Elgi EG SERIES MANUAL

Product Manual
EG Series
Electric Powered Screw Air Compressor
EG 37 - 150.0
Air - Cooled, Standard + VFD
460V, 3Ph, 60Hz
©
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005
Part / Document No. 019000165
Contact Info:
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005, India
Tel : 91 - 422 2589555
Fax : 91 - 422 2573697 (Domestic Business)
Fax : 91 - 422 2589401 (International Business)
E-mail : enquiry@elgi.com
Website : www.elgi.com
Machine Identification and Sale Record
Owner’s name / : ………………………………………………………………………………………………………

Company name
………………………………………………………………………………………………………
Phone number : ………………………………………………………………………………………………………
Contact person : ………………………………………………………………………………………………………
E-Mail address/ : ………………………………………………………………………………………………………

Phone number
………………………………………………………………………………………………………
Model : ………………………………………………………………………………………………………
Fab. No. : ………………………………………………………………………………………………………
Year of manufacture : ………………………………………………………………………………………………………
Motor : ……………………………………………………………………………………………kW (HP)
Capacity : ……………………………………………………………………………………m3/min (cfm)
Rated pressure : ………………………………………………………………………………………bar.g (psi.g)
Date of delivery : ………………………………………………………………………………………………………
Date of commissioning : ………………………………………………………………………………………………………
Dealer name/address : ………………………………………………………………………………………………………

………………………………………………………………………………………………………
………………………………………………………………………………………………………
Dealer’s signature : ………………………………………………………………………………………………………
NOTE The warranty on the compressor is valid only if all the details above are filled in and the dealer stamps and signs
this page. This report must reach the Regional Office/Head Office of ELGi within seven days of commissioning
date.
1.5
Table of Contents
Chapter Page No.

1.0 About ELGi 1.7
2.0 General functional description 2.1
3.0 GA drawing, P&I diagram 3.1
4.0 Technical data 4.1
5.0 Installation and operation 5.1
6.0 Maintenance 6.1
7.0 Controller 7.1
8.0 Air inlet and control system 8.2
9.0 Drive system 9.1
10.0 Discharge system 10.1
11.0 Cooling system 11.1
12.0 Lubrication system 12.1
13.0 Base and canopy system 13.1
14.0 Spare kit details 14.1
15.0 Electrical drawings 15.1
16.0 VFD setting details 16.1
1.6
1.0 About ELGi
ELGi, established in 1960, designs and manufactures a wide range of air compressors. The company has gained its
reputation for design and manufacture of screw compressors through strategic partnerships and continuous research and
development. Over the years, it has emerged as a multi-product, multi-market enterprise providing total compressed air
solutions to all segments. ELGi’s design capabilities translated into a wide range of products ranging from oil-lubricated and
oil-free rotary screw compressors, reciprocating compressors and centrifugal compressors.
ELGi is one of the few companies in the world capable of manufacturing wide range of airends and compressor packages.
ELGi has most modern manufacturing facilities with high precision grinding machines, turning centres, CNC horizontal and
vertical machining centres and also the latest self measurement technology to maintain precise, aerospace manufacturing
tolerances. ELGi’s manufacturing plants are ISO and EOHS certified.
Over two million ELGi compressors are powering business in 70+ countries worldwide. The company offers a strong sales
and service network with a well-knit distribution network of dealers and distribution, worldwide. ELGi has its own
manufacturing operations in India, Italy and USA with subsidiary offices in Australia, Bangladesh, Brazil, China, Indonesia,
Italy, Malaysia, Middle East, Sri Lanka and Thailand. The company is fast expanding its global footprint, attracting
distributors and customers with its new generation products.
Need help…?
In India
You can contact ELGi customer care system (ECCS) to take care of customer complaints. The ELGi CCS works for six days a
week from 08:30 to 21:30 IST (Monday to Saturday). The complaints can be logged by calling any of the following toll free
numbers or by e–mail.
Toll free : 1800 425 3544

E-Mail : ccs@elgi.com
Website : www.elgi.com
Before making service request for your compressor, keep ready the details printed on the name plate of the compressor and
machine identification and sale record of this manual. When ordering spare parts, refer to the lists provided in the parts
manual and identify the part number. Specify the part number and quantity, in addition to the name plate details.
Refer “ELGi services” for more details about ECCS under chapter “Maintenance”.
1.7
2.0 General functional description
Contents Page No.
2.1 Using the manual 2.2

2.1.1. Definitions and symbols 2.2
2.2 Introduction 2.3

2.3 Safety 2.4
2.3.1 Precautions during installation 2.4
2.3.2 Precautions during operation 2.5
2.3.3 Precautions during maintenance 2.7
2.4 Functional description 2.9

2.4.1 Air circuit 2.9
2.4.2 Oil circuit 2.9
2.4.3 Drive system 2.9
2.4.4 Control system 2.10
2.4.5 For retro-fitment of Standalone VFD with Compressor (C) version in field 2.10
General functional description 2.1

2.1 Using the manual
This operation and maintenance manual has been

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

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

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

compressor operating and maintenance personnel at
all times.

2.2 Introduction
Welcome to ELGi customer family. ELGi compressors are The design of the EG Series gives you a compact and self-
the source of compressed air in various segments across contained compressor. Because it contains no
the globe. reciprocating parts, it runs quietly and free of vibrations.
The discharge temperature of the coolant oil is low, less
ELGi compressors are known for
than 90oC (195oF), under normal conditions and therefore
 Greatest reliability prevents carbonized oil from forming in the compressor.
 Fewer maintenance interval Salient Features
 Ease of use
 Three-stage air filtration
 Highest safety
 Improved air filter life cycle
ELGi screw compressor is designed to give
 Noise-free package suitable for in-house operations
 High energy efficiency
 Variable capacity control system*
 Low maintenance cost
 High volumetric efficiency
 High discharge air quality
 Efficient air-oil separation by OSBIC (Oil Separation By
All the above assures a low life-cycle cost. Impact and Centrifugal action)
The rotors incorporate a specially designed eta-v profile  Reliable fan that works even at high temperature
– ELGi patented profile-which emphasizes on improving
 Isolated cooling system
reliability, performance and efficiency. Eta-v profile is the
latest and the most energy efficient profile in the industry  Robust cooling system
globally, assuring consistent performance during entire life  Industrial designed canopy
of the compressor. ELGi screw air compressors have a
 Compact and hardly space-intensive
compact design and compressor run with low noise or
vibrations. The capacity control system ensures optimum  Split type oil & after coolers for easy serviceability
air intake during start up, normal running and unloading  Flush type panels for easy handling
stages, minimizing power consumption. The oil separation
 Anti-vibration mounts for restricted vibration
system ensures that maximum oil is separated from the
compressed air, ensuring the best air quality with very  Increased life of consumables
little oil carry-over.  Integrated VFD (Variable Frequency Drive) and dryer*.
Uptime  Zero-leak flanged joints.
At ELGi, we are changing the way you look at compressed  Oil carry over < 1 ppm
air systems. It’s no longer just about delivering air. It’s  Advanced Neuron controller
about delivering uptime. Our uptime design ensures that
 Globally certified product - CE / UL and other country
the compressors would run cooler, cleaner and longer with
specific approvals.
longer service intervals. The uptime components are bests
in quality keeps your compressor to run smoothly, * For selected models.
efficiently and profitably. With uptime assurance we back
our pledge, with industry-leading warranties, parts
availability, loaner compressors and call centres staffed by
experts. We thank you for purchasing ELGi compressor
and assure you the best service during entire life of
compressor.
EG Series
Your EG Series compressor belongs to a family of rotary
screw compressors from ELGi. The compressor has only
two moving parts: the two rotors. A thin film of oil
separates the rotors to prevent wear. This also means that
the reliability of the compressor is unsurpassed.
The screw compressor technology ensures that output

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

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

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

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

compressors, provide a clear caution stating:
“DANGER” – Remotely controlled machine and will
start without notice
 Danger! Be aware that compressed air used for

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

1910.134 or F.D.A. 21 C.F.R. 178.3570 regulations. depressurize a hose fully before disconnecting it.
Failure to do so may cause severe injury or death.
 Insulate or use protective guards to cover pipes or other

parts that may exceed 80ºC (176ºF). High-temperature
pipes must have a clear marking as potentially
dangerous.
 Position the compressor on level surface. In case of

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

that it could inhale flammable or toxic fumes, vapors or
particles.
 Do not operate the compressor below or above its

operating limits.  Clean up spills of lubricants or other combustible
substances immediately.
 Wear ear protectors if you work in an environment
where the sound pressure level reaches or exceeds 90  Shut down the compressor and allow it to cool down
dB (A). before checking or adding oil. Remove sparks, flames
and other sources of ignition away from the
 Keep all the compressor doors shut during operation.
compressor.
For carrying out routine checks, the doors should open
only for short durations not more than 10 minutes.  Do not permit smoking in the vicinity of the compressor.
Wear ear protectors when opening a door.  Do not use flammable solvents for cleaning purposes.
 Keep hands, feet, floors, controls and walking surfaces  Keep electrical wiring and other terminals in good
clean and free of water or other liquid to minimize the
condition. Replace any wiring that has cracked, cut,
possibility of slips and falls. abraded or otherwise degraded insulation. Keep all
Pressure release terminals clean and tight.
 Know that annual servicing of the safety valve is  Keep grounded conductive objects such as tools away
necessary. It should be checked at the prescribed from exposed live electrical parts like terminals to avoid
pressure for operation. arcing, which might serve as a source.
 Use correct tools for maintenance and repair work.  Keep oily rags, trash, dry leaves, litter or other
Do not allow the manufacturers’ rated safe operating combustibles out of and away from the compressor.
pressure to exceed for pipes, valves, filters and other  Do not operate the compressor without a proper flow of
fittings. cooling air or with an inadequate flow of lubricant or
 It is hazardous to point the compressed air directly with a degraded lubricant.
towards any personnel. Keep personnel out of the line  Do not attempt to operate the compressor in a
of the discharge air when opening hoses or other points hazardous environment of any classification unless the
of compressed air discharge. compressor has been specially designed and
 Use only the correct type and size of hose end fittings manufactured for explosive applications.
and connections. When blowing through a hose or
airline ensure that the open end stays securely. A free
end will whip and may cause injury. Make sure to

Moving Parts  Keep hands, feet, floor, controls and walking surfaces
clean and free of fluid, water or other liquids to
minimize the possibility of slips and falls.
Hot surfaces
 Avoid bodily contact with hot oil and hot surfaces like
cooler, pipes etc.
 Keep all parts of the body away from all points of air
discharge.
 Keep a first aid kit handy. Seek medical assistance

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

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

any other part of the compressor when making
adjustments or repairs to exposed live parts of the
electrical system.

 Use only genuine spare parts. Refer the section “Use
genuine spare parts” in “Maintenance” chapter.
 Before switching on the compressor ensure that proper

earthing is done as per recommendation.
 Make all adjustments or repairs with one hand. This  Ensure that the compressor is cooled down before
minimizes the risk of creating a current path through maintenance is performed.
the heart.
 Conduct repairs only in a clean, dry, well-lit and

ventilated area.
 Do not leave the compressor unattended with open

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

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

obstructed by dirt or paint.
 Air outlet valve, i.e. pipes, couplings, manifolds, valves,

hoses, etc. are in good repair, free of wear or abuse.
 The air-oil tank is properly grounded.
2.3.3 Precautions during maintenance

 Use safety glasses and incorporate safe working
practices before maintenance work.
 Use appropriate tools for all maintenance works.

 If you are going to switch on remotely controlled
compressors must ensure that nobody is checking or
working on the compressor at that time. A warning sign
near the equipment’s start button is mandatory.
 Wait up to five minutes to ensure that the air in the air-

oil separator tank is released to start routing
maintenance.
 Vent all internal pressure prior to opening any line,

fitting, valve, drain plug, connection or other
components such as filters. Vent pressure by popping
up the safety valve.
 Display a maintenance chart near the compressor to

easily identify the maintenance intervals of regular
service items.

2.4 Functional description
Figure 1. Screw compressor systems - Schematic diagram
2.4.1 Air circuit separated of any moisture content by the moisture

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

element will result in noise and vibration. Anti-vibration
mountings reside below the air end and the motor. This
2.4.5 For retro-fitment of Standalone VFD
configuration reduces the transmission of vibration from
airend and motor to the structure, reducing noise and with Compressor (C) version in field
ensuring reliability of mounted parts on the structure. 1. Change the bearings to insulated type for motors
2.4.4 Control system >=90kw at Non Drive End side of Motor
2. Turndown only upto 50% for conversion models

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

signal arrives the solenoid valve from the control system.
Next, the inlet valve actuates and closes, and the
compressor runs in unloading mode. If unloading mode
continues for more than 5 minutes, i.e., compressed air is
consumed and thus no decrease in pressure occurs, the
system stops and switches to standby mode. If a drop in
pressure occurs in the receiver, the compressor returns to
loading mode automatically.
Suction modulation
When you operate a compressor without VFD, capacity
control occurs via a pressure regulator (for selected
models). When the consumption of air is less than the FAD
of the compressor, the line pressure will start increasing.
Whenever the line pressure goes up constantly beyond the
set pressure, the pressure regulator bleeds the excess air
to the atmosphere thereby reducing the amount of flow
into the actuator. The actuator is spring loaded, which, in
turn, closes the intake valve slightly and enables capacity
control. Similarly when the consumption of air is more
than the FAD, the line pressure starts decreasing and the
actuator progressively opens the intake valve. This
regulation is called intake modulation by throttling.
VFD modulation
VFD is an efficient way of controlling capacity as per
demand. In a compressor with VFD the power of
compressor varies proportionally with capacity reduction.
The VFD tunes the frequency, thereby adjusting the speed
based on the change in line pressure. The incoming flow
will automatically reduce because of reduced speed of the
motor. Conversely speed increases when line pressure
goes down below working pressure.

18 PRE FILTER 1
- CRITICAL CHARACTERISTIC (SAFETY/REGULATORY)
17 CONTROLLER 1
- SIGNIFICANT CHARACTERISTIC (FIT/FORM/FUNCTION/FINISH)
16 VARIABLE FREQUENCY DRIVE (VFD) 1
15 MOISTURE SEPERATOR WITH ADV 1

8
14 SAFETY VALVE 1
13 AIR OIL SEPERATOR 1
12 DRIVE COUPLING 1
DISCHARGE AIR
11 OIL AND AFTER COOLER ASSY 1 OUTLET
10 THERMAL VALVE BLOCK 1
9 CONTROL PANEL 1
17
8 COOLING FAN 2*
7 MINIMUM PRESSURE VALVE 1 9
6 INTAKE VALVE 1
5 AIR FILTER 1 16
VENTILATION
4 OIL FILTER 1 G1/2" MOISTURE
FOR PANEL
DRAIN
3 AIR - OIL SEPARATOR TANK 1
2 AIR END 1
1 MOTOR 1
S.NO DESCRIPTION QTY
1-1/4" -BSP(MALE)-EG30&EG37
HOT AIR OUTLET (FROM FAN) 1-1/2" -BSP(MALE)-EG45
VFD DISPLAY
PANEL
7
15
14
OIL POUR
5 OIL DRAIN
13
6
OIL SIGHT
AIR INLET (FOR COOLING FAN)

GLASS 2
10 COMPRESSOR
SUCTION
AIR IN
OIL DRAIN
SIZE G3/4"
3 4
AIR INLET FOR MOTOR COOLING
1 18 12 11
EARTHING POINT
MAIN POWER CABLE

ENTRY Ø2.36"
B
CENTRE OF GRAVITY
X Y Z
NOTE :
UNIT WEIGHT DETAILS (lbs) 38.5" 24.4" 26.3"
1. Indicates Ducting Dimension MODEL C CV Qty.

Sl.No. DESCRIPTION DRAWING No. Rev. REMARKS
2. All dimensions without tolerance are for reference only
3. Cooling air flow for duct is 275454 ft³/hr. EG 30 2183 2293 MODEL. EG 30,37,45 (USA & BRAZIL)
ELGI EQUIPMENTS LTD.,
Pressure drop in conduit should not be more than 0.00435 psi g
4. Minimum distance required around the compressor is 3.3ft EG 37 2447 2491 : -
MATERIAL
COIMBATORE - INDIA.
at all sides and 6.6ft at top (Installation requirement)
5. VFD available in CV version only EG 45 2513 2645.5 WEIGHT: GA DRAWING-EG SERIES
NAME DATE
C AND CV A
SS 31.01.17 REF.DRG.No. NEXT ASSY.

CAD
CHECKED SS 31.01.17 SCALE DRG.No.
NTS
01 53 1561 5
CHKD. BY APPROVED PMD 31.01.17 DRG.SHEET REVISION
REV. NO. ECO.No. DATE DESCRIPTION ALT. BY 1 2 R 0 1
- CRITICAL CHARACTERISTIC (SAFETY/REGULATORY)
- SIGNIFICANT CHARACTERISTIC (FIT/FORM/FUNCTION/FINISH)
101 AIR FILTER
102 CHOKE INDICATOR

Compressed Air
Discharge
103 INTAKE VALVE (NC)
104 AIR END
105 AIR - OIL SEPERATOR

TANK
AIR-OIL SEPERATOR
106
MINIMUM PRESSURE
107
VALVE
108 AFTER COOLER
109 SAFETY VALVE
110 THERMAL VALVE
111 OIL COOLER
112 OIL FILTER
113 MOISTURE SEPERATOR

(AUTO DRAIN)
114 OIL DRAIN VALVE
LEGEND PIPE SIZE

BLOW DOWN
115 VALVE (NO)
Air Line 1 1/4 , 1 1/2 inch SOLENOID VALVE (NC)

116
Pulse Line 1/4 inch B
Oil Line 3/4 inch
Air/Oil Line 2 inch
Envelope Line - Sl.No. DESCRIPTION Qty. DRAWING No. Rev. REMARKS
MODEL. EG 30,37,45 (USA & BRAZIL)

INSTRUMENT
ELGI EQUIPMENTS LTD.,
DESCRIPTION LOCATION RANGE
TAG NO COIMBATORE - INDIA.
: -
MATERIAL
TS01 TEMPERATURE SENSOR After Air end 0-150° C
After moisture 0 - 16 bar WEIGHT:

PS01 PRESSURE SENSOR
separator GA DRAWING-EG SERIES
116 SOLENOID VALVE (NC) on intake valve 220 V AC - NC NAME DATE
C AND CV A
SS 31.01.17 REF.DRG.No. NEXT ASSY.

CAD
CHECKED SS 31.01.17 SCALE DRG.No.
NTS
01 53 1561 5
CHKD. BY APPROVED PMD 31.01.17 DRG.SHEET REVISION
REV. NO. ECO.No. DATE DESCRIPTION ALT. BY 2 2 R 0 1
4.0 Technical data
Standard
Model - EG 30 EG 37 EG 45
Working pressure psi.g 100 125 150 175 100 125 150 175 100 125 150 175
cfm 203 178 152 136 247 212 192 171 300 266 221 197
FAD - Free air
3
delivery m /
5.75 5.04 4.30 3.85 6.99 6.00 5.44 4.84 8.49 7.53 6.26 5.58
min
Unloading pressure psi.g 107 132 157 182 107 132 157 182 107 132 157 182
Nominal power supply 460V (+/-10%), 60Hz(+/-

- 208-230 / 460V (+/-10%), 60Hz(+/-5%), 3 Phase
conditions 5%), 3 Phase
Main motor rating hp 40 50 60
Type of motors (main drive &

- Squirrel Cage Induction-TEFC & Cooling Fan Integrated Motor
fan drive)
Insulation and
- Class F IP55
protection of main motor
Frame size /
- 324T/L/B35 326T / B35T 364/5T / B35T
mounting type
Type of starter for main
- Automatic Star Delta
motor
Maximum fan motor rating
hp 1.48 (1.1) - 208V-230V & 1.45 (1.1) - 460V X 2 1.45 (1.1) X 2
per fan X no. of fans
Rated speed of fan motor rpm 1400 (208V-230V) / 1480 (460V) 1480
Safety valve set pressure psi.g 205
Standard + VFD
Model - EG 30 EG 37 EG 45
Working pressure psi.g 100 125 150 175 100 125 150 175 100 125 150 175
cfm 203 178 152 136 247 212 192 171 300 266 221 197
FAD - Free air
3
delivery m /
5.75 5.04 4.30 3.85 6.99 6.00 5.44 4.84 8.49 7.53 6.26 5.58
min
Unloading pressure psi.g 107 132 157 182 107 132 157 182 107 132 157 182
Nominal power supply

- 460V (+/-10%), 60Hz(+/-5%), 3 Phase
conditions
Main motor rating hp 40 50 60
Type of motors (main drive &

- Squirrel Cage Induction-TEFC & Cooling Fan Integrated Motor
fan drive)
Insulation and
- Class F IP55
protection of main motor
Frame size /
- 324T/L/B35 326T / B35T 364/5T / B35T
mounting type
Type of starter for main
- Through Variable Frequency Drive
motor
Maximum fan motor rating
hp 1.45 (1.1) - 460V X 2 1.45 (1.1) X 2
per fan X no. of fans
Rated speed of fan motor rpm 1480
Safety valve set pressure psi.g 205
Technical data 4.1

5.0 Installation and operation
Contents Page No.

5.1. Installation and commissioning 5.2
5.1.1 Unpacking 5.2
5.1.2 Disposal of packing materials 5.2
5.1.3 Handling the compressor 5.2
5.1.4 Site requirements 5.2
5.1.4.1 Ventilation 5.3
5.1.5 Electricals 5.4
5.1.6 Air pipe dimensions 5.5
5.1.7 Receivers for compressed air systems 5.7
5.1.8 Possible mistakes 5.7
5.1.9 Commissioning procedure 5.7
5.1.10 Oil fill procedure 5.8
5.2. Preservation for long idle storage 5.9

5.2.1 Airend 5.9
5.2.2 Motor 5.9
5.2.3 Air-oil separator tank 5.9
5.2.4 Rubber hoses 5.9
5.3. Operating instructions 5.10

5.3.1 Initial start-up checks 5.10
5.3.2 Initial start-up 5.10
5.3.3 Pre-start checks 5.10
5.3.4 Starting 5.10
5.3.5 During running 5.10
5.3.6 Stopping 5.11
5.3.7 Changing the compressor settings 5.11
Installation and operation 5.1

5.1 Installation and commissioning
Before the new EG series compressor is operated for the

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

against the packing list. The compressor is shipped with
the following
 Key for doors
 Operation and maintenance manual
 Checklist of parts of the machine
 Electrical drawing
5.1.2 Disposal of packing material Figure 3. Lifting using crane

The wood/cardboard used to make the shipping crates of
NOTE
the EG series compressors are biodegradable.
Removal of transit brackets:
The polyethylene covers wrapped around the compressor
Once you have placed the compressor in its final position,
and the polystyrene packing provided around the electrical remove the red painted transit brackets and store for
panels are not recyclable. They must be disposed off in future use.
accordance with prevailing local environmental laws. Locations:
5.1.3 Handling  Bracket in between the base and airend support
 Bracket in between the base and motor
1. Lift compressors using either a forklift/pallet truck
 Bracket in between the shroud and control panel box
(Fig.2) or a crane (Fig.3).
2. When using a forklift, ensure padding is used in 5.1.4 Site requirements

between the compressor and forklift (as shown in Fig.2)
 Install the air compressor in a clean, dry, cool and dust
to prevent damage to the compressor’s canopy.
free room as extreme temperatures (hot or cold),
3. When using a crane, please ensure stiff spreader bars moisture, air borne contaminants can significantly affect
are used (as shown in Fig.3) to prevent rope slings from compressor performance, durability and compressed air
damaging the compressor’s canopy. quality.
4. Do not drop the compressor.  Be aware the entrance to the compressor room should
5. Do not attempt to move the compressor by pushing or be high enough and wide enough to carry the
dragging it as this may cause jerky movements causing compressor in and out.
damage to the compressor.  Leave a minimum of 1m (3.28ft) space around the
compressor for safe and proper inspection, cleaning,
and maintenance activities.
 Leave minimum of 2m (6.56ft) space above the

compressor for hot air to flow away from the
compressor.
 Ensure the compressor is protected against direct

sunlight and rain.
 Avoid exposing the compressor to excessive moisture

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

 Ensure the room temperature is within 50ºC (122ºF) as for installing your compressor. No special foundation or
high ambient temperatures can reduced oil life due to anchoring is necessary for rotary screw compressors.
higher discharge oil temperature (DOT). It also results  Do not store toxic, volatile, or corrosive agents near the
in high approach temperatures affecting cooling and
compressor.
condensation efficiency in the after-cooler and in air
 Isolate the compressor from corrosive agents like
treatment equipment like air dryers.
ammonia, chlorine, salt spray, and other chemicals as
 Ensure the hot medium of other utility equipments like
these may erode the internal components and also
genset/dryer/ boilers, etc., hot medium not sucked by contaminate the oil and filters.
compressor inlet or that in any way room temperature
 Do not allow hot air from additional equipment to blow
does not rise to prevent high discharge oil temperature.
towards the compressor.
 Ensure the ambient temperature does not drop below
 If you operate in high dust applications like rice mills,
0ºC (32ºF). Provide air supply openings and adjustable
cement, flour mills, etc., it would be necessary to clean
louvers to ensure that the minimum temperature does
and replace the filters more often.
not drop down below 0ºC (32ºF).
 Good practice is to have overhead lifting in the
 Ensure unevenness of the surface is within 6mm
compressor room to facilitate any major overhaul. If an
(0.25").
overhead hoist is not available, you should be able to
use a mobile crane or forklift truck in your compressor
room at a minimum.
MINIMUM 2 m (6.6 ft) CLEARANCE
5.1.4.1 Ventilation
CEILING  A part of electric energy to your compressor motor is
converted into heat and this heat must be removed
from the compressor room by suitable ventilation.
ELGi SCREW AIR
COMPRESSOR  The ventilation requirements of the compressor are
listed in Table 1.
 The ventilation requirements could be achieved by the

following methods.
 Natural ventilation is sufficient if the temperature rise in

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

the temperature rise inside the room (measured by a
thermometer near the air inlet pre-filter mesh) is rises
ELGi SCREW AIR above 5ºC (9ºF) .
COMPRESSOR
 Ventilation with ducts: Ensure hot air exhaust from the
WALLS OR
OTHER compressor is diverted through the ducts when installed
EQUIPMENTS in an enclosed area. (contact ELGi for ducting
requirements)
MINIMUM CLEARANCE, X=1 m (3.5 ft)  Provide openings on walls/partitions close to the air
suction side of the compressor.
Figure 5. Horizontal clearance around the  Provide exhaust openings close to the ceiling for hot air
compressor exit.
 If the floor is splashed frequently with water while  If more than four compressors are installed in a room,
cleaning, then place your compressor on a raised good practice is to provide ducting arrangements. This
concrete plinth 100 to 150 mm (4 to 6 inches) high. will avoid hot air recirculation.
 Ensure the compressor base makes 100% contact  Be aware hot air recirculation in the enclosed area will
directly with the floor. affect the compressor performance.
 Know that an industrial floor with level surface capable  Ensure the air velocity in the supply and exhaust ducts
of supporting the weight if the compressor is sufficient does not exceed 4 m/s (13 ft/s).
 Know air velocity is ascertained during commissioning

using an anemometer.
 Do not connect cool air inlet ducts directly to the

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

bellows connector between the duct and the compressor.
 Contact ELGi in case you need to provide a duct

connection or filter fitment on the compressor.
5.1.5 Electricals Ensure that only authorized service technicians perform

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

1. Supply power to the compressor through a dedicated
switch disconnected fuse (SDF) unit of a suitable rating
mounted within 5 m (16.4ft) of the compressor. (This
architecture lets you isolate the compressor).
2. Use HRC (high rupturing current) fuse instead of an

MCCB (moulded case circuit breaker) to avoid possible
contactor and motor failure.
3. Refer to Table 2 for fuse and cable specifications for

380/400/415 V, 50Hz, 3-Ph power supplies.
4. Do not use an MCB (miniature circuit breaker) because

the selection of contactors is based on Type-2 co-
ordination.
5. Connect the earthling line to the point provided on the

base frame at the side of the compressor and motor.
Earthing point
Power cable entry
Figure 8. Earthing line of compressor

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

NPS Pipe size/ Inside diameter (mm)
Volume Flow FAD 1 1/2 2 2 1/2 3 4
40.89 52.50 62.71 77.93 102.26
(m3/
(cfm) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi)
min)
0.8 28 0.01 0.09
0.9 32 0.01 0.11
1.0 35 0.01 0.13
1.2 42 0.01 0.19
1.4 49 0.02 0.25 0.01 0.07
1.6 56 0.02 0.32 0.01 0.09
1.8 64 0.03 0.40 0.01 0.11
2.0 71 0.03 0.49 0.01 0.14
2.2 78 0.04 0.58 0.01 0.17
2.4 85 0.05 0.68 0.01 0.20 0.01 0.08
2.6 92 0.06 0.79 0.02 0.23 0.01 0.09
2.8 99 0.06 0.91 0.02 0.26 0.01 0.11
3.0 106 0.07 1.03 0.02 0.30 0.01 0.12
3.5 124 0.10 1.37 0.03 0.39 0.01 0.16
4.0 141 0.12 1.75 0.04 0.50 0.01 0.21
4.5 159 0.15 2.18 0.04 0.63 0.02 0.26 0.01 0.09
5.0 177 0.19 2.65 0.05 0.76 0.02 0.31 0.01 0.11
5.5 194 0.22 3.16 0.06 0.91 0.03 0.37 0.01 0.13
6.0 212 0.26 3.71 0.07 1.06 0.03 0.44 0.01 0.15
6.5 229 0.30 4.30 0.09 1.23 0.04 0.51 0.01 0.17
7.0 247 0.35 4.94 0.10 1.42 0.04 0.58 0.01 0.20
7.5 265 0.39 5.61 0.11 1.61 0.05 0.66 0.02 0.22
8.0 282 0.44 6.32 0.13 1.81 0.05 0.75 0.02 0.25
8.5 300 0.50 7.07 0.14 2.03 0.06 0.83 0.02 0.28 0.01 0.07
9.0 318 0.55 7.86 0.16 2.25 0.06 0.93 0.02 0.31 0.01 0.08
9.5 335 0.61 8.69 0.17 2.49 0.07 1.02 0.02 0.35 0.01 0.09
10.0 353 0.67 9.55 0.19 2.74 0.08 1.13 0.03 0.38 0.01 0.10
15.0 530 1.42 20.22 0.41 5.80 0.17 2.38 0.06 0.80 0.01 0.21
20.0 706 0.69 9.87 0.28 4.06 0.10 1.37 0.02 0.35
25.0 883 1.05 14.92 0.43 6.13 0.15 2.07 0.04 0.53
30.0 1059 1.46 20.90 0.60 8.59 0.20 2.90 0.05 0.75
35.0 1236 0.80 11.43 0.27 3.86 0.07 0.99
40.0 1412 1.03 14.63 0.35 4.94 0.09 1.27
45.0 1589 1.28 18.20 0.43 6.14 0.11 1.58
50.0 1765 0.52 7.46 0.13 1.92
55.0 1942 0.62 8.90 0.16 2.29
60.0 2118 0.73 10.46 0.19 2.69
65.0 2295 0.85 12.13 0.22 3.12
70.0 2471 0.97 13.91 0.25 3.57
75.0 2648 1.11 15.80 0.28 4.06
80.0 2824 1.25 17.81 0.32 4.58
85.0 3001 1.40 19.92 0.36 5.12
90.0 3177 0.40 5.69
95.0 3354 0.44 6.29
100.0 3530 0.48 6.92
150.0 5295 1.03 14.64
Table 3. Global series – Air pipeline dimensions
2. In case the main delivery pipe is more than 100 m (330

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

5.1.7 Receivers for compressed air
systems
Receiver
Compressed capacity
applications
Volume On/Off control Modulation control
m3 ft3 m3/min cfm m3/min cfm
0.3 10.59 Up to 1.13 Up to 40 Up to 1.7 Up to 60
0.5 17.66 1.14 - 2.4 41 - 85 1.7 - 3.4 61 - 120
1.0 35.32 2.4 - 4.0 86 - 140 3.4 - 6.7 121 - 235
1.5 52.97 4.0 - 6.4 141 - 225 6.7 - 10.0 236 - 355
2.0 70.63 6.4 - 8.8 226 - 310 10.0 - 13.0 356 - 470
3.0 106.0 8.8 - 12.6 311 - 445 13.0 - 20.1 471 - 710
4.0 141.3 12.6 - 16.1 446 - 570 20.1 - 26.7 711 - 945
5.0 176.6 16.1 - 19.8 571 - 700 26.7 - 33.4 946 - 1180
6.0 211.9 19.8 - 24.0 701 - 850 33.4 - 40.0 1181 - 1415
7.0 247.2 24.0 - 28.0 851 - 990 40.0 - 46.7 1416 - 1650
8.0 282.5 28.0 - 32.0 990 - 1130 46.7 - 53.3 1651 - 1885
Table 4. Global series—Receivers specifications
c. Re-grease the main motor if the compressor is not

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

technician will fill in the document known as the
3. Air oil separator (check and replace)
commissioning report and the warranty card provided in
4. Oil this manual.
a. Check for any external / internal damages of the During commissioning any modification suggested by the
package. technician should be performed before the compressor is
b. Monger the main motor and fan motor should be ready for regular use. Else, warranty becomes void. In
mongered to find the winding insulation conditions if the case of change of operator other than the person trained,
compressor is not commissioned for more than 1 year the new operator should be trained before he is dedicated

for operating the compressor.
Fill oil in the oil tank up to over fill cap
5.1.10 Oil fill procedure
Initial oil fill procedure Initial fill
Close the oil filling plug
Check whether your compressor comes with oil filled. This
can be checked through the oil sight glass on the air oil
separator. If not, follow the oil filling procedure given
below. Run the compressor for 10 minutes,
until the thermostatic valve opens
Stop the compressor
OIL FILL PORT Unscrew the oil fill plug by 3 turns only
(OVER FILL CAP) so that any entrapped air inside the
tank will bleed out it. By doing this the
sump pressure drops to atmospheric
pressure before opening the oil fill plug
OIL SIGHT GLASS
Refill oil in the tank until max level

indicated on the tank sight glass
Figure 9. Oil filling and oil sight glass location on Second fill
air oil seperator tank
Close the oil fill plug
Oil level check
 The oil level should be half of the oil sight glass after
fumes settle down following shutdown. Restart the compressor
 Ensure that the oil level sight glass and eye vision are
parallel while checking the oil level to avoid parallax Sl. Model Volume Initial fill Second
error. No. of oil (gallons) fill (After
required cranking)
(gallons) (gallons)
EG 30,
1 5.3 3.7 1.6
EG 37
2 EG 45 6.6 5.0 1.6
NOTE
Refill oil in the tank if the level falls below the minimum
level

5.2 Preservation for long idle storage
If your compressor is going to remain unused for six  Check the air-oil separator tank.
months or longer, special measures must be undertaken to  Replace the oil filter element similarly.
ensure the protection of the following components
 Flush the tank, airend with compressor oil and replace
 Airend the separator element before using the compressor
 Motors again.
 Air–oil separator tank 5.2.4 Rubber Hoses

 Rubber hoses
Test Recommendations for
5.2.1 Airend
To prepare the airend for 6-month storage: Age Recommendations
 Remove the airend discharge hose/pipe coupling. Up to 3 Use without further testing
 Rotate the drive coupling three times so that the oil
present inside the airend comes out through the 3 to 5 years Use after representative samples are
discharge port.
 Block the discharge port completely. Use after representative samples are
 Remove the inlet rubber duct connected to the intake 5 to 8 years subjected to proof, impulse, and burst
valve of the air filter assembly. pressure tests and cold bend and
 Turn the intake valve flap and pour rust preventive oil Over 8 years Scrap
(use Castrol DWX 32 or an equivalent grade) into the
airend through the intake valve.
 Rotate the coupling five times by hand so that the rust

preventive oil spreads all over the bearings, seals and
other parts of the airend.
 Drain the rust-preventive oil by opening the discharge

port plug fully.
 Refit the hose/pipe coupling on the discharge port.
 Take care to ensure that all the openings are plugged

always to avoid dust entry.
 Rotate the compressor shaft once in 7 days and ensure

free rotation.
 Repeat the procedure every six months.
 For more details contact ELGi office or distributer

network.
5.2.2 Motor
To prepare the motor for 1-year storage:
 Check the insulation of the motor winding.
 Remove any moisture in the motor.
 Check junction box terminals for tightness of the wires.
 Apply grease on the motor bearings.
5.2.3 Air-oil separator tank

To prepare the air-oil separator for 2-year storage:
 Drain the oil from the seperator tank.
 Remove the entire tank from the compressor after

disconnecting it from all hoses, the tank top plate, the
minimum pressure valve outlet line, and control pulse
lines and control switches.
 Clean the tank using ELGi compressor clean flushing oil.

5.3 Operating instructions
 If all the inputs from contact switches, pressure and

temperature transducers are normal, the display will
Please adhere to the safety instructions provided at the indicate "READY''.
section 2.3.2 : Precautions during operations
 Press the ''START'' (green) button on the controller.
5.3.1 Initial start-up checks  Machines with an automatic star-delta starter will have
6 seconds changeover time from star to delta and
 Check whether the oil level in the tank is up to the
another 10-seconds delta-to-run delay.
specified level. If not, top up oil as per the oil fill
procedure given in the maintenance section. 5.3.5 During running
 Open all doors and visually check the compressor for To ensure seamless running:
abnormality. Make sure all connections are tight.
 Monitor the controller display and control panel
 Open the electrical panel door of the compressor and indicators regularly when the compressor is running.
check that the three phases and earth cables are
 Graphic warning display: This gives graphically the
connected securely. (L1, L2, L3, and PE wires)
location of fault.
 Check the necessary earthing line in the panel/
compressor base.
 Ensure that all condensate drains are connected

properly.
 For water cooled compressors, ensure that the water

inlet and outlet valves are opened. Also make sure that
the inlet and outlet water drain valves are closed.
 For water cooled compressors, ensure that the water

quality is maintained as specified by ELGi.
5.3.2 Initial start-up

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

than 5 seconds will damage compressor parts or even
cause total damage.
5.3.3 Daily start checks

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

 Oil filter warning: Indicates that the oil filter element  If there is any possibility of freezing exists, drain the
needs to be replaced. The compressor will not cooling system completely.
shutdown automatically in this situation.
 High discharge temperature warning: The

compressor will shutdown automatically and the  Isolate power supply before the discharge ball valve
warning light on the controller will glow when the closes.
discharge temperature exceeds the preset value of 110  Do not use the emergency stop switch for normal
stopping
± 5ºC (230 ± 9ºF).
 Main motor overload trip: The compressor will

5.3.7 Changing the compressor settings
shutdown when the main motor is overloaded and the
corresponding warning light will glow. Change the compressor settings using the tactile keypad
and LCD panel on the controller. (Refer to Neuron manual
 Fan motor overload trip: The fan motor has internal
to learn more about the control panel and how to interpret
thermal overload protection, which safeguards the fan
of the message.)
motor. If the fan motor trips discharge oil temperature
will be high and the compressor will trip . Refer the VFD setting procedure manual for VFD
operations.
 Reset button: This button must be pressed before
restarting the compressor after it has shutdown with a
warning. The machine must be restarted only after
taking necessary remedial measures.
 Safety valve: This valve relieves the pressure in the air

-oil separator tank when it exceeds the set pressure.
Refer “Technical data”.
 Reverse direction switch: If the motor rotates in the

wrong direction, the reverse direction switch detects
and, in turn, trips off the compressor.
 After reaching the maximum cutoff pressure the

pressure sensor senses the pressure and cuts off the
solenoid electrical supply.
Cutout pressure
Model Type
bar (psi)
EG 11 - Standard, Working pressure +
EG 45 Standard +VFD 0.5 (7)
Working pressure +
Standard
EG 55 - 1 (15)
EG 160 Working pressure +
Standard +VFD
0.5 (7)
5.3.6 Stopping
 Press the stop (Red) button in the controller. The
compressor will come to a halt within 10 seconds.
 In case of emergency, to stop the compressor, use the

emergency stop switch. Correct the fault, rotate
counterclockwise and unlock the emergency switch.
Then press the reset button before the next start.
 Do not use the emergency stop switch for normal

stopping.
 Isolate power to the compressor.
 Close the air discharge valve.
 For water cooled models, close the water inlet valve.

6.0 Maintenance
Contents Page No.

6.1. Maintenance 6.2
6.1.1 Maintenance intervals 6.2
6.1.2 Maintenance of individual components & systems 6.3
6.1.2.1 Pre filter 6.3
6.1.2.2 Air filter 6.3
6.1.2.3 Air oil Separator 6.3
6.1.2.4 Oil top up and oil changeover 6.4
6.1.2.5 Oil filter 6.6
6.1.2.6 Intake valve 6.6
6.1.2.7 Blow down valve 6.8
6.1.2.8 Minimum pressure valve 6.8
6.1.2.19 Thermal valve 6.9
6.1.2.10 Electrical motor greasing 6.9
6.1.2.11 After and oil coolers 6.9
6.1.2.12 Cooler prefilter accessory 6.10
6.1.2.13 Drive coupling 6.10
6.1.2.14 Moisture separator and auto drain valve 6.10
6.1.3 Use only genuine spare parts 6.12
6.2. Troubleshooting 6.13

6.3. Decommissioning, dismantling & putting out of service 6.18
6.3.1 Waste disposal 6.18
6.3.2 Dismantling the compressor 6.18
6.3.3 Decommissioning the compressor 6.18
6.3.4 Disposal of consumables and replaced parts 6.18
6.4. ELGi services 6.19

6.4.1 ELGi customer care system (ECCS) 6.19
6.4.2 ELGi genuine spare parts 6.19
6.4.3 Air audit 6.19
6.5. Appendix 6.21

6.5.1 Conversion tables 6.21
6.5.2 Torque values 6.22
6.5.3 Service log book 6.23
6.6. Disclaimers 6.24
Maintenance 6.1
6.1 Maintenance
6.1.1 Maintenance intervals

Frequency Part Remarks
Oil level Check
MOS condensate Check
Daily
Warning / alarms Check
Condensate in AOS tank Check
Pre filter ( air intake, cooler, control panel) Clean
Weekly
Air filter element Clean *
Pre filter Clean
1000 hours or 3 months #
Moisture drain Clean
Oil & after coolers - air cooled (External) Check & Clean
Oil filter Replace
2000 hours or 6 months #
Oil Sampling **
50 Hz motor - 2 pole grease Replace
Pre filter ( air intake, cooler, control panel) Replace
Air filter element Replace
Oil – Air lube XD / Air lube FG Replace
# Air-oil separator element – Air lube XD / Air lube FG Replace
4000 hours or every year
50 Hz motor ( 4 pole ) grease Replace
60 Hz motor ( > 25HP ) grease Replace
Return line sight glass / orifice / NRV Check & Clean
Return line strainer Check & Clean
Air-oil separator element - UT Synthetic Replace
Oil - UT Synthetic Replace
60 Hz motor ( ≤ 25HP ) grease Replace
Electrical connections Check
Drive coupling element Replace
Pipe coupling element Replace
Intake valve kit Replace
Actuator kit Replace
8000 hours or every 2 years # MPV kit Replace
BDV kit Replace
Solenoid valve Replace
Safety valve Replace
MOS-ADV kit Replace
Control line filter-ADV kit Check & Replace
Hoses and Fittings Kit Replace
Blow down adjustment kit Check & Replace
Oil & after coolers - water cooled (External) Check & Clean
# - Whichever comes first * - As per air filter clog indicator ** - For USA region only
Table 5. Maintenance intervals
NOTE
The above life time guidelines are applicable only to standard operating and regular maintenance conditions recommended in
this manual. In the event of changes in the conditions, consult ELGi.
Precautions
ELGi Air Lube ELGi Air Lube
Volume
A. If the compressor is kept idle UT Synthetic FG
 Isolate the power supply. 5 litres (1.3 gallons) 000998067 000998079
 Close the main air outlet valve. 20 litres (5.3 gallons) 000998068 000998078
 Drain the water from the condensate system. 210 litres (55 gallons) 000998069 000998077
 Close the inlet and outlet water valve. (applicable only Table 6. Compressor oil
for water cooled compressors)
Sl. No. Motor make Grease
B. If the compressor is kept idle for more than 6
1 ELGi ESSO Polyrex EPL
months
2 SIEMENS Unirex N3 ESSO
 Follow the above steps. 3 WEG MOBIL Polyrex EM
 Refer to the section “Preservation for long idle storage”. Table 7. Electric motor grease
Maintenance 6.2
Hold the pre-filter between the louvers and slide upwards
slightly until the pre-filter bottom edge is visible
Disconnect all the power at the source before attempt to
perform maintenance or make adjustment. 2. Slide Downward
6.1.2 Maintenance of individual When the pre-filter bottom edge is

visible, slant the pre-filter forward and
components and systems
slide it downwards away from the
Check all accessories independently to verify that they are compressor
functioning as required and replace their components as
3. Pull Forward
necessary. After maintenance restart the compressor
as mentioned in section “Operating instructions”. When the top and bottom edges of the
pre-filter are free from the compressor,
6.1.2.1 Pre filter move the pre-filter forward to remove
completely.
Suction pre filter cartridge insert

procedure.
For insert sequence procedure from 3-2-1
6.1.2.2 Air filter

PRE FILTER CATRIDGE If the air filter clog indicator shows a red colour (meaning
the blocked condition) then the air filter needs to be
PRE FILTER CATRIDGE PRE FILTER ELEMENT cleaned or replaced (if the stipulated life has elapsed).
FILTER HOUSING
Fig 11. Pre filter

FILTER ELEMENT
Pre work
 Switch off the compressor and disconnect power supply
FILTER HOUSING
to the compressor.
 Close the discharge end ball valve.

Figure 12. Air filter
 Release air oil tank pressure and allow the tank to cool
for a few minutes. Pre work
Requirements  Switch off the compressor and disconnect power supply
 Compressed air, new pre-filter element (if needed) to the compressor.
Maintenance  Close the discharge end ball valve.
 Switch off the machine.  Release air oil tank pressure and allow the tank to cool
for a few minutes.
 Refer to the pre-filter cartridge removal & insert
procedure. Requirements
 Hold or fix the pre-filter assembly in the cleaning area.  Compressed air, new filter element (if needed).
 Clean the pre-filter with compressed air at less than 2.5 Maintenance
bar.g (36.3 psi.g) from the reverse or back side of the  Unlock the mounting clips provided on the filter
pre filter cartridge. housing.
 In case of major dust/dirt accumulation in the pre-filter  Rotate and remove the filter element carefully.
element, wash with clean water or light detergent.
 Clean the filter using moisture free compressed air at
 Do not use any acidic/alkaline chemicals for cleaning. less than 2.5 bar.g (36.3 psi.g).
 Repeat this process based on dust  Clean from the inside to outside.
conditions or at regular periodic intervals.
 Remove the dust ejector from the filter housing cap and
Suction pre-filter cartridge removal clean it carefully.
procedure
 Show bright light from inner side of the filter element to
1. Slide Upward inspect for damage or holes that result in leaks. Light
Maintenance 6.3
will emerge from the holes, indicating their locations. In
case of damages replace the filter element
 Inspect all rubber sealing and their contact surfaces of

the housing. Faulty rubber sealing must be replaced
immediately.
 Return the dust ejector back in correct (bottom)

TOP PLATE
position.
GASKET
 Return the filter element back in position, assemble the
filter housing cap such that the dust ejector settles in
bottom position, and lock the assembly using the
mounting clips.
SEPERATOR ELEMENT
 Inspect and tighten all air inlet connections prior to
resuming operation (if necessary).
 Reset the air filter clog indicator.

TANK
 If a clean element is to be stored for later use, it must
be stored in a clean container.
Figure 13. Air oil separator
6.1.2.3 Air oil separator
 Remove the hex head bolt from the top plate.
Pre work
 Swivel the top plate of the air oil tank.
 Remove the separator element.
to the compressor.
 Scrap the old gasket material from cover and flange on
the air oil tank. While doing so, take care not to let the
 Release air oil tank pressure and allow the tank to cool scraps fall into the air oil tank
for a few minutes.
 Inspect and clean the air oil tank for rust and dirt.
Requirements
 Stick the new gaskets on to the separator element one
 Strap wrench, new separator element, clean cloth. on either side.
Maintenance  Replace the new separator element into the air oil tank,
 Relieve oil pressure from the air oil tank and all fluid taking care not to dent it against the tank opening.
lines with the help of safety valve  Reposition the Top plate and assemble it by using
 Disconnect all piping connected to the air oil tank fasteners. Torque: 120 N-m (88.5 lb-ft).
 Disassemble the separator element by rotating it  Reconnect all piping.

counter-clockwise cover to isolate the air oil tank from  Clean the return oil strainer before restarting the
the return lines, service line, etc. machine.
TOP COVER NOTE

The air-oil separator tank is tested according to standards.
SCAVENGING LINE
TUBE
Regularly have inspections performed in conformity with
local regulations.
SEPERATOR 6.1.2.4 Oil top up & oil change over

ELEMENT
Proper compressor maintenance and operation is crucial
for the lubricant to function properly and last till its
estimated rated oil hours. The oil product shelf life is of
minimum 3 years and maximum 5 years. Products should
be kept properly sealed in the original container. Once the
seal is broken, the above stated life span of the product is
no longer applicable. Products should be stored in proper
storage warehouse that is away from direct sunlight and is
not exposed to weather elements like rain, typhoon and
DISCONNECT ALL PIPE LINES/ snow storms. The products should also be stored away
TUBE LINES from any heat source, high humidity and moisture areas.
Maintenance 6.4
If drums are stacked on ground level, they should all be c. Refill the compressor with new compressor oil.
stacked horizontally with the bung openings arranged at
d. Send a sample** of the compressor oil to ELGi for oil
the 3 and 9 o’clock position. analysis after 300 hours.
ELGi recommends that once the seal is broken, all
**: Applicable only for USA.
products be used immediately. ELGi does not encourage
reuse or recycling of any leftover fluids due to
contamination hazard. ELGi will not warrant the quality of NOTE
the product once the original seal is broken. Also ensure  The cleaner is not recommended to run longer than 500
that the oils are not mixed up between brands and types. hours.
 Change the oil filter and oil separator after oil change
Please refer Material Safety Data Sheet (MSDS) for oil spill over.
handling and disposal procedures.
Pre work Step 3: Filling the oil
 Switch off the compressor and disconnect power supply a. Add fresh oil; fill it up to the oil fill plug. (initial fill)
to the compressor. b. Close the oil fill plug.
 Close the discharge end ball valve. c. Pour oil into airend, then restart the compressor.
 Release air oil tank pressure and allow the tank to cool d. Allow it to run for about 10 minutes.
for a few minutes. e. Stop the compressor.
Requirements
 New oil, flushing fluid (if needed)
NOTE
 The compressor is originally filled with a particular oil, if
you want to change over to other types of oil, perform
steps 1, 2 and 3.
 But if you want to change the oil but continue with the
same kind (same brand & type) perform steps 1 and 3
only.
 Ensure that you drain at least 90% of oil capacity of the OIL FILL PORT
compressor; if not the residual oil can contaminate new (OVER FILL CAP)
oil.
 Ensure no oil spills on anti-vibration mount during
maintenance.
OIL LEVEL SIGHT
Maintenance GLASS
Step 1: Draining
a. Remove drain plug from the bottom of the separator

tank and drain out all oil. Drain oil while the compressor
is warm. Figure 14. Air oil separator tank– oil drain
b. Remove the pipe and drain plug from bottom of oil
cooler. Then completely drain.
c. Disconnect all oil pipe work which could trap oil and
drain completely.
d. Drain oil from the airend discharge pipe after

dismantling it.
e. Drain oil from the airend by hand rotation.
Step 2: Flushing (Only for oil change over)
Check the air-oil seperator differential pressure.

To flush clean/non-varnished machines, using:
COOLER
Mineral/PAO/PAG oils
a. Fill the compressor with the ELGi cleaner (use the same
compressor oil fill volume) and run the compressor.
DRAIN PLUG
b. After 500 hours of running, drain the cleaner as per
Figure 15. Cooler oil drain
step 1.
Maintenance 6.5
f. Unscrew the oil filling plug after 5 minutes so that
residual pressure in the tank is vented out through the NOTE
bleed hole in the oil fill plug. Suspended particulate matter should be less than 150spm
to achieve the specified consumable life. Guarantee
g. Refill the tank up to the oil fill plug. (second fill) becomes void if the compressor is operated above its
intended pressure.
h. Restart the compressor.
6.1.2.5 Oil filter 6.1.2.6 Intake valve

The oil filter is fitted between the oil cooler and the airend
unit. The components of the oil filter assembly are shown
in the figure. This is a full flow filter with a pleated Valves should not be opened when pressure is applied.
element. To service this filter, order the consumables kit
(available with ELGi service personnel) The procedure for NOTE
complete servicing of this filter is as follows.
The maintenance of following parts (valves) demands
Pre work highly skilled authorized personnel. So, it is recommended
that an ELGi service engineer does the maintenance.
to the compressor.
Pre work:
 Release air oil tank pressure and allow the tank to cool to the compressor.
for a few minutes.
Requirements
 Strap wrench, new oil filter, O-ring, and clean cloth. for a 10-minutes.
Requirements :
 Soft cloth, grease, liquid cleaner, Allen keys, screw

driver, spanner, pressure gauge, service kit (if needed).
Procedure :
THERMAL VALVE BLOCK
ADAPTOR
Disassembly :
OIL FILTER  Remove the hoses connected to the intake valve

(Suction hose filter to intake valve pulse line, BDV line)
 Remove the intake valve
 Block the airend intake opening port, to avoid entry of

any foreign particles inside the airend
Servicing of intake valve
 Replace the service kits ( K2,K2/A,K2/B,K3,K2 block) in

case of any failure or damage. Refer exploded view.
Figure 16. Oil filter
Function test :
Maintenance
 Connect the pressurized air to the control block and test
Dismantling method of oil filter: smooth opening and closing of valve for several times
 Hold the filter shell and & rotate it counter - clockwise Reassembly of intake valve
by strap wrench
 Ensure intake valve mating place (adaptor plate) free
Assembly of new oil filter: from dust and foreign particles
 Ensure the O-ring of the filter is damaged free.  Clean if any dust and foreign particles present in intake
 Clean the seating surface with clean cloth valve mating place
 Apply a thin film of oil on the mating surface of the  Mount the intake valve on the adaptor plate (refer
O-ring. intake system)
 Return the filter to its original position and rotate it  Ensure presence of sealing ring at the bottom of intake
clockwise manually. After tightening, rotate it further by valve
hand for one and a half times  Reconnect the pulse line, BDV line and suction hose
 Ensure no oil leaks from the mating surface. areas must not be damaged.
Maintenance 6.6
CONTROL ELBOW FOR-
UNIT PULSE LINE
CONNECTION
ELBOW FOR-
BLOW DOWN VALVE LINE
CONNECTION
HOUSING
SOLENOID VALVE
Figure 17. Intake valve
S. Service
Part number Description Remark
no kit
1 K2 B009405770009 Spare kit block Refer spare kit detail
table for complete
B009405770010(30 kW)
2 K3 Body spare parts kit intake valve kit part
B009405770011(37 & 45 kW) number
Control block unit kit

3 K2 block B009405770007
(blowdown block kit)
Figure 18. Intake valve—Exploded view
Maintenance 6.7
 Then reassemble MPV replacement (for 45kW)
 Unscrew the head and replace the old parts with new
NOTE parts using service kit (K)
After completion of intake valve assembly in package,
ensure to verify the performance
Extreme caution should be taken while removing the cap

6.1.2.7 Minimum pressure valve or cover from the body because of the spring.
Pre work

to the compressor.
FLANGE ASSEMBLY—MPV TO
for a few minutes. COOLER
MPV
 Release the receiver tank and downstream pressure.
Requirements
 New MPV kit, allen key, grease. FLANGE ASSEMBLY—TANK TO MPV
Maintenance
MPV replacement (for 30 & 37kW) AUTOL TOP 2000
Dismantling
 Isolate MPV from air-oil tank to MPV flange assembly 1
and MPV to cooler flange assembly

2
 Remove plastic plug (1) and pull out round-headed pin
9 3
(2).
 Unscrew and remove threaded ring (3) and remove 4

10
washer (9).
 Take out spring (4) and circlip (10). 11
 Remove piston (5), check valve (7),spring (6) and O-

5
ring (11).
6
Cleaning and Lubrication
 Clean the piston work-surface and sealing seat with a 7

liquid cleaner.
 Grease the threads, piston work-surface and check 8
valve work-surfaces with autoltop 2000 (supplied in

service Kit).
 Take care not to damage the seat and sealing surfaces
MPV replacement (for 30 & 37kW)
Reassembly AUTOL TOP 2000
 Put O-ring (11) into lower housing groove. Place check

valve (7) with spring (6) centrally onto valve seat in
housing (8).
 Insert piston (5), circlip (10) and spring (4). Lay washer
(9) on spring (4) as shown in drawing.
HEAD
 Screw in threaded ring (3) to its original position and
secure it with round headed pin(2). Insert plastic plug
(1).
Figure 19. Minimum pressure valve
Maintenance 6.8
6.1.2.8 Thermal valve  Start the motor and let it run for a minimum of one
hour to expel any excess grease from the drain opening
Pre work
before re-installing the drain plug.
 Stop the motor and lock out the switch.
to the compressor.
 Re-install the drain plug.
 Put the motor back in operation.
for a few minutes. 6.1.2.10 After and oil coolers
Pre work
THERMAL VALVE
BLOCK  Switch off the compressor and disconnect power supply
to the compressor.
THERMAL VALVE
ELEMENT  Close the discharge end ball valve.
for a few minutes.
Requirements
 Pliers, allen keys.
Maintenance
Figure 20. Thermal valve
External surfaces:
Requirements  Isolate the machine from the service line
 Pliers, screw driver, new thermal valve element, new O-  Vent the separator tank pressure before attempting
ring. maintenance
Procedure  Open both the LH panel and cooler inspection cover
Replacing thermal Valve  Use compressed air below 2.5 bar/36.3 psi maximum to
clean the outer surface of the cooler. Supply a jet of air
 Remove the thermal valve element from the thermal
in the direction opposite to cooling airflow direction
valve block body
 After cleaning the outer surface of the cooler properly
 Inspect and clean seating area in the housing
close the cooler with a cleaning plate and an LH panel.
 Replace with a new thermal valve.
6.1.2.9 Electric motor greasing COOLER CLEANING

PLATE
FASTNERS
Pre work
LH PANEL
to the compressor.
for a few minutes.
Requirements
 Recommended grease, cleaning cloth, grease gun.
Procedure
COMPRESSED AIR JET
 Stop the motor and lock out the switch.
Figure 21. Cooler external surface
 Thoroughly clean the grease inlet fitting or plug. If the
motor has a plug, remove the plug and clean the inlet. 6.1.2.11 Cooler prefilter accessory (optional)
 Remove the drain plug and wipe out any hardened Cooler prefilter cleaning & maintenance instructions
grease.  Switch off the machine.
 Slowly pump the grease into the grease inlet until the  Lift upward & take out the cooler pre filter from the
new grease comes out of the drain plug. compressor.
 Hold or fix the prefilter assembly in the cleaning area.
Maintenance 6.9
 Repeat the process based on dust conditions or regular
periodic intervals.
6.1.2.12 Drive coupling
HUB
ELEMENT
COOLER PREFILTER
COOLER PREFILTER
HUB
Figure 23. Drive coupling
Pre work
to the compressor.
for a few minutes.
Requirements
 Spanners, new coupling element.
COMPRESSED AIR
Maintenance
Replacing the coupling element:
 Open the cooler side panel covers
 Open the coupling guard from the adapter ring .
 Remove the three coupling screws and slide coupling

element on the shaft spline to free the coupling element
 Replace the old coupling element with a new coupling
 element
COOLER PREFILTER
 Tighten the coupling screws to the specified torque
ELEMENT
 Assemble the coupling guard and cooler side panel

HANDLE
cover
 Inspect every three months to ensure screws stay tight.
6.1.2.13 Moisture separator and auto

drain valve
Pre work
MOUNTING HOOK
COOLER PREFILTER  Switch off the compressor and disconnect power supply
FRAME to the compressor.
Figure 22. Cooler prefilter accessory
 Clean the pre-filter with compressed air at less than 2.5
bar.g (36.3 psi.g) from the reverse / back side of the  Release air oil tank pressure and allow the tank to cool
cooler prefilter. for a few minutes.
 In case of major dust / dirt accumulation in the pre- Requirements

filter element, wash with clean water or light detergent.  Spanner, screw driver, player, caustic soda.
Do not rinse.
 Do not use any acidic / alkaline chemicals for cleaning.
Maintenance 6.10
Maintenance  Restart the machine and check for any leaks at the
Dismantling joints. If leaks occur, stop machine and wait for sump
pressure to drop to atmospheric pressure.
 Disconnect the pressure sensor line on top of the
moisture separator  Remove the O-ring as described above, and inspect and
clean it
 Manually drain the condensate by using the manual
discharge plug located at the bottom of the auto drain  Ensure that the mating surfaces are clean and refit the
assembly. O-ring
 Remove the moisture separator from the machine
 Remove the bottom housing from the top housing. Moisture separator may be heavy. Caution should be taken
 Remove the auto drain assembly from the bottom housing. while removing it from the machine.
Cleaning and replacement

NOTE
 Inspect the O-ring and replace it with new one in the
 Avoid damaging the housing when removing or
kit, if necessary tightening the moisture separator. Do not use a pipe
wrench. If necessary, use a locking strap clamp/wrench
 Clean the housing and all other inner parts
 Install the separator in a vertical upright position,
 Ensure the mating surfaces of the O-ring are clean and observing the correct direction of air
free from foreign particles
 The auto drain assembly is not serviceable and must be

replaced with new one if not functioning
Reassembly
 The vortex generator cone and the cyclone arrestor

need only to be tightened moderately by hand. Over-
tightening may lead to failure or damage. ELGi assumes
no responsibility for failure or damage resulting from
such incorrect installation.
 Reassemble the auto drain assembly with the bottom

housing and the bottom housing with the top housing
 Reassemble the moisture separator in the machine and

connect the all pipe lines, pressure sensing line, and drain line
CAP SCREW
PE WASHER
TOP HOUSING
O-RING HOUSING
VORTEX GENERATOR
O-RING (CONE) -VANE
VORTEX GENERATOR
-CONE
TIE ROD
MANUAL DISCHARGE
ARRESTOR
ARROW
DIRECTION
INLET FROM COOLER OUTLET

BOTTOM HOUSING
EXTERNAL AUTO
DRAIN
Figure 24. Moisture separator and auto drain valve
Maintenance 6.11
6.1.3 Use genuine spare parts
It is very important to use genuine spare parts, to ensures that your compressor work as new for its lifetime. Spurious
spares may seem less expensive initially, but they severely compromises on quality. Spurious parts will prove cost-
ineffective in the long run, and may even result in total damage of the machine or cause serious accidents. The table
includes certain critical spurious parts. It is not an exhaustive list, and you are strongly advised to avoid all other spurious
spares that this table does not cover. Be aware of the consequences of using spurious spares including but not limited to the
ones described in the table.
Effect Spurious part Remarks
Due to dense filtration media, it creates in additional pressure drop and so causes
Higher power Air oil separator additional power consumption. Every1 bar (14.5 psi) of pressure drop results in ~7%
consumption additional power consumption.
Spurious oil loses its properties soon and may get solidified causing the rotor to
Lubricant
malfunction.
This imposes 10% additional resistance for air flow and creates more pressure drop
and thus additional load on motor. Inadequate separation deteriorates air quality,
Air oil separator
reduce the performance, and damages downstream components. It also results in
huge oil loss (1L / 200hr).
Reduced
Contaminants are not filtered properly and the contaminated oil affects the critical
performance
parts of airend. Thus it reduces performance and life (33% reduction) of the air end,
Oil filter
air oil separator etc. Contaminated oil also cause clogging and reduces the cooler
performance.
Dust carries over to the system and causes the same problems as caused by the
Air filter
spurious oil filter
Inadequate earthing can cause a separator to collapse (25% risk). Inadequate

Safety hazard Air oil separator
earthing can also cause fire and destroy the entire machine.
Higher power consumption means a higher operating cost.

Reduced performance leads to extra functioning and operating cost.
Spurious parts will damage the other components and accelerate maintenance
Cost
frequency and cost.
Higher consumption of consumables like oil (due to the use of spurious parts) will
result in, increased cost.
Maintenance 6.12
6.2 Troubleshooting
This guide lists the most likely indications with possible causes. For any problem, follow the diagnosis in sequential order as
mentioned in the following charts. Before doing any work in the compressor, be sure that electrical supply has been cut off
and the entire compressor is depressurized.
Problem Cause Solution (go sequentially)
Power supply not available Restore incoming power supply
(1) Correct the incoming voltage.
(2) Ensure isolator is within 5m (16 ft) from the compressor.

Incoming voltage is below limit
(3) Ensure sufficient power back up
(4) Select and use the correct cable size.
Emergency stop switch in pushed

Rotate counterclockwise direction and release
condition
Clean or replace the emergency switch.

Emergency stop switch malfunction
Tighten the wires at terminals
(1) Select correct fuse rating from selection chart.
(2) Check and correct the short circuit within the control
panel.
Isolator fuse blown.
(3) Dedicated isolator to be provided to the compressor.
(4) Check and correct the motor winding/ body short after
megger test.
Correct incoming voltage.

Incoming phase-to-phase voltage
Adjust main incoming transformer tapping.
imbalance of more than 5V
Compressor not
Correct the power factor to less than unity.
starting
Incoming phase to earth voltage
Correct the incoming voltage.
imbalance of more than 5V
Control MCB malfunction Replace MCB
Check for any short circuit or loose connection.
Control fuses inside compressor Replace the solenoid valve / control transformer if defective.
control panel blown
Replace the glass fuse (2A for Neuron, 1A for the control
circuit).
Replace the control transformer if defective.

Control transformer fuse blown Replace glass fuse (0.25A for Neuron, 0.5A for the control
circuit).
(1) Replace control transformer fuses.
No power supply to Neuron (2) Ensure tight connection of the 24V power supply connector
controller. to Neuron
(3) Replace control transformer (50VA).
(1) Replace the control transformer (50VA).
(2) Replace the control fuse.

No display in Neuron controller
(3) If 24V power supply to Neuron is okay then replace with
anew Neuron micro controller.
Maintenance 6.13
(1) Check and refill oil to correct the level. (in stopped
condition)
(2) Refer diagnosis procedure for high oil carry over.

Oil level is low
(3) Arrest oil leaks
(4) Ensure the correct grade of oil is used.
Room temperature is higher than

outside ambient temperature by Improve ventilation in compressor room
30°C (86°F)
Clean the cooler assembly / cooler pre filter mesh (if

available) externally by first using a fibre brush and then
blowing compressed air at 2.5 bar.g(36.3 psi.g).
Oil cooler clogged externally

For sticky dust, remove the cooler, close all the cooler ports
with dummy plugs and do a water-wash with soap oil.
Install the cooler prefilter mesh.
Check and correct the wiring connection to the cooling fan.

Cooling fan rotating in wrong
direction.
Replace with correct fan type.
Replace the fuse if blown.

Check fan motor fuse
Replace with the 2A fuse.
Cooling fan not working. Check and ensure the neutral connection is connected.
High discharge
oil temperature Replace the sensor.
Temperature sensor malfunction
Tighten/recrimp the connection with adaptor.
Replace oil filter.

Oil filter clogged
If required replace the oil (based on the condition of oil) and
run the compressor.
Thermal valve malfunctioning Replace the thermal valve element.
Clean the oil injection orifice.

Oil injection orifice chocked or
improper size
Replace with correct size.
Air filter clogged Clean or replace the air filter
Check pressure drop is less than 1bar (14.5 psi).
Separator element clogged Replace oil.
Replace separator element.
Poor quality of oil Replace oil.
Check for pressure drop across the oil cooler if less than 1.5
bar (22 psi).
Check and clean the cooler internally with 20L of isopropyl

Oil cooler clogged internally alcohol + toluene mixture in the 1:1 ratio and circulate for 4
hours with external 1 HP pump.
Refit the cleaned cooler and, if required, replace oil (based on

condition of the oil) and run the compressor.
Maintenance 6.14
Drain excess oil and maintain the recommended oil

High oil level
level.
Oil is milky Replace oil and maintain the recommended level.
1) Remove the return line NRV/orifice and clean it

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

Scavenge return line tube clogged
tube.
Scavenge return line tube gap not Remove the return line tube from
maintained (not applicable EG11 to EG22) the separator and correct it.
The spin-on separator internal pipe thread

Replace the internal pipe.
damaged (applicable to EN series)
High oil carry over High discharge oil temperature (DOT) Refer to the diagnosis procedure for high DOT.
Improper grade of oil Use ELGi recommended Air lube oil.
Separator punctured/collapsed (not

Replace with new separator.
applicable to EG11 to EG22 units)
Separator element bonding ruptured

Replace with new separator.
(not applicable to EG11 to EG22 units)
1) Use suitable higher capacity compressor or match

Compressor runs at lower pressure than demand to compressor capacity.
normal pressure.
2) Arrest all line leakages.
Minimum pressure valve (MPV) opening

earlier than at the specified opening
pressure* 4.5 bar.g (65.26psi.g). Replace MPV kit/assembly.
* 3.5 bar.g ( 50.8 psi.g) for compressors
with working pressure 4.5 bar.g
Neuron microcontroller pressure settings:
1) Unload pressure set value is above
Check and correct the unload pressure and high tank
specification.
pressure values in Neuron micro-controller
2) High tank pressure set value is below
specification.
1) Check and replace intake valve kit if required.
2) Check the solenoid valve and clean or replace if

Intake valve malfunction
required.
3) Check and replace the actuator kit if required.
BDV malfunction Check/replace

High tank pressure
Compressor started with air outlet ball
Open the outlet ball valve.
valve closed
Check the solenoid valve and clean or replace if

Solenoid valve malfunction
required.
Neuron microcontroller malfunction Replace the Neuron microcontroller
Pressure transmitter malfunction Replace the pressure transmitter
MPV stuck up (check with pressure gauge in

Replace the MPV kit.
AOS tank )
Separator element choked Replace the separator element
Maintenance 6.15
No control air supply to solenoid valve Replace / connect
1. Replace the solenoid valve assembly

Solenoid valve malfunctioning
2. Clean the orifice
No electrical supply for energising the

Replace the Neuron microcontroller
solenoid valve
Intake valve malfunctioning Check and replace the intake valve kit.
1. Clean or change BDV assembly.

Blow-down valve malfunctioning
2. Clean the orifice.
1. Check and change the MPV kit.

MPV malfunctioning
2. Check and change the MPV assembly
1. Check and reset the pressure regulator setting to

Pressure regulator (applicable only to EG 55
working pressure+0.3 bar (4.35 psi).
to EG 250) setting lower than working
pressure
2. Change the pressure regulator assembly.
Loading/unloading
Problem
Actuator failure (applicable only to EG 55 to
Check and change the actuator / kit / assy.
EG 250)
1. Air requirement is more than compressor

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

application pressure. 2. Arrest all pipeline leakages.
3. Excess pressure drop in pipe line.
1. Tighten the lap cable
2. Replace the lap cable

Pressure transmitter malfunction
3. Replace the pressure transmitter
4. Replace the Neuron microcontroller
Malfunction of R04 relay (loading/ unloading

Replace the Neuron microcontroller
relay) in Neuron microcontroller
Unload mode enabled in Neuron Disable 'unload mode' in operator settings of the
microcontroller Neuron microcontroller
Maintenance 6.16
Clean/change pre-filter mat by following these steps:

Switch off the machine.
Squeeze and pull out the pre-filter mat from the
Inlet air pre-filter mat clogged
canopy.
Clean pre-filter with compressed air at less than 2.5
bar /36.3 psi Refit the filter after cleaning.
Clogged air filter element Clean/change air filter element.
1. Air requirement is more than compressor

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

application pressure. 2. Arrest all pipeline leakages.
3. Excess pressure drop in pipe line.
No control air supply to solenoid valve. Replace / connect the control line tubes.
1. Replace the solenoid valve assembly

Solenoid valve malfunctioning
2. Clean the orifice

Pressure not built
up
No electrical control supply to solenoid valve Replace the microcontroller
Intake valve malfunctioning Check and replace intake valve kit.
1. Check and change the BDV assembly.

Blow down valve malfunctioning
2. Clean the orifice.
1. Check and change the MPV kit.

MPV malfunctioning
2. Check and change the MPV assembly
1. Check and reset pressure regulator setting

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

Check/change actuator / kit / assembly.
EG 250)
Replace separator element. If required, replace the

Separator element choked (increase in
oil (based on condition of the oil) and run the
pressure drop across separator)
compressor.
Maintenance 6.17
6.3 Decommissioning, dismantling and
putting out of service
If you do not intend to use the compressor or any of its 6.3.4 Disposal of consumables and
parts, you must dismantle and putting out of service. replaced parts
These tasks must be carried out in compliance with the
standards in force of that particular country.  The moisture condensate separated from the
compressed air contains oil particles. Disposal of
6.3.1 Waste disposal condensate and filter element is to be done in
 Use of compressor generates waste. The residues from accordance with the pollution control norms prevailing
agricultural, industrial, crafts, commercial and service at the time of compressor installation or use.
activities must be treated as waste, which needs to be  Parts of the compressor that are replaced have metal
disposed off properly. Deteriorated or obsolete and rubber components. These may be recycled and
machines are also classified as waste. disposed off according to pollution control regulations,
 Special attention must be given to active carbon filters respectively.
as they cannot be included in urban waste. Observe the  Rubber items such as AVMs, coupling elements, and O-
waste disposal laws in force where the compressor is rings should be disposed and replaced before running
used. again.
 It is mandatory to record loading or unloading of
NOTE
exhausted oils, obsolete machines and toxic harmful
wastes that derive from heavy or light industry ELGi is not responsible for the disposal of old oil or
condensate. It is the responsibility of customer to dispose
processes. of the foregoing in accordance with local environmental
 It is especially important that exhausted oils be statutory laws.
disposed off in compliance with the laws in the countries
of use.
6.3.2 Dismantling the compressor The compressor does not give any warnings during short
operating times. If it is operated below the dew point and
 Dismantle the compressor in accordance with all the moisture condensate may mix with oil. This will reduce the
precautions imposed by the laws in force in the country lubricating quality of the oil and lead to damage of
compressor.
of use.
 Before dismantling, request an inspection by the

relevant authorities. Disconnect the compressor from
the electrical system.
 Eliminate any interfaces the compressor may have with

other machines, making sure that interfaces between
remaining machines are unaffected.
 Empty the air oil tank containing the lubricating oil and
store in compliance with the laws in force.
 Proceed with the disassembly of the individual

compressor components and group them together
according to the materials they are made of: Steel,
Stainless Steel, Aluminium and plastic parts.
 Then scrap the machine in compliance with the laws in

force of the country of use.
6.3.3 Decommissioning the compressor

 Remove the foundation for the compressor.
 Unplug the power cable entry to the compressor.
 Drain the oil from the cooler and air oil tank. Dispose of
it properly.
 Make sure all the compressed air is vented out through

ball valves and safety devices residing in the
compressor.
 Ensure that all the external supply lines have been

properly disconnected from the compressor before
decommissioning.
Maintenance 6.18
6.4 ELGi Services
6.4.1 ELGi customer care system (ELGi  Southern Region: Tamil Nadu, Karnataka, Kerala,
Puducherry, Andhra Pradesh, Telangana, Andaman &
CCS)
Nicobar Islands.
ELGi provides dedicated customer care and after-sales
 Western Region: Maharashtra, Gujarat, Madhya
support through the ELGi customer care system (CCS), a
Pradesh, Goa, Lakshadweep Islands.
computerized system developed in-house. The CCS aims
to minimize the time taken to resolve customer  Eastern Region: Orissa, Chhattisgarh, Jharkhand,
complaints. West Bengal, Bihar and the North-Eastern states.
Service requests/complaints  Northern Region: Rajasthan, Uttar Pradesh, Delhi,

Haryana, Punjab, Uttaranchal, Himachal and Jammu &
The CCS toll-free telephone number 1800-425-3544
Kashmir.
(accessible within India through BSNL and MTNL lines)
takes the customer’s call to our centralized customer care Contact Numbers: You can contact CCS also with the
center in Coimbatore. Customers can register their service following numbers:
requirements or complaints here. Telephone: 0422-2589206 / 241 / 242 / 243/ 244 / 245 /
A unique tracking number is generated for each call logged 97900 21100
by the CCS. The customer receives an automatic e-mail Fax: 0422-2589240
acknowledgement with the tracking number and details of
Please send the following details to the mail, thus enable
the call for reference.
us to take immediate action.
A service engineer is assigned to the call, and the date and
1. Name of the customer
time of the engineer’s visit are communicated to the
customer by e-mail. Every requirement or complaint must 2. Compressor model
be resolved and closed in the CCS within a specified time 3. Fab. number
limit, failing which the complaint is automatically brought
4. Contact person name
to the notice of the manager. If the issue remains
unresolved, it will get escalated to the managing director. 5. Phone number
The CCS ensures that not only the customer complaints 6. Nature of complaint
are logged but they are also attended to on time, every 7. Hour meter reading
time.
You may use the CCS by sending e-mail to: ccs@elgi.com
Enquires
Customer satisfaction survey
A number of calls received by the CCS relate to customer
If you have used the CCS, you may be contacted for your
queries regarding products and spare parts. The details
feedback on our after-sales support. Your response helps
are noted, and basic information on product specifications
ELGi to improve its service.
and usage are provided. The caller is then referred to a
salesperson at the head office or the appropriate branch International customers:
for follow-up. Refer contact information at the end of this manual book.
The CCS database
6.4.2 ELGi genuine spare parts
The CCS also creates a database of customers, adding
When ordering spare parts, refer to the lists provided in
details of every new customer who calls, thereby building
the parts manual and identify the part number. Specify the
a large pool of installation details. These details are used
part number and quantity, in addition to the name plate
to provide value-added services to improve customer
details. Global support center of ELGi ensures the supply
satisfaction with ELGi products.
of the quality spares on time. Ensure that you are using
CCS-working hours the genuine spare parts so that your Compressor will be
The ELGi CCS works for six days a week from 08:30 to working efficiently and effectively. Refer to section 6.1.3
21:30 IST (Monday to Saturday). for details on need of using genuine spares.
Multi-lingual capability Please contact our After sales team for any compressor
accessory requirements like VFD, Air-Dryer, etc.
The coordinators at the CCS are multi-lingual. They can
handle calls in English and all the major regional 6.4.3 Air audit
languages of India.
We extend our proven capabilities in energy efficiency
Coverage: The CCS toll-free number 1800-425-3544 is initiatives by carrying out air audits for our customers.
accessible from the following areas:
ELGi conducts audits and trains end users in key energy
oriented functional areas. The audit reports prepared by
ELGi experts’ team include recommendations on short,
Maintenance 6.19
medium and long term measures for energy conservation,
along with financial estimates and analysis for
implementation.
This air audit objective is to provide the customer:
 The framework for systematic collection of data relevant

to the efficient operation of compressed air systems.
 A thorough analysis about the performance of the

compressed air system, identifying potential electricity
savings and to provide sound recommendations for
implementation of energy efficiency initiatives.
Data analysis will be comprised of the information about

different areas such as air leakages, inappropriate use of
compressed air, compressed air system network,
compressed air system supply including compressor
internal maintenance conditions and even more.
The final report issued to the customer end will serve

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

requirements from the customer end, the intensity in level
of audit (base level or investment level) will be decided.
Also post implementation monitoring after air audit will be
provided if requested from the customer end.
For further information on air audit contact ELGi.

E-Mail: ccs@elgi.com
Maintenance 6.20
6.5 Appendix
6.5.1 Conversion tables

Description From To Multiply by
Inches Millimetres 25.4
Metres Inches 39.37
Feet Millimetres 304.8

Length (L)
Metres Feet 3.281
Inches Thou 1000
Millimetres Micrometres 1000
Square metres Square feet 10.765
Area (A) Square feet Square inches 144
Square inches Square millimetres 645.16
Cubic metres Cubic feet 35.315
Cubic feet Cubic inches 1728
Cubic metres Litres 1000

Volume (V)
Cubic feet Litres 28.32
US gallons (liq) Litres 3.785
Imperial gallons (liq) Litres 4.546

3
Cubic feet per minute (cfm) Cubic metres per hour (m /h) 1.6988
Cubic feet per minute (cfm) lpm 28.32

Volumetric flow (Q)
Cubic metres per hour (m3/h) lpm 16.667
3
Cubic metres per minute (m /min) lps 16.667
Kilograms Pounds 2.205
Kilograms Grams 1000

Mass (M)
Kilograms Ounces 35.27
2
kg f/cm g psi g 14.223
psi g Pascal 6895

2
Pressure (P) bar g kg f/cm g 1.0197
bar g psi g 14.503
psi g kg f/cm2 g 0.0703
Degree Celsius (°C) Degree Fahrenheit (°F) °F = 9(°C)/5 +32
Temperature (T) Degree Celsius (°C) Kelvin (K) K = °C + 273.15
Degree Fahrenheit (°F) Degree Rankine (°R) °R = °F + 460
ft-lb f Joules 1.35582
ft-lb f Btu 0.001285

Heat (q), Work (W),
Joules Calories 0.2388
Energy (E)
Btu/h Calories/h 252
Kilowatts Btu/h 3411
Metric horsepower Kilowatts 0.7355

Power (P)
Imperial horsepower Kilowatts 0.7457
Table 8: Conversion table
Maintenance 6.21
6.5.2 Torque values
The tightening torque values for bolts and screws used in ELGi Compressors are provided in this section for reference. The
tolerance for the torque values is (-) 10% from the given value.
Thread size* Tightening torque (N-m) Tightening torque (lb-ft)
M4 2.9 2.13
M5 5.7 4.20
M6 9.8 7.22
M8 24 17.7
M10 47 34.66
M12 81 59.73
M16 197 145.28
M20 385 283.93
Table 9: Metric hexagonal head bolts and screws
Thread size (inches) Tightening torque (N-m) Tightening torque (lb-ft)
¼" 45 33.19
½" 85 62.69
¾" 170 125.38
1" 330 243.39
1¼" 430 317.15
1½" 510 376.15

Table 10: BSP threads
Thread size (inches) Tightening torque (N-m) Tightening torque (lb-ft)
9/16" 149 109.8875
7/8" 579 427.0125
Table 11: UNF threads
* Property class of 8.8 only
Maintenance 6.22
Total Moisture Trip
Oil level Pre
operated Line System Discharge removal Cooler record Operator
Date From Till in AOS Filter Comments
hours / pressure pressure temperature from AOS cleaning descrip- sign
tank Cleaning
day tank tion
Maintenance
Low/
Start/Stop normal/ Before
Time high/ starting
change
6.5.3 Service log book – record of maintenance
6.23
6.6 Disclaimers
Please read this document and the warranty terms accompanying the product carefully before using our product.
By purchasing our product, you agree that you will assume total responsibility and risk for your use of the product.
The warranty terms of the product have been provided separately.
1. ELGi is not liable for failure of the compressor ( hereinafter “compressor” or “product”) to perform its obligations if such
failure is as a result of Acts of God (including but not limited to fire, flood, earthquake, storm, hurricane or other natural
disaster), war, invasion, act of foreign enemies, hostilities (regardless of whether war is declared), civil war, rebellion,
revolution, insurrection, military or usurped power or confiscation, terrorist activities, nationalization, government
sanction, blockage, embargo, labour dispute, strike, lockout or interruption or failure of electricity or telephone service
and any other reasons beyond ELGi’s control.
2. ELGi does not take responsibility for any damage or injury resulting from neglecting the safety instructions, warnings,
cautions, precautions, or non-observance of the normal caution and care required for installation, operation, maintenance
and repair of the product, even if not expressly stated, and such instances are specifically disclaimed by ELGi.
3. The entire literature including product description or any other information in this manual exclusively belongs to ELGi and
is subject to copyright. No person has any right to copy, modify, distribute, transmit, display, perform, reproduce, publish,
license, create derivative works, transfer or sell any information, or deal with the same in any other manner, without the
knowledge and written concurrence of ELGi, violation of which would amount to infringement of rights of ELGi and would
necessitate legal action.
4. The information published in this manual may include inaccuracies, or typographical errors. Changes may be periodically
added to the information herein. Any changes/improvements may also be made to the products stated in this manual and
ELGi is not liable if the readers are not updated with information.
5. Likewise ELGi is responsible only till the point of first sale to the ultimate customer and not thereafter and only if the
product is purchased from authorized dealers of ELGi. ELGi disowns liability on account of purchase of any second hand
product or purchase otherwise from unauthorized dealers. ELGi shall not be liable for any indirect, incidental, punitive,
special or consequential losses or damages including any loss of profit, loss of production, loss of income or contract, loss
of goodwill, expected savings or business relationships, arising out of or in any way connected with the usage of the
product or information in this manual.
6. In no event ELGi shall be liable for any claims or loss having a value higher than the original purchase price of the product
sold by ELGi or its network of authorised dealers.
7. These Disclaimers and the contents of this manual shall be subject to the laws of India and any disputes pertaining to this
manual or anything stated therein or any product stated therein is subject to the exclusive jurisdiction of the courts in
Coimbatore, Tamil Nadu, India.
8. No liability in connection with the product will accrue to ELGi,
 If any welding or related operation involving heat is carried out in the compressor. Never weld or modify any parts
including pressure vessels.
 If any damages to the product directly or indirectly arise due to long storage (6 months) of product and subsequent
corrosion of internal parts and which leads to fire or malfunctioning of the product.
 If the compressor package and its accessories are installed in such a way to allow moisture, rain, freezing temperature or
sun damage to affect the safe operation of the unit.
 If the person who operates / maintains the compressor does not adhere to all work related safety practices and regulatory
requirements.
 If unauthorized personnel other than ELGi authorized or trained personnel carries out commissioning, installation,
operation, maintenance and any repair work on the compressor.
 If the compressor and the compressed air are used for unintended use or are misused.
 If the compressor is operated below or in excess of its pressure and temperature limits.
 If the compressor “ON/ OFF” switch is operated through remote control situated away from the compressor location
without giving any adequate notice / alarm before starting the product .
© Copyright ELGi Equipments Limited, India 2018. All Rights Reserved.
Maintenance 6.24
3 2 1 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1
R10 R9 R8 R7 R6 R5 R4 R3 R2 R1
X08
X07 X06 X05
X02 X03 X04

RS 485 RS 485
2B
1B
2A
1A
2 4 6 8
2 4 6 8 10 2 4 6 8 10 12
X01 1 3 5 7
1 3 5 7 9 1 3 5 7 9 11
P N
PE
CN
CN
CN
CN
X04
NC A1
1
2
RS 485
NC B1
3
4
NC A2
5
6
RS 485
NC B2
7
8
CONNECTION DETAILS
X03 X02
1
2
1
2
3
4
3
4
5
6
5
6
7
8
7
8
9
10
9
10
11
12

Elgi EG SERIES MANUAL

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Elgi EG SERIES MANUAL

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Product Manual

Part / Document No. 019000165

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

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

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

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

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

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

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

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

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

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

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

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

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

Chapter Page No.

2.0 General functional description 2.1

3.0 GA drawing, P&I diagram 3.1

4.0 Technical data 4.1

5.0 Installation and operation 5.1

6.0 Maintenance 6.1

7.0 Controller 7.1

8.0 Air inlet and control system 8.2

9.0 Drive system 9.1

10.0 Discharge system 10.1

11.0 Cooling system 11.1

12.0 Lubrication system 12.1

13.0 Base and canopy system 13.1

14.0 Spare kit details 14.1

15.0 Electrical drawings 15.1

16.0 VFD setting details 16.1

Toll free : 1800 425 3544

Contents Page No.

2.1 Using the manual 2.2

2.2 Introduction 2.3

2.3.2 Precautions during operation 2.5

2.3.3 Precautions during maintenance 2.7

2.4 Functional description 2.9

2.4.2 Oil circuit 2.9

2.4.3 Drive system 2.9

2.4.4 Control system 2.10

General functional description 2.1

This operation and maintenance manual has been

 Troubleshooting – identification and solving the

 Appendix – conversion tables, torque values, service

This manual must be made available to the

General functional description 2.2

Uptime  Zero-leak flanged joints.

The screw compressor technology ensures that output

General functional description 2.3

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

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

 For remotely controlled compressors and auto-start

 Danger! Be aware that compressed air used for

General functional description 2.4

 Insulate or use protective guards to cover pipes or other