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8/19/2019 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
enquiry@elgi.com.au
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
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