Dry-Running Rotary Screw Compressors. CSG-2 Series Two-stage, Flow rate up to 13.5 m³/min, Pressure 4, 6, 8 and 10 bar.

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1 Dry-Running Rotary Screw Compressors CSG-2 Series Two-stage, Flow rate up to 13.5 m³/min, Pressure,, and bar

2 CSG-2 series Innovation Quality KAESER Two-stage dry-running KAESER rotary screw compressors not only impress with their intelligent component layout, but also with their many innovative details all of course with renowned KAESER quality and KAESER s distinctive, contemporary design. Long-term efficiency Compressed air simply has to be available where and whenever it is needed. KAESER dry-running two-stage rotary screw compressors are therefore built to last and to ensure many years of dependable performance. Comprising tried and tested components that have been developed as a result of KAESER s near century of experience in mechanical engineering, KAESER compressors deliver the durability and compressed air availability to meet even the toughest of demands. Innovation you can trust Using all of the advantages that KAESER s advanced Research and Development Centre in Coburg has to offer, KAESER s engineers designed every detail of the two-stage dry-running rotary screw airend with maximum efficiency and performance in mind. Efficiency as standard KAESER quality and expertise really count when it comes to those all-important total system costs for asset investments, such as compressors or complete compressed air supply systems. Lowest possible compressed air costs and maximum availability can be guaranteed only through a combination of perfect interplay between energy effi ciency and service / maintenance, and by viewing the compressed air supply system as a whole. Service-friendly These versatile systems were engineered for maximum ease-of-use and servicing right from the outset of the design stage. Fewer wearing parts and the use of premium quality materials ensure reduced maintenance requirement, longer service intervals and extended service life. Excellent component accessibility as a result of generously sized maintenance doors and a swing-out cooler are just some of the features that make servicing so effortless. Potential energy-cost savings up to 70% Energy-efficiency: the essential requirement Life-cycle costs Energy costs Commissioning Investment costs Service costs Investment and service costs account for only a small part of a compressor s total life-cycle costs. Since energy accounts for the lion s share of those costs, it s wise to save with KAESER Life-Cycle Management. KAESER has been committed to minimising your energy costs for compressed air production for over 0 years. We also have the bigger picture in clear focus when it comes to service and maintenance, as well as maximum compressed air supply availability. Image: CSG SFC 2 3

3 KAESER compressor airends: precise durable efficient DURABLE Proven airends At the heart of every KAESER dry-running rotary screw compressor lies a tried and tested dry-running, two-stage rotary screw airend. Providing optimum performance and dependability, every airend ensures maximum efficiency throughout its entire service life. Durable coating The blasted and bonderised rotors are treated using the special Ultra Coat process to produce an innovative and durable coating which is resistant to temperatures of up to 300 C. Since this cost-reducing coating is highly abrasion-resistant, its sealing and protection performance remains consistent even after years of operation. Chromium steel rotors The second compression stage s rotors are made from stainless steel, which eliminates the risk of rotor seizing or jamming caused by corrosion. Airend cooling A cooling process known as jacket cooling is used in the low and high pressure compression stages of the airend to ensure optimal heat dissipation, which greatly enhances effi ciency. 5

4 Drive and controller: efficient advanced intelligent SIGMA CONTROL 2: optimum efficiency The internal SIGMA CONTROL 2 controller always ensures efficient control and monitoring of compressor operation. The large display and RFID reader provide easy communication and maximum security. Multiple interfaces enable seamless networking capability, whilst the SD card slot makes updates quick and easy. Speed control perfected Perfect matching of the SFC (SIGMA FREQUENCY CONTROL) frequency converter and drive motor enables exceptional efficiency across the machine s entire operating range whilst minimising machine vibrations. Moreover, the thermally insulated SFC control cabinet allows unhindered operation in ambient temperatures of up to +5 C. Energy-saving Needless to say, all KAESER CSG series rotary screw compressors are equipped with premium efficiency IE3 drive motors. The use of IE3 drive motors became mandatory in the EU and North America from the 1st of January Easy-access coupling The electric motor directly drives the airend via a maintenance-free coupling, which virtually eliminates transmission losses. As there is no need for complicated disassembly work, the easy-access coupling can be exchanged quickly and easily. 7

5 Intelligent detail solutions: big thinking for compact systems Hydraulic inlet valve The hydraulically operated inlet valves in KAESER dry-running rotary screw compressors are unaffected by contamination and condensate. This enhances their reliability and ease of maintenance compared to pneumatic valves. Fibre-free pulse dampers KAESER s new fibre-free pulse dampers keep pressure losses to an absolute minimum, help maintain consistent air quality and minimise unwanted vibration. In addition, their fibre-free design reliably eliminates the possibility of compressed air contamination. (1) Microfi lter (2) Oil mist extraction (3) Ejector () Return line to gear oil reservoir Dependable oil reservoir venting The microfilter in the oil tank venting system prevents intake of oil-laden air. This is another key detail to ensure that compressed air quality is reliably and efficiently maintained at all times. High efficiency condensate separator Thanks to its flow-optimised design, the newly developed condensate separator reliably separates the condensate downstream from the air coolers with minimal pressure loss. 9

6 Efficient cooling: with air or Air-cooling: Water-cooling: Air-cooling: low operating costs Air-cooled CSG units deliver reliable performance in ambient temperatures of up to +5 C thanks to energyefficient radial fans. To ensure maximum air cooler service life in the high-pressure stage, pre-cooling is performed using a stainless steel tube cooler. Parallel heat exchanger Both the low and high pressure stages of -cooled KAESER dry-running rotary screw compressors are equipped with their own dedicated parallel heat exchanger for enhanced heat transfer. This optimised cooling consequently improves specific power performance. Air-cooler combination, stage 1 and 2 Radial fan Energy-saving standstill fan When the large radial fan in air-cooled CSG units is switched off as part of the transition to standby mode, the energy-saving, temperature-controlled standstill fan reliably removes remaining heat in the compressor. Optimised cooler Water-cooled CSG compressors feature highly effi cient air/ heat exchangers. CuNiFe cooling pipes with internal star lamella fins provide optimum heat transfer and lowest possible compressed air discharge temperatures with minimal pressure loss. 11

7 Compressed air drying: consistently precise pressure dew point SECOTEC High efficiency refrigeration dryers Even for dry-running rotary screw compressors, refrigeration dryers are the go-to choice for delivering best possible energy efficiency and favourable investment costs when requiring pressure dew points to +3 C. Pressure dew points below +3 C are provided by desiccant dryers. HYBRITEC Combination dryers for maximum savings Delivering exceptionally efficient performance, HYBRITEC dryers combine the outstanding effi ciency of advanced refrigeration dryers with the extremely low pressure dew points of desiccant dryers (down to -0 C). Extreme dryers Heatless regenerated desiccant dryers KAESER S DC series heatless regenerated desiccant dryers achieve pressure dew points to -70 C, even under extreme operating conditions. For operation during the cooler months, HYBRITEC dryers feature frost protection mode in which both the refrigeration and desiccant dryers are switched on; during warmer months, the unit switches exclusively to refrigeration drying. If desired, these operating mode transitions can be performed automatically based on temperature. Over a four-month frost period, for example, combination dryers reduce energy costs by up to 7 % compared to single-stage heat-regenerated desiccant dryers. If a pressure dew point of -0 C is required year-round, HYBRITEC units are capable of reducing energy costs by up to 50 %

8 KAESER heat recovery Heat recovery: the fine art of saving energy Amortisation period < 1 year Space heating with warm exhaust air Heating made easy: Thanks to radial fans with high residual thrust, the reusable (warm) air from air-cooled CSG-2 systems can be easily ducted away to spaces that require heating and usually without the need for additional fans. Direct use of hot compressed air Thanks to hot air control from KAESER, hot compressed air can be seamlessly integrated into your production processes, e.g. to increase effi ciency and yield of jet mills. The SIGMA CONTROL 2 controller allows convenient setting of required temperature. Example amortisation calculation Inlet temperature 20 C Relative humidity 30 % Cooling inlet (primary) 20 C Cooling outlet (primary) 0 C Compressor power CSG bar(g) 93.kW Heat recovery potential based on total power consumption 7 % Recoverable heat capacity.2 kw Annual operating hours,000 hrs Kilowatt hours per year 505,29 kwh Energy costs 0.02 /kwh Annual energy cost savings,5 Up to +90 C hot Process, heating and service Compressor exhaust heat can be used to produce hot with temperatures up to +90 C, which can then be used for a wide range of applications. Reliable heat recovery The internal division into primary and secondary systems ensures reliable and consistent compressed air supply whilst also delivering optimal heat recovery performance. Amortisation period < 1 year 1 15

9 Heat recovery flow diagram General design Air-cooling HR Cold (1) Air fi lter/air inlet (2) Low pressure stage (Stage 1, LP) Secondary system (3) Pulsation damper (Stage 1) () Air cooler, Stage 1 (5) Condensate separator Cooling outlet () High pressure stage (Stage 2, HP) (7) Pulsation damper (Stage 2) Cooling inlet () Air cooler Stage 2 (with pre-cooler) (9) Condensate separator HR Cold Primary system (heat recovery system) HR Hot Optional Cooling outlet () Compressed air outlet (11) Radial fan (12) Gear oil cooler (13) Standstill fan, temperature-controlled (active at machine standstill) Cooling inlet Compressed air Image: CSG-2 RD standard version air-cooled Optional version featuring heat recovery; only possible with -cooling, oil cooler not shown Water-cooling (1) Inlet fi lter (2) Low pressure stage (Stage 1) (3) High pressure stage (Stage 2) () IE3 drive motor (5) Air cooler downstream from Stage 1 (air/) () Air cooler downstream from Stage 2 (air/) (7) Optional additional heat exchanger (air/) (Plate-type heat exchanger) () Heat exchanger (/) (9) Check valve () Water control valve (Actuated by SIGMA CONTROL) (11) Pump (12) Expansion tank (13) Condensate separator In two-stage dry-running rotary screw compressors, some 90 % of the usable heat is processed through the two air coolers (5) and (). KAESER therefore uses separate, high-quality heat exchangers developed specially to meet heat recovery requirements. The remaining % of usable heat is processed through the oil cooler and in the jacket cooling system of the compression stages. (1) Air fi lter/air inlet (2) Low pressure stage (Stage 1, LP) (3) Pulsation damper (Stage 1) () Air cooler, Stage 1 (5) Condensate separator () High pressure stage (Stage 2, HP) (7) Pulsation damper (Stage 2) () Air cooler, Stage 2 (9) Condensate separator () Compressed air outlet (11) Internal enclosure fan (12) Cooling outlet (13) Cooling inlet (1) Gear oil cooler Image: CSG-2 RD standard version -cooled 1 17

10 Equipment and options Technical specifications Complete unit Dry-running rotary screw compressor with 2-stage compression; condensate separator, condensate drain and fi bre-free pulse dampers for both compression stages; oil tank ventilation with microfilter, ready for operation, fully automatic, silenced. Airend 2-stage, dry-running rotary screw airend with integrated gearing and collection tank for gear oil. Rotors feature durable coating. Both high and low pressure compression stages feature jacket cooling; high pressure stage with chromium steel rotors. Drive: Precision gearing as per AGMA Q13/DIN Class 5 with helical spur gears. Drive motor Premium effi ciency IE3 drive motor, quality manufacture; IP 55 enclosure protection, Pt0 temperature sensor in windings; continuous measurement and monitoring of motor windings temperature. Cooling Optionally available with air- or -cooling. Radial fan with separate drive motor. Exhaust air discharged upwards. Air-cooled version: High-pressure side: aluminium cooler with stainless steel tube pre-cooler Electrical components Ventilated IP 5 control cabinet, automatic star-delta starter, overload relay, control transformer. SIGMA CONTROL 2 Full-text display, 30 selectable languages; soft touch icon keys; traffi c light style LEDs to indicate operating status; fully automatic monitoring and control; Dual, Quadro and Dynamic control modes provided as standard; SD card slot for data logging and updates; RFID reader; web server; interfaces: Ethernet; optional communications modules for: Profibus DP, Modbus, Profi net and Devicenet. Dynamic Control The Dynamic Control feature calculates run-on times based on the motor winding temperature. This reduces idling times and cuts energy consumption. Additional control options are stored in the SIGMA CONTROL 2 and can be called up as required. Options: Hot air connection DN 5 pipe connection at the pulse damper of the 2 nd compression stage; direct use of hot compressed air, e.g. for DHC dryer or as hot process air. Bolt-down machine mounts Machine mounts to bolt the machine to the fl oor. Air-cooled version: Silencer for inlet air opening Sound insulated connecting links upstream from heat exchangers. Cooling air filter mats Cooling air fi lter mats in the compressor intake area; reduces contamination of heat exchanger surfaces and inlet air fi lters. Water-cooled version: Heat recovery Heat recovery system can be optionally integrated; parallel switched tube-type heat exchanger; safety cooling system; safety pump, expansion tank, control valves. Additional heat exchanger downstream from 2 nd stage air-cooler Plate-type heat exchanger design; reduces outlet temperature for compressors with heat recovery. Model Rated motor power Air-/-cooled versions CSG CSG CSG CSG CSG SFC versions CSG 90-2 SFC 55 CSG SFC 75 CSG SFC 90 Working pressure Flow rate complete package at working pressure 1) Air-cooled version Dimensions W x D x H Sound pressure level 2) Water-cooled version Standard (air-cooled) Standard (-cooled) SFC (air-cooled) SFC (-cooled) Mass Flow rate complete unit at max. working pressure 1) Dimensions W x D x H Sound pressure level (with ducting) 2) kw bar m³/min mm db(a) kg m³/min mm db(a) kg x x x x x x x x x x x x x x x x ) Flow rate according to ISO 1217:2009, Annex C: absolute input pressure 1 bar(a); cooling and air input temperature 20 C 2) Sound pressure level according to ISO 2151 and the basic standard ISO 91-2, tolerance: ±3 db(a), measured at maximum pressure and maximum speed 11 bar and 5 bar versions available upon request. Specifi cations subject to change without notice. Mass 2355 x x x x x x x x x x x x x x x x Low-pressure side: aluminium cooler Aluminium cooler for gear oil KAESER hot air control Water-cooled version: Two shell and tube heat exchangers consisting of coated steel jacket and pipes made from CuNiFe; gear oil cooler. High temperature valve of quality manufacture; SIGMA CONTROL 2 regulates air temperature control downstream from the 2 nd stage pulse damper. 2,15 1,0 2,355 1,95 1,0 2,355 2,15 1,0 2,355 1,95 1,0 2,

11 The world is our home As one of the world s largest compressed air systems providers and compressor manufacturers, KAESER KOMPRESSOREN is represented throughout the world by a comprehensive network of branches, subsidiary companies and authorised partners. With innovative products and services, KAESER KOMPRESSOREN s experienced consultants and engineers help customers to enhance their competitive edge by working in close partnership to develop progressive system concepts that continuously push the boundaries of performance and compressed air efficiency. Moreover, the decades of knowledge and expertise from this industry-leading system provider are made available to each and every customer via the KAESER group s global computer network. These advantages, coupled with KAESER s worldwide service organisation, ensure that every product operates at the peak of its performance at all times and provides maximum availability. KAESER KOMPRESSOREN SE P.O. Box Coburg GERMANY Tel Fax productinfo@kaeser.com P-51/32ED Specifi cations are subject to change without notice. /15