed
in an enclosed area. (contact ELGi for ducting
WALLS OR
OTHER requirements)
EQUIPMENTS
 Provide openings on walls/partitions close to the air
suction side of the compressor.
MINIMUM CLEARANCE, X=1 m (3.5 ft)
 Provide exhaust openings close to the ceiling for hot air
exit.
Figure 5. Horizontal clearance around the
compressor  If more than four compressors are installed in a room,
good practice is to provide ducting arrangements. This
 If the floor is splashed frequently with water while
will avoid hot air recirculation.
cleaning, then place your compressor on a raised
concrete plinth 100 to 150 mm (4 to 6 inches) high.  Be aware hot air recirculation in the enclosed area will
affect the compressor performance.
 Ensure the compressor base makes 100% contact
directly with the floor.  Ensure the air velocity in the supply and exhaust ducts
does not exceed 4 m/s (13 ft/s).
 Know that an industrial floor with level surface capable
of supporting the weight if the compressor is sufficient  Know air velocity is ascertained during commissioning
for installing your compressor. No special foundation or using an anemometer.
anchoring is necessary for rotary screw compressors.  Do not connect cool air inlet ducts directly to the

Installation and operation 5.3

 compressor inlet side.

 To eliminate transmission of vibrations, provide a soft

bellows connector between the duct and the compressor.

Minimum Minimum
ventilation ventilation
Model
requirement requirement
(ft3/h ) (m3/h)
EG 11 94,537 2,677
EG 15 128,086 3,627
EG 18 157,185 4,451
EG 22 204,154 5,781
EG 30 242,576 6,869
Figure 6. Forced ventilation with exhaust fan
EG 37 299,185 8,472
EG 45 363,847 10,303
EG 55 464,246 13,146
EG 75 631,708 17,888
EG 90 705,481 19,977
EG 110 864,821 24,489
EG 132 1,033,801 29,274
EG 160 1,273,482 36,061
EG 200 1,718,976 48, 676
EG 250 1,718,976 48, 676
EG 90-P 708,765 20,070
EG 110-P 1,218,356 34,500
EG 132-P 1,218,356 34,500 Figure 7. Ventilation with ducts
EG 160-P 1,218,356 34,500
Table 1. Global series – Ventilation requirements

 Contact ELGi in case you need to provide a duct

connection or filter fitment on the compressor.

5.1.5 Electricals

Ensure that only authorized service technicians perform

electrical work. Study the electrical circuit diagram before
starting work.

Incoming Cable
Motor power Back up fuse Incoming Cable size Earth cable Gland Size
size
Model
208 - Cu Al
kW H.P 460V Cu Sq.mm Al Sq.mm Size Dia
230V Sq.mm Sq.mm
EG 11 11 15 100A 63A 4 X 10 4 X 16 4X4 4X6 2.5 Gauge 25 mm
EG 15 15 20 100A 63A 4 X 16 4 X 25 4X6 4 X 10 2.5 Gauge 25 mm
EG 18 18 25 125A 63A 4 X 25 4 X 35 4X6 4 X 10 2.5 Gauge 25 mm
EG 22 22 30 160A 63A 4 X 35 4 X 50 4 X 10 4 X 16 4 Gauge 28 mm
EG 30 30 40 200A 100A 4 X 50 4 X 70 4 X 16 3 1/2 X 25 4 Gauge 32 mm
EG 37 37 50 250A 125A 4 X 70 4 X 95 3 1/2 X 25 3 1/2 X 35 6 Gauge 35 mm
EG 45 45 60 125A 3 1/2 X 35 3 1/2 X 50 6 Gauge 35 mm
EG 55 55 75 160A 3 1/2 X 35 3 1/2 X 50 6 Gauge 35 mm
EG 75 75 101 250A 3 1/2 X 70 3 1/2 X 95 8 Gauge 50 mm
EG 90 90 121 250A 3 1/2 X 70 3 1/2 X 95 8 Gauge 50 mm
EG 110 110 147 315A 3 1/2 X 95 3 1/2 X 120 25 x 3 cu flat 1.75 inch
EG 160 160 214 400A 3 1/2 X 150 3 1/2 X 185 35 x 3 cu flat 2.25 inch

Table 2. Global series – Electrical requirements

Installation and operation 5.4

1. Supply power to the compressor through a dedicated 3. Refer to Table 2 for fuse and cable specifications for
switch disconnected fuse (SDF) unit of a suitable rating 460V, 60Hz, 3-Ph power supplies.
mounted within 5 m (16.4ft) of the compressor. (This 4. Do not use an MCB (miniature circuit breaker) because
architecture lets you isolate the compressor). the selection of contactors is based on Type-2 co-
2. Use HRC (high rupturing current) fuse instead of an ordination.
MCCB (moulded case circuit breaker) to avoid possible 5. Connect the earthling line to the point provided on the
contactor and motor failure. base frame at the side of the compressor and motor.

CONTROLLER

POWER CABLE
ENTRY
EARTHING
POINT

EARTHING
POINT
LEADS

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

2. In case the main delivery pipe is more than 100 m (330

NOTE
feet) long, use a pipe diameter that is one size bigger
The above table shows the pressure drops in 100m length
than shown in the table.
schedule 40 steel pipe at 7 bar (abs)

1. Use the pipe sizes (as in Table 3) for the delivery pipe
that connects to ball valve of the compressor.

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
1.0 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
2.0 70.63 6.4 - 8.8 226 - 310 10.0 - 13.0 356 - 470
3.0 106.0 8.8 - 12.6 311 - 445 13.0 - 20.1 471 - 710
4.0 141.3 12.6 - 16.1 446 - 570 20.1 - 26.7 711 - 945
5.0 176.6 16.1 - 19.8 571 - 700 26.7 - 33.4 946 - 1180
6.0 211.9 19.8 - 24.0 701 - 850 33.4 - 40.0 1181 - 1415
7.0 247.2 24.0 - 28.0 851 - 990 40.0 - 46.7 1416 - 1650
8.0 282.5 28.0 - 32.0 990 - 1130 46.7 - 53.3 1651 - 1885
Table 4. Global series—Receivers specifications

c. Re-grease the main motor if the compressor is not

5.1.8 Possible mistakes commissioned for more than 1- ½ years (18 months)
1. The compressor is installed on the wooden pallet of the d. Replace the AVMs if you detect any abnormal squeezing
packing case. or damage in the rubber part.
2. The compressor base is not making 100% contact with e. Check whether all the screws in the control panel are in
the floor. place and tightened properly.
3. The compressor is mounted on anti-vibration mounts. f. Check the oil cooler and after-cooler for any external fin
4. The isolator is more than 5m (16.40ft) away from the blockage and clear the blockage if necessary
compressor. g. Ensure that all the transit brackets are removed.
5.1.9 Commissioning procedure During commissioning
1. Please make preparations according to the installation The servicing technician performs a series of checks on the
section as given, before the compressor is machine and on the systems to which it connects, to
commissioned. ensure that it is in a condition to function safely and as
2. Ensure that the location meets the requirements of recommended. The servicing technician will then explain to
accessibility, ventilation and safety. the operate and maintain the equipment. This procedure is
referred to as the commissioning process.
3. Provide electrical power as recommended in the
installation section. The commissioning of the compressor ensures that it is
installed safely.
4. Select air pipe lines and receivers for your system
according to the tables provided in the installation The general operating conditions of the equipment
section. including the cleanliness of the atmosphere, the
temperature and the ventilation are checked. Technical
Checkpoints before commissioning
details relating to your system such as particulars of your
Replace the parts in compressor if it had been in storage electrical installation are noted. The operator of the
for more than one year. compressor is familiarized with all aspects of both its

1. Air filter normal running and dealing with unusual situations.

2. Oil filter Upon completion of the commissioning process, the

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
b. Monger the main motor and fan motor should be ready for regular use. Else, warranty becomes void. In
mongered to find the winding insulation conditions if the case of change of operator other than the person trained,
compressor is not commissioned for more than 1 year the new operator should be trained before he is dedicated

Installation and operation 5.7

for operating the compressor. Fill oil in the oil tank up to over fill cap
5.1.10 Oil fill procedure
Initial fill
Initial oil fill procedure
Close the oil filling plug
Check whether your compressor comes with oil filled. This
can be checked through the oil sight glass on the air oil
separator. If not, follow the oil filling procedure given
Run the compressor for 10 minutes,
below.
until the thermostatic valve opens

Stop the compressor

OIL FILL PORT

Unscrew the oil fill plug by 3 turns only
(OVER FILL CAP) so that any entrapped air inside the
OIL SIGHT GLASS tank will bleed out it. By doing this the
sump pressure drops to atmospheric
pressure before opening the oil fill plug
MAX MIN

BALL VALVE
OIL LEVEL INDICATOR FOR
90-160
Refill the oil in the tank upto half of the
oil sight glass
Figure 9. Oil filling and oil sight glass location on
air oil seperator tank
Second fill

Oil level check Close the oil fill plug

 The oil level should be half of the oil sight glass after
fumes settle down following shutdown.
Restart the compressor
 Ensure that the oil level sight glass and eye vision are
parallel while checking the oil level to avoid parallax
error. Sl. Model Volume Initial fill Second
No. of oil (gallons) fill (After
required cranking)
(gallons) (gallons)

EG 90,
1 25.4 15.4 10.0
EG 110

2 EG 160 28.5 19.5 9.0

NOTE
Refill oil in the tank if the level falls below the minimum
level

Installation and operation 5.8

 5.2 Preservation for long idle storage

If your compressor is going to remain unused for six  Check the air-oil separator tank.
months or longer, special measures must be undertaken to  Replace the oil filter element similarly.
ensure the protection of the following components
 Flush the tank, airend with compressor oil and replace
 Airend the separator element before using the compressor
 Motors again.

 Air–oil separator tank 5.2.4 Rubber Hoses

 Rubber hoses Test Recommendations for
5.2.1 Airend Rubber Hoses

To prepare the airend for 6-month storage: Age Recommendations

 Remove the airend discharge hose/pipe coupling. Up to 3

Use without further testing
years
 Rotate the drive coupling three times so that the oil
present inside the airend comes out through the Use after representative samples are
3 to 5 years
discharge port. subjected to proof-pressure test

 Block the discharge port completely. Use after representative samples are
subjected to proof, impulse, and burst
 Remove the inlet rubber duct connected to the intake 5 to 8 years
pressure tests and cold bend and
valve of the air filter assembly.
electrical tests.
 Turn the intake valve flap and pour rust preventive oil
Over 8 years Scrap
(use Castrol DWX 32 or an equivalent grade) into the
airend through the intake valve.

 Rotate the coupling five times by hand so that the rust

preventive oil spreads all over the bearings, seals and
other parts of the airend.

 Drain the rust-preventive oil by opening the discharge

port plug fully.

 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.

 Repeat the procedure every six months.

 For more details contact ELGi office or 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 the wires.

 Apply grease on the motor bearings.

5.2.3 Air-oil separator tank

To prepare the air-oil separator for 2-year storage:

 Drain the oil from the seperator tank.

 Remove the entire tank from the compressor after

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

 Clean the tank using ELGi compressor clean flushing oil.

Installation and operation 5.9

 5.3 Operating instructions

 If all the inputs from contact switches, pressure and

temperature transducers are normal, the display will
Please adhere to the safety instructions provided at the indicate "READY''.
section 2.3.2 : Precautions during operations
 Press the ''START'' (green) button on the controller.

5.3.1 Initial start-up checks  Machines with an automatic star-delta starter will have
6 seconds changeover time from star to delta and
 Check whether the oil level in the tank is up to the
another 10-seconds delta-to-run delay.
specified level. If not, top up oil as per the oil fill
procedure given in the maintenance section. 5.3.5 During running
 Open all doors and visually check the compressor for To ensure seamless running:
abnormality. Make sure all connections are tight.
 Monitor the controller display and control panel
 Open the electrical panel door of the compressor and indicators regularly when the compressor is running.
check that the three phases and earth cables are
 Graphic warning display: This gives graphically the
connected securely. (L1, L2, L3, and PE wires)
location of fault.
 Check the necessary earthing line in the panel/
compressor base.

 Ensure that all condensate drains are connected

properly.

 For water cooled compressors, ensure that the water

inlet and outlet valves are opened. Also make sure that
the inlet and outlet water drain valves are closed.

 For water cooled compressors, ensure that the water

quality is maintained as specified by ELGi.

5.3.2 Initial start-up

Open the air outlet ball valve, turn on power, and press
the start button (Green). Check whether the main motor
turns clockwise (when viewed from the main motor fan
side of the compressor). The correct direction of rotation
is also shown on the motor. Ensure correct direction of
rotation. If not, stop the compressor by pressing the stop
CLOCKWISE
button (Red) on the control panel. Open the isolating
GRAPHIC WARNING DISPLAY
switch and reverse the appropriate lines.

Running the compressor in the wrong direction for more

than 5 seconds will damage compressor parts or even
cause total damage.

5.3.3 Daily start checks

Before using the compressor everyday, you must prepare
it by performing these tasks:

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

specified level. If not, top up oil as per the oil fill Figure 10. Human machine interface
procedure given in the maintenance section.
 Discharge temperature sensor & warning: It is
 Open all doors and visually check the compressor for
fixed on the air-oil discharge pipe. It senses the
abnormality. Make sure all connections are tight.
temperature of the discharge air-oil mixture. The
 Refer section 6.1.1 for how to perform daily compressor will shutdown automatically and the
maintenance activities. warning light on the controller will glow when the
5.3.4 Starting discharge temperature exceeds the preset value of 110
± 5ºC (230 ± 9ºF).
To prepare to start the system, perform these tasks:
 Separator element warning: Indicates that the
 Open the air discharge valve.
separator element needs to be replaced. The
 Turn on power.

Installation and operation 5.10

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

 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.

 Safety valve: This valve relieves the pressure in the air

-oil separator tank when it exceeds the set pressure.
Refer “Technical data”.

 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 (psi)
EG 11 - Standard, Working pressure +
EG 45 Standard +VFD 0.5 (7)
Working pressure +
Standard
EG 55 - 1 (15)
EG 160 Working pressure +
Standard +VFD
0.5 (7)

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
counterclockwise and unlock the emergency switch.
Then press the reset button before the next start.

 Do not use the emergency stop switch for normal

stopping.

 Isolate power to the compressor.

 Close the air discharge 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 Oil change over procedure 6.3

6.1.3 Maintenance of individual components & systems 6.4

6.1.3.1 Pre filter 6.4

6.1.3.2 Air filter 6.4

6.1.3.3 Air oil Separator 6.4

6.1.3.4 Oil top up and oil changeover 6.5

6.1.3.5 Oil filter 6.6

6.1.3.6 Intake valve 6.7

6.1.3.7 Blow down valve 6.9

6.1.3.8 Minimum pressure valve 6.9

6.1.3.9 Pressure regulator valve 6.11

6.1.3.10 Thermal valve 6.12

6.1.3.11 Electrical motor greasing 6.12

6.1.3.12 After and oil coolers 6.12

6.1.3.13 Cooler prefilter accessory 6.13

6.1.3.14 Drive coupling 6.14

6.1.3.15 Moisture separator and auto drain valve 6.14

6.1.3.16 Anti Vibration Mount 6.14

6.1.4 Use only genuine spare parts 6.15

6.2. Troubleshooting 6.16

6.3. Decommissioning, dismantling & putting out of service 6.21
6.3.1 Waste disposal 6.21

6.3.2 Dismantling the compressor 6.21

6.3.3 Decommissioning the compressor 6.21

6.3.4 Disposal of consumables and replaced parts 6.21

6.4. ELGi services 6.22

6.4.1 ELGi customer care system (ECCS) 6.22

6.4.2 ELGi genuine spare parts 6.22

6.4.3 Air audit 6.22

6.5. Appendix 6.24

6.5.1 Conversion tables 6.24

6.5.2 Torque values 6.25

6.5.3 Service log book 6.26

6.6. Disclaimers 6.28

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, cooler, 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
Hoses and Fittings Kit Replace
Blow down adjustment kit Check & Replace
Oil & after coolers - water cooled (External) Check & Clean
# - Whichever comes first * - More frequently in dusty atmosphere ** - For USA / EUROPE region only

Table 5. Maintenance intervals

NOTE
The above maintenance schedule is valid for standard reference conditions (Refer Table A) and standard working pressure
(Refer technical data)
If the compressor is operating at low duty cycle, dusty environment, high humidity, high temperatures the maintenance
interval will be shorter.
In the event of change in operating / environmental conditions, consult ELGi.

REFERENCE CONDITIONS
Air inlet pressure (absolute) bar(g) / psi(g) 1 / 14.5

Air inlet temperature °C / °F 20 / 68

Relative humidity % 0
Table—A

NOTE
Depending on the ambient conditions and operating conditions of the compressors with variable frequency drive (i.e. with low
ambient / low duty cycle), thermal valve element to be replaced with a higher rating if necessary.

Maintenance 6.2
 Precautions
A. If the compressor is kept idle
 Isolate the power supply.
 Close the main air outlet valve.
 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”.

6.1.2 Oil change over procedure

TO
FROM Change Oil type in the Compressor
Present Oil in the
compressor ELGi Airlube XD ELGi Airlube UT ELGi Airlube UT ELGi Airlube FG
(Mineral) Synthetic Synthetic plus (Food Grade)
ELGi Airlube XD (Mineral)
000998066 - 5 Liters ELGI Air lube Cleaner ELGI Air lube Cleaner
ELGI Airlube FG Cleaner*
NA Cleaner Oil Cleaner Oil
000998053 - 20 Liters Cleaner Oil
000998074 - 20 Liters 000998074 - 20 Liters
000998055 - 208 Liters
ELGi Airlube UT Synthetic
000998092 - 5 Liters ELGI Airlube FG Cleaner*
NA NA No Cleaner required
000998090 - 20 Liters Cleaner Oil
000998093 - 208 Liters
ELGi Airlube UT
Synthetic plus
000998096 - 5 Liters ELGI Airlube FG Cleaner*
NA NA NA
Cleaner Oil
000998097 - 20 Liters
000998098 - 208 Liters
ELGi Airlube FG
000998079 - 5 Liters
NA NA NA NA
000998078 - 20 Liters
000998077 - 208 Liters
Table 6. Oil change over procedure

*Yet to be approved by ELGi

Procedure for change over of oil

Step 1 : Drain the present oil in the compressor completely

Step 2 : Fill in cleaner oil (Ref. above table) to the recommended oil quantity in the compressor

Step 3: Run the compressor for 500 hours and drain out the cleaner oil completely

Step 4: Replace Oil filter and Air oil separator

Step 5: Fill the compressor with new required oil type.

Sl. No. Motor make Grease Part Number

1 ELGi
EM Unirex N3 015404151
2 SIEMENS
3 WEG EM Polyrex N2 015404152
Table 7. Electric motor grease

Maintenance 6.3
  Switch off the compressor and disconnect the power
supply to the compressor.
Disconnect all the power at the source before attempt to
perform maintenance or make adjustment.  Close the discharge end ball valve.
 Release the air oil tank pressure and allow it to cool for
6.1.3 Maintenance of individual few minutes.
components and systems
Requirements
Check all accessories independently to verify that they are
 Compressed air, new filter element (if needed).
functioning as required and replace their components as
necessary. After maintenance restart the compressor Maintenance
as mentioned in section “Operating instructions”.
 Open the air filter door by using lock key and loosen the
6.1.3.1 Pre filter wing nut and replace it with a new air filter.

Pre work  Clean the filter using moisture free compressed air at

PRE FILTER CARTRIDGE AIR FILTER ELEMENT

Figure 12. Air filter

Fig 11. Pre filter less than 2.5 bar.g (36.3 psi.g).
 The direction of cleaning must be from inside to outside.
 Switch off the compressor and disconnect the power
supply to the compressor.  Do not forget to reset the Air Filter clog indicator which
is fitted in the Intake valve.
 Close the discharge end ball valve.
 Show bright light from inner side of the filter element to
 Release the air oil tank pressure and allow it to cool for
inspect for damage or holes that result in leaks. Light
few minutes.
will emerge from the holes, indicating their locations. In
Requirements case of damages replace the filter element
 Compressed air, new pre filter element (if needed)  Inspect all gaskets and gasket contact surfaces of the
Maintenance housing. Should faulty gaskets be evident, replace the
element immediately.
 Switch off the machine & Refer suction pre-filter
 After the element has been installed, inspect and
Cartridge Removal Procedure
tighten if necessary all air inlet connections prior to
 a) Slide Upward the Suction Pre-filter Cartridge. resuming operation.

 b) Slide Downward it downwards away from the M/c.  Replace the filter element back in position, assemble
the filter housing cap such that the dust ejector in
 c) Pull Forward to remove completely.
bottom position and lock the assembly using the
 Clean pre filter with compressed air below (36.3 psi.g). mounting clips.

 Refit the pre filter after cleaning Cartridge Insert  If a clean element is to be stored for later use, it must
sequence from c- b - a be stored in a clean container.

 Repeat this process based on dust conditions or regular 6.1.3.3 Air oil separator
periodic intervals
Pre work
6.1.3.2 Air filter  Switch off the compressor and disconnect power supply
If the air filter clog indicator shows a red colour (means to the compressor.
blocked condition) then the air filter has to be cleaned or
 Close the discharge end ball valve.
replaced (if the stipulated life has expired).
 Release air oil tank pressure and allow the tank to cool
for a few minutes.
Pre work
Requirements

Maintenance 6.4
 New separator element, clean cloth. be kept properly sealed in the original container. Once the
seal is broken, the above stated life span of the product is
Maintenance
no longer applicable. Products should be stored in proper
 Relieve oil pressure from the air oil tank and all fluid storage warehouse that is away from direct sunlight and is
lines with the help of safety valve not exposed to weather elements like rain, typhoon and
snow storms. The products should also be stored away
 Disconnect all piping connected to the top cover to
from any heat source, high humidity and moisture areas.
isolate the air oil tank from the service lines and return
If drums are stacked on ground level, they should all be
lines.
 Disassemble the top cover from the air oil tank by
unscrewing all tightening bolts. GASKET - SEPERATOR
ELEMENT
 Remove the separator element.
 Scrap the old gasket material from cover and flange on SEPERATOR
ELEMENT
the air oil tank. While doing so, take care not to let the
TOP PLATE
scraps fall into the air oil tank.
 Inspect and clean the air oil tank for rust and dirt.
 Fix the new gaskets after ensuring that the staples are
present in both the gaskets.
 Replace the new separator element into the air oil tank,
taking care not to dent it against the tank opening.
 Clean the under side of the air oil tank and remove any Figure 13. Air oil separator
rust. Paint the surface with epoxy paint. NOTE
 Reposition the Top plate and assemble it by using The air-oil separator tank is tested according to standards.
fasteners. Torque: 120 N-m (88.5 lb-ft). Regularly have inspections performed in conformity with
local regulations.
 Reconnect all piping.
 Clean the return oil strainer before restarting the
machine. stacked horizontally with the bung openings arranged at
the 3 and 9 o’clock position.
6.1.3.4 Oil top up & oil change over
ELGi recommends that once the seal is broken, all
Proper compressor maintenance and operation is crucial products be used immediately. ELGi does not encourage
for the lubricant to function properly and last till its reuse or recycling of any leftover fluids due to
estimated rated oil hours. The oil product shelf life is of contamination hazard. ELGi will not warrant the quality of
minimum 3 years and maximum 5 years. Products should the product once the original seal is broken. Also ensure
that the oils are not mixed up between brands and types.
Please refer Material Safety Data Sheet (MSDS) for oil spill
handling and disposal procedures.
Pre work
 Switch off the compressor and disconnect power supply
to the compressor.
 Close the discharge end ball valve.
 Release air oil tank pressure and allow the tank to cool
DISCONNECT ALL
for a few minutes.
PIPING’S CONNECTED
TO THE SUMP TOP Requirements
PLATE
 New oil, flushing fluid (if needed)

TOP COVER Maintenance

Step 1: Draining
SCAVENGING LINE TUBE
a. Remove drain plug from the bottom of the separator
tank and drain out all oil. Drain oil while the compressor
is warm.
SEPERATOR ELEMENT b. Remove the pipe and drain plug from bottom of oil
cooler. Then completely drain.
c. Disconnect all oil pipe work which could trap oil and
drain completely.

Maintenance 6.5
d. Drain oil from the airend discharge pipe after  Strap wrench, new oil filter and clean cloth, O-ring.
NOTE Maintenance
 The compressor is originally filled with a particular oil, if Dismantling method of existing oil filter :
you want to change over to other types of oil, perform
steps 1, 2 and 3.  Hold the filter shell and rotate it counter clockwise by
 But if you want to change the oil but continue with the strap wrench
same kind (same brand & type) perform steps 1 and 3
only.
 Ensure that you drain at least 90% of oil capacity of the
compressor; if not the residual oil can contaminate new
oil.
 Ensure no oil spills on anti-vibration mount during
maintenance.

dismantling it. OIL FILL PORT

(OVER FILL CAP)
e. Drain oil from the airend by hand rotation. OIL SIGHT GLASS

Step 2: Flushing (Only for oil change over)

MAX
Check the air-oil seperator differential pressure. MIN

For Oil change over procedure refer 6.1.2

a. Send a sample** of the compressor oil to ELGi for oil
OIL LEVEL INDICATOR FOR 90-160 BALL VALVE
analysis after 300 hours.
Step 3: Filling the oil Figure 14. Air oil separator tank– oil drain

a. Add fresh oil; fill it up to the oil fill plug. (initial fill)
b. Close the oil fill plug.
c. Pour oil into airend, then restart the compressor.
d. Allow it to run for about 10 minutes.
e. Stop the compressor.
f. Unscrew the oil filling plug after 5 minutes so that
residual pressure in the tank is vented out through the
bleed hole in the oil fill plug.
BALL
g. Refill the tank up to the oil fill plug. (second fill) VALVE

h. Restart the compressor.

6.1.3.5 Oil filter

The oil filter is fitted between the oil cooler and the airend
unit. The components of the oil filter assembly are shown
DRAIN PLUG
in the figure. This is a full flow filter with a pleated
Figure 15. Cooler oil drain
element. To service this filter, order the consumables kit
(available with ELGi service personnel) The procedure for
complete servicing of this filter is as follows.
Assembly of new Oil filter :
Pre work
 Ensure the gasket of the filter is damage free.
 Switch off the compressor and disconnect power supply
to the compressor.  Clean the seating surface with clean cloth
 Close the discharge end ball valve.  Apply a this film of oil on the mating surface of the
gasket
 Release air oil tank pressure and allow the tank to cool
for a few minutes.  Return the filter to its original position and rotate it
clockwise manually. After tightening, rotate it further by
hand for one and a half times
Requirements
 Ensure no oil leaks from the mating surface.
**: Applicable only for USA.
6.1.3.6 Intake valve
NOTE
 The cleaner is not recommended to run longer than 500
Pre work:
hours.
 Change the oil filter and oil separator after oil change  Switch off the compressor and disconnect power supply
over. to the compressor.

Maintenance 6.6
  for all 18mm (± 1mm)

OIL FILTER  lower edge hexagonal nut / upper edge housing

HEAD

HEX ADAPTOR

OIL FILTER

Figure 16. Oil filter

 Close the discharge end ball valve.

 Release air oil tank pressure and allow the tank to cool
for a 10-minutes.
Requirements :
 Soft cloth, grease, liquid cleaner, allen keys, screw
driver, spanner, pressure gauge.

Procedure :
Intake valve - EG 90, EG 110
Rolling diaphragm
Dismantling
 Dismantle angle joint (1) from plate (2). Dismantle air
supply line (3) and fixing screw (4) of the actuator.
Take out the actuator and screw off socket joint. For
change of rolling diaphragm see service instruction
actuator. Figure 17. Intake valve
Reassembly
 Screw-fix angle joint(1) - always observing dimension x Setting and function testing

NOTE  Open attachment screw (5) and bring throttle disk by

slight pressure into closed position - the actuator must
Suspended particulate matter should be less than 150spm be depressurized.
to achieve the specified consumable life. Guarantee
becomes void if the compressor is operated above its  Re-tighten attachment screw and put pressurized air
intended pressure. signal onto the actuator. The throttle disk must open
and close smoothly. Pay attention to possible offset of
(see below and drawing) then insert the axis of the actuator.

Valves should not be opened when pressure is applied. Service Instruction for Actuator
Service intervals
NOTE  Cylinder should be cleaned and greased after 8000
hours or every year.
The maintenance of following parts (valves) demands
highly skilled authorized personnel. So it is recommended  Piston seal and guide seal replaced after 16000 hours
that an ELGi service engineer does the maintenance.
or every two years.
Dismantling
into plate.
 For dismantling the cylinder cover (2)
 Secure fixation screw of actuator with Loctite 242 and
secure piston rod (6)with steel pin (4)
screw fix it. Connect air supply.
(not included in the spare kit).
Dimension X : Unlock bolts(12), take off cylinder
cover and remove O-ring (11) from cylinder. Remove

Maintenance 6.7
 steel pin and pull out piston assembly (5+6) along with
guide strip (8), spring (10) and bumper (9).
PISTON SEAL POSITION :
Mount the Piston Seal on piston from this side
Cleaning
 Clean piston unit (5+6) and interior of housing with
liquid cleaner and soft cloth. Let dry. Clean the cylinder
venting filter (15) or replace if needed. Grease the
piston sliding surface, Guide strip, piston seal (7) and
cylinder bore (cover complete sliding area) with the
lubricant contained in the service kit.
 Working and sealing areas must not be damaged!
Reassembly
 Place bumper (9) and spring (10) in to the bottom cover
(13).Insert piston assembly (5+6) with guide strip (8)
and seal (7) in to the housing. Insert pin (4), so that
piston assembly is held firmly.
 Before inserting piston rod, make sure that the inner
surface of bush (14) is clean. Place O-Ring (11) in
groove of cover (2). Fix cover (2) on housing (1).
 Fix all screws (12) with 7.74 lb-ft. Remove steel Pin.

Intake valve - EG 132, EG 160 - maintenance

Removing the actuator from intake valve

Removal procedure
 Loosen the nut holding the ball and socket joint(1) from
the lever(2).
 Loosen the securing screw cap of elbow fitting(3).
 Loosen the screw(4) of the actuator and remove it.
 For servicing the piston seal of intake actuator refer to
Figure 18. Actuator
service instruction for actuator
Reassembly  Work areas and sealing areas of the housing and its
threads have to be cleaned with liquid cleaner.
 Tighten the ball and socket joint of the actuator(1) with
the lever(2) of the intake valve.  Piston work areas have to be greased with autol top
2000 (in the service kit, pos.30).
 Tighten the nut (4) to secure the actuator fully with the
supporting lever(2) of the intake valve.  The thread and the area of the slide bushing (3)
(piston) must be greased by any means.
 Assemble the elbow fitting(3) to the actuator.
 Seat and sealing areas must by no means be damaged!

6.1.3.7 Blow down valve Maintenance

Reassembly
Dismantling
 Insert piston unit (4) into the housing. Cover housing
 Dismantle the valve completely from compressor. thread with Loctite 222.
 Loosen screw (2) in order to remove the piston unit (4).  Assemble O-ring (1) onto locking screw (2).
 Remove O-ring (1) from locking screw (2)
Cleaning
Maintenance 6.8
 Tighten locking screw (2) in until the upper edge of the  Close the discharge end ball valve.
locking screw (2) is on an even level with the upper
 Release air oil tank pressure and allow the tank to cool
edge of the housing.
for a few minutes.
 Release the receiver tank and downstream pressure.

Requirements
 New MPV kit, allen key, grease.
Maintenance
MPV disassembly
 Remove dust cap in the threaded ring (5)
 Remove protective pin (round head pin - 3)
 Insert M10 threaded rod through threaded ring (5) into
the thread ‘J’ in piston (12)
 Take M10 hex nut supplied in service kit and assemble
it on top of threaded ring
 Pretension the spring (9) by turning hex nut to 1-2 mm
(approx. 3 turns)

Figure 19. Intake valve-EG 132, EG 160

NOTE
After completion of intake valve assembly in package,
ensure to verify the performance
Function testing
Test valve function after each service or inspection at the
running compressor.
Inspection
Figure 20. Blow down valve
 Dismantle the valve and check component for wear.
 Unscrew the upper housing (10) by holding bottom
 Work areas and sealing areas of the housing and its
housing (8)
threads have to be cleaned with liquid cleaner.
 Remove the O-ring (6) from upper housing
 Piston work areas have to be greased with Autol
Top 2000.  Hold the upper housing along with threaded
rod-Spring/Piston setup
 The thread and the area of the slide bushing (3)
(piston) must be greased by any means.  Slowly loosen the hex nut (1)

 Seat and sealing areas must by no means be damaged.  Now the spring start to expand. Continue this until
spring decompress from its position fully ((Care to be
 Then reassemble
taken to avoid accident)
6.1.3.8 Minimum pressure valve  Remove threaded rod (2) and hex nut (1)
Pre work
 Remove the Piston (12)
 Switch off the compressor and disconnect power supply
 Remove the O-ring from the piston groove
to the compressor.
 Remove the check valve unit (7) and spring small (11)

Maintenance 6.9
  Take bottom housing (8) and assemble check valve unit
(7) centre to the valve seat in the bottom housing
Extreme caution should be taken while removing the cap
or cover from the body because of the spring.  Assemble the spring small (11) to the check valve unit
(7). The larger diameter of the Spring - small to be
 Remove the O-ring from check valve unit
seated against check valve unit
Cleaning and lubrication
 Assemble top housing (10) - Piston (12) assembly
 Clean piston sliding-surface and sealing seat with a centre to the check valve unit (7) and tighten it with
liquid cleaner. bottom housing (8)
 Grease the threads and piston sliding-surface with
grease supplied in service Kit
Function testing
 Lubricate the check valve unit sliding surface with Valve function to be tested at running of compressor after
compressor oil service.
 Seat and sealing surfaces must by no means be  Loosen hexagonal nut (1) and check whether the
damaged. threaded rod (2) moves upwards (MPVL opens) and
MPV assembly Sl. No Description
 Assemble new O-ring with the piston (12) groove
1 Nut M10
 Take spring - big (9) and assemble with piston (12)
2 Threaded rod M10x260
 Insert disc (4) at the top of the spring (9)
3 Protective pin
 Assemble the O-ring into the top housing (10) flange
4 Washer
 Assemble threaded ring with top housing (10)
5 Threaded ring
 Insert protective pin (3) to the thread ring through Top
6 O-ring - Top housing
housing
7 Check valve unit
 Insert the threaded rod (2) into the thread (J) in piston
(12) through threaded ring (5) 8 Bottom housing

 Assemble the M10 nut (2) with threaded rod 9 Spring - Big

 Pretension the spring - big (9) using hexagonal nut (2) 10 Top housing
by turning it to 1-2 mm (Approx. 3 turns)
11 Spring - Small

12 Piston

downwards (MPVL closes).

THREADS IN  Remove hexagonal nut and threaded rod
HOUSING

GREASE  Insert protective plug (3) into the threaded ring.

The maintenance of the minimum pressure valve is
minimal. The only part which normally requires
replacement is the O- ring on the piston.
PISTON SLIDING SURFACE 6.1.3.9 Pressure regulator setting
Maintenance
In factory
 Identify the working pressure of the compressor
 Keep the outlet valve fully open
 After rotating the cap fully clockwise now adjust the ball
valve to working pressure in the controller
 Now turn the pressure regulator cap counter clockwise
slowly, at a particular point the flap will slightly close
 Now the pressure regulator is set to the specified
THREADS IN PISTON SLIDING working pressure in the machine
BODY SURFACE
 An orifice provided in the pressure regulator is for the
CHECK VALVE UNIT
VALVE SEAT
SLIDING SURFACE modulation purpose, which will bleed continuously
during loading. During modulation the bleeding volume
Figure 21. Minimum pressure valve of air is more. During unloading, there is no bleeding.

Maintenance 6.10
In field
 Identify the working pressure of the unit which can be
noted from name plate of the compressor which is fixed
near the service line ball valve. CAP

 Switch off the compressor unit, release rotation lock of

pressure regulator cap by pulling it up as shown in A
( black color) and then only turn the pressure regulator
cap counter clock wise completely as shown in B. This
is called as zero bar working pressure setting
 At zero bar working pressure setting the intake
ORIFICE
butterfly valve flap will not open even after start delta
changeover (so compressor will not build pressure).
 After completing the above, now start the compressor.
 Turn the regulator cap clockwise slowly as shown in
Figure 22.1 “C”. Figure 22. Pressure regulator valve

MPV start of opening pressure : 3.5 bar(50.7 psi)

C. CLOCKWISE
MPV full opening pressure : 4.8 bar (69.6 psi)

 At zero bar working pressure setting the intake

butterfly valve flap will not open even after start delta D. COUNTER CLOCKWISE
changeover (so compressor will not build pressure).
B. LOCK
 After completing the above, now start the compressor.
 Turn the regulator cap clockwise slowly as shown in C.
A. UNLOCK
 At particular moment the discharge pressure of
compressor shown in PLC will be reaching working
pressure of the unit as in the name plate, stop the
pressure regulator rotation in that position.
 If the discharge pressure is not reaching the working
pressure of unit, Turn the cap counter clock wise or ORIFICE
clock wise accordingly.
 After adjustment, the black color cap to be pushed
down to its rotation locking position as shown in image D.
 Physically observe the compressor whether the
compressor is operating in Unload mode after reaching
set unload pressure either based on demand or by
closing the service line ball valve physically.
Figure 22.1 Pressure regulator valve
 You can observe the actuation of inlet butterfly valve by
the actuator when loading and unloading occurs. The hand during rotation. Beyond which you should not
compressor capacity can be modulated from 60% of rotate the cap further at all.
rated capacity to 100% of rated capacity based on air
 Without releasing the rotation lock of regulator cap as
demand variation of the customer.
shown in A, the cap should not be rotated either in
Regulator don’ts clockwise or anti clockwise direction.
 Do not open the suction side duct while doing regulator 6.1.3.10 Thermal valve
settings.
Pre work
 Do not keep your finger in between actuator and
 Switch off the compressor and disconnect power supply
butterfly valve.
to the compressor.
 While loading, due to modulation the air will release
 Close the discharge end ball valve.
from orifice of the regulator continuously, this is not
a leak.  Release air oil tank pressure and allow the tank to cool
for a few minutes.
 While unloading, residual air will release from regulator
orifice completely .It means air will move through this
orifice and it is normal Requirements
 When rotating the black color cap either in clockwise or  Pliers, screw driver, new thermal valve element, new
in anti clock wise direction, stopping point will be felt by O-ring.
Maintenance 6.11
Procedure to the compressor.
 Remove the two bolt flange assembled on thermal valve  Close the discharge end ball valve.
block.
 Release air oil tank pressure and allow the tank to cool
 Push the piston to and fro (Approx. 10 times) to direct for a few minutes.
the oil to tank (if any).
Requirements
 Remove O-ring spacer, piston thermal valve element &  Pliers, allen keys.
spring.
 Check spring visually and replace if required.
Maintenance
 Check and clean the sealing surface area in the housing.
External surfaces:
 Replace the element with a new element.
 Isolate the machine from the service line
 Place tray below thermal valve block.
 Vent the separator tank pressure before attempting
6.1.3.11 Electric motor greasing maintenance
Pre work  Open both the LH panel and cooler inspection cover
 Switch off the compressor and disconnect power supply  Use compressed air below 2.5 bar/36.3 psi maximum to
to the compressor. clean the outer surface of the cooler. Supply a jet of air
in the direction opposite to cooling airflow direction
 Close the discharge end ball valve.
 After cleaning the outer surface of the cooler properly
 Release air oil tank pressure and allow the tank to cool
close the cooler with a cleaning plate and an LH panel.
for a few minutes.
Requirements 6.1.3.13 Cooler prefilter accessory (optional)
 Recommended grease, cleaning cloth, grease gun. Cooler prefilter cleaning & maintenance instructions

Procedure  Switch off the machine.

 Stop the motor and lock out the switch.  Lift upward & take out the cooler pre filter from the
compressor.
 Thoroughly clean the grease inlet fitting or plug. If the
motor has a plug, remove the plug and clean the inlet.  Hold or fix the prefilter assembly in the cleaning area.

 Remove the drain plug and wipe out any hardened  Clean the pre-filter with compressed air at less than 2.5
grease. bar.g (36.3 psi.g) from the reverse / back side of the
cooler prefilter.
 Slowly pump the grease into the grease inlet until the
new grease comes out of the drain plug.  In case of major dust / dirt accumulation in the pre-
filter element, wash with clean water or light detergent.
 Start the motor and let it run for a minimum of one Do not rinse.
hour to expel any excess grease from the drain opening
before re-installing the drain plug.  Do not use any acidic / alkaline chemicals for cleaning.

 Stop the motor and lock out the switch.  Repeat the process based on dust conditions or regular
periodic intervals.
 Re-install the drain plug.

Figure 23. Thermal valve

 Put the motor back in operation.

6.1.3.12 After and oil coolers

Pre work
 Switch off the compressor and disconnect power supply

Maintenance 6.12
6.1.3.14 Drive coupling  Manually drain the condensate by using the manual
discharge plug located at the bottom of the auto drain
Pre work
assembly.
 Switch off the compressor and disconnect power supply
to the compressor.
 Close the discharge end ball valve.
 Release air oil tank pressure and allow the tank to cool
for a few minutes.
Requirements

COOLER PREFILTER

CLEANING PLATE

COOLER PREFILTER

COMPRESSED AIR JET

LEFT HAND SIDE PANEL (LH)

Figure 24. Cooler external surface

 Spanners, new coupling element.

Maintenance COMPRESSED AIR

 Unscrew the external collar from the coupling

assembly.
 Unplug the old element and replace it with a new
element
 No alignment check is required.
 The intermediate housing between the airend and the
motor is designed and fabricated to ensure correct
alignment of shafts when fitted.

6.1.3.15 Moisture separator and auto

drain valve COOLER PREFILTER
ELEMENT
Pre work
HANDLE
 Switch off the compressor and disconnect power supply
to the compressor.
 Close the discharge end ball valve.
 Release air oil tank pressure and allow the tank to cool
for a few minutes.
Requirements
MOUNTING HOOK
 Spanner, screw driver, player, caustic soda. COOLER PREFILTER
FRAME
Maintenance Figure 25. Cooler prefilter accessory
Dismantling
 Remove the moisture separator from the machine
 Disconnect the pressure sensor line on top of the
moisture separator  Remove the bottom housing from the top housing.
 Remove the auto drain assembly from the bottom housing.

Maintenance 6.13
Cleaning and replacement

HUB

COUPLING ELEMENT

Figure 26. Drive coupling

 Inspect the O-ring and replace it with new one in the

kit, if necessary
 Clean the housing and all other inner parts
 Ensure the mating surfaces of the O-ring are clean and
free from foreign particles
 The auto drain assembly is not serviceable and must be
replaced with new one if not functioning
Reassembly
 The vortex generator cone and the cyclone arrestor
need only to be tightened moderately by hand. Over-
tightening may lead to failure or damage. ELGi assumes
no responsibility for failure or damage resulting from
such incorrect installation.
 Reassemble the auto drain assembly with the bottom
housing and the bottom housing with the top housing
 Reassemble the moisture separator in the machine and
connect the all pipe lines, pressure sensing line, and drain line
 Restart the machine and check for any leaks at the
joints. If leaks occur, stop machine and wait for sump
pressure to drop to atmospheric pressure.
 Remove the O-ring as described above, and inspect and
clean it
 Ensure that the mating surfaces are clean and refit the
O-ring

6.1.3.16 Anti Vibration Mount

Anti Vibration Mount should be replaced during major
overhaul of airend or motor. If no such situation, replace
AVM every 5 years

Moisture separator may be heavy. Caution should be taken

while removing it from the machine.
NOTE
 Avoid damaging the housing when removing or
tightening the moisture separator. Do not use a pipe
wrench. If necessary, use a locking strap clamp/wrench
 Install the separator in a vertical upright position,
observing the correct direction of air

Maintenance 6.14
 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 27. Moisture separator and auto drain valve

6.1.4 Use genuine spare parts

It is very important to use genuine spare parts, to ensures that your compressor work as new for its lifetime. Spurious
spares may seem less expensive initially, but they severely compromises on quality. Spurious parts will prove cost-
ineffective in the long run, and may even result in total damage of the machine or cause serious accidents. The table
includes certain critical spurious parts. It is not an exhaustive list, and you are strongly advised to avoid all other spurious
spares that this table does not cover. Be aware of the consequences of using spurious spares including but not limited to the
ones described in the table.

Effect Spurious part Remarks

Due to dense filtration media, it creates in additional pressure drop and so causes
Air oil separator additional power consumption. Every1 bar (14.5 psi) of pressure drop results in ~7%
Higher power
additional power consumption.
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 Contaminants are not filtered properly and the contaminated oil affects the critical
performance 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.
Spurious parts will damage the other components and accelerate maintenance
Cost frequency and cost.
Higher consumption of consumables like oil (due to the use of spurious parts) will
result in, increased cost.

Maintenance 6.15
 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 (2A for Neuron, 1A for the control
circuit).

Replace the control transformer if defective.

Control transformer fuse blown
Replace glass fuse (0.25A for Neuron, 0.5A 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 (50VA).

(1) Replace the control transformer (50VA).

(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 6.16
 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
with dummy plugs and do a water-wash with soap oil.

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
run the compressor.

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
bar (22 psi).

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

condition of the oil) and run the compressor.

Maintenance 6.17
 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
specification.

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

Check the solenoid valve and clean or replace if

Solenoid valve malfunction
required.

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 6.18
 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
pressure 2. Change the pressure regulator assembly.
Loading/unloading
Problem
Actuator failure (applicable only to EG 55 to
Check and change the actuator / kit / assy.
EG 250)

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 6.19
 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 (applicable only to EG 55 to

Check/change actuator / kit / assembly.
EG 250)

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 6.20
 6.3 Decommissioning, dismantling and
putting out of service

If you do not intend to use the compressor or any of its  The moisture condensate separated from the
parts, you must dismantle and putting out of service. compressed air contains oil particles. Disposal of
These tasks must be carried out in compliance with the condensate and filter element is to be done in
standards in force of that particular country. accordance with the pollution control norms prevailing
at the time of compressor installation or use.
6.3.1 Waste disposal
 Parts of the compressor that are replaced have metal
 Use of compressor generates waste. The residues from and rubber components. These may be recycled and
agricultural, industrial, crafts, commercial and service disposed off according to pollution control regulations,
activities must be treated as waste, which needs to be respectively.
disposed off properly. Deteriorated or obsolete
machines are also classified as waste.  Rubber items such as AVMs, coupling elements, and O-
rings should be disposed and replaced before running
 Special attention must be given to active carbon filters again.
as they cannot be included in urban waste. Observe the
waste disposal laws in force where the compressor is
used.
 It is mandatory to record loading or unloading of
exhausted oils, obsolete machines and toxic harmful
wastes that derive from heavy or light industry NOTE
processes.
ELGi is not responsible for the disposal of old oil or
 It is especially important that exhausted oils be condensate. It is the responsibility of customer to dispose
disposed off in compliance with the laws in the countries of the foregoing in accordance with local environmental
statutory laws.
of use.

6.3.2 Dismantling the compressor

 Dismantle the compressor in accordance with all the
precautions imposed by the laws in force in the country The compressor does not give any warnings during short
operating times. If it is operated below the dew point and
of use. moisture condensate may mix with oil. This will reduce the
 Before dismantling, request an inspection by the lubricating quality of the oil and lead to damage of
compressor.
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.

6.3.4 Disposal of consumables and

replaced parts

Maintenance 6.21
 6.4 ELGi Services

6.4.1 ELGi customer care system (ELGi  Northern Region: Rajasthan, Uttar Pradesh, Delhi,
Haryana, Punjab, Uttaranchal, Himachal and Jammu &
CCS)
Kashmir.
ELGi provides dedicated customer care and after-sales
Contact Numbers: You can contact CCS also with the
support through the ELGi customer care system (CCS), a
following numbers:
computerized system developed in-house. The CCS aims
to minimize the time taken to resolve customer Telephone: 0422-2589206 / 241 / 242 / 243/ 244 / 245 /
complaints. 97900 21100

Service requests/complaints Fax: 0422-2589240

The CCS toll-free telephone number 1800-425-3544 Please send the following details to the mail, thus enable
(accessible within India through BSNL and MTNL lines) us to take immediate action.
takes the customer’s call to our centralized customer care 1. Name of the customer
center in Coimbatore. Customers can register their service
2. Compressor model
requirements or complaints here.
3. Fab. number
A unique tracking number is generated for each call logged
by the CCS. The customer receives an automatic e-mail 4. Contact person name
acknowledgement with the tracking number and details of 5. Phone number
the call for reference.
6. Nature of complaint
A service engineer is assigned to the call, and the date and
time of the engineer’s visit are communicated to the 7. Hour meter reading
customer by e-mail. Every requirement or complaint must You may use the CCS by sending e-mail to: [email protected]
be resolved and closed in the CCS within a specified time
Customer satisfaction survey
limit, failing which the complaint is automatically brought
to the notice of the manager. If the issue remains If you have used the CCS, you may be contacted for your
unresolved, it will get escalated to the managing director. feedback on our after-sales support. Your response helps
The CCS ensures that not only the customer complaints ELGi to improve its service.
are logged but they are also attended to on time, every International customers:
time.
Refer contact information at the end of this manual book.
Enquires
6.4.2 ELGi genuine spare parts
A number of calls received by the CCS relate to customer
queries regarding products and spare parts. The details When ordering spare parts, refer to the lists provided in
are noted, and basic information on product specifications the parts manual and identify the part number. Specify the
and usage are provided. The caller is then referred to a part number and quantity, in addition to the name plate
salesperson at the head office or the appropriate branch details. Global support center of ELGi ensures the supply
for follow-up. of the quality spares on time. Ensure that you are using
the genuine spare parts so that your Compressor will be
The CCS database
working efficiently and effectively. Refer to section 6.1.3
The CCS also creates a database of customers, adding for details on need of using genuine spares.
details of every new customer who calls, thereby building
Please contact our After sales team for any compressor
a large pool of installation details. These details are used
accessory requirements like VFD, Air-Dryer, etc.
to provide value-added services to improve customer
satisfaction with ELGi products. 6.4.3 Air audit
CCS-working hours We extend our proven capabilities in energy efficiency
The ELGi CCS works for six days a week from 08:30 to initiatives by carrying out air audits for our customers.
21:30 IST (Monday to Saturday). ELGi conducts audits and trains end users in key energy
Multi-lingual capability oriented functional areas. The audit reports prepared by
ELGi experts’ team include recommendations on short,
The coordinators at the CCS are multi-lingual. They can medium and long term measures for energy conservation,
handle calls in English and all the major regional along with financial estimates and analysis for
languages of India. implementation.
Coverage: The CCS toll-free number 1800-425-3544 is This air audit objective is to provide the customer:
accessible from the following areas:
 The framework for systematic collection of data relevant
 Southern Region: Tamil Nadu, Karnataka, Kerala, to the efficient operation of compressed air systems.
Puducherry, Andhra Pradesh, Telangana, Andaman &
Nicobar Islands.  A thorough analysis about the performance of the
compressed air system, identifying potential electricity
 Western Region: Maharashtra, Gujarat, Madhya savings and to provide sound recommendations for
Pradesh, Goa, Lakshadweep Islands. implementation of energy efficiency initiatives.
 Eastern Region: Orissa, Chhattisgarh, Jharkhand, Data analysis will be comprised of the information about
West Bengal, Bihar and the North-Eastern states. different areas such as air leakages, inappropriate use of
compressed air, compressed air system network,

Maintenance 6.22
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 6.23
 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 6.24
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 6.25
 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

6.26
 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

6.27
 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 6.28
Maintenance 6.29
Controller Manual
Neuron III

Version 3.6
July 2020
 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 (122 oF) 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,

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 392 oF)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

indicates damage, so that safe operation is not possible,

7.2.1. Equipment safety
then the device may be removed from operation.
The device, before delivery, was checked according to the
Carefully unpack the system. Open the doors and inspect
prescribed tests of the inspection scheme. 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

 PC interface through MODBUS - To download reports

7.4.1. Home screen display
and setting parameters
 Easy user interface 8 line graphical display and intuitive
 70 + Modbus parameters for DCS controls
menu navigation keys
 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
 Start Inhibit till sump pressure is within safe limits to
at the time of fault etc.
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.

Reverse 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 Temperature Input is Open (Probe Failure)
2. Dis. Temperature is higher than set Trip temp.
Glows when the
Differential 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
Differential 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 Active state

1 24V AC Phase 24 VAC P -

2 24V AC Neutral 24 VAC N -

3 24V Earth Earth -

7.5.2 X02: Digital inputs

Pin Function Id Active 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 Type 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 Active 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

** If Dew point sensor and Winding temperature are used, Winding temperature shall be connected here

\
Controller Manual 7.10
7.5.5 X05: Main motor relays

Pin Function Id Active 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 Active 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 Active 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 CV20 variant selected or winding temperature enabled, it will trip the compressor based on
Winding temp. high
SET value of MOTOR WINDING temperature

If CV20 variant selected or winding temperature enabled, it will trip the compressor if sensor
Winding temp. fail
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 Differential Pressure
Pressure. ( Only in Sump Pr. Enabled condition)
Warn Temperature W he n Discharg e te mp . e x ce e d s the se t warn temperature (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

Change 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

If CV20 variant selected or winding temperature enabled and if the temperature exceeds [SET
Winding temp Exceeded
value-10] of MOTOR WINDING temperature

Controller Manual 7.13

 immediately. This feature helps save the energy if very
7.6.1 Important user machine settings
little compressed air is used.
1. Control mode
NOTE
Local - Users can start and stop the compressor by using
If the compressor is started more than the specified
local start/stop key number of cycles per hour through the Standby sequence,
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 4
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 3

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 3

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 3

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

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

# Item Min Max Option Default Unit

Mode

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

2 Auto restart - - on / off off -

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

4 Tr unit - - cen / far cen -

Pressure

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 Delay

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

 # Item Min Max 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 Valve

18 Off time 1 180 - 4 minute

19 On time 1 15 - 5 Second

Load / Unload Source

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

Set dew point

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

22 High dew point 6oC(43oF) 12oC(54oF) 8oC(46oF) 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”.
# Item Min Max Option Default Unit

Sun to Sat / (---

1 Day - - --- -
means no schedule)

2 Action - - on / off off -

3 Time HH 00 23 - 00 Hour

4 Time MM 00 59 - 00 Minute

Unload  Load pressure + 7.5bar

5 ≤Max unload pressure - bar/psi
Pressure 0.5bar(7psi) (109psi)

6 Load pressure 4.0 bar(58psi) ≤Unload 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

# Item Min Max 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

Item Min Max 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

contrast, a small gain results in a small output response to
7.7.2.6 VFD Speed Control
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 should be enabled in Factory -> VFD settings to VFD_model

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 Max Option Default Unit

1 Set AFCT 0000 30000 - 2000H Hour

# Item
1 Warn 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 Max
programmable. It is used for automatic dryer control.
1 Hour 00 23
7.7.3.3 Temperature 2 Minute 00 59
Fan Temperature - Fan relay will energize if discharge 3 Second 00 59
temperature reaches the set value. It will de-energize
4 Date 01 31
when the temperature comes below 75°C from the set
value. Alternatively, fan start/stop is allowed for 15 times/ 5 Month 01 12
per hour. Beyond 15 times, the fan will not switch off. 6 Year 00 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 Max

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 Max Option Default Unit
3 Day light savings 0 2
1 Fan temp On 95oC Off - - C/F

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 Go to 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
3.5 10/02/20 Software version 2.09b
3.6 10/07/20 Software version 2.09c

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

▲ “UP” – Set Analog Values
 Package Discharge Pressure
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 Differential Pressure
Pressure. ( Only in Sump Pr. Enabled condition)

Warn Temperature W he n Discharg e te mp . e x ce e d s the se t warn temperature (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

Change 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.

Temperature not If the discharge temperature not raised above the inhibit temperature before the set inhibit
developing temperature time.

Winding temp. high/fail It will trip the compressor based on SET value of MOTOR WINDING temperature/ sensor open

Controller Manual 7.31

Menu Structure

Controller Manual 7.32

PARTS MANUAL
EG SERIES

ELECTRIC POWERED SCREW AIR COMPRESSOR

EG 90 to EG 160
8.0 Air inlet and control system (EG90V-EG110V)
[ Ref : 015311966—X015598 ]-VFD

Parts Manual 8.2

8.0 Air inlet and control system (EG90V-EG110V)
[ Ref : 015311966—X015598 ]-VFD

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

1 AIR FILTER ASSY. 1 B004700770036 29 PLAIN WASHER M10 1 000996010

2 SUCTION DUCT 1 015320815 30 SPRING WASHER M10 1 000996110

3 CLAMP 2 B505303 31 HEX BOLT M10X20 1 000906143

4 CONNECTOR 1 220371770 32 PLAIN WASHER M6 2 000996057

NC INTAKE VALVE 4INCH HPKG-

5 1 B009801070006 33 SPRING WASHER M6 2 000996106
120

6 PLAIN WASHER M20 4 000996020 34 HEX BOLT M6X16 2 000906084

SOLENOID MOUNTING
7 SPRING WASHER M20 4 000996120 35 1 015312372
BRACKET

8 HEX BOLT M20X65 4 000906246 36 BONDED SEAL WASHER 1 000959387

9 AIRFILTER CLOG INDICATOR 1 B012400770001 37 PARALLEL MSC 3/8” BSP 1 B010506360013

10 1/8 BSP BONDED SEAL WASHER 2 000959381 38 ST FITTING 1/8 TO 6MM OD 1 015403616

11 ERMETO 1/8 X 1/8 BSP SS03E 1 020403100 For VFD machines Sl.NO. 18,19,20 will not be used.

BUSF ADAPTER SERVICE

12 1 015402385
INDICATOR

13 BONDED SEAL WASHER 1 000959387

14 APAPTER 1/2" BSP X 3/8 BSP 1 015404017

15 ADAPTOR 7/8INCH UNF 2 015404014

ADJ. SS ELBOW 3/8 BSP X 12

16 1 B010506360082
MM

17 PMS ELBOW 9/16” 1 015403606

18 PRESSURE REGULATOR PRNE 1 B001501070001

19 MOUNTING BRACKET PRNE 1 B001501070006

20 NUT MOUNTING BRACKET PRNE 1 B001501070007

21 ST.ELBOW 1/4 BSP X 6MM 1 B009606780010

22 PMS COUPLING 1/4 BSP X 6MM 2 B009606780009

23 TUBE 6MM 0.3M 000920620

24 SLEEVE 2 000959763

25 ST.ELBOW 1/4 BSP X 6MM 1 B009606780010

26 3/2 SV 24VAC 60Hz 0-15BAR NC 1 B007300990008

27 MALE RUN TEE 1/4 BSP 1 B009606780017

28 BDV TUBE 1 015316270

Parts Manual 8.3

9.0 Drive system (EG110)
[ Ref : 015403253—X015258 ]

Parts Manual 9.1

9.0 Drive system (EG110)
[ Ref : 015403253—X015258 ]

Sl.
Description Qty. Part Number
No.

1 AIREND ASSEMBLY 1 X990381

W22 NEMA PREM EFF4P (150

2 1 B005106400060
HP)

3 ANTI VIBRATION MOUNT 6 B001406190016

4 AIR END MOUNTING BRACKET 1 015303882

5 DRIVE COUPLING 1 B005405550025

6 ADAPTER RING 1 015312854

7 NOISE CONTROL BOX 1 015310448

8 HEX BOLT M20X20 4 000906181

9 PUNCHED WASHER M12 20 000996060

10 SPRING WASHER M12 24 000996112

11 HEX BOLT M16X40 2 000906214

12 PLAIN WASHER M16 6 000996016

13 SPRING WASHER M16 6 000996116

14 HEX BOLT M20X50 2 000906243

15 HEX NUT M20 10 000948020

16 PLAIN WASHER M20 2 000996020

17 SPRING WASHER M20 10 000996120

18 HEX BOLT M20X65 8 000906246

19 HEX NUT M12 12 000948012

20 SPRING WASHER M10 4 000996110

21 HEX BOLT M10X20 4 000906143

22 PLAIN WASHER M10 4 000996010

23 SPACER MOTOR 4 015403023

24 HEX BOLT M12X55 12 000906188

25 HEX BOLT M12X60 8 000906189

26 HEX BOLT M16X75 4 000906221

Parts Manual 9.2

10.0 Discharge system (EG90-EG110)
[ Ref : 015308762—X014773 ]

Parts Manual 10.1

10.0 Discharge system (EG90-EG110)
[ Ref : 015308762—X014773 ]

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

1 DISCHARGE HOSE ASSY 1 015311339 38 ‘O’RING 2 990402910

2 RECEIVER TANK 1 015308468 39 OIL FILL PLUG 1 1/2" BSP 1 015402634

3 PIPE ASSY - COOLER TO MS 1 015306533 40 HEX BOLT M16X40 4 000906214

CONNECTOR PIPE MOS TO

4 2 015304841 41 HEX BOLT M12X25 2 000906182
AFTER COOLER PIPE

5 MOISTURE SEPARATOR 2 1/2" 1 B000306040010 42 OIL RETUN LINE TUBE 1 015316211

6 MOS TO OUTLET PIPE 1 015304873 43 SAFTEY VALVE GUARD 1 015305069

7 FLANGE ASSY - TANK TO MPV 1 015304073 44 ELBOW 1/4" BSP 2 B009606780010

8 MINIMUM PRESSURE VALVE 1 B009301070003 45 ‘O’RING 1 015403276

FLANGE ASSY - MPV TO

9 1 015304072 46 ‘O’RING 6 015402687
COOLER

10 MPV TO COOLER HOSE F6 1 015305606 47 ‘O’RING 1 015402687

11 ‘O’RING 1 220412320 48 HEX BOLT M12X40 2 000906185

12 OIL RETURN LINE 1 015401938 49 ELBOW QUICK FITTING 1/2" 1 000920612

13 BS ELBOW 1/8" 1 B010501230004 50 BLUE NYLON TUBE Ø12X10 0.85m B010301610005

14 ST FITTING 1/8 TO 6MM OD 1 015403616 51 QUICK CONNECTOR 1/2" BSP 2 000920512

15 SPRING WASHER M16 20 000996116 52 AFTER COOLER PIPE 1 015306532

16 HEX BOLT M16X65 4 000906219 53 AIR OIL SEPERATOR 1 B006700770023

17 HEX NUT M16 8 000948016 54 PLATE WASHER M10 2 000996010

18 DOWTY SEAL 1/4" 2 000959385 55 HEX BOLT M10X20 2 000906143

19 HEX PLUG 1/4"BSP 2 020498750 56 SAFETY VALVE 1 B012805340049

20 HEX BOLT M16X45 4 000906215 57 DOWTY SEAL 1" BSP 1 000959439

21 HEX BOLT M12X55 2 000906188 58 SLEEVE FOR 6X4 mm TUBE 4 000959763

22 HEX NUT M12 2 000948012 59 DISCHARGE RUBBER ELBOW 1 015306424

23 SPRING WASHER M12 8 000996112 60 LINE PRESSURE TUBE 4m 000920620

24 RUBBER BEEDING 0.25m 000468490 61 AUTO DRAIN VALVE 1 B000306040013

25 CLAMP AFTER COOLER PIPE 2 015402291 62 HEX BOLT M12X45 4 000983186

26 SPRING WASHER M10 6 000996110 63 CONNECTOR 2 1/2" NPT 1 015309869

UNF ST FITTING 1/8" BSP X

27 HEX BOLT M10X30 4 000906145 64 1 B010506580002
9/16"

28 ‘O’RING 4 015402871 65 OIL SIGHT GLASS 1 B004606240001

29 GASKET DISCHARGE 1 015403839 66 HEX BOLT M16 x 75 4 000906221

30 DOWTY SEAL 3/4" 2 000959438 67 QUICK FITTING 2 000920504

31 BSP PLUG 3/4" 1 015402654 68 PRESSURE TRANSMITTERS 2 00897902N

32 BSP LOCK NUT 3/4" 1 020499840 69 TEMP SENSOR 1 00897902C

33 BALL VALVE 3/4" BSP 1 B312716 *70 CONNECTOR PVC 1 015402658

34 HEX BOLT M20X65 4 000906246 *71 HOSE PVC 3/4" 1 000919503

35 SPRING WASHER M20 4 000996120 *72 CLAMP 3/4 " 1 000917501

36 SPACER 4 015402353 73 TUBINGS 6 mm 2.5m 000920620

37 OIL SIGHT GLASS 1 1/2" BSP 1 015306517 74 BULK HEAD CONNECTOR 1 B010500170002

75 1/4" MALE X 1/4" F BALL VALVE 1 B003105390005

Item no. 70,71,72 not shown in the diagram supplied loose condition

Parts Manual 10.2

11.0 Cooling system (EG110)
[ Ref : 015308758—X014769 ]

Parts Manual 11.1

11.0 Cooling system (EG110)
[ Ref : 015308758—X014769 ]

Sl.
Description Qty. Part Number
No.

1 SPRING WASHER M10 48 000996110

2 PLAIN WASHER M10 40 000996010

3 HEX BOLT M10 X 25 26 000906144

4 OIL AND AFTER COOLER 1 B012905830003

5 COOLER SHROUD ASSY 1 015312278

6 AXIAL FAN Ø710 2 018400044

7 HEX BOLT M10 X 35 17 000906146

8 RUBBER BEADING 4.5m 000468490

9 PUNCHED WASHER M10 12 000996059

10 HEX BOLT M10 X 30 8 000906145

11 BONDEL SEAL WASHER 3 000959387

12 HOSE CONNECTOR 1 B009606780012

13 STR GHT ADAPTOR 1 B010506360042

14 BALL VALVE 1 B003101230001

15 OIL DRAIN PLUG 1 B010506360004

16 SHROUD ARRESTING BRACKET 1 015308605

17 SHROUD ARRESTING BRACKET 1 015310295

Parts Manual 11.2

12.0 Lubrication system (EG90-EG110)
[ Ref : 015311977—X015603 ]

Parts Manual 12.1

12.0 Lubrication system (EG90-EG110)
[ Ref : 015311977—X015603 ]

Sl.
Description Qty. Part Number
No.

1 OIL FILTER BRACKET 1 015304881

2 HEX BOLT M10X25 2 000906144

3 PUNCHED WASHER M10 2 000996059

4 SPRING WASHER M10 4 000996110

5 THERMAL VALVE BLOCK 1 015312767

6 HEX BOLT M8X20 4 000906115

7 PUNCHED WASHER M8 4 000996058

8 SPRING WASHER M8 4 000996108

9 ‘O’RING 7 015400891

10 PIPE ASSY - TANK TO TV 1 015306426

11 HEX BOLT M12X45 4 000906186

12 PUNCHED WASHER M12 8 000996060

13 SPRING WASHER M12 14 000996112

14 THERMAL VALVE ELEMENT 1 B008706030003

HOSE ASSY - TV TO OIL

15 1 015306427
COOLER

HOSE ASSY - OIL COOLER TO

16 1 015306428
TV

17 HEX BOLT M12X40 5 000906185

18 HEX BOLT M12X30 1 000906183

19 HEX BOLT M12X35 4 000906184

20 OIL SAMPLING VALVE 1 B013206660001

21 HEX ADAPTOR 1" UNF 3 010440500

22 OIL FILTER 3 B004800770001

23 HOSE ASSY-TV TO AIREND 1 015312847

FLANG ASSY OIL INJECTION Ø

24 1 015305800
10

25 ‘O’RING 1 015402283

26 DOWTY SEAL 3/4" 1 000959438

27 M10X40 HEX BOLT 2 000906147

28 SPRING 1 015403636

29 SPACER 1 015403634

30 PISTON 1 015403633

31 COVER 1 015403635

ELECTRICAL SERVICE
32 1 B010700770001
INDICATOR

Parts Manual 12.2

13.0 Base & canopy system (EG110)
[ Ref : 015308759—X014770 ]

Parts Manual 13.1

13.0 Base & canopy system (EG110)
[ Ref : 015308759—X014770 ]

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

1 BASE ASSY 1 015313179 36 FILTER BOX 1 015317045

PILLAR ASSY - DISCHARGE

2 1 015315435 37 DUCT 1 015315585
SIDE

3 PANEL ASSY - AIREND SIDE 1 015312245

4 INTERCONNECTING MEMBER 1 015312246

PILLAR ASSY - COOLER SIDE

5 1 015312247
RH

BOTTOM PANEL ASSY - COOLER

6 1 015312248
SIDE

PILLAR ASSY - COOLER SIDE

7 1 015312250
LH

8 SIDE PANEL ASSY - RH 1 015312251

9 SIDE PANEL ASSY - LH 1 015312252

10 PILLAR - SERVICE DOOR ASSY 1 015312253

11 DOOR ASSY - SERVICE SIDE 1 015312254

12 CONTROL PANEL ASSY 1 015313194

13 DOOR ASSY - CONTROL PANEL 1 015313195

14 DRIER PANEL 1 015312257

15 PANEL ROOF ASSY - BIG 1 015312258

16 PILLAR DRIER PANEL ASSY 1 015312259

17 PANEL ROOF ASSY - SMALL 1 015312260

18 CONTROL PANEL PILLAR 1 015312261

19 SUPPORT BEAM SERVICE SIDE 1 015312316

20 SUPPORT BEAM FRONT SIDE 1 015312317

CONNECTING MEMBER REAR

21 1 015312319
SIDE

22 KEY PANEL DOOR 1 B15204790004

23 LOCK 2 6 B15204790006

24 LOCK 3 8 B15204790005

25 PLAIN WASHER - M8 20 000996008

SOCKET HEAD CAP SCREW -

26 20 000983081
M8X16

27 SPRING WASHER - M8 4 000996108

SUPPORT BEAM CONTROL

28 1 015312863
PANEL

SOCKET HEAD CAP SCREW -

29 18 000983089
M8X50

30 HANDLE 2 000921002

31 PLAIN WASHER M10 20 000996010

32 HEX BOLT M 10 X 25 20 000906144

TOP PANEL ASSY - COOLER

33 1 015312262
SIDE

34 FILTER BOX DOOR 1 015317047

35 CONNECTING MEMBER 2 015315582

Parts Manual 13.2

Kit details
Hose assembly kit details

Consumables kit details

S. No Description Part Number Qty.

HOSE ASSEMBLY MPV TO AFTER KI T (EG90,110,160) 012472819 1

HOSE ASSEMBLY TV TO OIL COOLER – (EG 90,110,160) 012472799 1

HOSE ASSEMBLY OIL COOLER TO TV KIT (EG 90,110,160) 012472809 1

HOSE ASSEMBLY TV TO AIREND KIT –(EG 90,110) 012477569 1

HOSE ASSEMBLY TV TO AIREND KIT – (EG160) 012475079 1

HOSE ASSEMBLY AIREND TO TANK KIT (EG 90,110) 012473689 1

HOSE ASSEMBLY AIREND TO TANK KIT (EG 160) 012473699 1

012474289 - Kit part number EG 90,110

S. No Description Part Number Qty.

OIL FILTER ELEMENT B004800770001

AIR FILTER ELEMENT B004700770036

AIR OIL SEPARATOR ELEMENT B006700770023

PRE FILTER B000606160001

012474299 - Kit part number EG 160

S. No Description Part Number Qty.

OIL FILTER ELEMENT B004800770001

AIR FILTER ELEMENT B004700770036

AIR OIL SEPARATOR ELEMENT B006700770018

PRE FILTER B016306250001

NOTE
B006700770028 - AOS gasket can also be used for EG 160 models separately.

Kit Details 14.1

Spare kit details

Cooler pre filter part numbers for accessories

S. No Description Part Number Remarks

COOLER PRE FILTER ASSEMBLY- F5 A010520 2 Nos. per M/c

COOLER PRE FILTER ASSEMBLY- F6 A010521 2 Nos. per M/c

Spares pre-filter element

S. No Description Part Number Remarks

PRE FILTER ELEMENT- COOLER F5 B016306250005 2

PRE FILTER ELEMENT- COOLER F6 B016306250006 2

S. No Description Part Number Remarks

IN TAKE VALVE KIT- (EG 90,110) B009401070002
IN TAKE VALVE KIT- (EG 160) B009401070004
PRESSURE REGULATOR - (EG 90,110,160) B001501070001
BLOW DOWN VALVE KIT - (EG 90,110) B009401070003
5 BLOW DOWN VALVE KIT - (EG 160) B009401070050 1
ACTUATOR REPAIR KIT WITH SPRING - (EG 90,110,160) B015401070005
7 24 V AC SOLENOID VALVE (EG 90,110,160) B007300990004
8 DRIVE COUPLING ELEMENT (EG90) B005401170005 1
9 DRIVE COUPLING ELEMENT (EG110,132,160) B005401170007
10 ‘O’ RING AND GASKET KIT 225 AIR END (EG 90 & 110) 012472769
11 ‘O’ RING AND GASKET KIT 284 AIR END - (EG 160) 012472779

PULSE LINE,PRESSURE SENSOR LINE,BLOW DOWN LINE,

12 012477519
ADV LINE AND CORRESPONDING SLEEVES-(EG 90 & 110)

PULSE LINE,RETURN LINE,BLOW DOWN

13 012477549
LINE AND CORRESPONDING SLEEVES- (EG 160)

14 MINIMUM PRESSURE VALVE KIT - (EG 90 - 160) B009301070004

15 ‘O’ RING FOR INTAKE VALVE (EG 90,110) B009801070027
16 ‘O’ RING FOR INTAKE VALVE (EG 160) B009801070028
17 ACTUATOR ASSEMBLY - (EG 90,110,160) B011501070001
18 NC THERMAL VALVE KIT 65 DEG. F5, F6 012477649 1
19 NC THERMAL VALVE KIT 75 DEG. F5, F6 012477659 1

20 BALL & SCORKET JOINT KIT –ACTUATOR BALL JOINT KIT B009401070011 1

21 MOS — ADV G1/2” CONNECTOR B000306040016 1

Kit Details 14.2

Insurance kit details—EG 90,110,160
Models

EG 90 C EG 90 CV EG
EG 160 C
110 C 110 CV 160 CV
Insurance kit details

Kit

S.No Description Part Number 012477989 012477999 012477809 012478009

1
IN TAKE VALVE KIT -
(EG 90, 110) B009401070002  -  -
2 IN TAKE VALVE KIT - (EG 160) B009401070004 -  - 
3
PRESSURE REGULATOR (EG
90,110, 160) B001501070001   - -

BLOW DOWN VALVE KIT (EG

4
90,110, 160) B009401070003    
BLOW DOWN VALVE KIT (EG
160) B009801070050    
ACTUATOR REPAIR KIT WITH
5
SPRING(EG 90, 110, 160) B015401070005    
ACTUATOR ASSEMBLY (EG 90,
6
110, 160) B011501070001    

24 V AC SOLENOID VALVE (EG

7
90,110, 160) B007300990008    

DRIVE COUPLING ELEMENT

8
(EG90 - 160), UCW 295 B005401170007    

9
O - RING AND GASKET KIT 225
AIR END 012472769  -  -
10
O - RING AND GASKET KIT 284
AIR END 012472779 -  - 
PULSE LINE, RETURN LINE,
BLOW DOWN LINE AND CORRE-
11
SPONDING SLEEVES - (EG 90, 012477519  -  -
110) 60 Hz

PULSE LINE, RETURN LINE,

BLOW DOWN LINE AND CORRE-
12
SPONDING SLEEVES - (EG 160) 012477529 -  - 
60 Hz

MINIMUM PRESSURE VALVE

13
KIT (EG 90 - 160) B009301070004    

14 PRESSURE TRANSMITTER 00897902N    

15 TEMPERATURE SENSOR 018400077    
Kit Details 14.3
 Models

EG 90 C EG 90 CV EG
EG 160 C
110 C 110 CV 160 CV
Insurance kit details

Kit

S.No Description Part Number 012477989 012477999 012477809 012478009

GASKET—AIR OIL
16
SEPARATOR ELEMENT B00670070028    
17 OIL LEVEL SIGHT GLASS 015306517    
18 SHAFT SEAL 013436272    
19 SPACER - 225 AIR END 013436295  -  -
20 INNER RING 013436293    
21 SPACER - 284 AIR END 990400900 -  - 
MOS - O DRAIN VE
22
ASSEMBLY
B000306040013    
23 OIL COOLER - (EG 90 & 110) * * B011905830018  -  -
24
AFTER COOLER - (EG 90 & 110) *
*
B013005830005  -  -
25 OIL COOLER A - (EG 160) * * B011905830033 -  - 
26 AFTER COOLER - (EG 160) * * B013005830006 -  - 
27 ELECTRICAL SERVICE INDICATOR B01070070001    

C : Standard version CV : Standard + Variable frequency drive

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 14.4

CONTROL PANEL EG90-110V 460V 60HZ
(POWER CIRCUIT)

01 83 6260 6
 CONTROL PANEL EG90-110V 460V 60HZ

66260
3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1

(CONTROL CIRCUIT)
R10 R9 R8 R7 R6 R5 R4 R3 R2 R1
X08

01 83
X02 X07 X06 X05

X03 X04
RS 485 RS 485

A2
A1

B1

B2
2 4 6 8
2 4 6 8 10 2 4 6 8 10 12
X01 1 3 5 7 9 1 3 5 7 9 11
1 3 5 7

P N

NC
NC

NC

NC
PE

RS 485 RS 485

B1

A2

B2
A1
2 4 6 8

X04
1 3 5 7

NC
NC

NC

NC
CONNECTION DETAILS

X02

2 4 6 8 10

1 3 5 7 9

2 4 6 8 10 12
X03

1 3 5 7 9 11
CONTROL PANEL EG90-110V 460V 60HZ
(BOM)

01 83 6260 6
CONTROL PANEL EG90-110V 460V 60HZ
(PANEL LAYOUT)

01 83 6260 6
 16.0 VFD setting procedure

Brief introduction to VFD in the global Software details (programming details)

series compressor Based on the compressor rating, VFD parameters are pre-
programmed in the Setup 1 location and in the compressor
In VFD model compressors, the Variable Frequency Drive controller. The setting details are available in Annexure 1.
(VFD) is integrated with the compressor. Simply put, the
During installation and commissioning, you can tune the PI
main motor is controlled through VFD instead of the star
at your own site to ensure smooth speed control according
delta starter.
to your requirements. Except for PI settings in the
Hardware (wiring) details
controller, no other setting is required to change. Similarly
The figure illustrates the wiring integrations with the VFD
and control panel/controller. The following section
describes the purpose of each connection in this
architecture.

1. 3 Phase connection to VFD

The input side phase sequence is critical for the fan

direction of rotation. During installation, the fan direction
needs to be checked and, if required, change the phase
sequence. However, the motor phase sequence is
controlled by VFD.

2. Motor connection

It is wired for the required phase sequence with respect to

your compressor requirements. Do not change the
configuration.

3. Start command to VFD

The Start/Stop command that flows to the VFD from the

controller rotates/stops the main motor.

4. Run feedback signal

in VFD, all settings are pre–programmed, so you need not
After reaching 40% of speed, VFD sends a run feedback
change any of the settings. During operation, you can
signal to the controller to switch on the solenoid valve to
change the load pressure set point according to your
the start loading process.
requirements. .
5. Trip command from VFD
The following parameters are important for the
During any abnormalities in the VFD drive, a trip signal correct drive operation
flows to the controller to stop the compressor. (To
 Right analog output feedback from the controller to
troubleshoot, refer to the VFD manual.)
VFD. (1V corresponds to AO scaling low reference and
6. Pressure feedback signal 5V corresponds to AO scaling high reference.)
The delivery pressure feedback signal propagates from the  The AO high and low reference scaling settings are
controller (analogue output CH1) to VFD to control motor configured in the factory setting menu in the Neuron II
speed. The feedback is an analogue voltage signal with a controller. You can view these parameters in the NII
range 1-5 V. controller. The corresponding low ref and high ref
7. RS485 communication settings must be verified in drive parameters 614 and
615, respectively.
An RS485 communication medium occurs between the
VFD and controller to read/write parameters such as  Ensure the dip switch in VFD (right behind the display)
voltage, current, power, frequency, and the analog scale is set in voltage mode.
setting.  Enter motor nameplate details in VSD settings (such as
All the above connections are factory wired and you only voltage, current (I max value-SF current), power,
need to connect the incoming supply to the compressor frequency, and RPM).
with the right wire size and incoming protection fuse (as  You need to adjust PI parameters at your site for
per the compressor manual). effective tuning to ensure smooth speed control to meet
your exact requirements.
NOTE
 You can edit the parameters 614 and 615 in the VFD
Ensure the dip switch in VFD (right behind the display) is
set in voltage mode. through the controller. Ensure this value matches the

VFD Settings 16.1

 AO scaling in the controller. Good practice is to not If pressure reduces and reaches the load point of the
attempt to change these settings on your own. Instead controller, then the compressor starts loading and the
contact ELGi . speed increases from 40% to maintain the set pressure.

For more details about VFD parameters and  If the machine runs in unload for more than the stand
troubleshooting, refer to the VFD manual that shipped by time set in the controller, the compressor stops and
along with the compressor. goes to standby mode. It waits till pressure reaches the

Operation set load point in the controller and then starts as per
the start sequence.
The Start command enables the compressor motor to start
and rotate in the required direction. It is issued from the If the drive does not respond to quick pressure changes
controller to VFD. (drop in set pressure) or responds very fast to pressure
changes (continuous increase and decrease in speed to
After receiving the Start command, VFD accelerates the
maintain set pressure), then adjust P and I settings in the
compressor motor to 40% speed (minimum speed setting
NII controller**.
in the controller). After ensuring the run feedback signal
from VFD and reaching 40% speed, the controller actuates ** One-time fine tuning is recommended during
the solenoid valve to start the loading process. Only then installation by an expert.
does VFD increase motor speed from 40% to 100% (max If you do not opt for speed change with respect to
speed setting in the controller). pressure, and instead opt to operate in fixed speed, then

Until the Target pressure is reached, the VFD delivers choose the optimum speed enable option in the operator

100% speed. Once the Target pressure is reached and the setting. The compressor then operates at optimum speed
demand becomes low, the speed reduces and stabilizes to during load and at unload speed during unload.
maintain the set pressure. The speed limit varies from
40% to 100% speed based on the demand and pressure NOTE
range. Max speed, min speed, optimum speed, and unload speed
Even when speed reaches 40% of the rating and the are all factory settings. Do not attempt to change these
settings. You can view set speed details in the operator
demand is still low, pressure increases and reaches load menu
pressure of +7 psi. At this point, the compressor switches
to unload mode and starts running at unload speed.

Trouble shooting

Fault Description Details to be checked

The PI settings in the controller to be reduced to have the speed respond to
pressure variation.
The compressor does not develop the required pressure (under-rating of the
The motor runs at full speed or
compressor) and always runs at max speed of the motor.
1 low speed (no speed change
Check the controller A/O scaling value (viewed in the operator menu) with respect
with respect to pressure)
to the VFD parameter 614,615.
Ensure unload is enabled in the controller.
Ensure optimum speed setting is enabled.

The motor speed changes The PI setting is too short. It continuously gives feedback to change motor speed
2 frequently and makes noise and produces very high response to pressure variation. In this case, PI values must
(acceleration and deceleration) be increased to have smooth speed changeover.

The motor runs at low speed The compressor runs in unload mode.
3
continuously (30Hz) Air demand is less and the standby time set is more than 3 minutes.

The compressor minimum and

maximum speed is not as per Check AO scaling values in the controller (operator menu view).
4
minimum and maximum speed Ensure VFD parameters 614 and 615 are the same.
limits set in the controller

Ensure VFD processes the start command and VFD display shows Ramping or
Running.
Check for any Trip Message in the VFD.
5 Motor not starting Verify that the ON status LED in the VFD glows. If not, press the Auto on button in
the VFD and ensure the ON LED glows.
Check the pressure is more than load pressure and the compressor is in standby
mode.

VFD Settings 16.2

 Fault Description Details to be checked

Check the run feedback signal from VFD.

Compressor does not switch to
6 Verify that the controller issues the load command.
load mode
Ensure that the solenoid valve receives supply and energizes.
Verify if the motor consumes more power than the nameplate value.
Ensure that the VFD parameter is correct.
Compressor trips from VFD and
7 Check the VFD trip history/details of the trip and make the required corrections as
the controller displays VFD fault
per
VFD troubleshooting guidelines.

FAQ What is the significance of max and min speed

settings in the controller?
What is target pressure?
This imposes limitation on Max/Min speed for selected
It is a set load pressure that VFD needs to maintain by compressor models. This limitation will change between
varying compressor motor speed. If demand is low, speed compressor models. This setting must not exceed the AO
reduces and pressure remains constant. If demand scaling range.
continues to be low, pressure increases and reaches load
What is the significance of the optimum speed
pressure
setting in the controller?
 Of 7 psi. When this occurs, the compressor switches to
If the compressor needs to operate in fixed speed, then
unload mode and starts operating at unload speed.
optimum speed must be enabled in the operator setting, If
What is the significance of P&I settings in the optimum speed is enabled, the compressor will operate at
controller? optimum speed during load and at unload speed during
The change in pressure with respect to time is not linear in unload. This feature affords flexibility to customers if the
all the cases, but the rate of change in pressure depends compressed air circuit has more than one VFD machine
on receiver and pipeline capacity of a particular customer. and one machine for speed control. Typically, one machine
The higher the storage capacity, the greater is the time is enough.
available for speed correction and for producing a The optimum speed setting lies between the range of min
response to pressure requirement, and the reverse is also and max speed settings.
true. In such a case, the P & I setting must be adjusted at
What is the significance of the unload speed setting
the site for smooth speed change-over. One-time fine
in the controller?
tuning is required at the site and the settings can be
adjusted through the controller. Unload speed is nothing but the speed at which the
compressor must operate during unload. This setting must
Why must be the direction of rotation verified in VFD
be in the range of min speed and max speed and less than
output?
optimum speed.
VFD output always causes clockwise rotation irrespective
of the input connection to the VFD. In case the compressor
needs to operate counterclockwise, the motor connection
from VFD output must be reversed. (Refer to the circuit
right direction of rotation.)

What is the meaning of main motor overload trip in

the controller?

The VFD trip is connected to the controller for main motor

trip display in the controller. Refer to VFD trip information,
verify the type of trip, and make corrections as per the
manual.

What is the significance of the AO scale setting in

the controller?
AO scaling with respect to 1V corresponds to min speed
and 5V corresponds to max speed. Based on this scaling
range and analogue input reference, VFD calculates the
required speed/frequency at which the compressor motor
must operate. AO scaling values in the controller settings
and in the drive parameters 614 and 615 need to be the
same.

VFD Settings 16.3

Annexure 1
ID Name Setup 1

1 Language English

2 Motor Speed Unit RPM

10 Active Set-up Set-up 1

20 Display Line 1.1 Small Motor Voltage

21 Display Line 1.2 Small Motor current

22 Display Line 1.3 Small Speed [RPM]

23 Display Line 2 Large Analog Input 53

24 Display Line 3 Large Frequency

40 [Hand on] Key on LCP Disabled

41 [Off] Key on LCP Disabled

42 [Auto on] Key on LCP Enabled

43 [Reset] Key on LCP Enabled

100 Configuration Mode Speed open loop

101 Motor Control Principle VVC+

104 Overload Mode Normal torque

106 Clockwise Direction Normal

120 Motor Power [kW] Motor name plate

122 Motor Voltage Motor name plate

123 Motor Frequency Motor name plate

124 Motor Current Motor name plate * SF

125 Motor Nominal Speed Motor name plate

139 Motor Poles Motor name plate

190 Motor Thermal Protection ETR Trip1

191 Motor External Fan Yes

300 Reference Range Min - Max

301 Reference/Feedback Unit RPM

302 Minimum Reference 900

303 Maximum Reference 2400

304 Reference Function Sum

310-[0] Preset Reference 0

313 Reference Site Remote

315 Reference Resource 1 Analog Input 53

316 Reference Resource 2 No Function

317 Reference Resource 3 No Function

340 Ramp 1 Type Linear

341 Ramp 1 Ramp Up Time

342 Ramp 1 Ramp Down Time

VFD Settings 16.4

 ID Name Setup 1

410 Motor Speed Direction Clockwise

411 Motor Speed Low Limit [RPM] 900

413 Motor Speed High Limit [RPM] 2400

419 Max Output Frequency 80

512 Terminal 27 Digital Input Coast inverse

540 Relay->Option relay 7-> Function relay Running

540 Relay->Option relay 8-> Function relay Alarm

610 Terminal 53 Low Voltage 1

611 Terminal 53 High Voltage 5

614 Terminal 53 Low Ref./Feedb. Value *** (Edit from NII Controller)

615 Terminal 53 High Ref./Feedb. Value *** (Edit from NII Controller)

830 Protocol Modbus RTU

832 FC Port Baud rate 9600

833 Parity/Stop bits No Parity,1 Stop bit

843-[0] PCD read Configuration (1603) – Status word

844-[1] PCD read Configuration (1605) – Main Actual Value ...

845-[2] PCD read Configuration (1612) – Motor Voltage

846-[3] PCD read Configuration (1613) – Frequency

847-[4] PCD read Configuration (1614) – Motor Current

848-[5] PCD read Configuration (1614) – Motor Current

849-[6] PCD read Configuration (1610) – Power KW

850-[7] PCD read Configuration (1610) – Power KW

851-[8] PCD read Configuration (1502) – Kwh Counter

852-[9] PCD read Configuration (1502) – Kwh Counter

853-[10] PCD read Configuration (1501) – Running Hours

854-[11] PCD read Configuration (1501) – Running Hours

855-[12] PCD read Configuration (1601) – Reference [Unit]

856-[13] PCD read Configuration (1601) – Reference [Unit]

857-[14] PCD read Configuration (1617) – Speed [RPM]

858-[15] PCD read Configuration (1617) – Speed [RPM]

859-[16] PCD read Configuration (1615) – Frequency [%]

NOTE
#Make ramp-up time (341) and ramp-down time (342) settings as follows:

Motor kW Ramp up time Ramp down time

11 KW to 45 KW 25sec 15 sec

55 KW and 75 KW 30 sec 20 sec

160 KW 30 sec 30 sec

VFD Settings 16.5

Compressor controller setting in Operator menu VFD
settings.

Min Default Unit

Optimum speed on/off on/off off -

P-Gain 0 50000 100 -

I-Gain 0 5000 100 -

I-Time 0 200 10 -

Max. speed RPM

Min. speed RPM

Optimum speed RPM

Factory setting can be viewed
UL speed RPM

High (5V) RPM

Low (1V) RPM

This information is for reference only. The settings are all

made at the factory. You need not perform these settings
at your site. However, P, I, and integral time settings need
to be configured during installation.

VFD Settings 16.6

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.7, Jalan Anggerik Mokara 31/44, Sek. 31, kota kemuning, 40460 Shah Alam, Selangor,
MALAYSIA
Malaysia, Tel: +603-5120-1544 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., Unit 1, 33 Kingsbury Street, Brendale Queensland - 4500. 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].

