Horizon Series

Electric Powered
Screw Air Compressors
Built to Last

11-75 kW

www.elgi.com

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

Screw compression elements are manufactured in-house using state-of-the-art

machining centres for rotor grinding and machining intrinsic castings of various
sizes. Elgis own V (eta V) profile rotors ensure energy-efficient compressed air
supply 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 has modern manufacturing facilities in India & abroad equipped with advanced high
precision grinding machines, turning centres and CNC horizontal and vertical machining
centres . Every manufactured component / product passes through stringent quality audits
and are tested to ensure performance and reliability. Our Manufacturing test rooms are
atmospheric controlled. All parts and finished products undergo stringent quality checks to
ensure that Elgi delivers only high quality products to its customers.

Horizon Series
For the last five decades, Elgi has been successfully manufacturing innovative products for diverse applications. Elgi partners with customers across
the globe in unique ways which transcend the ordinary company-customer interaction by providing solutions, services and support long after
product delivery. By exploring customer needs and applications, Elgi develops custom-engineered products - products which in turn, help the
customer build better end-products, boost performance and command better markets. The Horizon range of products is one among them. The
Horizon range of rotary screw air compressors are offered with advanced features that ensure high levels of reliability, efficiency and economy.
Built and tested to Elgis stringent manufacturing standards, the compressors are designed to perform in the most demanding conditions.

Features that set Horizon Series apart

HORIZON

High levels
of safety

Energy-efficient
High ambient
compatibility

Compact
Low life-cycle
cost

Eco-friendly

Moisture
separator
for 99% bulk
water free air

Robust construction with

reliability built into
every component

High quality
air output

Small Electric Powered

Screw Compressors
new horizons in performance
Energy-efficient
V (eta V)-profile airend
Designed and developed by Elgi, the unique V (eta V)-profile airends
ensure maximum energy-efficiency. They give highest output at low fuel
consumption. The Horizon series compressors powered by these airends
thus significantly reduce compressed air costs. Owing to high precision in
machining and assembly, the airends also ensure quiet operation and easy
maintenance.

Optimal capacity control

Air intake system
The volumetric efficiency of screw compressors lie in the air
intake system, which provides the direction and swirl into the
airend. The load and unload cycle which cannot be eliminated in
an air system process is a major contribution in power
consumption. The Horizon series incorporates the VARION type
intake valve, which helps in optimizing the power statistics at
varying loads.

99% Bulk water free air

Moisture separator with drain as standard
Depending on the humidity level of inlet air, bulk water remains
in compressed air at varying levels and causes corrosion of
piping, end tools, machinery and valves. Horizon series air
compressor has a custom-designed centrifugal type moisture
separator with an automatic timer controlled drain. This comes
as a part of the package at no extra cost and removes over 99%
of bulk water from the compressed air through float mechanism.
The result: corrosion free, longer life of end use equipments and
less load on the dryer.

Efficient air-oil separation

Air-oil separation with OSBID
A new horizon in superior air quality. Over the years, Elgi has perfected the OSBID process (Oil Separation By Impact and
Deceleration) for models E11-E22 to enable efficient separation of air and oil, with minimum pressure drop. This process
results in consistent quality of air, specifically during the working cycle and unloading. The oil carry-over level is
consistently less than 2 ppm, with the OSBID process. Elgi guarantees the OSBID process for the life of the compressor.
The tanks are CE and ASME certified to ensure high levels of safety
For E75 model, a unique OSBIC process of oil separation by impact and centrifugal action is applied.

Efficient power transmission

Direct drive
Horizons direct drive through flexible coupling ensures efficient power transmission and
constant free air delivery for its life. Unlike belt-driven screw compressors, there is no associated
power loss and belt slippage. The drive is maintenance-free for life. It has been observed that
there is an improvement in efficiency up to 5% over belt drive.
* as per ISO Standards

Cool air
Efficient and optimally sized split cooler
The cooling system with pusher type fans is of suitable design and capacity for operation of
0
the compressor in ambient conditions of 45 C The optimally sized split cooler delivers air at
10 deg.C above ambient. Designed to meet CE norms, the cooling system enables easy
ducting and maintenance. Air throw at the top of the compressor provides safety against hot
zones. Above all, the aluminum inter cooling pipes act as cooling media for oil & air.

Longer motor life

Heavy duty foot cum flanged motor
The heavy dutyTEFC/ IP55 foot cum flanged motor with reserve
power takes care of power fluctuations. High efficiency motors
are more energy-efficient which helps reduce power costs.
Operating within power capabilities, it provides energy saving
power costs.

Quick and low cost maintenance

Grouped service points
Service points are grouped together for easy service. Consumables such as air filter, oil filter and
separator element can be easily accessed. Components like safety valve, thermal valve, minimum
pressure valve, solenoid valve and intake valve are with in reach to facilitate easy maintenance.
Longer service intervals reduce maintenance costs.

Ideal for harsh environments

Robust design
The Horizon screw compressors are specially designed to perform at extreme environmental conditions from hot
summer to cold winter and from dry to extremely humid conditions. They keep your production running efficiently.

Intelligent
Control
Microcontroller edge
Saves Money
By ensuring higher life for major components by:
Control of sump pressure
Control of compressor electrical against impurities in
input power low voltage, shorter interruption
Data validation of critical parameters: pressure and
temperature

Saves Energy
Pressure scheduler enables optimization of compressor

usage and bring quicker ROI (return on investment)

On /Off control of fan motor depending on the oil

temperature
Elgis Neuron II is a high end RISC microcontroller for control of medium to
large screw air compressors. The system allows you to monitor and control
overall system performance with service indications, malfunction alarms and
safety shutdowns. It also includes a service and operational history feature
to provide real-time feedback and increases system productivity.

Built-in

Dryer dew point Integration

parameter (power, HMR, frequency, ampere, voltage )read out and closed
loop control
Automatic fan motor control based on discharge temperature thereby eliminating
thermal switch - up to E45
Selectable AO (pressure/temperature/dew point) for DCS integration
VFD

Saves Time
Easy navigation of menus in the controller
User friendly back-lit display panel
Easy to read warning and trip messages
On line display of temperature , status details
Display of running load, unload, standby hours etc
MIMIC display ensure communication to unskilled
maintenance operator

Other Benefits
Vast memory to store 99 fault reports and historical

day reports for 30 days

Smart Start Logic (SSL) automatically decides the start

delay required to ensure minimum wait time between

successive starts of compressor and dryer

Remote monitoring
DCS ( MODBUS RTU/RS 485)

Controller is enabled to synchronize with Distributed Control System control of compressor from central control panel
SCADA

Compressor control through PC with remote monitoring by Supervisory Control and Data Acquisition Process
Connection to phone (GSM)/ RS485 networking

Built to ensure high levels of safety

CE certified pressure vessel
Built with multiple levels of safety & interlock devices
Trips & warning messages in controller
Safety valve for mechanical blow off
Shut down by Neuron 11 incase of temperature bypass through sensor
Component endurance test/electrical testing for EMC, performance testing as per ISO1217 Annexure C Ed3
100% testing of airends and packages
Metallic pipes for connecting components

Safety and Interlocks

High Sump pressure trip through transmitter
High sump temperature through temperature sensor
Motor overload( main & fan ) through overload relays
Single phasing, voltage imbalance & reverse rotation through Single Phase Preventer
Safety valve as additional safety over the unload mode
Redundancy ensured in the controller in the event of data corruption
Guards over rotating elements as per CE directive

HORIZON
Features and Benefits
Robust cooling system
Canopy designed for high
ambient and dusty industrial
atmosphere

Advanced Neuron II controller

Heavy duty intake air filter

Proven high efficiency direct

driven airend
TEFC / IP55 motor with variants
for different markets

Easy access through lift panels & doors

Applications

Textile

Cement

Power Generation

Packing

Manufacturing

Engineering

A significant value addition

Downstream accessories
Elgis comprehensive range of air accessories provides you with the clean, dry air you need to extend the life of
your equipment and ensure the quality of your end product.

Air receiver
Capacity : 250-10000 ltrs.
2
Working pressure : 7-60 Kg/cm
Code of construction: ASME

sec. VIII Div.I or IS 2825

Downstream filter
Clean air solution

Capacity : 19-1200 cfm

2
Working pressure : 7-60 Kg/cm
Filtration range: 1-0.003 microns

Refrigeration air dryer

Capacity : 10-2000 cfm
2
Working pressure : 7-60 Kg/cm
0
Filtration range: +3 C. PDP

Automated supply
side controller (ASSC)

Drain valves

Elgis ASSC, master controller can manage upto 12 positive

displacement compressors - including compressors of different
capacities, different types (fixed speed, variable speed and
variable capacity), and in any combination or configuration

Capacity : upto 100 cfm

Working pressure : 7-13 bar

Timer controlled and zero loss

Energy Saving -The CONSERVE way

ELGI

Variable Frequency Drives(VFD)

The Elgi CONSERVE VFD matches compressor output with demand by varying motor speed and hence the
power consumption of the compressor reduces in line with the reduction in demand. The VFD also eliminates
the frequent load-unload cycle and the wasted power from the energy bill.
A fixed speed compressor operates on a load unload band of at least 10 psi around the working pressure
whereas with Elgi VFD, compressor can be operated within a band of 2 psi. Since compressor is not operated
under higher than working pressure requirements, there is substantial energy saving. For every 2 psi reduction
in operating pressure, there is 1% power saving.
In a fixed speed compressor with Star-Delta starter, starting current is as high as three times the full load
current (FLC). With Elgi VFD starting, starting current is less than the FLC. This helps to avoid using heavy rated
components like fuses, MCCB, cable size, generator rating, isolators etc.
For compressed air systems with fluctuating demand pattern, return on investment due to power saving will be
less than 12 months.

Advantages:

10 Year Life Cycle Cost

3% 3%

Electrical:
Low starting current
High efficiency
Improved power factor
Reduced maximum demand
Mechanical:
Minimum maintenance
Smooth start
Smooth control

4% 3%

28%
94%
Compressor without VFD

Compressor with

65%

Elgis full range of After sales products and services

Schematic diagram

1 . Air intake filter

2. Intake valve
3. Airend
4. Drive coupling
5. Electric motor
6. Minimum pressure valve
7. Separator element
8. Blowdown valve
9. Receiver tank
10. Ball valve-drain
11. Oil filter
12.Thermal valve
13. Oil cooler
14. After cooler
15. Ball valve - service line
16. Fan
17. Pressure transmitter
18. Temperature sensor
19. Moisture separator

2100

Elgis customer care centre works 12 hours a day and 6 days with two
shifts of staffing through a toll-free telephone number, 1800-425-3544 in
India.

Elgi serves the world marketplace. Over two million compressors are powering business in 63 countries worldwide. The company
offers a strong sales and service network of 14 domestic and 6 overseas offices, besides a well-knit distribution network of 114
dealers in India and 165 distributors worldwide. In addition to manufacturing facilities in India, Elgi has manufacturing facilities in
China 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

Singanallur, Coimbatore-641005, India, Tel: +91-422-2589555

Fax: +91-422-2573697 International Division: Fax: +91-422-2589401
Email: enquiry@elgi.com Visit us at www.elgi.com
Ahmedabad Ph:(91-79) 26583736, 26581274 Fax:26587683 Bangalore Ph:(9180) 22240674,22220296 22122479 Fax:22293274 Bhopal Ph:(91-755) 2578281,
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Ph:(91-4288) 257137Fax:257693 Global Support Centre Ph:(91-422) 2625868,
2625869 Fax:2625985

Production centre and offices: India, China, France

Wholly-owned subsidiaries and offices : France, Sharjah, Brazil, China
Overseas offices: Indonesia, Bangladesh, Thailand, Srilanka, Australia

Marketed by:
D/ 3696 /11/12/3000/2011/08/01/S

Elgi Equipments Ltd.