COMPRESSORS

Rotary Screw Compressors

ASD Series
With the world-renowned SIGMA PROFILE
Flow rate 0.89 to 6.39 m³/min, Pressure 5.5 to 15 bar

www.kaeser.com
 ASD Series

ASD – Even more efficient

KAESER KOMPRESSOREN pushes the boundaries of compressed air efficiency once again with its latest generation of
ASD (ASD.4) series rotary screw compressors. Not only do these optimised ASD compressors deliver more compressed air
for less energy, but they also combine ease of use and maintenance with exceptional versatility and environmentally respon-
sible design.

ASD – Multiple savings Perfect partners

The newly refined ASD systems save energy in multiple ASD series rotary screw compressors are the perfect part-
ways: the compressor airends feature further refined ners for high-efficiency industrial compressed air stations.
SIGMA PROFILE rotors and are controlled and monitored The internal SIGMA CONTROL 2 compressor controller
via the industrial-PC-based SIGMA CONTROL 2 compres- offers various communication channels, which allows
sor controller. This advanced controller matches com- seamless communication with advanced master control-
pressed air delivery to actual demand and uses dynamic lers, such as KAESER’s SIGMA AIR MANAGER, and
control to keep costly idling time to an absolute minimum. in-house centralised control systems. This enables simple
setup and achieves unprecedented levels of efficiency.

Variable speed with reluctance motor

The new synchronous reluctance motor combines the
Electronic Thermo Management (ETM)
advantages of asynchronous and synchronous motors Powered via an electric motor, the sensor-controlled tem-
in one drive system. The motor contains no aluminium, perature control valve integrated into the cooling circuit is
copper or expensive rare earth magnets, which makes the the heart of the innovative Electronic Thermo Management
drive durable and service-friendly. In addition, the function- (ETM) system. The new SIGMA CONTROL 2 compressor
al principle keeps heat losses in the motor to a minimum, controller monitors intake and compressor temperature in
resulting in significantly lower bearing temperatures. This order to prevent condensate formation, even with differing
ensures significantly extended bearing and motor service air humidity conditions. The ETM dynamically controls fluid
life. In conjunction with the perfectly matched frequency temperature – low fluid temperature enhances energy effi-
converter, the synchronous reluctance motor also deliv- ciency. This system also enables end users to better adapt
ers superior performance compared to an asynchronous heat recovery systems to suit their specific needs.
motor when it comes to losses, especially in the partial
load range.

Why choose heat recovery?

The question should in fact be: Why not? Amazingly, up

Up to
to 100 % of the (electrical) energy input to a compressor
is converted into heat. Up to 96 % of this energy can be

96 %
recovered and reused for heating purposes. This not only
reduces primary energy consumption, but also improves
the applicable company’s total energy balance.

usable for heating

2
Service-friendly design

Image: ASD 60

3
4
ASD series

Uncompromising efficiency

Save energy with the SIGMA PROFILE SIGMA CONTROL 2: Assured efficiency
At the heart of every ASD system lies a premium quali- The internal SIGMA CONTROL 2 controller ensures
ty airend featuring KAESER’s SIGMA PROFILE rotors. efficient compressor control and monitoring at all times.
Flow-optimised for impressive performance, these adv- The large display and RFID reader provide easy commu-
anced rotors help KAESER ASD systems set the highest nication and maximum security. Variable interfaces enable
standards for efficiency. seamless networking capability, whilst the SD card slot
makes updates quick and easy.

Tomorrow’s technology, today: IE4 motors Required temperature assured

KAESER is currently the only compressed air systems According to operating conditions, the innovative
provider to equip its compressors with super premium Electronic Thermo Management (ETM) system dynami-
efficiency IE4 motors as standard, thereby delivering maxi- cally controls fluid temperature to ensure safe prevention
mum performance and energy efficiency. of condensation accumulation and also boosts energy
efficiency.

5
 ASD T series

Premium compressed air quality with an

add-on refrigeration dryer

Power consumption ▀ Power consumption: KAESER add-on dryer

(kW) ▀ Power consumption: Refrigeration dryer with continuous control
▀ Energy saving: KAESER add-on dryer

100%

0%
10 12 18 20 Time (min)

Energy-saving control Dependable KAESER centrifugal separator

The integrated refrigeration dryer in ASD-T units provides A KAESER centrifugal separator fitted with an electronic
high-efficiency performance thanks to its energy-saving ECO-DRAIN condensate drain installed upstream from
control. The dryer is therefore active only when com- the refrigeration dryer ensures that condensate is reliably
pressed air actually needs to be dried: as a result, this pre-separated and drained, even when ambient tempera-
approach achieves the required compressed air quality tures and humidity are high.
with maximum efficiency.

3.5 kg

3.0 kg

2.5 kg
▀ New ▀ Legacy
2.0 kg

1.5 kg

1.0 kg

0.5 kg

0 kg
ASD 35 T ASD 40 T ASD 50 T ASD 60 T

Refrigeration dryer with ECO-DRAIN Minimal refrigerant requirement

The refrigeration dryer also features an ECO-DRAIN. The The refrigeration dryers in the new ASD-T units require ap-
advanced level-controlled condensate drain eliminates proximately 36 % less refrigerant than previous generation
the compressed air losses associated with solenoid valve dryers. This not only saves costs, but is also significantly
control, thereby saving energy and considerably enhanc- more environmentally friendly.
ing operational dependability.

6
Image: ASD 60 T

7
 High-efficiency drive system: Efficiency class IES2

< 20% losses

as benchmark IES2

± 20% benchmark IES1

> 20% losses
as benchmark IES0

The new EN 50598 standard Maximum energy efficiency

The European eco-compatible design standard EN 50598 For the variable frequency systems in the ASD series,
defines the requirements for drive systems in electrically KAESER meets the IES2 system efficiency standard,
driven production machines. It specifies system efficiency, which indicates the highest possible level under the
taking into account losses from the motor and frequency EN 50598 standard. IES2 designation indicates 20 % lower
converter. With 20 % lower losses compared to the bench- losses compared to the benchmark.
mark, KAESER systems meet the standard with ease.

8
ASD (T) SFC series

Speed-controlled compressor with

synchronous reluctance motor

Precision pressure control Durable and service-friendly

The flow rate can be adjusted within the control range Durable and service-friendly: the rotors of the synchronous
according to pressure. Operating pressure is kept constant reluctance motor do not contain aluminium, copper or
to within ±0.1 bar. This allows maximum pressure to be magnetic materials using rare earth metals. That makes
reduced, which, in turn, leads to significant energy and the bearings and rotors as easy to replace as those in
money savings. asynchronous motors. The functional principle keeps
heat losses to a minimum, resulting in significantly lower
bearing temperatures. This ensures extended bearing and
motor service life.

Separate SFC control cabinet Entire system EMC-certified

The SFC variable speed drive is housed in its own control It goes without saying that the SFC control cabinet and
cabinet to shield it from heat from the compressor. A SIGMA CONTROL 2 are tested and certified both as
separate fan keeps operating temperatures in the optimum individual components and as a complete system to EMC
range to ensure maximum performance and service life. directive EN 55011 for Class A1 industrial power supplies.

9
 ASD (T) SFC series

Maximum efficiency with variable frequency

synchronous reluctance motor

Efficient synchronous reluctance motor Combined with a high-performance frequency

This motor series combines the advantages of asynchro-
converter
nous motors and synchronous motors in one drive system. The Siemens frequency converter has a motor-matched
The rotors do not use aluminium, copper or expensive control algorithm. With the fine-tuned combination of a
rare earth magnets. Instead they are made of electrical frequency converter and a synchronous reluctance motor,
steel with a specialised profile and arranged in series. This KAESER achieves the top system efficiency level IES2
makes the drive highly durable and service-friendly. under the EN 50598 standard.

Flow rate (%)

100

Lower magnetic
resistance 70

30

Higher magnetic
resistance 0
0

0
:0

:4

:3

:1

:0

:4

:3

:1

:0

:4

:3

:1

:0

:3

:1

:0

:4

:3

:1

:0

:4

:3

:1

:0

:4

:3

:0

:4

:3

:1

:3
00

00

01

02

03

03

04

05

06

06

07

08

09

10

11

12

12

13

14

15

15

16

17

18

18

19

21

21

22

23

23

▬ Day 1 ▬ Day 2 ▬ Day 3 ▬ Day 4 ▬ Day 5 ▬ Day 6 ▬ Day 7 ▬ Day 8 ▬ Day 9 ▬ Day 10 ▬ Day 11
Time

How the reluctance motor works Minimal operating costs – exceptional productivity
In a synchronous reluctance motor, the torque is generat- Significantly greater efficiency – especially in the partial
ed by magnetic reluctance. The rotor has salient poles and load range – than comparable asynchronous systems
is made of a soft magnetic material such as electric steel, helps achieve considerable energy savings. The low mo-
which is highly permeable to magnetic fields. ment of inertia of synchronous reluctance motors allows
high cycle rates, thereby boosting machine and system
productivity.

10
Your benefits at a glance:

Best system efficiency: IES2 as per EN 50598

Maximum energy efficiency throughout the

control range

Durable and service-friendly drive

Advanced drive technology

Minimal operating costs, high productivity and

availability

Industrie 4.0 ready

Entire system EMC-certified

Efficiency

Saving
Asynchronous
reluctance

Synchronous
reluctance

Performance

Applications for speed-controlled compressor High efficiency in partial-load operation

systems with synchronous reluctance motors Synchronous reluctance motors achieve significantly better
A recent study shows that the typical compressed air con- efficiency in the partial-load range than asynchronous
sumption profile is in the 30-70 % range of the maximum. motors, for example. This allows savings of up to 10 %
This is where a speed-controlled rotary screw compressor compared with conventional variable-speed systems.
with synchronous reluctance motor can display its ener-
gy efficiency advantages in the partial-load range to the
fullest.

11
 25 %
ambient heat
100 %
total electrical power
25 %
consumption compressed
air energy
potential

Approx. 5 %
heat dissipation
from the drive Approx. 2 %
motor heat dissipated
by the compressor
into the ambient air

Approx. 76 % Approx.
heat energy 15 % Approx. 2 %
recoverable heat remaining in the
heat energy
through compressed air
recoverable
fluid cooling
through
compressed air
cooling

Approx. 96 %
recoverable heat energy

Savings calculation example for warm air heat recovery in terms of fuel oil
(ASD 60)
Maximum available heat capacity: 34.9 kW
Fuel value per litre of fuel oil: 9.86 kWh/l
Fuel oil heating efficiency: 90 % (0.9)
Price per litre of fuel oil: 0.60 €/l
34.9 kW x 2000 h per year
Cost saving: x 0.60 €/l = €4,719 per year
0.9 x 9.86 kWh/l

Further information regarding heat recovery:

http://www.kaeser.com/int-en/products/rotary-screw-compressors/heat-recovery/

12
Heat recovery system

Cost-effective heating

Up to
96 %
usable for heating

Heat recovery simply makes sense Space heating with warm exhaust air
Amazingly, 100 % of the electrical drive energy input to a It’s heating made easy: thanks to the high residual thrust
compressor is converted into heat energy. Of that heat, up radial fan, exhaust (warm) air can be easily ducted away
to 96 % is available for heat recovery purposes. to spaces that require heating. This simple process is
Use this potential to your advantage! thermostatically controlled.

Up to
+70°C
hot

Process, heating and service water Clean hot water

Hot water, up to 70 °C, can be produced from reusable If no other water circuit is interconnected, special fail-safe
compressor heat via PWT* heat exchanger systems. heat exchangers meet the highest demands for the purity
Please contact KAESER regarding higher temperature of the water being heated, as with cleaning water in the
requirements. food industry, for example.
*)
optionally installed within the package

13
 Heat recovery

Energy-saving, versatile and flexible

Required heating energy (%)

100 %

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

PTG plate heat exchanger system Required heating energy over the course of a
PTG plate-type heat exchangers consist of a package of year
pressed stainless steel plates. They provide excellent heat It goes without saying that heating is necessary during the
exchange characteristics with an impressively small form winter months. However, it is also required to a greater or
factor. PTGs can be integrated into existing hot water sup- lesser extent at other times of the year, such as in spring
ply systems and are suited for industrial applications. and autumn. Heating energy is actually required for ap-
proximately 2000 hours per year.

Conserve energy resources Feed heat energy to a heating system

In view of steadily rising energy prices, energy conserva- Up to 76 percent of the original input energy for the
tion is not only important for the environment, but is also compressor system can be recovered for use in hot water
becoming an economic necessity. Heat recovered from heating systems and service water installations. This
rotary screw compressors can be used not only for heating significantly reduces primary energy demand required for
purposes during the winter months, but can also reduce heating purposes.
energy costs when used in other processes.

14
15
 Equipment
Complete unit Cooling
Ready-to-run, fully automatic, super-silenced, vibration Air-cooled; separate aluminium cooler for compressed air
damped, all panels powder coated. Suitable for use in and cooling fluid; radial fan with separate electric motor,
ambient temperatures up to +45 °C. Electronic Thermo Management (ETM).

Sound insulation Refrigeration dryer

Panels lined with laminated mineral wool. CFC-free, R-134a refrigerant, fully insulated, hermetically
sealed refrigerant circuit, scroll refrigerant compressor with
energy-saving shut-off feature, hot-gas bypass control,
Vibration damping electronic condensate drain and upstream centrifugal
Double insulated anti-vibration mountings using rubber separator.
bonded metal elements.

Heat recovery (HR)

Airend Optionally available with integrated HR system (plate-type
Genuine KAESER single stage airend with energy-saving heat exchanger).
SIGMA PROFILE and cooling fluid injection for optimised
rotor cooling. 1:1 direct drive.
SIGMA CONTROL 2
“Traffic light” LED indicators show operational status at
Drive a glance, plain text display, 30 selectable languages,
Direct, high-flex coupling, without gearing. soft-touch keys with icons, fully automated monitoring
and control. Selection of Dual, Quadro, Vario, Dynamic
and Continuous control as standard. Ethernet interface;
Electric motor additional optional communications interfaces for: Profibus
DP, Modbus, Profinet and Devicenet; SD card slot for data
Standard system with premium efficiency IE4 motor, qual- recording and updates; RFID reader, web server.
ity German manufacture, IP 55, ISO F class insulation for
additional reserve; PT 100 winding temperature sensor for
motor monitoring; externally lubricated bearings.

SFC option SIGMA AIR MANAGER 4.0

Synchronous reluctance motor, quality German manufac- The further-refined adaptive 3-Dadvanced Control pre-
ture, IP 55, with Siemens frequency converter; meets IES2 dictively calculates and compares various operating
system efficiency standard; externally lubricated bearings. scenarios and selects the most efficient to suit the
compressed air application’s specific needs. The
SIGMA AIR MANAGER 4.0 therefore automatically
Electrical components optimally adjusts flow rates and compressor energy
IP 54 control cabinet, control transformer, Siemens fre- consumption in response to current compressed air
quency converter, floating contacts for ventilation systems. demand. This powerful feature is made possible by
the integrated industrial PC with multi-core pro-
cessor in combination with the adaptive 3-Dadvanced
Fluid and air flow Control. Furthermore, the SIGMA NETWORK bus
converters (SBC) provide a host of possibilities
Dry air filter; pneumatic inlet and venting valve; cooling to enable the system to be individually tailored
fluid reservoir with three-stage separator system; pressure to meet exact user requirements. The SBC can
relief valve, minimum pressure check valve, Electronic be equipped with digital and analogue input and
Thermo Management (ETM) and eco-fluid filter in the output modules, as well as with SIGMA NETWORK
cooling fluid circuit; fully piped connections, flexible line ports, to enable seamless display of pressure, flow
connections. rate, pressure dew point, power or alarm message
information.

16
How it works
The airend (3) is driven by an electric motor (4). The fluid (1) Intake filter
injected primarily for cooling purposes during the com-
(2) Inlet valve
pression process is re-separated from the air in the fluid
separator (5). The integrated fan ensures cooling of the (3) SIGMA PROFILE airend
compressor package and also provides sufficient flow
(4) IE4 drive motor
of cooling air through the oil cooler and compressed air
aftercooler (6 and 9). (5) Fluid separator tank

The controller ensures that the compressor produces com- (6) Compressed air aftercooler
pressed air within the set pressure limits. Safety functions
(7) KAESER centrifugal separator
protect the compressor against failure of key systems via
automatic shutdown capability. (8) ECO-DRAIN condensate drain

(9) Fluid cooler

(10) Electronic Thermo Management

(11) ECO fluid filter

(12) Radial fan

(13) Add-on refrigeration dryer

(14) Control cabinet with integrated SFC

frequency converter

17
 Technical specifications
Standard version

Operating Flow rate *) Max. working Drive motor rated Dimensions Compressed air Sound Mass
Model pressure Overall package at pressure power WxDxH connection pressure
operating pressure level **)

bar m³/min bar kW mm dB(A) kg

7.5 3.16 8.5

ASD 35 18.5 1460 x 900 x 1530 G1¼ 65 610
10 2.63 12
7.5 3.92 8.5
ASD 40 10 3.13 12 22 1460 x 900 x 1530 G1¼ 66 655
13 2.58 15
7.5 4.58 8.5
ASD 50 10 3.85 12 25 1460 x 900 x 1530 G1¼ 66 695
13 3.05 15
7.5 5.53 8.5
ASD 60 10 4.49 12 30 1460 x 900 x 1530 G1¼ 69 750
13 3.71 15

SFC - Version with variable speed drive

Operating Flow rate *) Max. working Drive motor rated Dimensions Compressed air Sound Mass
Model pressure Overall package at pressure power WxDxH connection pressure
operating pressure level **)

bar m³/min bar kW mm dB(A) kg

ASD 35 SFC (Prospectively available from mid-2018)

ASD 40 SFC 7.5 1.05 - 4.64 8.5 22 1540 x 900 x 1530 G1¼ 68 755

7.5 1.07 - 5.27 8.5

ASD 50 SFC 10 1.00 - 4.58 13 25 1540 x 900 x 1530 G1¼ 68 757
13 0.93 - 3.82 13
7.5 1.26 - 6.17 8.5
ASD 60 SFC 10 1.00 - 4.76 15 30 1540 x 900 x 1530 G1¼ 70 795
13 0.93 - 4.14 15

*) Flow rate complete system as per ISO 1217: 2009 Annex C/E: inlet pressure 1 bar (a), cooling and air inlet temperature 20 °C
**) Sound pressure level as per ISO 2151 and basic standard ISO 9614-2, tolerance: ± 3 dB (A)
***) Power consumption (kW) at ambient temperature 20 °C and 30 % relative humidity

18
T - Version with integrated refrigeration dryer (refrigerant R-134a)

Operating Flow rate *) Max. working Drive motor rated Refrigeration Dimensions Compressed Sound Mass
Model pressure Overall package at pressure power dryer power WxDxH air connection pressure
operating pressure consumption ***) level **)

bar m³/min bar kW mm dB(A) kg

7.5 3.16 8.5

ASD 35 T 18.5 0.8 1770 x 900 x 1530 G1¼ 65 705
10 2.63 12
7.5 3.92 8.5
ASD 40 T 10 3.13 12 22 0.8 1770 x 900 x 1530 G1¼ 66 750
13 2.58 15
7.5 4.58 8.5
ASD 50 T 10 3.85 12 25 0.8 1770 x 900 x 1530 G1¼ 66 790
13 3.05 15
7.5 5.53 8.5
ASD 60 T 10 4.49 12 30 0.8 1770 x 900 x 1530 G1¼ 69 845
13 3.71 15

T SFC - Version with variable speed drive and integrated refrigeration dryer

Operating Flow rate *) Max. working Drive motor rated Refrigeration dryer Dimensions Compressed Sound Mass
Model pressure Overall package at pressure power power WxDxH air connection pressure
operating pressure consumption ***) level **)

bar m³/min bar kW mm dB(A) kg

ASD 35 T SFC (Prospectively available from mid-2018)

ASD 40 T SFC 7.5 1.05 - 4.64 8.5 22 0.8 1850 x 900 x 1530 G1¼ 68 850

7.5 1.07 - 5.27 8.5

ASD 50 T SFC 10 1.00 - 4.58 13 25 0.8 1850 x 900 x 1530 G1¼ 68 852
13 0.93 - 3.82 13
7.5 1.26 - 6.17 8.5
ASD 60 T SFC 10 1.00 - 4.76 15 30 0.8 1850 x 900 x 1530 G1¼ 70 890
13 0.93 - 4.14 15

19
The world is our home
As one of the world’s largest compressed air system
providers and compressor manufacturers, KAESER
KOMPRESSOREN is represented throughout the world
by a comprehensive network of branches, subsidiary
companies and authorised partners in over 100 countries.

With innovative products and services, KAESER

KOMPRESSOREN’s experienced consultants and
engineers help customers to enhance their competitive
edge by working in close partnership to develop
progressive system concepts that continuously push the
boundaries of performance and compressed air efficiency.

Moreover, the decades of knowledge and expertise from

this industry-leading system provider are made available to
each and every customer via the KAESER group’s global
computer network.

These advantages, coupled with KAESER’s worldwide

service organisation, ensure that every product operates
at the peak of its performance at all times and provides
maximum availability.

P-651/2ED Specifications are subject to change without notice. .17/18

KAESER KOMPRESSOREN SE
P.O. Box 2143 – 96410 Coburg – GERMANY – Tel +49 9561 640-0 – Fax +49 9561 640-130
e-mail: productinfo@kaeser.com – www.kaeser.com