Rotary Lobe Blowers and Packages

Rotary Lobe Blowers and Packages Omega BB - HB Series Flow Capacities to: 5650 cfm Pressures up to psig, vacuums to Hg

A Family Tradition of Quality Kaeser has been designing and manufacturing superior industrial machinery since 1919. With over 90 years of manufacturing experience, we pride ourselves on upholding our traditions of quality and craftsmanship. Our reputation for reliability, energy efficiency, and excellent service has helped us grow into a global leader in blower and compressed air technology. Today, Kaeser employs over 4,000 people and our growing distribution network provides air system solutions and service throughout the world. 2

Contents Blower design and technical features... 4-5 Com-paK Plus blower packages... 6-9 HB blower packages...10-11 Specialty application blowers... 12-13 System design and options... 14- Quality manufacturing... 16-17 Product range and applications... 18-19 3

Advanced Blower Design All Omega blowers share a durable design that includes rigid casings, cast bearing supports, and onepiece rotors. The substantial casing construction and proprietary port design ensure smooth, quiet operation at all speeds. The precision machined, case-hardened, spur-type timing gears and oversized cylindrical roller bearings provide years of reliable service. Piston-ring seals ensure optimum internal sealing and oil-free air. Versatility Omega blowers can be mounted horizontally or vertically to suit the specific application. They are also available as complete blower packages. 4

One-piece rotors and sealing strips One-piece, ductile iron rotors are balanced to the closest tolerances for smooth, efficient operation at all speeds and pressures. Our over-sized shaft diameters and rigid construction minimize shaft deflection. Specially designed rotor sealing strips reduce sensitivity to contamination and intermittent thermal overloading. Superior casing The distinctive ribbed housing ensures strength, rigidity and aids in proper cooling. Integral bearing supports and head plates are machined into the castings to provide better strength and to maintain alignment in the most demanding applications. Our unique port design ensures smooth quiet operation at all speeds. Piston-ring sealing Heat-treated, metal labyrinth seals on both air and oil side seals ensure performance and long life. They are low-wear, can withstand high differential pressures, and are designed to be field repairable. The vented seal cavity ensures oil-free air delivery. Heavy-duty bearings Large cylindrical roller bearings are designed to handle the widely varying radial forces. Operational life over 160,000 hours is typical. Superior Warranty Protection Omega blowers are backed by our 24-month warranty against defects in material and workmanship. The blowers in our Com-paK Plus packages carry 5-year warranties. Further, Kaeser guarantees shipment of any standard part required for emergency breakdown repairs on any standard Omega blower within one working day of order receipt, or the parts are free. Reliable splash lubrication Drive and gear end splash rings ensure reliable lubrication that removes heat and flushes contaminants from bearings and gears. Easy-to-read oil sight glasses take the guess-work out of maintenance. Straight-cut gears Timing gears are case-hardened and precision ground to minimize vibration and mechanical noise. Straight-cut design prevents axial loading and ensures accurate rotorto-rotor timing for improved efficiency. 5

Com-paK Complete e Blower Packages Compact design The Com-paK is uniquely designed to minimize space requirements and reduce installation costs. All routine maintenance points are accessible from the front while all utility connections are located in the back. All pipe connections and cooling air apertures are located at the rear of the unit, which makes side-by-side installation possible. The fully-enclosed package design and proprietary Omega Plus tri-lobe blower design minimizes pulsation and noise. The Com-paK is complete with premium efficiency TEFC motor, silencers, and integrated controls. The package arrives ready for installation. 6

Innovative cabinet design Com-paK models are fully enclosed in powder coated and insulated steel cabinets. They all feature positive ventilation with dedicated fans to remove latent heat even when the main motor is off making Kaeser blower packages more reliable in a wide range of climates and uses. The process air circuit is separate from the ventilating air for improved efficiency. Instrumentation and controls Our standard instrumentation includes pressure/vacuum gauges, discharge temperature gauge (and switch), inlet filter differential pressure indicator and motor winding PTC. On select models, the more advanced Omega Control and Sigma Control 2 offer enhanced monitoring and equipment protection features (see sensors below). Sensors A wide range of sensors and switches for monitoring pressure, temperature, speed, oil level and filters are available. These ensure dependable blower operation and enable remote monitoring and visualization of operational status. Inlet silencer with integral filter Our silencers are designed for our blower noise frequencies. Absorptive material reduces pulsation noise and reusable polyester filter protects the blower from harmful particulates and minimizes pressure drop. Shown with integral frequency drive Automatic belt tensioner Our automatic v-belt tensioner maintains blower performance and efficiency without frequent adjustments. It also prolongs belt, pulley, and bearing life. A glance at the visual indicator tells you if adjustment is needed and helps prevent over-tensioning. 7

Complete, compact, and efficient Convenient access for all routine service V-belt tension indicator Filter inspection and change Oil level inspection and oil changes 8

Air intake The system s inlet and motor cooling air is drawn in from outside the sound enclosure from the cooler ambient surrounding. This not only improves motor and bearing cooling efficiency, but, for the same drive power, also achieves higher flow capacity volumes (Nm 3 ) and therefore lower specific power demand. Exhaust Air Cooling Air Low life-cycle costs Kaeser blower packages provide the optimum mix of low life-cycle features. Our unique combination of a complete scope of supply, simplified installation, energy efficiency, and ease of maintenance reduce your engineering, contracting, electric and service costs in a package that outlasts the competition. Maintenance Investment Energy Savings Electricity Smooth, quiet operation Our three-lobe blower designs minimize air pulsation in connected piping and our silencers are designed for the frequency of our blowers. Noise emissions and vibration are absorbed by our superior quality cabinet built with solid steel framing and panels, as well as heat-resistant sound insulation. Outdoor installation options With the addition of optional rainproof air inlets with bird protection screens, Com-paK Plus models are easily and inexpensively adapted to outdoor use. 9

HB Series Larger blower packages Our large flow HB packages feature many of the same advantages of our Com-paK Plus line with the exception of side-by-side installation. HB s come complete with motor, silencers, and basic instrument panel and are easily integrated with external Omega Frequency Control and master system controls. They can also be equipped for outdoor installation. Optional Omega Frequency Contol (indoor only) 10

Cabinet design As with CompaK Plus models, the HB package is fully enclosed in our powder coated and sound insulated steel cabinet. Cooling air for the motor and cabinet is pulled in separately from process air, and separate ventilation fans remove latent heat even when the main motor is off. Superior motors All Kaeser packages have premium efficiency TEFC motors. They are inverter ready for use with our Omega Frequency Control or other external frequency drive and feature PTC thermistors. Automatic belt tensioner Our automatic belt tensioner maintains efficiency with minimal adjustments. The Kaeser design prevents over-tensioning and prolongs belt, pulley, and bearing life. Unloaded Starting The optional unloaded-start valve reduces in-rush current and pneumatic shock on all Omega blower packages. Maintenance friendly Kaeser s package design makes routine maintenance easy. Access to service points for oil drains, filter inspection, and v-belt tensioning is very convenient through easily removable panels. Oil is changed through drain valves that are capped and gasketed to be leak free. 11

Blowers for special applications Kaeser offers a variety of blower designs for your special application Vacuum booster (WVC Series) Used in combination with a primary stage pump, the Omega WVC significantly increases pump suction capacity and vacuum performance. Optional frequency converters enable simultaneous activation of rotary vacuum and backing pumps at atmospheric pressure to significantly reduce pumping time and increase efficiency. Corrosion resistant construction Steam Blowers (B Series) Flows to 2900 lbs./hr. Kaeser s Omega B series blowers are specifically designed for compression of water vapor with vacuum operation in combination with water injection cooling. They feature Ni-Resist 3 casings, G-X8 CrNi stainless steel rotors, and Teflon shaft seals with stainless steel shaft sleeves. 12

Vacuum blowers (PV Series) Flows to 4300 cfm at 23.5 inches Hg For use in vacuum ranges up to 27 Hg vacuum. Kaeser s PV blowers have a unique design with pre-inlet injection cooling that is resistant to contamination in the air stream. Low pressure air is trapped between the rotors and the casing at the inlet of the blower (yellow). As the rotors turn toward the discharge (red), ambient air enters through the pre-inlet cooling ports (blue). This air provides the cooling needed for continuous process vacuums to 27 Hg in a single stage with no need for contacting seals or liquid injection. Drive shaft seal ring Gas tight blowers (N Series) Flows to 5350 cfm Pressures up to psig For nitrogen and other gas conveying applications, Kaeser s Omega N Series blower is available up to 5350 scfm. Our single-envelope design can be configured into special packages with an input shaft sliding-ring seal. 13

System Optimization The complete installation Give us your overall system requirements and let us design the optimal system that gives you the best combination of reliability, efficiency, and low life cycle costs. Omega blower sizing program Kaeser has developed PC based software to assist the engineer and end-user in optimizing blower selection to produce the most efficient process application possible. 14

Omega Frequency Control (OFC) Many applications benefit from variable speed drive. Kaeser s Omega Frequency Control (OFC) enables continuous speed adjustment to match the process flow to the demand. OFC offers enhanced control with a variety of signal inputs, outputs, and profibus connection. Available fully integrated on new units and for installed Omega blowers. Sigma Air Manager (SAM) SAM combines industrial PC and Internet technology to control up to 16 units. It minimizes energy consumption while insuring adequate flow. The controller alternates base and peak load blowers to balance service hours and improve reliability. Preprogrammed in 30 languages. Wall mounted. Kaeser Start Control (STC) This option provides reduced current starting (wye-delta) and enhanced instrumentation. Indicators include: power on, motor overload, oil level, dirty inlet filter, high discharge temperature and a general warning lamp. The IEC IP-54 enclosure is dust and splash tight. Wall or bracket mounted. Available fully integrated on new units and for installed Omega blowers. Air-cooled Aftercooler (ACA) For temperature sensitive applications, Kaeser offers two lines of air-cooled aftercoolers. The standard models provide outlet air temperatures within 10 F of ambient. Low energy models provide approach temperatures of 25 F. Features include TEFC/IP55 fan motor, process air temperature gauge, with a user-set maximum temperature switch. Wall or floor mounted.

State-of-the-Art Manufacturing Kaeser Omega blowers are manufactured in our extensive facility in Gera, Germany. State-of-the-art CNC lathes, milling machines, and grinding machines produce our high quality timing gears, proprietary rotors, housings, and other components to very precise tolerances. Continuous research and development keep Kaeser products at the forefront of technology and give our blowers a reputation for efficient operation, easy maintenance, and unparalleled reliability. Highly skilled technicians assemble each unit according to our ISO 9001/14001 procedures. The finished products must meet strict quality standards and pass through a rigorous inspection and testing program before shipment to our stocking centers around the world. Gera Plant Covering an area of almost acres, our blower plant in Gera, Germany produces Kaeser s wide range of rotary blowers. 16

Precision milling and grinding Omega rotor profiles and critical components are precision machined and then finished on a CNC grinder to an accuracy of 0.00005. Continuous quality control All Omega critical components such as rotors and casings are measured and verified using the latest in 3-D computer technology. Advanced machining centers State-of-the-art machining centers in climate controlled rooms produce the Omega blower components. Environmentally friendly powder coating system Sound attenuating enclosure panels are given their super-fine finish by a powder coating process where epoxy finish is baked on at 350 F. The corrosion and scratch resistant finish meets the highest quality standards. Meticulous blower assembly Highly trained specialists assemble each blower and complete packages according to our strict ISO 9001 standards. Comprehensive unit testing Every blower undergoes a run-test under maximum load conditions to verify mechanical integrity as well as a slip-test to verify performance. The test data is recorded in the machine documentation. Every package is shipped in set-up condition, oil-filled, and ready for operation. 17

The right blower for every application Performance Overview Model HB 1600 C HB 1300 C HB 950 C FB 791 C FB 621 C FB 441 C EB 421 C EB 291 C DB 236 C DB 166 C CB 131 C CB 111 C BB 89 C BB 69 C BB 52 C Max. Pressure (psig) 12 12 12 Flow Range (cfm) 60 120 175 230 300 350 400 500 600 800 1200 1800 2400 3500 3000 4700 4100 5300 6000 Maximum air delivery @ 4.35 psig in accordance to ISO 1217, Part 1, Annex C. 18

Wastewater treatment Positive-displacement, rotary-lobe blowers are used for aerobic digester aeration, anaerobic digester agitation, bio-gas recovery, filter backwashing, and chemical injection. Omega blowers efficiency superior package design and low noise levels make them the perfect supply for these systems. Process air Low pressure air and vacuum for a wide variety of process applications including paper converting, printing, vacuum hold-down, blow-off, product drying, product cooling, etc. By using a blower instead of a compressor for low pressure, high velocity process applications can reduce power requirements by more than 60%. Pneumatic conveying Rotary-lobe type blowers are perfect for conveying powder or granular bulk goods in pressure or vacuum transport systems. The Kaeser Omega Blower provides energy-efficient performance and reduces overall noise levels. Soil remediation and environmental applications Kaeser blowers are well suited for soil vapor extraction and other environmental remediation applications, both stationary and mobile. 19

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 Compressors, Inc. 511 Sigma Drive Fredericksburg, Virginia 22408 USA Phone: 540-898-5500 Toll Free: 800-777-7873 Email: info.usa@kaeser.com Kaeser Compressors Canada Inc. 3760 La Verendrye Street Boisbriand, QC J7H 1R5 CANADA Telephone: (450) 971-1414 Toll free: (800) 477-1416 info.canada@kaeser.com Kaeser Compresores de México S de RL de CV Calle 2 #123 Parque Industrial Juríca 76100 Querétaro, Qro. Telephone: 01 (442) 218 64 48 sales.mexico@kaeser.com Kaeser Compresores de Guatemala y Cia. Ltda. Calz. Atanasio Tzul 21-00, zona 12 El Cortijo II, Bodega 501 01012 Guatemala City Telephone: +502 2412-6000 info.guatemala@kaeser.com 2013 Kaeser Compressors, Inc. All rights reserved. 02/13 USOMEGABULTN www.kaeser.com