Product Manual EN Series Electric Powered Screw Air Compressor EN 4 - 125 208 - 230/460V, 3Ph, 60Hz
© ELGI EQUIPMENTS LIMITED Coimbatore, TN - 641 005 Part / Document No. 019000271 Contact Info: ELGI EQUIPMENTS LIMITED Coimbatore, Tel : Fax : Fax : E-mail : Website : TN - 641 005, India 91 - 422 2589555 91 - 422 2573697 (Domestic Business) 91 - 422 2589401 (International Business) enquiry@elgi.com www.elgi.
Machine Identification and Sale Record Owner’s name / Company name : ……………………………………………………………………………………………………… Phone number : ……………………………………………………………………………………………………… Contact person : ……………………………………………………………………………………………………… E-Mail address/ Phone number : ……………………………………………………………………………………………………… Model : ……………………………………………………………………………………………………… Fab. No.
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 Specification sheet 4.1 5.0 Installation and operation 5.1 6.0 Maintenance 6.1 7.0 Controller 7.1 8.0 Drive system 8.2 9.0 Cooling system 9.1 10.0 Base and canopy system 10.1 11.0 Airend system 11.1 12.0 Spare kit details 12.1 13.0 Electrical drawings 13.1 14.0 Branch address 14.1 1.
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.
2.0 General functional description Contents 2.1 Using the manual 2.1.1. Definitions and symbols Page No. 2.2 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 General functional description 2.10 2.
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.
2.2 Introduction Welcome to the ELGi customer family. ELGi compressors EN SERIES compressors ship in a compact design and are are the source of compressed air in various segments self-contained. The absence of reciprocating parts helps across the globe. the compressor run without noise or vibration.
2.3 Safety The operator must follow the safe working practices, instructions, procedures that this manual describes for safe operation. The maintenance personnel must be Ensure the operator is located far away from the intake of the compressor. 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.
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 inclined surface, contact ELGi.
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.
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 minimizes the risk of creating a current path through Ensure that the compressor is cooled down before maintenance is performed. the heart. Conduct repairs only in a clean, dry, well-lit and ventilated area.
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 airoil 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.
2.4 Functional description Figure 1. Screw compressor systems - Schematic diagram 2.4.1 Air circuit The oil separated and collected in this element is then Atmospheric air enters into the airend through the air passes through a minimum pressure valve (MPV). It intake system. The intake filters (pre filter and air filter) prevent the entry of foreign particles (such as dust) into the airend.
vibration mountings reside below the airend and the motor. This configuration reduces the transmission of vibration from both the airend and motor to the structure, reducing noise and ensuring reliability of the parts mounted on the structure. 2.4.4 Control system Depending on the demand for compressed air from the application at a particular time, the compressor needs to respond accordingly. The compressor, therefore, operates in either loading or unloading mode to meet this requirement.
15 M M M 9 M M LEGEND M
4.0 Technical data Standard Model Working pressure FAD - Free air delivery - Nominal power supply conditions Main motor rating Type of motors (main drive & fan drive) Insulation and protection of main motor EN 3 EN 4 EN 5 psi.g 125 150 125 150 100 125 150 175 100 125 150 175 cfm 9.9 8.8 13.5 13.1 21.7 19.3 17.2 15.4 29.9 26.5 24.2 21.0 0.28 0.25 0.38 0.37 0.61 0.55 0.49 0.44 0.85 0.75 0.69 0.
5.0 Installation and operation Contents 5.1. Installation and commissioning Page No. 5.2 5.1.1 Commissioning procedure 5.2 5.1.2 Unpacking 5.2 5.1.3 Handling the compressor 5.2 5.1.4 Site requirements 5.3 5.1.5 Ventilation and exhausting hot air 5.4 5.1.6 Electricals 5.4 5.1.7 Air pipe line 5.5 5.1.8 Oil filling procedure 5.7 5.1.9 Procedure for changing oil the compressor during service 5.7 5.1.10 Direction of rotation 5.8 5.2. Preservation for long idle storage 5.9 5.2.
5.1 Installation and commissioning 5.1.1 Commissioning Before you operate the new EN series compressor for the bail machine using slings. Always use slings and not the lifting bail to airlift compressors by helicopter. first time, install it at your site according to ELGi’s Installation specifications. ROPE / SLING For safe operation of the compressor, the servicing technician performs a series of checks on the compressor STIFF SPREADER BAR and the systems to which the compressor connects.
5.1.4 Site requirements Neither install the machine in a location where flame is Install the air compressor in a clean, dry, cool, and dust free room as extreme temperatures (hot or cold), moisture, and airborne contaminants can significantly affect compressor performance, durability, and compressed air quality. Be aware the entrance to the compressor room should be high enough and wide enough to carry the used nor place any inflammable objects near the compressor.
Guidelines to compressor ventilation setup: Follow these guidelines when providing ventilation for the compressor: Provide openings close to the floor level on walls/ partitions close to the air suction side of the compressor Provide exhaust openings close to the ceiling for hot air exit. Ensure the air velocity in the supply and exhaust ducts does not exceed 13.1ft/s (4m/s). Determine air velocity during commissioning using an anemometer.
7.5 kW 25 4/0.15 6/0.25 fault. 11 kW 32 6/0.25 10/0.4 If you hear any abnormal noise when operating the 15 kW 50 10/0.4 16/0.6 compressor, switch it off immediately and contact the ELGi service engineer. Earthing Follow all above points when you need to reinstall the Verify the total power supply requirements provided on the compressor at a different location.
Volume Flow FAD (m3/ min) 0.8 0.9 1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 8.5 9 9.5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 150 NPS Pipe size/ Inside diameter (mm) 2 2 1/2 3 52.50 62.71 77.93 1 1/2 40.89 (cfm) (bar) (psi) 28 32 35 42 49 56 64 71 78 85 92 99 106 124 141 159 177 194 212 229 247 265 282 300 318 335 353 530 706 883 1059 1236 1412 1589 1765 1942 2118 2295 2471 2648 2824 3001 3177 3354 3530 5295 0.01 0.01 0.01 0.01 0.02 0.02 0.03 0.03 0.04 0.
5.1.8 Oil fill procedure Shut off the compressor.
5.1.10 Direction of rotation Check the direction of rotation of the main motor when starting the compressor for the first time. You do this by switching on the compressor and switching it off within 5 sec. Press the green start button to power on and the red mushroom stop button to power down the compressor. The motor must rotate in the clockwise direction when viewed from the main motor cooling fan side.
5.2 Preservation for long idle storage If you do not intend to use the compressor for a prolonged period, take special measures to ensure the protection of the following components: 1. The airend 5.2.4 Disposal of packing The wood used in the shipping crates of the Encap series compressor is biodegradable. The polyethylene covers wrapped around the compressor 2. The motor and the polystyrene packing provided around the electrical 3. The air oil sump or receiver tank panels are not recyclable.
5.3 Operating instructions 5.3.1 Safety system and interlocking 5.3.4 Starting and normal operation device mode 5.3.1.1 Discharge temperature sensor When you switch on the machine, the motor runs in DOL/ This sensor enables the dryer to shut down the opens and the compressor starts loading. compressor if the discharge oil temperature mixture star delta mode. Within a few seconds, the inlet valve reaches a preset value of 230°F (110°C) ± 41°F (5°C). It 5.3.
6.0 Maintenance Chapter 6.1. Maintenance Page No. 6.2 6.1.1 Maintenance intervals 6.2 6.1.2 Daily operation 6.2 6.1.3 Air oil separator element (spin on type) 6.3 6.1.4 Oil filter (spin on type) 6.3 6.1.5 Oil cooler 6.3 6.1.6 Belt maintenance 6.3 6.1.7 Belt replacement 6.4 6.1.8 Belt and pulley data 6.4 6.1.9 Oil level check 6.6 6.1.10 Service procedure for minimum pressure valve 6.6 6.1.11 Service procedure for thermal valve 6.6 6.1.12 Condensate drain in tank 6.7 6.1.
6.1 Maintenance 6.1.
6.1.3 Air oil separator element (spin on type) AIR OIL SEPERATOR OIL FILTER Apply a thin film of oil on the mating surface of the gasket. To disassemble the existing air oil separator Switch off and isolate the machine from the service line. Vent air oil separator tank pressure and allow the tank to cool for a few minutes. Hold the air oil separator outer shell by the removed strap belt and rotate it counterclockwise, until it completely unscrews.
Loosen the lock nut mounted in the belt tension bolt. Screw the tension bolt clockwise. 6.1.8 Belt and pulley data Procedure for assembling taper lock bush Check the belt tension. Clean and de-grease the bore and taper surfaces of the bush and the tapered bore of the pulley. Step Insert the bush in the pulley hub and line up the 1 holes. (Half thread holes must line up with half straight holes.) Tighten the lock nut. Switch on the machine and verify running. 6.1.
Drive table DRIVE TABLE : EN2 - EN5 60HZ Sl. No Belt & Pulley parameters UOM 2.2 125 2.2 150 3.0 125 3.0 150 4.0 100 4.0 125 4.0 150 4.0 175 5.5 100 5.5 125 5.5 150 5.
DRIVE TABLE : EN7 - EN15 60HZ Sl.
Remove and discard O-rings 5 and 6. 6.1.14 Anti Vibration Mount Remove nipple 7. Anti Vibration Mount should be replaced during major overhaul of airend or motor. If no such situation, replace Remove parts 4 and 3. Replace parts 3 and 4 with new parts from the service AVM every 5 years kit. Replace nipple 7. Replace the new O-rings 5 and 6. Apply teflon grease on O-rings 5 and 6. Reassemble the complete valve. 6.1.
6.2 Troubleshooting This guide includes the most likely problems with possible causes. In case of a problem, follow the diagnosis in sequential order as mentioned in the following charts. Before performing any work in this unit, be sure to cut off electrical supply, depressurize the entire compressor, and isolate the unit. Problem Cause Power supply not available Solution (go sequentially) Restore incoming power supply. (1) Correct the incoming voltage.
Problem Cause Solution (go sequentially) (1) Check and refill oil to correct the level (in stopped condition). Oil level is low (2) Refer to the diagnosis procedure for high oil carry-over. (3) Arrest oil leaks. (4) Ensure the correct grade of oil is used. Room temperature is higher than outside ambient temperature by 30°C (86°F) Improve ventilation in the compressor room.
Problem Cause Solution (go sequentially) High oil level Drain excess oil and maintain the recommended oil level. Oil is milky Replace oil and maintain the recommended level. Scavenge return line tube clogged Remove and clean the clogged scavenge return line tube. Replace the internal pipe. 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.
Problem Cause No control air supply to solenoid valve Solution (go sequentially) Replace/connect 1. Replace the solenoid valve assembly. Solenoid valve malfunctioning 2. Clean the orifice. No electrical supply for energizing the solenoid valve Replace the Neuron microcontroller. Intake valve malfunctioning Check and replace the intake valve kit. 1. Clean or change the BDV assembly. Blow-down valve malfunctioning 2. Clean the orifice. 1. Check and change the MPV kit. MPV malfunctioning 2.
Problem Cause Solution (go sequentially) Clean/change the pre-filter mat by following these steps: Switch off the machine. Inlet air pre-filter mat clogged Squeeze and pull out the pre-filter mat from the canopy. Clean the pre-filter with compressed air at less than 7 bar g. 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 application pressure 1.
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 put it out of service. These replaced parts tasks must be performed in compliance with the standards in force of that particular country. 6.3.1 Waste disposal Use of the compressor generates waste.
6.4 ELGi Services 6.4.1 ELGi customer care system (ELGi CCS) ELGi provides dedicated customer care and after-sales support through the ELGi customer care system (CCS), a computerized system developed in-house. The CCS aims to minimize the time taken to resolve customer complaints.
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.
6.5 Appendix 6.5.1 Conversion tables Description Length (L) Area (A) Volume (V) Volumetric flow (Q) From To Inches Millimetres 25.4 Metres Inches 39.37 Feet Millimetres 304.8 Metres Feet 3.281 Inches Thou 1000 Millimetres Micrometres 1000 Square metres Square feet 10.765 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 Cubic feet Litres 28.
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.
Date Maintenance Till Start/Stop Time From Total operated hours / day Line pressure System pressure Discharge temperature Moisture removal from AOS tank Before starting Oil level in AOS tank Low/ normal/ high/ change Pre Cooler Filter cleaning Cleaning Trip record description Comments Operator sign 6.5.3 Service log book – record of maintenance 6.
Maintenance 6.
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.
01 83 6303 5 (POWER CIRCUIT) CONTROL PANEL - 3PH 208-230V/460V 60HZ
01 83 6303 5 (CONTROLLER CIRCUIT) CONTROL PANEL - 3PH 208-230V/460V 60HZ
01 83 6303 5 (BILL OF MATERIALS) CONTROL PANEL - 3PH 208-230V/460V 60HZ
COMPONENT LAY OUT 01 83 6303 5 (COMPONENT LAY OUT) CONTROL PANEL - 3PH 208-230V/460V 60HZ
