Rotary Screw Compressors

AIRTOWER

FAD 0.233 to 1.145 m3/min Pressure 7.5/10/13 bar

What do you expect from a compressor?

Compressed air should always be available in the correct volume and quality to meet your companys requirements. Condensate-free compressed air tailored to the specific application not only ensures maximum reliability, but also significantly reduces maintenance costs. At least two key components are required to achieve this: A compressor and a compressed air dryer. However, each unit usually requires its own floor space, which in many cases is at a premium. Even if sufficient room is available, the principle of Space is Money still applies. Therefore, the ideal solution would be a compact compressed air system that requires minimal floor space.

AIRTOWER Maximising Space

3 2

Energy-saving SIGMA PROFILE

Each KAESER rotary screw compressor airend uses SIGMA PROFILE rotors, specially developed by KAESER, that require approximately 15 percent less energy than conventional rotors with the same air delivery capacity.

Intelligent design
Unlike packaged systems that are crammed into one cabinet, a major design feature of the KAESER AIRTOWER range is that the compressor and dryer are both completely separate, independently functioning units. This means that each can be operated individually making it possible to isolate and service the dryer whilst the compressor is operating. Contained in its own separate cabinet there is sufficient space to allow the dryer components to be generously sized yet easily accessible.

1 5
Fully piped and ready to use, the standard AIRTOWER version is simply connected to an existing air receiver via ball-valve and hose.

SIGMA CONTROL
The SIGMA CONTROL automatically controls and monitors the compressor package. It is a robust PC-based industrial computer with real-time operating system and update capability. A plain text display and traffic-light style LEDs clearly show the operational state of the machine www.kaeser.com at a glance. A choice of four control modes is available to allow selection of the most appropriate for a specific application. Interfaces are provided for modem / printer, a second compressor for base-load sequencing or a data network (Profibus DP) connection that enables system access via KAESERs Teleservice facility. The refrigeration dryer is equipped with an independent control panel and on/off/emergency stop switch.

Servicing made easy:

Component accessibility is optimised through simplicity of design, wide opening doors and removable panels that greatly simplify maintenance. The compressor can be accessed through the door 1, hinged lid 2 and removable panel 3. When panel 4 is removed the dryer unit can be pulled out like a drawer so that all components to be serviced are accessible. Behind doors 5 and 6 are the separate control cabinets of the compressor and dryer, electrically equipped to EN 60204, protected from dust and splash-proof to IP54.

An alternative version allows the receiver to be connected upstream of the dryer. The air receiver is used as a condensate separator and must be fitted with an ECO-DRAIN automatic condensate drain.

The AIRTOWER solution

Modular in design, KAESER AIRTOWERS incorporate a powerful rotary screw compressor mounted directly above a highefficiency refrigeration air dryer, consequently eliminating the need for additional floor space. KAESER AIRTOWER systems fulfil all of your compressed air needs: they are efficient, quieter than quiet, require minimal maintenance, are extremely reliable, simple to install and deliver the very best in air quality.

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AIRTOWER 3 to 11: 0.68 m

0.

77

Dry Air as Standard

The Airtower produces dry air with a pressure dew point of +3 C reliably and cost-effectively. KAESER AIRTOWER systems have redefined the concept of compact compressor packages by using components of the highest quality. A centrifugal separator equipped with an electronic ECO DRAIN is installed upstream from the dryer to ensure reliable, efficient air drying. Condensate accumulating in the refrigeration dryer is removed safely and effectively without pressure loss via an electronic ECO DRAIN condensate drain.

Minimum space requirement - maximum system flexibility

AIRTOWER versions 3 to 11 have a footprint of only 0.53 m. The compressor and dryer are both designed as completely separate functioning modules. Unlike compact single-cabinet solutions, this means that each can be operated independently of the other, making it possible to isolate and service the dryer whilst the compressor continues to deliver compressed air.

The screw compressor a separate unit

Turnkey operation
The compressor, centrifugal separator and refrigeration dryer are delivered fully piped and ready for operation. The electronic condensate drain on the centrifugal separator is supplied already fitted and the dryer is equipped with power cable and plug.

Intelligent design means that no additional floor space is required for the refrigeration dryer

AIRTOWER 3 to 11: 0.53 m2

Compact footprint

Equipment
Complete package: ready for operation, fully automatic: rotary screw compressor, centrifugal separator with electronic condensate drain, refrigeration dryer, powder-coated panels throughout. Sound insulation: plastic foam with washable surface. Anti-vibration: dual anti-vibration mountings using rubber bonded metal elements. Compressor unit: KAESER rotary screw, single-stage airend with cooling fluid injection, V-belt drive with automatic tensioning, energy-efficient quality German electric motor to IP 54 and insulation class F with permanently greased bearings. Fluid and air flow: changeable filter mats in the cabinet inlet, dry air filter with silencer, pneumatic inlet and venting valve, cooling fluid reservoir tank with triple separation system, pressure relief valve, minimum pressure/check valve, thermostatic valve and microfilter, fixed pipework with flexible connectors, filled with SIGMA FLUID cooling fluid. Cooling: air-cooled, combined fluid and compressed air cooler (aluminium). Controller: ergonomic control panel, traffic-light style LEDs (green, yellow, red) show the operational status of the compressor, userfriendly operation via clearly marked icon keys and large display, fully automatic dual control (on-load-/off-load-/cycling control), monitoring of system pressure, airend discharge temperature, direction of airend rotation, hours counter (on-load/off-load), adjustable service interval, selection of measurement units (pressure: bar, psi, MPa; temperature: C, F), individually adjustable system pressure, group alarm volt-free contact, adjustable switching differential, electronic pressure transducer. Refrigeration dryer: CFC free, R 134a refrigerant, service module, thermally insulated, permanently sealed refrigerant circuit, hot-gas bypass regulation, electronic condensate drain. Electrical components: control cabinet to IP 54 containing star-delta starter (except Airtower 3), motor overload protection, control transformer, IP 54 control cabinet for the refrigeration dryer. Optional equipment: modulating control (partial load control), ambient temperature up to +46 C. Special version: without hoses or centrifugal separator.

Dimensions
Dimensions: AIRTOWER 3 to 11
680 624 335

Compressor cooling air outlet

Compressor cooling air inlet

Cooling air outlet Refrigeration dryer

Cooling air inlet Refrigeration dryer

412

774 669
Compressor power connection

522

Refrigeration dryer air outlet G3/4 - G1

1284 968
Refrigeration Refrigeration dryer dryer condensate drain DN 10 power connection

Specifications
Model
Max. working FAD*) overall package at pressure working pressure m3/min bar
7.5 0.313 0.233 0.424 0.329 0.583 0.466 0.36 0.816 0.684 0.551 1.145 0.975 0.795
* Performance data to ISO 1217: 1996, Annex C; ** Sound level to PN8NTC 2.3 at 1 m distance, free-field measurement

Rated motor power kW

2.2

Dryer power consumption kW

0.34

Rated motor power kW

R 134 a

Dimensions

Sound level** dB(A)

65

Weight

LxWxH
680 x 774 x 1284

kg
230

AIRTOWER 3

10 7.5

AIRTOWER 4

10 7.5

0.34

R 134 a

680 x 774 x 1284

66

230

AIRTOWER 6

10 13 7.5

0.34

R 134 a

680 x 774 x 1284

66

230

AIRTOWER 8

10 13 7.5

5.5

0.34

R 134 a

680 x 774 x 1284

68

240

AIRTOWER 11

10 13

7.5

0.34

R 134 a

680 x 774 x 1284

69

250

Different fields of application require different grades of air treatment

Choose the required grade of treatment according to your field of application:
Air treatment using a refrigeration dryer (+3 C pressure dew point)
KAESER

Explanation: THNF = bag filter cleans dusty and highly contaminated intake air ZK = centrifugal separator removes condensate ED = ECO Drain electronic level-controlled condensate drain FD = particulate filter 1 m separates dust particles (attrition) 1 m FE = microfilter 0.01 ppm separates aerosol oils and solid particles >0.01 m, oil content 0.01 mg/m3 FF = microfilter 0.001 ppm separates aerosol oils and solid particles >0.01 m, oil content 0.001 mg/m3 FG = activated carbon filter for adsorption of oil vapours, oil vapour content 0.003 mg/m3 FFG = combination filter comprising FF and FG

Examples: selection of treatment classes to ISO 8573-1

Solids Water Oil Bacteria

Dairies, breweries Food and semi-luxury food production Very clean conveying air, chemical plant Pharmaceuticals Weaving machines, photo labs
Paint spraying, powder coating Packaging, control and Instrument air General works air, quality sandblasting

A B C A B D E G

1 < 1

< 1
AMCS

FST

FE AMCS

KAESER

KAESER

ACT

FF

2 < 1 < 1 < 1

FFG AMCS

< 1 < 1 < 2

AMCS FE FF
KAESER

KAESER

< 1

KAESER

FST

KAESER

< 1
KAESER

FD

KAESER

< 1

KAESER

Air receiver

ECD

Airtower/ED THNF

Airtower rotary screw compressor with integrated refrigeration dryer, pressure dew point to +3 C FST = sterile filter for bacteria-free air Aquamat = condensate treatment system AMCS = air-main charging system

KAESER

AMCS

Degree of filtration:
2 4 3
Aquamat
ISO 8573-1

AMCS

Solid particles
Max. no. of particles per m3 with size d (m)
0.1<d<0.5 1.0<d<5.0 0.5<d<1.0 mg/m3 <0.1

Humidity
Pressure dew point (x=liquid water in mg/m3 )

Overall oil content

Class

mg/m3

A B C D E G

Aerosol oil 0.003 mg/m3, particle retention > 0.01 m, sterile, odourless and tasteless Aerosol oil 0.003 mg/m3, particle retention > 0.01 m Aerosol oil 0.003 mg/m , particle retention > 1 m
3

0 1 2 3 100 1 10000 100000 1000

as specified by user 0 10 500 1000 20000 <- 70 C <- 40 C <- 20 C < + 3 C < + 7 C < + 10 C x <0.5 0.5<x < 5.0 5.0<x <10.0 <0.01 <0,1 <1.0 <5.0

Aerosol oil 0.001 mg/m3 particle retention > 0.01 m Aerosol oil 0.01 mg/m3, particle retention > 0.01 m Aerosol oil 1 mg/m3 particle retention > 1 m

Contaminants:
+ + + + solids water oil bacteria -

4 5 6 7 8 9

< 5 < 5 < 40 < 10

KAESER KOMPRESSOREN GmbH

P O. Box 2143 96410 Coburg GERMANY Tel: +49 9561 640-0 Fax: +49 9561 640130 . www.kaeser.com e-mail: productinfo@kaeser.com

P-651/15ED.8/05 Specifications are subject to change without notice