Tandem ElectricPowered Screw AirCompressorsBuilt to last

90-160 kW

www.elgi.com

Screw compression elements are manufactured in-house usingstate-of-the-art machining centres for rotor grinding andmachining intrinsic castings of various sizes. Elgi’s own eta-V ( V)profile rotors ensure energy-efficient compressed air supply for alldemanding applications. Elgi is one of the few companies capableof manufacturing wide range of airends and compressor packagesin the world.

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Elgi’s experience in the design and manufacture of air compressors spans 50 years.Established in India in 1960 as a reciprocating air compressor manufacturing company, Elgigained its reputation for design and manufacture of screw compressors through strategicpartnerships and continuous research and development. Over the years, it emerged as amulti-product multi-market enterprise providing total compressed air solutions in allsegments. Elgi’s design capabilities translated into wide range of products ranging from oil-lubricated and oil-free rotary screw compressors, oil-free reciprocating compressors andcentrifugal compressors.

Elgi has modern manufacturing facilities in India & abroad equipped with advanced highprecision grinding machines, turning centres and CNC horizontal and vertical machiningcentres . Every manufactured component / product passes through stringent quality auditsand are tested to ensure performance and reliability. Our Manufacturing test rooms areatmospheric controlled. All parts and finished products undergo stringent quality checks toensure that Elgi delivers only high quality products to its customers.

Electric Powered Air Compressors

Energy Saving Solution

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

Automatic Supply SideController

Wide product range

Global Series11-22 kW / 2.01-3.85 m /min3

Encap Series2.2-15kW / 8-73 cfm

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

3

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

3

Clean Air Solution

Air Accessories

Reciprocating AirCompressors�

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Market leader in India with overa million installationsWide range of compressors forIndustrial, Automotive, Highvolume/ High pressure, Railway& Defense applications

Portable AirCompressorsWide range of diesel driven andelectric powered portable aircompressors for Industrial,Construction & Mining, Water-well drilling and Oil/Gas/CBMexploration

Oil Free Screw Air Compressors90-350 kW | 500-1700 cfm

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2 - 12 compressors integrationMulti-compressor control upto12 compressors

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 1st

stage

Tandem 2nd

stage

Single stage

Co

mp

ress

ion r

atio

Elgi offers tandem screw compressors to help industries reduce their operating and energy costs. It is a two-stage compressor, having energy efficiency asthe key feature.The compression is done in two-stages to improve the volumetric efficiency and thereby contributing to 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 whencompared to single-stage compressors

A single-stage compressor , operating at a discharge pressure of 9 bar, has a compression ratio of 1:9 (Ratio of Suction to Discharge of a ScrewAirend) . Ina two-stage compressor operating at the same discharge pressure, the compression ratio is divided between the two stages of tandem airend and is about1:3 in each stage .This makes the airend more reliable and efficient due to smaller loads on the bearings.The volumetric efficiency of two-stage is betterthan single - stage compression

Stage IIntermediatecooling

Stage II

Load/Unload controlModulation controlVSD control

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High efficiencyHigh energy savingHigh reliabilityPower Savings

Dual control mode

12%

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

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 EE90-115 model compressor, working pressure is 100 psig and max. pressure is 115 psigDue 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 outletconnectionModel Rated

PowerWorkingPressure WeightFAD

kW m /min3 cfmpsi g Kg

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

HP bar g

EE90-100 90 125 6.9 100 18.1 640 3900 2 1/2" NPT

EE90-125 90 125 8.6 125 16.1 568 3900 2 1/2" NPT

EE90-150 90 125 10.3 150 14.4 509 3900 2 1/2" NPT

EE110 -100 110 150 6.9 100 22.4 790 3970 2 1/2" NPT

EE110 -125 110 150 8.6 125 20.7 730 3970 2 1/2" NPT

EE110 -150 110 150 10.3 150 18.4 651 3970 2 1/2" NPT

EE132 -100 132 175 6.9 100 27.6 974 4040 2 1/2" NPT

EE132 -125 132 175 8.6 125 24.1 852 4040 2 1/2" NPT

EE132 -150 132 175 10.3 150 21.8 771 4040 2 1/2" NPT

EE160 -100 160 215 6.9 100 31.1 1100 4340 2 1/2" NPT

EE160 -125 160 215 8.6 125 29.5 1042 4340 2 1/2" NPT

EE160 -150 160 215 10.3 150 25.3 892 4340 2 1/2" NPT

Airend and motor shafts are coupled through a permanently alignedcushion type claw coupling. Elgi’s efficient coupling ensures efficientpower transmission and constant FAD throughout the life

Unique profile rotors formaximum air flow and minimum powerconsumption

eta-V ( V)η-

Elgi has perfected the“OSBIC”( Oil Separationby Impact and Centrifugal Action) processwhich enables efficient separation of air andoil with minimum pressure drop. The processresults in low oil carry-over ( < 2 ppm) level atthe output of the compressor

Energy efficient

Efficient air oil separationwith OSBIC

Efficient coupling

Microcontroller edge

Elgi’s Neuron II is a high end RISC microcontroller for control of medium tolarge screw air compressors.The system allows you to monitor and controloverall system performance with service indications, malfunction alarmsand safety shutdowns. It also includes a service and operational historyfeature to provide real-time feedback and increases system productivity

AUTO

Reports�

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Cumulative Report(Run Hours, Load Hours, Unload Hours, Stop Hours, FaultHours and remaining AFCT,OFCT,OSCT,OCT and RGT)

Detailed Report - Previous 15 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)

ver 1.0

DCS

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DCS ( MODBUS RTU/RS 485):

SCADA :Alerts on GSM:

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 ProcessConnection to phone (GSM)/ RS485 networking

Remote monitoring

28%

Advantages

ElectricalLow starting currentHigh efficiencyImproved power factorReduced maximum demand

MechanicalMinimum maintenanceSmooth startSmooth control

Load-Unload

Modulation

VFD

120

Controls

VFDSAVINGS

Load %

Inp

ut

Pow

er %

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

ModelCompatible

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

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 andvariable capacity), and in any combination or 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 ASSCcontroller delivers a unique combination of efficiency and reliability:

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

• Dynamically match the most energy efficient compressor or combination of compressors withcompressed air demand

• Manage the compressed air system at your minimum required pressure without compromisingthe reliability of your compressed air supply

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 more of the energy requiredto run that same compressor fully loaded. Systems with multiple compressors of varying sizes, types and configurations further complicate the task ofmanually coordinating and maintaining the correct compressor settings.The larger the system, the more 30% of unproductive energy will cost!

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 demand

Manage 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

The ASSC 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 system operation even in emergency situations makes the systemmore reliable. In addition to optimising the energy usage,efficient compressor utilization reduces costs due to less 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

Economy Series Filters

PF E 0400Filter 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

Air receiverDownstream filter

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Capacity : 250-10000 ltrs.Working pressure : 7-60 barCode of construction: ASMEsec. VIII Div.I or IS 2825

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Capacity : 19-1200 cfmWorking pressure : 7-60 barFiltration range: 1-0.003 microns

A significant value additionTypical Compressed Air Supply system

Air compressor

Particulatefilter

Dryer Oil FilterReceiver

Drain taps

Oil/WaterSeparator

Vapour filter

Demand Side Controller

Model

VA 00 010 250 0.25 12.5 1745 500VA 00 020 500 0.5 7 2060 600VA 00 020 500 0.5 10 2060 600VA 00 020 500 0.5 12.5 2010 622VA 00 030 750 0.75 12.5 2095 752VA 00 040 1000 1 7 2700 750VA 00 040 1000 1 10 2700 750VA 00 040 1000 1 12.5 2700 750VA 00 060 1500 1.5 7 2510 996VA 00 060 1500 1.5 10 2510 996VA 00 060 1500 1.5 12.5 2520 1020VA 00 080 2000 2 7 3185 1000VA 00 080 2000 2 10 3185 1000VA 00 080 2000 2 12.5 3185 1000VA 00 120 3000 3 7 2995 1310VA 00 120 3000 3 10 2995 1310VA 00 120 3000 3 12.5 2815 1314VA 00 160 4000 4 12.5 3590 1314VA 00 200 5000 5 12.5 3545 1500

Capacity

ltr. m3

Max WorkingPressure Dimensions (mm)

bar g Height Dia.

Dimensions are approximateAir receivers of higher capacities are available on request.All air receivers are made as per ASME section VIII Div 1/IS2825Level 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 tear and increase the life of the end use equipment.

Airmate Air Receiver

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 d C(150 F)0

Max. recommendedoperating temperature(Grade CF)

30 C (86 F)0 0

Min. recommended 1.5 C (35 F)0 0

Drain valvesTimer controlled and zero loss

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Capacity : upto 100 cfmWorking pressure : 7-13 bar

TotalCompressedAir Solution

Power GenerationCementTextileShip buildingAutomobileEngineering and more...

Elgi’s full range of After sales products and services

Compressor Health Check Systemand Service Agreements

Path to reducing compressed air cost

For enhancing performance and productivity

· Increase compressor life· No production interruptions· Reduces operational costs

Benefits that you get

For reliability and long service life

· Maximize lubricant service life· Reduces wear of compressor components· Low oil consumption· Provides excellent resistance to oxidation

Benefits that you get

Coolants and Lubricants

For ensuring complete peace of mind

· Combined advantage of warranty and annual maintenance· In the unlikely event of breakdown, your compressor shall be

restored within 24 hours· Optimal extended warranty scheme· Reduces compressor breakdowns

Benefits that you get

Benefits that you get···

·

·

·

Optimization of compressed air systemReduction in overall system pressureTransparent audit methodology to identify,analyse, and solve the wastage and misuse ofcompressed airReduce maintenance costs realized throughbetter use of compressed airSelection of compressed air piping anddistributionAir leak reduction

Elgi serves the world marketplace. Over two million compressors are powering business in 63 countries worldwide.The companyoffers a strong sales and service network of 14 domestic and 6 overseas offices, besides a well-knit distribution network of 114dealers in India and 165 distributors worldwide. In addition to manufacturing facilities in India, Elgi has manufacturing facilities inChina and France.Elgi has also set up warehouse facilities in Brazil and Middle East.

Customers

Personnel

Wholly owned Subsidiaries

Production Centres and Offices

Overseas Offices

Elgi Equipments Ltd.Singanallur, Coimbatore-641005, India, Tel: +91-422-2589555 Fax: +91-422-2573697 International Division: Fax: +91-422-2589401Email: enquiry@elgi.com Visit us at www.elgi.com

Production centre and offices:

Wholly-owned subsidiaries and offices :

Overseas offices:

India, China, France

France, Sharjah, Brazil, China

Indonesia, Bangladesh, Thailand, Srilanka, Australia

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