w p r e s s u r e

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 pro-
vides 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
Direct power transmission between the motor and impeller, combined with speed-con-
kWh
trolled flow rate regulation, ensure remarkable 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
with minimal installation effort. The intake air filter is al-
ready 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
 Applications – Flexible and versatile

Montage uses images from: © Valenty, navintar, industrieblick - stock.adobe.com

TANK YEAST AIR KNIFE
AERATION FERMENTATION

Food and pharma-

Water management Industry
ceutical industry

► Aeration, flotation ► Fermentation, dispersion ► Cooling air, combustion air

Flue gas desulphurisation

Always the first choice for an efficient and reliable

Efficient compressed air supply
Whether for use in water treatment applications, yeast
production, bioreactors, for air knife applications in the
Reliable steel industry, or for the purposes of flotation, turbo blow-
ers from KAESER impress with their reliability, efficiency
and exceptional ease of maintenance. Since they are

Low maintenance
completely oil-free, they are the ideal choice for sensitive
processes – such as those in the food industry.

3
 Turbo blower technology
Turbo blowers work on the principle of dynamic compression. The impeller of the radially-acting turbo compressor accel-
erates 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.
© KEBA Industrial Automation Germany GmbH, Simone Schuldis - Fotolia

Image: Magnetic bearing motor with attached impeller

The high-speed motor

A high efficiency permanent magnet synchronous motor with zero contact or wear, but also permits virtually unlimited
(PMSM) is responsible for the direct and loss-free gener- motor starting frequency.
ation of impeller speeds up to 30,000 rpm. The motor’s
Furthermore, the active magnetic bearing immediately de-
impressive performance is made possible due to its
tects and compensates for deflections to keep the motor
canned motor design, whereby the stator and magnetic
shaft safely in its rotational orbit. The magnetic bearing
bearing are encapsulated from environmental influenc-
control device is protected against power supply failure
es - and without a wearing shaft seal. In order to ensure
by regenerative motor operation. In the event of un-
effective and controlled cooling, the motor is exclusively
expected, drastic pressure surges, safety bearings
water-cooled, which also protects it from ingress of fine
provide further protection for the motor shaft so
dust.
that it can be brought to a controlled stop without
The motor shaft is levitated by a magnetic bearing that damage.
not only enables the high motor speeds to be achieved

4
What makes the KAESER
turbo blower so special?
Rather than using conventional aviation-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.

Image: KAESER PillAerator HP 4000 turbo blower and impeller

kW/(m³/min)

(m³/min)

Efficiency and control range Cooling concept

Different impeller versions (L, M, H) enable efficient As with modern e-vehicles, the motor and frequency con-
coverage of the power and pressure range required by the verter are water-cooled and are therefore independently
specific application at hand. As shown in the graph, power encapsulated from outside air. The water can be recooled
consumption can therefore be reduced to a minimum either with ambient air, or with an external secondary water
(yellow line) for the required flow rate. The particular aer- circuit, meaning that the heat contained in the cooling fluid
odynamics, which have been refined using complex flow can be subsequently recovered and reused.
simulations, provide a wide flow rate control range.

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
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 has exceptional control dynamics.
For example, speeds of 20,000 rpm are achieved 5 in
seconds.
Image: © KEBA Industrial Automation Germany GmbH

Intelligent magnetic bearing technology Cooler motor

There is more to KAESER’s magnetic bearing technol- With its clever cooling concept - which is independent from
ogy than meets the eye. The bearings are preloaded by ambient air conditions - and canned design, the motor
a permanent magnetic component, which relieves their not only ensures consistent cooling performance, but is
active, electromagnetic component. This consequently also encapsulated against environmental influences. As a
leads to lower winding currents and therefore to reduced result, there is no need for a wear seal between the blower
heat generation. stage and the motor shaft.

6
 Image: Machine layout

True flow rate Always clean

With the KAESER PillAerator, flow rate is measured in The intake filter provides reliable protection against
real-time at the machine inlet. The air inlet is therefore de- upstream influences such as filter breakthroughs and
signed as a nozzle equipped with corresponding pressure contaminated intake air ducts. The process air is filtered
and temperature sensors, to enable greater precision in both when it is drawn in from the ambient surroundings
delivering the required flow rate. 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-cooled 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

Water/air heat exchanger Water/water heat exchanger

The heat exchanger fan operates automatically depending This heat exchanger can be used to provide additional
on ambient conditions and cooling requirement. The con- support at high ambient temperatures, or can be selected
troller also decides when the water/water heat exchanger as the primary cooling system. It is designed as a hybrid
is activated to provide additional support if necessary. It is heat exchanger, so that exhaust heat from the motor and
also possible to select which option is used as the primary frequency converter can be transferred as effectively as
cooling system. possible should heat recovery be required.

8
Exhaust heat utilisation

Save money with heat recovery

The state-of-the-art cooling circuit design is the same as that used in today’s advanced e-vehicles. It protects the core com-
ponents, 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 us-
ing 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 • Usable for processes: Heating biology or bioreactors,
turbo blowers in the drive section, comprising the motor sludge conditioning and drying.
and its control technology. With good use of the machine,
• Usable for buildings: Low-temperature surface heating
this equates to between 6 and 12 kW for medium-sized
or support for the heating circuit, feed into a heat
turbo blowers (150 kW series) and 15 to 20 kW for large
pump to achieve a higher temperature level (service
turbo blowers (300 kW series).
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

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 consequently translates into an
annual CO2 emission of 44 to 73 tons – these figures are doubled for 300 kW series machines.

Approx. 6 %
Montage uses image from: © jokatoons - stock.adobe.com

Machine Process
Drive power Heat capacity

9
 Importance of the coolant for air-conditioning

AIR-
cooled 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 air-

cooled turbo stations with process air intake
via supply air ducting, and supply and ex-
haust air openings for machine room venti-
lation. 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
 WATER-
cooled operation

Water-cooled blower station

operation
In water-cooled operation, the effort re-
quired for room ventilation and cooling is
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 blow-
er, 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

User interface (HMI) Data centre

All performance and operating states can be displayed All other systems, such as the frequency converter, are
on the 9” colour touch panel and users can choose from coordinated via the powerful central processing unit con-
over 20 selectable interface languages. If remote control nected to the HMI. This bundles the flow of information via
capability is not available from the control centre, or if an the HMI and the programmable controller.
associated fault occurs, the machine can be operated
with manual setpoint input (flow rate, pressure or external
process variables).

12
 Image: Elements, electronics side

STOP
EMERGENCY ON

OFF

How it works
(1) Power supply
(2) Transformer
M (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 gener- In the event of a power failure, the machine is shut down
ated via a powerful frequency converter, which enables and comes to a controlled stop. Meanwhile, the power
variable-speed operation and therefore continuous flow supply for the magnetic bearing control unit is generated
rate adjustment to meet actual demand. The closed water by the motor and frequency converter. This eliminates the
cooling circuit ensures consistent frequency converter need for batteries or UPS packages and their associated
performance. 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

Operating data Status data

The operating point is displayed in the turbo blower’s The main components of the turbo blower are shown
characteristic map in real-time. Machine utilisation and clearly and unambiguously as a P+I diagram, from which
distance to operating limits can therefore be immediately their operating and status data can be read immediately.
seen at glance. Messages are displayed on the screen, This includes the components through which the process
are accessible at the press of a button and are archived as air flows, those of the cooling circuit, the motor (rotor posi-
a message history. Relevant process data and messages tion and magnetic bearing temperature) and the frequency
are also stored to SD card and can be analysed later as converter (voltage, current and temperature).
required.

14
 ~ ~

Master controller
Image: © by-studio - Fotolia

A master controller is available for con-

nection 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
Remote control from a control centre the blower station, as well as their switching
Modbus TCP, EtherNet/IP, Profinet and Profibus DP, each processes. In addition, the controller's bus
with a comprehensive process image, are available for protocol not only delivers the current pro-
communication and remote control via data bus connec- cess data, but also the status data of the
tion. The machine operating limits are also communicated individual machines to the master control
via these technologies to safeguard control. Alternatively, centre. PROFIBUS, PROFINET, Modbus
the machine can be controlled via analogue and digital TCP and EtherNet/IP are available for
interfaces. communication.

15
 s s o r ie s a n d o p t io n 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.

Control cabinet climate control Nitrogen variants – Nitrogen version

The optional climate control unit for control cabinet cooling A special version of the 150 kW turbo blower is available
enable turbo blower operation in ambient temperatures up for conveying of the inert gas nitrogen, e.g. for air knife
to 45°C (300 kW series) and even 55°C (150 kW series), applications in the steel industry. With this version, the
as long as the drive section is also supplied with sufficient suction-side process line can be connected directly. The
cooling water. The climate control units are thermally con- turbo blower’s exceptional control dynamics are highly
trolled, the cooling air in the control cabinet is decoupled valued for this purpose.
from the environment.

16
System solutions from KAESER
Since you generally require complete system solutions to meet your industrial process needs, rather than individ-
ual 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 No machine is 100 % mainte-
blowers, KAESER is always able to advise which technolo- nance-free. In order to keep key
gy is right for your specific application. Function and eff- processes running smoothly, you
iciency require correct coordination of the process needs need an efficient partner with a
with the properties of the particular blower technology. comprehensive service network.

gins
lann ing tem be
Expert p ient an
d e ffe c tive sys
re with
yo u
a d to an effic A E S E R is the n a l suppo
rt,
The ro g . K s s io
pert pla
nn in
provide
p ro fe omplete
with ex w a y to th ro u gh to c
tep of th
e analysis
every s in it ia l system
with
starting
o n d esign.
stati

17
 Assembly

Production Assembly Quality assurance

Highest possible vertical integra- “Made in Germany” represents the Prior to delivery, each blower is
tion of mechanical and electrical very highest standards with regards subjected to an intensive factory test
components at the KAESER factory to component manufacture and as- run. Performance data are checked
guarantees consistent quality and sembly in accordance with stringent and documented and core compo-
seamless interaction of every indi- quality regulations. This not only nents are serialised. This ensures
vidual part. includes hardware components, but correct functionality and guarantees
also software. traceability.

18
 Technical specifications

Permissible Flow rate *) Flow rate *) Maximum Weight

Model working Complete system at Complete system at sound pressure
pressure working pressure working pressure level **)

bar m³/min m³/h dB(A) kg 150 KW

HP 4000 0.4 – 1.4 17 – 88 1,000 – 5,300 74 1815 Speed:
30,000 rpm

MP 6000 0.3 – 1.2 22 – 113 1,300 – 6,800 75 1815 Dimensions WxDxH [mm]:
1800 x 1525 x 2125

LP 8000 0.3 – 1.0 25 – 128 1,500 – 7,700 76 1815 Comp. air connection ***):
DN250/PN10

Permissible Flow rate *) Flow rate *) Maximum Weight

Model working Complete system at Complete system at sound pressure
pressure working pressure working pressure level **)

300 KW bar m³/min m³/h dB(A) kg

Speed: HP 9000 0.4 – 1.3 47 – 180 2,800 – 10,800 75 3785

22,000 rpm

Dimensions WxDxH [mm]: MP 12000 0.3 – 1.2 52 – 227 3,100 – 13,600 75 3785
2930 x 2125 x 2155

Comp. air connection ***): LP 14000 0.3 – 1.0 73 – 263 4,400 – 15,800 75 3785
DN400/PN10

*) Pressure differential and flow rate, complete system as per ISO 5389:2005: absolute 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) – dependent upon operating point
***) Compressed air connection (with add-on diffuser)

Performance ranges
1600 1400

1400 1200
HP 9000
HP 4000
MP 12000
Pressure differential (mbar)

Pressure differential (mbar)

1200
1000
MP 6000 LP 14000
1000
800
LP 8000
800
600
600
400
400

200 200

0 1000 2000 3000 4000 5000 6000 7000 8000 0 2000 4000 6000 8000 10000 12000 14000 16000
0 16 33 50 66 83 100 116 133 0 33 66 100 133 166 200 233 266
Flow rate (m³/h), (m³/min) Flow rate (m³/h), (m³/min)
Image: Characteristic map for 150 kW series Image: Characteristic map for 300 kW series

19
The world is our home
As one of the world’s largest manufacturers of
compressors, blowers and compressed air systems,
KAESER KOMPRESSOREN is represented throughout the
world by a comprehensive network of branches, subsidiaries
and authorised distribution partners in over 140 countries.

By offering innovative, efficient and reliable products and

services, KAESER KOMPRESSOREN’s experienced
consultants and engineers work in close partnership with
customers to enhance their competitive edge and to develop
progressive system concepts that continuously push the
boundaries of performance and technology. Moreover,
decades of knowledge and expertise from this industry-
leading systems provider are made available to each and
every customer via the KAESER group’s advanced global IT
network.

These advantages, coupled with KAESER’s worldwide

service organisation, ensure that every product operates at
peak performance at all times, whilst providing maximum
availability.

P-990ED Specifications subject to change without notice. .3/22

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