Presentation on theme: "Sigma Rotary Screw Compressors"— Presentation transcript:
1 Sigma Rotary Screw Compressors New SX SeriesSigma Rotary Screw CompressorsKaeser Compressors would like to take this opportunity to introduce you to the re-designed SX series rotary screw compressor line.For years customers have depended on Kaeser for reliable equipment and complete compressed air solutions.The newly designed SX series rotary screw compressors are the next generation to carry on this tradition.Let’s take a look “under the hood” and see what makes this exciting new design tick.SX SeriesSX AirCenter™ SeriesSX T Series
2 Introducing the New SX Series Industry-leading compressor technology in a compact rotary screw compressor packageDesigned with the small shop owner in mindManufactured with rigorous quality control standards to provide years of reliable service
3 Kaeser’s Design Goals Complete unit re-design Easy access to maintenance components from one sideHigh reliability and efficiencySimple control systemEnhanced standard featuresModern lookCompetitive pricingOur research and development team continues to produce industry-leading compressor technology to meet virtually any compressed air need.Manufactured in a rigorous quality control program, our products are made to provide years of reliable service in the widest range of applications.When planning to redesign the SX series compressors, our design goals were clear.We wanted to completely re-design the unit from the inside out to incorporate the same modern design features as the slightly larger SM models.Keeping the service technician in mind, we also wanted to make performing maintenance tasks a bit more “user friendly”. Easier access to the serviceable components was the key to this design hurdle.Our hallmark has always been to produce the most cfm with the least amount of energy. The new SX incorporates a newly designed, smaller, yet highly efficient airend doesn’t disappoint in this area.The control system is a much more modern looking control than control panel on the earlier style SX compressors and offers more functional features as well.This unit incorporates the standard features of our larger units as well as some that are new and specific to the SX series models.All of this re-designing and we are still very competitive in the market place with this compressor. As with our larger units, features that come standard on our compressors are frequently add-on features that drive the cost of our competitors machines higher than their list price.Let’s look at the specific details…
4 SX PackagesAll SX series packages arrive complete and ready to supply air:Set package in placeConnect air dischargeConnect electrical supplySX series – Simple, complete rotary screw compressor packagesThe new SX series packages, like all our other compressors, arrive as a complete package ready to provide air.Simply:Set the package in placeConnect the air discharge line to the air systemConnect the electrical supplyand you’re ready to go.The new SX series – Simple, complete rotary screw compressor packages.
5 SX T PackagesSX T series contains an integrated refrigerated air dryer:Compressor and refrigerated air dryer in one packageDryer perfectly matched to flow capacity of compressorInternal connection between compressor and dryerSX T series – Convenient, space- saving rotary screw compressor packagesThe T series adds an integrated refrigerated dryer to the package.By doing this::We provide a compressor and refrigerated air dryer in the same packageThe dryer is matched to the compressors flow capacity for optimum performanceThe connection between the compressor and the dryer is internal to the package.All this adds up to a convenient, space-saving rotary screw compressor package.
6 SX Packages SX AirCenter™ – With an integrated air receiver: Complete air system in one packagePerfectly matched main componentsSX AirCenter™ – Energy efficient, compact, all-in-one compressed air systemKaeser’s SX Series AirCenter systems offer a single integrated package that includes the compressor, dryer, and air receiver all in one energy efficient, space-saving package.AirCenter packages:Are a complete air system all in one package.Are available with or without a refrigerated air dryer.Have components that are perfectly matched to provide optimum energy efficiency, ease of maintenance, and unrivalled durability.
7 Approach Temperature (°F) SpecificationsSX SeriesSX T SeriesSX AirCenter™ SeriesModelMotor (hp)Capacity at psig (cfm)Sound Level dB(A)Approach Temperature (°F)SX 33126210.8SX4415.96314.4SX 5521.26418SX 7.57.528.366Each of these new models is available with and integral refrigerated dryer which is denoted with the T after the model number. As the footnote in the lower right corner points out, the frame on these units is slightly larger to incorporate the dryer components.An AirCenter version is also available with each model. This is the compressor (and dryer if a T model) mounted on top of a receiver tank. The AirCenter models will ship from our manufacturing facility in Coburg already configured and ready to be installed in the customer’s location.The horse power rating of each machine is repeated in the model number.So the SX 5 is rated at 5 hp. This holds true for the T and AirCenter models as well.The capacities listed for each model are based on the compressor operating at 125 psig.Each model is designed to have the lowest sound emissions possible as shown in the chart.The aftercooler of each model is designed to remove the maximum amount of moisture possible from the discharge air stream by providing low approach temperatures.
8 Product Positioning Crossover units AS SK SM New SX * At 125 psig 20 / 25 / 30 hp92 to 124 cfm*Optional dryerSKSK 2015 / 20 hp64 to 78 cfm*Optional dryer and SFCSMSM 157.5 / 10 / 15 hp28 to 53 cfm*Optional dryer and SFCProduct positioning is important to us as well so that we can provide multiple solutions to better fit the customers’ needs.This graph of the various belt drive compressors shows there is and overlap between the largest horse power rating of the smaller unit and the lowest horse power rating of the next larger size unit.In the case of the SX and SM units, the largest SX unit is the SX 7.5 while the smallest SM unit is the SM The horse power rating on these compressors is identical and in this case the cfm delivery of both is very close.In the larger units, the cfm delivery is dramatically different for the same horse power ratings. Again, the crossover points allow us to better fit the needs of the customer.For example, the customers’ demand might be close to the upper limit of a smaller unit and they have no plans for future growth. The smaller machine will fit their needs nicely. Since they purchase the smaller unit:They won’t have the costs associated with producing more cfm than they needThey won’t have the higher purchase cost of the larger unitThey won’t have the increased maintenance cost of a larger unit of the same horse power.So, the smaller unit provides a better solution for that customer than the larger unit would in this case.New SXSX 7.53 / 4 / 5 / 7.5 hp12 to 28.3 cfm*Optional dryerCrossover units* At 125 psig
9 Standard Kaeser Features Sigma Control™ BasicSimple, reliable interfaceConvenient pressure control and system monitoringDisplays pressure, temperature, load and service hoursThese compressors come standard with the Sigma Control™ Basic. A simple yet reliable interface that offers convenient pressure control and system monitoring with status displays and service indicators. The display includes discharge pressure and temperature, load and service hours as well as fault indicators.As with all of our larger compressors, these units feature EPAct compliant TEFC drive motors. These highly efficient, totally enclosed, fan cooled motors come standard with class F insulation for long life in harsh environments.These units can be connected to 208, 230, or 460 VAC 3 phase, 60 Hz power supplies. This allows the unit to be placed in virtually any industrial shop and run off the existing power source.Along with the tri-voltage feature, these units incorporate the wye-delta reduced voltage starting mode to ensure low starting current and smooth acceleration. (SX 3 is direct-online start)The full enclosure is what makes the low sound levels possible. The enclosure also keeps dirt out of the unit.Another hallmark of a Kaeser compressor is the ability to drain the separator tank under pressure. This feature is on our largest units all the way down to these small work horses. By pressurizing the sump during oil changes, maintenance time is reduced, therefore helping to lower maintenance costs.The 4 micron inlet filter keeps large particles out of the inlet air stream in an overall effort to reduce contamination of the discharge air stream.A huge change to these units is the maintenance-free elastic belt. These belts don’t require any maintenance during the life of the belt. Once the belt is on, the only maintenance is to change it at the prescribed maintenance interval.
10 Standard Kaeser Features Drive Motor and StarterHighly efficient EPAct compliant drive motor208/230/460 tri-voltage* motor (single phase optional on 5 hp and 7.5 hp models) allows connection to any standard US voltage supplyWye-Delta start* ensures low starting current and smooth acceleration (SX 3 models feature direct on-line start)As with all of our larger compressors, these units feature EPAct compliant TEFC drive motors. These highly efficient, totally enclosed, fan cooled motors come standard with class F insulation for long life in harsh environments.These units can be connected to 208, 230, or 460 VAC 3 phase, 60 Hz power supplies. This allows the unit to be placed in virtually any industrial shop and run off the existing power source.Along with the tri-voltage feature, these units incorporate the wye-delta reduced voltage starting mode to ensure low starting current and smooth acceleration. (SX 3 and SX 3T models are direct-online start)* Optional with some competitors
11 Standard Kaeser Features Complete low-sound enclosure*Effectively reduces noise levels to as low as 62 dB(A)Keeps dust and dirt from entering cabinetPowder-coat finish* is durable and resists scratches better than spray painted finishesAs with all of our larger compressors, these units feature EPAct compliant TEFC drive motors. These highly efficient, totally enclosed, fan cooled motors come standard with class F insulation for long life in harsh environments.These units can be connected to 208, 230, or 460 VAC 3 phase, 60 Hz power supplies. This allows the unit to be placed in virtually any industrial shop and run off the existing power source.Along with the tri-voltage feature, these units incorporate the wye-delta reduced voltage starting mode to ensure low starting current and smooth acceleration. (SX 3 and SX 3T models are direct-online start)* Optional with some competitors
12 Standard Kaeser Features Pressurized fluid drain*Allows sump to be pressurized for faster fluid drainingSupplied maintenance hose quickly connects and routes pressurized fluid to collection containerThese compressors come standard with the Sigma Control™ Basic. A simple yet reliable interface that offers convenient pressure control and system monitoring with status displays and service indicators. The display includes discharge pressure and temperature, load and service hours as well as fault indicators.As with all of our larger compressors, these units feature EPAct compliant TEFC drive motors. These highly efficient, totally enclosed, fan cooled motors come standard with class F insulation for long life in harsh environments.These units can be connected to 208, 230, or 460 VAC 3 phase, 60 Hz power supplies. This allows the unit to be placed in virtually any industrial shop and run off the existing power source.Along with the tri-voltage feature, these units incorporate the wye-delta reduced voltage starting mode to ensure low starting current and smooth acceleration. (SX 3 is direct-online start)The full enclosure is what makes the low sound levels possible. The enclosure also keeps dirt out of the unit.Another hallmark of a Kaeser compressor is the ability to drain the separator tank under pressure. This feature is on our largest units all the way down to these small work horses. By pressurizing the sump during oil changes, maintenance time is reduced, therefore helping to lower maintenance costs.The 4 micron inlet filter keeps large particles out of the inlet air stream in an overall effort to reduce contamination of the discharge air stream.A huge change to these units is the maintenance-free elastic belt. These belts don’t require any maintenance during the life of the belt. Once the belt is on, the only maintenance is to change it at the prescribed maintenance interval.* Optional with some competitors
13 External Features Combination cooler (with filter mat) Compressor air intakeFluid level observation windowFeatures on the exterior of the compressor include the following:An observation window that allows the user to check the fluid level without opening the service panel.A separate air inlet for the control panel provides the coolest air possible for the electrical components of the compressor without having to go through the interior cabinet where the motor and airend are located. A pre-filter mat is also provided at the inlet to keep dust and dirt out of the control cabinet.The drive motor also has a separate cooling air inlet that includes a sound dampening suction channel that reduces overall noise levels of the unit.The intake for the compressor is located above the motor cooling air inlet so the coolest air possible enters the inlet valve without passing over the motor first.The combination oil cooler/aftercooler is fitted with a 40 (micron), cleanable filter mat to help protect the cooler fins from heavy dirt and debris. No tools are required to remove the filter mat when it is time to clean it.Motor/cabinet cooling air intakeControl panel cooling air intake (with filter mat)
14 Compressed air discharge External FeaturesCompressed air dischargeFrontBackThe cooling air for the entire cabinet is forced up and exits through the top of the removable access panel. Ducting this air enables heat recovery for significant energy savings.A flip-up panel protects a card that contains required maintenance intervals on one side and a drawing of the service parts required to perform each maintenance on the reverse side.The compressed air discharge is located on the rear of the cabinet as shown in the illustration.Flip-up panelCooling air discharge
15 Internal Features Inlet filter cartridge (located inside housing) Long-life fluid filterNew spin-on fluid separator cartridgeNew Sigma 05 airendThermostatic valve (installed in valve block)Maintenance-free elastic beltInternal features of the SX include:The ‘honeycomb shaped” inlet air filter cartridge is like the one used on SM, SK, and AS models. This filter keeps contaminants 4 (micron) and larger from entering the airend.The newly designed Sigma 05 airend is the smallest airend we produce. This airend has been designed to have higher suction capabilities and compress more air for less horsepower than previous designs for this size compressor.-The v-belts used in these compressors are maintenance-free belts. Once the belt is put on the machine and properly adjusted, it is set until it is time to change the belt. There is no re-tensioning required.All units are filled with Kaeser premium fluid to cool, clean, and lubricate the airend. A thermostatically controlled combination valve ensures perfect fluid temperature regulation that incorporates a cooler by-pass and 10 micron, long life fluid filter.We combine an over-sized, ASME certified, cyclone separator vessel with a convenient spin-on coalescing filter for superior fluid separation and exceptionally low oil carry-over (3 ppm or less) which results in less maintenance and better downstream air quality.The fluid filter is a 10 (micron) fluid filter that helps extend fluid life and protect the airend.
16 Internal Features Additional sound barriers Cooling air discharge 2Cooling air discharge12. Cabinet interior foam3. Cooling air in-take3The heavy-duty metal enclosure isn’t only one element of the new design that keeps the noise levels low.There are three additional sound barriers on the inside of the cabinet that help reduce sound levels to as low as 62 dB(A), more than 10 dB(A) quieter than comparable units.The first of the 3 interior sound barriers is the sound attenuating foam layer that is just below the cooing air discharge. This layer of foam extends below the top of the cabinet but creates an air passage for the cooling air to escape.The second sound barrier is the sound attenuating foam that covers virtually the entire interior surface of the cabinet walls.The last of the additional barriers is the inlet air duct that directs cooling air to the motor. This completely surrounds the non-drive end of the motor where the cooling fan is attached to help deaden the sound from the fan motor.
17 Internal Features New cooling fan design Cast as a single piece to ensure:Perfect balanceLow vibrationQuiet operationThe new fan design is a Kaeser engineering breakthrough.Cast as a single piece, the mounting hole is perfectly centered on every fan produced. By doing it this way instead of drilling, the fan is perfectly balanced.Even if the center mounting hole is only slightly off center it can cause the fan to vibrate as it rotates. Kaeser’s newly designed fan lends itself to far less vibration.The angle of the fan blades creates less resistance as the fan rotates. This increases the amount of airflow into the cabinet with a lower power requirement than conventional motor fans.The crescent shape of the fan blades also helps to further reduce noise levels form the compressor in conjunction with the 3 additional sound barriers mentioned previously.
18 Internal Features New cooling fan design Cast as a single piece to ensure:Perfect balanceLow vibrationQuiet operationMounted on non drive end of motor for optimal cooling effectThe fan is mounted on the non-drive end of the motor to optimize the cooling effect. By mounting the fan in this location, the entire surface of the fan is utilized to draw in more cooling air.The fan is directly facing the cooling air intake and no part of if is blocked by the drive motor which makes it much more efficient that traditional applications.
19 Cabinet cooling air intake Motor cooling air intake Internal FeaturesCabinet cooling air intakeNew cooling fan designCast as a single piece to ensure:Perfect balanceLow vibrationQuiet operationMounted on non drive end of the motor for optimal cooling effectThe inner and outer ring of fan blades are purposely facing in opposite directions. Doing this creates a separate intake path for the drive motor and a separate intake path for cabinet cooling air as shown by the arrows.Dual-flow fan isolates multiple cooling air intake paths with a single fanMotor cooling air intake
20 Internal Features New cooling fan design Housed in foam-covered air guiding ring to channel air precisely where it is neededTo ensure cooling air goes where it is needed most, the fan is housed in a foam-covered guiding ring. The guiding ring is a solid piece that sits directly behind the motor air intake and is attached to the motor to house the fan.As mentioned earlier, the foam covering also helps reduce noise levels.
21 Internal Features New cooling fan design Housed in foam-covered air guiding ring to channel air precisely where neededFlex-coupling reduces stress, vibration, and noiseA flex-coupling reduces stress and helps further reduce noise and vibration.
22 Four-Zone Cooling Air Flow Kaeser’s four-zone cooling air flow design:Eliminates pre-heatingIncreases cooling efficiency without increasing power consumptionPromotes longer lubricant and motor lifeThere are significant benefits associated with the four-zone cooling approach.Cooling air is not pre-heated by having to come in contact with warm components before performing the cooling function.The combination of the cool fan and four-zone cooling increases the cooling efficiency of the compressor without increasing power consumption.Cooling the lubricating oil increases the life of not only the lubricant but the motor and airend as well.All of these features make the SX compressor a force to be reckoned with in the 3 – 7.5 hp range.
23 Four-Zone Cooling Air Flow Zone 1 - Cool ambient air is drawn in through the coolersMaximizes aftercooler moisture removal capabilityEfficiently removes heat of compression from lubricantAs with all other Kaeser model compressors, the goal is to have the coolest fresh air possible in all areas or zones to cool the internal components.Zone 1 is where the coolest, fresh ambient air possible is drawn through the coolers. Efficiency of the compressor is increased by drawing the air directly from the ambient surroundings and not across components that are already hot.Cool air is the key to moisture removal in the compressed air stream. 75% to 80% of the moisture in the compressed air is removed at the aftercooler. If the air is warm, less moisture is condensed out of the air stream.The same holds true for the lubricant cooler. The lubricant is the “life blood” of the compressor and is used to remove the heat of compression from the airend. The coolest air possible aids in proper heat transfer and removal. Cooler temperatures promote longer lubricant, motor, and airend life.
24 Four-Zone Cooling Air Flow Zone 2 - Cool ambient air is drawn in through the motor/cabinet cool air intake located on the exterior of the cabinetFan draws air through center ring of blades to provide cool air directly to the motorCool air is drawn through outer ring of fan blades to direct cooling air into cabinetIn zone 2, cool ambient air is drawn into the motor intake by the fan and is distributed to the motor via the center ring of blades and the cabinet via the outer ring of blades on the fan.
25 Four-Zone Cooling Air Flow Zone 3 – Warm air heated by components is forced upwardCirculating air does not come into contact with incoming cool airAs the air circulates through the cabinet, it rises by way of both natural convection and being forced by the cooling fan. This warm air does not come into contact with the incoming cool air because of the foam covered guiding ring and the action of the cooling fan forcing the air into the cabinet.
26 Four-Zone Cooling Air Flow Zone 4 – Warm air is exhausted through a single opening in the top of the cabinetDucted exhaust air can be recovered for further energy savingsThe cooling air for the entire package (including the control cabinet) is exhausted through a single port at the top of the cabinet. This design promotes ducting which enables heat recovery for significant energy savings.
27 Maintenance FeaturesObservation window to monitor critical fluid levels without stopping compressorCoolers can be cleaned from the outsideSingle panel access for all filter and fluid changes (as well as full access to motor, airend, drive, fan, and valves)Filter mat removal without tools for faster cleaning/replacementSeparator tank quick-disconnect fitting and maintenance hose for pressurized oil changeSpin-on fluid filter and separator cartridge for quick changesThis slide hi-lites the key maintenance features of this unit. We have discussed these in previous slides. However, this shows the key features in one slide for greater emphasis.
28 SX T ModelAn integrated, non-cycling, refrigerated air dryer is perfectly matched to the compressor air flow and features:38°F pressure dew pointCFC-free, R134a refrigerantNon fouling, stainless steel heat exchangerInternal compressor-to dryer connection eliminates moisture separator at aftercoolerThe “T” models incorporate all of the standard features previously discussed plus the features listed here.The integrated dryer feature is offered as an option for the customer with limited floor space in their shop but still have the need for dry air. The “T” model fits this requirement nicely in a sleek, compact package.The dryer is controlled through the Sigma Control™ Basic and requires no additional electrical hook up.The dryer package includes a stainless steel separator and stainless steel plate type heat exchangers.It is safe to operate the package in ambient temperatures as high as 115°F (although it is highly recommended ambient temperatures do not exceed 100°F).The dryer will produce a 38°F pressure dew point at rated conditions using CFC-free, environmentally friendly R-134a refrigerant.
29 SX T Model FeaturesSingle-point electrical connection – No separate connection required for dryerSuitable for ambient temperatures up to 115°FEco-Drain – Efficient, electronic demand drainRemovable observation window – Easy access to Eco-Drain test buttonWhen moisture is condensed from the compressed air system by the dryer package, a reliable, no-loss Eco-Drain is used to drain the water away.The Eco-Drain is controlled by reliable capacitance sensors. Robust aluminum housings and patented pilot air-controlled valve technology ensure many years of reliable service even when subjected to harsh condensate.To allow for easy access to the test button, a pop-out sight glass is installed.For the customer that wants a higher level of control and programmability, an optional Sigma Control™ is available.
30 Removable observation window SX AirCenter™ Model FeaturesFully integrated, all-in-one air system with perfectly matched main components features:Uniform, integrated appearance52.8 gallon, internally powder-coated air receiverOptional air treatment package (with Eco-Drain and oil removal filter)Removable observation window – Easy access to Eco-Drain test buttonRemovable observation windowKaeser’s SX series AirCenter systems offer more space-saving compressed air production, treatment, and storage. This truly is a turnkey compressed air system.The three main components, the compressor, optional refrigerated dryer, and receiver tank are housed in a package that is uniform and integrated in appearance and are perfectly matched to provide optimum energy efficiency, ease of maintenance, and unrivaled durability.The 58.2 gallon receiver tank is ASME certified and includes a safety relief valve, pressure gauge, and manual drain and is internally powder-coated.The AirCenter is controlled from the Sigma Control™ Basic.
31 Warranty and Parts Guarantees 2-year warranty on airend, motor, and Sigma Control™ Basic24-hour emergency parts shipping guarantee for the first 5 yearsOptional 5-year warranty availableThe SX series features the same warranty as our other compressors:2 year warranty on the airend, motor and Sigma Control™ Basic for defects in materials or workmanship.The 24 hour emergency parts shipping guarantee for the first 5 years.The optional 5 year warranty is also available.