BSD/CSD/CSDX T SFC Series - f.electronic

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