ELECTRIC POWERED

SCREW AIR COMPRESSORS

E30-E45
ELGI NEURON II MICROCONTROLLER
220V/380/V, 3Ph, 60Hz

OPERATION AND MAINTENANCE MANUAL

NEURON II MANUAL
PARTS MANUAL
©
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005

Part / Document No. 01 90 03 420

Print Status
R00 - May - 2008
R00- May - 2010- Reprint
R01- Jan - 2011
R02- Mar - 2011

Replaces Earlier

Doc. No. : Nil

Date : Nil

Price: INR 500

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 Business)
E-mail : [email protected]
www.elgi.com
List of Contents

CHAPTER-I
OPERATION AND MAINTENANCE MANUAL
Introduction 1.0
Customer Care System 2.0
Commissioning process 3.0
Using this Operation & Maintenance Manual 4.0
Definitions and symbols 5.0
Technical specifications 6.0
Installation 7.0
Disposal of packing 8.0
Functional description 9.0
Operating precautions 10.0
Schematic Diagram 11.0
Operation 12.0
Maintenance 13.0
Disposal of consumables and replaced parts 14.0
Troubleshooting 15.0
Conversion tables 16.0
Torque values 17.0
Disclaimers 18.0
Index for operation and maintenance manual 19.0
Business Reply Card 20.0
Feedback Form 21.0

iii
CHAPTER-II
NEURON II MANUAL
Index 22.0
Technical Features 23.0
Controller terminal configuration 24.0
Main Menu Screen 25.0
Menu Structure 26.0
Data Interface 27.0
Construction & Dimension Drawing 28.0
Controller Identification 29.0
Revision Details 29.0
APPENDIX A: Mimic LED Table 30.0
APPENDIX B: Short Cut Key Functions 31.0
APPENDIX C 32.0
APPENDIX-D 33.0
CHAPTER-III
PARTS MANUAL
Air Inlet System 34.0
Discharge System 34.4
Cooling System 34.8
Lubrication System 34.10
Control System 34.14
Canopy System 34.16
Motor & Base Assembly System 34.18
Drawings 35.0
Recommended Spares 36.0
Recommended Oil 37.0

iv
Machine Identification and
Sale Record
Owner’s name : ______________________________

Address : ______________________________

Model : ______________________________

FAB No. : ______________________________

Year of manufacture : ______________________________

Motor : ___________________________kW

Capacity : ________________________m3/ min

Rated Pressure : _________________________bar g

Date of Delivery : ______________________________

Date of Commissioning : ______________________________

Dealer’s name/code : ______________________________

Dealer’s signature and stamp

Note: The warranty on this compressor is valid only if all the details
above are filled and the dealer stamps and signs this page

v
Message from the Managing Director

Dear ELGI customer,

It gives me great pleasure to welcome you to the family of users of Horizon

compressors from ELGI, among the most sophisticated rotary screw air
compressors available in the world today.

ELGI has designed your Horizon 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 Horizon compressor optimally.
Please familiarise yourself with all the information it contains.

I look forward to your continued satisfaction as a Horizon user. ELGI is honoured

to be your choice for all your compressed air needs.

Yours sincerely,

Jairam Varadaraj
Managing Director

vi
 About ELGI

ELGI is the technologically innovative company with five decades of expertise in the
manufacture of air compressors based in Cbe India. An ISO 9001:2000 company,
ELGI employs best in class practices and provides total in-house capabilities to decide
and manufacture products to meet international standards

ELGI is one of the few companies capable of manufacturing airends and compressor
packages in the world. It manufactures a wide range of air compressors such as
reciprocating air compressors, rotary screw air compressors, oil-flooded and oil-free
and centrifugal air compressors and also offers precision engineered components.

ELGI operates from two start-of-the art manufacturing plants in Cbe India. It operates
out of two advanced and sophisticated manufacturing facilities with R&D and CAD
facilities, a totally integrated machine shop, CNC helical rotor cutting machines, tool
management centres, and a metrology laboratory. The company has a dedicated
manufacturing facility for world renowned brands.

ELGI Manufacturing System is a customized blend of total quality management, total

productivity management and Lean manufacturing. The result : productivity is up 51%
and lead time to market has shrunk from eight weeks to just seven days.

ELGI has collaboration and tie-ups with leading foreign companies, institutions and
consultants that ensure the company remains at the cutting edge of manufacturing
technology. It has a committed and technically strong team of 1100 with 325 engineers.

ELGI has widened its global footprint by leveraging its off-shore manufacturing bases
in China, Brazil and Sharjah (UAE). The company has started its Chinese operations
in 2008 at Jiaxing, Shanghai to cater to the domestic market in that country. It has
also launched a full-fledged assembly facility in Brazil and has also set up a warehouse
facility in Middle East. In Europe the company has acquired Belair S.A of France,
which is engaged in assembly, sales and service of industrial compressors, piping
fitting and accessories for more than 25 years.

ELGI has a vast network of sales and service outlets manned by well trained highly
qualified and motivated engineers world wide. ELGI is a leading exporter of top blocks
of reciprocating air compressors and airends of screw air compressors for OEMs and
complete compressor packages all over the world. The company truly has a global
presence with over 30% of its products reaching end-users and OEMs in USA, Europe,
Australia, SE Asia and the Middle East. ELGI presently exports to 63 countries globally.

Driven by the philosophy of Think Long Run, ELGI believes in forging long running
partnerships with its stakeholders worldwide guided by reliability, technology, capability,
and values fuelled by innovation.

vii
Introduction

Your Horizon compressor belongs to a family of rotary screw compressors

from ELGI that currently has four members: E 30-E45.Overall, the features of
your Horizon translate to convenience for you. The compressor has only two
moving parts—the rotors—which do not touch each other but 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 Horizon 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 90ºC,
and therefore carbonised oil is not formed in the compressor.

The Horizon compressors feature a Varion capacity control system at the air
inlet side and a unique OSBID air–oil separation system. The capacity control
system ensures optimum air intake during start-up, normal running and
unloading. The OSBID system and the moisture separator at the outlet ensure
that oil and water are separated from the compressed air.

Please read the instructions in this manual carefully and follow them at all
times. The operating life and reliability of the compressor depend to a large
extent on correct operation and maintenance.

When calling your ELGI branch office, dealer or service centre 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 list provided in this manual and identify
the part number. Specify the part number and quantity in addition to the name
plate details.

1.0
ELGI’s Customer Care
System (CCS)
ELGI provides high-quality customer care and after-sales support through the
CCS, a computerised system developed in-house. The CCS aims to minimise
the time taken to resolve complaints.

Service Requests/Complaints

At the heart of the CCS is the toll-free telephone number 1800-425-3544 at

the centralized customer care centre at Coimbatore. Customers can register
their service requirements or complaints with coordinators here.

A unique tracking number is generated for each call logged by the CCS. The
customer is sent an automatic e-mail acknowledgement with the tracking
number and details of the call for reference.

A service engineer is assigned to the call, and the date and time of the engineer’s
visit are communicated to the customer by e-mail. Every requirement or
complaint must be resolved and closed in the CCS within a specified time
limit, failing which the call is brought automatically to the notice of the manager
higher in the hierarchy, up to the level of the Managing Director. Thus the CCS
ensures that not only are customer complaints logged, they are also attended
on time every time.

Enquiries

A number of calls received by the CCS relate to customers’ queries regarding

products and spare parts. The details are noted, and basic information on
product specifications and usage are provided. The caller is informed whom
to contact for further discussions. The enquiry is passed on to a salesperson
at the Head Office or the appropriate branch for follow-up.

The CCS Database

The CCS also creates a database of customers, adding every new customer
calling and thereby building a large pool of installation details. These details
are used to provide value-added services to improve customer satisfaction
with ELGI products.

CCS—Working Hours

Customers can now use the CCS from 08:30 to 21:30 IST six days a week
(Monday to Saturday). ELGI has received suggestions that the service be
extended to Sundays.

2.0
Multi-lingual Capability

The coordinators at the CCS are multi-lingual. They can handle calls in all the
major regional languages of India.

Coverage

The toll-free number of the CCS is accessible from the following areas:

Southern Region : Tamilnadu, Karnataka, Kerala, Pondicherry, Andhra

Pradesh, Andaman & Nicobar islands

Western Region : Maharashtra, Gujarat, Madhya Pradesh, Goa,

Lakshadweep islands

Eastern Region : Orissa, Chattisgarh, Jharkhand, West Bengal, Bihar and

the North-Eastern states

Northern Region : Rajasthan, Uttar Pradesh, Delhi, Haryana, Punjab,

Uttaranchal, Himachal and Jammu & Kashmir.

Other Contact Numbers

The CCS can also be availed through the following numbers:

Telephone : 0422-2589 206/2589 241/2589 242/2589 243

2589 244/2589 245/2589 325/3254 230
Fax : 0422-2589 240

Email : [email protected]

Customer Satisfaction Survey

If you have used the CCS, you may be contacted and your feedback sought
on the after-sales support received by you. Your response helps ELGI to
improve this service.

2.1
Commissioning Process

Before the new Horizon compressor is operated for the first time, it needs to
be installed at your site according to ELGI’s specifications. ELGI’s
commissioning engineer 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. The engineer 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 such as the cleanliness of the
atmosphere, temperature and ventilation are checked. Technical details relating
to your system such as particulars of your electrical installation are noted. The
operator of your compressor is familiarised with all aspects of both its normal
running and dealing with unusual situations. The commissioning process
provides to ELGI data that will help understand your requirements better.

Please make preparations for commissioning your Horizon compressor

according to the instructions provided in the Installation section of this manual.
Ensure that the location chosen meets the requirements of accessibility,
ventilation and safety. Provide electrical power as recommended in the
Installation chapter, in discussion with the ELGI commissioning engineer. Select
air pipe lines and receivers for your system according to the tables provided in
the same chapter.

Upon completion of the commissioning process, the commissioning engineer

will fill in a document known as the commissioning report. Please verify the
information filled in and attest the certificate of completion of commissioning.
The ELGI commissioning engineer will also sign the report. Kindly hand over
the commissioning report to the commissioning engineer. Please fill in also
the warranty card that comes along with the compressor and hand it over to
the engineer. The engineer will send the report and the card to ELGI’s Service
Department — Compressor Division, Head Office.

3.0
3.1
Using this Operation and
Maintenance manual
This operation and maintenance manual has been specially designed keeping
you in mind so that you can get the most out of your ELGI Horizon compressor.
Before you start using your compressor, do go through this manual thoroughly.
It contains vital information on operation as well as useful tips that will help
you keep your compressing running as good as new year after year.

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 information, illustrations and specifications in this manual are based on the
latest product information at the time of preparation of the manual. We reserve
the right to make changes in the product at any time without notice.

The manual must be available at all times to the personnel operating the
compressor.

4.0
Definitions and symbols

NOTE:

A Note clarifies procedures or conditions which may otherwise be misinterpreted

or overlooked. A Note may also be used to clarify apparently contradictory or
confusing situations.

CAUTION:

A Caution is to draw attention to a procedure which, if not done correctly, can

lead to equipment damage.

WARNING:

A 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.

SYMBOLS:

CAUTION DO NOT OPERATE

WARNING
DE-ENERGISE

OPERATION DO NOT ATTEMPT

REPAIRS
ENERGISED
(POWER ON)

CAN CARRY OUT DO NOT INHALE

REPAIRS OR
ADJUSTMENT

KEEP ACCESS
DOORS CLOSED

5.0
Technical Specifications

220V/380V/3ph, 60Hz E 30 E 37 E 45

Free delivery (m3/min (cfm))

at 7.0 bar g working pressure 5.41(191) 6.48(229) 8.01(283)
at 8.0 bar g working pressure 4.84(171) 5.92(209) 6.94(245)
at 9.5 bar g working pressure 4.53(160) 5.49(194) 6.74(238)
at 12.5 bar g working pressure 3.62(128) 4.62(163) 5.66(200)
Compressor main - motor power
30(40) 37(50) 45(60)
(kW(hp))

Motor rated speed (rpm) 1775 1780 1775

Motor frame size 200L 225 S 225 M

Fan motor power (kW(hp)) 1.5(2) 1.5(2) 1.5(2)

Fan motor rated speed (rpm) 1730

Fan motor frame size 90 L

Motor type (both main motor and

Totally enclosed fan cooled
fan motor)

Class of insulation of motors C l a ss F

Degree of protection of motors IP 55

Overall dimensions, Lx B x H 161675

75 x x8850
50 xx11375
365
(mm x mm x mm) 2000 x 980 x 1715

Net weight (kg) 1050 1100 1150

Optional downstream accessories

S Air receiver

S Air dryer

S Downstream filters

6.0
Installation

Handling the Compressor

Horizon compressors are shipped in wooden cases. They are to be lifted using
forklifts or cranes.

Please refer to the figures below for general guidance.

7.0
Installation

Wire

Spreader bars

7.1
Installation

S If the compressor is provided with a lifting bail then lift using the bail. If no
bail is provided, lift using slings. Compressors to be air lifted by helicopter
must not be supported by the lifting bail but only by slings.

S Prior to lifting, inspect the lifting bails and points of attachment for cracked
welds and for cracked,bent, corroded or otherwise degraded members
and for loose bolts and nuts.

S 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.

S Make sure the lifting hook has a functional safety latch, or equivalent,
and is fully engaged and latched on the bail.

S Use guide ropes or their equivalent to prevent twisting or swinging of the

machine once it has been lifted clear of the ground.

S Do not attempt to lift the compressor in high winds.

S Keep all personnel out from under the compressor when it is suspended.

S Lift the compressor no higher than necessary.

S Keep the lift operator in constant attendance whenever the compressor

is suspended.

S Set the compressor down only on level surfaces capable of supporting at

least its net weight plus an additional 10% allowance.

7.2
Installation

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:

S Key for doors

S Operation and Maintenance Manual
S Checklist of parts of the machine
S Electrical drawing

Tools may be provided on request. If any components are found missing, contact
ELGI immediately.

Compressor Location – Space around Compressor

Please observe all accident prevention regulations when installing

! this compressor.
WARNING

Install the compressor with adequate accessibility to ensure obstruction-free

operation and maintenance. Maintain a clearance around the compressor as
shown in the figure below.

7.3
Installation

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 45ºC. Excessively warm intake air affects the compressed
air output. When the discharge temperature of the compressor (temperature
at the compression unit) exceeds a set value, the compressor will switch off.
Also, the ambient temperature should not drop below +5ºC. Provide air supply
openings with adjustable louvres to ensure that the minimum temperature does
not drop below +5ºC in winter.

Never store combustible materials within a 10 m radius of the compressor.

The floor around the compressor must be of non-combustible material.

7.4
Installation

Ventilation and Exhausting Hot Air

Compressors may only be installed in a working area where the ambient noise
level does not exceed 85 dB(A).

Ensure adequate ventilation in the compressor installation area. The figure

provided indicates different ways in which this could be achieved.

Model Ventilating air

required
(m3/h)
E30 11880
E37 14650
E45 17820

7.5
Installation

Follow the guidelines herein for providing ventilation:

N Provide openings close to the floor level on walls/partitions close to the

air suction side of the compressor.

N Provide exhaust openings close to the ceiling for hot air exit.

N The air velocity in the supply and exhaust ducts should not exceed
4 m/s. The velocity is ascertained during commissioning using an
anemometer.

N Do not connect cool air inlet ducts directly to the compressor inlet side.
To eliminate transmission of vibrations, provide a soft bellows connector
between the duct and the compressor.

N Contact ELGI in case you need to provide a duct connection or filter

fitment on the compressor.

N A forced cool air flow should not be directed towards the compressor.

N The compressor is to be located such that the hot air from other machines
is not directed towards it.

Failure to observe the instructions regarding installation

and ventilation may result in an excessive increase or
decrease of the discharge temperature of the compressor,
! and the compressor will trip under high discharge
WARNING
temperature conditions. The output of the compressor will
also be affected.

7.6
Installation

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
Horizon compressor. A foundation is not necessary.

Electricals

You must provide a lockable main switch with pre-connected slow-blow main
fuses in accordance with industrial safety regulations.

Fuse ratings applicable for both 380 V and 220 V, 60 Hz/3 Ph power supplies
are mentioned in the electrical drawing.

Air Pipe-lines

Use the table below as guidance for selecting pipes for your system.

Free Nominal pipe diameter

air (cfm) ½ inch ¾ inch 1 inch 1¼ inch 1½ inch
80 lb 100 lb 125 lb 80 lb 100 lb 125 lb 80 lb 100 lb 125 lb 80 lb 100 lb 125 lb 80 lb 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 0.0058 0.0058 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
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
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
50 10.7 8.65 7.01 2.42 2 1.62 0.73 0.6 0.49 0.18 0.046 0.12
60 3.47 2.84 2.33 1.02 0.84 0.69 0.25 0.21 0.17
70 4.73 3.85 3.14 1.36 1.12 0.92 0.34 0.28 0.23
80 6.14 5.01 4.08 1.76 1.44 1.18 0.44 0.36 0.3
90 7.75 6.4 5.17 2.23 1.85 1.49 0.55 0.45 0.37
100 9.62 7.8 6.33 2.69 2.21 1.81 0.066 0.55 0.45
125 15.5 12.4 9.8 4.18 3.41 2.79 1.03 0.85 0.69
150 23 18.1 14.4 5.75 4.19 3.99 1.47 1.2 0.99
175 1.81 6.8 5.45 2 1.64 1.32
200 10.9 8.79 7.11 2.58 2.12 1.73

7.7
Installation

Receivers for Compressed Air Systems

The table below is given for your guidance in selecting an appropriate air receiver
for your system.

Receiver specifications Compressed capacity

Volume Modulation
Height Diameter Weight On/Off control
control
(mm) (mm) (kg) (cfm)
(ft3) (m3) (cfm)

0.25 8.83 1740 655 115 Up to 40 Up to 60

0.5 17.66 2100 780 210 41–85 61–120
1 35.32 2785 1000 344 86–140 121–235
1.5 52.97 2500 1250 783 141–225 236–355
2 70.63 3175 1250 954 226–310 356–470
3 105.95 2805 1565 1308 311–445 471–710
4 141.26 3580 1595 1564 446–570 711–945
5 176.58 3535 1780 2129 571–700 946–1180
6 211.89 4185 1780 2343 701–850 1181–1415
7 247.21 3640 2100 2885 851–990 1416–1650
8 282.52 3985 2100 3115 990–1130 1651-1885

Commissioning

Before the new Horizon compressor is operated for the first time, it must be
installed at your site by ELGI’s commissioning engineer. The following
instructions and specifications are given only for your reference. They are
applicable to standard Horizon compressors without additional
equipment(Receiver, Dryer etc). For identification of parts, refer to the
Functional Description section of this manual. An electrical circuit diagram is
delivered with every Horizon compressor (kept inside the electrical control
panel) for electrical wiring reference.

Before commissioning, check the equipment for any visual damage of parts.
Every ELGI screw compressor is subjected to a test run prior to despatch.
Transport damage at a later stage cannot, however, be excluded. Therefore,
observe the compressor closely during commissioning and the trial run.

7.8
Installation

N Remove the transport security bolts/clamps fitted on the compressor parts.

N Connect the compressor to the air network.

N Check the oil level in the receiver tank before starting the compressor.
The oil level should be up to the middle of the oil sight glass provided on
the receiver tank. The first oil-fill capacity of the E30–E45 compressors
is 20 litres. Initially pour 16 litres for all models. Run the unit for 3 min and
shut it down for 2 min for oil foaming to settle down. Pour the balance
quantity of oil to make up the first oil-fill capacity.

N Use ELGI Air Lube or an equivalent oil from the following list for optimum
performance of the compressor.

Ensure that the oil filter cartridge is fitted properly.

7.9
Installation

Keep the air outlet line ball valve provided at the rear of the compressor in the
fully open condition before starting the compressor.

Connect the moisture outlet line provided at the rear of the compressor to the
waste water disposal line.

7.10
Installation

Connect the earthing line to the point provided on the base frame at the front
of the compressor.

Control panel

Power cable entry

Check the power supply requirements from the name plate and connect the
leads L1, L2 and L3 to the terminals inside the electrical control panel on the
compressor.

7.11
Installation

Check the power supply requirements from the name plate and connect the
leads L1, L2 and L3 to the terminals inside the electrical control panel on the
compressor.

Ensure that only authorised electricians carry out the electrical

work. Study the electrical circuit diagram before starting work.
! Change transformer tappings & OLR setting according to voltage
WARNING
condition (415 & 380V) at site.

Check the direction of rotation of the main motor and the fan 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 front side (non-driving side).

7.12
Installation

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.Run the compressor at the recommended pressure.
CAUTION
! Running the compressor in the wrong direction for more than 5 s
CAUTION will cause damage to compressor parts or even total destruction.

N Select the auto soft touch in the NeuronII controller after switching "ON".
N Switch on the compressor after ensuring all the above points and run at
the rated pressure.

NOTE
All the settings for pressure sensor, electrical protection devices,
temperature sensor, etc. are set at the factory before despatch.

N In case of problems during the running of the compressor, check which

warning LEDs 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 is run, switch it off
immediately and contact the ELGI service engineer for remedy.

All the points listed in the foregoing are to 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 service engineer.

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
The sump or air–oil separator tank.

7.13
Installation

Airend

N Remove the airend discharge hose/pipe coupling fitted to the air receiver.
N Rotate the coupling three times so that the oil present inside the airend
comes out through the discharge port.
N Plug the discharge port.
N Remove the inlet rubber duct connected to the intake valve of the air filter
assembly.
N 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.
N 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.
N Drain the rust-preventive oil by opening the discharge port plug fully.
N Refit the hose/pipe coupling on the discharge port.
N Take care to ensure that all the openings are plugged always to avoid
dust entry.
N This procedure protects the airend for up to six months storage. It must
be repeated every six months during storage.

Motors
N Check the insulation of the motor winding.
N Remove moisture if any in the motor.
N Check the junction box terminals for tightness of the wires.
N Grease the motor.
N This procedure will protect the motor for up to one year storage.
N Air–oil separator tank
N Replace the oil filter element.
N Replace the air filter element.
N 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.
N Clean the tank using a water jet.

The separator tank may now be stored for up to two years. Replace the
separator element before using the compressor again.

7.14
Disposal of packing

The wood used to make the shipping crates of the Horizon 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.

8.0
Functional description

Dimensions of the compressor unit

9.0
Functional description

Parts of the compressor - Exterior

Main motor
Receiver tank

9.1
Functional description

9.2
 Functional description

Compression in a screw compressor

At the heart of the Horizon compressor is the compressor unit or airend driven
by an electrical motor. There are two rotors, the male rotor and the female
rotor, in the airend. These mesh with each other as they turn.

Air is trapped between the flutes and lobes of the rotors, getting progressively
compressed as the rotors turn. The compressed air flows out towards the
discharge port. One pocket of trapped air getting compressed progressively is
illustrated (next page).

9.3
Functional description

Compression in a screw compressor

In practice oil needs to be injected in large quantities into the air. It acts as a
coolant, removing the heat generated upon compression. It also serves to
seal leaks between the rotors and the housing, and lubricates the rotors and
the bearings and gears.

Internal cooling using oil permits the temperature at the compression end to be
maintained at approximately 80–85ºC when the ambient temperature is 30ºC.

9.4
Functional description

Air Intake System

Air is provided to the airend by the air intake system.

Air filter assy

Dust indicator

Intake valve

Air end

The filter prevents foreign particles like dust from entering the airend. The air
inlet valve controls the amount of air taken into the airend. The indicator on the
filter turns red when the filter element is to be cleaned or replaced.

Normally, when compressed air is being delivered in the service line, the intake
valve is open. When very little or no air is being supplied, the intake valve is
closed.

9.5
Functional description

Discharge system

Much of the oil is removed from the air–oil mixture by the OSBID process (see
next page), but some oil still remains in the air. To bring the oil content to within
the desirable limits, below 3 ppm, the lean mixture is passed through a high
efficiency separator element. Oil separated thus is returned to the lubricating
system through a scavenge line. The temperature of the air at this stage is still
higher than the desired temperature at the receiver. So it is cooled in a cooler to
a few degrees above the ambient temperature. The air passes through a minimum
pressure valve (see Safety system and interlocking devices in this section).
The minimum pressure valve is positioned downstream of the oil separator. It
maintains a minimum pressure for safe supply of oil to the compressor unit.
Before the air is discharged from the compressor to a receiver, moisture is
removed from it by a moisture separator. This separator removes 99% of the
moisture in the air. Air is provided to the airend by the air intake system.

NOTE
Consult ELGI for the selection and supply of a suitable dryer for your
requirements of dry air.
9.6
Functional description

The OSBID system

The compressed air produced by the airend is mixed with oil. This air–oil mixture
is delivered to a receiver tank. The Horizon compressors are equipped with an
air–oil separation system called the OSBID system. The OSBID process uses
the difference in the densities of air and oil to separate them.

9.7
Functional description

Cooling and lubrication system

The oil separated from the air–oil mixture is cooled in the oil cooler whose outlet
temperature is controlled by regulating fan flow by the neuron controller. The oil
is passed through an oil filter, which removes dust and other impurities before it
is injected into the airend. The oil circulation circuit is operated solely by the
pressure differential in the system and does not require any separate oil pump.

As stated previously, the oil has several critical functions in the compressor. It
removes the major part of the heat of compression, seals all clearances in the
airend and lubricates the bearings and gears. The properties of an oil that
determine its suitability for use in the compressor include its viscosity, wear
characteristics, demulsibility (tendency to lose emulsive nature), heat resistance
and thermal stability.

ELGI Air Lube, blended using heavy-duty hydraulic based oil with the right
amounts of additives under strict quality control checks, is recommended for
your compressor. ELGI Air Lube ensures best compressor performance.

9.8
Functional description

Cooling and lubricating system

The life of any mineral oil decreases by almost 30–40% for every 10ºC above
95ºC. It is recommended that the oil change frequency is varied in summer
and winter months for optimum benefits. A good record of the operating
temperature of the compressor is essential for this. Continuous operation of
the compressor at a temperature above 100ºC without changing the oil will
lead to varnish formation and will affect the life of the bearings and the airend.

Drain Period (h)

Environment
Air Lube Air Lube Air Lube
XD Plus Dura Plus
Normal industrial
applications with an
operating temperature
of 90ºC 1000 2000 6000

Dusty environments 750 1500 6000

The above figures are guidelines based on extensive trials in the field. However,
our Service Engineers can help you optimize the oil drain interval for your
application based on the operating temperature, pressure and the
environmental conditions prevailing at your installation.

9.9
Functional description

Capacity control system

The compressor is provided with a capacity control system at the air inlet to
ensure optimum air intake during starting, normal running and unloading. The
operation of this system is described in the Operation section of this manual.

Canopy

9.10
Functional description

Transmission system

Main motor

Adapter ring

Coupling guard

Drive coupling

Airend

Electrical system

The compressor starter is an automatic star–delta starter with safety interlocks.

When power is switched on, the control relay is energised if no fault is detected.
If any of the fault sensing switches is triggered the contact relay will not be
energised.

The fault warnings are displayed as described in the following section.

NOTE
Power should be supplied to the compressor through a fuse switch unit
of suitable rating mounted within 5 m of the compressor

9.11
Functional description

Electrical System

The compressor starter is an automatic star–delta starter with safety interlocks.

The compressor can be controlled in all modes (Local, Remote and DCS) by
the Neuron II, a dedicated microcontroller. Neuron II has eight digital inputs, two
analogue inputs and six relay outputs. The inputs are provided by contact
switches, pressure and temperature transducers. Neuron II control panel has
eight tactile push-buttons, alphanumeric LCD for display of compressor status
and related information, and 14 LEDs (Annunciation Window) for user interface.
If all the inputs are normal, the display indicates “READY”.

To start the compressor, press the “START” (green) push-button located on the
controller. The controller will switch on the relays in the correct order, and these
in turn will energise the delta contactor and the solenoid valve. The LCD display
will show the current status of the compressor. The compressor runs and builds
up pressure.

To stop the compressor, press the STOP (red) push-button. If the machine trips
due to a fault, press the Reset button after rectification of the fault.

Preprogrammed timer functions:

N Star–delta delay—determines the star-to-delta changeover time; set at
any value between 4 and 8 s.
N Delta-to-run (DTR) delay—decides the delay between the delta change
over and energising of the solenoid valve.
N Standby time (unload monitoring time)—stops the compressor if it is running
in unloaded condition for a set time (15 min) and starts the compressor
automatically on demand.

9.12
Functional description

NOTE
Ensure 24 V AC power supply to Neuron II controller. Can modify the
timer settings under m/c settings menu present in the controller.
Before starting the compressor, check following electrically.

Separator element warning

Indicates that the separator element needs to be replaced. The compressor

does not shut down automatically in this situation.

Oil filter warning

Indicates that the oil filter element needs to be replaced. The compressor
does not shut down automatically in this situation.

High discharge temperature trip

The compressor shuts down automatically and this warning light goes on when
the discharge temperature exceeds the preset value of 110±5ºC.

Main motor overload trip

This warning lights up and the compressor shuts down when the main motor
is overloaded.

Fan motor overload trip

The compressor shuts down and the warning lights up when the fan motor is
overloaded.

Graphic warning display

This gives graphically the location of a fault (condition requiring a warning).

Reset button

This button must be pressed before restarting the compressor after it has shut
down with a warning and remedial measures have been taken.

9.13
Functional description

Safety system and interlocking devices

Your Horizon compressor is equipped with the following devices for reliability
and safety:

Discharge temperature switch

This is provided to shut down the compressor if the discharge air–oil mixture
temperature reaches a preset value of 110 ± 5ºC. The temperature probe is
fitted on the airend outlet cover or receiver tank.

Minimum pressure valve

This valve is fitted at the outlet of the oil separator and maintains a minimum
receiver tank pressure of about 4 bar g. This facilitates proper air and oil
separation and oil circulation to the airend.

Pressure relief valve

The pressure relief valve relieves the pressure in the air–oil receiver tank
when it exceeds 140% of the working pressure.

Overload relays for main motor and fan motor

These relays are fitted on the electrical control panel. These relays ensure the
compressor is switched off when the power consumption exceeds a set value.

9.14
Operating precautions

ELGI designs and manufactures its products for smooth and safe operation.
However, the responsibility for safe operation rests with those who use and
maintain these products. The following precautions are offered as guidance.
When followed regularly, they will minimise accidents and failures throughout
the useful life of your Horizon compressor.

The compressor should be operated only by those who have been trained and
delegated to do so and have read and understood this operation and
maintenance manual. Failure to follow the instructions, procedures and
precautions given in this manual may increase the possibility of accidents and
failures.

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
WARNING improper earthing and reverse rotation.

When you know the compressor to be in an unsafe condition, tag it as unsafe

and render it inoperative by disconnecting the power supply so that others who
many not know of this unsafe condition will not attempt to operate it until the
condition is corrected.

Electrical arcing from compressor components can ignite

flammable liquids and vapours which can result in serious injury.
Never operate the compressor near flammable liquids or vapours.
! If the compressor is used to spray flammable materials, keep it
WARNING
at least 6 m away from the spray area.

Do not modify your Horizon compressor except with written approval from ELGI.

10.0
Operating precautions

Pressure release

N Manually pop up the pressure relief valve at least weekly when the
compressor is operating to make sure the pressure relief valve is not
blocked, closed, obstructed or otherwise inoperative.

Test ring

Safety valve

N Use only the correct tools for maintenance and repair work. Do not allow
the manufacturers’ rated safe operating pressure for pipes, valves, filters
and other fittings to be exceeded.

N Open the oil filter 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.

N Vent all internal pressure prior to opening any line, fitting, valve, drain
plug, connection or other component such as a filter. Vent pressure by
popping up the pressure relief valve.

10.1
Operating precautions

Pressure release - Contd.

N Keep personnel out of the line of the discharged air when opening hoses
or other points of compressed air discharge

Do not engage in horseplay with air hoses: serious injury or

! death may result.
WARNING

N Do not use air at a pressure greater than 2.5 bar g for cleaning purposes.

Fire and explosion

N Clean up spills of lubricants or other combustible substances immediately.

N Shut down the compressor and allow it to cool down before checking or
adding oil. Move sparks, flames and other sources of ignition away.

N Do not permit smoking in the vicinity.

N Do not use flammable solvents for cleaning purposes.

N Keep electrical wiring and other terminals in good condition. Replace

any wiring that has cracked, cut, abraded or otherwise degraded insulation.
Keep all terminals clean and tight.

N 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.

10.2
Operating precautions

N Keep oily rags, trash, dry leaves, litter or other combustibles out of and
away from the compressor.

N Do not operate the compressor without a proper flow of cooling air or with
an inadequate flow of lubricant or with a degraded lubricant.

N 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

N Keep hands, arms and clothing away from couplings, fans and other moving
parts.

N Do not attempt to operate the compressor with the fan guards, coupling
guards or other guards removed.

N Keep access doors closed except when making repairs or adjustments.

N Wear snug-fitting clothing and confine long hair when working around the
compressor, especially when hot or moving parts such as the cooler, the
airend, the thermal valve, the main motor or the fan motor are exposed.

N Prior to attempting to start the compressor or operate it, make sure that all
personnel are clear of the compressor.

N Prior to attempting repairs or adjustment, disconnect the power at the

source and verify at the compressor that the circuits are de-energised.
This minimises the possibility of accidental start-up or operation. This is
especially when the compressor is remotely controlled.

10.3
Operating precautions

N Keep hands, feet, floors, controls and walking surfaces clean and free of
water or other liquids to minimise the possibility of slips and falls.

Hot surfaces

N Avoid bodily contact with hot oil, hot coolant and hot surfaces.

N Keep all parts of the body away from all points of air discharge.

N 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

10.4
Operating precautions

N Do not use air from the compressor for respiration.

N 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

N 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
minimises the possibility of creating a current path through the heart.

N Attempt repairs only in a clean, dry, well lit and ventilated area.

N Do not leave the compressor unattended with open electrical enclosures.

If necessary to do so, disconnect the power to the compressor at the
source and lock it out so that power is not inadvertently restored.

N Disconnect, lock out and tag the power source prior to attempting repairs
or adjustments, turning the machinery manually or handling ungrounded
conductors.

10.5
Schematic Diagram

Schematic Diagram with 2 kg/cm2 Sump Pressure During Unloading Mode

Details of parts in Schematic Diagram

1. Air end 14. Oil drain hose

2. Intake valve 15. Oil drain valve
3. Air filter Assy 16. Tank receiver
4. Indicator air filter 17. Oil return line orifice
5. Temperature sensor 18. Pressure transmitter
6. Coupling 19. Pressure relief valve
7. Electric motor 20. Moisture drain outlet port
8. Minimum pressure valve 21. Moisture seperator
9. Blow down valve 22. Air outlet ball valve
10. After cooler (Air) 23. Oil filter
11. Solenoid valve 24. Thermo switch
12. Air-Oil seperator 25. Oil cooler
13. Oil sight glass 26. Fan (Electric motor driven)

11.0
Operation

Checks before starting the compressor

N Fill oil in the oil tank up to the half level of the oil sight glass. Tighten the
oil filling plug.

N Open all doors and visually check that the machine for suitability for
operation.

N Open the door of the electrical panel at the front of the compressor and
check the tightness of all electrical connections. Also check whether the
three phases are connected securely (red, yellow and blue wires).

Starting the equipment

N Press the start button (green) and check that the main motor turns
clockwise (when viewed from the front of the compressor). Stop the
compressor by pressing the stop button (red) on the Neuron II Controller.

N Run the compressor for 5 min. Stop the compressor and check the oil
level. Add or remove oil to bring the oil level up to the half level of the oil
sight glass.

Starting-mode

N When the machine is switched on the motor runs in the star mode. Pressure
develops in the air receiver and since the minimum pressure valve opens
at 2.5 bar g, the pulse goes to a normally open (NO) solenoid. The pulse
reaches the blow-down valve/intake valve. The blow-down valve releases
the sump pressure to atmospheric pressure and the intake valve closes.
The starting load of the motor is reduced thus.

Normal operation

N There is a star to delta changeover. The NO solenoid valve is energised

and becomes normally closed.The pulse goes to the intake valve and the
blow-down valve is stopped.The blow-down valve closes and the intake
valve opens.Now the pressure in the system goes up and the minimum
pressure valve opens the pressurized air to the discharge.

12.0
Operation

Unloading mode

N Load pressure & unload pressure values will be pre programmed in the
Neuron II Controller itself.

N After reaching the maximum set pressure (working pressure),the pressure

sensor senses the pressure and cuts off the solenoid electrical supply.
The solenoid valve becomes NO. The pulse goes to the intake valve and
the blow-down valve, which releases the sump pressure to atmospheric
pressure and the intake valve closes. The compressor runs, maintaining
the minimum sump pressure. The blow-down line is connected to the air
filter element for auto cleaning. Another line is provided to the airend for
better lubrication. During every unloading process the blow-down valve
releases air, which is routed to the air filter element for cleaning it. This
reduces cleaning and maintenance of the air filter.

Monitoring the running of the compressor

Monitor the indicators on the Neuron II front panel regularly when the compressor
is running. Under the following conditions, a warning light on the controller will
light up and the compressor will stop automatically:

N High discharge temperature

N Main motor overload
N Fan motor overload
N Reverse direction
N High sump pressure

The separator element and oil filter indicators will light up if these need to be
changed. However, under these conditions the compressor will continue to run
and will not stop.

Stopping

Press the stop button (red) on the controller front panel to stop the compressor.

12.1
Maintenance

The maintenance of Horizon compressors is minimal but important. The indicators

on the control panel of the compressor give warnings when servicing of the
suction filter or oil filter element is necessary.

Maintenance schedule

Daily: Prior to starting the machine, it is necessary to check the oil level in the
receiver tank (see Starting the compressor in the Operation section No.
10.1). Should the level be low, add the necessary amount. If the addition of oil
becomes very frequent, a problem has developed which is causing this
excessive loss. Refer to the section on excessive coolant consumption in the
Troubleshooting section for a probable cause and remedy.

After a routine start has been made, observe the instrument gauges and be
sure they monitor the correct readings for that particular phase of operation.
After the machine has warmed up it is recommended that a general check on
the overall machine and instruments be made to ensure that the compressor is
running properly.

After initial 100 h of running:

Do not remove caps, plugs or other components when the

! compressor is running or pressurised. Stop the compressor and
WARNING
relieve all internal pressure before doing so.

A check-up is necessary to detect and clean the system of any foreign materials.
Carry out the following operations.

N Clean the return line orifice(By pressurised air)

N Change the oil filter element

13.0
Maintenance

After every 1000 h of running:

N Change the compressor oil depending on the type of oil.

N Change the oil filter element

After every 1500 h of running:

N Change air filter element.

After every 4000 h of running:

N Change separator element.
N Clean receiver tank.
N Grease the motor. Use only a lithium based high temperature grease
such as Esso Unirex N 3 or Servo GEM N 3.

Maintenance of individual components and systems:

Check all the accessories independently to verify that they are functioning as
required and replace their components as necessary.
NOTE

The number of hours of running after which the filter, separator elements
and oil are to be replaced are given as a guideline for normal operating
conditions. They may vary depending on actual operating conditions.

Oil filter

The oil filter is fitted between the oil cooler and the compressor unit. The
components of the oil filter are shown in the figure below.

13.1
Maintenance

This is a full flow filter with a replaceable pleated element. For servicing this
filter, use repair kit (Available with service personnel) The procedure for
complete servicing of this filter is as follows.

Disassembly

N Disassemble the filter element by rotating it counter-clockwise.

N The hex adapter should be in the filter head during disassembly.
N Drain the oil present in the filter element.
N Once the recommended life of the element is over, it has to be replaced
with a new element.

Assembly of new filter element

N Ensure that the seal on the filter element is not damaged.
N Clean the seating surfaces.
N Lubricate the filter element.
N Assemble the filter element by rotating the filter element in the clockwise
direction; tightening by hand is sufficient.

13.2
Maintenance

Separator element

The separator element must be changed (a) when an indication appears on

the controller screen. Order a separator element kit (Refer insurance kit).
Observe the following procedure for separator replacement.

N Relieve oil pressure from the receiver tank and all fluid lines.

N Disconnect all piping connected to the receiver tank cover to isolate the
receiver tank from the return lines, service line, etc.

N Loosen and remove the hex head bolt from the cover plate.

N Lift the cover plate from the receiver tank.

N Remove the separator element.

N Scrap the old gasket material from the cover and flange on the receiver
tank. While doing so, take care not to let the scraps fall into the receiver
tank.

N Inspect and clean the receiver tank for rust and dirt.

N Fix the new gaskets after ensuring that the staples are present in both
the gaskets.

N Place the new separator element into the receiver tank, taking care not
to dent it against the tank opening.

N Clean the underside of the receiver tank and remove any rust. Paint the
surface with an epoxy paint.

N Replace the cover plate and fasten the cover on the receiver tank.

N Reconnect all piping. Ensure that the return line tube has a clearance of
1/4” above the bottom of the separator element. This will ensure proper
oil return flow to the compressor.

N Clean the return oil strainer before restarting the machine.

13.3
Maintenance

Receiver tank cover

Return line tube

Min 1/4"

Separator element

Air inlet filter

Clean the air filter using moisture free compressed air at less
than 2.5 bar g. The direction of cleaning should be from inside
to outside.
!
WARNING Do not forget to remove the air filter clog indicator from the old
air filter and fix it on the new air filter.

When the air filter clog indicator indicates a blocked condition, remove the air
filter and replace it with a new one.

N Shine a bright light from inside the element to inspect for damage or holes
that will cause leaks. The light will emerge from the holes, indicating their
location.

N Inspect all gaskets and gasket contact surfaces of the housing. Should
faulty gaskets be evident, replace the element immediately.

N After the element has been installed, inspect and tighten if necessary all
air inlet connections prior to resuming operation.

13.4
Maintenance

If a clean element is to be stored for later use, it must be stored in a clean

container.

Hub

Element

Hub

Drive coupling

N The unit has been provided with a flexible coupling, which has the following
advantages:

N There is no relative movement between connected parts and hence there

is no wear and tear.

N The coupling needs no lubrication and maintenance.

N The flexible element has a very long life and is the only part which needs
replacement.

N The coupling has torsional flexibility and dampening properties that allow
it to absorb torsional vibrations and shock loads.

If the flexible member undergoes failure, a loud noise is heard, indicating a

problem.

No alignment check is required. The intermediate housing between the airend

and the motor is designed and fabricated to ensure correct alignment of shafts
when fitted.

Disconnect all power at the source before attempting

! maintenance or adjustments.
WARNING

13.5
Maintenance

If you need to reduce the operating pressure to save energy,

! contact ELGI’s Service Engineer.
WARNING

Minimum pressure valve

Maintenance of the minimum pressure valve is minimal. The only part which
normally requires replacement is the O ring on the piston.

Housing

Cap
Plunger

Spacer
Valve seat

Teflon seat Spring

Washer
'O' ring
Allen screw

Piston

Housing

13.6
Maintenance

The minimum pressure valve cover is under heavy spring tension. Loosen the
cover bolts one turn at a time alternatively to relieve the spring tension.

Extreme caution should be taken when removing the cap or cover

! from the body because of the spring tension.
WARNING

N Remove the cap evenly to relieve the spring tension.

N Remove the spring.
N Remove the piston.
N Remove the O ring and discard it.
N Clean the piston.
N Replace the O ring.
N Coat the piston and O ring with grease.
N Replace the piston.
N Replace the spring and cap.

Inlet valve
Screw

Stopper

Gasket

Screw

Housing
Spring washer

Spring outer Washer

piston

Cup seal 'O' ring

Pressing pad
Piston

'O' ring Sliding pin

Spring
Cylinder cover Inner piston

13.7
Maintenance

Inlet valve maintenance usually involves replacement of the piston spring,

piston O ring, seal ring and check valve spring. Follow the procedure below
for proper installation:

N Remove the control lines from the fittings on the intake valve.

N Remove the four cap screws that attach the valve body to the airend and
remove the valve.

N Remove the snap ring and the Teflon O ring inside the valve body.

N Lift and remove the check valve assembly and spring from the inlet body
flange.

N Remove the piston cap, piston spring and piston.

N Clean the valve body as needed, making sure all the air passages are
clear and the old seal ring is removed from the inlet body flange.

N Reassemble the inlet valve using the new parts supplied in the repair kit.

N Install the cup seal on the piston, lightly oil the piston and install it in the
valve body.

N Install the new piston spring and replace the piston cap.

N Place the new check valve spring into the piston and install the check
valve assembly.

N Position the Teflon O ring in the valve body and install the snap ring.

N Clean the airend/intake valve flanges before installing the new flange
seal ring.

N Install the valve on the airend and apply a torque of 45–50 ft lb.

N Install the control lines and air inlet elbow.

N Start the compressor and check for proper operation of the intake valve.

13.8
Maintenance

Blow-down valve
Hex. Screw

Spring washer

Top cover

Gasket

'O' ring

Plunger

Main body

Valve

Valve cone

Spring

'O' ring

Bottom cover

Spring washer

Hex. Screw

Maintenance of the blow down valve is limited to replacement of the gasket and
internal ring and seat. Using the spare kit, follow the instructions given below
for proper installation.

N Remove the four screws on the top cover which hold the assembly together.
N Pull the top cover away from the body.
N Remove the old gasket and replace it with the new one.
N Align the top cover with the body, replace the four screws and tighten.
N To replace the valve seat, loosen and remove the two socket head screws
in the bottom cover.

13.9
Maintenance

N Pull the bottom cover from the main body.

N Remove the cover ring, spring, seat cup and seat. Discard the seat and
ring and replace them with the new ones in the kit.
N Reassemble the bottom cover.

Moisture separator

The water separator will operate indefinitely under normal working conditions.
However, at some time, it may be necessary to replace the seals, should the
housing leak.

13.10
Maintenance

N Isolate the housing from the air supply.

N Depressurise fully using the vent valve at the bottom of the bowl.
N Unscrew the bowl and remove it. If the pressure has not been completely
released from the housing, air will escape from the warning hole, giving an
audible alarm. Screw back the bowl and repeat step 2 before beginning
again.
N Check the condition of the O ring and replace it if necessary. Clean the
screw threads.
N The auto drain assembly is not serviceable and must be replaced if it is
faulty.
N Check the auto drain seal and replace it if it is worn.
N Replace the vent valve if it is faulty or leaking.
N Refit the bowl with the O ring seal.
N A sight glass is provided to monitor the functioning of the automatic drain.
Under certain conditions it can become contaminated. When this happens,
dismantle it and clean it. A replacement kit (Refer insurance kit ) is available.
N Repressurise and check for leaks. If leaks do occur they will most probably
be from the bowl O ring. Depressurise the housing and remove the
O ring as stated above. Inspect it and clean it. Ensure that the mating
surfaces are clean, refit the O ring and repressurise.

NOTE
When replacing the auto drain, take the opportunity to clean the inside of
the bowl and the screw threads.

Procedure for cleaning the cooler

The following procedure is suitable for cleaning the internal surfaces of copper
oil coolers:

N Mix toluene and isopropanol (isopropyl alcohol) in a 50:50 ratio by volume

and circulate this through the cooler for a minimum of four hours.

Handle toluene and isopropanol with care. These solvents are

! harmful and hazardous to humans.
WARNING

13.11
Maintenance

N For aluminium coolers, use a 5% by volume mixture of caustic soda in

water. Circulate this mixture at 60ºC in the cooler for five hours. The
duration of circulation may be increased if required.

N The exterior of both copper and aluminium coolers may be cleaned using
steam or mild caustic soda solution in water (5 %).

N Exteriors of coolers of compressors used in textile industries can be

cleaned at regular intervals using compressed air at less than 7 bar g to
avoid choking of the cooler fins with cotton.

Do not get rid of the cotton in the cooler fins by burning it. This
! may lead to deformation of the cooler. It may also lead to expansion
of the cooler joints, resulting in leakage
WARNING

Oil service procedure

N Drain the old oil from the separator tank.

N Drain the old oil from the oil cooler using an air jet. Direct the air jet from
the motor side and collect the oil from the moisture filter side. Open only
the inlet and outlet of the cooler. All other openings should be closed.

N Remove the oil filter element and drain the oil from the filter.

N Rotate the drive coupling manually and remove all the oil from the airend.

N Fill new oil as described in the manual in the Installation section

(Commissioning). Use only an oil recommended in this section.

N Replace the oil filter element.

N Refit all the plugs of the separator tank and the oil cooler.

N Run the compressor for a few minutes and stop it after closing the air
outlet line ball valve.

N Check the oil level in the separator tank again. It should be at the half
level of the oil sight glass after the foam has settled down. If it is less, add
oil till it reaches the half level.

13.12
Disposal of consumables and
replaced parts
The moisture condensate separated from the compressed air contains oil
particles. Disposal of the condensate and of filter elements is to be done in
accordance with the pollution control norms prevailing at the time of compressor
installation or use.

The compressor will not give warnings during short operating

times. It will operate below the dew point, and moisture condensate
! will mix with oil. This will reduce the lubricating qualities of the oil
WARNING
and lead to damage to the compressor.

Parts of the compressor that are replaced will have metal and rubber
components. These may be recycled and disposed of according to pollution
control regulations, respectively.

14.0
Troubleshooting

Problem: Machine not starting

Check Remedy

Main disconnect
Close switch
switch open

Line fuse blown Replace fuse

Control Transformer
Replace fuse
fuse blown

Reset. If trouble persists,

Motor starter check whether motor
overload tripped starter contacts are
functioning properly

Low incoming Do alternate

voltage arrangement

Wire loose Check wires for loose

connection connection

Emergency push
Replace emergency
button locked /
push button / replace
malfunctino

Due for consumbles

Change if accordingly
change (see warning
message)

Incoming RYB
Change if accordingly
phase connection
15.0
Troubleshooting
Problem: Machine status down with the air demand present

Check Remedy

Low incoming Do alternate

voltage arrangement

Loss of control Check for tappings of

voltage control transformer

Separator element
Check and replace
clogging / defective

Low pressure setting Set to correct

in Transmitter working pressure

Stand by time 10
Reset
minutes ( 6 times start
accordingly
& stop allowed) in 1 hr

15.1
Troubleshooting
Problem : High discharge temperature trip
Check Remedy
Proper ventilation in Make arrangement
exhaust and inlet for proper ventilation

Insufficient space Provide required space

around compressor around the compressor

Cooling air flow Clean cooler and check

restricted for proper ventilation

Cooler plugged Clean the cooler tubes

Ambient temperature Provide sufficient

is too high forced air ventilation

Low oil level Fill oil to correct

the level

Clogged oil filter Replace the filter

element

Poor quality oil Check and change

Cooling fan rotation Check wiring regularly

Temperature
Calibrate it
sensor in ambient

Check neutral Connect / ensure

connect given Neutral

Check fan motor fuse Replace if blown

15.2
Troubleshooting
Problem: Excessive oil in service line / consumption

Check Remedy

Line pressure if Do proper

less than 5 bar compressor selection

Loading / Unloading
Do proper
pattern, if unloading is
compressor selection
more than loading

Clogged return line

Clean strainer and
strainer or orifice
orifice

Separator element
Change separator
damage or not
element
functioning properly

Leak in lubrication Check all pipe

system connection for leakage

Drain and change the

Excess oil forming
oil

Oil level too high Drain to correct level

15.3
Troubleshooting
Problem: Oil leaking through suction side when the unit is shut off

Check Remedy

Oil - stop valve Check and

malfunctioning replace

Discharge check valve Check and

malfunctioing replace

Intake valve Check and replace

malfunction kit

Solenoid valve
Check and replace
malfunction

15.4
Troubleshooting
Problem : Pressure relief valve opens

Check Remedy

Defective pressure Replace pressure

relief valve relief valve

Defective separator Replace separator

element element

Minimum pressure
Replace MPV kit
valve struck

15.5
Troubleshooting
Problem :Machine not building up full discharge pressure

Check Remedy

Too much air Check for service line

demand leaks or open valves

Dirty air filter Change element

Pressure regulator Adjust regulator valve

valve out of as per the instruction
adjustment given in manual

Defective pressure Check diaphragm and

regulator valve replace if necessary

Intake valve Check and replace kit

malfunction

Solenoid valve Check and replace

malfunction

15.6
Troubleshooting
Problem: Excessive operating pressure

Check Remedy

Defective pressure Check and

transmitter replace

Defective solenoid Check and

valve replace

Defective blow down Check and

valve replace

Check the loading and

unloading relay of the
Controller defect
controller check the
pressure sensor in the
controller

15.7
Conversion Tables

Length (l)

From To Multiply by
Inches Millimetres 25.4
Metres Inches 39.37
Feet Millimetres 304.8
Metres Feet 3.281
Inches Thou 1000
Millimetres Micrometres 1000
Area (A)

From To Multiply by

Square metres Square feet 10.765

Square feet Square inches 144
Square inches Square Millimetres 645.16
Volume (V)

From To Multiply by
Cubic metres Cubic feet 35.315
Cubic feet Cubic inches 1728
Cubic metres Litres 1000
Cubic feet Litres 28.32
US gallons (liq) Litres 3.785
Imperial gallons (liq) Litres 4.546
Volumetric flow (Q)

From To Multiply by
Cubic feet per minute (cfm) Cubic metres per hour (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) Litres 28.32
US gallons (liq) Litres 3.785
Imperial gallons (liq) Litres 4.546

16.0
Conversion Tables

Mass (M)
From To Multiply by
Kilograms Pounds 2.205
Kilograms Grams 1000
Kilograms Ounces 35.27
Pressure (P)
From To Multiply by
Kgf/cm2 g Pounds/sq.inch(PSIg) 14.223
PSIg Pascals (Pa) 6895
Bar g kgf/cm2g 1.0197
Bar g PSIg 14.503
PSIg kgf/cm2g 0.0703
Temperature (T)

From To Conversion
Degrees Celsius (C) Degrees Fahrenheit (F) F= 9C/5 + 32
Degrees Celsius (C) Degrees Kelvin (K) F= C+273.15
Degrees Fahrenheit (F) Degrees Rankine (R) R= F + 460
Heat (Q), Work (W), Energy (E)

From To Multiply by
Ft-lbf Joules 1.35582
Ft-lbf Btu 0.001285
Keal kgf m 426.9
Joules Calories 0.2388
Btu/h Calories/h 252
Kilowatts Btu/h 3411

Power (P)

From To Conversion
Metric horsepower Kilowatts 0.7355
Imperial horsepower Kilowatts 0.7457

16.1
 Date

Operating hours

Line pressure

System pressure

Record of maintenance
Temperature
(noted on gauge)

Suction filter
Service Log Book
(cleaning/change)

Oil filter change

Oil level
(control/change)

Oil separator change

16.2
Cooler cleaning

Motor maintenance
Comments
Torque values

The tightening torque values for bolts and screws used in ELGI
compressors are provided in this section for reference.

Metric hexagonal head bolts and screws

Thread size Tightening torque (N m)

M4 3
M5 6
M6 10
M8 25
M10 50
M12 87
M14 139
M16 214
M18 304
M20 431
M22 586
M24 745
M27 1090
M30 1480
M33 2013
M36 2586
M39 3346
M42 4135

17.0
Torque values

UNC hexagonal head bolts and screws — Grade 5

Thread size (inches) Tightening torque (N m)

¼ 12
5/16 23
3/8 41
7/16 65
½ 99
5/8 193
¾ 341
7/8 550
1 824

UNC hexagonal head bolts and screws — Grade 5

Thread size (inches) Tightening torque (N m)

¼ 13
5/16 25
3/8 46
7/16 73
½ 111
5/8 217
¾ 379
7/8 602
1 898

The tolerance for the torque values is ±10 percent.

17.1
Disclaimers

1. The entire literature including product description or any other information

in the manual exclusively belongs to ELGI and is subject to copyright. No
person has any right to copy, modify, distribute, transmit, display, perform,
reproduce, publish, licence, create derivative works, transfer or sell any
information, or deal with the same in any other manner, without the
knowledge and written concurrence of ELGI, violation of which would
amount to infringement of rights of ELGI and would necessitate legal
action.

2. ELGI Equipments Ltd. is the exclusive owner of the trade name or mark
‘ELGI’ or any other mark, whether registered or not, represented in any
manner whatsoever in the said manual and any person who does any act
or omission, which is an infringement or which is tantamount to infringing
the said mark shall be doing so at the risk of legal action and besides
being held liable for infringement shall be liable for payment of damages
including loss of profits.

3. The information published in this manual may include inaccuracies, or

typographical errors. Changes may be periodically added to the
information herein. Any changes/improvements may also be made to the
products stated in the said manual and ELGI is not liable if the readers
are not updated with information.

4. Likewise ELGI is responsible only till the point of first sale to the ultimate
customer and not thereafter and only from authorized dealers of ELGI;
ELGI shall disown liability on the purchase of any secondhand machine
or purchase otherwise from authorized dealers. ELGI shall not be liable
for any indirect, incidental, punitive, special or consequential damages
arising out of or in any way connected with the usage of the products or
information in the said manual.

5. Even in respect of users of the products ELGI’s liability is limited to the

value of the product.

6. Any dispute pertaining to the said manual or anything stated therein or

any product stated therein is subject to the exclusive jurisdiction of the
courts in Coimbatore.

18.0
Index

Page
Air inlet filter maintenance 13.4
Air intake system 9.6
Blow-down valve maintenance 13.9
Checks before starting the compressor 12.0
Commissioning 3.0, 7.8
Conversion tables 16.0
Cooling and lubrication system 9.9
Discharge system 9.7
Disposal of consumables and replaced parts 14.0
Disposal of packing 8.0
Drive coupling maintenance 13.5
Electrical shocks 10.5
Electrical system for compressor 9.12
Fires and explosions 10.2
Foundation for compressor 7.7
Hot surfaces 10.4
Inlet valve maintenance 13.7
Handling the compressor 7.0
Location of compressor 7.4
Maintenance schedule 13.0
Minimum pressure valve maintenance 13.6
Moisture separator maintenance 13.10
Moving parts 10.3
Oil filter maintenance 13.1
OSBID system 9.8
Pressure release 10.1
Receivers for compressed air 7.8
Safety system 9.15
Separator element maintenance 13.2
Starting the compressor 12.0
Stopping the compressor 12.1
Toxic and irritating substances 10.4
Troubleshooting 15.0

19.0
Business Reply Card

To

The Marketing Department,

Elgi Equipments Limited,
Singanallur,
Coimbatore

From
Name:
Position:
Name of organisation:
Address:
Telephone number:
Email address:
Date:

I would like to have more information on the following the ELGI products and
services marked in the following:

N Electric driven rotary screw compressors

N Diesel powered rotary screw compressors
N Oil-free rotary screw compressors
N Dryers
N Filters
N Diesel engines
N Reciprocating compressors
N Vayu compressors
N Dr. Vayu compressors for dental applications
N Air Lube oil and other coolants
N Maintenance services
N Please send me your literature
N Ask your Sales Engineer to call on me

20.0
Feedback Form

We at ELGI would like to serve you better. Please help us to know how we
could do this. Fill in the answers to the following questions and send this form
to the Marketing Department, Elgi Equipments Limited, Singanallur,
Coimbatore.
1. How did you come know about the Horizon compressors?
Advertisement
Internet
ELGI Sales Engineer
Other user
Trade fair
Other (specify please)…………..
2. How do you rate the response of the Sales Engineer who called on you?
1 2 3 4 5
Very poor Very good
3. How do you rate the technical capability of the Sales Engineer who called
on you?
1 2 3 4 5
Very poor Very good
4. How do you rate the technical details provided for the products?
1 2 3 4 5
Very poor Very good
5. What is your rating of the timeliness of the delivery of the machine?
1 2 3 4 5
Very poor Very prompt
6. What is your rating of the commissioning service?
1 2 3 4 5
Unsatisfactory Excellent
7. Please give your suggestions:
Name:
Position:
Name of organisation:
Address:
Telephone number:
Email address:
Date:
Thank you for extending your help and giving your time.

21.0