Rotary Screw Compressors with variable frequency drive and refrigeration dryer modules BSD/CSD/CSDX T SFC Series Air deliveries from 0.87 to 16.10 m3/min Pressures 5.5 to 15 bar T SFC – What qualities do users look for in a compressor with variable frequency drive and a refrigeration dryer? appropriately modular BSD, CSD and CSDX – an economical basis The new BSD, CSD and CSDX series compressors with energy-saving 1:1 drive serve as the basis for the modular concept. Normally, the answer would be efficiency and reliability with compressed air of constant quality. KAESER has the answer flexible modular design That may sound simple, but a lot of very different factors play important parts. compressors can be combined durable and reliable because of their generously-sized BSD, CSD and CSDX screw Air system investment airends with SIGMA PROFILE A with refrigeration dryer and/or rotors turning at low speeds. SFC variable frequency drive Maintenance costs modules, allowing the most varied requirements of air quality and economy to be Energy costs, for example, taken over the lifetime of a system, add up to a multiple of investment costs. They are particularly efficient, T – Refrigeration dryer C BSD, CSD and CSDX compressors can be fulfilled. supplied with an atta- A further advantage is the ched refrigeration dryer minimised installation work module as required. The needed as the machines are prepared for immediate B compressor and dryer are accommodated in connection and operation. Energy costs separate cabinets with individual cooling air Potential energy savings apertures to increase operational reliability. This is why efficiency is vital in the production of compressed air. Just as vital is the reliability of air supplies in the quality and quantity needed - these are the most significant requirements for production plant. Sigma Frequency Control The SFC variable frequency drive module is available for all compressors in the range. The SFC module and the compressor form a 9 compact, hard-wired unit with a small footprint and 6 4 7 short communication paths 5 between the control electro1 nics and drive motor. The system is assembled, 8 3 tested and ready to go. 2 1 Inlet valve 2 Electric motor 3 Airend 4 Fluid separator with cartridge 5 Fluid cooler 6 Fluid filter 7 Compressed air aftercooler 8 SFC module 9 Controller with industrial computer Flexible, modular design The intelligent, modular concept of the T SFC machines provides the right answer to every application. The refrigeration dryer module (C) turns a standard rotary screw compressor into a compact compressed air system that can supply dried air of the highest demands. When the SFC module (B) is added, the compressor speed can be varied to adjust automatically to the air demand. KAESER can supply all possible combinations of these modules. C B A A = BSD, CSD or CSDX screw compressor B = SFC module = Refrigeration dryer module C BSD T – CSDX T Dependable centrifugal separator with compact dryer A centrifugal separator with an electronically controlled ECO-DRAIN is installed between the compressor and the dryer. This ensures dependable and efficient initial separation and drainage of condensate, even under conditions of high ambient temperature and humidity. Refrigeration dryer with ECO-DRAIN The dryer is also fitted with an ECO-DRAIN that works on a levelcontrolled basis and, in contrast to solenoid valves, does not vent Innovative: BSD T, CSD T and CSDX T series air when draining, The new compressor/dryer combinations conserving energy and contributing to operational are capable of meeting every conceivable reliability. demand made in daily practice, reliably and economically. turned into complete air supply systems Heat exchanger and separator in stainless steel by attaching dryer modules to deliver air The dryer's heat exchanger is non-corroding and re- Thrifty, rotary screw compressors are of highest quality. sistive to deposits. The The compressor and dryer are accommo- separate stainless steel dated in separate cabinets to increas condensate separator reliability and safety of operation. reliably removes accumulating condensate from the air, even CSD 102 T rear view Thermal insulation is omitted from the illustration Thermal insulation omitted when flow rates fluc- tuate. All the dryer's components and piping meet the strictest requirements of operational safety and reliability. Interconnected and ready to use SIGMA CONTROL The refrigeration dryer module in its separate cabinet is All components are easily accessible for attached to the standard air compressor and piped and maintenance, a further advantage that sor, refrigeration dryer wired ready for use. More than sufficient space allows all the increases availability. and condensate components of the dryer to be generously sized. SIGMA CONTROL constantly monitors the compres- drains. Also, the independent housing of the two modules prevents the heat of compression affecting the dryer. If required, dryer mal- Excellent cooling allows the machine to work reliably in functions can be ambient temperatures up to 45 °C. defined as warnings or alarms and forwarded to a control centre. SFC – consequent efficiency Built for higher ambient temperatures The generously-sized SFC module with its efficiently-cooled control cabinet allows trouble-free operation in ambient temperatures up to +45 °C. Constant pressure The air delivery of the BSD, CSD and CSDX compressors with SFC can be matched to current air demand as indicated by system pressure, by varying their speed within Innovative: BSD SFC, CSD SFC and CSDX SFC series Pressure in bar the control range. These rotary screw compressors with large, efficient airends, high performance SIGMA PROFILE rotors and directly-coupled drives with no transmission losses are real energy savers. This applies particularly to variable speed machines equipped with SIGMA FREQUENCY CONTROL. Depending on the size of the compressor, power-savings of up to 50 percent can be achieved in larger air systems. As a result, working pressure is kept Constant pressure Time Pressure – 0.1 + bar constant within the narrow band of ± 0.1 bar, depen- ding on the buffering capacity of the air network. The resulting reduction in maximum system pressure saves hard cash, as each bar of pressure saved lowers power consumption by around seven BSD 72 T SFC front view Other variable speed compressors percent. Soft starting with no current spikes KAESER SFC compressors Thanks to the controlled ramping up of drive motor starting current from zero to full load, the motor 800 % Transmission losses speed range. Furthermore, these machines can run at full Power consumption load over a 100 percent duty cycle with no increased service requirement. Maintenance costs The directly-coupled drive functions without any of the transmission losses associated with geared drives. No interference The electro-magnetic compatibility (EMC) of the components and of the complete machine has been tested and certified. Uncompromising energy-savers Full load current in percent Direct start 700 % Star-delta start Soft start 600 % SFC machine starting frequency (the number of motor starts 500 % possible without 400 % 300 % overheating within 200 % a given period of 100 % time) is almost 0% Time It has fewer components, a feature that brings unlimited. improved reliability, extended operational life and reduced noise Current peaks, damaging to the mains power net- BSD SFC, CSD SFC and CSDX SFC machines from KAESER are economical levels. The directly-coupled one-to-one drive brings triple savings: work and to equipment, are reliably eliminated rotary screw compressors with directly-coupled, variable frequency drives. firstly with efficient power transmission, without the need for expensive electronics. Their large, slow-speed KAESER airends with energy-saving SIGMA PROFILE secondly with reduced power consumption and Furthermore, the controlled acceleration and rotors show outstanding performance data over the whole of the controlled thirdly with lowered servicing and downtime costs. deceleration of moving parts reduces dynamic loading. BSD/CSD/CSDX T SFC – 1 An efficient condensate separator in stainless steel The separator tank in the refrigeration dryer is made completely of stainless steel and slow speed. Larger, low speed airends are more efficient, delivering more compressed is non-corroding. A deflector plate forces the compressed air streaming into the air for the same drive power. That is why KAESER developed airends especially for the separator into cyclonic motion. Finally, the air flows through a stainless steel wire web BSD, CSD and CSDX series that precisely match the individual drive power and motor that provides a very high degree of separation of 99.9 percent. This is almost con- speed of each machine in the range. The slightly higher cost of the larger airend is stant, despite fluctuating airflow, reliably maintaining the pressure dew point. Solid quickly recovered by the energy saved during operation. particles are also washed out and eliminated together with the condensate. The energy-saving, directly-coupled drive 6 SFC module The advantage of this drive is not just the elimination of transmission losses. The There are good reasons why frequency converters from Siemens are used for drive motor and the airend are joined by the coupling and its housing into a compact KAESER’s variable speed compressors. Converter efficiency is the maximum possible; and rigid unit that needs no regular maintenance apart from greasing the motor there is outstanding communication between the SFC module and SIGMA CONTROL bearings. Should the coupling ever need to be replaced it can be done in just a few and the compressor controller itself is based on a Siemens industrial computer. World- minutes without any disassembly of the unit. The opening in the coupling housing is wide service is guaranteed at all times because of Siemens' global presence. Finally, more than adequate to replace the two coupling sections. the SFC module and SIGMA CONTROL are tested and certified both as individual Coupling Airend 5 A given power can be used to turn a small airend at high speed or a larger airend at 2 Motor speed = airend speed SIGMA PROFILE AIREND eight decisive advantages components and as a system to EMC directive EN 55011 for class A1 industrial Drive motor power supplies. C D/ 3,6 C up to 00 rpm X SF D S BSD /C S others up t o 7, 000 rpm Low speeds 7 Flexible pressure selection Every BSD/CSD/CSDX SFC machine has the same mechanical components as those used The wide range of directly-coupled SIGMA PROFILE airends produced by KAESER make in fixed speed machines. This not only ensures highest reliability and availability but it possible to select the one that works most efficiently within the pressure and volume guarantees optimum energy efficiency as well. The lowest speed and the largest airend required. The right choice of airend results in the most economical pressure-to-frequency possible - the maximum speed of an BSD/CSD/CSDX SFC is only around 3,600 rpm - profile for the BSD/CSD/CSDX SFC machines. A pressure-to-frequency profile that are, after all, the basic requirements for really economical production of compressed air. ensures maximum flexibility both in pressure and volume under the aspect of highest Added to this is longer life and lower servicing effort. The use of standardised drive possible economy is programmed into the SFC module. 13 bar Pressure in bar 3 0.1 bar steps 10 bar 0.1 bar steps 7.5 bar motors is another contribution toward lasting availability. 0.1 bar steps 15 4 www.kaeser.com SIGMA CONTROL 8 Low specific power requirement SIGMA CONTROL is based on a robust, updateable industrial computer with a real- Large, low speed airends are more efficient. They deliver more compressed air for the time operating system. The operational state of the compressor is quickly ascertained same drive power, not just at full load but over the whole range of control – an with the help of coloured LEDs. A four-line, plain text display, easily understood icons important aspect as far as variable speed machines are concerned. 6.4 kW per m³/min and touch keys allow fast set-up and operation. SIGMA CONTROL regulates and moni- is taken as a reference value for very good specific power requirement (referred to the tors the compressor and the T and SFC modules fully automatically and shuts the effective electrical power consumption of an SFC compressor at 7.5 bar). Variable machine down immediately in the event of an alarm. Interfaces are provided as speed compressors are only economical if their specific power requirement is low over standard for connecting a modem, a second compressor and for connection to a data the whole of their control range. network (Profibus DP). 50 100 Hz 6.4 kW/m3/min at 7.5 bar Equipment panels powder coated. Direct torsional-elastic coupling, with- Air intake filter with pre-filtration; pneuma- out gearing. tic inlet and venting valves; pressure relief Panels lined with laminated mineral wool; maximum 72 dB(A) to PN8NTC 2.3 at one metre distance, free-field measurement. Industrial computer for monitoring and control, with interfaces for data communication comprising RS 232 for a modem, RS 485 for a slave compressor in base load sequenwww.kaeser.com cing mode and a Profibus DP interface for data networks. Prepared for Teleservice. valve; minimum pressure/check valve, rigid Electric motor Sound insulation SIGMA CONTROL piping with newly-developed flexible Premium-efficiency electric motor of pipe couplings. Cooling fluid reservoir with quality German make to IP 55 and three-stage separation insulation class F for additional reserve; system; thermostatic PTC thermistor sensors (full motor pro- valve and fluid filter. tection optional). Air cooling Motor/airend union Vibration damping Airend with integrated coupling flange. Dual antivibration mountings using rubber bonded metal elements. The standard version is Ergonomic control panel air-cooled featuring separate aluminium Red, yellow and green LEDs show the operational state of the machine at a glance. Four-line, plain text display; touch-keys and LED icon indications; display of motor speed. coolers for compressed air and fluid and a Electrical components radial fan driven by its own motor. Control cabinet to IP 54, control trans- Airend Genuine KAESER rotary screw, singlestage, fluid-injected airend with SIGMA PROFILE rotors. former, Siemens Refrigeration dryer MASTERDRIVE plug- CFC-free, R 134a refrigerant, fully in module with con- insulated, permanently sealed refrigerant trol unit; volt-free circuit, hot-gas bypass control, electronic contacts for condensate drain and centrifugal separator ventilation control. upstream. Dimensions 2080 BSD 2200 CSD 2600 CSDX Prime functions Fully automatic monitoring and SFC cooling air outlet Dryer cooling air inlet regulation of airend discharge temperature; monitoring of motor current, direction of airend rotation, air Dryer cooling air outlet super-silenced, vibration-damped, all Fluid and airflow Compressor cooling air outlet Ready for operation, fully automatic, Drive 1700 BSD 1865 CSD 2025 CSDX Complete machine Cooler cooling air inlet filter, fluid filter, separator cartridge; display of measured data, operating Motor SFC cooling air cooling air inlet inlet hours and service interval counters for primary components, status data and event memory data. Technical specifications T – version with refrigeration dryer module (R134a refrigerant) Rated motor power Model Working pressure Overall FAD* Max. at working pressure pressure bar m3/min SFC version with variable speed drive module Dryer power Sound consumption level**) Weight Model Working pressure Overall FAD* at working pressure m3/min 1005 BSD 1041 CSD 1285 CSDX Compressed air connection T SFC version with refrigeration dryer and variable speed drive Max. pressure Sound Weight level**) Model Working pressure Overall FAD* at working pressure m3/min Pressure range Dryer power Sound consumption level**) Weight Dimensions kg W x D x H mm kW bar 30 BSD 62T 7.5 10 13 5.65 4.45 3.60 8 11 15 1.3 67 1100 37 BSD 72T 7.5 10 13 7.00 6.50 4.40 8 11 15 1.3 67 1140 BSD 72 SFC 7.5 1.57- 6.25 6- 8.5 1.16- 5.34 9-11 10 0.87- 4.45 12-15 13 69 1140 BSD 72 T SFC 7.5 1.57- 6.25 6- 8,5 1.16- 5.34 9-11 10 0.87- 4.45 12-15 13 1.3 69 1280 2080 x 1005 x 1700 45 CSD 82T 7.5 10 13 8.25 6.90 5.50 8 11 15 1.9 68 1430 CSD 82 SFC 7.5 1.92- 8.20 6- 8.5 1.49- 6.90 9-11 10 1.10- 5.80 12-15 13 70 1430 CSD 82 T SFC 7.5 1.92- 8.20 6- 8,5 1.49- 6.90 9-11 10 1.10- 5.80 12-15 13 1.9 70 1600 2200 x 1041 x 1865 55 CSD 102T 7.5 10 13 10.15 8.20 6.75 8 11 15 1.9 69 1470 CSD 102 SFC 7.5 2.33- 9.90 6- 8.5 1.87- 8.95 9-11 10 1.40- 7.30 12-15 13 71 1470 CSD 102 T SFC 7.5 2.33- 9.90 6- 8,5 1.87- 8.95 9-11 10 1.,9 1.40- 7.30 12-15 13 71 1640 2200 x 1041 x 1865 75 CSD 122T 7.5 10 13 12.00 10.05 8.07 8 11 15 1.9 70 1500 CSD 122 SFC 7.5 2.89-12.28 6- 8.5 2.18-10.50 9-11 10 1.86- 8.90 12-15 13 72 1500 CSD 122 T SFC 7.5 2.89-12.28 6- 8,5 2.18-10.50 9-11 10 1.86- 8.90 12-15 13 72 1670 2200 x 1041 x 1865 75 7.5 CSDX 137T 10 13 13.70 11.86 9.88 8 11 15 2.2 72 2250 90 7.5 CSDX 162T 10 13 16.10 13.50 11.70 8 11 15 2.2 73 2350 * FAD to ISO 1217: 1996, Annex C; kW dB(A) kg bar bar dB(A) kg bar bar kW dB(A) 2080 x 1005 x 1700 1.9 2600 x 1285 x 2025 7.5 3.93-15.85 6- 8.5 3.36-14.03 9-11 CSDX 162 SFC 10 2.60-12.00 12-15 13 **) Sound level to PN8NTC 2.3 at 1m distance, free-field measurement 75 2400 CSDX 162 T SFC 7.5 10 13 3.93-15.03 6- 8,5 3.36-14.03 9-11 2.60- 12.0 12-15 2.2 75 2600 2600 x 1285 x 2025 Different fields of application need different grades of air treatment Explanation Choose the required grade of treatment according to your field of application: ED = ECO-Drain electronic level-controlled condensate drain Air treatment using a refrigeration dryer (+3 °C pressure dew point) A 1 4 < 1 Weaving machines, photo labs, pharmaceuticals B 1 4 < 1 D 1 4 < 1 Packaging, control and instrument air E 1 4 < 2 General works air, quality sandblasting G 2 4 3 FFG ED FF FE SFC CSD 102T ACT = activated carbon adsorber for adsorption of oil vapours, oil vapour content ≤0.003 mg/m³ Compressor THNF Aquamat for condensate separation Rotary screw compressor SFC T with integrated refrigeration dryer, pressure dew point down to +3 °C; compressor available with variable frequency drive Degree of filtration Aquamat Solid particles B C Oil vapour content ≤ 0.003 mg/m , particle retention >0.01 µm, sterile, odourless and tasteless Oil vapour content ≤ 0.003 mg/m3, particle retention >0.01 µm Oil vapour content ≤ 0.003 mg/m3, particle retention >1 µm 3 Contaminants + Solids - Total oil content PDP 100 1 0 – – ≤ -70 °C ≤0.01 10 – – ≤ -40 °C ≤0.1 10000 500 – – ≤ -20 °C ≤1.0 – 1000 – – ≤ -3 °C ≤5.0 – 20000 – – 1 – 2 – 100000 1000 3 – – 4 – – 5 – – (x=liquid water in g/m3 ) mg/m3 as specified by user 0 A Humidity Max. no. of particles per m3 with size d (µm) ≤ 0.1 Class Paint spraying, powder coating FST 6 – ≤5 ≤ 40 ≤ 10 ≤5 ≤ +7 °C – ≤ +10 °C – x ≤ 0.5 – D Aerosol oil ≤ 0.001 mg/m , particle retention >0.01 µm + water - 7 – E Aerosol oil ≤ 0.01 mg/m3, particle retention >0.01 µm + oil - 8 – – – 0.5 < x ≤5.0 – G Aerosol oil ≤ 1 mg/m3, particle retention >1 µm + bacteria - 9 – – – 5.0 < x ≤10.0 – 3 KAESER KOMPRESSOREN GmbH 96410 Coburg – Postfach 21 43 – GERMANY – Phone + 4 9 95 61 6400 – Fax + 4 9 95 61 640130 Website: www.kaeser.com – Email: [email protected] P-651/20ED.2/04 Specifications are subject to change without notice Pharmaceuticals Air receiver mg/m3 < 1 µm 4 1.0<d ≤ 5.0 2 FF ACT 0.1<d ≤ 0.5 C FD 0.5<d ≤ 1.0 Very clean conveying air, chemical plant FE ISO 8573-1 < 1 KAESER 4 KAESER 1 KAESER B KAESER Food and semi-luxury food production FST KAESER 4 KAESER 1 FE = microfilter 0.01 ppm separates oil aerosols and solid particles > 0.01µm, oil content ≤0.01 mg/m³ FF = microfilter 0.001 ppm separates oil aerosols and solid particles > 0.01µm, oil content ≤0.001 mg/m³ FG = activated carbon filter for adsorption of oil vaspours, oil vapour content ≤0.003 mg/m³ FFG = combination filter comprising FF and FG FST = sterile filter for bacteria-free compressed air KAESER A KAESER Dairies, breweries Bacteria KAESER Oil < 1 KAESER Solids Water FD = particulate filter 1 ppm separates dust particles (attrition) > 1µm KAESER Examples: selection of treatment classes to ISO 8573-1 THNF = bag filter cleans dusty and highly contaminated intake air
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