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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. To reach Regional Office/Head Office of ELGi within seven days of commissioning date.
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Table of Contents Chapter Page No. About ELGi General functional description GA drawing, P&I diagram Specification sheet Installation and operation Maintenance Controller Drive system Cooling system 10.0 Base and canopy system 10.1 11.0 Airend system 11.1 12.0 Spare kit details 12.1...
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Need help…? 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.
General functional description Contents Page No. 2.1 Using the manual 2.1.1. Definitions and symbols 2.2 Introduction 2.3 Safety 2.3.1 Precautions during installation 2.3.2 Precautions during operation 2.3.3 Precautions during maintenance 2.4 Functional description 2.4.1 Air circuit 2.4.2 Oil circuit 2.4.3 Drive system 2.4.4 Control system 2.10 General functional description...
Installation and commissioning - all site continuous process in ELGi. The details in this manual are requirements, procedures to be followed during likely to change without notice and ELGi reserves the right to installation, commissioning, preservation etc. incorporate such changes.
Introduction EN SERIES compressors ship in a compact design and are Welcome to the ELGi customer family. ELGi compressors self-contained. The absence of reciprocating parts helps are the source of compressed air in various segments the compressor run without noise or vibration. The across the globe.
Safety Ensure the operator is located far away from the intake The operator must follow the safe working practices, of the compressor. instructions, procedures that this manual describes for 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’.
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.
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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.
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 ...
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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.
Functional description Figure 1. Screw compressor systems - Schematic diagram 2.4.1 Air circuit Atmospheric air enters into the airend through the air The oil separated and collected in this element is then intake system. The intake filters (pre filter and air filter) returned to the airend through the scavenging line.
valve opens and the compressor starts loading. This ensures very little starting load. Next, the intake valve opens and the system starts building up pressure. Anti- 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.
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Technical data Standard Model EN 30X EN 37 Working pressure psi.g FAD - Free air delivery /min 5.63 4.81 4.30 3.79 7.05 5.86 5.41 4.84 Unloading pressure psi.g Nominal power supply 208-230 / 460 (+/-10%), 60Hz (+/-5%), 3 phase conditions Main motor rating Type of motors (main drive &...
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Installation and operation Contents Page No. 5.1. Installation and commissioning 5.1.1 Commissioning procedure 5.1.2 Unpacking 5.1.3 Handling the compressor 5.1.4 Site requirements 5.1.5 Ventilation and exhausting hot air 5.1.6 Electricals 5.1.7 Air pipe line 5.1.8 Oil filling procedure 5.1.9 Procedure for changing oil the compressor during service 5.1.10 Direction of rotation 5.2.
Always use slings and not the 5.1.1 Commissioning lifting bail to airlift compressors by helicopter. Before you operate the new EN series compressor for the first time, install it at your site according to ELGi’s Installation specifications.
Neither install the machine in a location where flame is CEILING used nor place any inflammable objects near the compressor. ELGi SCREW AIR Ensure the room temperature is within 45 C (113 F), as COMPRESSOR high ambient temperatures will result in reduced oil life due to higher discharge oil temperature (DOT).
460V 60Hz 3ph power supplies appear in the table To eliminate transmission of vibrations, provide a soft below. bellows connector between the duct and the Electricals 50Hz compressor. Incoming Contact ELGi in case you need to provide a duct Recommended Incoming aluminium Model pre-connected copper cable connection or filter fitment on the compressor.
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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. If the compressor had...
Shut off the compressor. Ensure sump pressure drops to atmospheric pressure Procedure for filling oil in a newly assembled machine Dismantle the joining plate and drain oil from the oil tank through the drain ball valve Open the oil fill cap Fill oil in the oil tank up to the over-fill cap Drain oil from the cooler through the drain plug Close the oil filling plug...
Operation sections of this manual to know more about the fault. If you hear any abnormal noise when you run the compressor, switch it off immediately and contact the ELGi service engineer. Follow all above points when you reinstall the compressor at a different location.
Preservation for long idle storage 5.2.4 Disposal of packing If you do not intend to use the compressor for a prolonged period, take special measures to ensure the protection of The wood used in the shipping crates of the Encap series the following components: compressor is biodegradable.
Operating instructions 5.3.4 Starting and normal operation 5.3.1 Safety system and interlocking mode device When you switch on the machine, the motor runs in DOL/ 5.3.1.1 Discharge temperature sensor star delta mode. Within a few seconds, the inlet valve This sensor enables the dryer to shut down the opens and the compressor starts loading.
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6.3.2 Dismantling the compressor 6.13 6.3.3 Decommissioning the compressor 6.13 6.3.4 Disposal of consumables and replaced parts 6.13 6.4. ELGi services 6.14 6.4.1 ELGi customer care system (ECCS) 6.14 6.4.2 ELGi genuine spare parts 6.14 6.4.3 Air audit 6.15 6.5. Appendix 6.16 6.5.1 Conversion tables...
Table 2. Maintenance intervals NOTE The above lifetime 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. Follow the above steps. Precautions Refer to the section “Preservation for long idle storage”.
Show bright light from inner side of the filter element to inspect for damage or holes that result in leaks. Light Disconnect all the power at the source before attempt to will emerge from the holes, indicating their locations. In perform maintenance or make adjustment.
3 and 9 o’clock position. ELGi recommends that once the seal is broken, all products be used immediately. ELGi does not encourage reuse or recycling of any leftover fluids due to TOP PLATE contamination hazard.
(available with ELGi service personnel) The procedure for c. Refill the compressor with new compressor oil. complete servicing of this filter is as follows. d. Send a sample** of the compressor oil to ELGi for oil Pre work analysis after 300 hours.
Valves should not be opened when pressure is applied. NOTE The maintenance of following parts (valves) demands highly skilled authorized personnel. So, it is recommended that an ELGi service engineer does the maintenance. Pre work: Switch off the compressor and disconnect power supply to the compressor.
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ELBOW FOR- CONTROL PULSE LINE UNIT CONNECTION ELBOW FOR- BLOW DOWN VALVE LINE CONNECTION HOUSING SOLENOID VALVE Figure 17. Intake valve Service Part number Description Remark B009405770009 Spare kit block Refer spare kit detail table for complete B009405770010(30 kW) intake valve kit part Body spare parts kit number B009405770011(37 &...
6.1.6 Minimum pressure valve Pre work Switch off the compressor and disconnect power supply to the compressor. Close the discharge end ball valve. Release air oil tank pressure and allow the tank to cool for a few minutes. ...
Start the motor and let it run for a minimum of one hour to expel any excess grease from the drain opening 6.1.7 Thermal valve before re-installing the drain plug. Pre work Stop the motor and lock out the switch. ...
Switch off the machine and allow the belts to cool 6.1.10 Belt maintenance sufficiently. The belts must be tensioned regularly in order to avoid Check the belt tension again. compressor efficiency loss, belt slippage, and belt failures. Repeat the belt tensioning procedure to set the belts up The belts are re-tensioned once every 2000 hrs.
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Belt and pulley data DRIVE TABLE : EN30X & EN37 60HZ Belt & Pulley Sl. No 30X-100 30X-125 30X-150 30X-175 37-100 37-125 37-150 37-175 parameters Drive pulley pitch circle diameter Driven pulley pitch circle diameter Type of belt Pitch length of belt 1257 1320 1482...
6.1.12 Condensate drain in tank If the duty cycle of the compressor (running hours) per day is less than 16 hours, check for water condensation in the air oil separator tank. When the compressor switches off, the hot air inside the tank might condense when the surrounding temperature lowers.
6.1.14 Use genuine spare parts It is very important to use genuine spare parts, to ensures that your compressor work as new for its life- time. Spurious spares may seem less expensive initially, but they severely compromises on quality. Spuri- ous parts will prove cost-ineffective in the long run, and may even result in total damage of the machine or cause serious accidents.
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.
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Problem Cause Solution (go sequentially) (1) Check and refill oil to correct the level (in stopped condition). (2) Refer to the 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 the compressor room.
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Replace the internal pipe. 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 Replace with a new separator. Separator element bonding ruptured Replace with a new separator.
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Problem Cause Solution (go sequentially) No control air supply to solenoid valve Replace/connect 1. Replace the solenoid valve assembly. Solenoid valve malfunctioning 2. Clean the orifice. No electrical supply for energizing the Replace the Neuron microcontroller. solenoid valve Intake valve malfunctioning Check and replace the intake valve kit.
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Clean/change the 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 the pre-filter with compressed air at less than 7 bar g. Refit the filter after cleaning. Clean/change air filter element Clogged air filter element 1.
It is mandatory to record loading or unloading of NOTE exhausted oils, obsolete machines, and toxic harmful ELGi is not responsible for the disposal of old oil or wastes that derive from heavy or light industry condensate. It is the responsibility of the customer to processes.
If you have used the CCS, you may be contacted for your CCS-working hours feedback on our after-sales support. Your response helps ELGi to improve its service. The ELGi CCS works for six days a week from 08:30 to 21:30 IST (Monday to Saturday). 6.4.2 ELGi genuine spare parts Multi-lingual capability When ordering spare parts, refer to the lists provided in The coordinators at the CCS are multi-lingual.
We extend our proven capabilities in energy efficiency initiatives by carrying out air audits for our customers. 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,...
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) 2.13...
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.
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Controller Manual Neuron XT Version 3.0 January 2018...
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Contents Page No. Abbreviations used 7.1. Technical specification 7.2. Installation instruction 7.2.1 Equipment’s safety 7.2.1.1 Static discharge warning 7.2.1.2 Assembly 7.2.1.3 Electrical connection 7.2.1.4 Power supply 7.2.2 General instruction 7.3. Front view 7.3.1 Terminal connection 7.4. Neuron-XT salient features 7.4.1 Home screen display 7.4.2 Records (view->...
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Contents Page No. 7.7.3.1 Calibration (offset) 7.16 7.7.3.2 Relay 7.16 7.7.3.3 Temperature 7.16 7.7.3.4 Auto drain valve 7.16 7.7.3.5 Maintenance 7.16 7.7.3.6 Self-test 7.16 7.7.3.7 Unload mode 7.16 7.7.3.8 Digital input 7.17 7.7.4 Customer care 7.17 7.8. Data interface 7.17 7.9.
Technical specification The following are the specifications that you must be familiar with for Neuron XT Definition : Pre programmed logic controller Function : Compressor control system Part number : 018362887 Working voltage : 19 to 28.8 VAC Power consumption : 10W (Max) Display : Monochrome graphics LCD (128 x 64)
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3Phase detection Phase loss /phase reverse detection before starting the compressor Communication ports Protocol : MODBUS RTU protocol Mounting : 128 x 99 mm - Panel Mounting overall dimensions : : 172 x 123x 80 mm Regulatory : CE, UL Operating temp : -10 ~ 50°C (14 F ~ 122...
7.2.2. General instruction 7.2.1. Equipment’s safety Observe the following procedures and instructions closely ELGi conduct thorough checks of the device before delivery to avoid damage to the control panel and its associated according to the prescribed tests of the inspection scheme.
Input output description 7.5.1 X01: Power supply Function state 24V AC Phase 24V AC Neutral 7.5.2 X02: Digital inputs Function Active state Digital inputs common 24VDC 24VDC emergency stop Emergency Fault if open Main motor Overload MMOL Fault if open Cooler Motor overload Cooler OL Fault if open...
7.5.5 X05: Single phase detector Function state R- Phase R - 120 Deg Phase Diff Y - Phase Y - 120 Deg Phase Diff B - Phase B - 120 Deg Phase Diff Controller Manual 7.10...
Main screen For more details refer machine settings in operator Discharge pressure at 0.1bar / 1psi resolution menu. Oil temperature at 1°C / 2°F resolution Trip or machine status like Run, Load, Unload, Standby etc., Warning messages ...
Message 3 - Compressor warning message Warning Description Warn temperature When discharge temp. exceeds the set warn temperature (Default is 105°C) Change oil filter When service remaining Hr. reaches 0000 Change air filter When service remaining Hr. reaches 0000 Change oil When service remaining Hr.
Menu structure Press any one of the following keys ∆ and ∇ to enter main menu 7.7.1 Main Menu Dis. Pr : 0.0 bar / 0 psi Dis. Tr : 25°C / 77°F Status View Operator Service Factory Customer care 7.7.1.1 Operator LEVEL 1 LEVEL 2...
7.7.1.3 View Service Time LEVEL 1 LEVEL 2 LEVEL View Service time Remaining AFCT: X X X X X hours Remaining OFCT: X X X X X hours Remaining OSCT: X X X X X hours Remaining OCT: X X X X X hours Remaining RGT: X X X X X hours Remaining Valve kit: X X X X X hours 7.7.1.4 View Cumulative Time...
Option Default Unit Warn RST second Star second second second Standby minute DCS Port Type Modbus Baud 9600/19200 9600 Parity None/Even/Odd None Length 7 / 8 Stop bit 1 / 2 *Auto Drain Valve (ADV) Off time minute On time Second Load / Unload Source LD / UL Source...
Password required. Item Option Default Unit NOTE 90°C 60°C 85°C Any setting changes should be made by an ELGi authorized (194° Temp (140°F) (140°F) service engineer only. Any attempt to change service settings by unauthorized people may lead to compressor Inhibit °C...
Unload or spp function. Default: Remote Load/Unload 7.7.4 Customer care If customer enter into the customer care menu, this message will appear URL: www.elgi.com E-mail: ccs@elgi.com 7.8 Data interface DCS port is Modbus RTU type. It enables you to interface with the generic DCS.
Troubleshooting Failure symptoms Possible causes Remedies No input supply Check incoming supply to compressor No display in LCD Please check the controller input voltage at connector Screen & Backlight was Transformer failure X01. Voltage should be 24V ± 15% VAC. not glown Controller failure.
7.10 Construction Plastic enclosures IP65 polyethylene front keypad Inputs and outputs through terminal block Front plate cutout dimensions 154 x 105 mm Enclosure dim 7.10.1 Dimension drawing PANEL CUTOUT DIMENSION 7.11. Revision Details Version Date Changes 02/03/2015 Initial Draft...
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Compressor Warning messages Warning Description Warn temperature When discharge temp. exceeds the set warn temperature (Default is 105°C) Change oil filter When service remaining Hr. reaches 0000 Change air filter When service remaining Hr. reaches 0000 Change oil When service remaining Hr. reaches 0000 Change grease When service remaining Hr.
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PARTS MANUAL EN SERIES ELECTRIC POWERED SCREW AIR COMPRESSOR EN 30X, EN 37...
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8.0 Air inlet and control system [ Ref : 015315272—X016550] Parts Manual...
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8.0 Air inlet and control system [ Ref : 015315272—X016550] Description Qty. Part Number AIR FILTER ASSY B004704620010 WASHER PLAIN M8 000996058 BOLT HEX M8X40 000906119 Rubber Connector 015402321 Flexible Hose B010406260004 Rubber Connector- 015402320 SS WORM CLAMP B005000530005 Intake valve B009800780008 NC INTAKE VALVE ADAPTOR 015310563...
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9.0 Drive system [ Ref : 015310622—X015310 ] EN 37– 100 PSI Parts Manual...
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9.0 Drive system [ Ref : 015310622—X015310] Description Qty. Part Number B001406190018 Structure assy 015309887 WASHER PUNCHED M10 000996059 WASHER SPRING M10 000996110 BOLT HEX M10X20 000906143 Electic Motor B005106400078 WASHER PLAIN M16 000996016 WASHER SPRING M16 000996116 BOLT HEX M16X55 000906217 AIREND MTG BRACKET FRONT 015309128...
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10.0 Discharge system [ Ref : 015310612—X015300 ] EN 30, EN 37 Parts Manual 10.1...
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10.0 Discharge system [ Ref : 015310612—X015300 ] Description Qty. Part Number PIPE ASSY AE TO TANK 015317592 O-RING ID69.4 X 3.5 010453920 WASHER SPRING M12 000996112 BOLT HEX M12X30 000906183 AOS TANK EG22-45KW 015318382 BOLT HEX M12X35 000906184 WASHER SPRING M12 000996112 Separator E30-E45 B006700770013...
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11.0 Cooling system [ Ref : 015310616—X015304 ] EN 37 Parts Manual 11.1...
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11.0 Cooling system [ Ref : 015310616—X015304 ] Description Qty. Part Number Cooler assy B012900690011 FAN WITH MOTOR 018400046 BOLT HEX M8X25 000906116 WASHER PLAIN M8 000996008 WASHER SPRING M8 000996108 Parts Manual 11.2...
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12.0 Lubrication system [ Ref : 015315274—X016552 ] EN 37 Parts Manual 12.1...
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12.0 Lubrication system [ Ref : 015315274—X016552 ] Description Qty. Part Number O-RING ID37.7 X 3.5 015402283 PIPE TANK TO TVB 015318151 WASHER SPRING M12 000996112 WASHER;PLATE;M12 000996060 BOLT HEX M12X30 000906183 WASHER SPRING M8 000996108 BOLT HEX M8X30 000906117 O-RING ID32.9 X 3.5 015402685 HEX ADAPTOR 1"UNFXM24...
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13.0 Base and canopy system [ Ref : 015310618—X015306] EN 37 Parts Manual 13.1...
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13.0 Base and canopy system [ Ref : 015310618—X015306] Description Qty. Part Number PILLAR ASSLY FRONT 015309109 PILLAR ASSLY REAR 015309110 REAR PANEL 015309112 SUCTION SIDE PANEL ASSLY 015309116 CONTROL PANEL BOX ASSLY 015309117 SHROUD ASSLY 015310094 COOLER ANGLE RH 015309120 COOLER ANGLE LH 015309121...
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Spare kit details Consumables kit details S. No Description Part Number Qty. Temperature sensor 018400079 Pressure transmitter 00897902N Intake valve kit B009405770005 Blow down valve kit B009405770007 Solenoid valve kit-24 V/50-60Hz B009405770014 012473729 (8000 Hrs Service kit) S. No Description Part Number Qty.
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012474059 012474079 012474069 S. No Description Part Number Qty. Hose assy TVB to Cooler kit 012474059 Hose assy Cooler to TVB kit 012474069 Hose assy TVB toAirend kit 012474079 Kit Details 12.2...
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