Booster Compressors The rotary screw market is our bread and butter but we do manufacture a line of piston compressors to meet a demand in that market also.

Why Use a Booster Compressor? Supplies high pressure applications from low pressure air system Avoid purchasing and installing separate high pressure system Point of use application Alternatives can be expensive and wasteful Pipeline Testing Why use a booster compressor when most industrial processes require between 90 and 125 psig? Some processes such as plastics molding, printing, turbine testing, and leak testing require much higher pressures. It is more efficient to take a portion of the existing plant air supply and install a booster compressor specifically sized to meet the pressure and flow requirements of the special process. The alternatives are to install a stand-alone, high pressure compressor or operate the entire plant at a higher pressure which is very costly and wasteful. It is much more sensible to go with the first option which is to install a stand-alone, high pressure compressor to meet the high pressure demands of the the single process. PET Bottle Production

Booster Compressor Location Main Air System (80 – 217 psig) High Pressure System (up to 650 psig) Compressor Separator with drain Tank with drain Filter with drain Booster compressor High pressure tank High pressure dryer High pressure filter The best bet is to install a booster compressor to meet the demand of the high pressure application. Looking at the illustration we see that the main plant air supplies air tools and processes requiring low pressure air between 80 and 100 psig and the high pressure system is installed after that. There is a pre-filter (KPF particulate) before the booster, the booster compressor, a separate receiver tank to store the high pressure air, a high pressure refrigerated dryer, and an after filter (probably a KOR oil removal filter.)

N-Series Boosters Model FAD in cfm Motor Power N 60-G, N153-G 10 to 49 This beverage company operates world wide, normally with only oil free compressors for their PET bottle production. Recently, Kaeser convinced them to install a Kaeser air system with oil flooded rotary screw compressors, Kaeser booster compressors, and air treatment equipment. They are extremely happy with the way the system is performing and plan to expand the compressor stations with even more of our compressors. This is a picture of the installation in . Model FAD in cfm Motor Power N 60-G, N153-G 10 to 49 3 to 5 hp N 253-G – N502-G 37 to 195 10 to 25 hp N 2001-G 724 50 hp

N-Series Booster Compressor Features Heavy gauge baseplate Alright, lets take a look at the features that are on every model booster compressor. Later on we will look at features specific to certain models. The heavy gauge baseplate is constructed of heavy gauge steel to provide the most stable mounting surface for all the components of the compressor.

N-Series Booster Compressor Features Heavy gauge baseplate Anti-vibration pads The anti-vibration pads are mounted underneath the baseplate. They serve 3 functions: They absorb vibration from the compressor and contribute heavily to the low noise factor associated with the compressor. Reduce vibration stress on the compressor components which extends the service life of the compressor. Eliminates the need for a separate mounting foundation for the compressor.

N-Series Booster Compressor Features Heavy gauge baseplate Anti-vibration pads TEFC motor The TEFC motors used on the booster compressors have the same features as the motors used on rotary screw compressors. We will not go over them again here. Note: Features and associated benefits are listed on the Features and Benefits List.

N-Series Booster Compressor Features Heavy gauge baseplate Anti-vibration pads TEFC motor Aluminum cylinder heads Aluminum cylinder heads help increase the service life of the compressor by offering improved heat transfer to help remove the heat of compression. Aluminum has better heat transfer capabilities than steel.

High pressure discharge hose N-Series Booster Compressor Features Heavy gauge baseplate Anti-vibration pads TEFC motor Aluminum cylinder heads High pressure discharge hose with check valve High pressure discharge hose The high pressure discharge connection allows for simple connection to the system with a supplied flexible hose. This eliminates the need for fitting rigid pipe and the associated material and labor costs of brazing etc. (if not using Kaeser SmartPipe™). The check valve (included) allows high pressure compressed air to flow in only one direction which prevents back-flow into the compressor from the system.

N-Series Booster Compressor Features Heavy gauge baseplate Anti-vibration pads TEFC motor Aluminum cylinder heads High pressure discharge hose with check valve Inlet filter with drain trap The inlet filter removes contaminates from the incoming ambient air which could harm the compressor cylinder heads.

N-Series Booster Compressor Features Heavy gauge baseplate Anti-vibration pads TEFC motor Aluminum cylinder heads High pressure discharge hose with check valve Inlet filter with drain trap Enhanced standard starter panel The enhanced standard starter panel allows the operator to control and monitor the booster. It features a Kaeser Control to monitor motor and temperature conditions and shut the booster down if necessary, a switch to turn the booster on and off, an hour meter, and an emergency stop pushbutton.

N-Series Booster Compressor Features Heavy gauge baseplate Anti-vibration pads TEFC motor Aluminum cylinder heads High pressure discharge hose with check valve Inlet filter with drain trap Enhanced standard starter panel Low rotational speeds Slower rotation speeds help increase service life and improve efficiency and reduce operating costs.

Booster Compressor Features (N 60-G and N 153-G Only) Finned copper cooling pipes The cooling pipes on the N 60-G and N 153-G are finned to help improve heat transfer to remove the heat of compression and increase the service life of the booster. This feature is only on these 2 models.

Booster Compressor Features (N 253-G to N 2001-G) Finned copper cooling pipes Instrument panel The instrument panel on the N 253-G – N 2001-G models includes gauges to monitor air temperature, inlet air pressure, discharge air pressure, and oil pressure to allow the operator to determine if the booster is operating properly within normal parameters or not.

Booster Compressor Features (N 253-G to N 2001-G) Finned copper cooling pipes Instrument panel Air-cooled aftercooler A generously proportioned aftercooler keeps discharge air temperatures low .

Booster Compressor Features (N 253-G to N 2001-G) Finned copper cooling pipes Instrument panel Air-cooled aftercooler Forced lubrication system The forced lubrication system increases reliability by forcing lubrication through the compressor which helps increase the service life by properly lubricating the components and carrying away the heat of compression. By using a full flow oil filter, oil change intervals are increased.

Booster Compressor Features (N 60-G to N 502-G) Sliding manual belt tensioner The following 2 features are available on models N 60-G – N 502-G. The sliding manual belt tensioner is a simple sliding v-belt tensioning device designed to make belt tensioning relatively easy. This type of tensioning device positions the motor instead of raising or lowering a swing frame as is the case with rotary screw compressors. By doing it this way, misalignment issues are avoided and the associated wear on the belts and pulleys. Proper belt tension prolongs belt and pulley life and increases efficiency.

Booster Compressor Features (N 60-G to N 502-G) Sliding manual belt tensioner 230/460VAC direct on-line start The 3 to 20 hp models feature direct online starting to deliver full torque when the motor is started.

Booster Compressor Features (N 2001-G) Automatic v-belt tensioner The following 3 features are available only on models N 753-G – N 2001-G. The automatic V-belt tensioner on theses models is more like the style we are used to seeing on the rotary screw compressors. It features the same type of roll pin indicator and method of tensioning.

Booster Compressor Features (N 2001-G) Automatic v-belt tensioner 460VAC wye-delta start The 30 – 50 hp models feature wye-delta starting to reduce the inrush current at start-up. This method of start reduces the starting torque by about 1/3 and slowly speeds up the motor instead of instantaneously jerking it to full speed. By doing this, there is much less shock to the equipment which helps prevent leaks and increase service life. A starter control panel is required to start these units.

Booster Compressor Features (N 2001-G) Automatic v-belt tensioner 460VAC wye-delta start Optional water-cooled aftercooler The water cooled aftercooler lowers approach temperatures to as low as 11°F above ambient temperature. The water cooled aftercooler is much smaller than the air cooled aftercooler. This feature reduces the foot print size of the booster significantly because the additional extension to mount the air cooled version is not required. Keep in mind however that if this option is chosen, water must be available and there will be the additional installation and piping expense.

DN-Series Boosters Model FAD in cfm Motor Power DN 22C 175 – 456 30 hp The latest Kaeser offering is a complete booster package. The DN series of boosters includes all the same components as mentioned with the N-Series, but with the added benefit of being factory assembled and package with the enclosure, starters and SC2. This eliminates the need for costly field installation efforts as well as a reduction in floor space. Model FAD in cfm Motor Power DN 22C 175 – 456 30 hp DN 30C 220 – 409 40 hp DN 37C 175 – 491 50 hp DN 45C 385 – 549 60 hp

DN-Series Boosters Max. initial pressure 190 psig Max. final pressure 650 psig Max. ambient temp 113°F at 4.5:1 compression ratio Air-cooled = standard Water-cooled = option Control cabinet UL508A Motors UL approval Motors NPE with 1x PT100 sensor As with all Kaeser products, the DN series is a complete offering with all necessary approvals and documentation

DN-Series Boosters Complete machine: Enclosure Sigma Control 2™ Starter cabinet Factory assembled Factory tested Options: Auxiliary heating Nitrogen version Whether for air service or nitrogen service, the boosters can be configured for either application.

DN-Series Booster Advantages Less floor space Easy to install Excellent accessibility Better protection SC2 Sensory array Optimized cooling Moving form the horizontal design to a vertical design drastically reduces floor space and simplified the cooling air flows. Being a complete machine has eliminated the need to mount and wire the control panel. With the addition of the SC2 and the sensor array, the machines are now fully protected and all maintenance records are maintained at the machine.

How to Size? Whether and N-Series or a DN-Series, the sizing is the same. All flows must be referenced in FAD and the inlet as well as the outlet pressure must be defined. Form here, the price pages or EDS will give you the performance of the booster you require. Be certain to note the booster series, motor size, inlet pressure, outlet pressure and booster RPM on your order to ensure that you receive the correct machine.

Presentation Changes 12/5/12 RRM Slide 8 – Changed picture to match bullet point (Aluminum cylinder heads. Original picture was of a cylinder not the head) 11/4/15 Slide 1 – Added DNC unit image Slide 4 – Removed old slide, created start of N-series section Slide 19,20,21 – Removed mentioned of N753G Slide 22-27 – DNC Boosters added 11/25/15 Slide 2 – Added text and adjusted spacing Slide 3 – Added text and adjusted spacing Slides 3 – 7 – Slight formatting changes and alignment Slide 8,9 – Added comment to slide, need a different picture! Slide 10 – Replaced illustration with photo of line filter and drain Slide 26 – Removed bullet point (already in speaker notes) and enlarged chart so it could be read. 12/9/15 V1.0 Per Dan these comments need to be incorporated at a future date. Slide 8 - There isn't a cylinder head in this picture. Need a different picture. Slide 9 - Need a photo of the high pressure discharge valve and check valve instead of this illustration.