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Suflante industriale de aer pentru aplicatii edilitare si industriale KAESER KOMPRESSOREN

Turbosuflante cu lagăre magnetice KAESER KOMPRESSOREN PillAerator

Limba: Engleza

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Tip documentatie: Fisa tehnica

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e r u s s e r p w Lo solutions Magnetic Bearing Turbo Blowers 150 kW and 300 kW Flow rate up to 267 m³/min, 16,000 m³/h, Pressure differential 0.3 to 1.3 bar www.kaeser.com Magnetic Bearing KAESER Turbo Blowers High performance – Efficient process air Featuring a high-speed motor, the PillAerator from KAESER is a directly coupled, oil-free compression turbo blower that provides exceptional efficiency, reliability and flexibility. The turbo impeller and motor shaft start, stop and rotate with zero wear, or the need for any need for lubrication, thanks to magnetic bearing technology. This future-forward turbo blower design is used in the low pressure range and is especially useful for applications with high flow rate and performance demands where maximum energy efficiency and process air availability are of key importance. Energy efficient 0 1 5 0, 0 kWh Direct power transmission between the motor and impeller, combined with speed-controlled flow rate regulation, ensure remarka

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ble efficiency. In addition, the wear-free magnetic bearing allows almost unlimited start/stop operation for intermittent aeration processes. Future-forward The motor and frequency converter are cooled by a sophisticated cooling concept, like that used in e-vehicles. The closed cooling water circuit not only protects both core components from environmental influences, but also makes their exhaust heat available for reuse. Reliable The magnetic bearing’s intelligent sensors ensure ideal shaft position at all times. Should drastic pressure changes or voltage losses occur, the machine shuts down independently of the power supply for its own protection, so that no damage can occur. Low noise and pulsation With a maximum sound pressure level of 76 dB(A), the PillAerator is one of the quietest process air generators available. As turbo machines, they do not generate any pressure pulsations in the connected pipework. Ready-to-run The turbo blowers are designed for immediate operation wi

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th minimal installation effort. The intake air filter is already integrated and the accessories for its installation are pre-assembled. This reduces the effort required for piping and installation of ventilation ducts - especially when using the water-cooling option already included as standard. 2 TANK AERATION YEAST FERMENTATION Water management Food and pharmaceutical industry ► Aeration, flotation ► Fermentation, dispersion Efficient Reliable Low maintenance AIR KNIFE Montage uses images from: © Valenty, navintar, industrieblick - stock.adobe.com Applications – Flexible and versatile Industry ► Cooling air, combustion air Flue gas desulphurisation Always the first choice for an efficient and reliable compressed air supply Whether for use in water treatment applications, yeast production, bioreactors, for air knife applications in the steel industry, or for the purposes of flotation, turbo blowers from KAESER impress with their reliability, efficiency and excep

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tional ease of maintenance. Since they are completely oil-free, they are the ideal choice for sensitive processes – such as those in the food industry. 3 Turbo blower technology © KEBA Industrial Automation Germany GmbH, Simone Schuldis - Fotolia Turbo blowers work on the principle of dynamic compression. The impeller of the radially-acting turbo compressor accelerates intake air in the circumferential direction, thereby increasing flow speed and, as a consequence, energy. Part of this energy is converted into an increase in static pressure in the downstream diffuser. With few moving components in this turbo machine, an increase in pressure with continuous flow is generated. Image: Magnetic bearing motor with attached impeller The high-speed motor A high efficiency permanent magnet synchronous motor (PMSM) is responsible for the direct and loss-free generation of impeller speeds up to 30,000 rpm. The motor’s impressive performance is made possible due to its canned motor de

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sign, whereby the stator and magnetic bearing are encapsulated from environmental influences - and without a wearing shaft seal. In order to ensure effective and controlled cooling, the motor is exclusively water-cooled, which also protects it from ingress of fine dust. The motor shaft is levitated by a magnetic bearing that not only enables the high motor speeds to be achieved 4 with zero contact or wear, but also permits virtually unlimited motor starting frequency. Furthermore, the active magnetic bearing immediately detects and compensates for deflections to keep the motor shaft safely in its rotational orbit. The magnetic bearing control device is protected against power supply failure by regenerative motor operation. In the event of unexpected, drastic pressure surges, safety bearings provide further protection for the motor shaft so that it can be brought to a controlled stop without damage. What makes the KAESER turbo blower so special? Rather than using conventional aviati

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on-based air bearing technology for its turbo blowers, KAESER uses smart astronautic magnetic bearing technology to assure uncompromising long-term availability, as is especially expected of machines in the water industry, for example. Moreover, the PillAerator offers significant additional advantages over other magnetic bearing blowers. kW/(m³/min) Image: KAESER PillAerator HP 4000 turbo blower and impeller (m³/min) Efficiency and control range Cooling concept Different impeller versions (L, M, H) enable efficient coverage of the power and pressure range required by the specific application at hand. As shown in the graph, power consumption can therefore be reduced to a minimum (yellow line) for the required flow rate. The particular aerodynamics, which have been refined using complex flow simulations, provide a wide flow rate control range. As with modern e-vehicles, the motor and frequency converter are water-cooled and are therefore independently encapsulated from outside a

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ir. The water can be recooled either with ambient air, or with an external secondary water circuit, meaning that the heat contained in the cooling fluid can be subsequently recovered and reused. 5 The turbo unit – The heart of the system The compact heart of system comprises the impeller, the turbo blower housing, the directly coupled motor, as well as the inlet nozzle and the blow-off valve. The recooling system for the motor and frequency converter cooling water is just as easily accessible and consists of air/water and water/water heat exchangers, a circulation pump and a control valve. In order to keep sound emissions at the air inlet to an absolute minimum, the turbo blower draws in air through an integrated silencer and filter. Dynamic drive Image: © KEBA Industrial Automation Germany GmbH Made from aerospace grade aluminium alloy, the turbo impeller is seated directly on the shaft of the slim rotor. Consequently, the motor not only allows high speed operation, but also

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has exceptional control dynamics. For example, speeds of 20,000 rpm are achieved 5 in seconds. 6 Intelligent magnetic bearing technology Cooler motor There is more to KAESER’s magnetic bearing technology than meets the eye. The bearings are preloaded by a permanent magnetic component, which relieves their active, electromagnetic component. This consequently leads to lower winding currents and therefore to reduced heat generation. With its clever cooling concept - which is independent from ambient air conditions - and canned design, the motor not only ensures consistent cooling performance, but is also encapsulated against environmental influences. As a result, there is no need for a wear seal between the blower stage and the motor shaft. Image: Machine layout True flow rate Always clean With the KAESER PillAerator, flow rate is measured in real-time at the machine inlet. The air inlet is therefore designed as a nozzle equipped with corresponding pressure and temperature sen

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sors, to enable greater precision in delivering the required flow rate. The intake filter provides reliable protection against upstream influences such as filter breakthroughs and contaminated intake air ducts. The process air is filtered both when it is drawn in from the ambient surroundings and when it is drawn in from ducts. To ensure low life cycle costs, all filters are designed as inserts that can be changed quickly and easily. 7 Future-forward cooling concept Cooling and use of exhaust heat In a closed circuit, a pump circulates the cooling fluid via the motor and frequency converter, as well as via water/air and water/water heat exchangers. Up to a certain ambient temperature, it is possible to select either automatically or directly whether air or external cooling water should be used as the primary cooling medium. Water is the best choice for higher ambient temperatures, or for heat recovery purposes. Cooling system 1. Magnetic bearing motor, water-cooled 2. Water-coo

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led frequency converter 3. Controllable water/air heat exchanger 4. Water/water heat exchanger 5. Maintenance-free circulation pump 6. Cooling water inlet and outlet with possibility for use of exhaust heat 8 Water/air heat exchanger Water/water heat exchanger The heat exchanger fan operates automatically depending on ambient conditions and cooling requirement. The controller also decides when the water/water heat exchanger is activated to provide additional support if necessary. It is also possible to select which option is used as the primary cooling system. This heat exchanger can be used to provide additional support at high ambient temperatures, or can be selected as the primary cooling system. It is designed as a hybrid heat exchanger, so that exhaust heat from the motor and frequency converter can be transferred as effectively as possible should heat recovery be required. Exhaust heat utilisation Save money with heat recovery The state-of-the-art cooling circuit

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design is the same as that used in today’s advanced e-vehicles. It protects the core components, ensures their effective cooling and enables utilisation of recyclable exhaust heat. In a closed circuit, cooling fluid circulates via the motor and frequency converter, as well as via water/air and water/water heat exchangers. Whether used for higher ambient temperatures or with heat recovery in mind, water is the primary coolant. Cooling mode selection explained: Primary coolant mode: Air = Direct space heating using warm air flow. Primary coolant mode: Water = Heat transfer via the medium of water with temperatures up to approx. 40 °C. Advantage: The heat from the drive section is always available – with the same temperature level, regardless of the season (in contrast to heat exchangers in the pressure line). Directly usable heat – guaranteed! Potential heat use: On average, approx. 6 % heat output occurs in modern turbo blowers in the drive section, comprising the motor and i

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ts control technology. With good use of the machine, this equates to between 6 and 12 kW for medium-sized turbo blowers (150 kW series) and 15 to 20 kW for large turbo blowers (300 kW series). • Usable for processes: Heating biology or bioreactors, sludge conditioning and drying. • Usable for buildings: Low-temperature surface heating or support for the heating circuit, feed into a heat pump to achieve a higher temperature level (service water or similar). When multiplied by the number of blowers in operation, this results in an impressive amount of potentially directly usable heat energy. Equivalence to familiar energy sources and CO2 emissions Approx. 6 % Machine Drive power Process Heat capacity Montage uses image from: © jokatoons - stock.adobe.com The exhaust heat from the drive trains of three turbo blowers (each with a power consumption of 160 kW) corresponds to a heating value of 15,000 to 25,000 litres of heating oil per year, depending on load. That consequentl

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y translates into an annual CO2 emission of 44 to 73 tons – these figures are doubled for 300 kW series machines. 9 Importance of the coolant for air-conditioning AIRcooled operation Air-cooled blower station operation When selecting the preferred coolant – air or water, or both in combination – it is important to consider the compressed air system as a whole. This especially applies to exclusively aircooled turbo stations with process air intake via supply air ducting, and supply and exhaust air openings for machine room ventilation. The lower the temperature difference between the outside environment and the inside of the machine room, the stronger the room ventilation needs to be, which can often present a challenge, particularly in existing buildings. In such cases, water offers an attractive alternative as the cooling medium. 10 WATERcooled operation Water-cooled blower station operation In water-cooled operation, the effort required for room ventilation and cooling i

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s significantly lower, both in terms of supply air and exhaust air. Exhaust air ducting can even be omitted entirely, since most of the exhaust heat from the machine can be removed from the room using water. The water piping shown below the pressure pipework is sufficient to achieve this. Since the preferred cooling medium can be switched over via the KAESER turbo blower, warm exhaust air can be used in winter, for example, to provide room heating or to preheat the intake process air via bypass flaps. 11 Electronics 12 User interface (HMI) Data centre All performance and operating states can be displayed on the 9” colour touch panel and users can choose from over 20 selectable interface languages. If remote control capability is not available from the control centre, or if an associated fault occurs, the machine can be operated with manual setpoint input (flow rate, pressure or external process variables). All other systems, such as the frequency converter, are coordinated vi

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a the powerful central processing unit connected to the HMI. This bundles the flow of information via the HMI and the programmable controller. Image: Elements, electronics side STOP EMERGENCY ON OFF How it works M (1) Power supply (2) Transformer (3) Fusing (4) Main contactor (5) Mains filter (6) Commutation throttle (7) Frequency converter (8) Condenser, intermediate circuit (9) Sinusoidal filter (10) Motor (11) Magnetic bearing electronics (12) Controller (13) Control panel Frequency conversion Safety concept The speeds required for the high-speed motor are generated via a powerful frequency converter, which enables variable-speed operation and therefore continuous flow rate adjustment to meet actual demand. The closed water cooling circuit ensures consistent frequency converter performance. In the event of a power failure, the machine is shut down and comes to a controlled stop. Meanwhile, the power supply for the magnetic bearing control unit is

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generated by the motor and frequency converter. This eliminates the need for batteries or UPS packages and their associated maintenance. 13 EVERY THING AT A GL ANCE and under control Speed and flow rate Pressures and temperatures Operating and maintenance hours System and status data Warning and fault messages Communication 14 Operating data Status data The operating point is displayed in the turbo blower’s characteristic map in real-time. Machine utilisation and distance to operating limits can therefore be immediately seen at glance. Messages are displayed on the screen, are accessible at the press of a button and are archived as a message history. Relevant process data and messages are also stored to SD card and can be analysed later as required. The main components of the turbo blower are shown clearly and unambiguously as a P+I diagram, from which their operating and status data can be read immediately. This includes the components through which the process air flows, th

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ose of the cooling circuit, the motor (rotor position and magnetic bearing temperature) and the frequency converter (voltage, current and temperature). ~ ~ Image: © by-studio - Fotolia Master controller Remote control from a control centre Modbus TCP, EtherNet/IP, Profinet and Profibus DP, each with a comprehensive process image, are available for communication and remote control via data bus connection. The machine operating limits are also communicated via these technologies to safeguard control. Alternatively, the machine can be controlled via analogue and digital interfaces. A master controller is available for connection of up to 10 turbo blowers. In ’Flow rate’ or ‘Pressure control’ operating mode, the master controller coordinates efficient operation of the individual machines within the blower station, as well as their switching processes. In addition, the controller's bus protocol not only delivers the current process data, but also the status data of the indiv

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idual machines to the master control centre. PROFIBUS, PROFINET, Modbus TCP and EtherNet/IP are available for communication. 15 s n io t p o d n a s ie r o s s Acce Your needs – Our solutions Climate control unit Diffuser Compensator Non-return flap The add-on parts are available to fit DIN and ANSI flanges, the diffusers are also offered as 90° versions. Pipe silencers are also available upon request. 16 Control cabinet climate control Nitrogen variants – Nitrogen version The optional climate control unit for control cabinet cooling enable turbo blower operation in ambient temperatures up to 45°C (300 kW series) and even 55°C (150 kW series), as long as the drive section is also supplied with sufficient cooling water. The climate control units are thermally controlled, the cooling air in the control cabinet is decoupled from the environment. A special version of the 150 kW turbo blower is available for conveying of the inert gas nitrogen, e.g. for air knife applic

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ations in the steel industry. With this version, the suction-side process line can be connected directly. The turbo blower’s exceptional control dynamics are highly valued for this purpose. System solutions from KAESER Since you generally require complete system solutions to meet your industrial process needs, rather than individual components, KAESER is the perfect partner for you. Our philosophy is to provide reliable and efficient holistic solutions that go beyond machine and control technology. This starts with expert planning and continues with customer focus and ready availability of service parts to keep your process running safely and efficiently at all times. Technological expertise Service/After-sales As a leading manufacturer of rotary lobe, screw and turbo blowers, KAESER is always able to advise which technology is right for your specific application. Function and efficiency require correct coordination of the process needs with the properties of the particular blow

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er technology. No machine is 100 % maintenance-free. In order to keep key processes running smoothly, you need an efficient partner with a comprehensive service network. gins tem be tive sys c e ff u e yo d re with ient an rt, an effic R is the E l suppo to S a d E n a A io o s K s . g fe o The r in r p nn omplete provide pert pla gh to c to u o y r a th w with ex e analysis tep of th l system every s ia it in h wit starting esign. d n o stati ing lann Expert p 17 Assembly 18 Production Assembly Quality assurance Highest possible vertical integration of mechanical and electrical components at the KAESER factory guarantees consistent quality and seamless interaction of every individual part. “Made in Germany” represents the very highest standards with regards to component manufacture and assembly in accordance with stringent quality regulations. This not only includes hardware components, but also software. Prior to delivery, each blower is subjected to an intensive fa