Kaeser Omega Blowers and Blower Packages

Kaeser Omega Blowers and Blower Packages
Although Kaeser manufactures many different products, this presentation is focused on our Omega Blower products.

Presentation Objectives
Introduction to Kaeser How blowers work and where they are used Blower features, benefits, and special purpose designs Blower package features and benefits System design, containerized systems and Kaeser Air Utility Accessories Quality control, performance benefits, and commercial features The goals of this presentation are to introduce you to Kaeser, discuss the features and benefits of our blowers and packages, and to provide an overview of our supporting services.

About Kaeser We have more than 92 years of manufacturing experience
We are 4,000 employees and growing We are a global company with representation in 89 countries Air systems are all we do We offer a complete line of air products Our products are manufactured in the U.S., Germany, and France Kaeser Compressors has been in business since Kaeser was first a precision machine shop that manufactured automotive parts such as cylinders and gears. After the second world war, Kaeser began manufacturing reciprocating compressors. In the mid-sixties, when rotary-screw compressors first appeared on the market, most compressor manufacturers either purchased air-ends or licensed the technology from SRM. Mr. Kaeser chose to design his own rotary-screw compressor profile (known as the Sigma profile). This is the innovation that made Kaeser one of the largest compressor manufacturers in the world. Our designs have significant advantages in terms of efficiency and service life. We employ more than 4,000 people, have representation in over 58 countries and we offer air products from 29.9” Hg to 650 PSIG.

Kaeser Manufacturing Sites
Fredericksburg, VA Coburg, Germany Gera, Germany Sonnefeld, Germany Pictured are some of our manufacturing facilities. The top image is our facility in the US. The Coburg facility manufactures reciprocating and rotary-screw compressors, The Gera facility manufactures blowers and Secotec compressed air dryers, and the Sonnefeld facility is our sheet metal fabricating plant.

Kaeser Standards of Excellence
ISO 9001 Certified - Continuous process improvement ISO Certified - Commitment to environmental protection At Kaeser Compressors, we take great pride in the quality of our products and services. We are certified as an ISO company both 9001 (which ensures we have systems in place for continuous process improvement) and (which ensures we have systems in place to deal with our waste products –everything from used compressor oil to waste paper). This level of certification requires us to ensure our distributors and representatives handle their waste products in an environmentally friendly manner and we are responsible for advising our end-customers. Kaeser is also a CE certified manufacturer. What is CE? You may be familiar with Underwriters’ Laboratories. UL certifies electrical component manufacturers. Electrical components that pass UL review are allowed to be labeled with a UL seal. CE is a similar program except that it applies to all manufactured products. For example, if you wanted to build a “cake mix packaging plant” and you want to make sure you receive good value on your investment, you would specify that the plant must be CE certified. This means that every component in the facility must be manufactured by a CE certified manufacturer and each component must have a CE label or a CE “Declaration of Incorporation.” CE Certified - Declarations of Incorporation are available

What is a Blower? High volume Low pressure (typically 2:1)
Positive-displacement Oil-free Internally gas cooled Blowers are high volume machines that operate at low pressures. They are different from compressors because there is no “over-compression.” For example, in a rotary-screw compressor, there is a large inlet port, a volume reduction between the rotors, a small outlet port, a discharge check valve, an air/oil separator, and a minimum pressure check valve. All of the components serve to ensure no air is released form the package until it is compressed to at least 60 PSIG. The difference between the system Total Dynamic Head and the compressor discharge pressure is wasted energy. Blowers, on the other hand, simply transfer air from one side of the casing to the other. Blowers are positive-displacement. When the blower is connected to a system, energy is used to overcome the friction losses in the system. Because there is no “over-compression”, blowers are more efficient than compressors in low pressure applications. Also, unlike centrifugal blowers, a positive-displacement blower produces a constant volume even if the system Total Dynamic Head changes. Another reason engineers specify positive-displacement blowers is because of the simple design. There is no coolant injection (blowers are oil-free) and no external cooling is required – they are cooled by the gasses passing through them.

Blower operating principle
What is a Blower? Our blowers are a dry-type design, so there can be no metal-to-metal contact. There are clearances between the rotors, cylinder, and end-plates. The clearances are like a fixed orifice that allows a percentage of the process gas to recirculate. This gas friction causes the blower temperature to increase. The flow of process gas out of the blower carries away this heat and prevents overheating. As the pressure head is increased, the percentage of process gas that is recirculated also increases so the blower speed must be increased to provide more cooling. If the pressure is increased to a higher value, the speed must again be increased. As you can see from this example, there is a limit to how fast is makes sense to turn a blower. This limit is a 2:1 compression ratio, about 15 pounds of pressure or 15 inches of mercury. Blower operating principle

Tri-Lobe Versus Two-Lobe
120° design Greatly reduced pulsation levels Quieter operation Reduced rotor deflection The state-of-the-art in rotary lobe blower technology is the tri-lobe design. Two-lobe blowers have low frequencies that can cause standing waves (or, resonance) in piping systems. Tri-lobe blowers operate at higher frequencies. A two-lobe blower has two impellers and each impeller has two sides. This means four discharge pulses per revolution. A tri-lobe blower has two impellers and each impeller has three sides. This means six discharge pulses per revolution and results in a frequency higher than the resonant frequency of the piping. [Using the images on the slide, indicate the difference between the two-lobe 180° design and the three-lobe 120° design]. Bi-directional rotation In smaller displacement models, 180° design is more resistant to contamination

Tri-lobe relief channel
Tri-Lobe Versus Two-Lobe Six pockets of air per revolution Relief channel allows internal and discharge pressure to equalize The impellers in a tri-lobe blower are closed to the inlet and outlet ports for a longer period of time so the discharge port is clearanced to minimize the difference between the internal pressure and the discharge pressure. Reducing pulsation and noise by 95% allows the use of smaller, more efficient silencers. Finally, because of the triangular shape, tri-lobe impellers are more resistant to deflection due to pressure surges in the system. 95% pulsation cancellation inside the blower Tri-lobe relief channel

Tri-Lobe Versus Two-Lobe
This slide indicates the difference in pulsations between a 2-lobe and a tri-lobe blower. Notice how the tri-lobe has significantly less pulsations. This is due to the equalization chamber in the tri-lobe that gradually opens the pocket of air to the discharge port. The difference in pressure between the inlet pocket of air and the system pressure is reduced which reduces the pulsations. With a two-lobe blower the pocket of air is opened 100% instantaneously. The difference in pressure results in a back flow of pressurized air in the discharge piping into the delivered pocket of air causing pulsations and the loud popping sound that is typical of a two-lobe blower. 1 Revolution Tri-lobe design and equalization channel efficiently reduce pulsations and noise

Applications Pneumatic conveying
The #1 application for blowers is pneumatic conveying where a blower imparts velocity to the air and material is fed into the piping system. The material is entrained in the air stream and carried to the delivery point. [Draw a head vs. capacity curve for the customer to illustrate the example] If the blower is a centrifugal blower, the system pressure increases when material builds-up in the piping system and the flow from the centrifugal blower decreases. When there is not enough air velocity to keep the material entrained, the system clogs. All of the energy from the driver is converted to heat and no work is accomplished. The system is down until the blockage is located and the system is manually cleaned. When a positive-displacement blower is used, the flow remains constant and air velocity is maintained or, enough pressure energy is developed to blow the clog out of the system. Pneumatic conveying systems with positive-displacement blowers are self-cleaning.

Applications Municipal and Industrial water and wastewater treatment
The second biggest market for blowers is water treatment. In potable water plants blowers are used to backwash filters, scour membranes, oxygenate water, and convey chemicals into the treatment process. In wastewater treatment plants blowers are used to: oxygenate the bacteria that consume the organic waste agitate liquids and sludge keep solids from settling-out in the holding areas backwash filters scrub membranes collect biogas In a diffused aeration wastewater treatment plant, approximately 70% of the electrical energy consumed is used to power blowers.

Applications Blow-off, product drying
Blowers efficiently deliver high velocity air to dislodge particulates or liquid droplets. How many times have you seen production personnel using an air hose to blow-off cuttings? That open-ended hose consumes the capacity of a 50 Hp compressor. If a blower were used instead of a compressor, the energy would be at least 50% less. If I were to pour table salt or even water on this table – could you move it by blowing on it? How much pressure do you think lungs can generate? The answer is less than two pounds. If you can do the job with only two pounds, then a blower capable of 15 pounds could also do the job. Why would you need a compressor capable of 100 pounds? It is the air mass and velocity (the kinetic energy) that does the work in this example, not the pressure (or potential energy).

Applications Environmental remediation
New environmental remediation processes depend heavily on blowers. In the past, if a site was contaminated by a volatile liquid (like gasoline) the only option to clean the site was to install multiple wells around the contamination plume to depress the ground water and then physically remove the contaminated soil. This process is very expensive and completely destroys the site. The soil removed must be treated or taken to a landfill. However, if air is injected into the soil through the well casings, the contaminant is volatilized more rapidly and, as a added benefit, the air injection oxygenates naturally occurring bacteria that may consume the contaminant. Blowers can also be used to pull a vacuum on the well casing and physically remove the contaminants. If the groundwater is contaminated, pumps are used to remove the contaminated groundwater and the contaminated water is treated in tanks which are dosed with the appropriate bacteria and aerated using blowers. These are just a few of the remediation processes that depend on blowers.

Applications Landfill gas extraction
Decomposition in landfills results in the release of methane, a greenhouse gas. Blowers are used to collect the methane and prevent release to the atmosphere. The methane can be used as fuel to fire boilers, heaters, or engine/generators.

Applications Agricultural spraying
Blowers driven by the tractor PTO (power take off) atomize liquids to apply pesticides, herbicide, and fertilizers. When electrostatic nozzles are used, the volume of liquids required for treatment is greatly reduced resulting in lower operating cost and less damage to the environment.

Applications Power generation using waste steam
Where producers have excess steam or need to reduce steam pressure, steam can be directed through the blowers. The blowers are used to drive generators.

Applications Thousands of process applications: Vacuum hold-down
Fish farming Industrial vacuum cleaning Mixing or metering gases Wash and rinse tank agitation Product heating For salespeople, one of the easiest ways to increase penetration into existing accounts (and avoid competition) is to look at their customers’ processes with an eye toward making them more efficient. Compressors are used to create pressure (potential energy) and blowers are used to create velocity (kinetic energy). Devices such as pneumatic cylinders, air motors, and actuators require potential energy. Process applications such as blow-off, drying, heating, or cooling require high velocity. Any time you see an open-ended point of use or a regulator in a compressed air system, it is probable that a blower can do the job more efficiently. Look at your customer’s processes and apply the most appropriate technology. Evaporation, vapor compression Product cooling Processes which require air at high velocity And many more…

Blower Design and Construction
24 models for air service 2.5” through 8” gear diameters Tri-lobe and two-lobe designs Pressures to 15 psig and vacuums to 15” Hg Flows to 5,500 icfm Package sizes to 335 hp Port sizes from 2 to 12 inches The standard Kaeser Omega blower product line covers the majority of the industrial market. We offer 6 two-lobe sizes and 18 tri-lobe sizes. These blowers have gear sizes up to 8” diameter. We can supply blowers and packages for flows up to 5,500 CFM, up to 15 pounds of pressure, or up to 15 inches of mercury. We build packages with motors as large as 335 horsepower.

Horizontal or vertical blower arrangement Drilled and tapped holes on all sides for versatile mounting Inlet and outlet connections are DIN flange Adapters are available for the inlet and outlet ports: NPT (4” and below) ANSI flange (6” and above) The Omega blower is a very flexible design. All of our blowers can be arranged for horizontal or vertical flow. Instead of feet only on the bottom the blower, we have drilled and tapped flats on all four sides of the casing which allows mounting from the top, either side, or the bottom as necessary for your system design. Another great feature is the fact that we use flange adapters on our standard blowers. This means that you can use the same blower regardless of your piping standard.

Large shafts to reduce deflection One-piece ductile iron rotor assemblies Now, let’s talk about the “nuts and bolts” of the Omega design. Our competitors have some of these features, none of our competitors have all of these features. The Omega design is one of the newest available and takes advantage of modern manufacturing techniques. [Draw an impeller cross section to show the difference in shaft size] Most of our competitors cast or extrude the center-section of the impeller and then insert a shaft. This means that the shaft must be smaller than the waist (or, narrowest point) of the impeller. This limits the strength of the impeller. Kaeser manufactures one-piece impellers. This means that our shafts can be as large as they need to be to prevent deflection under load. Many of our competitors have open impellers. This is where foreign material builds-up inside the rotor and causes unbalance. The resulting vibration will cause wear and early failure. Omega impellers are “closed” so there is no unbalancing. Solid or closed-end rotors standard

Advantages of the Kaeser rotor design: Tri-lobe design with large shaft diameters prevent rotor deflection due to high differential pressures The first critical speed is 4 times the recommended maximum speed The maximum bearing speed is twice the recommended maximum speed The clearances between the rotating elements and the stationary elements in a blower are very small. A small amount of shaft deflection can lead to catastrophic failure. Tri-lobe design, one-piece rotors are more rigid than two-lobe designs and help to prevent rotor deflection. The “critical speed” is the angular velocity which excites the natural frequency of a rotor. As the rotational speed approaches the object's natural frequency, the object begins to vibrate. Our conservative design prevents this problem.

Advantages of the Kaeser rotor design: Rotors are balanced to ISO 1940/1 G 2.5 (grade for turbines and turbo compressors) Our rotors are balanced to a standard normally reserved for high speed turbines to eliminate vibration and wear. For example, the difference in weight of the lobes on our largest rotor is less than 1 gram.

Splash lubrication (both ends) Not all blowers have oil lubrication but all “process quality” blowers have oil lubrication. Easy to read oil sight glasses (factory filled with lubricant)

Advantages of oil over grease lubricated bearings: Reduces friction Provides for cooling of the bearings Flushes contaminants out of bearing races When oil is changed, contaminants are flushed from blower sump Easily checked for proper oil level Allows for visual inspection of lubricant condition Verbally Summarize: Oil lubricated blowers always last longer than grease lubricated blowers.

SKF Explorertm, caged, full compliment cylindrical roller bearings for long L10 life “Full compliment” bearings have as many rollers as will fit in the race. With the maximum number of rollers, the load carrying capacity of the bearing is maximized. A bearing “cage” is used to maintain the separation of the rollers in the bearing race stabilizing the tangential position of the rollers reducing friction and wear. This normally results in fewer rollers than a “full compliment” bearing. SKF Explorer series bearings utilized by Kaeser offer the load carrying capacities of a “full compliment” bearing with the benefits of “caged” bearings.

Bearing part number: 3213 double-row ball bearing (same diameter)
Blower Design and Construction Bearing life example: Gear-side bearings on 6” gear blowers with similar displacement operating at 14.5 psid/1.0 bar - the same radial load of 1, lbf/5.6 kN 22,000 hrs. 2,000 rpm 240,000 hrs. 15,000 hrs. 3,000 rpm 160,000 hrs. Kaeser: Bearing part number: NUP 213 SKF Explorer cylindrical roller bearing Cdyn = 122 kN Brand A: Bearing part number: double-row ball bearing (same diameter) Cdyn= 78 kN (-26%) In this example, you can see the difference bearing selection can make in the case of 2 otherwise identical blowers. Please note that the variable in this equation is the dynamic load rating (Cdyn) which is provided by the bearing manufacturer. L10 = (C / P)10/3 × (B / n) × a

VitonTM lip seal with hardened shaft sleeve, polished and coated with tungsten carbide Precision, spur type, hardened timing gears Kaeser is able to provide our customers the benefit of roller bearing construction because of our gear design which eliminates axial loading. In our process, the gear blanks are hardened before machining for better accuracy. The final machining process is precision grinding to obtain a finish 10 times better than machining alone. This technology means Omega blower gears have less wear, are quieter, and there is better control over the impeller timing. Where the impeller shaft extends through the oil chamber cover on the drive-end of the blower, we use a Viton lip seal. Unlike many of our competitors, the sealing area is protected by a polished and plated shaft sleeve for longer life and so that the seals can be restored to new condition. Seal renewal can be accomplished without removing the front cover. Proprietary equalization channel on tri-lobe blowers

Optional Input shaft seal: Kaeser design sliding ring type seal Stator: carbon, rotor: DIN material code , 16MnCrS5, AISI 5117), Elastomers: Viton™ Positive seal to contain gases and prevent air ingress Can handle higher temperatures Allows for field repair Stationary ring Sliding ring spring loaded Sealing area Drive pin For the input shaft of the blower we offer an optional sliding ring seal. This is a high quality seal manufactured by Kaeser which will prevent gas and oil from escaping the blower. In normal air service, these seals are maintenance free. Kaeser has used this type of seal on our compressors for decades and has had excellent results.

Heavy-duty cast iron housing with integral headplate All other blower manufacturers have headplates which are separate from the cylinder. During the assembly of our competitors’ blowers, the headplates are manually located on the cylinder using feeler gauges so that the impellers are parallel to the cylinder bore. In our design the headplates are integral to the cylinder so that the CNC machining of the cylinder bore and the bearing holders ensures perfect impeller alignment. Our design does not depend on production line workers with feeler gauges. Because our design takes full advantage of CNC machining capabilities, we are able to reduce tolerances resulting in a more efficient blower. Piston ring labyrinth air and oil seals with vented cavity

Labyrinth seals: Gas side seals Four hardened-steel piston rings Provides reliable, long-life sealing Seals both the gas and oil chambers Kaeser uses 2 piston-ring type labyrinth seals to control the air-side leakage and 2 more to contain the oil on each end of each rotor (16 seals). The hardened piston rings expand against a casing wear ring in the headplate and are stationary. The shaft sleeve has grooves to accept the piston rings and the sleeve turns with the shaft. This low-wear design is very rugged and lasts a long time. Because we include replaceable wear surfaces, the assembly is fully repairable. The venting protects the blower from failure if the seals fail. Consider a rotor shaft seal that is not vented. If the seal fails, the pressure from the air chamber leaks out of the breather on the oil chamber. As the air passes through the oil chamber, it picks up the splashing oil and carries it out. In other words, if a rotor shaft seal fails on a non-vented blower, it will lead to bearing and gear failure due to a lack of lubrication. In our design, the leakage is vented out of the blower without losing oil. Oil side seals Rotor seal vents

Optional Gas Tight Sealing
Optional rotor seal vent piping: Rotor seal vents are recirculated to suction Gas is contained No possibility of air ingress even in the case of a labyrinth seal failure Filter with transparent bowl indicates seal condition Another advantage of our vented seal design is that the gas leakage from the blower can be controlled. For example, conveying systems which move product that will oxidize are flooded with nitrogen (which is expensive to produce). With the Omega blower design, the nitrogen that leaks past the seals can be recirculated back to the suction of the blower to prevent loss and minimize operating cost. To do this we simply connect a pipe the vents back into the intake of the blower (the low pressure side of the blower ).

Optional teflon cap ring seal: Teflon™ packing (between the working chamber and drain). Teflon™ lip seal (between the drain and oil chamber) Stator: carbon, rotor: DIN material code , 16MnCrS5, AISI 5117, Elastomers: Viton™ Improved corrosion resistance Can handle high differential pressures The optional Teflon Cap Ring rotor shaft seal design is available for applications with high inlet pressure or in applications where chemicals in the gas may corrode the iron piston ring type rotor shaft seals.

Optional casing and rotor materials: Stainless steel rotors: DIN , G-X8 CrNi 13, AISI 414 Stainless iron cylinders: Ni-Resist 3, DIN , GGL-NiCr 30 3, AISI A436 Optional materials offer improved corrosion resistance Kaeser offers special materials of construction for the rotors and casings.

Omega Special Blower Designs
PV series pre-inlet cooled blower: Dry-type exhauster design Vacuum to 27” Hg with a single-stage Available in the Omega and 8 series In vacuum applications, the inlet pressure is below atmospheric and the discharge pressure is atmospheric. The internal pressure is somewhere in between. In a pre-inlet cooled blower, there are additional ports between the inlet and outlet ports on the cylinder to allow atmospheric air to be inducted into the blower. This additional air cools the blower when the inlet vacuum is as low as 27 inches of mercury.

PV series pre-inlet cooled blower: For use on: Sweeper trucks Vacuum trucks Central vacuum systems Systems too dirty for lubricated machines Requires no water for sealing or cooling In an oil-flooded vane type vacuum pump, make-up oil is required. In a liquid ring pump, make-up water is required. In both cases, contaminants in the incoming gas stream will mix with and contaminate the sealing liquids which could lead to pump failure. Depending on the contaminants, the discharged liquids may be classified as hazardous waste. In contacting designs, the contaminates in the gas stream may cause excessive wear. Unlike other vacuum pumps which can operate continuously at this vacuum level, the Omega PV series pre-inlet cooled blower does not have any wear strips and does not require any water or oil injection.

WVC vacuum boosting blowers: For use as the pre-pump in a high vacuum system Improves system pump-down time Improves end vacuum Sealing oil/Cooling oil reservoir Closed rotors Our close coupled, magnetic drive blowers are used a super chargers for high vacuum systems. Sub-summarize blower features and benefits Flange-mounted motor Magnetic coupling

Omega Com-paK Plus™ Many blower manufacturers only offer the air end and depend on the customer, distributor, or fabricator to build the blower package. Imagine trying to buy a car in this environment. You would go to one vendor for the engine, another for the chassis, another for the coach, another for the radio, and so on. It would be impossible to get any one of the component manufacturers to accept engineering or warranty responsibility for the end-product. Kaeser is a Blower Package Manufacturer. We have offered complete packages since the inception of the product line. We designed the assembly, specified components that work together as a unit, manufactured the package on our production lines, and we accept system and warranty liability for the end-product. When you specify Kaeser, you get a complete product offering.

DB 236 C integrated package
Omega Com-paK Plus™ All inclusive, factory- manufactured packages Pre-assembled for easy installation Low friction loss for high wire-to-air efficiency Very price competitive Our newest packaged blower design is the innovative Com-paK Plus. This is the next generation in packaged blowers. In the past, compressor manufacturers focused on the compressor sale. The customers would purchase the aftercooler, moisture separator, motor, and controls from other vendors and build their own package. When rotary-screw compressors became popular, the market changed. Rotary-screw compressor packages were too difficult for the customers to fabricate so the compressor manufacturers “re-trained” their customers to purchase packages instead of bare compressors. The blower industry is only now going through a “rotary-screw” phase and most manufacturers are not interested in offering packages. The result is that there are some poorly designed packages installed with very little instrumentation or control. DB 236 C DB 236 C integrated package

Omega Com-paK Plus™ Inverter-rated, EISA compliant motor with PTC thermistors Absorptive inlet silencer with integral filter Easily removable belt guard Omega plus tri-lobe blower The Kaeser Com-paK Plus package includes many features other companies only offer as accessories and ship loose Combination discharge silencer/base Integral base with fork lift/ pallet jack access

Omega Com-paK Plus™ Ducted belt guard for better seal cooling
Our exclusive ducted belt guard directs air pushed by the motor fan across the input shaft seal of the blower. The fasteners for the guard are fully retained so they cannot be lost. Retained belt guard fasteners

Omega Com-paK Plus™ Motor lubrication point
Inlet silencer with replaceable absorptive media The lubrication fittings for the motor are conveniently located at the front of the package. The sound absorbing media in the inlet silencer can be replaced. Discharge silencer with domed head

Automatic V-Belt Tensioner
Visual indication of tension Easy maintenance Maintains tension Maintains efficiency Infrequent adjustments Prevents over-tensioning Prolongs component life All of our packages utilize this automatic belt tensioning device. This tensioner can be adjusted and indicates the proper tension. Because we use a belt guard, the belt tension can be adjusted while the package is in operation. Some other systems rely only on the weight of the motor and cannot be fine-tuned for the motor/drive combination.

Omega Com-paK Plus™ Inlet silencer adaptable for pressure or piped inlet Pressure relief valve protects blower Piped exhaust prevents recirculation of hot air and protects operator Unloaded start valve (optional) The inlet silencer is designed to minimize losses while attenuating blower pulsation noise. The mechanical relief valve is mounted so the customer is not dependent on others to determine where it should be installed or how it should be oriented. A flexible connector and vibration isolators limit transmission of noise and vibration. Vibration isolators Flexible connector

Com-paK Plus™ with integrated AFR and vent silencer
Omega Com-paK Plus™ When accessories are purchased with our Com-paK Plus package, they are incorporated. As you can see in this image, the unloaded start/pressure regulating valve is mounted, piped, and silenced. Fabricators often ship accessories loose for field mounting and the responsibility for correct orientation and location become the responsibility of the installer. Com-paK Plus™ with integrated AFR and vent silencer

Omega Com-paK Plus™ Low-cost polyester inlet filter is easily replaced
The inlet silencer incorporates a filter element to reduce friction losses and maximize the wire-to-air efficiency. The element is high efficiency (EN779 class G4, 99% at 5.0 microns) and low cost. The sight glasses on the blower oil sump are designed to allow the oil level to be checked by looking into the top of the package. The oil drains from each blower oil sump is piped to the front of the package for maintenance access. The oil chambers are kept separate so that differences in oil chamber pressure will not cause the oil to flow from one oil chamber to the other. On the larger packages, the oil fill ports are extended to the top of the belt guard to allow filling without disassembly. Oil drain valves with caps Oil chambers are separate 3D oil sight glasses

Omega Com-paK Plus™ Sound enclosure: Factory assembled Sheet steel
Powder-coated finish 20 dB(A) noise reduction Optional stainless-steel cover for outdoor installation The standard Com-paK Plus includes the sound attenuating enclosure. This is a 6-sided enclosure and the sub-base is designed to retain the full volume of oil from the blower oil chambers. The sub-base makes the assembly easier to handle and closes the bottom of the package for noise attenuation even when the package is mounted on grating or rack-mounted.

Omega Com-paK Plus™ Kaeser enclosures attenuate all blower noise sources: Blower discharge pulsations In-rush air noises Blower mechanical noises Gears Bearings Motor mechanical noises Cooling fan Enclosure cooling fans Relief valve Blowers are noisy. Our blower and accessories such as the enclosure and silencers are designed to work together to provide unmatched sound attenuation.

Omega Com-paK Plus™ Sound enclosure vent fan:
Factory installed enclosure vent fan sized to provide optimal flow at all drive speeds Provides constant flow during variable speed operation Operates independent of drive motor Can operate after blower is shut down to remove latent heat from motor windings Another consumer benefit is that Kaeser sound enclosures are power ventilated. Some other designs utilize fans mounted on the blower drive shaft. Blower packagers use different v-belt drives to operate the blowers at many different speeds so the fan speeds (and flows) vary. Positive displacement blowers are often used with variable frequency drives. When the frequency is less than 100%, the blower and motor get hotter. With a shaft-driven fan, the least ventilation occurs when the most cooling is needed. Ventilating the package after shut-down extends the life of the motor, lubricants, belts, and seals.

Oil chamber ventilating louvers (8K reduction)
Omega Com-paK Plus™ Special inlet louver smoothes cooling air flow to motor The sophisticated Kaeser enclosure design directs the cooling air to the areas that need external cooling the most. The ventilating air inlet louver directs the air over the motor without mixing with the warm air in the enclosure. Special louvers on the side of the cabinet flow air across the blower oil chambers. Oil chamber ventilating louvers (8K reduction)

Omega Com-paK Plus™ Omega Com-paK Plus™
Standard instrumentation and protection: Inlet filter differential gauge (45 mbar/0.65 psid) Discharge pressure gauge Discharge temperature gauge Discharge temperature switch Instrument cover to protect gauges Motor PTC thermistors Mechanical relief valve Mounted and piped instrumentation includes 3 gauges, discharge air temperature switch, motor winding thermistors, and a relief valve.

Omega Com-paK Plus™ Omega Com-paK Plus™ Optional instrument package:
Inlet filter differential pressure switch Discharge pressure switch Enclosure safety switch Oil temperature sensors Oil level sensors Terminal strip in electrical enclosure All instruments are mounted and wired to electrical enclosure Even though a temperature switch and motor PTC thermistors are included, installers sometimes do not know that these devices need to be connected and it is better if the internal wiring is already completed before delivery. With the “instrument package option” the fan , Motor PTC, and the temperature switch wiring are already connected to a terminal box on the front of the package. All other instruments purchased with the package are also mounted and wired.

Omega Com-paK Plus™ Optional integrated design with Omega Control Basic™: Highest level of protection for the blower and the operator Includes superior blower protection Remote start / stop Remote monitoring via dry contacts Optional blower speed monitoring Control panel is CE, UL, and EMV compliant The latest development in packaged blowers is our Integrated package with Omega Control Basic™. With these packages you get everything needed to start, control, and monitor the blower. The Omega Control is included to compliment our STC and OFC control panels and is specifically designed for our blower packages. The innovative design of our complete package is combined with our proven Omega Control Basic to provide the highest level of protection and safety available in any blower package.

Omega Com-paK Plus™ Optional integrated design with Omega Control Basic™: Omega Control Basic™ calculates differential temperature and pressure Available with: OFC variable frequency drive STC wye-delta reduced current starting Available for both pressure and vacuum packages Protects unit from system casualties and poor maintenance The controller monitors the: Inlet and discharge pressure Inlet and discharge temperature Differential pressure Differential temperature Maintenance timer advises when preventive maintenance is needed

Omega Com-paK Plus™ Optional integrated design with Omega Control Basic™: High safety, compliant with international electrical standards Ready to operate requires only connection to the piping and power supply Self-protecting; suitable for remote installations One vendor for sourcing One vendor for integration One vendor for after sales service Factory assembled Factory tested Ready to operate Self-protecting Single source responsibility Sub-summarize Com-paK Plus features and benefits. Discuss 3 levels of protection: Standard Package, Instrument Package, and Integrated Package.

Omega Com-paK Plus™ All maintenance is performed from the front of the package: 1 Pressure and temperature checks 2 1 2 Filter replacement The first design goal was to make the package easy to install. The sub-base and the incorporation of components normally line-mounted (the relief valve, instrumentation, and discharge check valve) accomplish this goal. The second design goal was to make the package easy to maintain. For this reason, all of the maintenance points are on the front of the package. 3 Belt tension and replacement 3 4 4 Oil checks and changes

Omega Com-paK Plus™ All utility connections are in the rear of the package: 1 Utility connections Process air inlet and outlet 2 2 5 4 3 Relief valve exhaust All of the utility and process connections are on the back of the package. 3 Control cubical cooling vents 4 1 2 5 Enclosure cooling vents 1

Omega Com-paK Plus™ Package installation: One next to the other
Reduced floor space Easy to install Saves on construction costs Full maintenance access The most unique feature of the Com-paK Plus design is that the packages can be placed side-by-side with only a few inches of clearance and very close to the wall. All other blower packages require several feet of access on all four sides for cooling and maintenance. A Com-paK Plus installation consumes much less valuable floor space. It is common to see specifications for waste water treatment plant expansions with text that reads: “Build a new blower room, install the new blowers and then rebuild the existing blowers”. With the Com-paK Plus design, it is less expensive for the plant to throw-away their existing blower packages and replace them with twice as many Com-paK Plus blower packages. Besides saving a tremendous amount of time and money (because they do not need to build a new blower building), they also receive the benefits of all new equipment that is more efficient, less noisy, and easier to maintain.

Omega Com-paK Plus™ Go from this… …to this!
Com-paK Plus packages require half the area of other designs and because the accessories such as relief valves, instrumentation, and check valves are incorporated in the package, the piping requires much less fitting.

Omega Com-paK Plus™ Lowest noise levels* in the industry
All components engineered to work together Tri-lobe technology Custom design silencers Advanced enclosure with effective sound-proofing Optional silencer for vacuum pump exhaust shown The combination of features results in one of the quietest blower packages available. Blower silencers are designed to attenuate blower pulsation noise. For vacuum blowers exhausting into a work area, we offer a silencer designed to attenuate the outlet air noise. * Free field conditions at 1 meter from equipment, installed values may differ.

Omega Com-paK Plus™ Quick-Ship series:
Kaeser stocks a full range of packaged blowers from 5 to 150 hp Most orders can be shipped within one working day Speed changes can be completed quickly Unlike other blower manufacturers and package fabricators, Kaeser maintains a large inventory of blowers, blower parts, and blower packages.

Omega Com-paK Plus™ Com-paK Plus™ series is currently available from 2 to 250 hp Packages are available from 75 to 335 hp We try to keep the Quick Ship series packages in stock but we build to order as well.

Omega Packages for High Flow
High flows up to 5,500 icfm NEMA or IEC frame motors Low and medium voltage motors Optional enclosure with separate process air and cooling air circuits Polyester inlet / in-line filter Spool piece with check valve Flanged expansion joint, shipped loose

Kaeser System Design Services
Kaeser designs complete systems with air system controllers, variable frequency drive and dual control Air Manager Room Exhaust Fan Common Header Intake Louvers Kaeser systems feature adaptive control for best efficiency Line Regulator

Kaeser Containerized Solutions
Systems are custom-built to meet customer specifications: Reduces the project construction and installation time Reduces project cost The image of the container (top, right) is actually a link. Click on the link and then the image can be rotated, shaded, etc.

Kaeser Air Utility We can supply a system and then invoice the user for the volume used: We own and maintain the equipment We guarantee “up time” It is not necessary to own the asset and be responsible for the maintenance and operation. Kaeser will install the air system, retain ownership, and be responsible for the operation and maintenance. The customer only pays for the air they use.

Accessories - Control Panels
Kaeser Start Control - STC Kaeser also offers a broad range of accessories such as control panels, variable frequency drives, after coolers, desiccant dryers, vacuum regulators, enclosure heaters, explosion proof motor enclosures, and so on. When we supply the accessories, they become part of our scope of supply and we accept system responsibility for our entire scope of supply. For example, when we provide a variable frequency drive for a blower package, it is mounted in a complete control panel and includes the transducer as well as programming.

On / off switch Kaeser Start Control - STC Kaeser control When the STC panel is purchased, there is provision for the instruments purchased with the blower package including the ventilating fan starter and the motor PTC trigger. Emergency stop button Hour meter

Kaeser Start Control - STC Motor Fan Liquid level Temperature The panel includes the Kaeser Control for all of the instruments purchased with the package. Pressure General warning Dirty filter Refer to manual

Omega Frequency Control – OFC 3 kW – 250 kW Variable frequency drive panels for pedistal mounting or wall mounting are also available.

Omega Frequency Control – OFC – 3 kW – 250 kW Programming panel with display The control panel includes a remote and emergency stop button. Emergency stop button

Omega Frequency Control – OFC 3 kW – 250 kW: 380V-480V, 3ph, 50-60Hz EMV filter class B (37 kW and up) IP 54 protection RS 485 interface with USS protocol Emergency stop switch Off button with galvanic separation

Omega Frequency Control – OFC 3 kW – 250 kW: Programming unit Control enclosure fan PID controller for external – 20 mA signal Remote on / off Alarm messaging Optional Profibus interface The Kaeser OFC is complete and contains all of the components needed for a safe, effective variable frequency control panel . It is not just a VFD module.

Sigma Air Manager™ The SAM is an adaptive control designed to automatically manage air and vacuum systems.

Sigma Air Manager Basic™
Accessories - Control Panels Reasons to use a master controller: Adaptive control of multiple blower packages Reduce energy costs Provide a reliable system Match blower output to system demand Control system pressure Balance blower package operating hours Sigma Air Manager Basic™

Sigma Air Manager Complete Air System Management
Omega Control Basic™ packages Non-Omega controlled blowers Overall air system control and monitoring Can receive input from process system controller

Accessories – Unloaded Start Valves
When to use unloaded start valves: Blower packages in parallel Reduced current starting Sparging systems Purposes: Accelerate drive motor to full-speed before loading Reduce in-rush current Prevent motor overloading Reduce pneumatic shock to system at startup An unloaded start valve is used anytime a unit will be started against a charged piping system. In sparging, for example, the water in the pipe will increase the pressure in the pipe since it takes some time to clear the pipe of water and get the system operating properly. The unloaded start valve at rest is normally-open. When the blower starts the valve is open to atmosphere and the pressure does not build as all of the air escapes to ambient. As the blower comes up to speed the unloaded start valve slowly closes and seals off the vent port to force the air into the pipe and open the discharge check valve. Using this valve allows the motor to accelerate to the design speed before it sees the full load and prevents over pressurizing the system and airend during start-up.

2 Main pipe Adjusting screw Orifice Diaphragm chamber Valve seat Valve disc Exhaust port 4 3 6 7 Adjustment of the valve will change the amount of time before the valve closes. Screwing in the adjustment decreases closing time and screwing it out increases closing time. The valve comes in the fully open or longest closing time. 5 1

The normally open valve is mounted on a piping tee When the blower is started, the pressure acts on the diaphragm and modulates the valve closed When the blower is shut down the valve cone is open. When the blower is started air will pass the valve disk and discharge to ambient pressure allowing for unloaded start. As the blower comes up to speed air will flow through the orifice in the valve stem and fill the chamber above the diaphragm. As pressure gradually builds, valve will modulate closed. Adjustment of the valve will change the amount of time before the valve closes. Screwing in the adjustment decreases closing time and screwing it out increases closing time. The valve comes in the fully open or longest closing time. Air from blower package

Air from blower package

Available models: AFE - standard unloaded start valve AFEM - unloaded start valve with solenoid valve to unload the system on demand AFR - unloaded start valve with pressure regulating function to maintain steady system pressure AFVM - unloaded start valve with vacuum regulating function to maintain steady system vacuum There are unloaded start valves for vacuum systems and unloaded start valves that also function as pressure or vacuum regulators. Unloaded start valves fitted with solenoid valves can be used to unload the blower by venting the control air to open the valve on demand. Auto/Dual Control (load/unload as well as start/stop) allows much better capacity control and minimizes the number of starts per hour on the drive motor. Sub-summarize: Accessories

Quality Control Kaeser manufactures all major components
All critical components (rotors and housings) are dimensionally checked prior to assembly Set-up clearances are checked and documented Kaeser is not an assembly plant for third-party machining. We manufacture all of the components used to build the blower. Our quality system insures that all components meet our quality standards. When building blowers, it is necessary to set the rotor end clearances and the impeller timing. The difference in our process is that we document the blower set-up.

Quality Control Bare blowers are run-tested for 30 minutes at full pressure and full speed All blowers are tested and conform to ISO 1217 Part 1, Annex C The mechanical run-test, slip-test, and clearance data are retained electronically All packages are mechanically tested prior to shipment 100% of the blowers we manufacture are run-tested to prove the mechanical integrity. To prove the performance of our blowers they are leak tested. When the blowers are used to build blower packages, the finished package is also tested.

Performance Benefits Energy efficient design means less bhp per cfm and lower power costs! Kaeser Omega Competitors Up to 20% more efficient! Life Cycle Cost Our precision machining and attention to detail mean closer tolerances and reduced leakage. Our innovative package design minimizes the air friction losses. The benefit is energy efficiency. Omega blowers are up to 20% more efficient than our competitors’ rotary-lobe designs. Time

Performance Benefits Low noise levels!
Omega blower are less noisy than our competitors’ designs. This is because of our tri-lobe technology with unique impeller, port and cylinder profiles, our quality components, and heavy-duty construction. The components used to manufacture our packages are designed specifically for the frequencies of our blowers. Noise levels are, ± 3 dB(A) in accordance with ISO 2151 in free-field conditions

Performance Benefits Lower noise levels Lower operating costs
Lower maintenance costs Longer life Lowest cost of ownership Lowest life-cycle cost Omega blowers are designed to be efficient, easy to maintain and to last a long time. All of this adds up to the lowest life cycle cost.

Commercial Advantages
24-month blower warranty 5-year warranty on blowers purchased as part of a Com-paK Plus™ package! Emergency replacement blower guaranteed available in one working day for 5 years. 2010 2009 2011 We back-up our products with the best customer support in the industry. We offer a 24-month warranty on our blowers. If the blower is purchased as a part of the Com-paK Plus package, the blower warranty is 5-years. In emergency situations, we also guarantee that we will make the blower or blower parts available for shipment in one working day or you do not have to pay for the material.

Dense network of qualified service technicians
Commercial Advantages Global network of stocking subsidiaries and distributors to provide after sales service Dense network of qualified service technicians No matter where you ship our equipment, there will be someone there to provide the customer service you deserve.

Commercial Advantages
System solutions Competitive prices Unsurpassed customer service and satisfaction Kaeser offers system solutions, customer satisfaction, and unsurpassed customer service.

Compressors and Vacuum Products
Rotary screw compressors Vacuum screws Booster compressors Mobilair portable compressors We also sell other air system products. This presentation covered our blower products but, we offer a full range of compressed air and vacuum products.

Air Treatment Equipment and Accessories
Filters Breathing air systems Dryers Sequencers Drain traps Flow controllers Condensate management

THE END! TAKE YOUR BOW!

Kaeser Omega Blowers and Blower Packages

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Kaeser Omega Blowers and Blower Packages

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