What do you expect from a compressed air system?
As a compressed air user, you expect maximum efficiency andreliability from your air system.
This sounds simple, but these advantages are influenced bymany different factors: energycosts, forexample, takenover the lifetimeof a com-pressor, add upto a multiple ofinvestmentcosts.
Efficient energy consumption therefore plays a vital role in theproduction of compressed air, as does reliability of the com-pressor. In many cases, a reliable compressed air supply isessential to guarantee maximum performance from valuableproduction systems.
Reliability also ensures a supply of constant quality compressed air that optimises efficiency of the air treatmentequipment downstream of the compressor.
With regards to sound protection, it is always better to keepnoise emissions to a minimum from the outset by using aquiet compressor rather than have to retro-fit sound protectionmeasures later on.
Last but not least, a truly efficient compressor is simple to maintain.
KAESER’s Solution:The CSD SeriesThe new CSD rotary screw compressorsfulfil every customer requirement:they are highly energy efficient, quieterthan quiet, require minimal maintenance,are extremely reliable and deliver thevery best in air quality. All of theseadvantages are aided through innovationsin compressor design, drive systems,cooling and ventilation, silencing andmaintenance methods. In summary, the new CSD series of rotary screw compressors is a meticulously engineered and reliable pro-duct range built to KAESER’s renownedhigh quality standards.
One-to-one drive - ultimate efficiencyThe CSD series is a range of compressors where the drive motor and the airendare designed to operate at the same low speed. This featuremakes possible direct coupling of the drive and compressionunits via a maintenance-free coupling, consequently avoiding thetransmission losses associated with gear driven units. One-to-onedrive reduces the number of components needed in comparisonwith gear drive, significantly increasing reliability and service life.Sound levels are also considerably lower. The benefits speak forthemselves: Efficient power transmission, optimal energyconsumption and reduced servicing / downtime costs.
Energy costsPotential energy savings
Maintenance costsCompressor system investment
CSD – The new standard in efficiency
Drive motor
Airend
Coupling
2980 rpm
Airend speed = Motor speed
Savings through logical designDirect intake ...
• ... of ambient air for cooling avoids pre-warming andensures excellent cooling. The difference between compressedair outlet and ambient temperature is only max. 7 K, whichreduces the energy requirement of downstream air dryingequipment.
• ... of drive motor cooling air from the surroundings ensuresreliable and effective motor cooling even under adverse conditions.
• ... of air for compression from outside the compressorcabinet improves compression efficiency; the position of the inletopening prevents pre-warming.
Three steps to greater efficiency:
3. Powerful Energy-Efficient RadialFanThe quiet and powerfulradial fan draws in coolambient air through thecooler. Its high residualthrust can deal with par-tial clogging of the coolerand still have enoughreserve to allow
connection of a long exhaust duct. In addition, theradial fan consumes significantly less drive powerthan conventional axial fans, saving even moreenergy.
2. One-to-one driveSome people talk ofdirect drive, but reallymean geared drive.Make sure you know thedifference. Maintenancecosts and transmissionlosses are virtuallyeliminated, as the motorand airend on CSD units
are connected via a simple coupling. Compared withcompressors using small, high speed gear-drivenairends, one-to-one provides optimum use of power.
Quieter than quietThe silent radial fan and directly coupledmotor reduce noise at source. The realtechnical advance is in the combination ofthese components with the new coolingsystem. The separate air flow paths allowalmost hermetic silencing without
influencing cooling efficiency. With a sound power level of no morethan 70 dB(A), the CSD series is approximately 10 dB(A) quieterthan a comparable compressor. This is equivalent to a 90 percentnoise reduction. Normal conversation can take place right next to therunning compressor.
1. Energy-saving SIGMA PROFILEKAESER’s SIGMA Profileairends save up to 15%energy compared withconventional screw com-pressor rotor profiles.The airends in CSD unitsuse even further refinedrotors.
SIGMA PROFILE airendA specific drive power can be used to turn a smaller airend at high speed or a
larger airend at slow speed. Larger, low speed airends are more efficient, deliveringmore compressed air for the same drive power. That is why KAESER developedairends especially for the CSD series that precisely match the individual drive powerand motor speed of each machine in the range. The slightly higher cost of the largerairend is quickly recovered by the energy saved during operation.
CSD – Eight Decisive Advantages
Energy-saving one-to-one driveThe 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 compactand durable unit that, apart from greasing of the motor bearings, requires no regularmaintenance. Should the coupling ever need to be replaced it takes just a fewminutes without any disassembly of the unit. The opening in the housing is morethan large enough to replace the two coupling sections. Furthermore, the low airendspeed (2980 rpm) in CSD units ensures maximum efficiency and durability, which inturn leads to low compressed air costs.
Innovative radial fanQuiet and efficient – the most important features of a radial fan. Low
peripheral speed means low noise. Power consumption is up to 50 percent lowerthan a comparable axial fan. Another advantage is the high residual thrustdeveloped that allows the use of exhaust ducting with a pressure drop of up to 80Pa without the need for an additional extractor fan.
Efficient cooling system
In addition to improved cooling efficiency, the system has other benefits to
offer. The inside of the cabinet remains clean because surrounding air is drawn
through the cooler into the cooler box and then exhausted directly upward out of the
machine. Dirt particles in the cooling air collect mainly on the air intake side of the
cooler, on CSD units that means outside the cabinet. Any clogging is easily noticed
and quickly cleaned off without the need for any dismantling work. Operational
reliability is improved and maintenance work significantly reduced.
More air, more savings...
* FAD to ISO 1217: 1996, Annex C; **)Sound level to PN8NTC 2.3 at 1m distance, free-field measurement
Model
Weight
kg
Dimensions
L x W x H
FAD*) overall package at working pressure
m3/min
Sound level**)
dB(A)
Rated motorpower
kW
Max. workingpressure
bar
CSD Series - Technical Specifications
Optimised oil separation systemCSD machines are fitted with a new, even more efficient separator system.
The cooling fluid is initially separated from the compressed air by centrifugal force inthe separator tank. Only a minimal amount of fluid remains to be removed by thehigh capacity, deep-bed filter in the separator cartridge. These two factors doublethe operational life of the cartridge compared with conventional systems and ensureminimum aerosol content in the compressed air delivery (< 1 mg/m3). The improvedair quality eases the burden on the downstream air treatment components. Theoptional filter pressure drop monitoring set further enhances efficient operation.
Synthetic coolant and special fluid filterThe synthetic cooling medium SIGMA FLUID makes possible an extension of
the fluid change interval to over 6000 hours. However, as a preventative protectionmeasure for your equipment, we strongly recommend that a fluid analysis be carriedout after 6000 operating hours due to the varied nature of environmental and intakeconditions. Less SIGMA FLUID is consumed in comparison with mineral oils and itsreduced emulsifying tendency simplifies condensate treatment and reduces disposalcosts. A specially developed glass fibre fluid filter with enhanced contaminationabsorption capability is able to clean the cooling fluid more effectively, which is whythe maintenance service interval has been able to be significantly increased. Thefluid filter and SIGMA FLUID reduce service costs and increase operational reliability.
Easy maintenanceAll models feature high quality, durable components that are positioned
logically and contribute to the outstanding performance and reliability of these com-pressor packages. Component accessibility is made simple through wide openingdoors, easy lift off panels and a sensible design that ensures unrivalled ease ofmaintenance. The rear and left side of CSD units can be positioned right next to awall to maximise use of space.
SIGMA CONTROLBased on robust PC architecture, the SIGMA CONTROL offers the possibility
of Dual, Quadro, Vario and Continuous control. Clearly marked navigation and inputkeys on the user interface are used to move around within the menu options of thefour line alpha-numeric display. This powerful compressor controller can also displayinformation in any 1 of 30 selectable languages at just the press of a button. TheSIGMA Control automatically controls and monitors the compressor package. The Profibus interface enables exchange of data and operational parameters allowingthe SIGMA Control to communicate with other air management systems such as theSIGMA Air Manager. Connection of a modem even allows maintenance and alarmmessages to be sent via SMS to relevant service locations.
CSD 82
CSD 102
CSD 122
7.5
10
13
7.5
10
13
7.5
10
13
8
11
15
8
11
15
8
11
15
45
55
75
69
69
71
1260
1300
1330
1650 x 1041 x 1865
1650 x 1041 x 1865
1650 x 1041 x 1865
8.25
6.9
5.5
10.2
8.2
6.75
12.0
10.05
8.07
The rated motor powers given in the technicalspecifications below are reference points forselection of a suitable CSD compressor system.
Please contact KAESER for specific FAD and motoroutput data relating to other working pressures.
AftercoolingFluid coolingInlet airMotor cooling air
www.kaeser.com
1
2
3
4 8
7
6
5
Max.workingpressure
barCSD
298
0rp
m
SIGMA PROFILE airendA specific drive power can be used to turn a smaller airend at high speed or a
larger airend at slow speed. Larger, low speed airends are more efficient, deliveringmore compressed air for the same drive power. That is why KAESER developedairends especially for the CSD series that precisely match the individual drive powerand motor speed of each machine in the range. The slightly higher cost of the largerairend is quickly recovered by the energy saved during operation.
CSD – Eight Decisive Advantages
Energy-saving one-to-one driveThe 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 compactand durable unit that, apart from greasing of the motor bearings, requires no regularmaintenance. Should the coupling ever need to be replaced it takes just a fewminutes without any disassembly of the unit. The opening in the housing is morethan large enough to replace the two coupling sections. Furthermore, the low airendspeed (2980 rpm) in CSD units ensures maximum efficiency and durability, which inturn leads to low compressed air costs.
Innovative radial fanQuiet and efficient – the most important features of a radial fan. Low
peripheral speed means low noise. Power consumption is up to 50 percent lowerthan a comparable axial fan. Another advantage is the high residual thrustdeveloped that allows the use of exhaust ducting with a pressure drop of up to 80Pa without the need for an additional extractor fan.
Efficient cooling system
In addition to improved cooling efficiency, the system has other benefits to
offer. The inside of the cabinet remains clean because surrounding air is drawn
through the cooler into the cooler box and then exhausted directly upward out of the
machine. Dirt particles in the cooling air collect mainly on the air intake side of the
cooler, on CSD units that means outside the cabinet. Any clogging is easily noticed
and quickly cleaned off without the need for any dismantling work. Operational
reliability is improved and maintenance work significantly reduced.
More air, more savings...
* FAD to ISO 1217: 1996, Annex C; **)Sound level to PN8NTC 2.3 at 1m distance, free-field measurement
Model
Weight
kg
Dimensions
L x W x H
FAD*) overall package at working pressure
m3/min
Sound level**)
dB(A)
Rated motorpower
kW
Max. workingpressure
bar
CSD Series - Technical Specifications
Optimised oil separation systemCSD machines are fitted with a new, even more efficient separator system.
The cooling fluid is initially separated from the compressed air by centrifugal force inthe separator tank. Only a minimal amount of fluid remains to be removed by thehigh capacity, deep-bed filter in the separator cartridge. These two factors doublethe operational life of the cartridge compared with conventional systems and ensureminimum aerosol content in the compressed air delivery (< 1 mg/m3). The improvedair quality eases the burden on the downstream air treatment components. Theoptional filter pressure drop monitoring set further enhances efficient operation.
Synthetic coolant and special fluid filterThe synthetic cooling medium SIGMA FLUID makes possible an extension of
the fluid change interval to over 6000 hours. However, as a preventative protectionmeasure for your equipment, we strongly recommend that a fluid analysis be carriedout after 6000 operating hours due to the varied nature of environmental and intakeconditions. Less SIGMA FLUID is consumed in comparison with mineral oils and itsreduced emulsifying tendency simplifies condensate treatment and reduces disposalcosts. A specially developed glass fibre fluid filter with enhanced contaminationabsorption capability is able to clean the cooling fluid more effectively, which is whythe maintenance service interval has been able to be significantly increased. Thefluid filter and SIGMA FLUID reduce service costs and increase operational reliability.
Easy maintenanceAll models feature high quality, durable components that are positioned
logically and contribute to the outstanding performance and reliability of these com-pressor packages. Component accessibility is made simple through wide openingdoors, easy lift off panels and a sensible design that ensures unrivalled ease ofmaintenance. The rear and left side of CSD units can be positioned right next to awall to maximise use of space.
SIGMA CONTROLBased on robust PC architecture, the SIGMA CONTROL offers the possibility
of Dual, Quadro, Vario and Continuous control. Clearly marked navigation and inputkeys on the user interface are used to move around within the menu options of thefour line alpha-numeric display. This powerful compressor controller can also displayinformation in any 1 of 30 selectable languages at just the press of a button. TheSIGMA Control automatically controls and monitors the compressor package. The Profibus interface enables exchange of data and operational parameters allowingthe SIGMA Control to communicate with other air management systems such as theSIGMA Air Manager. Connection of a modem even allows maintenance and alarmmessages to be sent via SMS to relevant service locations.
CSD 82
CSD 102
CSD 122
7.5
10
13
7.5
10
13
7.5
10
13
8
11
15
8
11
15
8
11
15
45
55
75
69
69
71
1260
1300
1330
1650 x 1041 x 1865
1650 x 1041 x 1865
1650 x 1041 x 1865
8.25
6.9
5.5
10.2
8.2
6.75
12.0
10.05
8.07
The rated motor powers given in the technicalspecifications below are reference points forselection of a suitable CSD compressor system.
Please contact KAESER for specific FAD and motoroutput data relating to other working pressures.
AftercoolingFluid coolingInlet airMotor cooling air
www.kaeser.com
1
2
3
4 8
7
6
5
Max.workingpressure
bar
CSD
298
0rp
m
Comprehensive design know-how
EquipmentDimensions:
Compressed air supply systems are oftenhighly complex and can only beefficiently operated in the long term ifcareful planning is implemented duringeach stage of design, system expansion
and modernisation. KESS (KAESER’sEnergy Saving Service) providescomprehensive analysis of your com-pressed air usage, enabling KAESER’sexperts to plan and design a system
that is specially tailoredto meet all of your com-pressed air requirements.The service combines triedand tested compressed aircomponents, user adviceand services with cutting-edge technology to ensuremaximum efficiency –KAESER air systemstypically operate at 95percent load capacity ormore.
Every KAESER com-pressed air system illus-trates KAESER’s commit-
ment to producing application-specificquality compressed air at the lowestpossible cost, combined withunsurpassed reliability. This standard is
Ergonomic control panelRed, yellow and greenLEDs show the opera-tional state of themachine at a glance.Also features a four-line plain text display,30 selectablelanguages, touch keys
with icons and a duty cycle indicator.
Prime functionsFully automatic monitoring and regulationof airend discharge temperature;monitoring of motor current, direction ofairend rotation, air filter, fluid filter andfluid separator cartridge, display of per-formance data, service intervals ofprimary components, operating hours,status data and event memory data.Selection of Dual, Quadro, Vario andContinuous control modes as required.
(For further information refer to SIGMA CONTROL/SIGMACONTROL BASIC brochure P-780)
achieved with products of thehighest quality and throughdecades of experience in designand construction of compressedair systems. Use this expertise toyour advantage and let KAESERdesign your compressed airsystem.
Valuable information and adviceregarding KAESER services,planning and analysis can befound under ‘Services’ on theKAESER website –www.kaeser.com.
1865
DriveDirect, torsional-elastic coupling, without gearing.
Electric motorHigh efficiency CEMEP EFF1 motorsconsume less power for greater output and are standard throughout therange of KAESER compressors. Themotors are protected to IP55 andconform to insulation Class F for greaterpower reserve.
Connection from motor to airendAirend with integral coupling flange.
Electrical componentsControl cabinet to IP 54, containingautomatic star-delta starter, motor over-load protection, control transformer andvolt-free contacts for ventilation control.
Fluid and airflowDry air intake filter with initialseparation, inlet and venting valves,fluid reservoir with three-stage separatorsystem, pressure relief valve,minimum pressure/check valve, ther-mostatic valve and fluid microfilter, allfully piped using newly-developed elasticcouplings.
CoolingThe standard version is air-cooled,separate aluminium coolers for com-pressed air and fluid, radial fan drivenby its own motor.
SIGMA CONTROLInterfaces for data communicationcomprising RS 232 for a modem orprinter, RS 485 for a slave compressorin base load sequencing mode and aProfibus DP interface for data networks.Prepared for Teleservice.
Complete unitReady for operation, fully automatic,super silenced, vibration damped, allpanels powder coated.
Sound insulationLined with washable plastic foam;maximum 70 dB (A) to PN8NTC 2.3 at1m distance, free-field measurement.
Vibration dampingDual antivibration mountings usingrubber bonded metal elements
AirendGenuine KAESER
rotary screw, single-stage airend withSIGMA PROFILE
and cooling fluid injection.
1650
Com
pres
sor
Coo
ling
air
outle
t
Coo
ling
air
outle
t
Coo
ler
Cooling air inletfor cooler
Compressorinlet air
Motor inlet air
97980
Compressedair connection
R2
721
636
216
58
www.kaeser.com
1041
P-6
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KAESER KOMPRESSOREN GmbHP.O. Box 2143 – 96410 Coburg – GERMANY – Tel: +49 9561 640-0 – Fax: +49 9561 640130www.kaeser.com – e-mail: [email protected]
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
Dairies, breweries
Choose the required grade of treatment according to your field of application:
Food and semi-luxury food production
Very clean conveying air, chemical plant
Air treatment using a refrigeration dryer (+3 °C pressure dew point)
For air mains subject to sub-zero temperatures: treatment systems with desiccant dryers (pressure dew point to -70 °C)
Pharmaceuticals
Weaving machines, photo labs
Paint spraying, powder coating
Packaging, control and instrument air
General works air, quality sandblasting
Shotblasting
Low quality shotblasting
Conveying air forwaste water systems
No quality requirements
Pharmaceuticals, dairies, breweries
Microchip production, optics,food and semi-luxury food production
Paint spraying
Photo labs
Process air, pharmaceuticals
Applications subject to sub-zerotemperatures, especially dryconveying air, paint spraying,fine pressure controllers
Explanation:
THNF=bag filtercleans dusty and highly contaminated intake air
ZK=centrifugal separatorremoves condensate
ED=ECO Drainelectronic level-controlled condensate drain
FB=prefilter 3 µmseparates liquid droplets and solid particles >3 µm, oil content ≤5 mg/m3
FC=prefilter 1 µmseparates oil droplets and solid particles >1 µm, oil content ≤1 mg/m3
FD=particulate filter 1 µmseparates dust particles (attrition) >1 µmFE=microfilter 0.01 ppmseparates aerosol oils and solid particles>0.01 µm, aerosol content ≤0.01 mg/m3
FF=microfilter 0.001 ppmseparates aerosol oils and solid particles>0.01 µm, oil content ≤0.001 mg/m3
FG=activated carbon filterfor adsorption of oil vapours, oil vapour content ≤0.003 mg/m3
FFG=combination filtercomprising FF and FG
RD=refrigeration dryerpressure dew point to +3 °C
DD=desiccant dryer for compressed air drying; DC series - heatlessregeneration, pressure dew point to -70 °C; DW, DN, DTL and DTW series - heat regenera-tion, pressure dew point to -40 °C
ACT=activated carbon adsorberfor adsorption of oil vapours, oil vapour content ≤0.003 mg/m3
FST= sterile filter for bacteria-free air
Aquamat = condensate treatment system
AMCS = air-main charging system
FSTSolids Oil BacteriaWater
Solids Oil BacteriaWater
A
B
A
C
B
D
E
G
1
1
4
4
4
4
4
4
4
4
1
2
1
1
1
2
G 72
H 73
I 93
J 98
1
1
1
1
1
1
2
3
3
4
4
5
<
<
<<
<
<
<
<
<
ACT FF
FF
FE
FC
FB
FD
FD
ACT
A
A
B
C
F
11
11
11
12
11-3
1-3
1-3
1-3
1-3
2
B 11-31
<
<
<
<
<
<
<
<
FST
FST
FE
KAESER rotary screw compressors
other machines
FFG
FE
FD
KA
ES
ER
KA
ES
ER
KA
ES
ER
KA
ES
ER
KA
ES
ER
KA
ES
ER
KA
ES
ER
KA
ES
ER
KA
ES
ER
FG DD
FE ED
RD ED Compressor
Aquamat
Aquamat
Compressor THNF
THNF
KA
ES
ER
KA
ES
ER
KA
ES
ER
KA
ES
ER
KA
ES
ER
KA
ES
ER
KA
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ER
KA
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KA
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KA
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ER
KA
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ER
FST
KA
ES
ER
KA
ES
ER
KA
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ER
Contaminants:+ solids -
+ water -
+ oil -
+ bacteria -
Aerosol oil ≤ 0.003 mg/m3, particle retention > 0.01 µmsterile, odourless and taste-free
Aerosol oil ≤ 0.003 mg/m3, particle retention > 0.01 µm
Aerosol oil ≤ 0.003 mg/m3, particle retention > 1 µm
A
B
C
D Aerosol oil≤ 5 mg/m3, particle retention > 3 µmAerosol oil ≤ 5 mg/m3, particle retention > 1 µmUntreated
E
F
G
H
I
J
ZKRDFilters
Air receiver
Installation for heavily fluctuating air demandExamples: selection of treatment classes to ISO 8573-1
Filters
Air receiver
Installation for heavily fluctuating air demand
KA
ES
ER
DD FE ZK
KA
ES
ER
Clas
s
<0.
1
Pressure dewpoint
(x=liquid water in
mg/m3 )
–
–
–
–
–
0.1<
d<0.
5
100
100000
–
–
–
0.5<
d<1.0
1
1000
10000
–
–
–
–
–
–
1.0<
d<5.0
0
10
500
1000
20000
µm
–
–
–
–
–
< 5
< 40
–
–
mg/
m3
–
–
–
–
–
< 5
< 10
–
–
mg/m3
<0.01
<0.1
<1.0
<5.0
–
–
–
–
–
<-70 °C
<-40 °C
<-20 °C
<+ 3 °C
<+ 7 °C
<+ 10 °C
x <0.5
0.5<x < 5.0
5.0<x <10.0
0
1
2
3
4
5
6
7
8
9
Degree of filtration:
Solid particlesMax. no. of particles per m3 with size d (µm)
ISO 85
73-1 Humidity
Oil con-centration
as specified by user
<
<
<
AMCS
AMCS
AMCS
AMCS
AMCS
AMCS
AMCS
AMCS
AMCS
AMCS