ELGi EG Series User manual

EG 11 to EG 22
(15 HP to 30 HP)
Standard and Standard + VFD
208 - 230V / 460V, 3Ph, 60Hz
EG SERIES ELECTRIC POWERED
SCREW AIR COMPRESSOR
OPERATION AND MAINTENANCE MANUAL

Part / Document No. 019400022 Rev R08
Print Status
April 2017

List of Contents
OPERATION AND MAINTENANCE MANUAL
Introduction 5
Salient Features 7
Safety 8
Operating Precautions 8
Technical Specifications 10
Commissioning Process 11
Installation 11
Disposal Of Packing 20
Functional Description 21
Maintenance 27
Maintenance Schedule 41
Decommissioning Dismantling And Putting Out Of Service 42
Disposal Of Consumables And Replaced Parts 42
Troubleshooting 43
Conversion Tables 47
Torque Values 48
Service Log Book 49
Glossary 51
3

Machine Identification and Sale Record
Owner’s Name : ________________________________________________________
Phone Number : ________________________________________________________
Contact : ________________________________________________________
E Mail Address : ________________________________________________________
Model : ________________________________________________________
Serial Number : ________________________________________________________
Year of manufacture : ________________________________________________________
Motor : ______________HP/kW _____________________________________
Capacity : _____________________cfm _______________________________
Rated Pressure : ____________________psi (g) _____________________________
Date of Delivery : ________________________________________________________
Date of Commissioning : ________________________________________________________
Distributor’s Name/Address : ________________________________________________________
Distributor’s Signature
4
Operation and Maintenance Manual

Using the Manual
This operation and maintenance manual has been specially designed to get the most out of your Elgi EG Series compressor.
Before you start using your compressor, go through this manual thoroughly. It contains vital information on operation as well
as useful tips that will help you to maintain your compressor as good as new for years to come. It is essential to maintain the
compressor as recommended in the maintenance section.
The manual has been prepared with utmost care to help you understand the various systems of the compressor thoroughly
through descriptions, information and illustrations.
All the information, illustrations and specifications in this manual are based on the latest product information at the time of
preparation of the manual. Elgi reserves the right to make changes in the product at any time without notice.
When calling your Elgi branch office, distributor or service center regarding your compressor, keep at hand the details present
on the name plate of the compressor and entered in the inside front cover of this manual.
When ordering spare parts, refer to the lists provided in Parts Manual portion and identify the part number. Specify the part
number and quantity in addition to the name plate details.
The manual must be available at all times to the personnel operating the compressor.
Definitions and Symbols
This information is related to your safety and also to preventing any problems relevant to equipments used. To help you
recognize this information, we use the following symbols
NOTE:
Note clarifies procedures or conditions which may otherwise be misinterpreted or overlooked. Note may also be used to clarify
apparently contradictory or confusing situations.
CAUTION:
Caution is to draw attention to a procedure which, if not done correctly, can lead to equipment damage.
WARNING:
Warning calls attention to dangerous or hazardous conditions inherent to the operation, cleaning and maintenance of the
equipment which may result in personal injury or death of the operator or other persons.
DO NOT OPERATE
DE-ENERGISE
DO NOT ATTEMPT
REPAIRS DO NOT INHALE
KEEP ACCESS DOORS
CLOSED
OPERATION
ENERGIZED
(POWER ON)
CAN CARRY OUT REPAIRS
OR ADJUSTMENT
SYMBOLS:
WARNING
!
WARNING
CAUTION
!
CAUTION
5

Message from the Managing Director
Dear Elgi Customer,
It gives me great pleasure to welcome you to the family of users of EG Series compressors from Elgi , among the most
sophisticated rotary screw air compressors available in the world today.
Elgi has designed your EG Series compressor to be reliable, safe, easy to maintain and friendly to use in meeting your
compressed air requirements. This user manual will enable you to use the EG series compressor optimally. Please familiarize
yourself with all the information it contains.
I look forward to your continued satisfaction as a EG series user. Elgi is honored to be your choice for all your compressed
air needs.
Yours sincerely,
Jairam Varadaraj
Managing Director
6
Operation and Maintenance Manual

About Elgi
Elgi, established in 1960, designs and manufactures a wide range of compressors. The company has gained its reputation
for design and manufacture of screw compressors through strategic partnerships and continuous research and development.
Screw compressor elements are manufactured in-house using state-of-the-art machining centres for rotor grinding and machining
castings of various sizes. Elgi’s own eta-V profile rotors ensure energy-efficient compressed air supply for all demanding
applications. Elgi is one of the few companies capable of manufacturing wide range of airends and compressor packages in
the world. Elgi’s patent portfolio is a testament to the company’s continuous research and innovation capability.
Elgi has modern manufacturing facilities in equipped with advanced high precision grinding machines, turning centres and
CNC horizontal and vertical machining centres. Screw airends are manufactured with the latest rotor grinding technology,
coupled with measurement technology to maintain precise manufacturing tolerances. Elgi’s manufacturing plants are both
ISO and EOHS certified.
Elgi serves the world marketplace. Over two million compressors are powering business in 63 countries worldwide. The
company offers a strong sales and service network with a well-knit distribution network of dealers and distributors worldwide.
Elgi has its own manufacturing facilities in China, France, India and Italy. Additionally, Elgi has warehouse operations to stock
units and parts in Australia, Brazil, UAE and USA.
EG Series
Your EG Series compressor belongs to a family of rotary screw compressors from Elgi. The compressor has only two moving
parts the rotors which are separated by a thin film of oil, so that there is no wear. This also means that the reliability of the
compressor is unsurpassed.
The screw compressor technology ensures that there is no reduction in output capacity even after many years of operation.
It involves a continuous flow of air through helical cavities in the screw and so the compressed air delivery is pulsation free.
The design of the EG Series gives you a compact and self-contained compressor. Because it has no reciprocating parts, it
runs quietly and free of vibrations. The discharge temperature of the coolant oil is low, less than 1950F, under normal conditions
and therefore carbonized oil is not formed in the compressor.
Salient Features
 Two-stage air filter
 Improved air filter life cycle
 Silent package suitable for inhouse operations
 Variable capacity control system
 High volumetric efficiency
 Efficient air-oil separation by OSBIC (Oil Separation By Impact and Centrifugal action)
 Reliable fan which works even at high temperature
 Isolated cooling system
 Robust cooling system
 Industrial designed canopy
 Compact and occupies less space
 Split type oil coolers for easy serviceability
 Flush type panels for easy handling
 Anti-vibration mounts restricts vibration
 Increased life of consumables
 Integrated VFD (Variable Frequency drive) and Dryer.
 Zero leak flanged joints.
 Oil Carry over < 1 ppm
 Advanced Neuron II Controller
 Globally Certified product - CE / UL and other Country specific approvals.
7

Safety
 The operator should follow the instructions, procedures and decals given in this manual for safe operation
 The maintenance personnel should be adequately trained, and have read and completely understood this operation and
maintenance manual
 Compressed air and electricity can be dangerous. To prevent injury before attempting any maintenance, be sure to disconnect
the power at the source and the compressor is relieved of all pressure
 Ensure that all the protective covers are in place and that the canopy/doors are closed during operation
 Remove red colored brackets at the airend, motor and shroud while commissioning the compressor
 Danger! 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. Failure to do so may cause severe injury or death.
 Do not allow compressed air to come into contact with food and related items unless it is treated specfically.
 This air Compressor is intended to be used for generating compressed air for industrial use only.
Operating Precautions
Pressure Release
 Annual servicing of safety valve and the kit is necessary. The kit should be checked at standard
pressure
 Use only the correct tools for maintenance and repair work. Do not exceed the manufacturers’ rated
safe operating pressure for pipes, valves, filters and other fittings.
 Open the oil fill cap only when the compressor is not running and is not pressurized. Shut down the compressor
and bleed the receiver tank to zero internal pressure before removing the cap
 Vent all internal pressure prior to opening any line, fitting, valve, drain plug, connection or other components
such as a filters. Vent pressure by popping up the safety valve
 Keep personnel out of the line of the discharged air when opening hoses or other points of compressed air
discharge
 Do not use air at a pressure greater than 35 PSI for cleaning purposes
 Use ear Protection when compressed air is vented out.
Fire And Explosion
 Clean up spills of lubricant or other combustible substances immediately
 Shut down the compressor and allow it to cool down. Move sparks, flames and other sources of ignition away. Do not permit
smoking in the vicinity when checking or adding oil
 Do not use flammable solvents for cleaning purposes
 Keep grounded conductive objects such as tools away from exposed live electrical parts like terminals
to avoid arcing, which might serve as a source of ignition. Keep all terminals clean and tight
 Keep electrical wiring and other terminals in good condition. Replace any wiring that has cracked, cut, abraded or otherwise
degraded insulation
 Keep oily rags, trash, dry leaves, litter or other combustibles out of and away from the compressor
Never start the compressor unless you know it is safe to do so. Do not attempt to operate the compressor when it
is known to be in an unsafe condition. Examples of unsafe conditions include improper grounding of the machine
and reverse rotation of the motors
Electrical arcing from compressor components can ignite flammable liquids and vapors which can result in
serious injury. Never operate the compressor near flammable liquids or vapors. If the compressor is used to
spray flammable materials, keep it at least 20 ft away from the spray area
WARNING
!
Do not engage in horseplay with air hoses: serious injury or death may result
WARNING
!
PULL THE RING TO
RELEASE PRESSURE
SLOT FOR
RELEASING
THE
PRESSURE
8
Operation and Maintenance Manual

 Do not operate the compressor without a proper flow of cooling air or with an inadequate flow of lubricant or with a degraded
lubricant
 Do not attempt to operate the compressor in a hazardous environment of any classification unless the compressor has
been specially designed and manufactured for explosive applications
Moving Parts
 Keep hands, arms and clothing away from couplings, fans and other moving parts
 Do not attempt to operate the compressor with the fan guards, coupling guards or other guards removed
 Keep access doors closed except when making repairs or adjustments
 Wear snug-fitting clothing and confine long hair when working around the compressor, especially when hot or moving parts
such as the cooler, the air end, the thermal valve, the main motor or the fan motor are exposed
 Keep hands, feet, floors, controls and walking surfaces clean and free of fluid, water or other liquids to minimize the
possibility of slips and falls
 Rotating fan blades can cause serious injury. Disconnect power supply before attempting service
Hot Surfaces
 Avoid bodily contact with hot oil, hot coolant and hot surfaces
 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 as they may lead to infection
Toxic And Irritating Substances
 Do not use air from the compressor for respiration
 In the event of ingestion of oils, coolants and lubricants used in the compressor, seek medical treatment
promptly. Wash with soap and water in the event of skin contact
Electrical Shock
 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. Make all such adjustments
or repairs with one hand. This minimizes the possibility of creating a current path through the heart
 Attempt repairs only in a clean, dry, well lit and ventilated area
 Do not leave the compressor unattended with open electrical enclosures. If it is necessary to do so, disconnect the power
to the compressor at the source and lock it out so that power is not inadvertently restored
 Disconnect, lock out and tag the power source prior to attempting repairs or adjustments, turning the machinery manually
or handling ungrounded conductors
 All electrical installation must be in accordance with recognized electrical codes and any local health & safety codes
 Only authorised and qualified trained personnel should carry out any electrical work on the compressor.
 Regularly check that all electrical connections are tight and in good condition.
Dos
 Read the manual in detail and follow the instructions
 Clean the air compressor package regularly
 Keep the air filter clean
 Use only genuine Elgi spares
 Use only clean and recommended lubricants
 Maintain correct oil level and use proper tools
 Attend immediately to anything unusual in the air compressor
 Maintain log book to monitor operation of compressor
 Attend repairs / service with qualified technicians only
9

Don’ts
 Neglect the routine attention
 Allow any leakage in the system
 Keep any tools or loose items on the compressor/other modules and Meddle with any adjustments or settings
 Use cleaning agents, when changing oil and do any repair work while the unit is running
 Overload the compressor for a long period
Technical Specification
Standard Compressor
NOTE: C - Standard Compressor, CV - Standard Compressor with Variable Frequency Drive
Tolerance for S.No:3 will be +4OF
Item
Model EG 11 (15 HP) EG 15 (20 HP) EG 18 (25 HP) EG 22 (30 HP)
1 Working Pressure psi.g 100 125 150 175 100 125 150 175 100 125 150 175 100 125 150 175
2 Free Air Delivery
cfm 71 64 57 49 92 85 78 69 116 107 91 80 140 132 112 95
m3/min 2.01 1.81 1.61 1.39 2.61 2.41 2.21 1.95 3.28 3.03 2.58 2.27 3.96 3.74 3.17 2.69
3Air Discharge
temperature oF Ambient Temperature + 18
4Safety valve set
pressure psi.g 205
5 Motor power HP 15 20 25 30
kW 11 15 18.5 22
6 Type of Motors Squirrel cage induction TEFC & Cooling fan integrated motor
7Type of Starter for
Main Motor
C
-
Automatic Star Delta
CV Through Variable Frequency Drive
8 Speed of motor rpm 1765
9 Voltage CVolts 208 - 230/460
CV 460
10 Frequency Hz 60
11 Speed of fan motor rpm 1490 (208 - 230V) / 1560 (460V)
12 Fan Motor Power/Fan HP
(kW)
0.35 (0.26) -208 to 230V
0.39 (0.29) - 460V
11kW - 1 Fan, 15 to 22kW - 2 Fans
13 Length inch 56
14 Width inch 28
15 Height inch 58
16 Weight
C lb 1301 1344.8 1499 1521
CV Ib 1410 1521 1565 1576
17 Oil recommended ELGI Airlube UT Synthetic
18 Air outlet port size inch 1” NPT Thread
10
Operation and Maintenance Manual

Commissioning Process
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 specifications.
The servicing technician carries out a series of checks on the machine and the systems to which it is connected to ensure that it
is in a condition to function safely and as desired. He will then describe to the operator of your compressor how the equipment
is to be operated and maintained. This procedure is referred to as the commissioning process.
The commissioning of your compressor ensures that it is installed safely. The general operating conditions of the equipment
including the cleanliness of the atmosphere, the temperature and the ventilation are checked. Technical details relating to
your system such as particulars of your electrical installation are noted. The operator of your compressor is familiarized with
all aspects of both its normal running and dealing with unusual situations.
Please make preparations according to the instructions provided in the Installation section for your EG Series compressor to
be commissioned. Ensure that the location chosen meets the requirements of accessibility, ventilation and safety. Provide
electrical power as recommended in the Installation section. Select air pipe lines and receivers for your system according to
the tables provided in the same section.
Upon completion of the commissioning process the technician will fill in the document known as the commissioning report
and the warranty card.
Unpacking
Unpack the compressor from the packing case by removing the nails. Unscrew the bolts holding the compressor to the base
of the crate
Once all 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
Tools may be provided on request. If any components are found missing, contact Elgi immediately
Installation
Handling the compressor
EG Series compressors can be lifted either using forklifts or cranes. Please refer to the figures below for general guidance
Option 1
 If the compressor is provided with a lifting hook then lift using the hook as shown in image. If no hook is provided, lift it
using slings.
 Prior to lifting, inspect the lifting hooks and points of attachment for any cracks in hooks and in welds, any abnormal bends,
corrosion of parts, loosening of bolts & nuts.
11.0
Installation
11

 Make sure the entire lifting, rigging and supporting structure has been inspected, is in good condition and has a rated
capacity of at least the net weight of the compressor. If you are unsure of the weight, then weigh the compressor before
lifting it.
 Make sure the lifting hook has a functional safety latch, or equivalent, and is fully engaged and latched on the hook.
 Use guide ropes or equivalent to prevent twisting or swinging of the machine once it has been lifted completely off the
ground.
 When the compressor is lifted up by crane, use cushioning materials at he four points of the bottom for prevention of
damaging the cover. Cushion should be padded at 4 lifting points for prevention of damages.
 If you are using the guide ropes to lift the machine for installation, Ensure that the rope is not touching the canopy at the
bottom and top to avoid scratches and rope marks or any other severe marks on canopy.
 Do not attempt to lift the compressor in high winds. Keep all personnel away from the compressor when it is suspended.
 Do not lift the compressor higher than the required height.
 Keep the lift operator in constant attendance whenever the compressor is suspended.
 Set the compressor down only on level surfaces, capable of supporting at least its net weight plus an additional 10 per
cent allowance.
Option 2
 Apply cushion materials for protecting the packaged unit from being damaged. Confirm that the front edge of the fork is
surely put through the holes with the edges of the fork.
 Make sure the fork lift is capable of handling the weight of the compressor & its two arms is fully engaged with the compressor
package as shown in image.
Compressor Location – Space Around Compressor
Install the compressor with adequate accessibility to ensure obstruction-free operation and maintenance. Maintain a clearance
around the compressor as mentioned in GA Drawings
Compressor Location – General Requirements
 The compressor room or the area around the compressor should be clean, dry, cool and free of dust. The room temperature
for the compressor should preferably be below 115°F. Excessively warm intake air affects the compressed air output. When
the discharge temperature of the compressor (temperature at compression unit) exceeds the factory-set value of 230°F,
the compressor will trip off. Also, the ambient temperature should not drop below +40°F. Provide air supply openings with
adjustable louvers to ensure that the minimum temperature does not drop below +40°F in winter.
 Never store combustible materials within a 35ft radius of the compressor. The room housing the compressor must be
equipped with fire fighting equipment. The floor around the compressor must be of non-combustible material.
 Compressor should be Rept on a levelled floor .
 Remove the Bottom of the Packing case.
Please observe all accident prevention regulations when installing this compressor
WARNING
!
12
Operation and Maintenance Manual

Installation
GA drawing – EG 11 to EG 22 (15 HP to 30 HP)
AIR INLET
(FOR COOLING FAN)
(30"±0.2")
27"
28"±0.4"
X
Y
(8") (27") (8")
58"±0.4"
51"±0.4"
4"
56''±0.4"
(7")
(7") (7")
Z
MAIN POWER
CABLE ENTRY Ø1.97"
EARTHING
POINT
DISCHARGE
AIR OUT
G
1
4
" MOISTURE
DRAIN
CENTRE OF GRAVITY
X Y Z
27.95" 23.62" 11.81"
NOTE :
1. Indicates Ducting Dimension
2. 'a' mentioned place for fork lift access 3. 'b' mentioned place for pallet truck access
HOT AIR OUTLET (FROM COOLING FAN)
AIR INLET FOR MOTOR COOLING
1" NPT MALE AIR
OUTLET PIPE
FAN1 FAN 2
COMPRESSOR SUCTION
AIR IN
bb
aa
VFD DISPLAY
PANEL
3"±0.2"
10"
3"
17"typ
24"typ
45"typ
5.6"
31"
15"
2.8" 1.6"
7"
7"
12"
1.14"
Ø0.59" -4No's
M6x4 For ducting
OIL POUR
OIL SIGHT
GLASS
OIL DRAIN SIZE G1/2"
VENTILATION
FOR PANEL
OIL DRAIN
(3.6")
NOTE: A minimum of 3.3 ft clearance is required on all sides of compressor and 6.6 ft clearance above the unit.
13

Ventilation and Exhausting Hot Air
Ensure adequate ventilation in the compressor installation area. Your compressor has a ventilating air requirement of
247202 ft3/hr. The figure provided indicates different ways in which this could be achieved
If your compressor is fitted with ducts as shown in the figure, the ventilating air requirement is only a third of the value specified
herein
Follow the guidelines herein for 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
 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
 The compressor is to be located such that the hot air from other machines is not directed towards it
 Provide adequate lights for easy reading of displays and see the parts clearly when doors / panels are opened.
Foundation
An industrial floor with a level surface capable of supporting the weight of the Compressor (refer to the technical specifications)
is sufficient for installing a EG Series compressor.
41°F
11.5
Installation
Ventilation and Exhausting Hot Air
Ensure adequate ventilation in the compressor installation area. Your compressor
has a ventilating air requirement of 247,202 cf/h. The figure provided indicates
different ways in which this could be achieved
If your compressor is fitted with ducts as shown in the figure, the ventilating air
requirement is only a third of the value specified herein
NOTE
•Suspended particulate matter should be less than 150 spm to achieve
the specified consumable life
•No guarantee shall be given if the compressor is operated above
its intended pressure
A
B
I Possibility II Possibility
B
A
B
A
B
A
C
Natural Forced Force & above 5
Force & above 0
Stores
Winter Option
V Possibility
IV Possibility
III Possibility
Summer Option
C
C
NOTE :
A = Intake air aperture with louvres
B = Exhaust air inlet area, should
match the cooler area
Air pressure considered 1 bar.
absolute
Pressure drop in conduit should not
be more than 30 Pa
A = Intake air aperture with louvers B = Exhaust air inlet area, should match the cooler
area air pressure considered 14.5 psi g absolute
14.5 psi g
0.00435 psi g
NOTE: Suspended particulate matter should be less than 150 spm to achieve the specified consumable life
No guarantee shall be given if the compressor is operated above its intended pressure
14
Operation and Maintenance Manual

Electricals
You must provide a lockable main switch with pre-connected slow-blow main fuses as per industrial safety regulations. The
power supply should be 460 Volts 3 phase with Earth (PE). The fuse and cable specifications for 460 V, 60 Hz ,3 PH power
supplies are listed in the table below.
NOTE: Power should be supplied to the compressor through a fuse switch unit of suitable rating mounted within 15 ft of
the compressor
Global Series E11 E15 E18 E22
Motor Power (kW/hp) 11/15 15/20 18.5/25 22/30
Power Supply 208V 60Hz 3PH
Nominal Current (A) 45.1 61.6 77.2 92
Cable Material Copper Conductor only
Power Supply Cable (AWG) (L=15ft) 4X8 4X6 4X4 4X4
Upstream fuses (A) (Type RK/CC/J) 63 80 100 125
Switching Fuse Unit (A) 63 100 100 125
Global Series E11 E15 E18 E22
Motor Power (kW/hp) 11/15 15/20 18.5/25 22/30
Power Supply 230V 60Hz 3PH
Nominal Current (A) 43.2 58.6 70.8 84.4
Cable Material Copper Conductor only
Power Supply Cable (AWG) (L=15ft) 4X8 4X6 4X4 4X4
Upstream fuses (A) (Type RK/CC/J) 63 80 100 125
Switching Fuse Unit (A) 63 100 100 125
Global Series E11 E15 E18 E22
Motor Power (kW/hp) 11/15 15/20 18.5/25 22/30
Power Supply 460V 60Hz 3PH
Nominal Current (A) 21.6 28.9 35.4 42.2
Cable Material Copper Conductor only
Power Supply Cable (AWG) (L=15ft) 4X12 4X10 4X8 4X8
Upstream fuses (A) (Type RK/CC/J) 32 40 50 63
Switching Fuse Unit (A) 32 63 63 63
15

Air Pipe Lines
Use the table below as guidance for selecting pipes for your system
Receivers for Compressed Air Systems
The table below is given for your guidance in selecting an appropriate air receiver for your system.
Commercial steel pipe size for compressed air line / air pressure losses in 100 ft length
Free
air
(cfm)
1/2 inches 3/4 inches 1 inches 1 1/4 inches 1/2 inches
80
lb
100
lb
125
lb
80
lb
100
lb
125
lb
80
lb
100
lb
125
lb
80 lb 100 lb 125 lb 80lb 100 lb 125
lb
10 0.45 0.38 0.31 0.11 0.09 0.08 0.04 0.03 0.02 0.0086 0.0071 0.0058
20 1.74 1.42 1.17 0.41 0.34 0.28 0.13 0.1 0.08 0.032 0.026 0.021 .014 0.12 .010
30 3.84 3.13 2.54 0.9 0.74 0.6 0.28 0.23 0.19 0.068 0.056 0.046 .031 .026 .021
40 6.93 5.55 4.53 1.55 1.28 1.05 0.46 0.38 0.31 0.116 0.096 0.079 .053 .044 .036
50 10.7 8.65 7.01 2.42 2 1.62 0.73 0.6 0.49 0.18 0.046 0.12 .081 .067 .055
60 3.47 2.84 2.33 1.02 0.84 0.69 0.25 0.21 0.17 .12 .095 .078
70 4.73 3.85 3.14 1.36 1.12 0.92 0.34 0.28 0.23 .16 .13 .10
80 6.14 5.01 4.08 1.76 1.44 1.18 0.44 0.36 0.3 .20 .16 .14
90 7.75 6.4 5.17 2.23 1.85 1.49 0.55 0.45 0.37 .25 .20 .17
100 9.62 7.8 6.33 2.69 2.21 1.81 0.066 0.55 0.45 .30 .25 .20
125 15.5 12.4 9.8 4.18 3.41 2.79 1.03 0.85 0.69 .46 .38 .32
150 23 18.1 14.4 5.75 4.19 3.99 1.47 1.2 0.99 .65 .54 .44
175 1.81 6.8 5.45 2 1.64 1.32 .90 .73 .60
200 10.9 8.79 7.11 2.58 2.12 1.73 1.15 .95 .78
250 1.82 1.48 1.20
300 2.55 2.10 1.72
350 3.53 2.86 2.35
400 4.53 3.70 3.03
450 5.80 4.65 3.80
500 7.12 5.79 4.71
Receiver specifications Compressed capacity
Volume Height Diameter Weight On/Off control Modulation Control
m3ft3inches inches kg cfm cfm
0.25 8.83 68.5 25.7 115 Up to 40 Up to 60
0.5 17.66 82.6 30.7 210 41-85 61-120
1 35.32 109.6 39.3 344 86-140 121-235
1.5 52.97 98.4 49.2 783 141-225 236-355
2 70.63 125 49.2 954 226-310 356-470
3 105.95 110.4 61.6 1308 311-445 471-710
4 141.26 141 62.8 1564 446-570 711-945
5 176.58 139.2 70 2129 571-700 946-1180
6 211.89 164.7 70 2343 701-850 1181-1415
7 247.21 143.3 82.6 2885 851-990 1416-1650
8 282.52 156.8 82.6 3115 990-1130 1651-1885
16
Operation and Maintenance Manual

Earthing
Check the total power supply requirements from the name plate before connecting the compressor to the electrical lines
Connect the earthing line to the point provided on the base frame at the side of the compressor
Connect the leads L1, L2, L3 and PE to the terminals inside the electrical control panel of the compressor as shown in pic
below:
 Connect the compressor to the air network
 Use Elgi recommended Air lube UT Synthetic oil for optimum performance of the compressor
Removal of the Antivibration Mount and shroud Arresting bracket
Ensure that only authorized electricians carry out the electrical work. Study the electrical circuit diagram before
starting work. Transformer tappings & OLR settings need to be adjusted according to voltage conditions
(230V / 460V) at site.
WARNING
!
11.10
Installation
Check the total power supply requirements from the name plate before connecting
the compressor to the electrical lines
Connect the earthing line to the point provided on the base frame at the side of
the compressor
EARTHING POINT
POWER CABLE ENTRY
DETAIL - A
CONTROL PANEL
LOCKING CLAMPS AND LOCKING BOLTS
FOR MOTOR AND AIREND (TO BE REMOVED AFTER
THE COMPRESSOR IS INSTALLED)
Remove AVM arresting brackets from Motor and Airend side once compressor is installed
!
WARNING
7302 italy change view 7.11
7271 change view :8.11
7226 change view :9.11
7302 italy change view 7.14
7271 change view : 8.14
7226 change view : 9.14
17

Oil Fill Procedure
Oil Level Check
 Oil level should be above oil sight glass after fumes settle down post shutdown
 Ensure that the oil level sight glass and eye vision is parallel while checking the oil level to avoid parallelex errors.
11.13
Installation
Oil Fill Procedure
NOTE
•Suspended particulate matter should be less than 150 spm to achieve the specified
consumable life
•No guarantee shall be given if the compressor is operated above its intended
pressure
Oil filling port
(Over fill cap)
Oil level
sight glass
OIL SIGHT
GLASS
OIL FILLING
PORT (OVER
FILL CAP)
NOTE: Refill the oil in the tank if the level falls below minimum level
Fill oil in the oil tank up to over fill cap
Close the oil filling plug
Run the compressor for 10 minutes, until the
thermostatic valve opens
Stop the compressor
Ensure sump pressure drops to atmospheric
pressure & Unscrew the plug only 3 turns to
escape any air in system
Refill the oil in the tank until max level
indicated on the tank and close the oil fill
plug
Restart the compressor
Initial fill
Second fill
18
Operation and Maintenance Manual

MOISTURE
OUTLET
PORT
Installation
Keep the air outlet line ball valve in fully open condition before starting the compressor
Connect the moisture outlet line provided at the side of the compressor as shown in above figure to the waste water disposal line.
Check the direction of rotation of the main motor when starting for the first time by switching ON the compressor (pressing
the green Start button) and switching OFF (pressing the red mushroom Stop button) immediately. The motor must rotate in
the clockwise direction when viewed from the main motor fan cooling side. If the direction of rotation is not correct, isolate the
machine from the electrical lines and interchange any two phases. Re-start the compressor and ensure that the direction of
rotation of the main motor and the fan motor is clockwise
IMPORTANT
After connecting incoming electrical phase lines, please check
if both the LED’s of Single Phase Preventer (SPP) in the control
panel glow. This ensures correct incoming wiring sequence and
the compressor is ready for start. If it is not set right, flip the
incoming phases for correct wiring sequence
Switch “ON” the compressor after ensuring all the safety points
 In case of problems during the running of the compressor, check
which warning LED’s are illuminated on the control panel of the
compressor and refer to the Functional Description and Operation
sections of this manual
 If any abnormal noise is heard when the compressor runs, switch
it off immediately and contact the Elgi service engineer for remedy
 All the points listed earlier should be followed, when the
compressor is re-installed at a different location
 If the compressor has been stored for an extended period before
commissioning, contact the Elgi distributor.
Open
Running the compressor in the wrong direction for more than 5 seconds will cause damage to compressor parts
or even total destruction
!
WARNING
Ensure that only authorized electricians carry out the electrical work. Study the electrical circuit diagram before
starting the work
!
WARNING
CLOCK WISE
19

Extended Storage
 If your compressor is expected not to be used for a prolonged period, special measures must be undertaken to ensure the
protection of the following components: the airend, the Motors, and the Air–Oil sump tank
Airend
 Remove the airend discharge hose/pipe coupling fitted to the air receiver
 Rotate the coupling three times so that the oil present inside the airend comes out through the discharge port
 Block the discharge port completely
 Remove the inlet rubber duct connected to the intake valve of the air filter assembly
 Press the puppet intake valve and pour rust-preventive oil (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
 This procedure protects the airend for up to six months storage. It must be repeated every six months during storage
Motors
 Check the junction box terminals for tightness of the wires
 Apply Grease on the motor (use Lithium based or equivalent)
 This procedure will protect the motor for up to one year storage
The sump or air–oil separator tank
 Remove the entire tank from the compressor after disconnecting it from all hoses, the tank top lid, the minimum pressure
valve outlet line, control pulse lines and control switches
 Clean the tank using DW X 32 oil or equivalent
 Check the Air–oil separator tank
 Replace the oil filter element
 Replace the air filter element
The separator tank may now be stored for up to two years.
Flush the Tank, airend with compressor oil and replace the separator element before using the compressor again
Disposal of Packing
The wood used to make the shipping crates of the EG Series compressors is biodegradable.
The polyethylene covers wrapped around the compressor and the polystyrene packing provided around the electrical panels
are not recyclable. They must be disposed of in accordance with prevailing environmental laws.
NOTE: For package preservation / long storage Contact ELGI for further details.
NOTE: All settings for pressure, temperature, electrical protection devices, etc, are set at factory before dispatch
20
Operation and Maintenance Manual