vii

About ELGI

Elgi's experience in the design and manufacture of air compressors spans 50 years.Established in India in 1960 as a reciprocating air compressor manufacturing company,Elgi gained its reputation for design and manufacture of screw compressors throughstrategic partnerships and continuous research and development. Over the years, itemerged as a multi-product multi-market enterprise providing total compressed airsolutions in all segments. Elgi's design capabilities translated into wide range of productsranging from oil-lubricated and oil-free rotary screw compressors, oil-free reciprocatingcompressors and centrifugal compressors.

Screw compression elements are manufactured in-house using state-of-the-artmachining centres for rotor grinding and machining intrinsic castings of various sizes.Elgi own ηV (eta V) profile rotors ensure energy-efficient compressed air supply for alldemanding applications. Elgi is one of the few companies capable of manufacturingwide range of airends and compressor packages in the world.

Elgi has modern manufacturing facilities in India, China and France. It's equipped withstate-of- the-art high precision rotor cutting and grinding machines, turning centres ,CNC horizontal and vertical machining centres.

All manufactured components / products pass through stringent quality audits and aretested to ensure performance and reliability. Our Manufacturing test rooms areatmospheric controlled. All parts and finished products undergo stringent quality checksto ensure that Elgi delivers only high quality products to its customers.

Over two million compressors are powering business in 63 countries worldwide. Thecompany offers a strong sales and service network of 14 domestic and 6 overseasoffices, besides a well-knit distribution network of 114 dealers in India and 165distributors worldwide. Elgi has set up warehouse facilities in Brazil and Middle East.

Driven by the philosophy of Think Long Run, Elgi believes in forging long runningpartnerships with its stakeholders worldwide guided by reliability, technology, capabilityand values fuelled by innovation.

Appendix A

26.0

Mimic Led Table

# LED Description

1 Auto Indicates the machine is in Automaticon/off mode. LED glows in AmberColour when

1. Pressure Schedule is enabled (or)Auto Restart is enabled

2 Air Filter Glows in Amber colour when 1.Air Filter Service is due based onservice hours2. Air Filter Digital Input(DPAF) is Open & DPAF is enabled

3 Main Motor Overload Glows in Red when the Main MotorOverload Digital Input is Open.

4 Reverse Rotation Glows in Red when the ReverseRotation Digital Input is Closed

5 Cooler fault Glows in Red when the cooler DigitalInput is Open

6 Pressure Glows in Red when 1. HSP DigitalInput is Open 2. Analog PressureInput is Open (Probe Failure) Dis.Pressure is higher than set HSP

7 Temperature Glows in Red when 1. AnalogTemperature Input is Open (ProbeFailure) 2. Dis. Temperature is higherthan set Trip temp.

8 Differential Pressure Glows in Amber when 1. DPOFDigital Input is Open & DPOF isenabled Oil Filter Service is due

9 Differential Pressure Glows in Amber when 1. Oil SeparatorFilter Service is due 2. On HighDifferential Pressure (Only if SumpPressure enabled)

10 Start & Stop 1. Glows in Red when machine isstopped / idle 2. Glows in Greenwhen machine is running

Appendix B

27.0

APPENDIX B: Short Cut Key Functions

Note1: All shortcut key functions only when the display is on Main Screen.Note2: On every press of the key NEXT message is displayed.

“LEFT” – Warning messages

Warning Description

DPAF Differential Pressure Air Filter Due ForService

DPOF Differential Pressure Oil Filter Due ForService

Dryer Probe Failure Pt100 Sensor Probe Failure

Low Dew Point Live Dew Point less than the Set LowDew Point

High Dew Point Live Dew Point greater than the Set HighDew Point

High Differential pressure Difference Between the Sump & DischargePressure is greater than the set maxDifferential Pressure value.

Warn Temperature Discharge Temperature exceeds the setWarn value

Change Air Filter Air Filter Due For Service

Change Oil Filter Oil Filter Due For Service

Change Oil Separator Oil Separator Due For Service

Change Oil Oil Change Due For Service

Change Grease Re Grease Due For Service

Start Stop Exceeded No. of Start and Stop per hour exceeded

“RIGHT” - Live analog values1. Live differential pressure

2. Live sump pressure

3. Live Pt100 temperature

“UP” – Set analog values1. Set load pressure

2. Set unload pressure

3. Set start sump pressure

4. Max differential pressure

“DOWN” – Today report1. Date

2. Load and stop hours

3. Unload and fault hours

4. Run and standby hours

5. Start count and load count

Appendix B

27.1

Appendix C

28.0

APPENDIX C: Modbus Table [Function Code: 0x03(Read) & 0x10(Write)]

# Data Address Type Bytes Example/ Access

Description Format

Cumulative Time & Count Registers

1 Load Hours 1010 BCD 4 HHHHHH:MM R

2 Unload Hours 1012 BCD 4 HHHHHH:MM R

3 Run Hours 1014 BCD 4 HHHHHH:MM R

4 Stop Hours 1016 BCD 4 HHHHHH:MM R

5 Fault Hours 1018 BCD 4 HHHHHH:MM R

6 Standby Hours 101A BCD 4 HHHHHH:MM R

7 No of Start 101C BCD 4 NNNNNNNN R

8 Load Count 101E BCD 6 NNNNNNNNNNNN R

9 Utilization % 1022 BCD 2 XXXX R

Service Remaining Time Registers

10 Rem AFCT 1029 ULong 4 H800927BF = R

Minutes -599999

11 Rem OFCT

Minutes 102C ULong 4 H800927BF = R

-599999

12 Rem OSCT 102F ULong 4 H800927BF = R

Minutes -599999

13 Rem OCT 1032 ULong 4 H800927BF = R

Minutes -599999

14 Rem RGT 1035 ULong 4 H800927BF = R

Minutes -599999

Mode Registers

15 Control Mode 1040 BCD 2 0001-DCS

0002-Local

0003-Remote R/W

16 Unload Mode 1041 BCD 2 0001-Disabled

0002-Enabled R/W

17 Auto Restart 1042 BCD 2 0001-OFF

0002-ON R/W

18 Pr Unit 1043 BCD 2 0001-BAR

0002-PSI R/W

# Data Address Type Bytes Example/ Access

Description Format

19 Tr unit 1044 BCD 2 0001-Centi

0002-Farhen R/W

20 Pr. Schdl 1045 BCD 2 0001-OFF

(on/off) 0002-ON R

Analog Registers

27 Dis. Pressure 104A BCD 2 1200 (/100) =

12.0 bar R

28 Dis. 104B BCD 2 1100 (/10) =

Temperature 110 C R

29 Dew Point /

Ambient

Temperature 104C BCD 2 MSB 01 = +

MSB 02 = -

LSB = 30 R

30 Sump Pressure 104D BCD 2 1200 (/100) =

12.0 bar R

31 Diff Pressure 104E BCD 2 0100 (/100)

=1.0 bar R

32 Set Unload 104F BCD 2 0120 (/10)

Pressure = 12.0 bar R/W

33 Set Load 1050 BCD 2 0080 (/10) =

Pressure 8.0 bar R/W

34 Set Diff 1051 BCD 2 0010 (/10) = R/W

Pressure 1.0 bar

35 Trip Temp 1052 BCD 2 0110 = 110 C R

36 Warn Temp 1053 BCD 2 0105 = 105 C R/W

37 Low Dew Point 1054 BCD 2 MSB 01 = +

MSB 02 = -

LSB = 30 R/W

38 High Dew Point 1055 BCD 2 MSB 01 = +

MSB 02 = -

LSB = 30 R/W

39 Fan Temp 1056 BCD 2 0070 = 70 C R/W

Appendix C

28.1

Appendix C

28.2

# Data Address Type Bytes Example/ Access

Description Format

21 Auto Restart 1060 BCD 2 0100 R/W

Delay (Sec)

22 Star Delay (Sec) 1061 BCD 2 0005 R/W

23 DTR Delay (Sec) 1062 BCD 2 0010 R/W

24 RTS Delay (Sec) 1063 BCD 2 0010 R/W

25 Standby Time 1064 BCD 2 0005 R/W

(Min)

26 Max. No of Start 1065 BCD 2 0005 R/W

per hour

RTC Registers

40 Hour 106A BCD 2 0023 R

41 Minutes 106B BCD 2 0059 R

42 Seconds 106C BCD 2 0059 R

43 Date 106D BCD 2 0031 R

44 Month 106E BCD 2 0012 R

45 Year 106F BCD 2 0009 R

46 Day 1070 BCD 2 0001Sunday -1 R

Status Registers

47 General Status 1071 UInt 2 Refer table R

48 Warning Status 1072 UInt 2 Refer table R

49 Fault Status 1073 UInt 2 Refer table R

Function Code: 0x01(Read Coil) & 0x05(Write Coil)

0x01 Read Coil (Start / Stop)

0x05 Write Coil (Start / Stop)

Frame Type ID Function Address Quantity of Data

Code coils

Request XX 01 2000 0001 —

Response XX 01 — Byte count: 01 ON 0x01

OFF 0x00

Frame Type ID Function Address Quantity of Data

Code coils

Request XX 01 2000 0xFF00 Start

0x0000 Stop

Response XX 01 2000 0xFF00 Start

0x0000 Stop

Appendix C

28.3

Note: Function Code 0x10 (Write), 0x05 (Start/Stop) and 0x01 (read Start/Stop)will function only if “Control Mode” is set to “DCS”. Refer: Operator/Machine/Mode (Chapter 5.2.1)

On improper master request, any one of the following exception response

is sent

Code 01: Illegal function

Code 02: Illegal data address

Code 03: Illegal data value

Status Register Bit Definition:

Bit Position General Warning Fault

0 Ready DPAF HSP

1 Star DPOF Cooler

2 Run Dryer probe failure Main motoroverload

3 Run load Low dew point Reverse rotation

4 Run unload High dew point Pressure probefailure

5 Stop busy High differential Temperature probe

pressure Failure

6 Idle Warn temperature Trip temperature

7 Emergency Change air filter Sump pressure not

stop developing

8 Start inhibit Change oil Sump pressure filter probe failure

9 Start Change oil Power failure

ack wait separator

10 Standby Change oil Reserved

11 Reserved Change grease Reserved

12 Reserved Reserved Reserved

13 Reserved Reserved Reserved

14 Reserved Reserved Reserved

15 Reserved Reserved Reserved

Appendix C

28.4

Appendix-D Flow charts (Start, Stop, Load /unload /standbysequence)

Start Sequence:

STAR

ON

MAIN ‘ON’

NO. OF. START

INCREMENT

DELTA ON

STAR OFF

Return

Delay for 100msecs

(Fixed)

STAR TO DELTA delay ‘x’ sec

(Star delay)

Delta to run delay ‘x’ sec

(DTR)

Start Sequence

Appendix D

29.0

29.1

Appendix D

Is

STAR ON?

LOAD “OFF”

DELTA & MAIN

OFF

(RTS delay)

Run to stop ‘x’ sec

“IDLE” delay for 5 secs

Fixed delay

READY

Yes

No

Stop

Is

MAIN ON?Return

Yes

No

Stop Sequence:

RUN LOAD/UNLOAD/STANDBY

IsDeltaON?

Load ‘ON’

Return

Load ‘OFF’

IncrementLoad Count

IsDIS Pr

< Load pr

pr.Is

DIS>UL pr

Return

NO

Yes

NO

Yes

No

Yes

Standby mode: In unload mode, if the pressure exceeds the set load pressurein the preset standby time, and is less than number of start/stop cycles duringthat time, the compressor goes into the standby mode ( or the compressorstops as per the stop sequence).

In standby mode, if the pressure drops below the set load pressure, thecompressor starts automatically as per the start sequence.

29.2

Appendix D

36.0

BASE AND CANOPY ASSY

STANDARD, STANDARD + DRYER, STANDARD +DRYER + VFD VERSION

BASE AND CANOPY ASSY

36.1

1 015305301 Base Assy 1

2 015305303 Front Pillar1 Assy 1

3 015305306 Front Pillar2 Assy 1

4 015305302 Rear piller 1 Assy 1

5 015305304 Rear Pillar2 Assy 1

6 015305435 Side Pillar Assy 1

7 015305307 Front Cover Assy 1

8 015305310 Control Panel Assy 1

9 015305312 Door LT Assy 1

10 015305305 Door RT Assy 1

11 015305313 Side Cover Assy 1

12 015305280 Side Cover Assy - RH 1

13 015305295 Door Top Cover Assy 1

14 015305292 Top Cover Assy 1

15 015305297 Cooler Box Assy 1

16 015305293 Rear Cover 2 Assy 1

17 015305296 Top Cover Holder Assy 1

18 015305294 Silencer Bkt Assy 1

19 015402391 Cooler Box MTG BKT3 Assy 1

20 000921002 Handle 1

21 B011604790006 Lock 4

22 015402415 Cooler Inspection Cover 1

23 B011604790005 Hinge 6

24 015402419 L Mount Bkt 4

25 - M8 x 16 Socket head Cap screw 42

Part No. Description Qty.S.No. Remarks

36.2

BASE AND CANOPY ASSY

36.3

26 - M6X12 Soc Head Cap Screw 8

27 - M6 x 13 CSK screw 12

28 - M12X30 Hex Bolt 19

29 - M12 spring washer 19

30 - M8 spring washer 3

31 - M10X20 Hex Bolt 4

32 015304759 Air outlet connection assy 1

33 B010406050001 Rubber beeding 3.7m Control panel box

B010406050001 Rubber beeding 1.3m Front pillar1 assy

B010406050001 Rubber beeding 1.4m Side pillar assy

B010406050001 Rubber beeding 2.4m Rear cover 1 assy

34 015401189 CONNECTOR AF ASSY 11-15KW 1 11kW &15kW – 7.5 to13 ,18,22kW-13bar

35 015401188 CONNECTOR AF ASSY 18-22KW 1 18Kw & 22kW- 7.5 ,8.5,10 bar

36 015302681 COOLER MTG PLATE ASSY_11-15KW 1 11 and 15kW models

37 015302682 FAN DUCT PLATE ASSY 1 11kW models

38 015302678 Rear Cover 1 Assy 11-15kw 1 11 and 15kW models

39 015302679 Rear Cover 1 Assy 18-22kw 1 18 and 22kW models

40 015302684 VFD MTG BKT 1 VFD versions

Part No. Description Qty.S.No. Remarks

ELGI provides dedicated customer care and after-sales support through the

CCS, a computerized system developed in-house. The CCS aims to minimize

the time taken to resolve complaints

Service Requests/Complaints

At the heart of the CCS is the toll-free telephone number 1800-425-3544 (with in

india BSNL MTNL lines) at the centralized customer care center in Coimbatore.

Customers can register their service requirements or complaints with coordinators

here

A unique tracking number is generated for each call logged by the CCS. The

customer is sent an automatic e-mail acknowledgement with the tracking number

and details of the call for reference

A service engineer is assigned to the call, and the date and time of the engineer’s

visit are communicated to the customer by e-mail. Every requirement or

complaint must be resolved and closed in the CCS within a specified time limit,

failing which the call is brought automatically to the notice of the manager

higher in the hierarchy, up to the level of the Managing Director. Thus the CCS

ensures that not only are customer complaints logged, they are also attended

on time every time

Enquiries

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

products and spare parts. The details are noted, and basic information on product

specifications and usage are provided. The caller is informed whom to contact

for further discussions. The enquiry is passed on to a salesperson at the Head

Office or the appropriate branch for follow-up

The CCS Database

The CCS also creates a database of customers, adding every new customer

calling and thereby building a large pool of installation details. These details are

used to provide value-added services to improve customer satisfaction with

ELGI products

ELGI’s Customer Care System (CCS)

2.0

CCS—Working Hours

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

(Monday to Saturday)

Multi-lingual Capability

The coordinators at the CCS are multi-lingual. They can handle calls in all the

major regional languages of India

Coverage

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

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

Andaman & Nicobar islands

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

Islands

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

North-Eastern states

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

Uttaranchal, Himachal and Jammu & Kashmir

Other Contact Numbers

The CCS can also be availed through the following numbers:

Telephone : 0422-2589 206/2589 241/2589 242/2589 243

2589 244/2589 245/ 97900 21100

Fax : 0422-2589 240

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

ccs@elgi.com

Customer Satisfaction Survey

If you have used the CCS, you may be contacted and your feedback sought on

the after-sales support received by you. Your response helps ELGI to improve

this service

2.1

Commissioning Process

3.0

Before the new Global Series compressor is operated for the first time, it needs

to be installed at your site according to ELGI’s specifications. ELGI’s

commissioning engineer carries out a series of checks on the machine and the

systems to which it is connected to ensure that it is in a condition to function

safely and as desired. The engineer will then describe to the operator of your

compressor how the equipment is to be operated and maintained. This procedure

is referred to as the commissioning process

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

general operating conditions of the equipment including the cleanliness of the

atmosphere, the temperature and the ventilation are checked. Technical details

relating to your system such as particulars of your electrical installation are

noted. The operator of your compressor is familiarised with all aspects of both

its normal running and dealing with unusual situations. The commissioning

process provides to ELGI data that will help understand your requirements

better

Please make preparations according to the instructions provided in the Installation

section for your Global Series compressor to be commissioned. Ensure that

the location chosen meets the requirements of accessibility, ventilation and

safety. Provide electrical power as recommended in the Installation section, in

discussion with ELGI’s commissioning engineer. Select air pipe lines and

receivers for your system according to the tables provided in the same section

Upon completion of the commissioning process the commissioning engineer

will fill in the document known as the commissioning Report. Please verify the

information filled in and attest the certificate of completion of commissioning.

The commissioning engineer will also sign the report. Kindly hand over the

commissioning report to the commissioning engineer. Please fill in also the

Warranty Card that comes along with the compressor and hand it over to the

engineer. The engineer will send the report and the card to ELGI’s Service

Department — Compressor Division, Head Office

Construction

24.0

Corrosion & dust protected back cover

IP65 polyethylene front keypad

Inputs and outputs through terminal block, board to wires, disconnect

able, screw terminals

Front plate dimensions 260 x 145mm

Enclosure dimensions 235 X 120 X 70 mm

Operating temperature - 0ºC to +75ºC

Relative humidity <85% RH non-condensing @ 40ºC

6.1 Dimension Drawing

70

120

Panel Front Plate

Panel Cut out Dimension

All dimensions are in mm

120

235

X04

X01 X06

X07

X02X03ISPX05

260

145

133

100

Controller Identification

25.0

While Communicating to Elgi, please mention the following:

Type of controller

SL no

Batch NO

Revision Details

For any other clarification in the controller please contact ELGI

Toll Free No : 1800-425-3544

e-mail ccs@elgi.com

Version Date Changes

1.0 2 April 2009 Initial Draft

1.1 13 July 2009 Pilot Batch S/W Version 1.1

1.2 01.02.2010 Pilot batch SW version 1.1D

33.0

COOLER BOX SUB ASSY

33.1

FOR, STANDARD VERSIONSTANDARD + DRYER VERSIONSTANDARD + DRYER + VFD VERSION

1 015302868 COOLER BOX 1

2 015400879 COOLER INSPECTION COVER 1

3 000983083 SCR SOC HD M8X20 10.9 ZYP 20

4 000996106 SPRING WASHER M6 20

5 015401539 COOLER BOX MOUNTING BRACKET 31

6 015302871 COOLER BOX TOP COVER 1

7 008972040 FAN MOTOR ASSEMBLY 2 15kW TO 22kW

008972040 FAN MOTOR ASSEMBLY 1 11kW

8 000996057 PLAIN WASHER M6 8

9 000996106 SPRING WASHER M6 8

10 000983064 SOC HD BOLT M6 X 20 8

COOLER BOX SUB ASSY

Part No. Description Qty.S.No. Remarks

COOLER SUB ASSY

34.0

FOR, STANDARD VERSIONSTANDARD + DRYER VERSIONSTANDARD + DRYER + VFD VERSION

1 B007700690023 COOLER 18kW to 22kW 1

B007700690022 COOLER 11kW to 15kW 1

B007700690024 COOLER 30kW 1

2 000959923 SWIVEL ELBOW 1 1/4" TO 30MM TUBE 1 STD VERSION

000959921 ST FITTING 1-1/4 TO 30mm OD 1 DRYER VERSION

3 000959920 ST FITTING 3/4 TO 18mm OD 2

4 000959921 ST FITTING 1-1/4 TO 30mm OD 1

5 000959926 PLUG 3/8 1

6 000983083 SCR SOC HD M8X20 10.9 ZYP 6

7 000996108 WASHER SPRING REC SEC M8 6

8 000996058 WASHER PUNCHED M8 6

COOLER SUB ASSY

34.1

Part No. Description Qty.S.No. Remarks

Controller Terminals Configuration

20.0

X03: Main Motor Relays

Connector type: 4 pole combicon

Pin Function Id Active state

1 Common for Main, Star and Delta Common -contactors

2 Main Contactor Main Energised

3 Star Contactor Star Energised

4 Delta Contactor Delta Energised

X01: Power supply

Connector type: 3 pole combicon

Pin Function Id Active state

1 24V AC Phase 24 VAC P -

2 Earth Earth -

3 24V AC Neutral 24 VAC N -

X02: Relays

Connector type: 10 pole combicon

Pin Function Id Active state

1 Common - Load Relay Common

2 Load Relay L / UL Load whenEnergised

3 Common - Fan Relay Common

4 Fan Relay Fan Energised

5 Common - Auto Drain Valve Relay Common

6 Auto Drain Valve Relay ADV Energised

7 Common – Dryer Relay Common

8 Dryer Relay/ programmable relay Dryer / Pr2 Energised

9 Common - Programmable Relay Common

10 Programmable Relay Pr1 Energised

Controller Terminals Configuration

20.1

X04: Digital Inputs

Connector type: 11 pole combicon

Pin Function Id Active state

1 Digital Inputs Common – 24VDC 24VDC -

2 Emergency Stop Emergency Fault if open

3 Differential Pressure Oil Filter DPOF Fault if open

4 Reverse Rotation Rev. Rot Fault if closed

5 Differential Pressure Air Filter DPAF Fault if open

6 Remote Start Stop Control Remote Stop if open/start on Closure

7 High Sump Pressure HSP Fault if open

8 Cooler Fault Input Cooler Fault if open

9 Main Motor Overload MMOL Fault if open

10 24V Supply Ground -24V DC (provision forcheck DI

voltage)

11 No Connection - -

X05: Analog Inputs

Connector type: 8 pole combicon

Pin Function Id Type Range

1 Discharge pressure Dis. Pr 4-20 ma 0 to 16 bar

2 15 to 24VDC 18V

3 Discharge Temperature Dis. Tr + KTY10 0 to 150°C4 Discharge Temperature Dis. Tr -

5 Sump Pressure Sump Pr 4-20 ma 0 to 16 bar

6 15 to 24VDC 18V

7 Dryer or Ambient Pt100 + Pt100 -50 to +90°Ctemperature

8 Dryer or Ambient Pt100 -temperature

Controller Terminals Configuration

20.2

X06: Analog Outputs and VFD

Connector type: 5 pole combicon

X07: Communication

Connector type: 6 pole combicon

Pin Function Id Type Protocol/Range

1 VFD Interface VFD A RS485A FC Protocol

2 VFD Interface VFD B RS485 B

3 Supply Ground For 5V 0VDC - -

4 Dis. Pressure Output AO1 Voltage(1-5V) 0 to 16 bar

5 Programmable Analog AO2 Voltage 0 to 160C /

Output (1-5V) 0 to 16 bar /-

65 to 95C

Pin Function Id Type Protocol/Range

1 DCS Interface-Modbus

RTU DCS A RS485 A Modbus-RTU

2 DCS Interface –Modbus -

RTU DCS B RS485 B

3 FPD Interface FPD A RS485 A ASCII

4 FPD Interface FPD B RS485 B

5 Add On Interface Add-On A RS485 A Modbus

6 Add On Interface Add-On B RS485 B

Neuron II has two types of Data Interface

Analog output

DCS Port

5.1 Analog output

Two channels are available for analog output. The first channel will output thecurrent discharge pressure value from 0.0 -16.0 bar, converted from 1 - 5V.

The Second channel is programmable. User can select any one of the following

menu: “Operator/ Machine/ Mode/ Analog output”

a. Dis. Temperature 0 -160 C, converted from 1 - 5V

b. Sump Pressure 0 - 16.0 bar, converted from 1 - 5V

c. Pt100 Temperature -65 - 95 C, converted from 1 - 5V

Note: Analog output will be 0V, in case of probe failure.

5.2 DCS Port

DCS port can be of Modbus RTU type to interface to Generic DCS system orSCADA type to interface to ELGI SCADA software.

User can select the Port type in menu “Operator/ Machine/ DCS Port”. TheID, Baud Rate, Parity, data Length, Stop Bit are also user settable. The Modbusdata table will be provided based on the request (A CD contains address tableand activation key)

Data Interface

23.0

Decals Diagram

8.0

Decals Diagram

8.1

Decals Diagram

8.2

Decals Diagram

8.3

5.0

Definitions and symbols

This information relates to protecting your safety and preventing equipment

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

NOTE:

A Note clarifies procedures or conditions which may otherwise be misinterpreted

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

confusing situations

CAUTION:

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

lead to equipment damage

WARNING:

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

operation, cleaning and maintenance of the equipment which may result in

personal injury or death of the operator or other persons

WARNING

CAUTION

OPERATION

ENERGISED

(POWER ON)

CAN CARRY OUT REPAIRS

OR ADJUSTMENT

KEEP ACCESS DOORS CLOSED

DO NOT OPERATE

DE-ENERGISE

DO NOT ATTEMPT

REPAIRS

DO NOT INHALE

SYMBOLS:

Disposal of Consumables andReplaced PartsThe moisture condensate separated from compressed air contains oil particles.Disposal of the condensate and of filter elements is to be done in accordancewith the pollution control norms prevailing at the time of compressor installationor use

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

The compressor does not give warnings during short operatingtimes. It will operate below the dew point and moisturecondensate may mix with the oil. This will reduce the lubricatingqualities of the oil and lead to damage to the compressor

16.0

!WARNING

10.0

Disposal of Packing

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

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

DRIVE SUB ASSY 22kW - 7.5 & 8.5

30.0

30.1

DRIVE SUB ASSY 22kW - 7.5 & 8.5

FOR,STANDARD VERSIONSTANDARD + DRYER VERSIONSTANDARD + DRYER + VFD VERSION

1 B005100560099 MOTOR 22kW 1 SIEMENS

B005101770001 MOTOR 22kW 1 ELGI

2 - ADAPTER RING AND AIR END ASSY

990301380 AIREND ASSY 1

990301850 ADAPTER RING 1

3 B005401170045 DRIVE COUPLING 48/40 1

4 000906217 HEX BOLT M16 X 55 4

5 000948016 HEX NUT M16 4

6 000996116 SPRING WASHER M16 4

7 015301521 AIREND MOUNTING BRACKET 1

8 000906211 HEX BOLT M16 X 25 2

9 000996061 PLAIN WASHER M16 2

10 B001401300003 ANTI VIBRATION MOUNT 5

11 000906184 HEX BOLT M12 X 35 4

12 000906181 HEX BOLT M12 X 20 1

13 000996060 PLAIN WASHER M12 9

14 000996112 SPRING WASHER M12 9

15 010453920 'O" RING -ID 69.44X 3.53 1

16 015301655 DISCHARGE PIPE BOTTOM 159 S 1

17 000959387 BONDED SEAL WASHER 1

18 015400921 OIL INJECTION HOSE 1

19 990401530 ORIFICE Dia 0.8, G1/8 1

20 B004100170001 1/8" NON RETURN VALVE F-F 1

21 000959913 ST FITTING 1/8 BSPP to 6mm TUBE 1

22 000906185 HEX BOLT M12 X 40 4

23 000959381 1/8 BSP BONDED SEAL WASHER 2

Part No. Description Qty.S.No. Remarks

30.2

DRIVE SUB ASSY 18kW -7.5, 8.5, 10, 22kW - 10

30.3

FOR, STANDARD VERSIONSTANDARD + DRYER VERSIONSTANDARD + DRYER + VFD VERSION

1 B005100560099 MOTOR 22kW 1 SIEMENS - 22kW model

B005101770001 MOTOR 22kW 1 ELGI - 22kW model

B005100560098 MOTOR 18kW 1 SIEMENS - 18kW Model

B005101770006 MOTOR 18kW 1 ELGI - 18kW Model

2 - ADAPTER RING AND AIR END ASSY

990301370 AIREND ASSY 1 18KW-7.5,8.5, 22KW-10

990304220 AIREND ASSY 1 18KW-10

990301850 ADAPTER RING 1

3 B005401170045 DRIVE COUPLING 48/40 1

4 000906217 HEX BOLT M16 X 55 4

5 000948016 HEX NUT M16 4

6 000996116 SPRING WASHER M16 4

7 015301521 AIREND MOUNTING BRACKET 1

8 000906211 HEX BOLT M16 X 25 2

9 000996061 PLAIN WASHER M16 2

10 B001401300003 ANTI VIBRATION MOUNT 5

11 000906184 HEX BOLT M12 X 35 4

12 000906181 HEX BOLT M12 X 20 1

13 000996060 PLAIN WASHER M12 9

14 000996112 SPRING WASHER M12 9

15 010453920 'O' RING -ID 69.44X 3.53 1

16 015301526 DISCHARGE PIPE 1

17 000959387 BONDED SEAL WASHER 1

18 015400921 OIL INJECTION HOSE 1

19 990401530 ORIFICE Dia 0.8, G1/8 1

20 B004100170001 1/8" NON RETURN VALVE F-F 1

21 000959913 ST FITTING 1/8 BSPP to 6mm TUBE 1

22 000906185 HEX BOLT M12 X 40 4

23 000959381 1/8 BSP BONDED SEAL WASHER 2

DRIVE SUB ASSY 18kW - 7.5, 8.5, 10, 22kW - 10

Part No. Description Qty.S.No. Remarks

30.4

DRIVE SUB ASSY15kW - 7.5 & 8.5

30.5

FOR, STANDARD VERSIONSTANDARD + DRYER VERSIONSTANDARD + DRYER + VFD VERSION

1 B005100560097 MOTOR 15kW 1 SIEMENS

B005101770005 MOTOR 15kW 1 ELGI

2 015401094 MOTOR MOUNTING FLANGE 2

3 B001401300003 ANTI VIBRATION MOUNT 5

4 000983143 SCR SOC HD M12X30 10.9 ZYP5-8u 4

5 000906183 HEX BOLT M12 X 30 4

6 000996112 SPRING WASHER M12 4

7 000996012 PLAIN WASHER M12 4

8 B005401170047 DRIVE COUPLING 42/40 1

9 990301850 ADAPTER RING 1

10 990304230 AIREND ASSY 15 - 7.5 1

990303310 AIREND ASSY 15 - 8.5 1

11 000906217 HEX BOLT M16 X 55 4

12 000948016 HEX NUT M16 4

13 000996116 SPRING WASHER M16 4

14 015301521 AIREND MOUNTING BRACKET 1

15 000906211 HEX BOLT M16 X 25 2

16 000906181 HEX BOLT M12 X 20 1

17 990401530 ORIFICE Dia 0.8, G1/8 1

18 B004100170001 1/8" NON RETURN VALVE F-F 1

19 000959913 ST FITTING 1/8 BSPP to 6mm TUBE 1

20 000959387 BONDED SEAL WASHER 1

21 015301526 DISCHARGE PIPE 1

22 015400921 OIL INJECTION HOSE 1

23 010453920 'O" RING -ID 69.44X 3.53 1

24 000906184 HEX BOLT M12 X 35 4

25 015401815 ADAPTER G 1/2 WITH 5MM ORIFICE 1

26 000959381 1/8 BSP BONDED SEAL WASHER 2

DRIVE SUB ASSY 15kW - 7.5 & 8.5

Part No. Description Qty.S.No. Remarks

30.6

DRIVE SUB ASSY 11kW - 7.5, 8.5, 10 & 13,15kW - 10, 15kW - 13, 18kW - 13, 22kW - 13

30.7

FOR, STANDARD VERSIONSTANDARD + DRYER VERSIONSTANDARD + DRYER + VFD VERSION

1 015401094 MOTOR MOUNTING FLANGE 2 11kW and 15kw

2 000983143 SCR SOC HD M12X30 10.9 ZYP5-8u 4 11kW and 15kw

3 B001401300003 ANTI VIBRATION MOUNT 5

4 B005100560096 MOTOR 11kW 1 SIEMENS

B005101770004 MOTOR 11kW 1 ELGI

B005100560097 MOTOR 15kW 1 SIEMENS

B005101770005 MOTOR 15kW 1 ELGI

B005100560098 MOTOR 18kW 1 SIEMENS

B005101770006 MOTOR 18kW 1 ELGI

B005100560100 MOTOT 22kW 2 pole 1 SIEMENS

B005101770002 MOTOR 22kW 2 pole 1 ELGI

5 000906183 HEX BOLT M12 X 30 4 11kW and 15kW

000906185 HEX BOLT M12 X 40 4 18kW to 30kW

6 000996112 SPRING WASHER M12 4

7 000996012 PLAIN WASHER M12 4

8 B005401170048 DRIVE COUPLING 42 / 35 1 11KW 7 to 13, 15KW - 10,13

B005401170046 DRIVE COUPLING 48 / 35 1 18KW-13, 22KW-13

9 015301828 ADAPTER RING 1

10 000906217 HEX BOLT M16 X 55 4

11 000948016 HEX NUT M16 4

12 000996116 SPRING WASHER M16 4

13 013336425 AIREND ASSY 11 - 7.5, 15 - 13 1

013336424 AIREND ASSY 11 - 8.5 1

013336440 AIREND ASSY 11 - 10 1

013336439 AIREND ASSY 11 - 13 1

013336442 AIREND ASSY 18 - 13 1

013336419 AIREND ASSY 22 - 13 1

DRIVE SUB ASSY 11kW - 7.5, 8.5, 10 & 13, 15kW -10, 15kW - 13, 18kW - 13, 22kW - 13

Part No. Description Qty.S.No. Remarks

30.8

DRIVE SUB ASSY 11kW - 7.5, 8.5, 10 & 13,15kW - 10, 15kW - 13, 18kW - 13, 22kW - 13

14 000906147 M8 X 40 8

15 000996108 SPRING WASHER M8 8

16 000948008 HEX NUT M8 8

17 000906181 HEX BOLT M12 X 20 3

18 015401078 AIREND MTG BRACKET 1

19 000959387 BONDED SEAL WASHER 1

20 015401430 Adaptor M22XM20 orifice 4.5 1 11kW 7 to 13, 15 - 10 & 13

015401431 Adaptor M22XM20 Orifice 6 1 18-7 to13, 22-13

21 015400921 OIL INJECTION HOSE 1

22 015401951 O RING ID 47.29X 2.62 1

23 015301815 DISCHARGE PIPE ASSY 102 1

24 000906184 HEX BOLT M12 X 35 4

25 990401530 ORIFICE Dia 0.8, G1/8 1

26 B004100170001 1/8" NON RETURN VALVE F-F 1

27 000959913 ST FITTING 1/8 BSPP to 6mm TUBE 1

28 000983141 SOC HD M12X20 1

29 000959381 1/8 BSP BONDED SEAL WASHER 2

30.9

Part No. Description Qty.S.No. Remarks

DRIVE SUB ASSY 11kW - 7.5, 8.5, 10 & 13, 15kW -10, 15kW - 13, 18kW - 13, 22kW - 13

44.0

Part Number Description Qty

008927051 MCB 1

008929010 Contactor 1

008936131 Timer 1

008947161 Control cable 10 Metre

018360643 Press sleeve 20

DRYER RETROFITMENT KIT

DRYER KIT 11kW TO 15kW and 18kW-13Bar, 22kW-13Bar

Part Number Description Qty

B00500110007 INTEGERATED DRYER 1

015401491 PIPE COOLER OUT TO DRYER 1

000959921 ST FITTING 1-1/4 TO 30mm OD 1

000959923 SW ELBOW 1-1/4 TO 30mm OD 1

015402263 HOSE DRYER TO BV 1

22041038B PLUG;HEX;SOCKET;1/4"NPT 1

000906121 BOLT HEX M8X50 8.8 ZYP 5-8M 2

000906117 BOLT HEX M8X30 8.8 ZYP 5-8M 2

000948008 NUT HEX M8 - 8ZYP 2

035400026 O RING ID 37.5X43.5X3 1

Electrical accessories

DRYER KIT 18kW-7.5,8.5,10Bar, 22kW-7.5,8.5,10Bar

Part Number Description Qty

00500110001 INTEGERATED DRYER 1

015401491 PIPE COOLER OUT TO DRYER 1

000959921 ST FITTING 1-1/4 TO 30mm OD 1

000959923 SW ELBOW 1-1/4 TO 30mm OD 1

015402263 HOSE DRYER TO BV 1

22041038B PLUG;HEX;SOCKET;1/4"NPT 1

000906121 BOLT HEX M8X50 8.8 ZYP 5-8M 2

000906117 BOLT HEX M8X30 8.8 ZYP 5-8M 2

000948008 NUT HEX M8 - 8ZYP 2

035400026 O RING ID 37.5X43.5X3 1

44.1

DRYER RETROFITMENT KIT

11/15 kW Spare parts list of F2 Integrated air dryer

S.No. Item code Description Qty

1 B000505600001 Compressor 1

2 B000505600003 Condenser fan 1

3 B000505600005 Hot gas by pass valve 1

4 B000505600006 ADV valve spare kit 1

5 B000505600007 Pressure switch 1

6 B000505600008 Temperature transmitter 1

7 B000505600009 Capacitor 1

S.No. Item code Description Qty

1 B000505600002 Compressor 1

2 B000505600004 Condenser fan 1

3 B000505600005 Hot gas by pass valve 1

4 B000505600006 ADV valve spare kit 1

5 B000505600007 Pressure switch 1

6 B000505600008 Temperature transmitter 1

7 B000505600010 Capacitor 1

18/22kW - Spare parts list of F2 Integrated air dryer

Electrical and general assembly drawing :(a) E11/15 electrical drawing :

43.0

(b) E18/22 ELECTRICAL DRAWING :

43.1

c) E11/E15 /E18 / E22 GENERAL ASSEMBLY DRAWING :

43.2

11.0

Functional Description

BLEED 159 - Direct Drive airends

This product is part of an ELGI initiative to extend the range of existing Direct

Drive airends in Electric Powered Screw Compressors. Currently, these base

models cater to only specific capacities (FAD). A Direct Drive airend has the

obvious advantage that it rotates at the prime mover speed, owing to direct

coupling, without the use of an intermediate belt or gear drive. Compared to

small gear-driven airends, the direct-drive airends provide cost savings, no-

loss power transmission and gain in operating efficiency

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

same Direct Driven speed for capacities upto 23% lower than the Base capacity.

Bleed can thus substitute for gears for airends upto 23% Capacity reduction

In this case, capacity is reduced not by speed reduction (as with gears & belt

drives), but by removing air early in the compression cycle and recirculating it

to suction. This effectively reduces the length/lobe volume enclosed by the

rotors for further compression, improving the capacity. The provisions for BLEEDs

in the rotor housing of these airends make them visibly different from their gear

& belt driven counterparts, though rotors & other components are same.

Implemented with Axis 159 lubricated airends, BLEED 159 offers advantages

like improved mechanical efficiency, elimination of the gear box, reduced noise

Direct Drive

profile & longer bearing life than the equivalent 102 Gear Driven models. Another

bonus is that a few of these BLEED airends can be scaled up to a higher

operating pressure without changing the Motor or Airend. This enables

compressor paackage modifications to be done on-site

Functional Description

11.1

11.2

Functional Description

Compression in a Global Series compressor

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

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

Gear Drive

11.3

Functional Description

Compression in a screw compressor

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

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

11.4

Functional Description

Air Intake System

Air is provided to the airend by the air intake system

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

• Suspended particulate matter should be less than 150 spmto achieve the specified consumable life

• No guarantee shall be given if the compressor is operatedabove its intended pressure

NOTE:

11.5

Functional Description

Discharge system

Much of the oil is removed from the air–oil mixture by the advance three stageseparation techniques, but some oil still remains in the air. To bring the oilcontent to within the desirable limits below 1ppm, the lean mixture is passedthrough a highly efficient separator element. The oil separated thus is returnedto the lubricating system through the scavenge line. The air passes through aminimum pressure valve. The minimum pressure valve is positioned downstreamof the oil separator. It maintains a minimum pressure for safe supply of oil to thecompressor unit. The air temperature at this stage is still higher than the desiredtemperature at the receiver. So it is cooled in an after-cooler to a few degreesabove the ambient temperature. Before the air is discharged to the externalreceiver, moisture is removed from it using a moisture separator

Consult ELGI for the selection and supply of a suitable dryer for yourrequirements of dry air

NOTE

11.6

Functional Description

Cooling and lubrication system

The oil separated from the air-oil mixture is cooled in the oil cooler. A thermalelement controls the flow of oil to the cooler, depending on the temperature ofthe oil. The cooler is bypassed by the oil if the temperature is low enough, suchas in the initial flow when the compressor is started. The oil is passed throughan oil filter which removes dust and other impurities before it is returned to theairend. The oil circulation circuit is operated solely by the pressure differentialand does not require any separate oil pump

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

11.7

Functional Description

ELGI Air Lube, blended using heavy-duty hydraulic based oil with the rightamounts of additives under strict quality control checks, ensures satisfactorycompressor performance

The life of any mineral oil decreases by almost 30–40% for every 10°C above90°C. It is recommended that the oil change frequency is varied in summer andwinter months for optimum benefits. A good record of the operating temperatureof the compressor is essential for this. Continuous operation of the compressorat a temperature above 100°C without changing the oil will lead to varnishformation and will affect the life of the bearings and the airend

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

• Suspended particulate matter should be less than 150 spmto achieve the specified consumable life

• No guarantee shall be given if the compressor is operatedabove its intended pressure

NOTE:

11.8

Functional Description

Transmission system

NOTEPower should be supplied to the compressor through a fuse switchunit of suitable rating mounted within 5 m of the compressor

Electrical system and controls

The compressor starter is an automatic star–delta starter with safety interlocks.If no fault is detected in the controller, Ready message is displayed. If anyfault is detected, trip warning is displayed

The fault warnings are displayed as described in the following section

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

11.9

Functional Description

Electrical System

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

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

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

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

Preprogrammed timer functions:

Star-delta delay-determines the star-to-delta changeover time; set atany value between 6 and 10 sec

Delta-to-run (DTR) delay-decides the delay between the delta change overand energising of the solenoid valve

Standby time (unload monitoring time)-stops the compressor if it is runningin unloaded condition for a set time (5 min) and starts the compressorautomatically on demand

11.10

Functional Description

Separator element warning

Indicates that the separator element needs to be replaced. The compressordoes not shut down automatically in this situation

Oil filter warning

Indicates that the oil filter element needs to be replaced. The compressor doesnot shut down automatically in this situation

High discharge temperature trip

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

Main motor overload trip

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

Fan motor overload trip

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

Graphic warning display

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

Reset button

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

NOTE

Ensure 24 V AC power supply to Neuron II controller. Modify thetimer settings under m/c settings menu present in the controlleraccording to requirement. Before starting the compressor, check thefollowing electrically

11.11

Functional Description

Safety system and interlocking devices

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

Discharge temperature sensor

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

Minimum pressure valve

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

Pressure relief valve

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

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

Overload relays for main motor and fan motor

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

11.12

Functional Description

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

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

When you know the compressor to be in an unsafe condition, tag it as unsafeand render it inoperative by disconnecting the power supply so that others whomany not know of this unsafe condition will not attempt to operate it until thecondition is corrected. Do not modify your Global Series compressor exceptwith written approval from ELGI

Electrical arcing from compressor components can igniteflammable liquids and vapours which can result in serious injury.Never operate the compressor near flammable liquids or vapours.If the compressor is used to spray flammable materials, keep it atleast 6 m away from the spray area

Never start the compressor unless you know it is safe to do so.Do not attempt to operate the compressor when it is known to bein an unsafe condition. Examples of unsafe conditions includeimproper earthing of the machine and reverse rotation of the motors

!WARNING

!WARNING

38.0

Installation and Comissioning Requirements

a) INSTALLATION AND COMMISSIONING PROCEDURES:

1. Install the dryer in a closed, clean, air compressor package. The packagemust be adequately ventilated at the dryer condenser portion. The dryershould not be directly exposed to sources of heat. The temperature of thepackage should not exceed 45°C

2. Make sure that the dryer is not installed near any equipment which doesnot comply to the electromagnetic compatibility directives and which maydegrade dryer operation

3. Ensure the dryer is installed in vertical position and kept level

4. Fix the anchor points if it is necessary

5. Connect the compressed air to the dryer inlet with rust-free pipes

6. Connect a drain pipe to the Drain valve port connection (1/2'’F)

7. Connect the compressed air to the dryer output with rust-free pipes

8. Check all the connectors for leak proof and ensure the mountings arefirmly fixed

(i) AMOUNT OF GAS TO BE CHARGED:

S.No. Model Capacity (cfm) Gas used Quantity (kg)

1 E11/15 98 R407C 0.9

2 E18/22 136 R407C 1

b) ELECTRICAL CONNECTIONS:

Connect the electrical power cable to the supply as specified on wiring diagramin the manual; ensure the supply is well grounded

c) EXTENDED STORAGE:

If the dryer is to be stored for a long time before installation and use,follow there instructions:

Do not remove the dryer from its original carton (Particularly when packedwith plastic film and bubble sheet)

Ensure the air inlet and the outlet are correctly blocked so as to protectthe system from foreign materials

The machine should be protected from atmospheric dust and water

The storage area should be frost protected

Make sure to archive the attached documents

2. FUNCTIONAL DESCRIPTION:

SUB-SYSTEM PARTS:

a) Refrigerant compressor

b) Condenser

c) Cooling fan

d) Heat exchangers

e) Hot gas bypass valve

f) Auto drain valve

g) PT 1000

h) Expansion device

i) Pressure switch

j) Pressure gauge

a) REFRIGERANT COMPRESSOR:

Compressor is the heart of the refrigeration system. It compresses the lowpressure vapour refrigerant into high pressure vapour refrigerant

38.1

b) CONDENSER:

Condenser is a heat transfer surface. Heat from the hot refrigerant vapor, fromthe discharge side of the compressor, passes through the walls of the condenserand condenses the refrigerant in to liquid with the help of the condensing medium(air). As a result of losing heat to the condensing medium, the refrigerant vaporis first cooled to saturation and then condensed into the liquid state

c) COOLING FAN:

Condenser fan is used in the refrigeration unit. It is used to transfer the heat,from the hot vapour refrigerant, to the cooling medium of air through convectionmethod

d) HEAT EXCHANGERS:

The Heat exchanger or Evaporator removes heat from compressed air by meansof cold and low pressure Freon. The Evaporator uses two different medium airand refrigerant through which the heat transfers from higher temperature tolower temperature side. In our unit, heat transfers from hot air to cold refrigerant.Heat exchangers are divided into two regions Air/Air Heat exchanger and Air/Freon Heat exchanger. The moist compressed air (dirt, oil and water vapor)enters into the Air/Air Heat exchanger where it is pre-cooled by the outgoing airand thus conserves energy

The compressed air then passes through the evaporator. It is cooled up to +3oCby the refrigerant. At this sub-cooled temperature, the moisture present in theair is condensed and removed by the Auto drain valve

The cool saturated air passes through the Air to Air Heat exchanger, where itpre-cools the incoming air and gets heated up (Re-heating process). Thus thissystem provides clean dry air at the outlet. Built-in cyclone separation andAutomatic drain valve are provided at the base of the heat exchanger to removethe moisture. The heat exchangers are designed for maintaining the constantheat transfer rate

e) HOT GAS BYPASS VALVE:

It is a by pass valve, which bypasses the hot vapor refrigerant from the dischargeside of the compressor to the Freon inlet of the heat exchanger. Its purpose isto maintain the suction pressure of the compressor to prevent entering of liquidinto the suction side of the compressor. The hot gas bypass valve worksautomatically, by using a solenoid valve or diaphragm type which always passessome amount of hot gas, depending upon the Dew point temperature and loadcapacity of the dryer

38.2

f) AUTO DRAIN VALVE:

Automatic drain valve is fitted at the bottom of the heat exchanger. Its purposeis to drain the condensate water automatically, with the help of operating pressurein a sequence of our convenient setting time

g) PT 1000

It is an electronic unit, which is used to sense the dew point

h) EXPANSION DEVICE:

It is also known as metering device or throttling device. Elgi uses capillary tubeas an Expansion device. Its function is to divide the refrigeration system intohigh low pressure sides. It is connected in the liquid line between the condenserand the Evaporator. The liquid refrigerant from the condenser enters the capillarytube. Due to the frictional resistance offered by a small diameter tube thepressure of the refrigerant gets dropped. The low pressure refrigerant enters theEvaporator to cool the compressed air and removes the moisture. It also controlsthe flow of refrigerant, according to the load on the evaporator

i) PRESSURE SWITCH:

It is an electrical switch, used to control the cooling fan (on/off). The powersupply is given to the fan through the pressure switch. There is a sensingelement present in the switch, which sense the pressure of the Freon, At onpressure 300 psi g the power supply passes to the fan and it starts running.When the pressure reduces and meets the off pressure 240 psi g the powersupply will cut off and the fan will shut down

j) PRESSURE GAUGE:

The pressure gauge is used to display the Freon discharge pressure (liquidstate) of the condenser

38.3

18.0

Index

1.0 Technical Features 23.0

2.0 Controller terminal configuration 24.0

3.0 Main Menu Screen 25.0

4.0 Menu Structure 26.0

4.1 View 26.0

4.1.1 Operator 26.1

4.1.2 Fault Report 26.1

4.1.3 Day Report 26.2

4.1.4 Service Time 26.2

4.1.5 Cumulative Time 26.3

4.1.6 VFD 26.3

4.2 Operator 26.4

4.2.1 Machine 26.5

4.2.2 Schedule 26.7

4.2.3 Maintenance 26.7

4.2.4 Language 26.8

4.2.5 Change Password 26.8

4.3 Service 26.9

4.3.1 Calibration 26.9

4.3.2 Relay 26.10

4.3.3 Change Password 26.10

4.3.4 Maintenance 26.10

4.3.5 Clock 26.11

4.3.6 Self Test 26.11

4.3.7 Change Password 26.11

4.4 Factory menu 26.12

4.4.1 Machine 26.13

4.4.2 Change Password 26.14

4.4.3 Integrator Dryer 26.14

4.5 Customer care 26.14

5.0 Data Interface 27.0

5.1 Analog output 27.0

5.2 DCS Port 27.0

6.0 Construction & Dimension Drawing 28.0

7.0 Controller Identification 29.0

8.0 Revision Details 29.0

APPENDIX A: Mimic LED Table 30.0

APPENDIX B: Short Cut Key Functions 31.0APPENDIX C 32.0

APPENDIX-D 33.0

9.0

Installation

Installation

9.1

If the compressor is provided with a lifting bail then lift using the bail. If nobail is provided, lift it using slings. Compressors to be air lifted by helicoptermust not be supported by the lifting bail but by slings

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

Make sure the entire lifting, rigging and supporting structure has beeninspected, is in good condition and has a rated capacity of at least the netweight of the compressor. If you are unsure of the weight, then weigh thecompressor before lifting it

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

Use guide ropes or equivalent to prevent twisting or swinging of the machineonce it has been lifted clear of the ground

Do not attempt to lift the compressor in high winds

Keep all personnel away from the compressor when it is suspended

Lift the compressor no higher than necessary

Keep the lift operator in constant attendance whenever the compressor issuspended

Set the compressor down only on level surfaces capable of supporting atleast its net weight plus an additional 10 per cent allowance

9.2

Installation

Unpacking

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

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

Key for doors

Operation and Maintenance Manual

Checklist of parts of the machine

Electrical drawing

Tools may be provided on request. If any components are found missing, contactELGI immediately

Please observe all accident prevention regulations when installingthis compressor

Compressor Location – Space around Compressor

Install the compressor with adequate accessibility to ensure obstruction-freeoperation and maintenance. Maintain a clearance around the compressor asshown in the figure below on Page 9.4

WARNING

!

9.3

Installation

Compressor Location – General Requirements

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

Never store combustible materials within a 10 m radius of the compressor. Theroom housing the compressor must be equipped with fire fighting equipment.The floor around the compressor must be of non-combustible material

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

9.4

InstallationN

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9.5

Installation

Ventilation and Exhausting Hot Air

Ensure adequate ventilation in the compressor installation area. Your compressorhas a ventilating air requirement of 7000 m3/h. The figure provided indicatesdifferent ways in which this could be achieved

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

NOTE

• Suspended particulate matter should be less than 150 spm to achievethe specified consumable life

• No guarantee shall be given if the compressor is operated aboveits intended pressure

9.6

Installation

Follow the guidelines herein for providing ventilation for the compressor:

Provide openings close to the floor level on walls/partitions close to theair suction side of the compressor

Provide exhaust openings close to the ceiling for hot air exit

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

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

To eliminate transmission of vibrations, provide a soft bellows connectorbetween the duct and the compressor

Contact ELGI in case you need to provide a duct connection or filterfitment on the compressor

A forced flow of cool air should not be directed towards the compressor

The compressor is to be located such that the hot air from other machinesis not directed towards it

Failure to observe the instructions regarding installation andventilation may result in an excessive increase or decreaseof the discharge temperature of the compressor, and thecompressor will trip under high discharge temperatureconditions. The output of the compressor will also be affected

Foundation

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

!WARNING

9.7

Installation

Electricals

You must provide a lockable main switch with pre-connected slow-blow mainfuses as per industrial safety regulations.The power supply should be 380/415Volts 3 phase with Neutrol

The fuse and cable specifications for 380 V or 415 V, 50 Hz/3 Ph power suppliesare listed in the table below

Air Pipe-lines

Use the table below as guidance for selecting pipes for your system

E11 32A 4Cx6 3½ x 16E15 50A 4Cx10 3½ x 25E18 50A 4Cx10 3½ x 25E22 63A 4Cx16 3½ x 35

ModelRecommended

pre-connected fuserating (A)

IncomingAluminium cable

size cu(mm2)

Incoming Coppercable size cu(mm2)

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

Nominal pipe diameter½ inch ¾ inch 1 inch 1¼ inch

80 lb 100 lb 125 lb 80 lb 100 lb 125 lb 80 lb 100 lb 125 lb 80 lb 100 lb 125 lb 80lb 100 lb 125 lb

10 0.45 0.38 0.31 0.11 0.09 0.08 0.04 0.03 0.02 0.0086 0.0071 0.0058

20 1.74 1.42 1.17 0.41 0.34 0.28 0.13 0.1 0.08 0.032 0.026 0.021 .014 .0 12 .010

30 3.84 3.13 2.54 0.9 0.74 0.6 0.28 0.23 0.19 0.068 0.056 0.046 .031 .026 .021

40 6.93 5.55 4.53 1.55 1.28 1.05 0.46 0.38 0.31 0.116 0.096 0.079 .053 .044 .036

50 10.7 8.65 7.01 2.42 2 1.62 0.73 0.6 0.49 0.18 0.046 0.12 .081 .067 .055

60 3.47 2.84 2.33 1.02 0.84 0.69 0.25 0.21 0.17 .12 .095 .078

70 4.73 3.85 3.14 1.36 1.12 0.92 0.34 0.28 0.23 .16 .13 .10

80 6.14 5.01 4.08 1.76 1.44 1.18 0.44 0.36 0.3 .20 .16 .14

90 7.75 6.4 5.17 2.23 1.85 1.49 0.55 0.45 0.37 .25 .20 .17

100 9.62 7.8 6.33 2.69 2.21 1.81 0.066 0.55 0.45 .30 .25 .20

125 15.5 12.4 9.8 4.18 3.41 2.79 1.03 0.85 0.69 .46 .38 .32

150 23 18.1 14.4 5.75 4.19 3.99 1.47 1.2 0.99 .65 .54 .44

175 1.81 6.8 5.45 2 1.64 1.32 .90 .73 .60

200 10.9 8.79 7.11 2.58 2.12 1.73 1.15 .95 .78

250 1.82 1.48 1.20

300 2.55 2.10 1.72

350 3.53 2.86 2.35400 4.53 3.70 3.03450 5.80 4.65 3.80500 7.12 5.79 4.71

Freeair

(cfm)1½ inch

9.8

Installation

Receivers for Compressed Air Systems

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

0.25 8.83 1740 655 115 Up to 40 Up to 60

0.5 17.66 2100 780 210 41–85 61–120

1 35.32 2785 1000 344 86–140 121–235

1.5 52.97 2500 1250 783 141–225 236–355

2 70.63 3175 1250 954 226–310 356–470

3 105.95 2805 1565 1308 311–445 471–710

4 141.26 3580 1595 1564 446–570 711–945

5 176.58 3535 1780 2129 571–700 946–1180

6 211.89 4185 1780 2343 701–850 1181–1415

7 247.21 3640 2100 2885 851–990 1416–1650

8 282.52 3985 2100 3115 990–1130 1651-1885

Volume

(ft3) (m3)

Receiver specifications Compressed capacity

Height(mm)

Diameter(mm)

Weight(kg)

On/Offcontrol (cfm)

Modulationcontrol(cfm)

Commissioning

Before the new Global Series compressor is operated for the first time, it mustbe installed at your site by ELGI’s commissioning engineer. The followinginstructions and specifications are given only for your reference. They areapplicable to standard air-cooled Global Series compressors without additionalequipment (receivers, Driers etc). For identification of parts, refer to the FunctionalDescription section of this manual

Before commissioning, check the equipment for visual damage of parts. Anelectrical circuit diagram is delivered with every Global Series compressor (keptinside the electrical control panel) for electrical wiring reference

Every ELGI screw compressor is subjected to a test run prior to despatch.Transport damage at a later stage cannot, however, be excluded. Therefore,please observe the compressor closely during commissioning and the trial run

9.9

Installation

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

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

Control panel

Earthing point

Power cable entry Detail-A

A

9.10

Installation

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

Connect the compressor to the air network

Fill the oil as per the oil fill procedure

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

Ensure that only authorised electricians carry out the electricalwork. Study the electrical circuit diagram before starting work

Transformer tappings & OLR settings need to be adjustedaccording to voltage conditions (380V/415V) at site

!WARNING

9.11

Installation

Removal of the AVM arresting bracket

Locking Clamps and Locking Bolts

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

9.12

Installation

NOTE

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

• No guarantee shall be given if the compressor is operated above its intendedpressure

Oil Fill Procedure

9.13

Shut off the compressor

Drain oil from the oil tank throughthe drain ball valve

Drain oil from the cooler through thedrain plug

Drain oil from the discharge pipe afterdismantling it

Drain oil from the airend by handrotating

Add new oil . Fill it upto the maximumlevel as indicated on the drawing

Close the oil fill plug

Restart the compressor and allow itto run for about 10 minutes, until thethermostatic valve opens

Stop the compressor

Open the oil fill plug after 5 minutes

Refill the oil tank to the maximum levelindicated on the drawing

Restart the compressor

Installation

Procedure for filling oil in newlyassembled machine

Procedure for changing oil incompressors on-site

Fill oil in the oil tank up to themaximum level indicated in thedrawing

Close the oil filling plug

Run the compressor for 10 minutes,until the thermostatic valve opens

Stop the compressor Open the oil filling plug after 5

minutes

Refill the oil tank, it can be filled uptothe maximum level as indicated onthe drawing

Restart the compressor

NOTE

1. Prior to starting the machine, ensure all the plugs and ports are closed. Check if all thedismantled components are assembled properly

2. Do not remove plugs or ports when the compressor is running or pressurized. Stop thecompresor and relieve all internal pressure before doing so

3. Do not check the oil level when the compressor is running

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

Installation

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

9.14

9.15

The direction of rotation of motor forgear driven Airend is clockwise(C.W.)where as in case of direct driven Airendthe direction of rotation is counterclockwise(C.C.W.) , from motor cowlingside

Gear Models : E11- all pressures

E15 - 10, 13

E18 - 13

E22 - 13

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

Installation

Check the direction of rotation of the main motor and the fan motor when startingfor the first time by switching on the compressor (pressing the green Startbutton) and switching off (pressing the red mushroom Stop button) immediately.The motor must rotate in the clockwise direction when viewed from the frontside (non-drivingside). If the direction of rotation is not correct, isolate the machinefrom the electrical lines and interchange any two phases. Re-start the compressorand ensure that the direction of rotation of the main motor and the fan motor isclockwise

W A R N I N G

Ensure that only authorised electricians carry out the electricalwork. Study the electrical circuit diagram before starting work

Change transformer tappings & OLR setting according to voltageconditions (415V/380V) at site

9.16

Installation

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

rated speed

In case of problems during the running of the compressor, check whichwarningLEDs are illuminated on the control panel of the compressor and referto the Functional Description and Operation sections of this manual

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

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

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

Extended storage

If your compressor is expected not to be used for a prolonged period, specialmeasures must be undertaken to ensure the protection of the followingcomponents:

The airend

The motors

The sump or air–oil separator tank

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

CAUTION

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

!CAUTION

9.17

Installation

Airend

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

Rotate the coupling three times so that the oil present inside the airendcomes out through the discharge port

Block the discharge port completely

Remove the inlet rubber duct connected to the intake valve of the air filterassembly

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

Rotate the coupling five times by hand so that the rust preventive oilspreads 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 dustentry

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

Motors

Check the insulation of the motor winding

Remove moisture if any in the motor

Check the junction box terminals for tightness of the wires

Grease the motor

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

Air–oil separator tank

Replace the oil filter element

Replace the air filter element

9.18

The sump or air–oil separator tank

Remove the entire tank from the compressor afterdisconnecting it from all hoses, the tank top lid, the minimumpressure valve outlet line, control pulse lines and controlswitches

Clean the tank using DW X 32 oil

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

Installation

1.0

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

from ELGI. Overall, the features of your Global Series translate to convenience

for you. The compressor has only two moving parts—the rotors—which are

separated by a thin film of oil, so that there is no wear. This also means that the

reliability of the compressor is unsurpassed

The screw compressor technology ensures that there is no reduction in output

capacity even after many years of operation. It involves a continuous flow of air

through helical cavities in the screw and so the compressed air delivery is

pulsation free

The design of the Global Series gives you a compact and self-contained

compressor. Because it has no reciprocating parts, it runs quietly and free of

vibrations. The discharge temperature of the coolant oil is low, less than 90°C,

and therefore carbonized oil is not formed in the compressor

The Global Series compressors feature a Varion capacity control system at the

air inlet side and a three stage separation system including a unique OSBIC

air–oil separation system. The capacity control system ensures optimum air

intake during start-up, normal running and unloading. The three - stage separation

system and the moisture separator at the outlet ensure that oil and water are

separated from the compressed air

Please read the instructions in this manual carefully and follow them at all

times. The operating life and reliability of the compressor depend to a large

extent on correct operation and maintenance

When calling your ELGI branch office, dealer or service centre regarding your

compressor, keep at hand the details present on the name plate of the

compressor and entered in the inside front cover of this manual

When ordering spare parts, refer to the lists provided in Appendix B of this

manual and identify the part number. Specify the part number and quantity in

addition to the name plate details

Introduction

31.0

INTAKE SUB ASSY

31.1

INTAKE SUB ASSY

FOR, STANDARD VERSIONSTANDARD + DRYER VERSIONSTANDARD + DRYER + VFD VERSION

1 015400909 GASKET INTAKE VALVE 1 DIRECT DRIVEN 159 MODELS

015401050 GASKET INTAKE VALVE 1 GEAR DRIVEN 102 MODELS

2 015400984 ADAPTER INTAKE VALVE 1 DIRECT DRIVEN 159 MODELS

3 000906214 HEX BOLT M16 X 40 4 DIRECT DRIVEN 159 MODELS

4 000996116 SPRING WASHER M16 4 DIRECT DRIVEN 159 MODELS

5 010430390 GASKET AIREND 1

6 B009801070012 INTAKE VALVE -NC-50MM 1 11kW to 22kW

7 015400928 AIR FILTER BRACKET 1

015401108 AIR FILTER BRACKET 1 15kW - 7 to 10bar

015401048 AIR FILTER BRACKET 1 GEAR DRIVEN MODELS

8 B004700770016 ELBOW 90° 1 18Kw & 22kW- 7.5 ,8.5 ,10 barmodels

B004700770015 ELBOW 90° 1 11kW &15kW - 7.5 to 13 ,18kW-13, 22kW-13bar models

9 B004700770002 AIR FILTER ASSY 1 18Kw & 22kW- 7.5 ,8.5 ,10 barmodels

B004700770005 AIR FILTER ASSY 1 11kW &15kW - 7.5 to 13 ,18kW-13, 22kW-13bar models

10 B005000530003 ELBOW CLAMP 2

B005000530002 ELBOW CLAMP 2

11 000906184 HEX BOLT M12 X 35 4

12 000996112 SPRING WASHER M12 4

13 000996108 SPRING WASHER M8 2

14 000996058 PUNCHED WASHER M8 2

15 000948008 HEX NUT M8 2

16 000906119 HEX BOLT M8 X 40 2

17 000959913 ST FITTING 1/8 BSPP to 6MM 1

Part No. Description Qty.S.No.

Remarks

INTAKE SUB ASSY

31.2

INTAKE SUB ASSY

FOR, STANDARD VERSIONSTANDARD + DRYER VERSIONSTANDARD + DRYER + VFD VERSION

Part No. Description Qty.S.No.

Remarks

31.3

18 22037897E BUSH REDUCING ADAPTER 1

19 22047681B ELBOW; TMS; 1/4"X1/4"NPT 1

20 000996060 PLAIN WASHER M12 4

21 000986816 SCREW GRUB M6 x 6 3

22 015401213 SLEEVE STOPPER 1

23 B009900350001 SUCTION DUCT WOUT CUF 1

24 000468490 BEEDING RUBBER 1

25 015400702 STAND PIPE ADAPTER 1/8 1

26 22037106A TEE; RUN; TAPER MALE; 1/4" 1

27 015303319 PIPE SET-BLOWN DOWN LINE 1 DIRECT DRIVEN 159 MODELS

015303457 PIPE SET-BLOWN DOWN LINE -102A/E 1 GEAR DRIVEN 102 MODELS

28 B007300990004 SOLENOID VALVE NC,24V,50HZ 1

29 22047682A TEE; BRANCH; TM; 1/4"X1/4"NPT 1

30 000959763 SLEEVE FOR 6x4MM TUBE 2

31 000920620 TUBINGS 6MM 0.33 m

32 B004700770017 SERVICE INDICATOR 1

a) SCHEDULE MAINTENANCE:

Maintenance

INSPECTION AND MAINTENANCE SCHEDULE

Maintain the components once, as per the given time (hrs)

S.No.Parts to beinspected Dew

pointDischargepressure

ADVCondenser

FanCondenser Dryer

Electrical

1.Check &

clean24 hrs 24 hrs 168 hrs -- 168 hrs -- -

2.Check thefunction

- 24 hrs 24 hrs -- - - 24 hrs

3.Check

pressuredrop

- - - - -8760hrs

-

4.Inspect &replace

- - R -- - - -

5. Repaint -- - - - - R --

R – As Required

b) SERVICE PROCEDURES OF ALL THE SPARE COMPONENTS :

1. SERVICE OF REFRIGERANT COMPRESSOR :

Switch off the air compressor and stop the dryer. Remove the dryer from thecompressor package. Evacuate the refrigerant in to the atmosphere, throughcharging port. Using the brazing kit de-braze the suction and discharge pipeend. Remove the compressor. Replace the new one and again braze the jointscarefully.Once the compressor has been replaced the capillary tube and theFreon dryer should be replaced with a new one. Put the refrigerant circuit invacuum for 8 hrs. Charge the gas at a specified quantity (kg). Connect theelectrical supply and switch on the air compressor. Run the dryer. Checksuction pressure & discharge pressure (Suction = 50 – 75 psi g, Discharge =240 – 350 psi g)

2. SERVICE OF CONDENSER:

Clean the condenser daily to remove the dust particles attached to the fins ofthe condenser because it affects the process of condensing the refrigerant

41.0

This obstructs in the fan flow. Disconnect the power supply and stop the dryer.Remove the dryer from the compressor package. Evacuate the refrigerant intothe atmosphere. De-braze the inlet and outlet of the condenser. Replace thenew one and again braze the joints carefully. Replace the new capillary tubeand the freon dryer. Put the Refrigerant circuit in vacuum for 8 hrs. Charge thegas at a specified quantity (kg) Connect the electrical supply and switch on theair compressor. Run the dryer. Check suction pressure & discharge pressure(Suction = 50 – 75 psi g, Discharge = 240 – 350 psi g)

(i) INSTRUCTIONS FOR CONDENSER CLEANING :

1. Switch off the air compressor and stop the dryer

2. Open the front door of the dryer and the back door of the ELGI compressorfor easy removal of dust particles

3. Using compressed air, clean the dust accumulated on the condenser finsfrom backside of the dryer with air gun

4. Ensure there is no dust inside the dryers. reassemble the doors

3. SERVICE OF CONDENSER FAN :

Switch off the air compressor and stop the dryer (disconnect the electricalconnection). Remove the dryer from the compressor package. Dismantle thefan. Replace a new one. Connect the electrical connections internally. Asssemblethe dryer unit inside the air compressor package. Connect the main dryer supplyto the ELGI electrical panel board. Run the dryer

4. SERVICE OF HEAT EXCHANGER :

Switch off the air compressor package (disconnect the electrical and stop thedryer connection). Evacuate the compressed air by removing the one touchdummy in the air outlet connection, carefully. Dismantle the air inlet and outletconnections of the heat exchanger Remove the dryer from the compressorpackage. Release the refrigerant into the atmosphere. Using the brazing kitde-braze the Freon inlet & outlet of heat exchanger. De-weld the air IN/OUTconnections if necessary. Completely dismantle the heat exchanger and replace

41.1

a new one. Weld and braze the inlet and outlet connections of air and Freon.Put the Refrigerant circuit in vacuum for 8 hrs. Charge thegas at a specifiedquantity (kg). Connect the electrical supply. Switch on the air compressor. Runthe dryer. Check suction pressure & discharge pressure (Suction = 50 –75 psi g,Discharge = 240 – 350 psi g)

5. SERVICE OF HOT GAS BYPASS VALVE:

Switch off the air compressor (disconnect the electrical connection) and stopthe dryer. Remove the dryer from the compressor package. Release therefrigerant into the atmosphere. Using spanner disconnect the two endconnections of by pass valve and replace the new one. Connect the ends tightly.Put the Refrigerant circuit in vacuum for 8 hrs, charge the gas at a specifiedquantity (kg). Connect the electrical supply and switch on the air compressor.Run the dryer. Check suction pressure & discharge pressure (Suction = 50 – 75psi g, Discharge = 240 – 350 psi g)

6. SERVICE OF AUTOMATIC DRAIN VALVE :

Stop the dryer; Close the ball valve in the drain valve inlet connection, throughwhich the air is passed for draining the moisture (water, dust particles, oilcontaminants etc.). Disconnect the electrical connection, to the 24 V AC coil.Remove the coil carefully. If the coil is burn out (or) not energizing, replace inwith a new coil. If there is any problem in the drain valve, dismantle all theparts. Clean the parts by using compressed air and with a waste cloth. If youfind any of the parts gets damaged, replace that specific parts. After cleaningand assembling the drain valve, assemble the 24 V AC coil and connect thepower supply. Open the ball valve for air supply. Connect the power supply tothe drain valve, run the dryer. Check if the valve is draining the water properly

41.2

8. SERVICE OF EXPANSION DEVICE:

Stop the dryer. Switch off the air compressor (disconnect the electricalconnection). Remove the dryer from the compressor package. Release therefrigerant into the atmosphere. Using the brazing kit, de-braze the inlet & outletend of capillary tube and remove the part. Replace the new one and again brazethe joints carefully. Put the Refrigerant circuit in vacuum for 8 hrs. Chargespecified quantity (kg) of the gas. Connect the electrical supply and switch onthe air compressor. Run the dryer. Check suction pressure & discharge pressure(Suction = 50 – 75 psi g, Discharge = 240 – 350 psi g)

9. SERVICE OF PRESSURE SWITCH:

Stop the dryer. Switch off the air compressor package (disconnect the electricalconnection). Disconnect the power supply of the pressure switch, Assemblethe switch through the thread connection. Dismantle the switch and replace thenew one. Connect the power supply to the switch. Switch on the dryer

10. SERVICE OF REFRIGERANT PRESSURE GAUGE :

Refrigerant pressure gauge indicates the pressure at the discharge side of thecondenser. If it fails by showing error pressure, switch of the air compressorand stop the dryer (or disconnect the electrical connection). Remove the dryerfrom the compressor package. Release the refrigerant into the atmosphere.Loosen the pressure gauge adaptor using spanner. Remove the faulted gaugeand replace it with a new one. Place the Refrigerant circuit in vacuum for 8 hrs.Charge specified quantity (kg) of the gas. Connect the electrical supply andswitch on the air compressor, run the dryer. Check suction pressure & dischargepressure (Suction = 50 – 75 psi g, Discharge = 240 – 350 psi g)

41.3

1. Dewpoint High flow or low pressure Correct the flow andof compressed air PressureHigh discharge pressure Refer point no.05 or lowLarge quantity of hot gas Close the hot gas bypassbypassed valveHigh return gas entry in to Open the hot gas bypassthe refrigeration compressor valve(suction line ice formation)Low gas Charge gas to maintain

the suction pressureExpansion device block (Ice Service the expansionformation on the inlet line device / replaceto heat exchanger)

2. Low dewpoint Less quantity of hot gas Open the hot gas bypass(or dew point bypassed Valvelesser than 1°C)

3. Compressor Thermal over load relay Allow the compressor tonot functioning tripped cool and restart, clean

the condenserWinding broken Replace the compressorWinding short Replace the compressorPumping failure, Replace the compressorFailure of freon to buildpressureWiring problem Check the wiring

4. Neuron+ not Power supply connection Correct the connectiondisplaying the loose or disconnectedDew pointtemperature

Check the wiring of Correct ittransmitterPT 1000 Replace the PT 1000failure

5. High Discharge Refrigeration line block, Clear the blockpressure after the condenser

Expansion device block Clear the blockCondenser dirty Clean or blow off condenser dust

c) TROUBLE SHOOTING :

Trouble Root cause Solution

41.4

6. Compressor Less return gas in the Close hot gas by passthermal overload suction line Valverelay trip orcompressor gettingoff and not getting on

Less return gas in the Charge gas to maintainsuction line the suction and discharge

pressureWinding open Replace the compressorGas leak in the system Arrest the leak & charge

the gasCondenser dirty Clean condenser dust

7. Compressor Low gas Charge the gashead is hotand less High gas Purge gas to maintain thereturn gas in suction and dischargethe suction line pressure

Expansion device block Clean the blockHot gas bypass valve Close the hot gas bypassopened more ValveInlet temperature high Clean the after coolerInlet flow rate high Correct the flow rate

8. Pressure drop Inlet compressed air flow Correct the flow rateagainst the higher than the rateddryer or noair at the outlet

Dewpoint less than 1°C Increase dewpoint setting

9. Water at the outlet Inlet compressed air flow Correct the flowhigher than the ratedInlet compressed pressure Correct the pressurelower than the ratedInlet temperature is higher Correct the temperaturethan the ratedDe-mister drain valve is not Service or replace theworking drain valveAir inlet and outlet Correct the connectionconnections wrongly givenBypass line partially open Close the bypass valveproperly

Trouble Root cause Solution

Contact our authorised service center for any assistance

41.5

Main Menu Screen

21.0

Message 1: Based on the short cut keys pressed (refer APPENDIX B)

Message 2: Compressor Status or fault message

- Pressure schedule

- If Blank →→→→→ Pressure schedule is disabled

- If “PS” →→→→→ Pressure schedule is enabled

- If “PS” blinking →→→→→ Waiting for pressure schedule acknowledgement

- Control Mode (*/$)

- *L →→→→→ Local, ON/OFF control from local keypad

- *R →→→→→ Remote, ON/OFF control from remote input

- *D →→→→→ DCS, Control is from DCS System

- $M →→→→→Manual, Start command given after power failure

- $A →→→→→ Auto, Compressor will automatically restart after power failure

Dis. Pr : 6.0 bar

Dis. Tr : 32°C

Message 1

Message 2

Warning

HH:MM:SS DD/MM1 2

1

2

Main Menu Screen

21.1

Message 2 - Compressor Status or Fault 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

Idle When the controller is in idle, User interface will notfunction during this period for 5 seconds

Emergency stop Emergency Stop Push Switch is ON

Start inhibit xx.x During the start, if sump pressure is higher than theset sump pressure value for starting, this message isdisplayed XX.X denotes the live sump pressure value.The compressor starts only if the pump pressure valueis below the set value.

Start inhibit If the sump pressure is not used (Disabled) then the

“seconds” controller will ensure a minimum of 60 seconds

delay between the stop and the start. Count stops if

“STOP” key is pressed

Auto restart If the compressor is in Auto Mode, the controller“seconds” will ensure a minimum delay (user set, e.g. 90 sec)

between the stop and the start operations. Count stopsif “STOP” key is pressed

Start ack wait This message is displayed when the compressor waitsfor user acknowledgement, after fault clearance. Bypressing “START” key user can acknowledge

Main Menu Screen

21.2

Status Description

Pr. Probe failure Discharge pressure sensor probe failure

Tp. Probe failure Temperature sensor probe failure

Sump Pr. probe Sump pressure sensor probe failureFailure

HSP (A) Case 1: Sump pressure is enabled when the sumppressure exceeds the set high sump pressure value.

Case 2: Sump pressure is disabled when the dischargepressure exceeds the set high sump pressure value.

HSP (D) HSP digital input opens due to high sumppressure

Cooler Cooler digital input opens due to cooler fault

Main motor MMOL digital input opens due to main motoroverload overload.

Rev Rot / Ph fail If the Rev Rot input closes, when the motor is running,due to motor reverse rotation or phase failure.

Trip temperature Discharge temperature exceeds the set triptemperature value

Sump pressure This function is displayed when the sump pr sensor isnot developing activated. After the Start, the sump pressure should

be at least 1.0 bar in 10 seconds. If this isnot achieved fault may occurs.

Power failure Mains supply is interrupted for more than 30 msec

Low voltage Mains supply voltage is less than the 67% of ratedvoltage, compressor is tripped and the controlleroperation is stopped until the Mains supply returns tonormal (at least 75% of the rated)

Menu Structure

22.0

From the default screen, press shortcut keys to view the following (ReferAppendix B)

Set load, unload, start sump & maximum differential pressure values

Current day report

Warning messages (All warning messages can be viewed)

Current sump pressure, diff pressure & ambient temperature or dew point

Press “Enter” Key to display main menu

View

OperatorFault

Report

Day

ReportService

Time

Cumulative

TimeVFD

4.1 View

No password required.

On view parameters, the preset parameters like mode, pressure values,temperature values, timer settings, DCS parameters, last 99 fault reports, last30days report, remaining service hrs due, cumulative time details and VFDparameters can be viewed. The values cannot be altered through this menu.

Scroll up or down by using up and down keys to select the menu. Then pressEnter to enter the selected menu.

Dis. Pr : 6.0 bar

Dis. Tr : 32°C StatusView

Operator

Service

Factory

Customer Care

Main Menu

22.1

Menu Structure

4.1.1 Operator

View Operator Mode Control mode Local / Remote / DCS

Unload mode Enable / Disable

Auto restart ON/ OFF

Pressure unit PSI / Bar

Temperature unit Fahren / Centi

Pressure Unload pressure X X . X b or p (bar orpsi)

Load pressure X X . X b or p

Pr. schedule ON/ OFF

Start sump pressure X X . X b or p

Max .diff pressure X X . X b or p

Delay Warn RST delay X X X s(second)

Star delay X X s

DTR delay X X s

RTS delay X X s

Standby time Sby X X m minute)

St/Sp PH X X

DCS port Type Modbus / SCADACompr. ID X X

Baud rate 9600/19200

Parity None / Even

Length 8 / 7

Stop bit 2 / 1

Temperature Trip temperature X X X C or F

Warn temperature X X X C or F

Fan temperature X X X C or F

Low dew Pt X X C or F

High dew Pt X X C or F

LEVEL 4LEVEL 1 LEVEL 2 LEVEL 3

4.1.2 Fault Report

LEVEL 1 LEVEL 2 LEVEL 3

View Fault report Fault code: XX, Message

Time: HH:MM:SS

Date: DD/MM/YY

Dis.Pr: X X .X

Dis.Tr: X X X

Status: Load/ UnLoad /OFF

Use , to select the Fault record number (1 to 99).

Menu Structure

22.2

Fault Code:01 & 09 – Reserved

02-Main motor overload, 03-Cooler, 04-HSP(Analog), 05–Trip temperature, 06-Reverse rotation, 07-Pressure probe failure, 08-Temperatureprobe failure, 0A-HSP(Digital), 0B-Power failure( Short Power Interrupt), 0C-Sump pressure not developing , 0D-Sump pressure probe failure.

On the fault report, parameters such as line pressure, discharge temperature andstatus of compressor will be displayed. This will help to troubleshoot the failure.

4.1.3 Day Report

Use , to select the Record number (1 to 30).

L- Load, St – Stop, UL – Unload, F- Fault, R- Run, Sby- Standby,STC – Start Count, LDC Load Count

On the fault report, parameters such as line pressure, discharge temperatureand status of compressor will be displayed. This will help to troubleshoot thefailure.

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

4.1.4 Service Time

The remaining service hours for the consumable parts can be viewed and theservice due is completed. The countdown then will be shown in negative(- hrs).

LEVEL 1 LEVEL 2 LEVEL 3

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

Remaining OFCT: X X X X X X hours

Remaining OSCT: X X X X X X hours

Remaining OCT: X X X X X X hours

Remaining RGT: X X X X X X hours

Menu Structure

On this menu, the cumulative hours including number of start/stops, number ofload/unloads and percentage of utilization can be viewed. With this CumulativeTime feature, the Emergency stop hours will be accounted in stop hours, andnot under fault hours. This enables the user to view the real fault hours. Thesedetails will further guide for energy savings in compressed air.

4.1.6 VFDWhen the VFD is connected to the compressor, user can view the followingparameters of VFD on Neuron II.

1. Voltage in V

2. Current in A

3. Frequency in Hz

4. Power in KW

5. Run Hours

6. Kilowatt Hour (Multiply the value shown by 100 to get the real KWH)

7. Status of the VFD

4.1.5 Cumulative Time

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 X X X X X X

Load Count X X X X X X X X X

Utilisation X X %

22.3

22.4

Menu Structure

4.2 Operator

Password protected. The operator has to receive the password from thecompressor commissioning engineer

With this menu, the operator parameters can be adjusted to match therequirement. Minimum and maximum limits are fixed for all the value adjustmentparameters. When the setting exceeds these values, there will be an indicationof ‘out of range’.

Operator

Machine Schedule Maintenance LanguageChange

Password

Mode PressureSet

Delay

DCS

Port

Auto Drain

Valve

Set Dew

Point

22.5

Menu Structure

4.2.1 Machine

# Item Min Max Option Default Unit

1 Auto restart - - on / off off -

2 Pr unit - - bar / psi bar -

3 Tr unit - - cen / fah cen -

4 Control mode - - loc/rem/dcs loc -

5 Unload mode - - en/dis dis -

6 Analog output 2 - - Tmp / Sp /Pt / off off -

Pressure

7 Unload > load < max - 7.5 bar bar/psipressure pressure unload (Varied

+0.5 pressure according(bar) (bar) to pr

model)

8 Load 4.0 (bar) < unload - 5.5 bar bar/psipressure pressure- (Varied

0.5 (bar) accordingto pr

model)

Set Delay

9 Warn RST 90 300 - 90 second

10 Star 6 10 - 6 second

11 DTR 10 60 - 10 second

12 RTS 5 30 - 5 second

13 Standby 1 99 - 5 minute

14 St/Sp per hr 3 10 - 5 -

DCS Port

15 Type - - Modbus / modbus -SCADA

16 ID 01 99 - 01 -

17 Baud rate - - 9600/19200 9600 bps

18 Parity - - None /Even None -

19 Length - - 8 / 7 8 -

20 Stop bit - - 2 / 1 2 -

Auto Drain Valve

21 Off time 1 150 - 4 minute

22 On time 1 15 - 5 Second

Set Dew Point

23 Low dew point -6 C +2 C - -2 C C/F

24 High dew point 6 C 12 C - 8 C C/F

22.6

Menu Structure

Important Function Keys:

Auto restart ON: Switches On the compressor automatically after a powerfailure. The internal timer counts the power Off period and the period whenpower resumes. The compressor starts after elapsing the set time by thisfunction, ensuring the compressor availability immediately after a power failure.

On the screen A will be displayed and the Auto lamp is On, indicating that thecompressor can be automatically started. If it doesn’t, M (manual) will bedisplayed. This mode indicates that a manual start is required after power failure.

Local: The compressor is switched On/ Off through the start and stop buttonsin the controller.

Remote: The compressor is switched On/Off only through Digital input (Remote),and cannot be operated through the controller push buttons.

DCS : The compressor is operated only through modbus.

In Remote and DCS modes, the compressor can be stopped through theEmergency stop. The Auto LED will glow, in both these modes, indicating thatthe compressor can be automatically started.

Unload mode: This key verifies the functions of the compressor with out loading.If this mode is selected, the relay out put (load / unload) will be de energized.During this mode, the compressor runs continuously in Unload mode. If thefunction is disabled, then the compressor operates as per the pressure set inthe controller.

Load pressure & unload pressure: The user can adjust these values withinthe limits of the factory. The value is set at a minimum load pressure of 4 bar.The maximum unload pressure is set as per the indication on the compressorname plate. The minimum differential is 0.5 bar.

Menu Structure

22.7

4.2.2 Schedule

Enable Pressure Schedule, and use ²%, ¼% to select the schedule number(1 to 32).

Then Press “Enter” to set the following

Once the pressure scheduler is selected, PS blinks on the screen. Toacknowledge this, press “START” button. When pressed, the compressor startsand stops as per the pressure scheduler. The start / stop keys are not activatedin this mode, after the user acknowledges it.

The controller is designed to accommodate changes in the schedule in betweenperiods. It avoids the necessity of marking changes in schedules in an order.For example, consider the two periods: Monday schedule (1-4) and Tuesdayschedule (5-8). If the user wants to make changes to the Monday schedule, hecan enter the changes in the 9 schedule (that follows after the Tuesday schedule).

4.2.3 Maintenance

Once the consumable part is replaced, enter in to the maintenance menu. Typethe changed part as Yes. Set the remaining service hours as per the 100%service hours.

# 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 -

# Item Min Max Option Default Unit

1 Day - - Sun to Sat /-- (means no

schedule) -

2 Action - - on / off —- -

3 Time HH 00 23 - —- Hour

4 Time MM 00 59 - —- Minute

5 Unload > Load < Max - bar/psiPressure Pressure Unload

+0.5 Pressure(bar) (bar)

6 Load Pressure 4.0 bar < Unload - —- bar/psiPressure – 0.5 (bar)

22.8

Menu Structure

4.2.4 Language

The user language can be selected, Default is in English.

4.2.5 Change Password

Procedure for changing the password

1. Enter the old password

2. If old password is correct, next screen is displayed. If wrong, the controlcomes out of the ‘change password’ screen

3. When the ‘next’ screen is displayed, enter the new password

4. Re-enter new password

5. If new password matches both the entries, the password will be updated.If mismatch occurs, the control goes back to step 3.

Pressing Esc will bring the control back to the main menu screen

# Item

1 English

2 Hindi

3 Portuguese

Menu Structure

22.9

4.3 Service

Password protected. Only Elgi Service engineers are authorized to change themenu.

4.3.1 CalibrationSelect the parameter needed for calibration using the ²%, ¼%keys. Then Press“Enter” to calibrate.

Discharge Pressure/ Discharge Temperature/ Sump Pressure Calibration

Run the compressor. Measure the value using a standard and recently calibratedmeter, when the value is stable. Enter the meter reading in the set value fielddisplayed on the Neuron II. Set Value should not exceed +/- 1 bar and +/- 10 Cthe actual value.

Pt 100 Calibration

Measure the value using a standard and recently calibrated meter, when thedew point/ ambient temperature is stable. Enter the meter reading in the setvalue field displayed on the Neuron II. Set Value should not exceed +/- 3 C theactual value.

Note:

Calibration should be done when the compressor is switched Off , and ensurethe digital outputs (relay terminals) are disconnected from the controller.

Calibration for pressure should be done for the pressure sensor at 8 bar (in baronly), and at 100 Deg C (in Centigrade only).

(3.3k resistor=100Deg C)

Analog Output 1 & 2

Calibration for analog output is done for two values: one at zero and the otherat 8.0 bar / 80 degree C. These values are set by connecting a Variable Resistor(TRIM POT) to the analog input channel. Measure the analog output value (canbe viewed in the DCS/VFD / or any master unit where this output is connected).Enter this value in “set pressure:”

Service

Calibration RelayFan

Temp Maintenance ClockSelf

Test

,

Menu Structure

22.10

4.3.2 RelaySelect the Programmable Relay 1 or 2 using the , keys. Then Press “Enter”to assign any of the following functions for the relay.

4.3.3 Change Password

The fan temperature set point is used to start the fan when set temperature isreached. Stop the fan when the temperature reaches 10 Deg C or lesser thanthe set temperature. This setting is used to control On / Off settings of the fan,based on the discharge oil temperature.

The maintenance due is fixed by Elgi Service Engineer based on the spareparts used.

4.3.4 Maintenance

# Item

1 Warn

2 Load

3 Service

4 Standby

5 Trip

6 Remote

7 Ready

Default:

Relay 1 = Warn

Relay 2 = Trip

Note: If Dryer is enabled, the Programmable Relay2 is not user programmable. It is used for automaticdryer control.

# Item Min Max Option Default Unit

1 Fan temperature 60 C 85 C - 85 C C / F

# Item Min Max Option Default Unit

1 Set AFCT 000000 999999 - 001500H Hour

2 Set OFCT 000000 999999 - 001000H Hour

3 Set OSCT 000000 999999 - 004000H Hour

4 Set OCT 000000 999999 - 001000H Hour

5 Set RGT 000000 999999 - 001500H Hour

Menu Structure

22.11

4.3.5 Clock

The clock setting of the controller is not changed, if used in India. When usedoverseas, the time is set according to the local timings, at the time ofcommissioning

4.3.6 Self Test

Self Test for testing the Controller Display, Mimic Leds, Keys, Input/Output,Memory & Communication Ports working.

Follow the instructions displayed on the screen.

# Item Min Max

1 Hour 00 23

2 Minute 00 59

3 Second 00 59

4 Date 01 31

5 Month 01 12

6 Year 00 99

7 Day Sun/Mon/Tue/Wed/Thu/Fri/Sat

Warning

Self-Test should be conducted only after disconnecting the compressor fromthe controller. (Use connect power supply X01 3 pin connector) DO NOT performself-test when the controller is connected to the compressor. Doing so will causesevere damage to the compressor.

4.3.7 Change Password

1. Enter the old password

1. Enter the old password

2. If old password is correct, next screen is displayed. If wrong, the controlcomes out of the ‘change password’ screen

3. When the ‘next’ screen is displayed, enter the new password

4. Re-enter new password

5. If new password matches both the entries, the password will be updated. Ifmismatch occurs, the control goes back to step 3.

Pressing Esc will bring the control back to the main menu screen

4.4 Factory menu

Password protected. Only Elgi authorized persons are allowed to change thesetting.

Menu Structure

22.12

Factory

MachineChange

PasswordDryer

Compressor

InfoDPAF DPOF

Max.

Pressure

Settings

Temperature

Settings

4.4.1 Machine

Menu Structure

22.13

If the sump pressure sensor is enabled, the Star sump pressure and themaximum differential pressure values will function. In this mode, the highsump pressure is activated based on the sump pressure in the Air oilsump.

# Item Min Max Option Default Unit

1 Rating - - 11 to 315 22 KW

2 Pressure - - LP/ 7.0to12.5 LP bar

3 Fab no Alpha:A Alpha:Z - AAAA -(10 digit) num:0 num:9 000000

4 DPAF - - on/off off -

5 DPOF - - on/off off -

Max. Pressure Settings

6 Max UL > Unload <13.5bar - 7.5 bar bar

Pressure Pressure /psi

7 High sump > Max < Max - 10.5 bar bar

pressure Unload Unload /psipressure pressure

+0.5 +3

8 Sump - - enable/ disable -pressure disable

9 Start sump 0.0 bar 16.0 bar - 1.0 bar barpressure /psi

10 Max. 0.0 bar 2.0 bar - 1.5 bar bardifferential /psi

pressure

Temperature Settings

11 Trip 80 C 120 C - 110 C C / F

temperature

12 Warn 70 C 110 C - 105 C C / F

temperature

Menu Structure

22.14

4.4.2 Change Password

1. Enter the old password

2. If old password is correct, next screen is displayed. If wrong, the controlcomes out of the ‘change password’ screen

3. When the ‘next’ screen is displayed, enter the new password

4. Re-enter new password

5. If new password matches both the entries, the password will be updated.

If mismatch occurs, the control goes back to step 3.

Pressing Esc will bring the control back to the main menu screen

4.4.3 Dryer

# Item Min Max Option Default Unit

1 Dryer mode - - on/off off -

2 Dryer Delay 2 10 - 3 Minute

This mode is enabled, if dryer is part of the compressor. The dryer is switchedon and off through the controller, provided the compressor is switched On.When the compressor is On, dryer is switched On; and the dryer is switchedOff when the compressor is on Off mode. The time interval between the stopand start operations is decided by dryer delay time setting, which enables thesafe operation of dryer and compressor.

4.5 Customer Care

Dis. Pr : 6.0 bar

Dis. Tr : 32oC

Status

Toll Free No

1800-425-3544

e-mail ccs@elgi.com

v

Machine Identification and SaleRecord

Owner’s name : ________________________________________

Address : ________________________________________

Model : ________________________________________

FAB No. : ________________________________________

Year of manufacture : ________________________________________

Motor : ________________kW_____________________

Capacity : _____________________m3/ min_____________

Rated Pressure : _______________________bar g____________

Date of Delivery : ________________________________________

Date of Commissioning : ________________________________________

Dealer’s name/code : ________________________________________

Dealer’s signature and stamp

Note: The warranty on this compressor is valid only if all the details

above are filled and the dealer stamps and signs this page

15.0

The maintenance of Global Series compressors is minimal but important. Theindicators on the control panel of the compressor give warnings when servicingof the suction filter or oil filter element is necessary

Maintenance schedule

Daily : Prior to starting the machine, it is necessary to check the oil level in thereceiver tank (see Starting the compressor in the Operation section No.10.1)Should the level be low add the necessary amount. If the addition of oil becomesvery frequent, a problem has developed which is causing this excessive loss.Refer to the section on excessive coolant consumption in the Troubleshootingsection for a probable cause and remedy

After a routine start has been made, observe the instrument gauges and besure they monitor the correct readings for that particular phase of operation.After the machine has warmed up it is recommended that a general check onthe overall machine and instruments be made to ensure that the compressor isrunning properly

After initial 100h of running :

Maintenance

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

Clean the return line orifice

Change the oil filter element

Do not remove caps, plugs or other components when thecompressor is running or pressurised. Stop the compressor andrelieve all internalpressure before doing so

!WARNING

15.1

Disassembly of existing Separator:

Switch off and isolate the machine from service line Vent the separator tank pressure and allow it to cool for few minutes Hold the separator outer shell by the removed strap belt & rotate it counter

clockwise , until it completely unscrewsThe helix adapter should be in the Separator headduring disassembly Check the recommended life of oil separator. Once the recommemded life

is over, it has to be replaced with a new element

Assembly of new Separator:

Ensure gasket of the separator is not damaged

Clean the gasket-seating surface with a clean cloth

Apply a thin film of oil on the mating surface of the gasket

Return the separator to its original position & handrotate it in clockwisedirection

Ensure there are no oil leaks from the mating surface. In case of leakage,check the gasket

After tightening by hand, rotate it further

Air Oil Separator Element (Spin-on Type)

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

NOTE

Maintenance

15.2

Oil Filter (Spin -on Type)

Maintenance

Dismantling method of existing Oil Filter :

Isolate the machine from the service line, vent the Separator tank pressureand allow if to cool for few minutes

Hold the filter shell and & rotate it counter - clockwise by hand

Assembly of new Oil Filter :

Ensure the gasket of the filter is not damaged

Clean the seating surface with a clean cotton

Apply this film of oil on the mating surface of the gasket

Return the filter to its original position & rotate it clockwise manually. Aftertightening, rotate it further by hand for one and half rotation

Ensure there are no oil leaks from the mating surface

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

NOTE

NOTE

• Suspended particulate matter should be less than 150 spm to achievethe specified consumable life

• No guarantee shall be given if the compressor is operated aboveits intended pressure

15.3

Caution: When the air filter log indicates a blocked condition, remove the air filter

and replace it with a new one. Do not forget to remove the air filter logindicator from the old air filter and fix it on the new filter

Clean the air filter element using moisture free compressed air at lessthan 2.5 bar g. Supply the compressed air from inside to outside of thefilter element

Inspection of filter element: Shine a bright light from inside the filter element to inspect for damage or

holes that will cause leaks. The light will emerge from the holes, indicatingtheir location

Dismantling Air Filter: Shut down the compressor Release the three clips of Air filter end cover by hand Pull the Air filter end cover away from the filter housing Take it out axially giving it a mild shake Bring the indicator back to normal positionAssembly of New Air Filter: Ensure the seal of filter element is not damaged Clean the filter element housing with cotton Insert the filter element axially into the filter housing by hand, free of oil &

dirt Place the End cover on the filter housing and firmly clamping it with

stretching clips

Air Filter: Spin-on Type

For details refer Airinlet System

Maintenance

Air FilterEnd cover

Clips

15.4

Maintenance

Cleaning the internal surfaces of Oil

For aluminum coolers, use a 5% by volume mixture of caustic soda inwater. Circulate this mixture at 600C in the cooler for 5 hrs. The duration ofcirculation can be increased based on requirement

Cleaning of external surfaces of Oil Cooler

Isolate the machine from the service line

Vent the separator tank pressure before attempting maintenance

Open both the LH panel & cooler inspection cover

Use compressed air at less than 7 bar g to clean the outer surface of thecooler. Supply the jet of air in opposite direction of cooling airflow direction,through the cut out shown in figure below

Close the cooler inspection cover & LH panel

Oil Cooler

Handle toluene and isopropanol with care. These solvents areharmful and hazardous to humans

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

!WARNING

!WARNING

15.5

Cleaning pre-filter

Switch off the machine

Squeeze and take out the filter from the panel board

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

Refit the filters after cleaning

Repeat this process every 100 hrs, for increased life of separator and Airfilter elements

Pre- Filter

Maintenance

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

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

NOTE:

15.6

Coupling element provides flexible coupling between the motor & the airend

Malfunctioning of coupling element results in sound & vibratin

Replacement method of Coupling Element:

Drive Coupling Element

Isolate the machine from the service line

Before attempting maintenance, release the separator tank pressure andallow if to cool for few minutes

Disconnect power supply to the motor

Open the cooler side panel covers

Open the Coupling guard by using spanner

Remove the three coupling screws & slid coupling element it on the shaftspline to free the coupling element

Replace the old coupling element with a new coupling element

Tighten the coupling screws to the specified torque

Assemble the coupling guard and cooler side panel cover

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

The inspection interval for Coupling hub screw is three months.

The inspection interval for Coupling element screen is three months.

NOTE

Maintenance

Disconnect all power at the source before attemptingmaintenance or adjustments!

WARNING

15.7

MPV Replacement:

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

Release the receiver tank and downstream pressure

Unscrew the four bolts

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

Grease the new MPV kit

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

Tighten the bolts

Adjust stud protrusion (6mm) to achieve a minimum pressure of 4.5 bar g

Minimum Pressure Valve (MPV)

Maintenance

Extreme caution should be taken while removing the cap orcover from the body because of the spring tension!

WARNING

15.8

Replacing thermal Valve

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

Release the receiver tank and the downstream pressure

Remove the circlip using plier

Take out the thermal valve from the separator body

Inspect and clean seating area in the housing

Replace with a new thermal Valve

Assemble the valve in its place & lock it by circlips

Remove the plug using a M6 screw

Thermal Valve

Maintenance

15.9

Frequent Checks:

Check the insulation of the motor winding

Remove moisture from the motor

Check the junction box terminals and cable connectors

Grease the motor

Greasing Intervals:

Grease the 2 Pole motors after every 2000h of running

Grease the 4 Pole motors after every 4000h of running

Recommended Greases are:

Use only a lithium based high temperature grease ESSO UNIREX N3 orany Equivalent brand of Lithium soap based Grease

Electric Motor

Maintenance

If the compressor is lying idle for more than a year, fresh grease shouldbe applied after removing the old grease

The compressor Motor IR (Insulation Resistance) value should beverified before starting

NOTE

15.10

Function of NRV-flaps

Dismantling:

He valve must be completely dismantled from the compressor. Then removethe bearing bolts (4) and take out pin (5). Take out NRV-flap

Cleaning:

Clean interior of housing with liquid cleaner. Free thread of possibleremainders of Loctite.Seat and sealing areas must by no means bedamaged!

Reassembly:

Wet a bearing bolt with Loctite 242 and screw it into the thread, InstallNRV-flap/ NRV-flap and counterweight in the housing according to drawing.Press the pin (4) through the bearing bores into the pre-assembled bearingbolt. Wet the second screw with Loctite 242 and screw it in. Lock bothscrews with 50 N-m

Function testing:

Check easy moving of NRV-flap manually. It must have slight axial playand must not touch the housing

1. Rotary drive unit

He valve must be completely dismantled from the compressor.( Additionallythe control discs has to be moved to closed position by pressure airsignalbefore)

Turn out Tensilock screws (10) and take out control disc (1) (with magnet).( take off pressurized air. )

Take off plastic plug (11). Turn out MHT-nut (15) and remove the 2 rings(13+14) below. Attention: When screwing off cover (8). Spring (6) is pre-tensioned, therefore press by Hand onto the cover when turning out! Takeout sealing ring (7), piston unit (9), spring(6), rod (12) and the remaining 2rings (16+17)

Intake Valve

Attention ! Always depressurize valves before opening it !

Maintenance

!

15.11

Cleaning:

Clear rod (12) of Loctite remainders. Clean working area of the piston unit(9) with liquid cleaner and soft cloth. Grease screw drive of rod (12) andpiston working area with AUTOL TOP 2000. The flattened medium part ofthe rod and the thread must be absolutely free of grease. Seat and sealingareas must by no means be damaged.

Reassembly:

1. Insert two discs (16+17) into housing according to drawing. The sinterarea of the first disc (17) (grey) has to point off the housing in direction tothe second steel disc (16). Turn piston unit (9) on rod (12) until stop. Holdrod in a way that the flattened part looks upward. Then turn piston unitback until for the first time a guiding area is parallel with the flattened partof the rod.

2. HAKG: Insert together with spring (6) according to drawing into thehousing against the spring pressure, in a way that flattened part points tothe counterweight section of the housing.

3. Block rod (12). Install two discs (13+14) acc. to drawing. The sinterarea of the first disc (13) (grey) has to point away from the housing indirection to the second steel disc (14). Wet MHT-nut (15) with Loctite 270,lock it and then loosen it again by 1/6 turn. Insert sealing ring (7) in grooveprovided in the cover (8). Put cover (8) on top and fix it by turning. ConnectionE must look downward. Loosen blocking of rod.

4. Install control disc (1) according to drawing. The bore for idle operationmust always Point at the counterweight section of the housing. WetTensilock bolts (9) with Loctite 270 and lock them. Lock with 9 N-m. Installplastic plug according to drawing.

Function testing:

Connect to pressurized air (see data sheet HAK: control air lower pressurerange!) and test smooth opening/closing for several times, Adjust by turningMHT-nut (15) in either direction if needed. Pay attention to Loctite (see LoLoctite – description). If the time is too long, clean Loctite off the nut andwet again.

Intake Valve

Maintenance

15.12

Service kits:

HAK50 90-663868

Detail: Rotary drive unit

Note: Schematic diagrams only!

Intake Valve

Maintenance

15.13

Blow-down Valve

Complete Service and Dismantling

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

Cleaning

Work and sealing areas of the housingand its threads have to be cleaned withliquid cleaner and possible Loctiteremainders have to be removed. Pistonwork areas have to be greased with AutolTop 2000 (in the service kit, pos.30).The thread and the area of the slidebushing (3) (piston) must be greasedby any means. Seat and sealing areasmust not be damaged

Reassembly

Insert piston unit (4) into housing. Cover housing thread with Loctite 222.Assemble O-ring(1) onto locking screw (2). Screw locking screw (2) in until theupper edge of the locking screw (2) is on an even level with the upper edge ofteh housing. VVF. Additionally insert O-ring (5) into housing

Function testing

Test valve function after each service or inspection at the running compressor

Inspection

Dismantle valve and check componenet for wear. Work and sealing areasof the housing and its threads have to be cleaned with liquid cleaner andpossible Loctite remainders have to be removed. Piston work areas have to begreased with Autol Top 2000 (in the service kit, pos.30) The thread and thearea of the slide bushing (3) (piston) must be greased by any means. Seat andsealing areas must not be damaged. Then reassemble valve as described aboveand test for its functioning

Maintenance

35.0

MOISTURE SEPARATOR SUB ASSY

FOR STANDARD VERSION

MOISTURE SEPARATOR SUB ASSY

35.1

1 000959924 MALE ST CONNECTOR 1-1/4 1

2 015304758 MOISTURE SEPERATOR SHELL 1

3 035400026 O RING ID 37.5x43.5x3 2

4 000906145 BOLT HEX M10X30 8.8 ZYP 4

5 000996110 SPRING WASHER M10 4

6 015402260 HOSE MOISTURE SEPERATOR TO BALLVALVE 1

7 22037903A HEX NIPPLE 1/4" NPT 1

8 220374810 BALL VALVE 1/2" 1

9 015400598 STD PIPE ADAPTER 1/4" 1

10 22047683A TMS COUPLING 1/4" TO 1/4" NPT 1

11 B007300170002 SOV 2/2 NC 24V AC 1

12 000920504 QUICK FITTINGS CONN 1/4BSP-6 2

Part No. Description Qty.S.No. Remarks

vi

Message from the Managing Director

Dear ELGI customer,

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

Series compressors from ELGI, among the most sophisticated rotary screw air

compressors available in the world today.

ELGI has designed your Global Series compressor to be reliable, safe, easy to

maintain and friendly to use in meeting your compressed air requirements. This

user manual will enable you to use the Global series compressor optimally.

Please familiarise yourself with all the information it contains.

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

honoured to be your choice for all your compressed air needs.

Yours sincerely,

Jairam Varadaraj

Managing Director

14.0

Operation

Checks before starting the compressor

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

Fill oil up to the half level of the oil sight glass. Tighten the oil filling plugusing a spanner

Open all doors and visually check that the machine for suitability foroperation

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

Check the nessary earthing line in the panel / compressor base

Starting the equipment

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

Starting and normal operation mode

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

Unloading mode

After reaching the maximum cut out pressure,the pressure sensor sensesthe pressure and cuts off the solenoid electrical supply. The solenoid valvebecomes NC. The pulse goes to the intake valve and the blow-down valvestops, which releases the sump pressure to atmospheric pressure andthe intake valve closes. The compressor runs, maintaining the minimumsump pressure. The blowdown line is connected to the air filter elementfor auto cleaning. During every unloading process the blow-down valvereleases air, which is routed to the air filter element for cleaning it. Thisreduces the cleaning requirements of the air filter

14.1

Monitoring the running of the compressor

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

High discharge temperature

Main motor overload

Fan motor overload

Stopping

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

Changing the compressor settings

Change the compressor settings using the tactile keypad and the LCD onthe NeuronIIcontroller. panel. (Refer to Appendix A for details of the controlpanel and interpretation of the messages)

Operation

12.0

Operating Precautions

Pressure release

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

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

Open the oil filter cap only when the compressor is not running and is notpressurized. Shut down the compressor and bleed the receiver tank tozero internal pressure before removing the cap

Vent all internal pressure prior to opening any line, fitting, valve, drainplug, connection or other components such as a filters. Vent pressure bypopping up the pressure relief valve

12.1

Keep personnel out of the line of the discharged air when opening hosesor other points of compressed air discharge

Fire and explosion

Clean up spills of lubricant or other combustible substances immediately

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

Do not use flammable solvents for cleaning purposes

Keep grounded conductive objects such as tools away from exposed liveelectrical parts like terminals to avoid arcing, which might serve as asource of ignition. Keep all terminals clean and tight

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

Operating Precautions

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

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

!WARNING

12.2

Operating Precautions

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

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

Do not attempt to operate the compressor in a hazardous environment ofany classification unless the compressor has been specially designedand manufactured for explosive applications

Moving parts

Keep hands, arms and clothing away from couplings, fans and other movingparts

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

Keep access doors closed except when making repairs or adjustments

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

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

Prior to attempting repairs or adjustment, disconnect the power at thesource and verify at the compressor that the circuits are de-energised.Thisminimises the possibility of accidental start-up or operation. This isespecially when the compressor is remotely controlled

12.3

Operating Precautions

Keep hands, feet, floors, controls and walking surfaces clean and free offluid, water or other liquids to minimize the possibility of slips and falls

Hot surfaces

Avoid bodily contact with hot oil, hot coolant and hot surfaces

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 ofinjury. Do not ignore small cuts and burns as they may lead to infection

Toxic and irritating substances

Do not use air from the compressor for respiration

12.4

In the event of ingestion of oils, coolants and lubricants used in thecompressor, seek medical treatment promptly. Wash with soap and waterin the event of skin contact

Electrical shock

Keep all parts of the body and any handheld tools or other conductiveobjects away from exposed live parts of the electrical system. Stand on adry or insulating surface and do not contact any other part of the compressorwhen making adjustments or repairs to exposed live parts of the electricalsystem. Make all such adjustments or repairs with one hand. Thisminimizes the possibility of creating a current path through the heart

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

Do not leave the compressor unattended with open electrical enclosures.If it is necessary to do so, disconnect the power to the compressor at thesource and lock it out so that power is not inadvertently restored

Disconnect, lock out and tag the power source prior to attempting repairsor adjustments, turning the machinery manually or handling ungroundedconductors

Operating Precautions

Parts Manual

Parts lists on the drawing:

1. Refrigerant compressor

2. Condenser

3. Condenser fan

4. Heat exchanger

5. Hot gas by pass valve

6. Automatic drain valve

7. PT 1000

8. 24 V AC coil

9. Pressure switch

10. Pressure gauge

42.0

10

1

8

2 3

9

7

5

4

6

a) INSTRUCTIONS TO OPERATOR:

Only a minimum level of experience in handling compressed air isnecessary to operate a refrigeration dryer and the operator should be familiarwith the following terminologies:

Pressure in kg/cm2

Flow in cfm

Dew points in ºC

Components of a fluid network: compressor, valves, drains, taps, pressuregauges, filters, tanks and other pressurized equipments

b) INSTRUCTIONS AT BEFORE STARTING THE DRYER:

1. Assemble the dryer with the given mounting provisions rigidly

2. Connect the inlet and outlet end connections with the rust free pipes. Usethread sealant to prevent loosening of connections and any leakages

3. Connect the power supply to the dryer

4. Check, if it is earthed properly

5. After assembling the dryer, check for any damage in the copper tubes

6. Check the Idle pressure of the dryer. This should be 150 – 180 psi g forR407C gas

c) INSTRUCTIONS AT AFTER STARTING THE DRYER :

1. Check the running of compressor. Malfunction will produce noise andvibration

2. Check the discharge pressure of the refrigerant

3. Check if the pressure switch is operating correctly

4. Check whether the drain vale is operating or not

Operations

40.0

36.4

PULSE LINE, OIL RETURN LINEASSY. DETAILS

36.5

1 012448199 HOSE MPV TO COOLER KIT

2 012449099 HOSE MOS TO BALL VALVE KIT

3 012448399 HOSE MANIFOLD TO COOLER KIT

4 012448499 HOSE COOLER TO MANIFOLD KIT

5 012448599 HOSE OIL INJECTION KIT

6 012449199 HOSE DRYER TO BALL VALVE KIT

7 012448799 PIPE COOLER OUT TO DRYER KIT

Part No. DescriptionS.No.

6.0

Safety

General Information

The operator should follow the instructions, procedures and decals given in this

manual for safe operation

The maintenance personnel should be adequately trained, and have read and

completely understood this operation anhd maintenance manual

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

attempting any maintenance, be sure to disconnect the power at the source

and the compressor is relieved of all pressure

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

closed during operation

All electrical installation must be in accordance with recogonised electrical codes

and any local health & safety codes

Remove red coloured brackets at the airend and motor while commissioning

the compressor

Death or serious injury may occur from inhaling compressed air. Always wear

safety equipment while operating the compressor. Refer OSHA safety standards

Do not allow compressed air to come into contact with food

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

service

Read the safety guidelines before installation and operation

WARN ING

Schematic Diagram

39.0

13.0

SCHEMATIC DIAGRAMP AND I - OFF MODE

1. Air Filter2. Choke Indicator3. Intake Valve with Check Valve NC4. Airend5. Motor6. Temperature Sensor7. Air Oil Separator Tank8. Oil Drain9. Safety Valve10. Air Oil Separator Element11. Orifice12. Thermostatic Valve13 & 18. Oil and Air cooler14. Oil Filter

15. 3/2 Solenoid Valve NC16. Blow Down Valve No17. Minimum Pressure Valve with check valve19. Moisture Drain Automatic20. Ball Valve21. Auto Drain Valve22. Pressure Transmitter23. Outlet Valve24. Fan with Motor

Schematic Diagram

36.6

SPARE KIT DETAILS FOR 11kW TO 22kW:

S.No DESCRIPTION PART NUMBERS REMARKS

1 INTAKE VALVE KIT B009401070007 8000hrs

2 BLOW DOWN VALVE KIT B009401070003 8000hrs

3 DRIVE COUPLING ELEMENT 18kW TO 22kW B011201170002 8000hrs

4 DRIVE COUPLING ELEMENT 11kW TO 15kW B011201170003 8000hrs

5 O-RING AND GASKET KIT 159 AIREND 012447599 8000hrs

6 O-RING AND GASKET KIT 102 AIREND 012447699 8000hrs

7 PULSE LINE, RETURN LINE, OIL LEVEL TUBES,

CORRESPONDING FERRULE AND SLEEVE KIT 012447799 8000hrs

8 MINIMUM PRESSURE VALVE KIT B009301070008 8000hrs

SERVICE KIT DETAILS FOR 4000Hrs:

S.No PART NUMBERS DESCRIPTION REMARKS

1 B004800770001 OIL FILTER ELEMENT-75 LPM 2Nos

2 B005700770004 AIRFILTER ELEMENT 1No

3 B006700770010 AIR OIL SEPERATOR SPINON 1No

S.No PART NUMBERS DESCRIPTION REMARKS

1 B004800770001 OIL FILTER ELEMENT-75 LPM 2Nos

2 B005700770005 AIRFILTER ELEMENT 1No

3 B006700770010 AIR OIL SEPERATOR SPINON 1No

012436999 - 4000Hrs Kit 11-15kW and102 model

012437999 - 4000HrsKit18kW-22kW except 13b

32.0

TANK SUB ASSY

32.1

1 015301557 SEPERATOR TANK ASSY 1

2 015400911 TANK MOUNTING BRACKET 1

3 000996112 SPRING WASHER M12 4

4 000906184 HEX BOLT M12 X 45 4

5 000996110 SPRING WASHER M10 12

6 015401941 1/2" NPT PIPE NIPPLE X 80 length 1

7 015301535 SEPERATOR BLOCK BODY 1

8 B312701 1/2"NPT BALL VALVE 1

9 B008401880001 Safety Valve For 7.5 bar model 1

B008401880002 Safety Valve For 10 bar model 1

B008401880003 Safety Valve For 13 bar model 1

B008401880005 Safety Valve For 8.5 bar model 1

10 22037905F PLUG HEX 1" NPT 1

11 000959931 BANJO1/4 BSPP TO 8mm 2

12 B010301230002 TRANSPARENT TUBE 8X6 0.21m

13 015400891 O ring 1

14 - DISCHARGE PIPE 1 refer drive system

15 000906145 HEX BOLT M10 X 30 4

16 000996110 SPRING WASHER M10 4

17 000996059 PLAIN WASHER M10 4

18 015400922 O ring 1

19 000959914 ST FITTING G1/2 TO 16MM TUBE 1

20 015400912 OIL SUCTION PIPE 1

21 000959928 ST FITTING G1/2 TO 18MM TUBE 1

22 000959915 PLUG G 1/8 1

23 000959916 ELBOW 1/8" TO 6MM TUBE 1

24 22047681B ELBOW; TMS; 1/4"X1/4"NPT 1

25 B009301070008 MINIMUM PRESSURE VALVE 1

TANK SUB ASSY

FOR, STANDARD VERSIONSTANDARD + DRYER VERSIONSTANDARD + DRYER + VFD VERSION

Part No. Description Qty.S.No. Remarks

32.2

TANK SUB ASSY

32.3

26 000959920 ST FITTING 3/4" TO 18MM TUBE 2

27 015400875 SEPERATOR FILTER NIPPLE 1

28 015400877 INTERNAL PIPE 1

29 B006700770010 AIR OIL SEPERATOR 1

30 010440500 OIL FILTER NIPPLE 1

31 B004800770001 OIL FILTER 1

32 015401073 SPRING 1

33 015400932 PISTON 1

34 B008706030003 THERMAL ELEMENT 65°C 1

35 015400874 THERMAL PLUG 1

36 015400890 O ring 1

37 000917237 CIRCLIP B37 1

38 000959923 SWIVEL ELBOW 1 1/4" TO 30MM TUBE 1

39 000906147 HEX BOLT M10 X 40 8

40 000906153 HEX BOLT M10 X 70 2

41 000906159 HEX BOLT M10 X 110 2

Part No. Description Qty.S.No. Remarks

19.0

Technical Features

8 no’s of Optically Isolated Digital Inputs of 24VDC

01 = Emergency Stop

02 = Differential Pressure Oil Filter - DPOF

03 = Reverse Rotation

04 = Differential Pressure Air Filter - DPAF

05 = Remote Start/Stop

06 = High Sump Pressure

07 = Cooler

08 = Main Motor Overload

8 no’s of Output Relay (SPDT 250V AC 10A, 1,00,000 cycle electric life)

01 = Main contactor

02 = Star contactor

03 = Delta contactor

04 = Load Valve

05 = Fan

06 = Auto Drain Valve

07 = Dryer (if Dryer is Connected- else Programmable -Load,Service, Standby, Warn, Trip, Remote, Ready)

08 = Programmable [Load, Service, Standby, Warn, Trip, Remote,Ready]

Technical Features

19.1

4 no’s of Analog Input Channels1 no of 4-20mA Channel, 0 to 16 bar for Discharge Pressure

1 no of RTD (KTY10) channel, 0 to 150 degree C for Discharge Temperature

1 no of 4-20mA channel, 0 to 16 bar for Sump Pressure

1 no of RTD (Pt-100) channel, -50 to +90 degree C for Drier Dew Point orAmbient Temperature

2 no’s of Analog Output Channels1 to 5 VDC, One for Discharge Pressure and One Programmable (SumpPressure, Discharge temp, Dew point/Ambient)

9 no’s of Function keys

Up, Down, Left, Right, Enter, Escape, Start, Stop and Reset.

1 no of Display128X64 White Backlight Graphical LCD

9 no’s of LED’s for Visualization Alarm & Machine Status

Auto

Air Filter

Main Motor Overload

Reverse Rotation

Cooler

Pressure

Temperature

Differential Pressure Oil Filter

Differential Pressure Separator Element

1 no. of Dual LED for Start/Stop Indication

Green for start and Red for stop

1 no. of Non – Volatile Memory

For storage of 30 Day’s reports & 99 Fault Reports

1 no. of Real Time Clock

With Battery life of about 10 years

4 no’s of Communication Port (RS485, 2 wire)

Serial Port 1: MODBUS-RTU or SCADA Port

Serial Port 2: Dedicated FPD Port (For future use)

Serial Port 3: Add-On I/O Interface Port (expansion possibility)

Serial Port 4: VFD Interface Port

1 no. of In System Programming (ISP) Port –For program / Data down loading

and data uploading

Power Supply Input: 24VAC +/- 25%, 50Hz / 60Hz, 1A (In built Protectionpresent for Surge, Over Current)

19.2

Technical Features

17.0

Troubleshooting

Problem: Machine not starting

Main disconnectswitchopen

Line fuse blown

Control transformerfuse blown

Low incomingvoltage

Wire looseconnection

Emergencypush button

locked/malfunction

Due for consumableschange (see warning

message)

Incoming R YBphase connection

Motor starteroverload tripped

Close switch

Replace fuse

Replace fuse

Do alternatearrangement

Check wires forloose connection

Replace emergencypush button/replace

Change ifaccordingly

Change ifaccordingly

Reset. If trouble ispersists, check whethermotor starter contactsare functioning or not

Check Remedy

17.1

Problem: Machine status down with the air demand present

Troubleshooting

Low incomingvoltage

Loss of controlvoltage

Low pressuresetting in controller

Stand by time10 minutes

(6 times start & stopallowed in 1 Hr.)

Do alternatearrangement

Check for tappings ofcontrol voltage

Set to correctworking pressure

Resetaccordingly

Check Remedy

17.2

Troubleshooting

Problem : High discharge temperature

Make arrangementfor properVentilation

Provide requiredspace around the

compressor

Clean cooler andcheck for proper

ventilation

Clean the coolertubes

Provide sufficientforced air ventilation

Fill oil to correctthe level

Replace the filterelement

Check and change

Check wiringregularly

Calibrate it

Connect/ensureNeutral

Proper ventilation inexhaust and inlet

Insufficient spacearound compressor

Cooling air flowrestricted

Cooler plugged

Ambient Temperatureis too high

Low oil level

Clogged oil filter

Poor quality oil

Cooling fanrotation

Temperature sensorin ambient

Check neutralconnect given

Check fanmotor fuse

Replace ifblown

Check Remedy

17.3

Troubleshooting

Problem: Excessive oil in service line / consumption

Line pressure if lessthan 5 bar

Loading/Unloadingpattern, if unloading is

more than loading

Clogged lonestrainer or orifice

Do proper compressorselection

Do proper compressorselection

Clean strainer andorifice

Separator elementdamage or not

functioning

Change separatorelement

Leek inlubrication system

Check all pipeconnection for

leaks

Excess oilFoaming

Drain andchange the oil

Oil leveltoo high

(off condition)

Drain the oil tocorrect level

Check Remedy

17.4

Troubleshooting

Problem: Pressure relief valve opens

Check Remedy

Defective separatorelement

Replace separatorelement

Minimum pressurevalve struck

Replace valve kit

Wrong stud lengthin MPV (6mm)

Adjust accordingly

Working pressureset in controller

Set according tointended working

pressure

Blockage in intakevalve actuation line

Check and cleanthe intake valve

actuation line

High pressurein the sump

Replace theseparator element/Clean the cooler

Replace pressurerelief valve

Defective pressurerelief valve

17.5

Troubleshooting

Problem: Machine fails to build up full discharge pressure

Check Remedy

Too muchair demand

Dirty air filter

Intake valvemalfunction

Check for service lineleaks or open valve

Change element

Check andreplace kit

Solenoid valvemalfunction Check and replace

Pressure sensor inambient

(should be zero)

Calibrateaccordingly

Check for internalpiping leaks

Tight and arrestthe leaks

17.6

Troubleshooting

Problem : Excessive operation pressure

Check Remedy

Defect in pressuretransmitter

Defective solenoidvalve

Defective BDV

Check and replace

Check and replace

Check and replace

Defective intake valve Check and replace

Controller defect

Check the loading andunloading relay of thecontroller Check the

pressure sensor in thecontroller

7.0

Technical Specifications

E11 E15 E18 E22

Free air delivery (cfm)

@ 7.0 bar g working pressure 71 96 115 136

@ 8.0 bar g working pressure 65 88 110 132

@ 9.5 bar g working pressure 60 80 98 114

@ 12.5 bar g working pressure 49 69 80 98

Compressor main - motor kW(HP) 11(15) 15(20) 18.5(25) 22(30)

Motor type (main motor) Totally enclosed fan cooled

Class of insulation of motor Class F

Degree of protection of motor IP 55

Overall dimensions

LXBXH (mm) 1425x720x1470

Models Pressure WeightComp. With dryer With dryer+ vfd

bar g Kg Kg Kg

E11 – 7.5 7.5 534 605 612

E11 – 8.5 8.5 534 605 612

E11 – 10 10 534 605 612

E11 – 13 13 534 605 612

E15 – 7.5 7.5 630 701 708

E15 – 8.5 8.5 630 701 708

E15– 10 10 630 701 708

E15 – 13 13 565 636 643

E18 – 7.5 7.5 680 788 806

E18 – 8.5 8.5 680 788 806

E18– 10 10 680 788 806

E18 – 13 13 600 709 728

E22 – 7.5 7.5 700 810 828

E22 – 8.5 8.5 700 810 828

E22– 10 10 700 810 828

E22 – 13 13 630 740 758

4.0

This operation and maintenance manual has been specially designed keeping

you in mind so that you can get the most out of your ELGI Global Series

compressor. Before you start using your compressor, go through this manual

thoroughly. It contains vital information on operation as well as useful tips that

will help you keep your compressing running as good as new year after year. It

is essential to maintain the compressor as recommended in the Maintenance

section

The manual has been prepared with utmost care to help you understand the

various systems of the compressor thoroughly through descriptions, information

and illustrations. Use the parts lists in Appendix B when ordering replacement

parts for your compressor

All the information, illustrations and specifications in this manual are based on

the latest product information at the time of preparation of the manual. ELGI

reserves the right to make changes in the product at any time without notice

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

compressor

Using the Manual

37.0

11kW KIT

018360634 - CNTRL PANEL_E22_E30_VFD_F2

018360747 - POW.WIRING-E15,VFD-F2 PROJ

018360656 - E22 CNTRL HARNES.DRYER-VFD-F2

B012000510023 - VFD 11kW

A0180035 - CANOPY ACC. E11-E22_VFD - F2

15kW KIT

018360634 - CNTRL PANEL_E22_E30_VFD_F2

018360747 - POW.WIRING-E15,VFD-F2 PROJ

018360656 - E22 CNTRL HARNES.DRYER-VFD-F2

B012000510024 - VFD 15kW

A0180035 - CANOPY ACC. E11-E22_VFD - F2

18kW KIT

018360634 - CNTRL PANEL_E22_E30_VFD_F2

018360748 - POW.WIRING-E18 VFD-F2 PROJ

018360656 - E22 CNTRL HARNES.DRYER-VFD-F2

B012000510025 - VFD 18kW

A0180035 - CANOPY ACC. E11-E22_VFD - F2

22kW VFD

018360634 - CNTRL PANEL_E22_E30_VFD_F2

018360653 - E22-POW.WIRING-VFD-F2 PROJ.

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