1. Kaeser Direct Drive Compressors
FSD
Introducing the Kaeser FSD rotary screw compressor.
These compressors range from 350 to 450 hp.

2. Premium Quality Components
High quality (4µm) air inlet filter
High-volume, heavy-duty radial fan (top exhaust)
Sound-proof enclosure
Three-stage vertical separator system
Fluid cooler
High-efficiency
Sigma Profile
airend
Starting at the compressor intake we have a 4 micron inlet air filter. This will keep dust and dirt out of the compressor and air stream.
To keep the unit quiet as possible we have a sound enclosure standard on all compressors.
The heart of a Kaeser compressor is the high-efficiency airend. Designed to give more CFM per hp.
The airend is direct coupled to the electric motor. This coupling greatly reduces friction and energy losses between the motor and airend.
Kaeser uses TEFC high efficiency motors. Also reducing energy costs.
External grease fittings for the drive motor and fan motor reduces maintenance time.
The after cooler and fluid cooler have an outside to inside air flow. This air flow provides the coolest air possible reducing discharge air temperature and fluid temperature.
To draw in this cool air we use a high volume radial fan. This fan not only moves a high volume of air but it is quiet while moving this air.
Aftercooler
External grease fittings for drive motor and fan motor
Direct drive coupling
High-efficiency
drive motor

3. Sigma Profile Advantage
Old
Optimized Sigma Profile 5:6 design provides enhanced specific performance
New
Larger displacement
Kaeser airends are optimized by a 5:6 rotor design. This design increases performance and efficiency of the airend. As you can see in the drawings this design is further optimized by the profile of the airend rotors. The blue area indicates the larger volume that is created by the new profile design over the older design.

4. Sigma Profile Advantage
Optimized Sigma Profile 5:6 design provides enhanced specific performance
Larger displacement
This picture indicates the volume of air that is carried around the outside of the airend and ultimately compressed into the air system.
Greater flexibility in pressure selection

5. Sigma Profile Advantage
High-precision ground finish on rotors creates less fluid friction and shear
Closer tolerances and unequal diameter rotors significantly reduce back-flow
Designed and manufactured exclusively by Kaeser
Kaeser makes all of our airends so we control all aspects of machining and thus fit and tolerances are kept to our exacting specifications. These precision machined components along with tight clearances, greatly reduce efficiency losses from back flow.

6. Standard Drive Motor Features
High efficiency for lower input kW
TEFC design protects from dirt, dust, moisture, etc.
Class F insulation
100% copper windings
EPAct compliant
Anti-vibration motor mounts
Wye-Delta soft start
Remote grease fittings
Temperature sensor on each winding
Kaeser uses high efficiency motors to help reduce input kW.
These motors are TEFC with class F insulation.
100% copper windings increase efficiency of the motor.
Wye-delta starting reduces inrush current which in turn will reduce the over all usage of power. These motors have sensors embedded into the windings to sense high temperatures and will protect the motor from over temperature.

7. Direct Drive Coupling airend speed = motor speed
Most efficient drive system
1:1 direct drive
Minimizes radial loads on motor and airend
No gears = no gear noise or loss of efficiency
Cast iron spool piece assures perfect alignment
Kaeser coupling requires no maintenance
airend speed = motor speed
Kaeser’s direct drive units are the most efficient method of transferring power from the motor to the airend.
With no gears or belts, noise is reduced and efficiency is increased.
This coupling system does not require any maintenance during its lifetime.

8. Improved Air Flow Design
Parallel cooling air flows eliminate pre-heating the air
Exhaust air
By separating the air flows, critical components receive the coolest air possible
Cooler intake air maximizes compression efficiency
Outside to inside flow on coolers promotes low approach temperatures
Kaeser carefully engineers every package to offer customers a number of quality benefits. For instance, the parallel cooling air design ensures that all critical components receive the coolest ventilation possible. The fluid cooler, aftercooler, drive motor, and intake air all receive the coolest air possible to maximize package performance.
And since hot air rises, Kaeser uses a high quality radial fan to blow the hot air out the top of the compressor.
Be certain to remind customers that all compressors produce a lot of heat. To prevent the compressor's hot air discharge from heating up the compressor room, it is strongly recommended that the exhaust air be ducted outside the compressor room. If you have an adjacent area that the customer pay's to heat, consider ducting the compressor to supply heat to the room and save on the heating bill during winter months!
Top discharge makes efficient ducting and heat recovery easy
Fluid cooler
Aftercooler
Airend intake
Motor cooling

9. Improved Air Flow Design
Cooling system employs a radial fan design with significant benefits:
Increased air flow with less input kW improves overall energy efficiency and approach temperatures
Increased static pressure for ducting and heat recovery
Quiet operation - noise levels 83 dB(A)
The cooling system for the compressor employs a redial fan which provides many benefits for the compressor and cooling system.
The radial design is a high volume fan with increased airflow and lower input kW.
This increased airflow and reduced kW add up to higher efficiency in the cooling system. Another benefit is the fan while producing all the airflow runs quiet with sound levels as low as 83dB(A)
Heavy duty radial fans

10. High-Efficiency Fluid and Aftercoolers
Fluid Cooler
Maintains optimal operating temperature
Thermostatically controlled
Drain plug for complete fluid change
Aftercooler
Integral aftercooler eliminates need for external cooler
Compressed air temperatures as low as 9°F above ambient
Condenses up to 80% of total moisture in air
The fluid cooler is thermostatically controlled to maintain an optimal temperature for the compressor. The cooler has an easy to reach drain for complete fluid changes.
The aftercooler reduces the discharge air temperature as low as 9°F above ambient temperatures. 80% of the condensate will condense in the aftercooler to be separated from the air stream.

11. Three-Stage Vertical Separator
First stage: Air and lubricant enter the separator tank through a newly designed, low-restriction, contoured duct, which forces the mixture to spin. This cyclonic action removes up to 99% of the lubricant.
Since Kaeser rotary screw air compressors are oil cooled the oil needs to be separated from the air stream. This is accomplished by three stages of separation.
The first stage is centrifugal separation. Spinning the air and oil mixture around the outside of the separator tank forces the oil to separate from the air removing 99% of the oil.

12. Three-Stage Vertical Separator
Second stage: Air and remaining lubricant flow through the outer coarse coalescing filter media removing all but the finest oil aerosols.
Second stage
Third stage
Third stage: Air then flows through the inner fine coalescing filter media ensuring that air exiting the separator contains no more than 2 ppm of oil.
The second stage consists of coarse coalescing filter media. This further removes the oil in the air stream.
The third stage is a fine coalescing filter media to remove the remaining oil to as low as 2 ppm of oil.

13. Three-Stage Vertical Separator
Quick release fittings to check pressure differential
Sump pressure gauge
Quick release fluid drain allows simple pressurized fluid changes
Easy-to-read sight glass
Separator lid lift device
Vibration isolators reduce stress on pipe connections
The separator had quick couplings on the wet side and dry side of the separator. This provides for an accurate measurement of the pressure differential across the separator element.
To check oil levels an easy to read sight glass is provided.
To reduce vibration in the unit vibration isolators are provided to reduce noise and also reduces stress on the piping.

14. High-Quality Flex Pipe Connections
All air and fluid pipes are made of steel and feature flexible connections. This eliminates stress build-up and reduces the likelihood of cracks resulting in leakage.
Fittings are sealed with a special compound for extra leak protection.
Flexible connectors are provided to further reduce stress on the fittings and piping.

15. Sigma ControlTM
Programmable maintenance timers ensure service is done according to your schedule.
Four password levels limit access to critical operation settings.
Detailed operating, maintenance and alarm history allow easy troubleshooting
Operational statistics such as duty cycle, cycle frequency, individual component hours, and more
Kaeser has provided an advanced Sigma Control to control and monitor the compressor operation. Parameters that are programmed into the Sigma Control are protected by 4 levels of password security. Different levels of passwords provide different access levels to change programming information. The Sigma Control provides several different control mode that can be utilized to increase efficiency of your compressed air system. The sigma control can be programmed to sequence two compressors.
The sigma control also will monitor and store information from Maintenance scheduling to warning and alarm messages.

16. Sigma ControlTM User-friendly touch pad with LCD panel
Multiple languages
Intel® industrial microprocessor
Profibus, RS232 and RS485 interface ports
Certified EMI (Electromagnetic Interference) protection
Software upgrades keep the compressor you buy today up-to-date tomorrow
Built by Siemens for Kaeser
This controller is user friendly. With multiple languages you can choose the language that best suits your needs.
The controller is an industrial grade microprocessor built by Siemens capable of profibus, RS232 and RS485 communication through interface ports.
The software is designed and maintained by Kaeser and can be upgraded to keep the controller up-to-date.

17. Full Enclosure Heavy-duty door gaskets protect against dirt and dust
Powder-coated doors and panels with heavy sound insulation increase durability and decrease sound levels
Internal and external anti-vibration mounts protect piping and electrical connections
Heavy-gauge steel frame and floor increase rigidity and keep out dirt and dust
The enclosure not only provides sound reduction but helps provide proper ventilation to the several components. The paint is powder coated to give years of corrosion resistance and keep you unit looking new.
The frame is a heavy gauge steel to increase rigidity and has a solid floor to capture noise and contain any fluid spills.

18. Energy Savings Sigma Profile airend design
1:1 direct drive - no losses
Excellent motor efficiencies
Cooling fan design
Minimal pressure drop across separator, piping, valves and cooler
Heat recovery ready
To recap:
Energy savings come from
The efficiently designed airend with Sigma profile reduces energy costs.
1:1 direct drive reduces energy losses
TEFC high efficiency motors help to reduce energy costs.
The radial fan moves high volumes of air while operating very quiet and with low energy costs.
To greatly increase overall energy costs the heat rejected from the compressor can be ducted to provide heating of your plant.

19. Performance Certificates
CAGI data sheets are used to compare energy efficiency among different makes and models of compressors.
Members of CAGI test compressors in accordance with CAGI/PNEUROP PN2CPTC2 test code and report the results on this form.
The test code is based on total package performance.
Kaeser offers CAGI sheets for these compressors to accurately certify the performance of the units.
Being a member of CAGI Kaeser compressors are tested according to the CAGI/PNEUROP PN2CPTC2 test code and you can be assured that these numbers are as accurate as possible.
The input electricity (kW) to the package is measured, as is the compressor capacity at the terminal point of the package.

20. Ease of Maintenance Once per year package maintenance
8,000 hour fluid filter*
Easy fluid change device
No maintenance 1:1 direct drive coupling
Sigma Control™ reminders and statistics
Easy access to all components
* Depending on environment
Kaeser takes maintenance very serious and these compressors are designed with this in mind. From easy access to the maintenance locations to once a year fluid and fluid filter changes. The Sigma Control can be programmed to remind the operator to carry out maintenance when required.

21. SFC - Sigma Frequency Control
Kaeser's premiere variable speed drive option:
Drive controls completely integrated with Sigma Control™ for easy operation
Superior part load efficiency
Constant, stable system pressure
Siemens MASTERDRIVE technology for reliability, efficiency, long-term support
Premium noise filters, heavy-duty shielding and galvanic separation prevent electrical interference
SFC 315
For the ultimate in control and flexibility an SFC (Sigma Frequency Control) is provided. The SFC provides superior part load efficiencies. The SFC is completely integrated into the compressor and Sigma Control. This drive is manufactured by Siemens and utilizes the MASTERDRIVE technology.
With premium filtering, shielding, and galvanic separation the drive system is protected from electrical interference.