ELGi EN 30X-100 Operation, Maintenance And Parts Manual Download Page 6

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Chapter

Page No.

1.0

About ELGi

1.1

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

8.1

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

Table of Contents

Summary of Contents for EN 30X-100

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Page 3: ...Product Manual EN Series Electric Powered Screw Air Compressor EN 37 100 208 230 460V 3Ph 60Hz...

Page 4: ...Document No 019000744 Print Status Jan 2018 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 Bu...

Page 5: ...pressure bar g psi g Date of delivery Date of commissioning Dealer name address Dealer s signature The warranty on the compressor is valid only if all the details above are filled in and the dealer s...

Page 6: ...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 1 9 0 Cooling system 9 1 10 0 Base and canopy system 10 1 11 0 Airend system...

Page 7: ...ce 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...

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Page 9: ...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 circ...

Page 10: ...or its disposal etc ELGi services services from ELGi CCS air audit spare parts Appendix conversion tables torque values service log book Refer to the parts manual to identify the part number of the re...

Page 11: ...ance we back our pledge with industry leading warranties parts availability loaner compressors and call centres staffed by experts We thank you for purchasing an ELGi compressor and assure you the bes...

Page 12: ...s 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 cont...

Page 13: ...ardous to point the compressed air directly towards any personnel Keep personnel out of the line of the discharge air when opening hoses or other points of compressed air discharge Use only the correc...

Page 14: ...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 irritati...

Page 15: ...ressure 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 grounde...

Page 16: ...on 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...

Page 17: ...the lean mixture through the air oil separator element to ensure an oil content of 3 ppm and less in the air The oil separated and collected in this element is then returned to the airend through the...

Page 18: ...gy and reduce wear and tear on the machine The control system ensures a smooth start without overloading the motor The compressor is started in star mode during which most of the compressed air is ven...

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Page 22: ...l power supply conditions 208 230 460 10 60Hz 5 3 phase Main motor rating hp 40 50 Type of motors main drive fan drive Squirrel cage induction TEFC Insulation and protection of main motor Class F IP55...

Page 23: ...tion of rotation 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 Disposal of Packing 5 9 5 3 Operating instructions 5 10 5 3 1 Sa...

Page 24: ...tion After completing the commissioning process the technician will fill in the commissioning report and the warranty card 5 1 2 Unpacking Unpack the compressor from the packing case by removing the n...

Page 25: ...n where flame is used nor place any inflammable objects near the compressor Ensure the room temperature is within 45o C 113o F as high ambient temperatures will result in reduced oil life due to highe...

Page 26: ...earth PE or 208 230V 460V 3 Ph 60Hz with earth PE The fuse and cable specifications for 208 230V 60 Hz 1 Ph 208 230V 60Hz 3ph and 460V 60Hz 3ph power supplies appear in the table below You must also p...

Page 27: ...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...

Page 28: ...01 0 17 7 247 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 8 282 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 0...

Page 29: ...l after cranking Litres Litres Litres 1 EN30 to EN45 19 5 14 3 7 6 1 3 MAXIMUM OIL LEVEL OIL FILL PLUG WITH BREATHER HOLE JOINING PLATE Dismantle the joining plate and drain oil from the oil tank thro...

Page 30: ...he compressor and ensure that the direction of rotation of the main motor is counterclockwise and the fan motor is clockwise Switch on the compressor after ensuring all the above points and let it run...

Page 31: ...long It must be repeated every six months during prolonged storage 5 2 2 Motor Check the insulation of the motor winding Remove any moisture in the motor Check junction box terminals for tightness of...

Page 32: ...ou commission the machine only in closed atmosphere air and on a level surface Provide a clearance space of 3ft 1m around the compressor The machine should be commissioned on a levelled surface Use on...

Page 33: ...6 7 6 1 12 Condensate drain in tank 6 7 6 1 13 Procedure for draining the condensate 6 7 6 1 14 Use genuine spare parts 6 7 6 2 Troubleshooting 6 8 6 3 Decommissioning dismantling putting out of serv...

Page 34: ...lace Oil Air lube XD Air lube FG Replace Air oil separator element Air lube XD Air lube FG Replace 50 Hz motor 4 pole grease Replace 60 Hz motor 25HP grease Replace Electrical connections Check Return...

Page 35: ...ages 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 p...

Page 36: ...tion 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 contamination hazard ELGi will not warrant t...

Page 37: ...g of this filter is as follows 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 c...

Page 38: ...ervice kits K2 K2 A K2 B K3 K2 block in case of any failure or damage Refer exploded view Function test Connect the pressurized air to the control block and test smooth opening and closing of valve fo...

Page 39: ...NOID VALVE S no Service kit Part number Description Remark 1 K2 B009405770009 Spare kit block Refer spare kit detail table for complete intake valve kit part number K3 B009405770010 30 kW Body spare p...

Page 40: ...ke out spring 4 and circlip 10 Remove piston 5 check valve 7 spring 6 and O ring 11 Cleaning and Lubrication Clean the piston work surface and sealing seat with a liquid cleaner Grease the threads pis...

Page 41: ...n the grease inlet fitting or plug If the motor has a plug remove the plug and clean the inlet Remove the drain plug and wipe out any hardened grease Slowly pump the grease into the grease inlet until...

Page 42: ...runs without wobbling Let the machine run for 30 minutes Switch off the machine and allow the belts to cool sufficiently Check the belt tension again Repeat the belt tensioning procedure to set the b...

Page 43: ...W BELT N 431 462 439 479 447 479 455 488 395 425 402 431 406 435 412 441 6 No of belts Nos 3 3 3 3 4 4 4 4 7 Span length mm 362 338 360 329 362 343 332 338 8 Mass of belt g m 80 DRIVE TABLE EN30X EN37...

Page 44: ...pending on the moisture quantity The condensate which is denser than oil will settle at the lower part of the tank 6 1 13 Procedure for draining the condensate To drain the condensate in the tank Swit...

Page 45: ...s the same problems as caused by the spurious oil filter Safety hazard Air oil separator Inadequate earthing can cause a separator to collapse 25 risk Inadequate earthing can also cause fire and destr...

Page 46: ...rol panel 3 Dedicated isolator to be provided to the compressor 4 Check and correct the motor winding body short after the megger test Incoming phase to phase voltage imbalance of more than 5V Correct...

Page 47: ...Replace the fuse if blown Replace with the 2A fuse Cooling fan not working Check and ensure the neutral connection is complete Temperature sensor malfunction Replace the sensor Tighten recrimp the con...

Page 48: ...psi g 4 5 bar Replace MPV kit assembly Neuron microcontroller pressure settings 1 Unload pressure set value is above specification 2 High tank pressure set value is below specification Check and corre...

Page 49: ...n compressor capacity 1 Replace the compressor 2 Arrest all pipeline leakages 1 Replace the compressor 2 Arrest all pipeline leakages 3 Excess pressure drop in pipeline 1 Replace the compressor 2 Arre...

Page 50: ...alve malfunctioning 1 Replace the solenoid valve assembly 2 Clean the orifice No electrical control supply to solenoid valve Replace the microcontroller Intake valve malfunctioning Check and replace t...

Page 51: ...onents and group them together according to the materials they are made of Steel Stainless Steel Aluminum and plastic parts Then scrap the machine in compliance with the laws in force of the country o...

Page 52: ...ion with ELGi products CCS working hours The ELGi CCS works for six days a week from 08 30 to 21 30 IST Monday to Saturday Multi lingual capability The coordinators at the CCS are multi lingual They c...

Page 53: ...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...

Page 54: ...m3 h 1 6988 Cubic feet per minute cfm lpm 28 32 Cubic metres per hour m3 h lpm 16 667 Cubic metres per minute m3 min lps 16 667 Mass M Kilograms Pounds 2 205 Kilograms Grams 1000 Kilograms Ounces 35...

Page 55: ...htening torque N m Tightening torque lb ft 9 16 149 109 8875 7 8 579 427 0125 Table 13 4 UNF threads Thread size inches Tightening torque N m Tightening torque lb ft 45 33 19 85 62 69 170 125 38 1 330...

Page 56: ...ill Total operated hours day Line pressure System pressure Discharge temperature Oil level in AOS tank Moisture removal from AOS tank Pre Filter Cleaning Cooler cleaning Trip record descrip tion Comme...

Page 57: ...rs day Line pressure System pressure Discharge temperature Oil level in AOS tank Moisture removal from AOS tank Pre Filter Cleaning Cooler cleaning Trip record descrip tion Comments Operator sign Low...

Page 58: ...st 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 pur...

Page 59: ...Controller Manual Neuron XT Version 3 0 January 2018...

Page 60: ...t report 7 8 7 4 3 Remote function both MODBUS as well as digital input 7 8 7 4 4 Other interfaces and communication 7 8 7 4 5 Safeguard 7 8 7 5 Input output description 7 9 7 5 1 X01 Power supply 7 9...

Page 61: ...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 Troubleshooting 7 1...

Page 62: ...F Air filter OF Oil filter Min Minimum Max Maximum UL Unload En Enable Dis Disable L Load St Stop F Fault R Run Sby Standby STC Start count LDC Load count Ph Fail Phase failure Pr Pressure Tr Temperat...

Page 63: ...y output load unload programmable relay 2 no s X05 Phase reverse Phase loss detection Relay outputs 6 Ports Rated voltage 24VDC 230VAC Rated load 10A 230VAC Contact resistance max 100milli ohms Insula...

Page 64: ...ressor 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 14o F 122o F Storage temp 10 70...

Page 65: ...ing used Switch off the device before carrying out any wiring work Do not connect or disconnect any wire when the device is operating 7 2 1 4 Power supply Ensure that the supply voltage corresponds wi...

Page 66: ...view fault report 99 fault reports Faults with run hour and status of the machine at the time of fault etc 7 4 3 Remote function both from MODBUS as well as digital input Remote loading and unloading...

Page 67: ...motor Overload MMOL Fault if open 4 Cooler Motor overload Cooler OL Fault if open 5 Remote load and unload spp Remote L UL spp Unload if open Trip if open 6 Remote start stop Remote Start Stop Stop if...

Page 68: ...7 10 Controller Manual Pin Function state 1 R Phase R 120 Deg Phase Diff 2 Y Phase Y 120 Deg Phase Diff 3 B Phase B 120 Deg Phase Diff 7 5 5 X05 Single phase detector...

Page 69: ...e minimum delay user set e g 60 sec between stop and start count stops if STOP key is pressed Start ack wait This message is displayed after a fault is cleared and waiting for user acknowledgement By...

Page 70: ...If the actual pressure is less than the load pressure then the compressor will restart automatically after 10 sec delay This feature helps save the energy if very little compressed air is used 10 Sta...

Page 71: ...or p Delay Warn RST delay X X X s second Star delay X X s DTR delay X X s RTS delay X X s Standby time X X m minute St Sp PH X X DCS port Type Modbus ID X X Baud 9600 19200 Parity None Even Add Length...

Page 72: ...L 2 LEVEL View Cumulative time Load X X X X X X hrs X X Min Unload X X X X X X hrs X X Min Run X X X X X X hrs X X Min Stop X X X X X X hrs X X Min Fault X X X X X X hrs X X Min Standby X X X X X X hr...

Page 73: ...nd 11 RTS 5 30 10 second 12 Standby 3 99 3 minute DCS Port 13 Type Modbus 14 ID 1 99 1 15 Baud 9600 19200 9600 bps 16 Parity None Even Odd None 17 Length 7 8 8 18 Stop bit 1 2 1 Auto Drain Valve ADV 1...

Page 74: ...intenance The system will warn when it reaches 0000 hours for you to change the filter The time limit will vary depending on the model Contact your authorized dealer to learn more Good practice is to...

Page 75: ...nto the customer care menu this message will appear 7 8 Data interface DCS port is Modbus RTU type It enables you to interface with the generic DCS You can set the device ID in menu Operator Machine D...

Page 76: ...th Gnd voltage should be b w 0 4 to 2VDC If it is different change the controller 5 Tr probe failure message in display Loose connection in connector position X02 9 10 Check the loose connection at bo...

Page 77: ...puts 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 1 0 02 03 20...

Page 78: ...running in delta Run load Compressor in load Run unload Compressor in unload Stop busy Stop sequence in progress Emergency stop Emergency stop push switch is on Temperature inhibit XX While starting...

Page 79: ...failure HSP If discharge pressure exceeds the set high sump pressure value Cooler If the cooler digital input opens due to cooler fault Main motor overload If the MMOL digital input opens due to main...

Page 80: ...7 22 Controller Manual Menu Structure...

Page 81: ...PARTS MANUAL EN SERIES ELECTRIC POWERED SCREW AIR COMPRESSOR EN 30X EN 37...

Page 82: ...8 2 Parts Manual 8 0 Air inlet and control system Ref 015315272 X016550 21...

Page 83: ...3 1 015403257 11 WASHER PLAIN M10 4 000996010 12 WASHER SPRING M10 4 000996110 13 BOLT HEX M10X30 4 000906145 14 BOLT SOC HEAD CAP M16X30 4 000985201 15 WASHER SPRING M16 4 000996116 16 WASHER PUNCHED...

Page 84: ...9 1 Parts Manual 9 0 Drive system Ref 015310622 X015310 EN 37 100 PSI...

Page 85: ...1 B005106400078 7 WASHER PLAIN M16 4 000996016 8 WASHER SPRING M16 4 000996116 9 BOLT HEX M16X55 4 000906217 10 AIREND MTG BRACKET FRONT 1 015309128 11 AIREND MTG BRACKET REAR 1 015309129 12 WASHER P...

Page 86: ...10 1 Parts Manual 10 0 Discharge system Ref 015310612 X015300 EN 30 EN 37...

Page 87: ...BV FLANGE ASSLY 1 015309137 18 LOCK NUT 3 4 INCH 1 020499840 19 VALVE ASSY BALL 3 4 BSP 1 011409580 20 OIL DRAIN PLUG 3 4 INCH 1 015402654 21 O RING ID30 0 X 2 6 1 220412320 22 3 4BSP BONDED SEAL WAS...

Page 88: ...11 1 Parts Manual 11 0 Cooling system Ref 015310616 X015304 EN 37...

Page 89: ...0 Cooling system Ref 015310616 X015304 Sl No Description Qty Part Number 1 Cooler assy 1 B012900690011 2 FAN WITH MOTOR 1 018400046 3 BOLT HEX M8X25 4 000906116 4 WASHER PLAIN M8 4 000996008 5 WASHER...

Page 90: ...12 1 Parts Manual 12 0 Lubrication system Ref 015315274 X016552 EN 37...

Page 91: ...02685 9 HEX ADAPTOR 1 UNFXM24 1 010440500 10 OIL FILTER ELEMENT 75 LPM 1 B004800770001 11 COOLER TO TVB PIPE 1 015309132 12 HOSE ASSY TVB TO COOLER 1 015309912 13 OIL INJECTION HOSE ASSLY 1 015309133...

Page 92: ...13 1 Parts Manual 13 0 Base and canopy system Ref 015310618 X015306 EN 37...

Page 93: ...5 CONTROL PANEL BOX ASSLY 1 015309117 6 SHROUD ASSLY 1 015310094 7 COOLER ANGLE RH 1 015309120 8 COOLER ANGLE LH 1 015309121 9 FRONT PANEL BOTTOM 1 015309911 10 CONTROL PANEL DOOR 1 015309910 11 HEX S...

Page 94: ...r Filter Element B005700770006 1 2 Oil Filter 10lpm B004800770001 1 3 Air Oil Separator B006700770013 1 S No Description Part Number Qty 1 Temperature sensor 018400079 1 2 Pressure transmitter 0089790...

Page 95: ...2 Kit Details S No Description Part Number Qty 1 Hose assy TVB to Cooler kit 012474059 1 2 Hose assy Cooler to TVB kit 012474069 1 3 Hose assy TVB toAirend kit 012474079 1 012474059 012474069 0124740...

Page 96: ...12 3 Kit Details...

Page 97: ...POWER CIRCUIT 8 3 1 0 6 2 2 2 9...

Page 98: ...CONTROL CIRCUIT 6 2 1 8 0 3 2 2 9...

Page 99: ...BOM 8 1 0 3 6 2 2 2 9...

Page 100: ...PANEL LAYOUT 0 2 6 3 1 8 2 2 9...

Page 101: ...POWER CIRCUIT 8 3 1 0 6 2 2 2 9...

Page 102: ...CONTROL CIRCUIT 6 2 1 8 0 3 2 2 9...

Page 103: ...BOM 8 1 0 3 6 2 2 2 9...

Page 104: ...PANEL LAYOUT 0 2 6 3 1 8 2 2 9...

Page 105: ...Road No 1 Raipur 492 003 Chhattisgargh Tel 91 97520 93008 Fax 91 771 4073759 E mail enquiry elgi com TIRUCHENGODE 4 2 Nandhini Complex 1st Floor Velur Road Tiruchengode 637 211 Tel 91 4288 257137 Fax...

Page 106: ...avu Taluk Coimbatore 642 109 India Tel 91 422 2587000 FELLOW SUBSIDIARIES DOMESTIC ATS ELGI LIMITED Kurichy Private Industrial Estate Kurichy Coimbatore 641 021 India Tel 91 422 2589999 2672201 3 Fax...

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