ATS ELGI AIR XPRESS User manual

TYREINFLATOR
(BuiltinCompressor)
NEW GEN BIC TYPE INFLATOR
MODEL: AIR XPRESS
TPLNO: S15024
Operation,Maintenance&PartsManual

2
©
ATSElgiLimited
Coimbatore,TN-641021,India
PrintingStatus
R01Dec2021
ContactInfo:ATS
ElgiLimited
Kurichy,Coimbatore,TN-641021
Phone : [phone]
Fax : [phone]
e-mail : [e-mail]
TollFreeNo. : 1800-203-3544

3
CONTENTS
PageNo.
1. Introduction 4
2. TechnicalData 6
3. Scopeofsupply 8
4. Installation 8
5. DescriptionofControllerUnit 9
6. OperatingInstruction 13
7. MaintenanceSchedule 14
8. TroubleShooting 15
9. PartsList 17
9.1.Parts list old model 19
10. ElectricalWiringDiagram 24
12. Do’s&Don’ts 26
13. ATSElgiWarrantyPolicy 28
11.Electrical line Diagram 25

4
1. INTRODUCTION
1. PrincipleofOperation:
Thisproduct,Tyreinflatorisele
ctronicpre-settypewith
microprocessordrivencontroller
unit.
Apiezoelectrictransducer,calledh
ereaspressuresensor,isemplo
yedtoconverttheinputenergyfr
omtheformofcompressedairt
oelectricalsignaloutput.Theel
ectricalsignalsthusderivedar
e
modulated,manipulatedandpr
ocessedinthecontrollerunitwitht
hehelpofmicroprocessors.Thisint
urnprovidestheoperator
themeans ofoperating the
unitwithdisplaysandcompressed
air routingtodesiredports.
Theunit,apartfromthecontrollera
ndsensorhasa12Vrelaymodul
etoregulatesupplytooperating
elements,Solenoidvalvestodire
ctairtodifferentportsasactivat
edbythecontrollerlogic,abuzz
ertoindicatetotheoperatorwhent
hesetpressureisreachedinthetyre
underinflationandsilencerattheex
haustportofair.
2. Application:
Thisproductisusedforinflatingan
ddeflatingtyresofallsizesdesign
edforfillingcompressedairupto1
70psiwithapresetpressure
easilysetatthe
controllerdisplaypanel.A
detailedlistofvehiclesandresp
ectiverequiredpressureare
availableinthelaterpartofthisman
ual.
3. Operation:
Whentherequiredpressureissetint
hecontrollerandthefootvalveispre
ssedoverthetyrevalveinavehicle
orotherwise,theair
underpressureflowfromthetyrean
dreachesthecontrolthroughthep
ressuresensor.The
pressureinsidethetyreisconv
ertedbythepressuresensortoele
ctricsignalsisthenregisteredint
hecontroller.
Themicroprocessoristhenind
uctedintooperation.Firstacomp
arisonofpressuredifferenceb
etweensetandexistingtyrepres
suretakeplace.Then,accordingly
thesolenoidsareoperatedbythec
ontrollerlogic,wherepredefinedp
ortare
openedorclosedforeitherinflat
ingordeflatingthetyres.
Once,thesetpressureisreache
d,anaudiblebuzzersignalissettor
eachtheoperator
awarenesstoindicatethatthecycl
eofoperationiscompletedsucces
sfully.
Whenthetyreisdeflated,theair
isdirectedtotheexhaustport
wheretheairisexhaustedthrougha
silencer.

5
4. General
Atthisjuncture,wewishtothank
youforpurchasingthisqualitypr
oduct.Thismodernpneumaticm
achinehasbeendesignedtopro
videyouwith
manyhoursofusefulservice.
ThisOperationandMaintenance
Manualprovidesyouwitheasy
-to-
understandoperatinginstructio
ns.Readtheentiremanualandf
ollowalltheinstructionstokeepy
ournew
pneumaticmachineintopoper
atingcondition.
Thismanualcomprisesofapart
slistinadditiontoarecomme
ndedspareslist,providingyoui
nformationthatyouneedtoorderp
arts.
5. Trainingneeds
Regardingtrainingeitheronthispr
oductoranyotherproductsofELG
I,pleaserefertosectiontitled"Tr
ainingCentre
Information"givenlaterinthisma
nual.
6. ProductReferences,
I llustrationsandSpe
cifications
Allinformations,illustrationsands
pecificationsinthismanualare
basedonthelatestproductinfor
mationavailableatthetimeofprinti
ng.Wereservetherighttomakech
angesatanytimewithoutnotice.
06. ServiceInformation
Serviceonthispneumaticmac
hinewithinandafterthe
Telephone : [phone]
Fax : [phone]
Email : enquiry@ats-
elgi.comCustomerCareTollFree# : 18002033544
Note
e Proofofpurchasewillberequiredforwarrantyservice.
e Makesurethismanualisreadandcarefullyunderstoodbeforestarting/
operatingthismachine.
Warrantyperiodcanbeperformed
byanyATSELGIBranchesandau
thorizeddistributors/dealers.
ToobtainthelistingofATSELGIbr
anchesandauthorizeddistribu
tors/dealersinyourarea.
1. Retainthemanualcarefullythr
oughoutthelifeoftheequipment
,inordertoprocurecorrectspares.
2. Whileorderingspareparts,thefoll
owingparticularsmustbe

6
clearlymentionedtoensuresu
pplyoftherightspareparts.
1. Model
2. FabricationNo.
3. Yearofmanufacture
4. Partname
2. TECHNICAL DATA
5. Partnumber
6. Requiredquantity
3. Duetoimprovementsbeingmadec
onstantlyandcontinuously,theill
ustrationsanddescriptionsonthi
smanualarenotbinding
No. Description Unit Data
1
Model
—
-
AIR XPRESS
2 OperatingPressure psi 0-170
3 PressureSettingRange psi 7-170
4 OverLoadPressure psi 150
5 InputPowerSupply VAC
230
+10%-15%
6 TotalPowerConsumption KW 1.5
5 ControllerDetails —- —-
a Display —- —-
1.Type —- LCD
2.No.ofDigits Nos
1
3.Features —- Unit & pressure display, function
select display, error signal and rolling
bar.
4. Resolution psi 1
b MeasuringResolution psi ±1
c NumberofOperatingKeys Nos 6
d OperatingTemperature DegC 0to55
e OperatingVoltage VAC 230
+10%-15%
f Power W 10
g ElectricalProtection —- 3A,fuse
h CycleEndIndication–
Inflation/Deflation —- ContinuousBeepSignal

7
No. Description Unit Data
i Accuracy % ±0.5%offullscale
6 LengthofOutletAirHose M 10
7 LengthofPowercard M 1.5
8 CompressorDetails —- —-
a Model —- VayuRAC2Hp
b OperatingPressure Kgf/cm2 10
c Displacement lpm 249
d Motor —- —-
1.Type —- SinglePhasePermanent
SplitCapacitor(PSC)
2.Rating hp 2
3.Voltage VAC
230
+10%-15%
e ElectricalProtection —- 20A, 2P MCB
f Mounting —- TankMounted
g TankCapacity Litre 27
9 OverallDimensionLXWXH mm 335 X 503 X 1037 ± 10mm
10 Weight —- 95kg Approx
11 GADrawingNo. —- 150330120

8
3. SCOPEOFSUPPLY
1. BuiltinCompressorcomprisingof
Cabinetcontainingmainelementsviz.compressorwithtank,SMPS
Board,ControllerPCB,MCB,solenoidvalves,pressersensor,Buzzeret
c.
2. StandardAccessories
SpiralhoseAssembly10Mwithclip on connector,
3corecableof1.5mlong
4. INSTALLATION
- Don’tunpacktheequipmentunlessthesiteisreadyforinstallation.
- Theunitneedselectricalconnectionwith230volt(+10%-15%)AC
Singlephaseforfunctioning.Thepowercordwithofsuitablespecificat
ionissuppliedwiththisunit.
- Check/Filltheoilinthecompressorcrankcaseareasrecommended.
- Take outthe(PU tube)autodrain valveoutletto
theoutsideofthecabinet.
- Connecttheelectricalcablewiththemainpowersupply.
- Ensureproperearthingisgiven.
Note
e Donotoverloadcompressorforalongperiodeventhoughitis
ofcontinuousrating,aswerecommendintermittentuseonly.
RECOMMENDEDOIL QTY
ELGIAIRLUBE 200ML

5. DESCRIPTIONOFCONTROLLERUNIT
5.1 DescriptionofLED:
OPERATING INSTRUCTION
Powering on the unit, the display will switch on as below:
9

10
1. Unit select
Device has four units that can be chosen by the user. kpa – psi –
bar - kgf
Unit set here will become default unit for following usage, do not
need to set unit each time.
Press【i】,【SET】will be shown on the LCD screen, and the
unit will be flashing.
Press 【+】or【-】to choose the unit.
Press【 】to confirm.
2. Set OPS
Press【i】twice,【SET】and【OPS】will be shown on the LCD
screen, 【OPS】will be flashing.
Press 【+】or【-】to choose the OPS value.
Press【 】to confirm. If OPS value is not zero, 【OPS】will be
displayed at the LCD screen.
3. Set the default pre-set pressure value
The default pressure value of 【】 is 15 psi/1 bar，【】is 30
psi/2.1 bar, The user can reset the value according to their
requirement, they can save the value for permanent use.
Press【】 or 【】，The default value of 【】 or 【】will show on
the screen.
Press【＋】or【－】to choose one.
Then press【 】to confirm

11
OPERATING INSTRUCTION
4. Inflation and Deflation
Press【P1】or【P2】to choose a target pressure value
Press 【+】or【-】to select target pressure.
Connect with tyre, ensure no air leaks, inflator will work automatically.
When inflation is finished, machine will stop automatically and BEEP to
remind users.
Disconnect the air hose from tyre, finish inflation.
Remark:
1. Press 【i】to enter the function setting mode. After select the unit,
press 【i】again to enter the 【OPS】setting directly, press 【i】
thrice the device will quit out of the setting mode without save any
selection.
2. When OPS function is on, device will inflate to target pressure plus
OPS value first, then deflate to tyre pressure desired, for example: A
final target of 32 psi or 2.2 bar with an OPS setting of 16 psi or 1.1 bar
gives a sum of 48 psi or 3.3 bar. This sum of 48 psi or 3.3 bar is the
Over Pressure setting for tyre. Tyre will inflate to the sum value and
deflate to the final target pressure.
3. If tyre pressure is lower than 3 psi or 0.2 bar, device will not start
automatically. Then press 【 】for 2 second to start manually.
During inflation, device will check tyre pressure automatically, rolling bar will be
on, and left to right means inflating, right to left means deflating.

12
.
Control panel functional key details
:
Reduce final target pressure
Increase final target pressure
Function Select: Unit Change/OPS set
Function Select Confirm/Start to inflate/Stop. Used this button to start the
inflation process when the pressure in the tyre is less than: 3 Psi, 20 Kpa
or 0.2 Bar.
LCD display

13
6. OPERATINGINSTRUCTION
6.1COMPRESSORUNIT:a).S
TARTING:
- Checkthemainpower,shouldbematchedwiththerequiredpower.
- Switchonthemainpowersupply.MCB(20A).
- Turnthepressureswitchknobfittedonthetankintoposition“1”.
- Thecompressoriscontrolledbythepressureswitchwhichstopsitwhent
ankpressurereachesmaximumvalue(170psi)andrestartsitwhenitfall
stomaximumvalue(110psi).
- Loadittomaximumpressureandcheckexactlyhowthemachineisope
rating.
Note
e
Themotorofthiscompressorisequippedwithanautomatictherm
albreakerlocatedinsidethewinding–
thisstopsthecompressorwhenmotortemperaturereachesexces
sivelyhighvalues.Ifthebreakeristripped,thecompressor.Restarta
utomaticallyafter10to15
minutes.
6.2.CONTROLLERUNIT
a)INFLATING/ DEFLATING TYPE:
- Switchontheselectorswitch
- Pre-Setthedesiredpressurebyusing+ / -keys
- Connectthefootconnectortothetyre(unitwillinflate/deflateauto
matically)
- Waitforthebeepsignal
- Removetheconnectionfromthetyre
- UseTyrekeyforempty[Airlessthan7psipressure]tyreonly.

14
7. MAINTENANCESCHEDULE
a). Compressor
1. Beforeattemptinganymaintenancejobsonthecompressor,makesure
ofthefollowing.
- Mainswitchcontrollerunitswitchandpressureswitch-allarein
‘off’position.
- Nopressureintheairtank.
2. Every50hoursofworking:dismantlethesuctionfilterandcleanthefilterin
gelementbyblowingcompressoraironit.
3 Thecondensatewaterintankmustbedesiredeverydaybyopeni
ngthedrainvalveunderthetank.
4 Oilchange
- First100hoursofworking,afullchangeofoilisrecommended.
- Unscrewtheoildrainplugonthehousingcover,allowalltheoiltofl
owoutandre screwtheplug.
- Pouroilintotheupperholeofthehousingcoveruntilitreachesthe
levelindicatedonthestick.
s -
Checktheoillevelinthecrankcaseonceinaweekandtoppingupitifnece
ssary.
b).TyreInflator
- Checktherubberwasherinthefootconnectorat
leastonceinaweek.
- Checktheelectricalwiringat leastonceinamonth
- CleantheSolenoidvalvestembycompressorair.

15
8. TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
SOLUTION
Air leak Leak in the connection Check the pneumatic Connection
The inflator works,
But no air inflated Obstruction in filters or in air system Clean the filters and check the air tube
No display Check power supply Reconnect
Inflation does not
start, although the
pressure is set and
the hose is
connected with tyre
Air hose
improperly connected Check the hose connection, make sure
that no air leaks
Tyre pressure is below
0.2bar (3psi) Press
The unit deflates
very slowly The silencer plug on is blocked Remove and clean the silencer plug
Er1 Pressure sensor broken Power off, change
pressure sensor
Er2 Unstable pressure, faulty hose
connector Replace hose connector or re-connect hose to the tyre
Er3 Connected Tyre
pressure is too high
pressure> 13 bar (188.5psi)
Stop inflating this tyre
Er4 Wrong connections at air inlet
and outlet Refer to wiring diagram and connect magnetic valve accordingly
Er5 Low Voltage Check the power supply
Er8 Air supply lower than
set inflate pressure Stop inflating this tyre

16
Problem Possible causes Solution
Pressuredropintank Leakage through joints,
connections
Atmaximumpressureintank,
applysoapwatersolution
ontoallconnectionsandjoints.
Lookforbubblesandtighten
Connectionsorjointswhere
leakageisvisible
Thecompressor
stopsanddoesnot
startagain
Poorelectricalconnection Checkelectricalconnection.
Motortripswitchhascutin Clean&tightenasnecessary
Motorwindingsburnt ContactATSELGIService
Technician
Motorshafttightand
doesnotrotate
Motor bearings failure ContactATSELGIService
Technician
Seizure of piston
Cylinder becauseof ContactATSELGIService
Technician
inadequat
e
lubrication
Seizureofconnectingrod
with crank pin because
ofinadequatelubrication ContactATSELGIService
Technician
Thecompressor
doesnotreachset
pressureandover
heatseasily
Compressorcylinderhead
tovalveflatgasketdamaged
ContactATSELGIService
Technician Dis-assemble
headandreplacebroken
Oil level low Topupoiltocorrectlevel
Oilcarryoverin
compressed
Oillevelhighairand
breathervalve
Oil viscosity too low Changeoilofrecommended
grade
Breather not working
properly Cleanbreather&checkagain
Piston rings to cylinder
clearanceexcessive Cleanclearanceandchangeif required
Compressornot
stoppingwhen
maximumpressureis
reached Safetyvalvemalfunction Cleanchangethesafetyvalve

17
Exploded view / part list

18
9.PARTLIST

19
9.1.PARTLIST – OLD MODEL
Fig3
PARTSLISTFORTYREINFLATORBUILTIN
COMPRESSOR

20
Sl.No DESCRIPTION QTY. ITEMCODE
1 CABINET 1 150330960
2 COMPRESSORVAYURAC2HP 1 340303930
3 TANKCOMPRESSOR 1 150330710
4 CONTROLLERWITHOUTSMPS 1 150402410
5 VIBRATIONMOUNT 4 150481260
6 ACPIPEASSY 1 150330720
7 FUSE,2A 1 008927011
8 MCB,20A 1 008927022
9 RETRAIDENTFIBRE 2 000999821
10 HOSEASSYNYLON7mWITH
S.E.F.CONNECTOR 1 150400180
*13 BUZZER 1 150402030
14 PRESSURETRANSMITTER 1 150400260
15 SOLENOIDVALVE2/2NC 1 150402300
16 SMPSBOARD 1 150302240
17 FRC1/4"BSP 1 150402150
18 PU8HOSE 6m 1 200450130
19 BOLT,HEX,M6X20 4 000906086
20 NUT, HEX, M6 4 000948007
*Notshowninthefig