Future-ready with Super-premium-efficiency IE4 Motors

02.02.18 Members

Kaeser Compressors has just announced the launch of its latest generation of ESD series rotary screw compressors. Equipped as standard with super-premium efficiency IE4 motors, end users can now enjoy even lower energy consumption for significant energy cost savings.

The latest generation of ESD series rotary screw compressors from Kaeser consume up to 8 percent less energy than previous models, yet deliver 6.5 per cent higher flow rates. Numerous optimisation measures, such as further-improved Sigma Profile screw compressor blocks and the use of IE4 motors, have significantly improved the overall energy profile.

The exceptional performance of the ESD series compressors is due in large to Kaeser’s refined technical concept. At the heart of every ESD system lies a flow-optimised rotary screw compressor block with energy-saving Sigma Profile rotors that allows the ESD series compressors to set the new standard when it comes to specific power.

The use of IE4 super premium efficiency motors (that comply with, and exceed prevailing Australian GEMS regulations for 3 phase electric motors) underlines Kaeser’s continued commitment to providing maximum efficiency, not only to save energy, but also to assure compressor competitiveness well into the future. 

IE4 motors are the technology of tomorrow, as current regulations introduced in January 2015 simply require the use of IE3 class motors.

Moreover, the Electronic Thermal Management system delivers additional energy advantages, as do the environmentally-friendly fluid filter and integrated Sigma Control 2 controller. Electronic Thermal Management consistently controls the oil temperature within a constant, safe differential relative to the dew point (condensation temperature) - which also helps avoid unnecessarily high screw compressor block discharge temperatures - thereby contributing to higher overall energy savings and extended service life.

Kaeser’s engineers have also equipped the new ESD series compressors with another small, but clever, detail to aid heat recovery. Amazingly, a compressor converts 100 percent of its input drive energy into heat, of which 96 percent can be recovered and used for heating purposes – the associated savings benefit is therefore huge. With optional heat recovery equipment, a second Electronic Thermal Management system ensures optimum use of the heat energy that arises from the compression process. For example, when all of the heat energy has been fed into the heat recovery system, the intelligent Sigma Control 2 controller recognises that cooling is no longer required from the system cooler – so it simply deactivates the fan at the fluid cooler, which in turn leads to further energy cost savings.

Energy-saving, environmentally-friendly fluid filter

The principles of resource conservation are also consistently applied inside the compressor unit: the environmentally-friendly fluid filter elements now simply sit in an aluminium housing, with no need for a sheet metal enclosure. The filter elements themselves are completely free of metal, making disposal straightforward: at the end of their service life, they can be thermally disposed of without additional pre-treatment.

Controller ensures optimised operation

The advanced Sigma Control 2 compressor controller provides comprehensive monitoring of the compressor and, if equipped, the frequency converter (SFC variable speed control option). It also enables the compressor to utilise powerful networking solutions and allows straightforward connection to a master control system, such as the Sigma Air Manager 4.0, or to a control centre.

Kaeser’s new ESD compressors are therefore perfectly equipped to benefit from all of the advantages that true Industrie 4.0 production environments have to offer.

The ESD series rotary screw compressors are available with drive powers of 200 and 250 kW, and produce flow rates from 8.6 to 44.5 m³/min, designed for pressures up to 15 bar.