Global Series F2 21-08-2011...6 Standby Hours101A BCD 4 HHHHHH:MM R 7 No of Start 101C BCD 4...
Transcript of Global Series F2 21-08-2011...6 Standby Hours101A BCD 4 HHHHHH:MM R 7 No of Start 101C BCD 4...
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:
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 [email protected]
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 [email protected]
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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