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Horizon Series Electric Powered Screw Air Compressors Built to Last 90-250 kW

Elgi Screw Compressor

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Horizon Series ElectricPowered Screw Air

CompressorsBuilt to Last

90-250 kW

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Screw compression elements are manufactured in-house using state-of-the-artmachining centres for rotor grinding and machining intrinsic castings of varioussizes. Elgi’s own eta-V ( -V) profile rotors ensure energy-efficient compressed airsupply for all demanding applications. Elgi is one of the few companies capable of

manufacturing wide range of airends and compressor packages in the world.Elgi’spatent portfolio is a testament to the company’s continuous research andinnovationcapability.

η

Elgi, established in 1960, designs and manufactures a wide range of compressors.The Company hasgained its reputation for design and manufacture of screw compressors through strategicpartnerships and continuous research and development. Over the years it emerged as a multi-product, multi-market enterprise providing total compressed air in all segments. Elgi’s designcapabilities translated into wide range of products ranging from oil-lubricated and oil-free rotaryscrew compressors, reciprocating compressors and centrifugal compressors. Elgi has its ownmanufacturing operations in India, China and France, and subsidiarycompanies in Brazil,Middle EastandAustralia.Thecompanyisfastexpandingitsglobalfootprintattractingdistributorsandcustomerswithitslatestgenerationproducts.

Elgi has modern manufacturing facilities in India,China and France equipped with advanced

highprecisiongrinding machines, turning centres and CNC horizontaland vertical machiningcentres. Screw airends are manufactured with the latest rotor grinding machines, coupledwith measurement technology to maintain precise manufacturing tolerances. Elgi'smanufacturing plants areboth ISOand EOHS certified.The products aremanufactured undercontrolled environment to ensurethat itsquality continuesto meet thehighest standards.

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Electric Powered

Energy Saving Solution

Variable Frequency DriveCapacity : 11-250 kWStandalone ready to use package

Automatic Supply SideController

Air Compressors

Refrigeration Air DryerCapacity : 1-90 m /minWorking pressure : 7 – 13 bar gDew point : +3 C PDP

3

o

Large Single-Stage(above 75 kW)90 250 kW | 16.7 43.9 m /min– –   3

Air FilterCapacity : 1 – 90 m /minWorking pressure : 7– 13 bar gFiltration Range : 1 – 0.003 microns

3Air ReceiverCapacity : 0.3 - 20mWorking pressure : 7 - 13 bar g

3

Clean Air Solution

Air Accessories

Tandem Two-Stage75 - 160 kW | 16.0 - 30.7 m /min3

Oil FreeScrew AirCompressors90-315 kW500-1700 cfm

2 - 12 compressors integrationMulti-compressor control upto

12 compressors

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Tandem Two-Stage Screw Air Compressors75 - 160 kW | 16 - 30.7 m /min3

Compression ratio comparison for a 9 bar g Compressor

0

2

4

6

8

10

Tandem 1ststage

Tandem 2ndstage

Single stage

      C     o     m    p      r    e     s     s 

      i    o     n    r    a      t       i    o 

Elgi offerstandemscrew compressors to help industries reduce their operating and energy costs. It is a two-stage compressor, havingenergy efficiency asthe key feature.The compression is donein two-stages to improve thevolumetric efficiency andthereby contributingto decrease in power consumptionand increase in saving energy costs.Tandem air compressors consume 8-12% less power and offer a return on investment within 8-15 months whencomparedtosingle-stagecompressors

A single-stagecompressor , operating at a dischargepressureof 9 bar, has a compression ratioof 1:9(Ratio of Suction to Discharge of a ScrewAirend) . Ina two-stagecompressor operating at thesame dischargepressure, thecompression ratiois divided between thetwo stagesof tandemairend andis about1:3 in each stage .This makes the airend more reliable and efficientdue to smaller loads on the bearings.The volumetric efficiency of two-stage is better

thansingle-stagecompression

Stage IIntermediatecooling

Stage II

Load/Unload controlModulation controlVSD control

High efficiencyHigh energy savingHigh reliability   P ow e  r    

S       a   v    i       n   g    s

Dual control mode

  1  2  %

Auto dual control, operates on modulation mode from 100-60% loadingand in load-unload mode for loads below 60%Constant pressure due to gradual opening or closing of suction valve withrespect to demand ( multi-point control)Option for selecting load-unload / modulation auto dual mode for all largescrew compressor models as a standard featureSmooth operation by modulation ensures longer life of airend, valves andall mechanical components. It also ensure no sudden spikes or drop in line

pressureLowest power consumption in its class of compressor controls, even withfluctuating loads

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Electricity

Equipment

Maintenance

Single-Stage Compressor

3%Equipment   Maintenance

3%

Electricity

Tandem Saving

Equipment

Maintenance

Tandem Two-Stage Compressor

Electricity 81%

Maintenance 3%

Equipment 4%Tandem Saving 12%

Typical lifetime cost of compressed air over 10 years

All models are available in air-cooled as standard and water-cooled variants as optionMax. pressure or unload pressure for all models is 1 bar above the working pressure i.e. for a EE90-8, working pressure is 7 bar and max pressure is 8 barDue to continuous engineering improvements, the specifications are subject to change without prior notice

Note:

Energy savingsThe annual power cost for a 100kW compressor running on continuousduty is US$ 126000 while a Tandem two-stage compressor usesUS$ 111000 and saves power costs annually by US$ 15000

Tandem Two-stage screw air compressor range

Electricity 94%

Air outletconnection

Model50 Hz Rated

PowerWorkingPressure   WeightFAD

kW   m /min3 cfmbar g   Kg

EE75-8 75 7 16.0 565 3300 2 " NPT

EE75-9 75 8 15.2 535 3300 2 1/2" NPT

EE75-10.5 75 9.5 13.3 470 3300 2 1/2" NPT

EE75-13.5 75 12.5 11.5 405 3300 2 1/2" NPT

EE90-8 90 7 18.4 650 3400 2 1/2" NPT

EE90-9 90 8 16.7 590 3400 2 1/2" NPT

EE90-10.5 90 9.5 15.3 540 3400 2 1/2" NPT

EE90-13.5 90 12.5 13.2 465 3400 2 1/2" NPT

EE110-8 110 7 22.6 800 3600 2 1/2" NPTEE110-9 110 8 21.2 750 3 2 1/2" NPT

EE110-10.5 110 9.5 19.6 691 3 2 1/2" NPT

EE110-13.5 110 12.5 16.4 580 3 2 1/2" NPT

EE132-8 132 7 27.3 965 3700 2 1/2" NPT

EE132-9 132 8 24.9 881 2 1/2" NPT

EE132-10.5 132 9.5 23.6 832 2 1/2" NPT

EE132-13.5 132 12.5 19.7 695 2 1/2" NPT

EE160-8 160 7 30.7 1085 3850 2 1/2" NPT

EE160-9 160 8 30.5 1076 2 1/2" NPT

EE160-10.5 160 9.5 28.0 990 2 1/2" NPTEE160-13.5 160 12.5 23.2 820 2 1/2" NPT

1/2

600

600

600

3700

3700

3700

3850

38503850

Dimension LXBxH(mm): 3400 x 1620 x 1972 mm

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Airend and motor shafts are coupled througha permanently alignedcushion type claw coupling. Elgi’s efficient coupling ensures efficientpowertransmissionandconstantFAD throughoutthelife

Unique profile rotors formaximum air flow and minimum powerconsumption

eta-V ( -V)η

Single-Stage Screw Air Compressors

Elgihasperfectedthe“OSBIC”(OilSeparationby Impact and Centrifugal Action) processwhich enables efficient separation of air and

oil with minimum pressure drop. The processresults in low oil carry-over ( < 2 ppm) level attheoutputofthecompressor

Energy efficient

Efficient air oil separationwith OSBIC

Efficient coupling

90 - 250 kW | 16.7 - 43.9 m /min3

Microcontroller edge

Elgi’s Neuron II is a high end RISC microcontroller for control of medium tolarge screw aircompressors.Thesystem allowsyou to monitor andcontroloverall system performance with service indications, malfunction alarmsand safety shutdowns. It also includes a service and operational historyfeature to provide real-timefeedbackand increasessystem productivity

AUTO

Reports

Cumulative Report(Run Hours, Load Hours, Unload Hours, Stop Hours, Fault

Hours and remaining AFCT,OFCT,OSCT,OCT and RGT)Detailed Report - Previous 30 Days (Load Hours, Unload Hours, Stop Hours,Fault Hours, and Number of times machine stopped due to standby)Fault Report - (Previous 99 Faults in chronological Order with Real Timestamping and type of fault)

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Single-stage screw air compressor range - Standard pressure

Air outletconnection

Model50 Hz   Rated

PowerWorkingPressure   WeightFAD

kW   m /min3 cfmbar g Kg

E90-8 90 7 17.0 602 3200 2 1/2" NPTE90-9 90 8 16.1 570 3200 2 1/2" NPTE90-11 90 10 14.0 493 3200 2 1/2" NPT

E110-8 110 7 20.0 706 3300 2 1/2" NPTE110-9 110 8 19.1 675 3300 2 1/2" NPTE110-11 110 10 16.9 598 3300 2 1/2" NPT

E132-8 132 7 24.2 855 3500 2 1/2" NPTE132-9 132 8 22.8 806 3500 2 1/2" NPTE132-11 132 10 20.1 710 3500 2 1/2" NPT

E160-8 160 7 28.4 1003 3600 2 1/2" NPTE160-9 160 8 26.1 923 3600 2 1/2" NPTE160-11 160 10 23.3 822 3600 2 1/2" NPT

E200-8 200 7 37.7 1330 5400 3" FlangeE200-9 200 8 34.7 1225 5400 3" FlangeE200-10.5 200 9.5 31.9 1125 5400 3" FlangeE200-13.5 200 12.5 25.5 900 5400 3" Flange

E250-8 250 7 43.9 1552 5550 3" FlangeE250-9 250 8 41.7 1474 5550 3" Flange

E250-10.5 250 9.5 36.7 1295 5550 3" FlangeE250-13.5 250 12.5 32.1 1134 5550 3" Flange

Single-stage screw air compressor range - Low pressure

Model   RatedPower

WorkingPressure   WeightFAD

kW   m /min3 cfmbar g Kg

All models 90kW and above are available in air-cooled and water-cooled variantsMax. pressure or unload pressure for all models is 1 bar above the working pressure. i.e. For a E90-8, working pressure is 7 bar and max. pressure is 8 bar.Due to continuous engineering improvements, specifications are subject to change without prior notice.

Note:

Dimension LXBXH (mm): Air cooled models - 2745 x 1620 x 2020mm Water cooled models - 2745 x 1620 x 1900mm

Dimension LXBXH(mm): 4100 x 2100 x 2050 mm

Air outletconnection

A/C W/CHP psi g

ver  1.0

DCS

DCS (MODBUS RTU/RS 485):

SCADA :

Controller is enabled to synchronize with Distributed Control System – control of compressor from control panelof customer

Compressor control through PC with remote monitoring by Supervisory Control and Data Acquisition Process

Remote monitoring

E90-5.5 90 125 4.5 65 17.2 608 3100 2 ½" NPT 3" NPTE110-5.5 110 150 4.5 65 20.1 710 3150 2 ½" NPT 3" NPTE132-5.5 132 175 4.5 65 24.4 860 3300 2 ½" NPT 3" NPTE160-5.5 160 215 4.5 65 30.3 1070 3600 2 ½" NPT 3" NPTE200-5.5 200 270 4.5 65 37.5 1325 5100 3" Flange 3" Flange

E250-5.5 250 335 4.5 65 43.6 1540 5400 3" Flange 3" Flange

Dimension LXBXH(mm): E90-160 Air cooled models - E90-160 Water cooled models -E200-250 -

2745 x 1620 x 2020mm 2745 x 1620 x 1900mm4100 x 2100 x 2050 mm

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  2 8  %

Advantages

ElectricalLow starting currentHigh efficiencyImproved power factorReduced maximum demand

MechanicalMinimum maintenanceSmooth startSmooth control

Load-UnloadModulation

VFD

120

Controls

VFDSAVINGS

Load %

     I    n    p      u 

     t       P

    o     w    e     r

      % 

10 20 30 40 50 60 70 80 90 100

100

80

60

40

20

0

Example: For a demand of 70 % of full load, the savings from ELGI Conserve compared to a fixed speedcompressor will be about 28% of full load power

Model  Compatible

Compressor Model

ELVD 75 E75 & EE75ELVD 90 E90 & EE90ELVD 110 E110 & EE110ELVD132 E132 & EE132ELVD 160 E160 & EE160ELVD 200 E200ELVD 250 E250

Energy saving - The CONSERVE way

Matches compressor outputwith demandby varying motor speed.The power consumption reduces inline with the reduction in demand. Helps in eliminating the frequent load-unload cycle and also the

wastedpowerfromtheenergybill.

A fixed speed compressor operates on a load unload band of at least 10 psi around the workingpressure whereas with Elgi VFD, compressor can be operated within a band of 2 psi. Since thecompressor is not operated under higher than working pressure requirements, there is substantialenergysaving.For every2 psireduction in operatingpressure, there is 1%powersaving.

In a fixed speed compressor with Star-Delta starter, starting current is as high as three times the fullload current(FLC).WithElgiVFD starting,starting currentis less than theFLC.Thishelpsto avoid usingheavyrated components like fuses,MCCB,cablesize,generator rating, isolatorsetc.

For compressed air systems with fluctuating demand pattern, return on investment due to powersavingwillbelessthan12months.

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Automated Supply Side Controller (ASSC)

ELGI’s ASSC , Master controller can manage up to 12 positive displacement compressors –including compressors of different capacities, different types (fixed speed, variable speed andvariablecapacity),and in any combinationor configuration.Through advanced control functionalityand universal connectivity the ASSC will work with your existing compressors, from ELGI or anymanufacturer, to improve operating efficiency and reduce energy costs. Here’s how the ASSCcontrollerdeliversa uniquecombination of efficiency and reliability:

• Operate compressors only as needed, bringing standby compressors on-line incrementally duringperiods of increaseddemand

• Dynamically match the most energy efficient compressor or combination of compressors withcompressedairdemand

• Manage the compressed air system at your minimum required pressure without compromisingthereliabilityof your compressed airsupply

In multiple compress installation, it is difficult to choose the correct combination of compressors manually.This results in wastage of 20 - 60% of power. To cut such operating costs, ELGI has introduced the AutomatedSupply Side Controller

The Big Picture at a GlanceBe Energy Efficient While Increasing Reliability

Running a compressor in standby mode (unloaded), to ensure maximum capacity when needed, uses approximately 30%or moreof the energy requiredto run that same compressor fully loaded. Systems with multiple compressors of varying sizes, types and configurations further complicate the task ofmanuallycoordinatingand maintaining the correct compressorsettings.The larger the system,the more30%of unproductiveenergy willcost!

The primary functions of Energy Control Mode in ELGI ASSC System Automation are:

• Match compressed air supply to compressed air demand, dynamically• Utilize the most energy-efficient combination of air compressors to satisfy demandManage multiple compressors at minimum required pressure band•

Manage Your Battery of Air Compressors Efficiently

Air Demand   100%

7.0

7.5

8.0

8.5

Optimised System Pressure

Additional cost ofinput power aboveassumed optimum

bar 

6.5

+0.5% +0.5% +0.5% +0.5% +0.5%

1

2

3

4

5

CAP 

!

!

Pressure Optimisation

TheASSC eliminates the complexity of compressor control coordination and increases energy efficiency. Only the specific compressors operate at a giventime. Other compressors used for normal operations with manual control will be kept offline and shall be available during emergency requirements orduring primary equipment breakdown.This ability to tap existing resources to maintain systemoperation even in emergency situations makes the systemmorereliable.Inadditiontooptimisingtheenergyusage,efficientcompressorutilizationreducescostsduetoless downtime

1

2

4

3

5

100%Air Demand

+6.25%

+5.00%

+3.75%

+2.50%

+1.25%

1

2

4

3

5

Conventional Cascade

100%Air Demand

+6.25%

+5.00%

+3.75%

+2.50%

+1.25%

Additional cost ofinput power aboveassumed optimum

System Pressure

Energy Consumption   -   Pressure

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ELRD600 600 16.99 16 415 50 Three 900 1200 1350 275 Air/ WaterELRD750 750 21.24 16 415 50 Three 900 1200 1475 375 Air/ WaterELRD900 900 25.48 16 415 50 Three 900 1200 1725 425 Air/ WaterELRD1100 1100 31.15 16 415 50 Three 900 1200 1725 425 Air/ WaterELRD1254 1254 35.51 16 415 50 Three 900 1200 1725 1000 Air/ Water

ELRD1552 1552 43.95 12.5 415 50 Three 1300 1800 1650 1200 Air/ WaterELRD1750 1750 49.55 12.5 415 50 Three 1300 1800 1650 1500 Air/ Water

Modelcfm

Flow   MaxPressure

bar g

Electrical

Volts   Hz   phase   length   breadth   height

Dimensions in mmweight

KgCoolingmedia

Features:

Standard controller/visual performance indicatorMechanical type cycle controller for higher reliabilityCapillary refrigerant expansion

High efficiency tube in tube copper heat exchangerCondensate drains (both timer operated and zero options available)

Clean Air SolutionAirmate Refrigeration Air Dryer

4 Bar 5 Bar 6 Bar 7 Bar 8 Bar 9 Bar 10 Bar 11 Bar

0.75 0.85 0.93 1 1.06 1.11 1.15 1.18

Working Pressure

factor

Correction factors

25 C 30 35 40 45 50 55 60

1.22 1.20 1.15 1.05 1 0.85 0.8 0.7

0 0 0 0 0 0 0 0C C C C C C CInlet temp.

factor

20 25 30 35 40 45 50

1.20 1.14 1.10 1 0.91 0.87 0.78

0 0 0 0 0 0 0C C C C C C CAmbient temp.

factor

Economy Series FiltersPF E 0020

Filter type   Economy   Filter size

Filter Type   Pipesize

Flow rates@7 bar g (100 psi g)

cfm   m /h3

Engineering Data

Dimensions (mm)Weight

(kg)

Designation - Economy Series Filters

H W C   D

w

CH

DCLEARANCE TOCHANGE ELEMENT

(Filter Type)E 0400 G 2 424 720 575 150 405 280 6

(Filter Type)E 0620 G 2 635 1079 1015 280 830 450 28

(Filter Type)E 0840 G 2 1/2 847 1439 1015 280 830 580 33(Filter Type)E 1120 G 3 1129 1918 1315 320 1120 850 40

(Filter Type)E 1600 G 4 1694 2878 1100 410 710 580 80

(Filter Type)E 2540 G 4 2541 4317 1100 410 810 580 80

(Filter Type)E 3300 G 4 3388 5756 1370 410 1140 850 90

PFFFCF

- PreFilter- Fine Filter- Carbon Filter

Due to continuous engineering improvements, technical specifications are subject to change without prior notice.

Airmate Filters

Customized models are available on request

Performance data is measured at 7 bar, inlet temperature 45 C, ambient temperature 35 C, pressure dew point +3 C. Customised models also available on request. Dryers of highercapacities also available.

0 0 0

Dryers of higher capacities are also availableDue to continuous engineering improvements, technical specifications are subject to change without prior notice.

3m/min

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Maximum recommended pressure differential forelement change: (PF, FF filters only) 340m bar.

Initial ‘dry’

Grade PF - 70m bar (1.0 psi)Grade FF 100m bar (1.5 psi)Grade CF 70m bar (1.0 psi)

differential pressure

--

Initial ‘wet’

Grade PF - 140m bar (2.0 psi)Grade FF 200m bar (3.0 psi)Grade CF N/A

differential pressure

--

Technical Data

Ordering example: To order a 0.01 micron filter flowing 125 cfm at 7 bar specify type FF 0127.Replacement element is FFE0127.

For Flow Rates at other pressures, apply the factor shown

Line bar g 1 2 3 5 7 9 11 13 15 17 20

Pressure psi g 15 29 44 73 100 131 160 189 218 247 290

Correction Factor 0.38 0.53 0.65 0.85 1.0 1.13 1.25 1.36 1.46 1.56 1.7

The CF Filter will not remove CO/CO or other toxic gases or fumes.2

Maximum operating pressure 16 bar g(0019 to 2119) with Autodrain (232 psi g)

Maximum operating pressure 20 bar g(0018 to 2119) with manual drain (290 psi g)

Maximum recommendedoperating temperature(Grade PF/FF)

66 C(150 F)

0

0

Max. recommendedoperating temperature(Grade CF)

30 C(86 F)0 0

Min. recommended   1.5 C(35 F)0 0

Model

VA 00 010 250 0.25 12.5 1745 500VA 00 020 500 0.5 12.5 2010 622VA 00 030 750 0.75 12.5 2095 752VA 00 040 1000 1 12.5 2700 750

Capacity

ltr. m3

Max WorkingPressure   Dimensions (mm)

bar g Height Dia.

• Dimensions are approximate• Air receivers of higher capacities are available on request.• All air receivers are made as perASME section VIII Div 1/IS2825• Level sensing auto drains are also available.• Due to continuous engineering improvements, technical specifications are subject to change without prior notice.

The Elgi Air Receiver is engineered to handle the stress of fluctuating air demands, reduce wear and tearand increase the life of the end use equipment.

Airmate Air Receiver

Air-oil mixture   Oil   Air

2

1

3

4  5

6

7

89

5

10

13

1112

15

16

14

Compressor Air/Oil Schematic(single-stage)

1. Air Intake filter2. Intake valve3. Airend4. Drive coupling5. Electric motor6. Minimum pressure valve7. Separator element8. Separator tank9. Drain valve10. Oil filter11. Thermal valve

12. Fan13. Oil cooler14. After cooler15. Ball valve-service line16. Pressure transmitter

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     I     (       A     )       /      6      1     0      8      /      0      5      /      1     2     /      1     0      0 

     0      /      2     0      1     2     /      0      6      /      0      1     /      S 

Distributed by:

Elgi Equipments Australia Pty Ltd.

Production centre and offices: Wholly-owned subsidiaries and offices :

Overseas offices:

India, China, France

France, Sharjah, Brazil, China, AustraliaIndonesia, Bangladesh, Thailand, Srilanka

1/35 Steel Place Morningside, QLD, 4170 ,Australia+61 73106 0589

 www.elgi.com.au

Ph:Toll Free No.:

E-mail: Web:

1800-813-1777

[email protected]

Elgi serves the world marketplace. Over two million compressors are powering business in 63 countries worldwide. The company offers astrong sales and service network with a well-knit distribution network of 114 dealers and 165 distributors worldwide. Elgi has its ownmanufacturing facilities in India, China and France. It has also set up warehouse facilities in Brazil, Middle East and Australia.

Customers

Typical Compressed Air Supply system

Air compressor

Particulate

filter

Dryer   Oil Filter  Receiver

Drain taps

Oil/WaterSeparator

Vapour filter