Oil-free Screw Compressors

CSG-2, DSG-2, and FSG-2 Series

Capacities from: 192 to 1774 cfm
Pressures from: 45 to 145 psig

kaeser.com
Oil-free Rotary Screw Compressors
The new dimension in oil-free compression
With logical component layout and exceptional attention to detail, Kaeser’s 2-stage oil-free air
compressors were designed specifically with the user in mind. Kaeser’s renowned quality offers
peace of mind and built for a lifetime™ reliability.

Long-term reliability Lowest life cycle costs

Compressed air simply has to be available where and Kaeser quality and expertise really count when it comes to the
whenever it’s needed. Kaeser’s 2-stage oil-free rotary screw all-important total system costs for complete compressed air
compressors are built to last and ensure many years of systems. Lowest possible compressed air costs and maximum
dependable performance. With nearly a century of experience availability can be guaranteed only through a combination
in engineering, Kaeser’s components are tried and tested to of perfect interplay between energy efficiency and service /
deliver the durability and compressed air availability needed to maintenance, and by viewing the compressed air supply system
meet the toughest demands. as a whole.

Innovation you can trust Service-friendly

Using all of the advantages that Kaeser’s advanced Research These versatile systems were engineered for maximum ease-
and Development Center in Coburg, Germany has to offer, of-use and servicing right from the outset of the design stage.
Kaeser’s engineers have designed every detail of these oil-free Fewer wearing parts and using premium quality materials
air compressors with maximum efficiency and performance in ensure reduced maintenance requirements, longer service
mind. intervals, and extended service life. Excellent component
accessibility as a result of generously sized maintenance doors
and a swing-out cooler are just some of the features that make
servicing these units so effortless.

Energy Costs Savings Potential: up to 70%

Energy efficiency
Energy Costs Capital and maintenance costs account for only a small part of
a compressor’s total life cycle costs. Since energy accounts for
the largest portion, Kaeser has been committed to minimizing
your energy costs for compressed air production for over 40
Commissioning
years.

Life Cycle Costs

Capital Costs

Maintenance Costs

2
3
4
Kaeser airends: Precise, durable, efficient

Proven airends Durable coating

At the heart of every Kaeser oil-free compressor lies a rugged, The blasted and bonderized rotors are treated using a special
two-stage rotary screw airend proven to withstand the toughest coating process which provides an innovative and durable
operation. Providing optimum performance and dependability, coating resistant to temperatures up to 575°F. Because this
every airend ensures maximum efficiency throughout its entire coating is highly abrasion-proof, its sealing and protection
service life. performance remain consistent — even after years of operation
— ­providing additional cost savings.

Chromium steel rotors Jacket-cooled airend

The second compression stage’s rotors are made from Jacket cooling is used in the high pressure compression stage
stainless steel, which eliminates the risk of rotor corrosion and of the airend to ensure optimal heat dissipation, which greatly
seizing. enhances efficiency.

5
Efficient drive systems with advanced control

Sigma Control 2™ Integrated web server

The onboard controller ensures efficient control and compressor The Sigma Control 2 is equipped with its own web server,
operation monitoring. The large display and RFID reader making compressor status visualization possible via Intranet/
provide easy communication and maximum security. Multiple, Internet. This means that operational data and maintenance/
selectable interfaces enable seamless networking capability, alarm messages can be viewed, with password protection,
while the SD card slot makes updates quick and easy. from any PC running a standard Internet browser. This feature
benefits users by simplifying operation and maintenance.

Sigma Air Manager 4.0 Kaeser Connect

This advanced master control system can coordinate operation The Sigma Air Manager 4.0’s integrated web server provides
of up to 16 rotary screw compressors with maximum energy visual display of all compressed air system data in the form of
efficiency and also enables seamless documentation of all HTML pages. The information is available anytime, anywhere,
operational parameters. and can be visualized in real-time on all network-capable
devices.

6
7
Service-friendly

(1) Hydraulic inlet valve (2) Fiber-free pulsation dampeners

The hydraulically operated inlet valve on Kaeser oil-free rotary Kaeser’s fiber-free pulsation dampeners keep pressure losses
compressors is unaffected by contamination and condensate. to an absolute minimum, help maintain consistent air quality,
This makes the valve more reliable and easier to maintain than and minimize unwanted vibration. In addition, their fiber-free
pneumatic styles. design reliably eliminates the possibility of compressed air
contamination.

8
(3) Easy access coupling (4) High efficiency condensate separator
The electric motor directly drives the airend with zero Thanks to its flow-optimized design, the newly developed
transmission losses via a maintenance-free coupling. As there condensate separator reliably separates the condensate
is no need for complicated disassembly or alignment work, the downstream of the aircoolers—with minimal pressure loss.
easy-access coupling can be exchanged quickly and easily.

9
 115°F
Cleaning made simple Reliable operation even in extreme heat
Cleaning the aircoolers on DSG-2 and FSG-2 models is Air-cooled units can operate dependably in ambient
convenient and easy thanks to our unique swing-out design— temperatures up to 115°F thanks to the durable and energy-
no crane is needed. Service technicians can clean the coolers efficient radial fan.
in considerably less time and right next to the machine, without
the risk of contaminating the unit’s interior.

10
 Air-cooling

Dependable performance—
Even under extreme conditions
The benefits:
• Cooling water infrastructure not needed

• Meticulously designed machines with logical component

layout make maintenance and service work quick and
easy, ensuring further savings

• The heated cooling air can be easily re-used for space-

heating

Outstanding durability thanks to pre-cooling Energy-saving interior ventilation

Highly effective pre-cooling with a stainless steel tube cooler on When the large radial fan in air-cooled oil-free compressors
the high pressure side ensures outstanding air cooler durability. is switched off as part of the transition to standby mode, this
Furthermore, this durable cooler combination also delivers energy-saving, temperature-controlled standstill fan reliably
comparably low compressed air discharge temperatures. removes the remaining heat in the compressor package.

11
Water-cooling

Compact energy savers

The benefits:
• Exceptionally low compressed air discharge temperature
thanks to separate high quality air coolers

• Load-dependent cooling water for optimum compressor

cooling and simultaneous, efficient cooling-water usage

• Compact design

Parallel heat exchanger Optimized water cooler

Both the low and high pressure stages of Kaeser’s water- Water-cooled compressors feature highly efficient air/water heat
cooled oil-free screw compressors are equipped with their own exchangers. Cupronickel (CuNi10Fe) cooling pipes with internal
dedicated parallel heat exchanger for enhanced heat transfer. star lamella fins provide optimum heat transfer and the lowest
This optimized cooling improves specific power performance. possible compressed air discharge temperatures with minimal
pressure loss.

12
 SIGMA CONTROL 2
compressor controller

Water control valve Water volume

Smart control Permanent adjustment

Water-cooled oil-free compressors feature sealed water control The important but time consuming task of performing hydraulic
valves that are actuated via the onboard Sigma Control 2. The adjustment of both aircoolers is carried out continuously
controller precisely adjusts water volume to meet actual load and automatically when the machine is in operation. Cooling
requirement. performance is therefore optimally matched to the operating
conditions.

13
14
Variable frequency drive (SFC)
Kaeser’s oil-free screw compressors are available with integrated Sigma Frequency Control (SFC) to provide superior part load
efficiency and steady pressure in applications with varying air demands. Standard features include EMI filters and line reactors for
extra electrical system protection.

Specific power (kW/100 cfm)

Conventional
speed control

Efficient
SFC speed control

Flow rate (cfm)

VFD drive from Siemens Optimized specific power

Together, the moderate maximum speed and near-constant
SFC versions feature the latest in Siemens drive technology for
specific power across the wide variable speed control range,
enhanced reliability, world-wide support, and easy integration
achieve significant energy savings throughout the entire
into system controls. The Siemens frequency converter has a
operating curve.
control algorithm adapted to the motor. With the finely turned
combination of a frequency converter and a synchronous
reluctance motor, Kaeser achieves the “IES2” highest system
efficiency class as defined by the DIN-EN 50598 standard.

Premium efficiency drive motors Safe operation even in hotter environments

Kaeser uses premium efficiency Totally Enclosed Fan Cooled A generously-sized SFC module and efficient control cabinet
(TEFC) motors with class F insulation for extra protection from cooling allow Kaeser variable frequency drive compressors to
heat and contaminants. Each of the three motor windings is be used in high ambient temperatures.
actively monitored through its own Pt100 temperature sensor.
Kaeser is currently the only compressed air systems provider to
equip its compressors with super premium efficiency IE4 motors
as standard. Standard voltages are 460 or 575 V (3-phase, 60
Hz). Other voltages are available.
15
Integrated refrigerated dryer (T models)
Kaeser’s CSG-2 (50 - 125 hp) models are available with an optional integrated refrigerated dryer to ensure compressed air drying
for the intended application and all flow rates. These high quality industrial machines protect your pneumatic equipment and protects
from moisture — even under the harshest conditions.

dp ≤ 1.5
Energy-saving drying
An integrated design, together with the generously-dimensioned
aluminum block heat exchanger, keeps pressure loss less than
1.5 psi. The energy-saving scroll refrigeration compressor helps
achieve compressed air energy savings.

Excellent accessibility
All refrigerated dryer components are easily accessible via the
service door on the front of the unit, making dryer service and
maintenance work a breeze.

16
Centrifugal separator with Eco-Drain
Before flowing into the refrigerated dryer, the compressed air
passes through Kaeser’s unique centrifugal separator which
efficiently removes accumulating condensate. This reduces the
load on the dryer as well as energy consumption. A zero loss
Eco-Drain is standard to automatically remove the captured
moisture.

Global Warming Potential

Climate friendly R-513A refrigerant

In addition to energy saving controls, our integrated dryers
feature the new R-513A refrigerant with 56% lower global
warming potential (GWP) than common dryer refrigerants.
Combined with our advanced heat exchanger design, we need
only half the refrigerant — resulting in the most climate friendly
dryer possible.

17
 32
Pressure dew point (°F)

14 Partial-flow
regeneration
-4

-22 Full-flow
regeneration
 Full-flow regeneration  Partial-flow regeneration -40

Regeneration area: Hot air removes moisture from the desiccant 50 68 86 104 122
Drying area: Moisture is drawn into the desiccant from the cold air Coolant temperature (°F)

Full-flow regeneration Consistent drying

Unlike other designs, the i.HOC® (Integrated Heat of The advantages of full flow regeneration become obvious,
Compression Dryer) system uses 100% of the heat of especially with increased coolant temperatures. Kaeser
compression from the second compressor stage for drying rotary drum dryers achieve outstanding drying results without
purposes (full-flow regeneration). This heat is produced and additional electric heating for air regeneration.
available for use at no extra cost.

18
 Integrated Heat of
Compression Dryer
(i.HOC®)
All Kaeser oil-free compressors are available with an optional
integrated heat of compression dryer. The patented i.HOC®
rotary drum dryer from Kaeser uses up to 100% of the heat of
compression for energy saving drying. Thanks to its full-flow
regeneration method, these dryers deliver reliable pressure dew
points as low as -22°F (-30°C)—without electrical heating or
additional cooling of the regeneration air. Available either air-
cooled or water-cooled on all models.

The benefits:
• Dependable pressure dew points below freezing even with
high ambient or coolant temperatures

• Pressure dew point stability even at the lowest compressor

load — without the need for a partial load compensator.

• Available with pressure dew point control as required

• Highly effective drying and heat recovery with water-cooled

compressors

104.5

103.0
Regeneration air i.HOC
inlet outlet
101.5
psig

100.0

98.5
Radial fan
inlet

Dew point control No pressure loss

The i.HOC® rotary drum dryer’s intelligent control ensures dew The radial fan at the bottom of the dryer equalizes drying
point stability even with fluctuating flow rates and at compressor process pressure losses as required, thereby guaranteeing
partial load. When commissioned, the target pressure dew point maximum pressure dew point stability and quality—the pressure
is reached after just one rotation of the drum. at the i.HOC® dryer outlet is higher than at the inlet.

19
 3

2 5

1 Hot air enters dryer from compressor 4 Separator and Eco-Drain remove liquid

2 Hot air generates wet desiccant 5 Dry desiccant adsorbs water vapor

3 Cooler condenses water to liquid 6 Air exits dryer

20
i.HOC®
Ultra efficiency and low pressure dew points

Durable, low-dust drum Variable speed drum motor

The silica gel desiccant is embedded in a precisely The speed of the drum is automatically adjusted to actual
manufactured drum with plain thrust bearings for exceptionally compressor performance in order to regenerate the desiccant
high run-out qualities. The superior sealing between the as effectively as possible. This is the key to ensuring
desiccant and the regeneration sections reduces pressure dew consistently low pressure dew points at varying loads.
point fluctuations and increases energy efficiency. Low dust
desiccant extends downstream filter life.

Durable and efficient Condensate separation

Thanks to computational fluid dynamics optimization, the flow- A highly efficient condensate separator downstream of the
optimized radial fan installed in the base of the dryer efficiently second stage heat exchanger removes condensate absorbed
compensates for the pressure losses in the i.HOC cooling path. during the regeneration process. Moisture is removed via Eco-
Drain to prevent contamination and increase service life.

21
Air treatment options
Depending on the pressure dew point you need, Kaeser offers several options, from traditional refrigerated
dryers to heatless desiccant dryers. The i.HOC dryer presents a unique combination of low dew point,
space savings, and superb energy efficiency. Contact your local authorized Kaeser representative to
discuss your air treatment needs.

Refrigerated dryer Integrated heat of compression dryer

For many oil-free applications, refrigerated dryers are the go-to For dew points as low as -22°F, the optional i.HOC drum dryer
choice for delivering the best possible energy efficiency and is integrated into the package. The hot compressed air from the
lowest investment cost for dew points down to 38°F. For lower second compression stage is used to regenerate the desiccant.
dew points, a desiccant dryer is needed.

38°F -22°F
Cost Comparisons
Annual Energy Costs
$30,000

$25,000

$20,000

$15,000

$10,000

$5,000

0
Refrigerated Heat of Heatless Blower Purge
Dryer Compression Dryer Desiccant Dryer Desiccant Dryer
Based on 8760 hours of operation, maximum ambient temperature 100°F, air pressure at dryer inlet 100 psig, maximum air
temperature at dryer inlet 100°F, maximum air flow rate of 1000 scfm, and $0.10/kWh.

22
 + +

Heated desiccant dryer Heatless desiccant dryer

For dew points as low as -40°F, Kaeser heated exhaust If extremely low dew points are needed, the Kaeser KAD
or blower purge desiccant dryers (KED and KBP) are cost heatless desiccant dryer can reach dew points as low as
effective choices, especially for larger flow applications. -100°F. KAD dryers are initially less expensive than blower or
exhaust purge dryers, however they have the highest operating
costs due to purge losses.

-40°F -100°F

$250,000

$200,000

$150,000

$100,000

$50,000

0
1 2 3 4 5 6 7
Refrigerated Dryer Heat of Compression Heatless Desiccant Blower Purge
Dryer Dryer Desiccant Dryer

Based on 8760 hours of operation, maximum ambient temperature 100°F, air pressure at dryer inlet 100 psig, maximum air
temperature at dryer inlet 100°F, maximum air flow rate of 1000 scfm, and $0.10/kWh.

23
Heat recovery

Air-cooled compressors
Recovering warm compressor exhaust air is an innovative way
to seize savings potential. Kaeser has the expertise to help you
with everything you need to know and will be with you every
step of the way.

Water-cooled compressors
Using the compact heat recovery module integrated directly into
the compressor, generating hot water for production or auxiliary
heating purposes couldn’t be simpler. Cost and space-intensive
external infrastructure is not necessary with Kaeser’s solutions
and the amortization period of the heat recovery module is
usually less than a year (see sample calculation below).

Example amortization calculation water-cooled compressor

Inlet temperature 68°F
Relative humidity 30%
Cooling water inlet (primary) 68°F
Cooling water outlet (primary) 176°F
Compressor power consumption CSG-130-2 145 psi(g) 130 hp
Heat recovery potential based on total power consumption 87%
Recoverable heat capacity 113 hp
Annual operating hours 6,000 hrs
Kilowatt hours per year 505,296 kWh
Fuel costs $0.10 / kWh
Annual fuel cost savings $50,530

Amortization period < 1 year

24
 Up to
195°F
hot
Process, heating, and service water Space heating with warm exhaust air
Compressor exhaust heat can be used to produce hot water Heating is made easy thanks to radial fans with high residual
with temperatures up to 195 °F, which can then be used for a thrust. The reusable warm air from air-cooled oil-free screw
wide range of applications. compressors can be easily ducted away to spaces that require
heating—and usually without the need for additional fans.

25
Technical Specifications
SFC Units
FAD Complete Unit
at Max Working
Pressure Rated Standard Air-cooled (4) Units Water-cooled Units
Pressure Sound
Air-cooled Motor
Model Range (1) Level
(acfm) (2) Power
(psig) (dB(A)) (3)
(hp)
Dimensions Weight Dimensions Weight
Min. Max.
W x D x H (in.) (lb.) (5) W x D x H (in.) (lb.) (5)

CSG 70-2 SFC 60 99 337

CSG 70-2T SFC 90 111 297 75 74 5236 5236
CSG 70-2RD SFC 125 126 250

CSG 90-2 SFC 60 117 412

CSG 90-2 T SFC 90 114 374 75 75 5236 5236
CSG 90-2 RD SFC 125 126 321 98 x 645/8 x 84¼ 98 x 645/8 x 77½
60 141 472 T: 111¾ x 645/8 x 84¼ T: 111¾ x 645/8 x 77½
CSG 120-2 SFC 90 161 470 RD: 1235/8 x 645/8 x 84¼ RD: 1235/8 x 645/8 x 77½
CSG 120-2 T SFC 100 76 5545 5545
CSG 120-2 RD SFC 125 147 431
145 170 404

CSG 130-2 SFC 125 183 474

CSG 130-2 T SFC 125 76 5820 5820
CSG 130-2 RD SFC 145 193 473

65 310 795
DSG 180-2 SFC 90 332 761
150 81 9149 8488
DSG 180-2 RD SFC 125 312 665
145 337 615
65 278 823
DSG 220-2 SFC 90 295 821
175 81 9370 8708
DSG 220-2 RD SFC 125 320 773
135¼ x 687/8 x 937/8 135¼ x 687/8 x 811/8
145 378 737
RD: 1681/8 x 687/8 x 937/8 RD: 1681/8 x 687/8 x 811/8
65 309 967
DSG 260-2 SFC 90 330 966
200 82 9700 9039
DSG 260-2 RD SFC 125 347 911
145 364 858
100 382 1059
DSG 290-2 SFC
125 418 1058 250 84 10,141 9480
DSG 290-2 RD SFC
145 447 1057
100 553 1529
FSG 420-2 SFC 14,440 13,779
125 608 1422 350 83
FSG 420-2 RD SFC 17,086 16,314
145 653 1334 152 x 81¾ x 1077/8
143¾ x 81¾ x 873/8
182¼ x 81¾ x 1077/8
100 621 1789 176¼ x 81¾ x 877/8
FSG 500-2 SFC 15,432 14,771
125 666 1702 450 84
FSG 500-2 RD SFC 18,078 17,306
145 702 1612

For NOTES see back page

Specifications are subject to change without notice.

26
Fixed Speed Units
FAD Complete Unit Standard Air-cooled (4) Units Water-cooled Units
Rated
Pressure at Max Working Sound
Motor
Model Range (1) Pressure Level Dimensions Weight Dimensions Weight
Power
(psig) Air-cooled (dB(A)) (3) W x D x H (in.) (lb.) (5) W x D x H (in.) (lb.) (5)
(hp)
(acfm) (2)

CSG 55-2 90 247

CSG 55-2T 50 73 5005 5005
CSG 55-2 RD 125 192

CSG 70-2 60 344

CSG 70-2 T 90 298 60 73 5093 5093
CSG 70-2 RD 125 245
60 390
CSG 90-2 90 342 98 x 645/8 x 77½
98 x 645/8 x 84½
CSG 90-2 T 75 74 5236 T: 111¾ x 645/8 x 77½ 5236
125 296 T: 111¾ x 645/8 x 84¼
CSG 90-2 RD RD: 1235/8 x 645/8 x 77½
RD: 1235/8 x 645/8 x 84¼
145 273
60 461
CSG 120-2 90 459
CSG 120-2 T 100 75 5545 5545
CSG 120-2 RD 125 421
145 420

CSG 130-2 125 457

CSG 130-2 T 125 76 5820 5820
CSG 130-2 RD 145 456

65 581
DSG 140-2 90 579
125 80 7496 6834
DSG 140-2 RD 125 576
145 512
65 694
DSG 180-2 90 692
150 81 7826 7165
DSG 180-2 RD 125 689
145 576
65 820
135¼ x 687/8 x 937/8 135¼ x 687/8 x 811/8
DSG 220-2 90 819
175 81 RD: 1681/8 x 687/8 x 937/8 8047 RD: 1681/8 x 687/8 x 817/8 7385
DSG 220-2 RD 125 780
145 689
65 966
DSG 260-2 90 964
200 82 8378 7716
DSG 260-2 RD 125 908
145 816
100 962
DSG 290-2
125 961 250 84 8819 8157
DSG 290-2 RD
145 961
For NOTES see back page Continued next page

Specifications are subject to change without notice.

27
Fixed Speed Units—Continued
FAD Complete Unit at Standard Air-cooled (4) Units Water-cooled Units
Rated
Pressure Max Working Sound
Motor
Model Range (1) Pressure Level Dimensions Weight Dimensions Weight
Power
(psig) Air-cooled (dB(A)) (3) W x D x H (in.) (lb.) (5) W x D x H (in.) (lb.) (5)
(hp)
(acfm) (2)
90 1144
FSG 300-2 12,236 11,574
125 1006 250 82
FSG 300-2 RD 14,881 14,110
145 795
65 1391
90 1388
FSG 350-2 300 82 12,677 12,015
125 1261
145 1148
125 1261
FSG 350-2 RD 300 82 15,322 14,551
145 1148 152 x 81¾ x 107½
65 1591 182¼ x 81¾ x 1077/8 143¾ x 81¾ x 87½
90 1589 176¼ x 81¾ x 87½
FSG 420-2 350 83 13,118 12,456
125 1501
145 1261
90 1589
FSG 420-2 RD 125 1501 350 83 15,763 14,991
145 1261
FSG 500-2 125 1769 13,779
450 83
FSG 500-2 RD 145 1586 16,424 13,118
FSG 501-2* 15,653
145 1766 450 77 N/A N/A
FSG 501-2 RD*

NOTES:
(1) Other pressures available from 45 to 145 psig. (2) Performance rated in accordance with CAGI/ISO 1217 test code. (3) Per ISO 2151 using ISO 9614-2.
(4) Dimensional drawings for air-cooled and water-cooled units as well as “T” and RD models are available on request from your local authorized Kaeser distributor.
(5) Weights may vary slightly depending on airend model.
460 or 575 V, 3 ph, 60 Hz; other voltages available. Compressors are available water-cooled with stainless steel, plate type heat exchangers as standard equipment.
Shell and tube heat exchangers are available on request.
Specifications are subject to change without notice.

www.kaeser.com

Kaeser Compressors, Inc. Kaeser Compressors Canada Inc. Kaeser Compresores de México Kaeser Compresores de
511 Sigma Drive 3760 La Vérendrye Street S de RL de CV Guatemala y Cia. Ltda.
Fredericksburg, VA 22408 USA Boisbriand, QC J7H 1R5 CANADA Calle 2 #123 Calz. Atanasio Tzul 21-00, zona 12
Telephone: 540-898-5500 Telephone: (450) 971-1414 Parque Industrial Juríca El Cortijo II, Bodega 501
Toll Free: 800-777-7873 Toll free: (800) 477-1416 76100 Querétaro, Qro. 01012–Guatemala City
info.usa@kaeser.com info.canada@kaeser.com Telephone: 01 (442) 218 64 48 Telephone: +502 2412-6000
sales.mexico@kaeser.com info.guatemala@kaeser.com

© 2020 Kaeser Compressors, Inc. All rights reserved. 03/20

USOIL-FREE