Salient Characteristics-Direct Drive Rotary Screw Compressor ASD-FSD Specification.pdf

ROTARY SCREW AIR COMPRESSORS ASD – FSD

OPTIONAL REFRIGERATED DRYER AND

OPTIONAL VARIABLE FREQUENCY DRIVE

KAESER MODELDSD175, 175 HP, 909 CFM-FAD AND 125 PSIG

SPECIFICATIONS

A. General Rotary Compressor Package

1. Air compressor shall be a single-stage, fluid-injected, air-cooled rotary screw compressor completely pre-piped and with pre-wired control panel. Compressor shall be Kaeser Compressors, Inc., model DSD 175 or pre-approved equivalent.

2. This product shall be manufactured in a plant whose quality management system is certified / registered as being in conformity with ISO 9001.

3. Compressor shall be tested as a completely assembled, piped and wired unit.

4. Maximum capacity shall be 909 acfm (per CAGI) at a discharge pressure of 125 psig. Compressor shall be capable of continuous full-flow operation 24 hr./day at rated capacity and pressure.

5. Motor voltage shall be 460 V, 3 phase, 60 Hz. Control system voltage shall be 115 V, 1 phase, 60 Hz, with a stabilized 24V DC power supply for the Sigma Control 2™ system.

6. Standard compressor package shall be suitable for use in a 40ºF to 115ºF ambient temperature range.

7. ASD-DSD 175: Compressor shall have optional integral refrigerated dryer with moisture separator and automatic condensate drains.

B. Airend

1. Compressor shall be fitted with an air inlet filter rated at 1 micron or better to provide maximum protection to the airend. Filter shall utilize a pre-separation process to collect larger particles before air enters the filter element.

2. Rotors - Airend rotors shall have a Sigma profile. Rotors shall be precision-machined from ductile cast iron. All cast parts were manufactured in a plant whose quality management system is certified / registered as being in conformity with ISO 9001.

3. Casing - Airend casing shall be cast iron construction.

4. Bearings - Airend rotors shall be supported on both ends by cylindrical roller bearings to carry radial loads. Angular contact ball bearings shall be installed on the discharge end of each rotor to carry thrust loads with minimal friction.

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C. Drive Motor

1. Motor

1.1. Motor shall have TEFC enclosure.

1.2. Motor winding shall be 100% copper (aluminum is not acceptable) and designed for reduced voltage wye-delta starting.

1.3. Motor service factor shall be a minimum of 1.2.

1.4. Motor nominal speed shall be 1800 rpm.

1.5. Motor insulation shall be Class “F” (Class “B” is not acceptable).

1.6. Motor must meet or exceed Energy Independence and Security Act (EISA 2007) standards for motor efficiency. Motor efficiency shall be 96.2 % or higher.

1.7. Motor pull-up torque shall be 150% or higher.

1.8. Drive motor grease fittings shall be mounted on motor exterior for ease of maintenance.

1.9. ASD-CSD: Drive motor shall be protected with a Pt100 thermistor for optimum temperature monitoring and advanced control.

1.10. DSD-FSD: Drive motor shall be protected with three Pt100 thermistors (one for each winding) for optimum temperature monitoring and advanced control.

2. Direct Drive

2.1. Compressor drive shall be 1:1 direct drive via torsionally elastic coupling for high efficiency and minimal maintenance

2.2. Compressor drive shall require no regular maintenance other than regular greasing of motor bearings.

2.3. Coupling shall be enclosed in a cast housing with alignment pins for proper alignment, and wide opening for easy access.

3. Optional Variable Frequency Drive

3.1. ASD SFC, BSD SFC, and CSD SFC units (excluding SFC 110M) – Motor shall have Synchronous Reluctance Motor design (SynRM).

3.2. CSD SFC 110M – Motor shall be Permanent Magnet Motor (PMM).

D. Control Cabinet

1. Control cabinet shall be designed to meet or exceed NEMA 12 standards.

2. Electrical components shall be UL and/or CSA listed and labeled as required.

3. Electrical schematic diagram shall be included in the service manual for reference.

4. Cabinet backplate shall be galvanized for improved grounding.

5. Starter(s) shall be integrally mounted and wired in the compressor package and located in the control cabinet. Starter(s) shall be magnetic, wye-delta, reduced voltage starter(s), to ensure low starting current and reduce thrust-bearing loads.

E. Standard Compressor Instrument Panel

1. Instrument panel shall consist of a Sigma Control 2™ system, or an approved equal. Control system shall be designed for temperatures ranging from – 4ºF to +140ºF.

2. The controller shall be an industrial PC with a centralized database. The unit shall include a stabilized 24V DC power supply and a real-time clock with a scheduling timer. A buffer battery with a lifetime of ten years shall be included for protection of system memory and internal clock. The unit shall be EMI (electromagnetic interference) protected to ensure proper functioning of the industrial PC in industrial conditions. The unit shall include additional digital and analog inputs and outputs for monitoring of standard and optional sensors.

3. Standard communications include: RFID for user access and security, Ethernet for remote monitoring with included Web Server, and an SD card reader slot to enable long term data logging and saving of system parameters.

4. Optional communications protocol includes: Profibus DP, EtherNet/IP, Modbus TCP, Modbus RTU, Devicenet, and Profinet.

5. A user interface shall be integral to the unit, and shall include ergonomic controls with LED indication of important functions, and a background illuminated, plain text and graphical display capable of displaying information in many languages.

6. The controller shall monitor critical compressor and control functions and shut the compressor down in the event of motor overload, high airend temperature, incorrect rotation, or loss of drive.

F. Compressor Control

1. Compressors shall have the option of Quadro, Vario, Dual, Mono (previously Continuous), and Dynamic control as standard. Switchable modulation control is an acceptable option. Compressors shall start and automatically load if system demands it. Compressors shall have adjustable time delay to shut down the compressors after running unloaded for a predetermined period of time to avoid excessive motor starting.

2. Compressor shall cut in at 95psig and cut out at 110 psig.

G. Compressor Enclosure

1. Compressor shall have steel frame assembly and be completely enclosed, including bottom. All models shall include hinged doors and/or removable access panels for easy access to the compressor for maintenance.

2. Enclosure shall be heavily sound insulated, and compressor shall have a maximum full load sound level of 75 dB(A) at 3 feet in accordance with ISO 2151 and ISO 9614-2. All sound dampening material shall be oil repelling and cleanable.

3. Compressor frame shall be isolated from the floor by rubber vibration pads. No special foundation shall be required.

4. Additional vibration proofing shall be provided for the airend, drive motor and separator tank to reduce stress on piping and electrical connections.

5. All access panels/doors shall have slotted key locks or handles, and shall be gasketed to minimize dust and dirt entering the enclosure. A door key shall be provided.

6. The air inlet to the compressor airend shall enter the package through a separate port and not through the fluid and/or air coolers to avoid preheating.

7. Cabinet panels shall have a “powder coat” type paint finish, which shall be durable and scratch-resistant.

8. Ambient cooling air shall enter the electrical cabinet of the enclosure after passing through a 40-micron filter mat.

H. Internal Piping

All major air and oil pipes shall be made of steel and feature flexible connections with o-ring seals to reduce the likelihood of cracks and leaks.

I. Lubrication/Cooling System

1. Compressor shall have a differential pressure fluid circulation system. Compressors requiring a pump and/or stop valve are not acceptable.

2. Compressor shall be factory filled with full synthetic or optional food grade lubricant.

3. Fluid filter shall be snap-in type capable of removing particles down to 10 microns or less and shall be thermally disposable.

4. Compressor fluid cooler shall utilize an Electronic Thermal Management (ETM) system to maintain optimum operating temperature. This is achieved by enhanced monitoring of the discharge temperature and a constant regulation of the fluid temperature.

5. Compressor shall have an ASME separator tank with integral fluid separator element and minimum of 232 psig working pressure. Separation system shall include three stages, mechanical separation and a two-stage deep-bed coalescing filter. Compressor package shall have a maximum fluid carryover of 1 - 3 ppm. Separator shall also include sump pressure gauge, fill plug, fluid level sight glass, and quick disconnects. A pressure drop visual indicator shall monitor separator cartridge life for improved efficiency and serviceability. ASME coded safety relief valve(s) shall be installed on fluid separator tank. Separator shall also be equipped with quick disconnect and fluid drain hose for pressurized fluid changes.

6. Fluid coolers and aftercoolers shall be easily accessible for ease of maintenance. Air-cooled aftercooler and fluid cooler shall be integrally mounted to the compressor enclosure. Ambient air shall be drawn into the package directly through the fluid and air aftercooler so cooling air flow is not pre-heated by the motor and airend. Aftercooler approach temperature shall be 16.2 °F or less.

7. Fluid cooler shall include drain plugs to facilitate complete fluid removal without costly flushing.

8. The aftercooler shall include an integral moisture separator with automatic condensate drain. The integral moisture separator shall be of stainless steel to prevent corrosion. The moisture separator and electronic demand condensate drain trap shall be mounted internal to the package as standard equipment. The drain trap shall be monitored by the Sigma Control 2™.

9. ASD-BSD: A single speed radial-type fan shall be used to provide intensive cooling, quiet operation and high static pressures to facilitate ducting of exhaust air for removal or heat recovery. Fan motor grease fittings shall be mounted on enclosure exterior for ease of maintenance.

10. CSD 90-175: A variable speed radial-type fan shall be used on the fluid and after-cooler to provide intensive cooling, quiet operation and high static pressures to facilitate ducting of exhaust air for removal or heat recovery. Fan motor grease fittings shall be mounted on enclosure exterior for ease of maintenance.

11. DSD-FSD: A variable speed radial type fan shall be used on the fluid-cooler in addition to a single speed radial type fan on the air-aftercooler to provide intensive cooling, quiet operation and high static pressures to facilitate ducting of exhaust air for removal or heat recovery. Fan motor grease fittings shall be mounted on enclosure exterior for ease of maintenance.

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J. Optional Integral Refrigerated Dryer: ASD-DSD 175 T

1. Dryer shall be fully integrated to the compressor package and be capable of producing a pressure dew point as low as 38°F.

2. Dryer fan motor shall be TEAO (Totally Enclosed Air Over) and rated IP44.

3. Dryer shall be rated for 232 psig maximum working pressure with a pressure drop not to exceed 1.5 psid.

4. Refrigerant type shall be R-513A or approved equivalent.

5. Moisture separators and electronic demand condensate drain traps shall be mounted internal to the package. The drain traps shall be monitored by the Sigma Control 2™.

6. Dryer option shall include aluminum heat exchangers for high efficiency and low pressure drop.

K. Optional Variable Frequency Drive (SFC 18-SFC 315)

1. SFC drive shall be AC variable frequency drive using Pulse Width Modulation technology, integrally mounted and wired in the compressor package.

2. SFC drive shall be Siemens “Sinamics” system or approved equal.

3. SFC drive shall have “soft start” starter system for unlimited motor starts.

4. Starter system shall be integrally mounted and wired in the SFC drive, and located in the drive enclosure.

5. Compressor drive shall utilize a Safe Torque Off (STO) safety feature that quickly stops the motor to ensure no torque generating energy can unintentionally start the motor. A contactor on the line side of the drive shall not be required.

6. SFC drive shall include line reactors for stable power supply.

7. SFC drive shall include RFI filters within the control module.

8. SFC drive shall utilize shielded motor and control signal cables and shall be protected from Electro Magnetic Interference for durability in industrial environments.

9. SFC drive shall have programmable and selectable auto re-start after loss of power.

10. SFC drive shall be direct drive via torsional elastic coupling for high efficiency and reduced maintenance.

11. SFC drive shall require no regular maintenance other than greasing of motor bearings.

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L. Testing and Inspection

1. These parts must be inspected in a plant whose quality management system is certified / registered as being in conformity with ISO 9001.

2. Each compressor shall be run and tested for leaks, pressure, temperature, rotation, and full load amp draw.

M. Standard Limited Warranty

Compressor package shall be warranted to be free of defects in material and workmanship for a minimum period of 18 months from date of shipment or 12 months from date of start-up whichever occurs first. Compressor airend assembly, drive motor, magnetic motor contactor(s), and Sigma Control 2™ shall be warranted to be free of defects in material and workmanship for a minimum period of 30 months from date of shipment or 24 months from date of start-up whichever occurs first. There shall be no restrictions based on the purchase of special lubricants or maintenance kits.

N. Optional Five-Year Limited Warranty*

In addition to the standard limited warranty, the compressor airend assembly, drive motor, and Sigma Control 2™ unit shall be warranted to be free of defects in material and workmanship for a minimum period of 66 months from the date of shipment or 60 months from the date of start-up whichever occurs first. The following restrictions shall apply:

• Warranty shall apply to standard rotary screw compressors only.

• Warranty shall apply to compressor packages with a full load operating pressure of less than 145 psig.

• Customer shall return a completed warranty card at compressor startup.

• Customer shall use genuine Kaeser S-460 or FG-460 full synthetic lubricant only.

• Customer shall purchase one annual maintenance kit at time of purchase.

• Customer shall purchase one kit per year for the life of the warranty.

• Any additional maintenance or repair parts purchased during warranty period shall be genuine Kaeser parts only.

• Initial fluid change shall be after first 3,000 hours or one year whichever occurs first.

• Fluid shall be changed annually after initial change, regardless of hours.

*Limited availability, equivalent programs exist in all markets. Consult the local Kaeser representative for details.

O. Startup Service

Startup service shall be provided by factory-trained technicians at no charge to ensure equipment is running properly and adjusted to factory specifications. Maintenance instructions shall be discussed with customer to ensure they understand routine maintenance procedures. The maintenance training shall be conducted at the time of equipment startup.©

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