Transcript
Rotary Screw Compressors
ASD Series
FAD: 2.09 to 5.51 m3/min Pressures: 5.5 to 15 bar
Three steps to greater efficiency:
ASD – energy-saving and quiet as a whisper
What do you expect from a compressor?
1. The SIGMA Profile
Above all, you, as a user, would expect maximum economy and reliability from your air supplies. That may sound simple, but a lot of very different factors play an important part. Power costs, for example, taken over the lifetime of a compressor, add up to a multiple of investment costs.
KAESER’s SIGMA PROFILE saves up to 15 percent
ASD investment cost
energy compared
Maintenance costs
Potential energy savings
Kaeser’s answer –
Fresh ideas save energy
the ASD series
Direct inlet ...
The new ASD compressors put the
even further improved profiles.
and ensures adequate cooling. The temperature difference
practice; they are economic in power
between the compressed air and the surrounding air is only
consumption, quiet, need little mainte-
6-8 K. This means less power consumption by downstream
nance and reliably deliver compressed
air treatment equipment.
air of the highest quality.
Efficient use of energy is, therefore, of greatest importance in the production of compressed air. The reliability of the compressors is of equal importance: in many applications expensive manufacturing processes depend entirely on a reliable supply of compressed air.
rotor profiles. ASD machines are fitted with new airends with
• ... of cooling air from the surroundings avoids pre-warming
user’s requirements into operational
Energy costs
with conventional
2. The one-to-one drive
• ... of motor cooling air from the surroundings ensures
These advantages have been achieved with innovations in compressor design,
reliable and effective motor cooling even under adverse
drive systems, cooling and ventilation,
conditions.
silencing and servicing and maintenance
Some speak of direct drive when they really mean geared drive. Make sure you know the difference; on ASD machines all
• ... of air for compression from outside the compressor
methods.
that is between the motor and the airend
cabinet improves compression efficiency; the position of the
The new ASD series is a fully developed,
is a coupling.
inlet opening prevents pre-warming.
That’s why there
reliable product of KAESER quality.
are no transmis-
Reliability is a word that also applies to the quality of air produced and this can only come from efficient air treatment equipment.
sion losses. Furthermore, the technique of using a larger airend
Protection from noise pollution is better achieved by quieter compressors rather than subsequent sound containment measures.
turning at a slower speed is particularly efficient, delivering more compressed air and consuming less power. 9
And finally, a really efficient compressor is less costly to maintain.
6 8
7
4 5 1
Quiet as a whisper – max. 66/69 dB(A)
One-to-one drive – ultimate efficiency 3
The motor drives the airend without transmission loss via a
2
maintenance-free, direct coupling.The heavy duty airend is
2945 rpm airend speed = motor speed
3. The radial fan Quietly and powerfully
The quiet radial fan and directly
the radial fan draws
coupled components reduce
surrounding air in
1 Inlet valve 2 Electric motor
pressure at the motor’s relatively low speed. Compared to a
noise at source. This advanced
through the cooler.
geared drive the direct coupling has fewer components bringing
concept should be seen in
Its high residual thrust
3 Airend 4 Fluid separator with cartridge 5 Fluid cooler
improvements in reliability and operational life. This type of
combination with the new
drive also contributes significantly to reduced noise emission.
cooling system. The
6 Fluid filter
the KAESER ASD with the one-to-one drive saves money in
7 Compressed air aftercooler
three ways: no transmission losses, less energy consumption
8 Control cabinet 9 Controller with industrial computer
and lower maintenance and downtime costs.
specially selected to deliver the required performance and
Compared to compressors with small, high-revving airends, Airend
Coupling
Drive motor
can deal with partial clogging of the cooler
separate cooling air flow
and still have enough reserve to allow
paths allow almost hermetic
connection of a long exhaust duct.
silencing without influencing cooling efficiency. You
By nature of its design the radial fan con-
can talk quite normally next to an ASD.
sumes less drive power than conventional axial fans, saving even more energy.
More compressed air for less energy
ASD – eight decisive advantages 1
SIGMA PROFILE airend
5
Optimised separation system
A specific air delivery can be achieved with a small airend at high speed or with a
In the new ASD machines, the cooling fluid is initially separated from the compressed
larger airend at low speed. Larger, low speed airends are more efficient, delivering
air by centrifugal force in the separator tank. Only minimum fluid remains to be
more compressed air for the same drive power. That is why KAESER developed
removed by the high-capacity, deep-bed filter in the separator cartridge. These two
airends especially for the ASD series that precisely match the individual drive power
factors double the operational life of the cartridge compared with conventional systems
and motor speed of each machine in the range. The slightly higher cost of the larger
and ensure minimum aerosol content in the compressed air delivery (less than 1 mg
airend is quickly recovered by the energy saved in operation.
per cubic metre). The improved air quality makes less work for the downstream air treatment components. The optional filter pressure drop monitoring option is a further contribution to efficient operation.
2
Energy-saving one-to-one drive
The advantage of this drive is not just the elimination of transmission losses. The motor and airend are joined by the coupling and its housing to form a compact and
A
OTHERS: up t o 80 00
The rated motor powers given in the technical
Please contact KAESER for specific FAD and
specifications below are reference points for
motor output data relating to other working
selecting the right size machine.
pressures.
3 SD
rpm 000
durable unit that, apart from greasing the motor bearings at long intervals, needs no
rp m
regular maintenance . Should the coupling ever need to be replaced it takes just a few minutes; the opening in the coupling housing is more than large enough to replace the two coupling sections. The ASD airend turns at only 3000 rpm; lower speed means increased efficiency and durability and reduced compressed air costs.
3
Innovative radial fan
6
SIGMA FLUID PLUS / optimised fluid filter
The synthetic compressor cooling fluid SIGMA FLUID PLUS and the new type of glass-fibre filter have extended the fluid change interval to 9000 operating hours under normal working conditions and up to 6000 hours under more extreme conditions (fluid analysis is recommended with relation to actual local conditions). Lower vapour pressure reduces consumption and the amount of fluid contained in the condensate. The low emulsifying tendency makes condensate treatment simple and inexpensive. The long-life glass-fibre filter has high capacity to capture contaminants from the fluid, contributing to reliability and long service intervals.
7
Easy maintenance
Quiet and efficient - the most important features of a radial fan. Low peripheral speed
Changing the fluid filter, the air inlet element and the separator cartridge is carried
means low noise emission! Power consumption is up to 50 percent lower than a
out, like all other service work, from the front of the machine. Front access speeds
comparable axial fan. Another advantage is the high residual thrust developed that
up work, resulting in reduced downtime and maintenance costs. The rear and
allows the use of exhaust ducting with a pressure drop of up to 80 Pa without the
left-hand side of the ASD can be close to a wall for maximum use of space. The
need for an additional extractor fan.
image shows the air inlet filter element being changed.
ASD series – technical specifications Pressure
Model
FAD*) at working Maximum pressure Rated motor pressure of power
Dimensions
Sound level**
Weight
bar
m 3/min
bar (g)
kW
W x D x H mm
dB(A)
kg
ASD 32
7.5 10 13
3.15 2.72 2.09
8 11 15
18.5
1350 x 921 x 1505
65
580
ASD 37
7.5 10 13
3.91 3.13 2.66
8 11 15
22
ASD 47
7.5 10 13
4.57 3.84 3.01
8 11 15
25
ASD 57
7.5 10 13
5.51 4.44 3.67
8 11 15
30
1350 x 921 x 1505
1350 x 921 x 1505
1350 x 921 x 1505
*) *Free air delivery to ISO 1217: 1996, Annex C; **Sound level to PN8NTC 2.3 at 1m distance, free-field measurement
66
66
69
655
665
720
4
Clever cooling system
8
SIGMA CONTROL
In addition to improved cooling efficiency, the system has other benefits to offer. The
The SIGMA CONTROL is based on a robust, updateable industrial computer with a
inside of the cabinet remains clean because surrounding air is drawn through the
real-time operating system. The operational state of the compressor is quickly ascertained
cooler into the cooler box and then exhausted directly upward out of the machine.
with the help of ‘traffic light’ LEDs. A four-line, plain text display, user-friendly icons and
Contamination in the cooling air is trapped on the outside of the cooler and is readily
touch keys allow fast setup and operation.
noticed and cleaned off without any dismantling work. Operational reliability is
The SIGMA controller automatically regulates and monitors the compressor. In case of
improved and maintenance work significantly reduced.
an alarm the safety shutdown sequence immediately switches the compressor off. Dual, Quadro, Vario and Continuous control modes are available for selection. Interfaces are provided as standard for connecting a modem or printer, a second compressor in base load sequencing and for connection to a data network (Profibus DP).
www.kaeser.com
More compressed air for less energy
ASD – eight decisive advantages 1
SIGMA PROFILE airend
5
Optimised separation system
A specific air delivery can be achieved with a small airend at high speed or with a
In the new ASD machines, the cooling fluid is initially separated from the compressed
larger airend at low speed. Larger, low speed airends are more efficient, delivering
air by centrifugal force in the separator tank. Only minimum fluid remains to be
more compressed air for the same drive power. That is why KAESER developed
removed by the high-capacity, deep-bed filter in the separator cartridge. These two
airends especially for the ASD series that precisely match the individual drive power
factors double the operational life of the cartridge compared with conventional systems
and motor speed of each machine in the range. The slightly higher cost of the larger
and ensure minimum aerosol content in the compressed air delivery (less than 1 mg
airend is quickly recovered by the energy saved in operation.
per cubic metre). The improved air quality makes less work for the downstream air treatment components. The optional filter pressure drop monitoring option is a further contribution to efficient operation.
2
Energy-saving one-to-one drive
The advantage of this drive is not just the elimination of transmission losses. The motor and airend are joined by the coupling and its housing to form a compact and
A
OTHERS: up t o 80 00
The rated motor powers given in the technical
Please contact KAESER for specific FAD and
specifications below are reference points for
motor output data relating to other working
selecting the right size machine.
pressures.
3 SD
rpm 000
durable unit that, apart from greasing the motor bearings at long intervals, needs no
rp m
regular maintenance . Should the coupling ever need to be replaced it takes just a few minutes; the opening in the coupling housing is more than large enough to replace the two coupling sections. The ASD airend turns at only 3000 rpm; lower speed means increased efficiency and durability and reduced compressed air costs.
3
Innovative radial fan
6
SIGMA FLUID PLUS / optimised fluid filter
The synthetic compressor cooling fluid SIGMA FLUID PLUS and the new type of glass-fibre filter have extended the fluid change interval to 9000 operating hours under normal working conditions and up to 6000 hours under more extreme conditions (fluid analysis is recommended with relation to actual local conditions). Lower vapour pressure reduces consumption and the amount of fluid contained in the condensate. The low emulsifying tendency makes condensate treatment simple and inexpensive. The long-life glass-fibre filter has high capacity to capture contaminants from the fluid, contributing to reliability and long service intervals.
7
Easy maintenance
Quiet and efficient - the most important features of a radial fan. Low peripheral speed
Changing the fluid filter, the air inlet element and the separator cartridge is carried
means low noise emission! Power consumption is up to 50 percent lower than a
out, like all other service work, from the front of the machine. Front access speeds
comparable axial fan. Another advantage is the high residual thrust developed that
up work, resulting in reduced downtime and maintenance costs. The rear and
allows the use of exhaust ducting with a pressure drop of up to 80 Pa without the
left-hand side of the ASD can be close to a wall for maximum use of space. The
need for an additional extractor fan.
image shows the air inlet filter element being changed.
ASD series – technical specifications Pressure
Model
FAD*) at working Maximum pressure Rated motor pressure of power
Dimensions
Sound level**
Weight
bar
m 3/min
bar (g)
kW
W x D x H mm
dB(A)
kg
ASD 32
7.5 10 13
3.15 2.72 2.09
8 11 15
18.5
1350 x 921 x 1505
65
580
ASD 37
7.5 10 13
3.91 3.13 2.66
8 11 15
22
ASD 47
7.5 10 13
4.57 3.84 3.01
8 11 15
25
ASD 57
7.5 10 13
5.51 4.44 3.67
8 11 15
30
1350 x 921 x 1505
1350 x 921 x 1505
1350 x 921 x 1505
*) *Free air delivery to ISO 1217: 1996, Annex C; **Sound level to PN8NTC 2.3 at 1m distance, free-field measurement
66
66
69
655
665
720
4
Clever cooling system
8
SIGMA CONTROL
In addition to improved cooling efficiency, the system has other benefits to offer. The
The SIGMA CONTROL is based on a robust, updateable industrial computer with a
inside of the cabinet remains clean because surrounding air is drawn through the
real-time operating system. The operational state of the compressor is quickly ascertained
cooler into the cooler box and then exhausted directly upward out of the machine.
with the help of ‘traffic light’ LEDs. A four-line, plain text display, user-friendly icons and
Contamination in the cooling air is trapped on the outside of the cooler and is readily
touch keys allow fast setup and operation.
noticed and cleaned off without any dismantling work. Operational reliability is
The SIGMA controller automatically regulates and monitors the compressor. In case of
improved and maintenance work significantly reduced.
an alarm the safety shutdown sequence immediately switches the compressor off. Dual, Quadro, Vario and Continuous control modes are available for selection. Interfaces are provided as standard for connecting a modem or printer, a second compressor in base load sequencing and for connection to a data network (Profibus DP).
www.kaeser.com
Equipment Fluid and air flow
Direct, torsional-elastic coupling,
Dry air intake filter with initial separa-
super-silenced, vibration damped,
without gearing.
tion, pneumatic inlet and venting
all panels powder coated.
Electric motor
valves, fluid reservoir with three-stage
Sound insulation
Premium-efficiency electric motor of
separator system, pressure relief valve,
Lined with washable plastic foam;
quality German make to IP 55 and
minimum pressure/check valve,
maximum 66/69 dB(A) to PN8NTC 2.3
Insulation Class F for additional
thermostatic valve and fluid microfilter,
at one metre distance, free-field
reserve; PTC thermistor sensors
all fully piped using newly-developed
measurement.
(full motor protection) optional.
elastic couplings.
Vibration damping
Joint between electric motor and airend
Air cooling (standard)
Dual antivibration mountings using
Airend with integral coupling flange.
Separate aluminium coolers for
rubber bonded metal elements.
Electrical components
Airend
Control cabinet to IP 54, containing
Genuine KAESER rotary screw,
automatic star-delta starter, motor over-
SIGMA CONTROL system
load protection, control transformer and
Interfaces for data communication
relay contacts for ventilation control.
comprising RS 232 for a modem or
single-stage airend with SIGMA PROFILE and
Red, yellow and green LEDs show the operational state of the machine at a glance. The panel also contains a fourline plain text display, touch keys with duty cycle indicator. www.kaeser.com
Prime functions
Fully automatic monitoring and regula-
motor-driven radial fan.
tion of airend discharge temperature;
in base load sequencing mode and a Profibus DP interface for data networks. Prepared for Teleservice.
Cooling air inlet Cooler
pictograms and a
compressed air and fluid, separate,
printer, RS 485 for a slave compressor
cooling fluid injection.
Dimensions
User-friendly control panel
Cooling air inlet Motor
monitoring of motor current, direction of airend rotation, air filter, fluid filter 1350
and fluid separator cartridge (option); display of performance data, service intervals of primary components,
Compressor cooling air outlet
Drive
Ready for operation, fully automatic,
1505
Complete package
operating hours, status data and event memory data. Selection of Dual, Quadro, Vario and Continuous control Cooling air inlet Cooler
modes as required. (See SIGMA CONTROL brochure P-780)
Comprehensive design know-how
Cooling air inlet Motor
production facility. This ser-
dard has been achieved through years of
vice combines elements
experience in system and plant design,
such as compressed air
computer-aided analysis and 3-D design
components, user advice
aids. Take advantage of this expertise
and services that have
and have your air system designed by
proven themselves over the
KAESER!
years with new ideas made
Useful information on the subjects of
possible by the optimised
advice, analysis and the design or update
use of data processing in the
of your air system can be found under
compressed air field. Air
‘Services’ in the KAESER website –
systems planned and
www.kaeser.com.
designed by KAESER are characterised by their efficient use of energy. Compressor duty cycles of Compressed air supply systems can be
design or modernisation. KESS (Kaeser’s
95 percent and more are common.
highly complex depending on the appli-
Energy Saving Service) is available to you
Air quality tailored to the application at
cation. They can only be efficiently oper-
as a comprehensive service concept that
lowest cost and with high operational
ated over the long term if just as much
determines the optimum means of sup-
reliability is a further characteristic typi-
importance is placed on this fact during
plying the compressed air needed in your
cal of Kaeser air systems. This high stan-
921
Different applications need different grades of treatment Choose the required grade of treatment according to your field of application: Air treatment using a refrigeration dryer (+3 °C pressure dew point)
1
4
General works air, quality sandblasting
G
2
4
3
Shotblasting
G
2
7
3
H
3
7
4
Low quality shotblasting
Conveying air for waste water systems No quality requirements
I J
FF
FE
FG=activated carbon filter for adsorption of oil vapours, oil vapour content ≤ 0.003 mg/m³ FFG=combination filter comprising FF and FG RD=refrigeration dryer pressure dew point to +3 °C
FC
FB
DD=desiccant dryer DC series: heatless regeneration, pressure dew point to -70 °C, DW, DN, DTL, DTW series: heat regeneration, pressure dew point to -40 °C
Aquamat
ACT=activated carbon adsorber for adsorption of oil vapours, oil vapour content ≤ 0.003 mg/m³
KAESER rotary screw compressors
3
7
4
FST=sterile filter provides bacteria-free compressed air
other machines
6
7
Aquamat=condensate treatment system
6
For air mains subject to sub-zero temperatures: treatment systems with desiccant dryers (pressure dew point to -70 °C)
Applications subject to subzero temperatures, especially dry conveying air, paint spraying, fine pressure controllers
F
1-3
KAESER
< 1
FST
FD
DD FE
2
1-3
AT
ED
FE ZK
Compressor
THNF
Aquamat
Oil vapour content ≤ 0.003 mg/m3, particle retention > 0.01 µm, sterile, odourless and tasteless
D
B
Oil vapour content ≤ 0.003 mg/m3, particle retention > 0.01 µm
F
C
Oil vapour content ≤ 0.003 mg/m3, particle retention > 1 µm
G
E
Solid particles
Aerosol oil ≤ 0.001 mg/m3, particle retention > 0.01 µm Aerosol oil ≤ 0.01 mg/m3, particle retention > 0.01 µm Aerosol oil ≤ 0.01 mg/m3, particle retention > 1 µm Aerosol oil ≤ 1 mg/m3, particle retention > 1 µm
H I J
Humidity
Max. no. of particles per m3 with size d (µm)
Pressure dew point (x=liquid water in mg/m3 )
Overall oil content
1
0
–
–
<- 70 °C
<0.01
10
–
–
<- 40 °C
<0.1
500
–
–
<- 20 °C
<1.0
1000
–
–
< + 3 °C
<5.0
–
–
< + 7 °C
–
1
–
100
2
– 100000 1000
3
–
–
10000
4
–
–
–
5
–
–
–
20000
mg/m3
as specified by user
0
1
A
bacteria -
Class
Air receiver
FG
oil -
+
ISO 8573-1
Filter
KAESER
1
1-3
< 1
water -
+
Degree of filtration:
ACT
KAESER
B
Photo labs
1
< 1
FD
KAESER
A
1-3
FE
KAESER
Process air, pharmaceuticals
2
< 1
solids -
+
Installation for heavily fluctuating air demand
KAESER
C
1-3
KAESER
Paint spraying
1
FST
KAESER
B
1-3
KAESER
Microchip production, optics, food and semi-luxury food production
1
Bacteria
KAESER
A
Oil
< 1
KAESER
Solids Water
Pharmaceuticals, dairies, breweries
Contaminants: +
6
–
< 5 < 5
< + 10 °C
–
7
–
< 40 < 10
x <0.5
–
8
–
–
–
0.5
3 µm Aerosol oil ≤ 5 mg/m3, particle retention > 1 µm Untreated
KAESER KOMPRESSOREN GmbH 96410 Coburg – Postfach 21 43 – GERMANY – Phone + 4 9 95 61 6 400 – Fax + 4 9 95 61 64 01 30 www.kaeser.com – email: [email protected]
P-651/2ED.4/03 Specifications are subject to change without notice.
E
< 2
mg/m3
Packaging, control and instrument air
FF=microfilter 0.001 ppm separates aerosols and solid particles > 0.01µm, aerosol content ≤ 0.001 mg/m³
µm
< 1
Compressor THNF
ED
1.0 0.01µm, aerosol content ≤ 0.01 mg/m³
0.5 1µm
0.1 1µm, oil content ≤ 1 mg/m³
KAESER
4
ZK
<0.1
Weaving machines, photo labs
FFG
FST
KAESER
1
A
FF
ACT
KAESER
B
Pharmaceuticals
2
FD
RD
KAESER
4
C
FE
FB=prefilter 3 µm separates liquid droplets and solid particles > 3µm, oil content ≤ 5 mg/m³
Filter Air receiver
KAESER
1
< 1
Very clean conveying air, chemical plant
1
KAESER
4
< 1
B
ED=ECO Drain electronic level-controlled condensate drain
FST
KAESER
4
< 1
Food and semi-luxury food production
ZK=centrifugal separator separates accumulating condensate
KAESER
< 1
1
KAESER
4
A
Bacteria
KAESER
Dairies, breweries
Oil
KAESER
Solids Water
Installation for heavily fluctuating air demand
KAESER
Examples: selection of treatment classes to ISO 8573-1
Explanation: THNF=bag filter Cleans dusty intake air
