Booster

KAESER Kompressoren / [Link] / Page 1

Booster groups

• One-cylinder type
N 60-G

• Two-cylinder types
N 153-G / N 253-G / N 351-G / N 502-G

• Three-cylinder typen
N 753-G / N 1100-G / N 1400-G / N 2001-G

KAESER Kompressoren / [Link] / Page 2

Design Details

• One-cylinder Type N 60-G

- only air cooled

- direct drive
- 2.2 kW motor
- optional idling control (AP),
only in connection with YΔ-drive
- no oil level monitoring
- gauge pressure max. 35 bar

KAESER Kompressoren / [Link] / Page 3

Design Details
• Two-cylinder types N 153-G

- only air cooled

- based on N 253-G
- direct drive
- 2.2 kW / 4.0 kW motor
- optional idling control (AP),
only in connection with YΔ-start
- no oil level monitoring
- gauge pressure max. 40 bar

KAESER Kompressoren / [Link] / Page 4

Design Details
• Two-cylinder types
N 253-G / N351-G / N501-G
- only air cooled
- star-delta start (control box must
be ordered at Kaeser)
- connection box
- 11 kW / 18.5 kW motor
- standard idling control
- standard oil level monitoring
- gauge pressure max. 45 bar
- oil pumpe
- manometer for inlet pressure
- manometer for outlet pressure
- manometer for oil pressure
- temperature gauge with switch point
for compressed air temperature

KAESER Kompressoren / [Link] / Page 5

Design Details
• Three-cylinder types
N 753-G / N 1100-G / N 1400-G / N 2001-G
- air or water cooled
- star-delta-start (control box
must be ordered at Kaeser)
- connection box
- 22 kW / 45 kW motor
- standard idling control
- standard oil level monitoring
- gauge pressure max. 45 bar
- oil lpump
- manometer for inlet pressure
- manometer for outlet pressure
- manometer for oil pressure
- temperature display with switch point
for compressed air temperature
- combined pneumatic inlet and venting valve
- pressure switch for pre-pressure monitoring included
KAESER Kompressoren / [Link] / Page 6
Automatic Belt Tensioning

old new
(manual) (automatic)

KAESER Kompressoren / [Link] / Page 7

Oil lubrication

KAESER Kompressoren / [Link] / Page 8

Booster control
Start-Stop-Control:
No electrical control box required, booster is switched to
full load / idle via a pressure switch with integrated overload protection.

 

KAESER Kompressoren / [Link] / Page 9

Booster control
Idling control (Dual control), electric :
Only possible star-delta start.
Special Kaeser YΔ- control box necessary due to additional functions:

The following takes place when the cut-out pressure is reached:


- inlet valve closes, venting valve opens 
- drive motor runs further
- idle period timer will start
- pressure requirement during idling leads to a short
reaction time and refilling of net
- engine will switch off after sequence of idle period without pressure requirement
in interim time; when the net pressure falls till to cut-in pressure, the motor will
run again via YΔ- switching
Advantages:
- faster reaction time
- additional internal Booster cooling during idling
- high pressure side smaller air receiver possible

KAESER Kompressoren / [Link] / Page 10

Booster control
Idling control:
Inlet
filter
check valve


Inlet in larger types:

venting
valve valve combined control valve for
pneumatic inlet- / venting
valve
KAESER Kompressoren / [Link] / Page 11
Booster control
Idling control:
check valve

Inlet
combined
 filter
 control valve for
pneumatic inlet
/ venting valve

Venting
valve Inlet
valve

KAESER Kompressoren / [Link] / Page 12

Influences on Booster performance
Booster:
Intake from a closed system variable inlet pressure influences the effective free air
delivery and the power consumption

to low pressure net

to high
pressure net

KAESER Kompressoren / [Link] / Page 13

Influences on Booster performance
What influences the effective (FAD) of a Booster ?

Booster speed Booster inlet pressure:

Example: N 753-G 10/45 bar Example: N 753-G with 1100 rpm

FAD at 1100 rpm: 7,65 m³/min FAD at 10 bar: 7.65 m³/min

Motor airend performance: 30 kW Motor airend performance: 30kW

FAD at 990 rpm: 6,9 m³/min FAD at 9 bar: 6.75m³/min

Motor airend performance: 27 kW Motor airend performance: 29 kW

KAESER Kompressoren / [Link] / Page 14

Influences on Booster performance

Compression principle

KAESER Kompressoren / [Link] / Page 15

Compressed air production
Effective FAD at reciprocating compressoren
Pressure drop Leak loss Warming
intake side of inlet air Dead
Theoretical space
inlet volume

Losses

Effective
FAD

KAESER Kompressoren / [Link] / Page 16

Booster Design
Allowed cut-in period /capacity:
Depends on:
- pressure relation
P End (a) / P Ein (a)
 - Ambient
temperature

- Compressed air
inlet temperature

Influence on:
compressed end
temperature

KAESER Kompressoren / [Link] / Page 17

Booster Design
correct data for conditions varying from standard:

Please enquire at IS / Project team



FAD / (volume x Inlet pressure (a)) = Volumetric degree of efficiency

We will work out a solution with complete technical data

with our technical department.

KAESER Kompressoren / [Link] / Page 18

Duration and service interval

KAESER Kompressoren / [Link] / Page 19

Duration and service interval
Service works arising for N 60-G and N 153-G

Interval Jobs to be done

Daily Check oil level in crankcase
24 h after commissioning Check V-belt tension
or replacing V-belt

50 h after commissioning Check all electrical screw connections if tight and

tighten if required

Carry out compressor oil change

KAESER Kompressoren / [Link] / Page 20

Duration and service interval
Service works arising for N 60-G and N 153-G
Interval Jobs to be done
Every 500 h or Carry out compressor oil change
at least yearly Change oil filter (Venting crankcase)
Check and clean dirt trap
Check V-belt tension
Check safety valve
Check and clean magnetic valve

Every 2 000 h Replace solenoid valve

Every 3 000 h Check cylinder head function and the valves

Every 10 000 h Change motor bearings

General overhaul of compressor

KAESER Kompressoren / [Link] / Page 21

Duration and service interval
Service works arising for N 253-G and larger

Interval Jobs to be done

Daily Check oil level in crankcase
24 h after commissioning Check V-belt tension
or after replacing
V-belt

50 h after Check all electrical screw connections if tight and

tighten if necessary No
commissioning oil change required
200 h after commisioning Carry out compressor oil change
Replace oil filter

KAESER Kompressoren / [Link] / Page 22

Duration and service interval
Service works arising for N 253-G and larger

Interval Jobs to be done

Every 500 h Check and clean air inlet filter
or at least yearly Check and clean dirt trap
Check V-belt tension
Check and clean check valve
Check safety valve

Clean sieve on compressed air after cooler

Every 1 000 h Carry out compressor oil change

KAESER Kompressoren / [Link] / Page 23

Duration and service interval
Service arising for N 253-G and larger

Interval Jobs to be done

Every 2 000 h Renew solenoid valve
Check function cylinder head and valves
Every 3 000 h Check function cylinder head and valves

Alle 12 000 h Replace motor bearings

General overhaul of compressor

KAESER Kompressoren / [Link] / Page 24

Installation instruction
Cooling air flow system

cooling air
outlet

cooling air inlet

cooling air outlet

cooling air inlet cooling air inlet cooling air inlet

KAESER Kompressoren / [Link] / Page 25
Installation instruction
Cooling air flow system
cooling air inlet

cooling air
outlet

cooling air cooling air

inlet outlet

KAESER Kompressoren / [Link] / Page 26

 Innovations 2-cylinder Booster
N 351-G N 350-G
enlarged
Separate steel compressed air after
grid belt guard cooler

cooling air
guide plate

screwable lubricated oil

machine feet filter

Instrument and filter for

connection box discharge air

modified crankcase venting

(oil collecting tank)

KAESER Kompressoren / [Link] / Page 27

Innovations 2-cylinder Booster
Filter for crankcase venting

No more oil
collecting tank
required
Lubricated oil
sump will be
sucked oil pump.

KAESER Kompressoren / [Link] / Page 28

Innovations 2-cylinder Booster

monitoring compressed lubricating oil

air outlet temperature circulation with dirt
trap

KAESER Kompressoren / [Link] / Page 29

Innovations 2-cylinder Booster
Lubricating oil pump N 253-G till N 502-G

1 oil filler

2 inspection glass

4 3 lubricating oil filter

3
4 oil pressure switch

KAESER Kompressoren / [Link] / Page 30

Innovation 2-cylinder Booster

Display on instrument table: Addtional changes:

- oil pressure - gauge pressure till max. 45 bar
- inlet pressure - motor drive IP 55 at N 351-G
- compressed air temperature at cooler - outlet discharge air to compressed
outlet with potential free contakt air aftercooler
- outlet pressure Booster - revised belt guard grid for easy
maintenance

KAESER Kompressoren / [Link] / Page 31

What is the result of the listed aspects?
One in practice and a German TÜV certified quality solution!



KAESER Kompressoren / [Link] / Page 32

Compressed air quality

KAESER Kompressoren / [Link] / Page 33