Premium Rotary Screw Compressors - Canfield & … Rotary Screw Compressors. At Kaeser, ... Profibus,...

SX - HSD SeriesCapacities from: 8.8 to 3069 cfmPressures from: 50 to 217 psig

Premium Rotary Screw Compressors

At Kaeser, we pride ourselves on being the leading innovator in compressed air system technology. With over 90 years’ experience in precision manufacturing, we have a well-earned reputation for superior product quality and reliability. In the field, Kaeser specializes in indi-vidually evaluating each customer’s compressed air application, and providing the most efficient and effective air system solution. Prompt and dependable customer service, quality assurance, training, and engineering support contribute to the value customers have come to expect from us. We aim for excellence in everything we do.

Kaeser Compressors, Inc.

2

3

Today, Kaeser employs over 4,000 people and our growing subsidiary and distribu-tion network provides air system solutions throughout the world.

4

Built for a lifetime

70% of Your Long Term Compressor Cost is Electricity

Analyze the total cost of a compressed

air system and you’ll realize that power

cost is significant. In just one year it

could exceed the price of the compres-

sor itself. Over a period of ten years, this

could consume 70% of your overall air

system costs. That’s why it is important

to investigate energy efficiency when

considering a new compressor or design-

ing an air system.

Maximum efficiency and reliability have long been synonymous with Kaeser Compressors. Our commitment to excellence drives us to continually enhance and optimize our compressed air system solutions. With a cutting edge research and development team committed to producing industry leading products, Kaeser constantly strives to offer lasting solutions for our customer’s compressed air needs. Our rotary screw compressors deliver on all accounts.

Kaeser’s unique Sigma Profile airend and intelligent Sigma Control 2™ system, combined with the latest one-to-one drive technology mean that our compressors can guarantee exceptional energy savings, without compromising on durability or ease of maintenance. Our customers expect excellence and we make it happen.

Built to perform. Built to last. Kaeser compressors are built for a lifetime.

Electricity

MaintenanceEquipment

5

A Perfect Match

Sp

ecif

ic P

erfo

rman

ce (

kW/1

00 c

fm)

Optimum Speed

Airend Speed

Larger airends turning at slower speeds are more efficient and deliver more compressed air for the same drive power.

Kaeser’s design philosophy is to develop slower running airends with optimized profiles that can pay for themselves in

a short period of time with increased energy savings.

V-Belt Drive Compressors

6

Atmospheric air is drawn through the

inlet filter and valve (1) into the airend

where it is compressed. The airend is

driven by an electric motor (3).

Synthetic cooling fluid, Sigma

Premium Fluid, is injected into the airend

to serve as coolant, lubricant and seal-

ant. Under normal conditions the air

reaches a temperature of about 180°F

during compression.

A multi-stage separator (4) removes

the coolant from the compressed air and

the air emerges from the separator with

a remaining fluid content of less than

3 ppm. The fluid then passes through the

cooler (5) , the filter (6) and back to the

point of injection. A thermostatic valve

(7) regulates and optimizes the fluid

temperature.

After leaving the separator,

compressed air passes through the

minimum pressure / check valve (8)

and finally through the aftercooler (9) ,

where it is cooled to within 10°F to 20°F

above ambient temperature. Most of the

moisture is now liquid and ready to be

removed.

The air leaves the compressor

through a threaded or flanged connec-

tion 10 .

1 2

3

4

5 6

7

8

9

10

How do Kaeser screw compressors work?

1

2

3

4

5

67

8

9

10

Sigma Profile airendKaeser uses a number of newly designed airends.

They are precision machined to close tolerances

and optimized in size

and profile to match

the low airend

speeds with their

best specific perfor-

mance (see A Perfect

Match curve on Page 5).

7

Sigma Control Basic™A simple and reliable interface offers convenient

pressure control and

system monitoring

with status displays

and service indica-

tors. Displays include

discharge pressure

and temperature, load and service hours, as well

as fault indicators.

11

11

Efficient Separator SystemA three-stage separator (ASME or CRN) combines

centrifugal action and a

2-stage coalescing filter to

reduce fluid carry over to

2 ppm or less. Quick release

fittings, drain and fill ports are

arranged for fast and easy fluid

changes from sump and cooler

without any pumping device.

The easy-to-read fluid level

indicator can be checked with-

out opening or stopping the

compressor through a window

in the service panel.

High-Efficiency Coolers with Filter MatConveniently located on the outside of the unit, our

standard high-efficiency

coolers provide maxi-

mum cooling resulting in

approach temperatures

as low as 11°F for more

moisture separation at the

compressor discharge and

better air quality. A filter

mat simplifies cooler maintenance. Dirt and dust

build up on the outside of the filter, where it is eas-

ily seen and removed. This extends cooler service

intervals and increases thermal reserve for harsher

conditions.

TEFC Motor with Reduced Voltage StarterHigh-efficiency, totally enclosed, fan cooled

(TEFC) motors with

Class F insulation are

standard for long life in

harsh environments. Tri-

voltage 208-230/460 or

575 V, 3-phase, 60 Hz is

standard. Other voltages

are available. Magnetic Wye-Delta reduced voltage

starters ensure low starting current and smooth

acceleration.

Belt Drive with Automatic TensioningA new ribbed single belt drive efficiently trans-

fers power from motor to airend.

Our unique automatic tensioning

device maintains proper tension to

maximize energy efficiency, pro-

long belt life and simplify routine

maintenance. The belt tension can

easily be verified through a window

in the service panel.

Versatile V-belt DriveKaeser was one of the first compressor manufacturers to implement the V-belt drive.

Kaeser screw compressors with V-belt drive are economical and reliable.

An important feature is automatic belt tensioning , which ensures excellent

transmission efficiency and reduced maintenance costs. Screw compressors with

V-belt drives are also especially flexible and can be easily modified if a change in

working pressure becomes necessary.

One-to-One Direct Drive Compressors

8

Optimized EfficiencyIn Kaeser packages, one-to-one drive

reduces the number of components

needed compared to a gear-driven unit,

increasing reliability and service life.

Kaeser has selected oversized

airends specifically matched to produce

the required output in flow and pres-

sure. Compared to compressors using

small, high-speed, gear-driven airends,

the one-to-one drive provides triple sav-

ings: no-loss power transmission, lower

power consumption, and reduced main-

tenance and related downtime costs. One-to-One Direct DriveAirend RPM = Motor RPM

9

Sigma Control 2™Sigma Control 2 - a rugged industrial control-

ler which offers

unsurpassed

compressor

control and

monitoring.

It has a large,

easy-to-read plain text display with up to 30

language options. An RFID reader eliminates the

need for manual password entry and simplifies

preventive maintenance.

The Sigma Control 2 has a communica-

tions port adaptable to Profinet, Devicenet,

Profibus, and Modbus for seamless integration

into master control/monitoring systems. An

Ethernet port with built-in web server enables

remote viewing.

Standard software includes several

advanced control profiles (including Automatic

Dual, Quadro, and Vario control), which makes

it ideal for multiple compressor systems. Easily

upgradable via the SD card slot.

Sigma Profile Airend Our single-stage, flooded rotary screw airend

delivers pressures up to

217 psig, and features

our power saving Sigma

Profile™ design. Our

airends are precision

machined and optimized in size and

profile to match the airend speeds with their best

specific performance (see A Perfect Match curve

on page 5).

True Direct DriveIn our design, the motor is directly connected to

the airend with a one-to-one

coupling, providing maximum

transmission efficiency. This

true direct drive eliminates

gear drive components, heat and power losses. It

is also maintenance free, increasing reliability and

uptime. A cast housing is doweled and pinned to

assure perfect alignment.

Fluid Separation SystemOur separator tank has a 3-stage separation

system that ensures very low

pressure drop, fluid carry-over

(1-3 ppm), and extended filter

service life.

Our no-leak design

features rigid steel piping,

flexible connections and vibra-

tion isolators. Each pressure

vessel is ASME coded (CRN in

Canada) and includes wet side/

dry side fittings to check

differential pressure, an easy to read fluid level

indicator, and our unique quick drain system.

Premium Efficiency Drive MotorKaeser uses only premium efficiency Totally

Enclosed Fan Cooled

(TEFC) motors with

class F insulation for

extra protection from

heat and contaminants.

Remote grease fittings

make maintenance a breeze.

460 or 575 V, 3-phase, 60 Hz.

Other voltages are available.

Unique Air Flow Design Optimizes Cooling

In Kaeser’s “split-cooling” design, sepa-

rate cooling air inlet zones for the coolers

and drive motor ensure optimum cooling.

Drawing ambient air separately results in

longer lubricant life and a cooler running

motor. This also results in much lower

approach temperatures, improving mois-

ture separation and air quality.

To increase reliability and reduce

maintenance costs, the coolers are con-

veniently located on the outside of the

unit, where dust and dirt build-up are

easily seen and can be removed without

dismantling the cooler.

Powerful radial fans pull air through

the coolers and create a vacuum within

the cabinet that effec-

tively cools the motor

even under severe

operating conditions.

Top exhaust allows for

convenient ducting and

reduces the system footprint.

Reduced Voltage StartingMagnetic Wye-Delta reduced voltage starting is

standard. This energy saving feature ensures

low starting current and smooth acceleration.

Sigma Frequency Control

10

Unmatched PerformanceKaeser Sigma Frequency Control combines Siemens AG drive technology with our

proprietary Sigma Profile airend and Sigma Control system. Our engineers have opti-

mized the airend design to accommodate a wide flow range with unmatched efficiency.

The drive motor and airend operate at low rotational speeds, resulting in exceptional

reliability and long life. Kaeser’s SFC units range from 8 to 515 kW and are incredibly

quiet, with noise levels as low as 67 dB(A). SFC models up to 132 kW are also avail-

able with integrated dryers.

Integrated System DesignEven though variable frequency drive compres-

sors can have an effective flow range of 20% to

100%, the efficiency (kW/cfm) is not constant

over the whole speed range. The best efficiency

is normally between 40% and 85%. As the graph

illustrates, the Sigma Profile airend has a clear

efficiency advantage over a wider flow range than

its competition.

Integrated Systems

11

Kaeser rotary screw compressors are also available in a variety of configurations.

These package systems can be customized to suit your specific compressed air and

clean air treatment needs.

AirCenters come with integral refrigerated dryer and ASME coded receiver tank

“T” SeriesWhile all Kaeser compressors are available as

stand alone units, most models are also avail-

able with clean air treatment equipment built in.

The “T” series rotary screw compressors

feature integral refrigerated dryers with stain-

less steel, plate-type heat exchangers, moisture

separators and condensate drains. These

work together to remove moisture and other

contaminants from your air system to improve

product quality and help reduce wear on pro-

duction equipment.

The T models include a new space-saving

cabinet that reduces overall footprint and pro-

vides easy access to service points. They also

feature single point hook up to simplify your

installation.

AirCentersTo further reduce your installation time

and space requirements, Kaeser offers its

AirCenters. These are complete air systems

that include not only the dryer but the air

receiver tank as well. Available with either one

(simplex) or two (duplex) Sigma rotary screw

compressors, they come pre-assembled with

a refrigerated air dryer mounted on a hori-

zontal receiver tank. Available in a wide range

of models from 3 to 60 hp, these units are

perfect for small shops or plants. All systems

are completely piped and wired, and ready for

installation. Clean Air Treatment Packages with

coalescing filters and condensate drains are

available options.

AS Series with integrated refrigerated air dryer

12

State-of-the-Art Manufacturing

Meticulous airend assemblyHighly trained specialists assemble each airend

according to our strict ISO 9001:2008 standards.

Kaeser’s extensive manufacturing facili-

ties in Coburg, Germany, cover over

25 acres. State-of-the-art Computer

Numerically Controlled (CNC) machin-

ing equipment and highly accurate lathe,

milling and grinding machines produce

our proprietary airends, housings and

other components to very precise toler-

ances.

The assembly facilities are carefully

planned to produce large numbers of

compressors in the most efficient and

expedient manner. Highly skilled techni-

cians assemble each unit according to

our ISO 9001:2008/14001:2004 proce-

dures. The finished products must meet

strict quality standards and pass through

a rigorous inspection and testing pro-

gram before shipment.

Precision milling and grindingSigma Profile rotors are precision-machined

and finished on a CNC grinder to an accuracy of

1/1000 mm.

Continuous quality controlThe airend’s finished dimensions are measured

and verified using the latest in 3D computer

technology.

13

Research and developmentKaeser’s research and development team continues to produce industry leading air

system technology. All of our products are designed individually for efficiency, reli-

ability and minimal maintenance, and are built to work together for an unparalleled

systems and solutions approach to each application.

Research and Development CenterAdvanced machining centersState-of-the-art machining centers in climate-

controlled rooms produce the Sigma Profile

rotors and casings. These machining centers

operate 24 hours a day to keep up with the

demand for Kaeser premium quality compres-

sors.

Environmentally friendly powder coating systemAll Kaeser rotary screw compressors feature

powder-coated enclosures. Our unique powder

coating technique applies a super fine glaze to

each individual enclosure panel without pollut-

ing the surrounding environment. The panels

are baked at 350°F for a corrosion-proof and

scratch-resistant finish.

Comprehensive unit testingOnce the manufacturing and assembly process

is complete, each screw compressor undergoes

a comprehensive testing procedure to verify its

mechanical and electrical operation prior to ship-

ment. These strict testing standards ensure the

highest product quality available.

To ensure its equipment solutions meet every expectation, Kaeser offers a wide vari-

ety of pre-sale and after-sale support services, including: system baselining with Air

Demand Analysis (energy audits), flow metering, air quality analysis, leak detection,

and compressor fluid analysis. We also offer customer seminars on system design for

reducing maintenance and energy costs.

Much More Than Just Equipment

14

Air Demand Analysis (ADA)Kaeser’s compressed air energy audits stand

out in the industry for their completeness and

accuracy.

Our ADA will identify and help you eliminate

air system inefficiencies related to leaks, inad-

equate

piping,

storage or

controls.

It will also

help you

reduce

waste and

scrap caused by inconsistent pressure in pro-

duction equipment. Further, it will help you cut

maintenance costs by optimizing run time and

reducing excess cycling. ADA documentation will

also help you apply for electric utility rebates.

Kaeser Energy Savings SystemOur unique Kaeser Energy Savings System

(KESS) software simulates power requirements

of different system scenarios. This helps identify

solutions that will achieve the greatest efficiency

without compromising pressure/flow require-

ments or system reliability.

Leak detectionKaeser uses the latest generation in ultrasonic

leak detectors with onboard data logging. In

addition to tagging your leaks, you will receive

a detailed

report with the

location and

approximate

leak rate of

each leak

found. With

this informa-

tion, you can

determine the

best leak repair

plan.

Accurate system drawings and schematics ensure proper pipe sizing and storage as well as adequate ventilation.

• Collect detailed information on your

system components, environmental

conditions, and physical layout.

• Collect appropriate supporting graphi-

cal data such as photographs, sche-

matic drawings and sketches.

• Gather input on specific problems your

plant is currently facing, and discuss

desired outcomes.

Your Kaeser field representative will visit your site to:

15

Our factory-trained representatives work closely with our application engineers to

design a complete, custom system tailored to the end-user’s requirements. Whether

it’s a system enhancement for a small collision center or a complete turnkey installa-

tion for a chemical processing plant, Kaeser will recommend the right solution based

on operating conditions, air quality needs, capacity and pressure requirements, and

application-specific regulations.

Custom Designed Solutions

Superior system control

Our Sigma Air Manager with 3D Control is a

major advance in compressed air system

controls. Its more powerful intelligence achieves

the highest energy effi ciencies. Further, with

SAM’s full communications capabilities, the

entire system can be monitored and analyzed

from any location as a stand alone network or

part of a larger plant control system. In the event

of system problems, SAM’s remote monitoring

capabilities can allow our service technicians to

view system status and diagnostic codes prior

to making a service call to minimize trouble-

shooting and repair time.

Sigma Air Manager features Sigma Air

Control Basic, software that displays your

compressed air system information in real-time

on your desktop or laptop computer through a

standard Internet browser. Simple HTML pages

show the compressors’ operational state, SAM’s

operating panel, and the system pressure

trends, as well as service and alarm messages.

(See our Sigma Air Manager and Sigma

Control 2 brochures for details)

16

Do you produce your water, gas, and electricity? Probably not. So why own and oper-

ate compressors if you don’t have to? Let Kaeser — The Air Systems Specialist —

plan, install, and maintain a complete air system in your plant, so you can focus your

attention on running your business.

Sigma Air Utility is a proven solution. We design, build, own, operate, maintain,

and stand behind your compressed air system. We guarantee you the air you need,

at the pressure you need, and at the quality you need — at all times. On top of that, it

will be the most energy efficient air system you’ve ever had.

Sigma Air Utility can be delivered in pre-assembled modules or installed in your plant compressor room.

Sigma Air Utility

Compressed Air PipingKaeser’s SmartPipe™ is a modular compressed

air distribution system that offers both lower

installation costs and lower long term operating

costs.

Fast to install and easy to modify, Kaeser

SmartPipe™ is the most versatile compressed air

distribution system available. Our combination of

lightweight materials and connectors dramatically

reduce labor and installation time, especially in

overhead installations.

SmartPipe’s smooth calibrated aluminum

construction has a low friction coefficient, pro-

viding the best possible laminar flow. Full bore

fittings further minimize pressure drop for opti-

mum flow and energy efficiency. Leak free con-

nectors prevent air loss and wasted energy.

SmartPipe is ideal for installations requiring

the highest quality air. Available in sizes ranging

from 1/2” – 6” in diameter, its aluminum material

will not rust or corrode. Further, it has no rough

surfaces or interior restrictions that accumulate

contaminants. The smooth interior with full bore

design allows them to flow to your dryers and

filters for efficient removal.

17

Kaeser is committed to providing the

best after-sales service in the industry

through our factory-trained, national

distribution network. We have imple-

mented the Kaeser Factory Certified

Training (KFaCT) program to ensure the

highest standards in local service.

KFaCT incorporates information on

system basics, air system installation,

maintenance, troubleshooting, and clean

air treatment. Kaeser’s training program was

developed in conjunction with stan-

dards from the Department of Energy’s

Compressed Air Challenge and the

Compressed Air and Gas Institute and

includes non-Kaeser training materials to

give technicians quality, unbiased edu-

cation in compressed air systems.

Kaeser’s Compressed Air Seminars are

designed to provide helpful information

for air system specifiers and end users.

These seminars are available on both

general and industry specific levels,

depending on the customer’s need.

Focused on system design with an

emphasis on reliability and energy

efficiency, Kaeser’s seminars are intend-

ed for plant engineers and maintenance

managers. Topics include installation

considerations, system audits, and

suggestions for preventive maintenance.

Kaeser also offers Service Schools

designed specifically for existing Kaeser

owners to train users on preventive

maintenance, troubleshooting, and

repair. Each seminar is tailored to meet

the customers’ needs and includes

classroom lectures and hands-on train-

ing. Our schools are conducted at our

training facility or on-site at the custom-

er’s facility.

Kaeser Compressed Air Seminars

Factory-trained Sales and Service

Kaeser Credentials• Our Systems Engineering Department

includes DOE-certified AirMaster Plus special-

ists.

• We support the Compressed Air Challenge

initiative to train industrial users in air system

“best practices.”

• We were early advocates of the Compressed

Air & Gas Institute’s initiative to develop a

standardized compressor energy data sheet

... and to encourage other manufacturers to

accurately assess the power consumption of

their equipment.

• We are ISO 9001:2008 and ISO 14001:2004

Certified and are committed to continually

improving our efficiency without compromis-

ing our quality.

Rotary Screw Compressors

Model Capacity at Operating Pressure (cfm)125 psig 160 psig 217 psig

SX 3 12 9.2 —SX 4 16 13 8.8SX 5 21 17 13

SX 7.5 28 24 19


SM 7.5 32 27 19SM 10 42 35 27SM 15 53 44 34


SK 15 71 59 46SK 20 88 77 63


AS 20 92 77 59AS 25 111 94 72AS 30 124 104 83


ASD 25 112 89 72ASD 30 132 110 85

ASD 40S 162 127 106ASD 40 191 159 123


BSD 40 193 157 —BSD 50 236 190 154BSD 60 288 230 185


CSD 60 290 232 186CSD 75 345 283 226

CSD 100S 417 340 276CSD 100 494 410 332CSD 125 565 480 399


DSD 125 569 424 —DSD 150 671 544 —DSD 175 660 636 526DSD 200 862 639 530DSD 250 1003 837 615


ESD 250 1261 978 816ESD 300 1501 1236 957

SX Series

DSD Series

ESD Series

SM Series

SK Series

AS Series

ASD Series

BSD Series

CSD Series

NOTE: SX 3 through DSD 175 are also available with integral dryer

18

Variable Speed Drive


FSD 350 1522 1271 —FSD 400* 1744 — —FSD 450 1990 1497 1250


HSD 500 2264 1815 —HSD 550 2521 1956 1632HSD 600 2762 2214 1773HSD 650 3002 2472 1914

ModelCapacity at 460V* at Operating Pressure (cfm)

Min / Max 110 psig 125 psig 145 psig**

SFC 8MIN 13 12 13MAX 48 48 42

SFC 11MIN 22 22 22MAX 76 72 65

SFC 15MIN 29 28 30MAX 98 95 86

SFC 18SMIN 33 33 27MAX 113 113 98

SFC 18MIN 24 23 22MAX 130 124 116

SFC 22MIN 29 29 28MAX 157 150 139

SFC 30SMIN 38 37 36MAX 205 195 180

SFC 37MIN 55 54 42MAX 242 226 201

SFC 45MIN 69 69 52MAX 310 295 262

SFC 55MIN 77 76 67MAX 374 357 320

SFC 75SMIN 100 100 72MAX 463 441 383

SFC 90SMIN 120 118 99MAX 509 484 438

SFC 110SMIN 136 134 116MAX 618 588 531

SFC 75MIN 127 126 —MAX 559 528 —

SFC 90MIN 127 126 125MAX 627 595 547

SFC 110MIN 150 147 141MAX 735 692 629

SFC 132SMIN 209 208 279MAX 830 781 706

SFC 132MIN 209 208 279MAX 919 867 788

SFC 160MIN 230 226 198MAX 1074 1017 929

SFC 200MIN 303 300 227MAX 1305 1240 1091

SFC 250MIN 358 357 294MAX 1466 1384 1271

SFC 315 MIN 470 466 346MAX 2091 1988 1769

SFC 410 MIN 413 410 346MAX 2624 2525 2264

SFC 515 MIN 417 353 346MAX 3037 2633 2543

FSD Series

HSD Series

SFC Series

* FSD 400: Maximum with this airend is 145 psig

19**Higher pressures are available. For more information see our SFC brochures - USSFC-BELT and USSFC-DIRECT

*Performance data values are only valid for 460V/3 ph/ 60 Hz. Please consult Kaeser for 575V data.

The Air Systems Specialist

We strive to earn our customers’ trust by supplying superior quality

equipment and services. Our products are designed for reliable

performance, easy maintenance, and energy efficiency. Prompt

and dependable customer service, quality assurance, training, and

engineering support contribute to the value our customers have come

to expect from Kaeser. Our employees are committed to implementing

and maintaining the highest standards of quality to merit customer

satisfaction. We aim for excellence in everything we do.

Our engineers continue to refine manufacturing techniques and

take full advantage of the newest machining innovations. Extensive

commitment to research and development keeps our products on the

leading edge of technology to benefit our customers. With over 90

years of experience, Kaeser is the air systems specialist.

Kaeser Compresores de México S de RL de CVCalle 2 #123Parque Industrial Juríca 76100 Querétaro, Qro.Telephone: 01 (442) 218 64 [email protected]

Kaeser Compressors Canada Inc.3760 La Verendrye StreetBoisbriand, QC J7H 1R5 CANADA Telephone: (450) 971-1414Toll free: (800) 477-1416 [email protected]

© 2013 Kaeser Compressors, Inc. All rights reserved. 03/13

USSCRWBULLTN

Kaeser Compressors, Inc.511 Sigma DriveFredericksburg, Virginia 22408 USAPhone: 540-898-5500Toll Free: 800-777-7873Email: [email protected]

www.kaeser.com

Kaeser Compresores de Guatemala y Cia. Ltda.Calz. Atanasio Tzul 21-00, zona 12 El Cortijo II, Bodega 50101012–Guatemala CityTelephone: +502 [email protected]

Premium Rotary Screw Compressors - Canfield & … Rotary Screw Compressors. At Kaeser, ... Profibus,...

Documents

Transcript of Premium Rotary Screw Compressors - Canfield & … Rotary Screw Compressors. At Kaeser, ... Profibus,...