Professional Documents
Culture Documents
TS - 03 - 05 - 07 - 10 - 15 - HN - TS10 - HT
TS - 03 - 05 - 07 - 10 - 15 - HN - TS10 - HT
TS - 03 - 05 - 07 - 10 - 15 - HN - TS10 - HT
Dos
Dont’s
1
Safety instructions
Never place your hands, fingers or other body parts near the
compressor’s moving parts.
Always disconnect the compressor from the power source and remove
the compressed air from the air tank before servicing, inspecting,
maintaining, cleaning, replacing or checking any parts.
When not in use, the compressor should be stored in dry place, remove
the electrical supply. Keep out of reach of children. Lock – out the
storage area.
Cluttered areas invite injures. Clear all work areas of unnecessary tools,
debris, furniture etc.
Do not let visitors contact compressor extension cord. All visitors should
be kept safely away from work area.
2
Safety instructions
Replacement parts not original may void your warranty and can lead to
malfunction and resulting injuries. Genuine parts are available from
your dealer.
When the compressor is not used, disconnect it from the power source
and open the drain cock to discharge the compressed air from the air tank.
Drain tank
Drain tank daily or after 4 hours of use. Open drain fitting and tilt
compressor to empty accumulated water.
Dress properly
Do not wear loose clothing or jewellery. They can be caught in moving
parts. Wear protective hair covering to contain long hair.
3
Safety instructions
The motor air vent must be kept clean so that air can freely flow at all
times. Check for dust build-up frequently.
Electrical installation
This compressor motor and starter should properly grounded with correct
size copper wire to avoid electrical shock and damage to the equipment.
WARNING
Avoid electrical shock hazard. Never use this
compressor with a damaged or frayed electrical cord
or extension cord. Inspect all electrical cords regularly.
Never use in near water or in any environment where
electric shock is possible.
4
Technical Specifications
01 Model TS 03 120 HN
lpm 302.74
cfm 10.69
lpm 249.95
cfm 8.82
06 Type of configuration V
08 Cylinders No. 2
13 Volumetric efficiency % 78
16 Motor rating HP 3
kW 2.2
5
Technical Specifications
20 Class of insulation F
21 Electric supply
6
Technical Specifications
03 Displacement m3/h 30
lpm 501.27
cfm 17.7
lpm 409.79
cfm 14.47
06 Type of configuration V
08 Cylinders No. 2
13 Volumetric efficiency % 78
16 Motor rating HP 5
kW 3.7
7
Technical Specifications
20 Class of insulation F
21 Electric supply
8
Technical Specifications
03 Displacement m3/h 42
lpm 700.93
cfm 24.75
lpm 584.82
cfm 20.65
06 Type of configuration V
08 Cylinders No. 2
13 Volumetric efficiency % 78
kW 5.5
9
Technical Specifications
20 Class of insulation F
21 Electric supply
a) Voltage V 380/400/415
b) Phase 3
c) Frequency Hz 50
a) Intercooler kgf/cm2 6
b) Aftercooler kgf/cm2 16.2
c) Air receiver kgf/cm2 14
34 Air receiver capacity litre 220/500 Ltrs
10
Technical Specifications
lpm 1001.98
cfm 35.38
lpm 852.98
cfm 30.119
06 Type of configuration W
08 Cylinders No. 3
13 Volumetric efficiency % 80
16 Motor rating HP 10
kW 7.5
11
Technical Specifications
20 Class of insulation B
21 Electric supply
a) Intercooler kgf/cm2 8
b) Aftercooler kgf/cm2 16
c) Air receiver kgf/cm 2
14
34 Air receiver capacity litre 220L / 420L / 500L
WE WOE
35 Overall dimensions
(lxbxh) mm 220 L 1595x810x1205 1595x680x1205
420 L 1675x885x1350 1675x745x1350
500 L 1925x885x1350 1925x745x1350
36 Nett weight Kg -- --
12
Technical Specifications
lpm 1537.24
cfm 54.28
lpm 1249.78
cfm 44.13
06 Type of configuration W
08 Cylinders No. 3
13 Volumetric efficiency % 80
16 Motor rating HP 15
kW 11
13
Technical Specifications
20 Class of insulation F
21 Electric supply
14
Technical Specifications
lpm 996.884
cfm 35.2
lpm 849.61
cfm 30
06 Type of configuration V
08 Cylinders No. 2
15
Technical Specifications
20 Class of insulation F
21 Electric supply
a) Voltage V 415
b) Phase Ph 3
c) Frequency Hz 50
b) Aftercooler kgf/cm2 16
c) Air receiver kgf/cm2 14
34 Air receiver capacity litre 420
WE WOE
35 Overall dimensions
(lxbxh) mm 1665x880x1315 1665x740x1315
16
System operation
The atmospheric air aspirated through the inlet air fiters is compressed in
the cylinders of the reciprocating air compressor driven by the prime mover.
This cooled compressed air then enters into the high pressure cylinder,
there it is further compressed to attain the specified pressure.
During the second stage of compression, the heat is further generated and
in normal condition, the compression end temperature amounts to
approximately 190oC. This compressed air passes through an after cooler
where the compression heat is dropped to a permissible level. At the end of
after cooler pipe, a safety valve is provided which opens when the
compressed air pressure in the after cooler, exceeds the predetermined set
pressure.
The cooled pressurised air passes through a non return valve into a
reservoir called air receiver / delivery pipe As the compressed air flows
continuously into the air receiver / delivery pipe, pressure gets built up in
the receiver / delivery pipe.
A safety valve is provided on the air receiver / delivery pipe to bleed the
excessive air pressure from the air receiver / delivery pipe whenever the
pressure switch fails to respond the pressure rise inside the air receiver
/ delivery pipe.
At one end of the air receiver / delivery pipe a ball valve is fitted to draw out
the compressed air to service line.
17
Product Representation
18
Product Representation
19
Product Representation
To atm
Atmospheric To Service
Air
No Description Qty
1. Inlet air filter 1
2. Compressor unit 1
3. Electric motor 1
4. After cooler 1
9. Pressure guage 1
20
Product Representation
No Description Qty
01. Inlet air filter 2
02. Compressed unit 1
03. Electric motor 1
04. After cooler 2
05 Safetyvalve (After cooler) 1
06. Non return Valve 1
07. Pressure switch with unloader valve 1
08. Safety Valve (Air receiver) 1
09. Pressure guage 1
10. Ball Valve (service) 1
11. Air receiver 1
12. Drain Valve 1
21
Product Representation
No Description Qty
01. Inlet air filter 2
02. Compressed unit 1
03. Electric motor 1
04. After cooler 2
05 Safetyvalve (After cooler) 1
06. DUV / Solenoid Valve 1
07. Silencer 1
08. Non return valve 1
09. Pressure guage 1
10 Safety valve ( air receiver) 1
11 Pressure Guage 1
12. Ball Valve (service) 1
13. Air receiver 1
14. Drain Valve 1
22
Functions of various systems
The Reciprocating air compressor unit converts the rotary motion into
reciprocating motion with the help of crankshaft and connecting rod
assembly. Due to the reciprocating motion, the air is sucked into the cyclinder,
compressed and the compressed air is delivered into the air receiver. In case
of L.P. cylinders combined disc valves perform suction and discharge
operations where as the stainless steel finger type valve plates platform the
opening closing of suction and discharge ports provided on the valve flat on
H.P. cylinder. An oil splasher is fitted to the connecting rod to lubricate all the
moving parts.
Crankcase
The crankcase is made of high grade cast iron an houses the crankshaft
assembly and cylinders. It act as the sump for lubricating oil and is provided
with a breather, drain plug and a dipstick assembly. The breather maintains a
partial vacuum in the crankcase to facilitate better lubrication.
The cylinders and cylinder heads are made of high grade cast iron and they
have close deep fins for effective cooling. The hardness of the cylinders is
closely controlled to ensure high wear resistance.
The pistons are of automotive type made out of low expansion aluminium
alloy. They are provided with plain compression rings, stepped compression
rings and slotted oil control rings.The rings are made of special quality close
grained cast iron and designed for controlling wear and oil consumption
minimum. The gudgeon pins are of chrome steel case hardened and precision
ground.
23
Functions of various systems
Inter Cooler
The Intercooler consists of aluminium body with fins for effective cooling.
Drive System
The drive system transmits the power required to drive the compressor from
the prime mover. The drive system comprises of a drive pully mounted on the
motor shaft and a driven pulley mounted on the crankshaft on the
compressor unit. The motion is transmitted between the pulleys through V
belts. A belt guard is provided on the side of the drive system ensures
protection of the operator.
Electric Control
The electric motor is connected in series to the Direct online Starter. When
the starter is switched ON, the motor starts running. The electric power
supply to the motor is controlled by the pressure switch response to the air
pressure inside the air receiver /delivery pipe. Whenever the air pressure of
the air receiver / delivery pipe exceeds the pre-determined set valve, the
pressure switch cuts OFF the supply to the motor and whenever pressure
drops down to the set pressure, the pressure switch cuts IN the power
supply to the motor through starter.
Air Receiver
In tank mounted model, the air receiver is used to store the compressed air.
Whenever compressed air is required. The ball valve in the service line is
operated to draw the compressed air. All the elements / modules of the
compressor package is mounted on the air receiver.
24
Safety devices
Vents excess air pressure to atmosphere in the air receiver / delivery pipe in
the event of failure of pressure switch responding to the pressure rise above
the upper set limit of pressure switch (CUT OFF)
For above 15 H.P. model, the DUV vents the pressurised air from the after
cooler to atmosphere. When the air pulse from solenoid valve lifts the piston
in delivery unloader valve. (For below 10 H.P.models, the pressure switch
has unloading system).
Interlocking devices
Pressure Switch
If cuts OFF power supply to the motor whenever air pressure inside the air
receiver / delivery pipe exceeds the pre-determined set value and cuts ON
the power supply to the motor whenever the air pressure drops down to the
diffrential set value.
Non-return valve
Non-return valve is one way automatic, spring loaded shut off valve which
allows the compressed air into the air receiver / delivery pipe and prevents
the air from returning to the after cooler.
25
Electrical system
# The electrical circuit diagram is shown in Figure (Refer page no. 23 & 24).
# The overload relay is set for equal to the motor name plate current for
star delta / DOL starter respectively.
# The tripped overload relay is reset by depressing the ‘Stop' button of the
starter.
# On releasing the latch, the compressor will restart and run continuously
till the rated output pressure is attained.
2 10 4Cx.5 Sq.mmCu
3 16 4Cx1.5 Sq.mmCu
5 20 4Cx2.5 Sq.mmCu
10 25 4Cx4 Sq.mmCu
15 32 4Cx6 Sq.mmCu
NOTE
Power should be supplied to the compressor through a
fuse switch unit of suitable rating mounted within 5m of
the compressor
26
Electrical system
Main Supply
415V AC 50 Hz
L1 L2 L3
7
1 3 5
8 2 4 6
Contactor
Pressure Switch
98 96
O/L Relay
Stop / Reset / Trip
95 DOL Starter
A B C
Motor
27
Incoming Supply
415V 3Ph AC
L1 L2 L3
D1
A1 A2
On Delay
16 A1 A2
15 A1 A2
1 3 5 7 11 21 1 3 5 7
2 4 6 8 12 22 2 4 6 8
K3 K2
Delta main
23 24
98
Start 96
Stop Reset
A1 A2
1 3 5 7 11 21 95
2 4 6 8 12 22
K1
Star
28
Pressure Switch
Neutral
Solenoid Valve
A2 B2 C2 A1 B1 C1
To Motor To Motor
# Starter entry glands are fixed properly to avoid dust formation inside the
contactor points.
# Incoming wire to the starter from the main switch shall be,
2.5 Sq.mm up to 10 HP
# Avoid the loop line connection from the out going line of the isolation
switch of compressor to any other motor / equipments.
# Avoid loose connection on all the points check from main electrical board,
isolation switch, starter entry, starter outlet and the compressor motor
terminals.
# Ensure the thermal over load relay settings as per motor name plate,
which is rated full load current of the motor for the DOL starters.
The settings are set at the 0.58 times rated the full load current of the
motor for the Star - Delta Starters.
NOTE
Examine the package for transit damages Locate a
levelled ground in an airy room for compressor erection.
Leave 1000 mm space around the compressor for
adequate cooling and easy maintenance accessibility
29
Installation
Location of Compressor
WARNING
Never install the compressor near the boiler, furnace,
in an enclosed compartment or at any place where
the atmospheric air is hot and dirty.
Select a location to permit sufficient unobstructed air flow in and out of the
compressor room to keep the operating temperature stable. The minimum
distance that the machine should be from surrounding walls is within working
limits. The machine should be installed at a minimum of 1000 mm from the
surrounding walls. It is imperative to provide adequate cross ventilation to
prevent excessive ambient temperature rise. Compressor room temperature
shall be limited to max 45O C.
Foundation
After selecting a suitable location, foundation shall be laid as per the detailed
drawing given below and then erect the compressor. The level of the
compressor must be checked by placing a spirit level on top of the air receiver/
base.
30
Installation
Foundation details
Dimension on foundation of
TS 03 / 05 / 07 / 10 / 15 120 HN & TS 10 HT
NOTE
After anchoring the foundation bolts, ensure proper floor
level
Pour proper quantity of oil and check the oil level during installation. The
level is checked by looking at the oil level indicator provided on the
crankcase. If the oil level is low, add sufficient quantity of oil.
NOTE
Fill the lubricating oil into the crankcase through
breather hole after removing the breather from the end
cover.
31
Installation
WARNING
Before starting the unit, fill the crankcase with
correct grade and proper quantity of oil since the oil
is drained completely prior to shipping.
32
Installation
Ensure proper belt tension between the drive pulley (motor pulley) and driven
pulley (compressor pulley). If the belt tension is not correct, loosen the nut
lock and turn the tension adjusting bolt provided on the motor plate. On
completion of the adjustment, tighten the lock nut. When correctly adjusted,
the belt should have a play of 10 mm about their mean position.
WARNING
Too much belt tension will lead to excessive load
on the compressor and motor bearings.
Electrical preparation
Interior and other electrical wiring are carried out during the manufacturing
stage at factory itself. Nevertheless a thorough check up on the connections
if necessary to ensure a stage of trouble free first start up.
33
Installation
Care is taken to keep your Electrical work to the minimum possible. The
necessary electrical work should be done only by a qualified electrician. A
few electrical check should be made to help assure that first start up will be
trouble free.
a) Check the incoming voltage. Ensure that the incoming voltage is same as
that of the voltage that the machine is wired for.
c) Connect the electrical power supply with correct rating of fuses. Avoid
loop lines from the compressor wiring points.
e) 'DRY RUN' the electrical controls by disconnecting the motor leads from
the starter and energise it by releasing the stop button.
34
Installation
After the electrical wiring has been done, it is necessary to check the
direction of the motor rotation. This can be done by jogging the stop button
on the Star-delta Starter. When looking at the oil level indication side of the
crankcase, the shaft should turn counter clockwise. If the crankcase is not
turning counter clockwise, disconnect the power to the starter and
exchange two of the three power input leads. i.e. red and blue then recheck
rotation.
35
Operation
General
While ELGI has built into compressor a comprehensive array of controls and
indicators to assure you that it is operating to full capability, you will want to
recognise and interpret the reading which will call for service or indicate the
beginning of a malfunction. Before starting your ELGI compressor, read this
section thoroughly and familiarize yourself with the controls and
indicators - their purpose, location and use.
# Fill the recommended grade of oil in the crankcase to the required level.
# Check that the compressor rotates freely by hand and there are no mechanical
obstructions.
WARNING
Before connecting the power supply to the
compressor, ensure the stop button in the starter
is latched.
# Run the compressor for a while and close the shut off valve. then carry
out a check on all adjustments given in clause 10 - 9 of maintenance
section of this manual.
# Re-inspect the machine for temperature and leaks, the following day.
36
Checks During Compressor Operation
# Check whether the compressor is running smoothly and that the running
sound is normal.
# The compressor crankcase and delivery pipe shall be hand-felt to ensure
that their temperatures are within touchable limits thoroughout the duration
of operation of the compressor.
# Observe for air leaks at the joints of the pipes and if noticed, stop the
compressor and rectify the defects.
On subsequent start up, check the proper oil level is visible in the dipstick
and simply release the latch in the starter.
WARNING
Do not touch the delivery parts of the compressor
since they are very hot. Touching may cause burns.
37
Operation
Purpose of Controls
S.
Control indicator Purpose
No
3. Oil level indicator Helps to keep a visual check on the oil level
in the crankcase. Check oil level only when
the machine is shut down. Do not overfill.
6. Non - return valve Allows the compressed air into the air
receiver/delivery pipe and prevents the air
receiver from returning to the after cooler.
38
Maintenance
As you proceed in reading this chapter, it will be easy to see that the
maintenance programme of the unit is quite minimum but important.
39
Maintenance
# Check the oil level in the crankcase. Replenish with thecorrect grade if
required.
# Dismantle the drain valve from air receiver and clean. Run the compressor
for some time without the drain valve to blow out all the moisture and dirt
from the air receiver.Reassemble the drain valve.
# During the oil change, the compressor should be run for a short while and
draining of the oil should be done only when the oil is warm.
NOTE
Carry out the first oil change after 150 hours of
operation and subsequent oil changes after every 500
hours of operation.
40
Maintenance
# The breather valve should be dismantled, cleaned and checked for perfect
seating of the diaphragm and reassembled.
# Drain the oil and replenish with correct grade and quantity.
# Remove the L.P cylinder heads. Dismantled the disc valves / Finger valves.
Decarbonise the valve discs, springs and valve plates.
# All the pipe lines should be checked for leaks at joints and replace packings
if necessary.
# Decarbonize the after cooler pipe and the intercooler by any one of the
following methods:
NOTE
Do not immerse the After cooler in Benzene or
Toluene solution for longer period of time, which will
result in damage to the After coolers.
41
Maintenance
NOTE
Replace a set of belts even if a single belt is found
worn out.
# Carryout the annual preventive maintenance with tune up kit through Elgi
authorised dealer.
# Connect the in line water hose pipe with ball valve assembly in the
receiver tank which is going to be tested
# Switch on the LP water pump and fill the Receiver tank(which is going
to be tested) with water. Lock the socket / Elbow, after the tank is
completely filled with water without air entrapment.
# Clean the weld area with air / dry cloth to remove water
42
Maintenance
# Pressurize the Tank (with Water) thro pump and maintain the hydro test
pressure as per drawing / below test conditions.
Check the receiver tank for any water leak in the weld area at the
following conditions
b) After 15 Minutes
c) After 30 Minutes
d) If any leak noticed, mark the leak area and rework accordingly.
e) Re-do the hydro test following above steps in case of any weld rework
f) If no leak noticed, connect the outline water hose pipe to the drain
valve and drain the water from the receiver tank by applying air pressure.
g) Record the test observations and rework (if any) and re-test observations
in a Test report and maintain in a file
Test conditions :
43
Maintenance
NOTE
Users are advised to adhere to the requirements of
pressure test regulations of Government & Safety
Agencies, with respect to air receivers.
i) Pressure Switch
# The pressure switch operating pressures are adjusted at the factory and
do not require re-adjustments.
# The upper limits should never be exceeded. Figure given below for
Pr. adjustments.
j) Pressure Adjustment
# Unlock and turn the control knob clockwise for increasing the cut off
pressure.
# Turn the control knob counter clockwise for decreasing the cut off pressure.
k) Diffrential Adjustment
# Depress the knob against the spring and turn clockwise for decreasing
the differential pressure i.e. to increase the cut pressure.
NOTE
It is necessery to keep the compressor Pressure switch
correctly adjusted as it is uneconomical to run the
compressor at higher pressure, if air pressure is
required is lower.
44
Maintenance
45
Troubleshooting
Check Remedy
Check Remedy
46
Troubleshooting
Check Remedy
Piston cylinder
Check and change as required.
clearance excessive
Check Remedy
47
Troubleshooting
Check Remedy
Check Remedy
Puncture diaphragm
because of frequent Replace diaphragm and reset
operations (hunting) for pressure with more differential.
a very long time due to
very low differential.
48
Troubleshooting
Check Remedy
Check Remedy
Defective seating of
inlet and delivery Open, clean and refit after careful check.
valve plates.
49
Troubleshooting
Check Remedy
Problem : During compressor operation air leaks through the cross hole
of unloader
Check Remedy
Check Remedy
Check Remedy
Sparking of contact/
Replace contact assemblies.
melted contact points.
50
Troubleshooting
Check Remedy
Check Remedy
Loose connection in
starter mains/coil Tighten all the wires in starter.
terminals.
Pressure switch
Check pressure switch function.
malfunctioning.
51
Troubleshooting
Check Remedy
Check Remedy
52
Troubleshooting
Check Remedy
OLR malfunctioning
(Check if the motor Increase the OLR set point slightly
current is equal or less or replace the OLR
than set limit even when
it gives the nuisance
tripping)
53
Troubleshooting
Check Remedy
Check Remedy
54
Troubleshooting
Check Remedy
Loose connections of
solenoid valve wires Tighten the earth wire & contactor.
in starter.
Check Remedy
55
Troubleshooting
Check Remedy
Loose connection in
starter terminals / coil
Terminals, Pressure Correct the loose connections.
switch terminals.
Check Remedy
Motor fan not rotating. check the motor fan is properly fixed &
rotating with motor.
56
Troubleshooting
Check Remedy
57
Genuine spares
Protect your precious investments with genuine ELGI spare parts. Stringent
quality checks, over four decades of experience and state-of-the-art
technology makes each and every ELGI genuine spare part superior. ELGI
spares make your compressor last longer and enhance compressor
productivity.
Filters :
Valves :
58
Genuine spares
Cylinders :
Piston :
# Low expansion aluminium alloy for better thermal properties
Piston Rings :
# Low expansion aluminium alloy for better thermal properties
59
Genuine spares
# Crank shafts on both sides supported by heavy duty bearings for better
load carrying capacity
Tune-up kit :
60
Spare parts list
61
62
TS 03 HN
63
64
TS 03 HN
65
66
RAC unit model : TS 03 120 HN
RAC unit model : TS 03 120 HN
67
68
RAC unit model : TS 03 120 HN
RAC unit model : TS 03 120 HN
69
70
RAC unit model : TS 03 120 HN
RAC unit model : TS 03 120 HN
71
72
TS 03 HN
73
74
TS 03 HN
75
76
RAC Package model : TS 05 120 HN
RAC Package model : TS 05 120 HN
77
78
RAC Package model : TS 05 120 HN
RAC Package model : TS 05 120 HN
79
80
RAC unit model : TS 05 120 HN
RAC unit model : TS 05 120 HN
9 Bush 1 00 04 3218 0
13 Pre-filter 1 00 03 1783 0
81
82
RAC unit model : TS 05 120 HN
RAC unit model : TS 05 120 HN
83
84
RAC unit model : TS 05 120 HN
RAC unit model : TS 05 120 HN
85
86
RAC package model : TS 07 120 HN - 220 ltrs
RAC package model : TS 07 120 HN - 220 ltrs
87
88
RAC package model : TS 07 120 HN - 220 ltrs
RAC package model : TS 07 120 HN - 220 ltrs
89
90
RAC package model : TS 07 120 HN - 500 ltrs
RAC package model : TS 07 120 HN - 500 ltrs
91
92
RAC package model : TS 07 120 HN - 500 ltrs
RAC package model : TS 07 120 HN - 500 ltrs
93
94
RAC unit model : TS 07 120 HN
RAC unit model : TS 07 120 HN
9 Bush 1 00 04 3218 0
13 Pre-filter 1 00 03 1783 0
95
96
RAC unit model : TS 07 120 HN - 200/500 ltrs
RAC unit model : TS 07 120 HN - 220/500 ltrs
97
98
RAC unit model : TS 07 120 HN - 200/500 ltrs
RAC unit model : TS 07 120 HN - 220/500 ltrs
99
100
RAC package model : TS 10 120 HN - 220 ltrs
RAC package model : TS 10 120 HN - 220 ltrs
101
102
RAC package model : TS 10 120 HN - 220 ltrs
RAC package model : TS 10 120 HN - 220 ltrs
103
104
RAC package model : TS 10 120 HN - 420 & 500 ltrs
RAC package model : TS 10 120 HN - 420 & 500 ltrs
105
106
RAC package model : TS 10 120 HN - 420 & 500 ltrs
RAC package model : TS 10 120 HN - 420 & 500 ltrs
107
108
RAC unit model : TS 10 120 HN
RAC unit model : TS 10 120 HN
109
110
RAC unit model : TS 10 120 HN
RAC unit model : TS 10 120 HN
111
112
RAC unit model : TS 10 120 HN
RAC unit model : TS 10 120 HN
113
114
Reciprocating air compressor package - tank mounted model : TS 10 120 HT - 420 Ltrs
RAC package model : TS 10 120 HT
115
116
Reciprocating air compressor package - tank mounted model : TS 10 120 HT
RAC unit model : TS 10 120 HT
117
118
Reciprocating air compressor package - tank mounted model : TS 10 120 HT
RAC unit model : TS 10 120 HT
119
120
RAC package model : TS 15 120 HN
RAC unit model : TS 15 120 HN
121
122
RAC package model : TS 15 120 HN
RAC package model : TS 15 120 HN
123
124
RAC unit model : TS 15 120 HN
RAC unit model : TS 15 120 HN
125
126
RAC unit model : TS 15 120 HN
RAC unit model : TS 15 120 HN
127
128
RAC unit model : TS 15 120 HN
RAC unit model : TS 15 120 HN
129
130
RAC unit model : TS 15 120 HN
RAC unit model : TS 15 120 HN
131
2a 2a
2 2
2b 2b
2c 2c
1 1
1a 1a
1b 1b
1c 1c
2c 2c
2a
2
2b
2c
1a
1b
1c
2c
132
Piston assembly
133
2a
2
2b
2c
1a
1b
1c
2c
134
Piston assembly
Piston assemblydia 90
135
2
5
4
136
Piston assembly
137
Inlet air filter assembly Safety Valve assembly 1/2" BSP - Air receiver
Safety Valve Assembly 3/4" BSP - Air receiver
138
Inlet Air Filter Assembly
Fig. No. Description Qty. Drg. /Part No.
4. Spring 1 ----
9. Cover 1 ----
139
Delivery unloader valve cum Non - return valve
Solenoid valve assembly assembly - 1" BSP
140
DUV cum Solenoid valve assy & NRV assembly
-2 Valve seat 1 -
-3 'O' rings 4 -
-4 Plunger 1 -
-4 Spring 1 ----
141
Pressure switch assy
with unloader valve
142
Pressure switch assembly with unloader valve.
-1 Cover 1 00 03 1045 0
-2 Packing 1 00 04 1171 0
-5 Flange 1 00 05 1020 0
-7 Diaphragm 1 00 05 1201 0
143
Breather valve assy Breather valve assy
(for TS 10 HT model)
144
Valve assembly
145
Kit spares
Kit, tune up, TS 03 120 HN, tank mounted for 2500 hours
Kit No (02 24 3387 9) for 2500 Hrs ............................................. K 0206099
S.No. Description Qty. Drg. /Part No.
1 Filter element assembly 1 00 04 4371 0
146
Kit spares
Kit, tune up, TS 05 120 HN, tank mounted for 2500 hours
Kit No (02 24 3388 9) for 2500 Hrs ............................................. K 02 06 100
147
Kit spares
Kit, tune up, TS 07 120 HN, tank mounted for 2500 hours
Kit No (02 24 3389 9) for 2500 Hrs ............................................. K 02 06 101
2 Seat 2 00 04 3222 0
148
Kit spares
Kit, tune up, TS 10 120 HN, tank mounted for 2500 hours
Kit No ............................................................................................... K 0206108
149
Kit spares
Kit, tune up, TS 10 120 HT, tank mounted for 2500 hours
Kit No ........................................................................................... 02 24 0248 9
151
Kit spares
Kit, tune up, TS 15 120 HN, tank mounted for 2500 hours
Kit No for 2500 Hrs ................................................................... K 02 06 109
152
Kit spares
Kit, tune up, TS 15 120 HN, tank mounted for 2500 hours
Kit No for 2500 Hrs ................................................................... K 02 06 109
153
Recommended Oil
Bharat Hindustan
Indian Oil Castrol
Petroleum Petroleum
154
Recommended Oil
NOTE
Lubricating oil is filled into the compressor by
removing the breather assembly. Lubricating oil is
drained by unscrewing the drain plug. The electric
motor bearings should be lubricated by using a
special grease gun or by removing the end covers.
Performance Benifits :
# Specially formulated for reciprocating compressors with group 2
plus base oil.
# Provides active protection against rust and corrision during shut down
155
N O T E S
156
157
158
159
©
ELGI EQUIPMENTS LIMITED
Singanallur, Coimbatore, TN - 641 005, INDIA.
Revision Status
Replaces Earlier
Contact Info :
ELGI EQUIPMENTS LIMITED
Coimbatore, TN - 641 005, INDIA.
e-mail : info@elgi.com
www.elgi.com
HORIZON
ELECTRIC POWERED
RECIPROCATING AIR COMPRESSORS
TANK MOUNTED
CHAPTER-iI
PARTS LIST MANUAL
Piston assembly
Kit spares
Recommended oil
Maintenance chart
iv
162
List of Contents
CHAPTER-i
OPERATION AND MAINTENANCE MANUAL
User Information
Safety
Installation
System Operation
Electrical Systems
Maintenance
Trouble Shooting
Recommended Spares
iii
163
Message from the Managing Director
Yours sincerely,
Jairam Varadaraj
Managing Director
vi
164
Machine Identification and
Sale Record
Owner’s name :
Address :
Model :
FAB. No. :
Year of manufacturing :
Motor :
Capacity :
Rated Pressure :
Date of delivery :
Note : The warranty on this compressor is valid only if all the details
above are filled and the dealer stamps and sign this page
v
165
Introduction
We are confident; the equipment you have purchased will give you
satisfactory service for its life. We thank you for giving us an opportunity to
serve you with our compressor.
viii
166
About ELGI
ELGI Equipments Limited, an ISO 9001 company, is the flagship of the ELGI
group. It has grown spectacularly over the last 45 years into a multi-market,
multi-product enterprise, transforming itself to meet the challenges of globalization.
ELGI is Asia’s largest and most integrated manufacturer of air compressors. It
is also a leader in automotive service equipment, with a comprehensive range
of products, and a manufacturer of diesel engines. The company has a strong
presence in the global market. It is one of the leading exporters in India, with
more than 30 percent of its production reaching endusers and OEMs in over 45
countries across the world.
vii
167
Users’ important information
SAFETY
WARNING
Death or serious bodily injury could result from
improper or unsafe use of compressor. To avoid these
risks, follow the basic safety instructions.
NOTE
Make sure this manual is read and carefully understood
before starting/ operating this machine.
Proof of purchase will be required for warranty
service.
x
168
Users’ important information
Read and understand all of the operating instructions, safety precaution and
warnings in the Instruction Manual before operating or maintaining this
compressor.
Most accidents that result from compressor operation and maintenance are
caused by the failure to observe basic safety rules or precautions. An
accident can often be avoided by recognising a potentially hazardous
situation before it occurs, and by observing appropriate safety procedures.
Never use this compressor in a manner that has not been specifically
recommended by manufacturer, unless you first confirm that the planned
use will be safe for you and others.
1. MODEL
2. FAB NUMBER
3. YEAR OF MANUFACTURE
4. PART NAME
5. PART NUMBER
6. REQUIRED QUANTITY
ix
169
xii
170
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 compressor 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.
xi
171
ELGI EQUIPMENTS LIMITED
TEST CERTIFICATE FOR AIR COMPRESSOR
COMPRESSOR UNIT
Model : TANK
Motor No. :
Motor Speed : 1420 / 1430 / 1460 rpm Working Pressure : 12.0 Kg/cm 2
SETTINGS
PACKING SLIP
SI.No. Description Quantity
Inspected By : Date :
INSPECTION AND SERVICE RECORD
174
175
176
177
Refer page no
43 & 44