Bomba de Vacio BSV SC2 Kaeser

Operator Manual
Rotary screw vacuum pump
BSV SIGMA CONTROL 2

9_5773 32 USE
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
Original instructions
/KKW/SBSV 2.12 en Z1 SBA-SCHRAUBEN-SC
/KKW/SSC 2.08 Z1
20170313 144737
Contents
1 Regarding this Document

1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alerts and their symbols ............................................................................ 2
2 Technical Data
2.1 Nameplate ........................................................................................................................ 4
2.2 Options ............................................................................................................................. 4
2.3 Weight .............................................................................................................................. 4
2.4 Temperature ..................................................................................................................... 5
2.5 Ambient conditions ........................................................................................................... 5
2.6 Ventilation ........................................................................................................................ 5
2.7 Pressure ........................................................................................................................... 6
2.8 Inlet conditions ................................................................................................................. 6
2.9 Suction rate ...................................................................................................................... 6
2.10 Cooling Oil Recommendation .......................................................................................... 6
2.10.1 Basic Information ................................................................................................ 6
2.10.2 KAESER Lubricants ............................................................................................ 7
2.11 Cooling oil charge ........................................................................................................... 7
2.12 Motors and power ............................................................................................................ 7
2.13 Noise emission ................................................................................................................. 8
2.14 Power Supply ................................................................................................................... 8
2.15 Power supply specifications ............................................................................................. 9
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 11
3.2 Specified use .................................................................................................................... 11
3.3 Improper use .................................................................................................................... 11
3.4 User's responsibilities ....................................................................................................... 12
3.4.1 Observe statutory and universally accepted regulations .................................... 12
3.4.2 Qualified personnel ............................................................................................. 12
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 13
3.5 Dangers ............................................................................................................................ 13
3.5.1 Safely dealing with sources of danger ................................................................ 13
3.5.2 Safe machine operation ...................................................................................... 15
3.5.3 Organizational Measures .................................................................................... 16
3.5.4 Danger areas ...................................................................................................... 17
3.6 Safety devices .................................................................................................................. 17
3.7 Working life of safety functions ........................................................................................ 17
3.8 Safety Signs ..................................................................................................................... 18
3.9 Emergency situations ....................................................................................................... 19
3.9.1 Correct fire fighting ............................................................................................. 19
3.9.2 Treating injuries from handling cooling oil .......................................................... 20
3.10 Warranty ........................................................................................................................... 20
3.11 Environment protection .................................................................................................... 21
4 Design and Function
4.1 Enclosure ......................................................................................................................... 22
4.2 Machine function .............................................................................................................. 23
4.2.1 Floating relay contacts ........................................................................................ 23
4.2.2 Safety devices .................................................................................................... 23
4.3 Operating panel SIGMA CONTROL 2 ............................................................................. 24
Operator Manual Rotary screw vacuum pump

9_5773 32 USE BSV SIGMA CONTROL 2 i
Contents
4.4 Operating modes and control modes ............................................................................... 27

4.4.1 Operating modes ................................................................................................ 27
4.4.2 Control modes .................................................................................................... 27
4.5 Options ............................................................................................................................. 28
4.5.1 Machine mountings ............................................................................................. 28
4.5.2 Super sound-proofing ......................................................................................... 28
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 29
5.2 Installation conditions ....................................................................................................... 29
5.2.1 Determining location and clearances .................................................................. 29
5.2.2 Ensuring adequate ventilation ............................................................................ 30
5.2.3 Exhaust duct design ........................................................................................... 31
6 Installation
6.1 Ensuring safety ................................................................................................................ 32
6.2 Reporting Transport Damage ........................................................................................... 32
6.3 Connecting to the vacuum network .................................................................................. 33
6.4 Air discharge line from the oil separator tank ................................................................... 33
6.5 Connecting the power supply .......................................................................................... 34
6.5.1 Setting up main voltage connection for a Tri-voltage machine ........................... 35
6.6 Options ............................................................................................................................. 35
6.6.1 Anchoring the machine ....................................................................................... 35
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 36
7.2 Instructions to be observed before commissioning or re-commissioning ......................... 36
7.3 Checking installation and operating conditions ................................................................ 37
7.4 Setting the overload protection relay ................................................................................ 38
7.5 Filling cooling oil in the airend .......................................................................................... 38
7.6 Starting the machine for the first time .............................................................................. 39
7.7 Setting the setpoint pressure ........................................................................................... 39
7.8 Setting the display language ............................................................................................ 39
7.9 Checking the door interlock switch ................................................................................... 40
7.10 Setting the control mode .................................................................................................. 41
7.10.1 DUAL .................................................................................................................. 41
7.10.2 VARIO ................................................................................................................. 42
7.10.3 CONTINUOUS .................................................................................................... 42
7.10.4 MODULATING control ........................................................................................ 42
7.10.5 MODULATING control: Setting the vacuum regulator ........................................ 42
8 Operation
8.1 Switching on and off ......................................................................................................... 43
8.1.1 Switching on ....................................................................................................... 43
8.1.2 Switching off ....................................................................................................... 43
8.2 Switching off in an emergency and switching on again .................................................... 44
8.3 Switching on and off from a remote control center ........................................................... 44
8.4 Using the timer for switching on and off ........................................................................... 45
8.5 Interpreting operation messages ...................................................................................... 46
8.6 Acknowledging alarm and warning messages ................................................................. 46
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 48
9.2 Other faults ....................................................................................................................... 48
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 50

ii BSV SIGMA CONTROL 2 9_5773 32 USE
Contents
10.2 Following the maintenance plan ....................................................................................... 51

10.2.1 Logging maintenance work ................................................................................. 51
10.2.2 Resetting maintenance interval counters ............................................................ 51
10.2.3 Regular maintenance tasks ................................................................................ 51
10.2.4 Cooling oil change interval .................................................................................. 52
10.2.5 Regular service tasks ......................................................................................... 53
10.3 Cooler maintenance ......................................................................................................... 53
10.3.1 Checking the cooler for clogging ........................................................................ 54
10.3.2 Checking the cooler for leaks ............................................................................. 54
10.3.3 Cleaning the cooler ............................................................................................. 54
10.4 Filter mat maintenance ..................................................................................................... 55
10.5 Changing the gas ballast air filter ..................................................................................... 56
10.6 Changing the vacuum filter .............................................................................................. 57
10.7 Drive motor maintenance ................................................................................................. 58
10.8 Drive belt maintenance .................................................................................................... 58
10.9 Checking the safety relief valve ....................................................................................... 60
10.10 Checking the overheating safety shutdown function ........................................................ 61
10.11 Testing the EMERGENCY STOP push button ................................................................. 62
10.12 Checking the cooling oil level ........................................................................................... 62
10.13 Venting the machine ........................................................................................................ 63
10.14 Replenishing cooling oil ................................................................................................... 64
10.14.1 Venting the machine ........................................................................................... 65
10.14.2 Topping off with cooling oil and trial run ............................................................. 66
10.15 Changing the cooling oil ................................................................................................... 68
10.16 Changing the oil filter ....................................................................................................... 70
10.17 Changing the oil separator cartridge ................................................................................ 71
10.18 Documenting maintenance and service work .................................................................. 74
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 75
11.2 Ordering consumable parts and operating fluids/materials .............................................. 75
11.3 KAESER AIR SERVICE ................................................................................................... 75
11.4 Completing the Declaration of Decontamination .............................................................. 76
11.5 Service Addresses ........................................................................................................... 76
11.6 Spare parts for service and repair .................................................................................... 76
12 Decommissioning, Storage and Transport
12.1 Decommissioning ............................................................................................................. 79
12.2 Packing ............................................................................................................................ 79
12.3 Storage ............................................................................................................................. 79
12.4 Transport .......................................................................................................................... 80
12.4.1 Safety .................................................................................................................. 80
12.4.2 Transport with a forklift truck ............................................................................... 80
12.4.3 Transport with a crane ........................................................................................ 80
12.5 Disposal ........................................................................................................................... 81
12.6 Battery disposal ................................................................................................................ 82
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 83
13.2 Dimensional Drawing ....................................................................................................... 86
13.3 Electrical Diagrams .......................................................................................................... 88
13.3.1 Electrical diagram 1 of 2 ..................................................................................... 88
13.3.2 Electrical diagram 2 of 2 ..................................................................................... 113

9_5773 32 USE BSV SIGMA CONTROL 2 iii
Contents

iv BSV SIGMA CONTROL 2 9_5773 32 USE
List of Illustrations
Fig. 1 Three-phase star (wye); 4 wire; center point solidly grounded ................................................... 8
Fig. 2 Three-phase star (wye); 3 wire; center point solidly grounded ................................................... 9
Fig. 3 Location of safety signs .............................................................................................................. 18
Fig. 4 Enclosure overview .................................................................................................................... 22
Fig. 5 Machine overview ....................................................................................................................... 23
Fig. 6 Keys - overview .......................................................................................................................... 24
Fig. 7 Indicators – overview .................................................................................................................. 25
Fig. 8 RFID sensor field ........................................................................................................................ 26
Fig. 9 Machine mountings .................................................................................................................... 28
Fig. 10 Recommended machine placement and dimensions [inches] ................................................... 30
Fig. 11 Connecting to the vacuum network ............................................................................................ 33
Fig. 12 Connecting the air discharge line ............................................................................................... 33
Fig. 13 Inlet valve oil filling port .............................................................................................................. 38
Fig. 14 Location of the door interlock switch .......................................................................................... 40
Fig. 15 Setting the control mode ............................................................................................................ 41
Fig. 16 Switching on and off ................................................................................................................... 43
Fig. 17 Switching off in an emergency ................................................................................................... 44
Fig. 18 Switching on and off from a remote control center ..................................................................... 45
Fig. 19 Using the timer for switching on and off ..................................................................................... 46
Fig. 20 Acknowledging messages .......................................................................................................... 47
Fig. 21 Cooler maintenance ................................................................................................................... 54
Fig. 22 Filter mat maintenance ............................................................................................................... 56
Fig. 23 Changing the gas ballast air filter ............................................................................................... 57
Fig. 24 Changing the vacuum filter ......................................................................................................... 58
Fig. 25 Drive belt maintenance ............................................................................................................... 59
Fig. 26 Check the safety relief valve ...................................................................................................... 60
Fig. 27 Testing the EMERGENCY STOP push button ........................................................................... 62
Fig. 28 Checking the cooling oil level ..................................................................................................... 63
Fig. 29 Venting the machine ................................................................................................................... 64
Fig. 30 Venting the machine to atmospheric .......................................................................................... 66
Fig. 31 Replenish cooling oil .................................................................................................................. 67
Fig. 32 Changing the cooling oil, oil separator tank ............................................................................... 69
Fig. 33 Draining the oil from the cooler .................................................................................................. 70
Fig. 34 Changing the oil filter .................................................................................................................. 71
Fig. 35 Changing the oil separator cartridge .......................................................................................... 72
Fig. 36 Transport with a forklift truck ...................................................................................................... 80
Fig. 37 Transport with a crane ................................................................................................................ 81
Fig. 38 Battery disposal .......................................................................................................................... 82

9_5773 32 USE BSV SIGMA CONTROL 2 v
List of Illustrations

vi BSV SIGMA CONTROL 2 9_5773 32 USE
List of Tables
Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1

Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Options ....................................................................................................................................... 4
Tab. 5 Machine weight .......................................................................................................................... 4
Tab. 6 Temperature ............................................................................................................................... 5
Tab. 7 Ambient conditions ..................................................................................................................... 5
Tab. 8 Ventilation .................................................................................................................................. 5
Tab. 9 Pressure ..................................................................................................................................... 6
Tab. 10 Inlet conditions ........................................................................................................................... 6
Tab. 11 Suction rate [cfm] ....................................................................................................................... 6
Tab. 12 Cooling oil charge quantity ......................................................................................................... 7
Tab. 13 Compressor motor ...................................................................................................................... 7
Tab. 14 Noise emission ........................................................................................................................... 8
Tab. 15 Noise emission, super silenced .................................................................................................. 8
Tab. 16 Power supply details 208V/ / 3 / 60Hz ........................................................................................ 9
Tab. 17 Power supply details 230V / 3 / 60Hz ......................................................................................... 9
Tab. 21 Danger areas .............................................................................................................................. 17
Tab. 22 Category and Performance Level ............................................................................................... 17
Tab. 23 Safety Signs ............................................................................................................................... 18
Tab. 24 Keys ........................................................................................................................................... 24
Tab. 25 Indicators .................................................................................................................................... 25
Tab. 26 RFID sensor field ........................................................................................................................ 26
Tab. 27 Discharge air line marking .......................................................................................................... 34
Tab. 28 Voltage selection ........................................................................................................................ 35
Tab. 29 Overload protection relay settings. ............................................................................................. 35
Tab. 30 Re-commissioning after storage ................................................................................................. 37
Tab. 31 Installation conditions checklist .................................................................................................. 37
Tab. 32 Control modes ............................................................................................................................ 41
Tab. 33 Machine identification ................................................................................................................. 45
Tab. 34 Remote control center identification ........................................................................................... 45
Tab. 35 Machine identification ................................................................................................................. 46
Tab. 36 Other faults and remedies .......................................................................................................... 48
Tab. 37 Advise others that the machine is being serviced. ..................................................................... 50
Tab. 38 Regular maintenance tasks ........................................................................................................ 52
Tab. 39 Cooling oil change intervals ....................................................................................................... 53
Tab. 40 Regular service tasks ................................................................................................................. 53
Tab. 41 Logged maintenance tasks ........................................................................................................ 74
Tab. 42 Consumable parts ...................................................................................................................... 75

9_5773 32 USE BSV SIGMA CONTROL 2 vii
List of Tables

viii BSV SIGMA CONTROL 2 9_5773 32 USE
1.1 Using this document

1.1 Using this document
The operating manual is a component of the product. It describes the machine as it was at the time
of first delivery after manufacture.
➤ Keep the operating manual in a safe place throughout the life of the machine.
➤ Supply any successive owner or user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Further documents

Further documents included with this operator manual are:
■ Certificate of acceptance / operating instructions for the pressure vessel
■ User manual for SIGMA CONTROL 2
Missing documents can be requested from KAESER.

➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you provide the data from the nameplate when ordering documents.
1.3 Copyright
This service manual is copyright protected. Queries regarding use or duplication of the documenta‐
tion should be referred to KAESER. Correct use of information will be fully supported.
1.4 Symbols and labels

➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of disregard
DANGER Warns of an imminent danger Will result in death or severe injury
WARNING Warns of a potentially imminent danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Tab. 1 Danger levels and their definition (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
Example:

9_5773 32 USE BSV SIGMA CONTROL 2 1
The type and source of the imminent danger is shown here!

The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1. The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe
injury may occur.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
1.4.2 Potential damage warnings

Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
Warning notices for damages are identified by their signal term.

Signal term Meaning Consequences of disregard
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
Example:
The type and source of the imminent danger is shown here!

Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.
1.4.3 Other alerts and their symbols

This symbol identifies particularly important information.

2 BSV SIGMA CONTROL 2 9_5773 32 USE
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
The conditions relevant to safety shown here will help you to avoid dangerous situations.
Option H1 ➤ This symbol denotes lists of actions comprising one stage of a task.
Operating instructions with several steps are numbered in the sequence of the operating steps.
Information relating to one option only are marked with an option code (e.g., H1 indicates that
this section applies only to machines with machine mountings). Option codes used in this oper‐
ator manual are explained in chapter 2.2.
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... as is a solution.
This symbol identifies important information or measures regarding the protection of the envi‐
ronment.
Further information Further subjects are introduced here.

2 Technical Data
2.1 Nameplate
2 Technical Data
2.1 Nameplate
The machine's nameplate provides the model designation and important technical information.
The nameplate is located on the outside of the machine:

■ above the cooler,
or
■ on the rear of the machine.
➤ Enter the data from the nameplate into the table for reference.
Feature Value
Model
Part No.
Serial No.
Year of manufacture
Rated power
Rated motor speed
Maximum working pressure
Minimum inlet pressure
Ambient temperature
Tab. 3 Nameplate
2.2 Options
The table contains a list of possible options.
➤ Enter options here for reference:
Option Option code Available?

Adjustable machine mountings H1
Enclosure: super sound-proof H17
Tab. 4 Options
2.3 Weight
The weight given is the maximum. Actual weights of individual machines are dependent on equip‐
ment fitted.
BSV 80 BSV 100

Weight [lb] 1410 1587
Tab. 5 Machine weight

2 Technical Data
2.4 Temperature
2.4 Temperature
BSV 80 BSV 100
Minimum cut-in tempera‐ 40 40
ture [°F]
Typical airend discharge 160 – 205 160 – 205
temperature during oper‐
ation 1) [°F]
Maximum airend dis‐ 230 230
charge temperature [°F]
(automatic safety shut-
down)
1)
The machine continuously changes the airend discharge temperature corresponding to the am‐
bient temperature.
Tab. 6 Temperature
2.5 Ambient conditions

BSV 80 BSV 100
Maximum altitude 3000 3000
amsl* [ft]
Permissible ambient tem‐ 40 – 105 40 – 105
perature [°F]
Cooling air temperature 40 – 105 40 – 105
[°F]
* Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 7 Ambient conditions
2.6 Ventilation
The values given are minimum guide values.
BSV 80 BSV 100

Inlet aperture Z see fig‐ 3.2 4.3
ure 10 [sq. ft.]
Forced ventilation with 2648 3531
exhaust fan:
Flow rate [cfm] at 0.4 in.
wc
Tab. 8 Ventilation

2 Technical Data
2.7 Pressure
2.7 Pressure
Feature BSV 80 BSV 100
Maximum vacuum 99 / 0.295 99 / 0.295
[%] / [“HgA]
Pressure relief valve acti‐ 14.5 14.5
vating pressure [psig]
Tab. 9 Pressure
2.8 Inlet conditions

BSV 80 BSV 100
Intake air temperature 40 – 105 40 – 105
[°F]
Maximum permissible 0.65 0.65
water vapor pressure*
[psia]
* Higher values are permissible only after consultation with the manufacturer.
Tab. 10 Inlet conditions
2.9 Suction rate

Suction pressure [“HgA] BSV 80 BSV 100
10.0 296 367
7.25 296 367
1.45 247 304
Tab. 11 Suction rate [cfm]
2.10 Cooling Oil Recommendation

A sticker showing the type of oil filled is located near the oil separator filler.
Information for ordering cooling oil can be found in Chapter 13.3.
2.10.1 Basic Information

Lubrication of an air compressor is essential to reliable operation. Carbon and varnish can form in
compressor cooling oils. These deposits block the flow of lubricant and cause excessive wear and
failure of moving parts. Contamination of the lubricant can allow the formation of acids, causing ex‐
tensive internal corrosion. Water may be condensed decreasing the lubricity.
Lubricants in rotary compressors do much more than lubricate. During the compression process, it
acts as a sealant in the airend which is important for maximum efficiency. The lubricant also ab‐
sorbs much of the heat of compression to cool the airend and reduce the temperature of the com‐
pressed air. It’s not enough that a compressor cooling oil lubricates well, it must stand up to the
heat, pressure and contaminants that are present in every air compressor.

2 Technical Data
2.11 Cooling oil charge
2.10.2 KAESER Lubricants

KAESER synthetic lubricants should be stored in a protected location to prevent contamination. Do
not reuse drums; flush and send to reconditioner.
Although the KAESER synthetic is not highly flammable, it will burn. While KAESER synthetic com‐
pressor cooling oil is less flammable than equal viscosity mineral oils, it cannot be classified as a
fire-resistant fluid. It has a flash point above 460 °F. Since the user has total control over the condi‐
tions of the compressor lubricant, he assumes total responsibility for its safe usage.
Material Safety Data Sheets are available for each lubricant from your authorized KAESER Service
representative.
Regardless of the lubricant selected, the KAESER SIGMA lubricants will separate readily from wa‐
ter. If condensate occurs it can easily be removed. Let the compressor sit so that any water can
drain back to the separator tank and separate to the bottom. See chapter 10.15 proper draining
procedure.
KAESER has several lubricants available that are specially formulated to match these demands.
They feature excellent lubricity, outstanding demulsibility (ability to separate from water), and long
life.
S-SERIES:
■ S-Series SIGMA compressor cooling oils are synthetic lubricants.
■ S-Series SIGMA compressor cooling oils are formulated from the most advanced synthetic lu‐
bricants. These “synthetic” lubricants begin as high quality petroleum feed stock. They are then
refined, processed and purified into fluids with very consistent molecular structure. These oils
are carefully blended to produce extremely consistent lubricants with superior properties.
SIGMA synthetic lubricants feature all the advantages of both PAO and diester fluids.
■ S–460 lubricant is recommended for compressors operating in ambient temperatures between
40°F and 105°F.
2.11 Cooling oil charge

BSV 80 BSV 100
Fluid volume* [gal] 10 10
Topping off volume [qt] 8.5 8.5
(minimum–maximum)
Tab. 12 Cooling oil charge quantity
2.12 Motors and power

Compressor motor
BSV 80 BSV 100

Rated power [hp] 20 25
Enclosure protection TEFC TEFC
Rated speed [rpm] 3600 3600
Tab. 13 Compressor motor

2 Technical Data
2.13 Noise emission
2.13 Noise emission

Noise emission [dB(A)]
BSV 80 BSV 100

Noise emission [dB(A)] 71 71
Noise pressure level in operation at maximum working gauge pressure as per ISO 2151 and the
basic standard ISO 9614-2, uncertainty: ±3 dB(A)
Tab. 14 Noise emission
Option H17 Noise emission [dB(A)]
BSV 80 BSV 100

Noise emission [dB(A)] 68 68
Noise pressure level in operation at maximum working gauge pressure as per ISO 2151 and the
basic standard ISO 9614-2, uncertainty: ±3 dB(A)
Tab. 15 Noise emission, super silenced
2.14 Power Supply

Basic requirements
The machine is designed for an electrical supply according to National Electric Code (NEC), edi‐
tion 2014, particularly article 670 and NFPA 79, edition 2015, particularly section 4.3. In the ab‐
sence of any user-specified alternatives, the limits given in these standards must be adhered to.
Consult manufacturer for any other specific power supply.
The incoming line within the control panel should be as short as possible.
If external sensors or communication lines are to be connected to the machine, use shielded ca‐
bles and insert the same through EMC fittings into the control panel.
Three-phase
Do NOT operate package on any unsymmetrical power supply. Also do NOT operate package on
power supplies such as a three phase WYE system with center point not solidly grounded or three-
phase (open) delta.
The machine requires a symmetrical three-phase power supply transformer with a WYE configura‐
tion output as shown in Figure 1 and Figure 2. In a symmetrical three phase supply the phase an‐
gles and voltages are all the same.
Other power supplies are not suitable.
Fig. 1 Three-phase star (wye); 4 wire; center point solidly grounded

2 Technical Data
2.15 Power supply specifications
Fig. 2 Three-phase star (wye); 3 wire; center point solidly grounded
Further information Please contact an authorized KAESER service representative for options.
The electrical diagram 13.3 contains further specifications for electrical connection.

The following multi-strand copper core wires are given according to 2014 NEC 310.15(B)(16) for
40 °C ambient temperature.
If other local conditions prevail, like for example high temperature, the cross section should be
checked and adjusted according to 2014 NEC 110.14(C), 220.3, 310.15, table 310.15(B)(2)(a),
430.6, 430.22, 430.24, 670.4(A) and other local codes.
Dual element time delay fuses are selected according to 2014 NEC 240.6, 430.52 and ta‐
bles 430.52, 430.248 and 430.250. We strongly suggest using a separate copper conductor for the
equipment GROUNDING. 2014 NEC table 250.122 will point out the ”minimum size”, however, we
recommend a ground conductor the same size as the power leads, if local codes allow.
Further information The electrical diagram in chapter 13.3 contains further specifications for electrical connection.
Rated power supply 208V / 3 / 60Hz
BSV 80 BSV 100

Pre-fuse [A] 90 110
Supply 1) 4x AWG4 4x AWG3
Consumption [A] 51 62
1)
75 °C
Tab. 16 Power supply details 208V/ / 3 / 60Hz
Rated power supply: 230V / 3 / 60Hz
BSV 80 BSV 100

Pre-fuse [A] 80 100
Supply1) 4x AWG4 4x AWG4
1)
75 °C
Tab. 17 Power supply details 230V / 3 / 60Hz

2 Technical Data
BSV 80 BSV 100

Pre-fuse [A] 50 60
1)
75 °C
BSV 80 BSV 100

Pre-fuse [A] 40 50
1)
75 °C
Rated power supply 575V / 3 / 60Hz
BSV 80 BSV 100

Pre-fuse [A] 35 40
Supply 1) 4x AWG10 4x AWG10
1)
75 °C

3.1 Basic instructions

The machine is manufactured to the latest engineering standards and acknowledged safety regula‐
tions. Nevertheless, dangers can arise through its operation:
■ danger to life and limb of the operator or third parties,
■ damages to the machine and other material assets.
Disregard of warning or safety instructions can cause serious injuries!
➤ Use this machine only if it is in a technically perfect condition and only for the purpose for
which it is intended; observe all safety measures and the instructions in the operator manual.
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety!
3.2 Specified use

The machine is intended solely for industrial use in generating a vacuum. Any other use is consid‐
ered incorrect. The manufacturer is not liable for any damages that may result from incorrect use.
The user alone is liable for any risks incurred.
Typical applications are:

■ vacuum forming (e.g. plastic film)
■ vacuum conveying (e.g. granules)
■ vacuum packaging
■ vacuum evacuation
■ vacuum emptying (e.g. liquid containers)
■ vacuum degassing (e.g. in the production of bricks, insulators and foams)
■ vacuum drying
■ vacuum filtration
■ vacuum handling devices
■ vacuum clamping devices
➤ Check with KAESER if the intended application is not mentioned above.

➤ Comply with the specifications listed in this operator manual.
➤ Operate the machine only within its performance limits and under the designated ambient con‐
ditions.
➤ Discharge air from the oil separator tank must be led outdoors and may not be used for any
other application or process.
3.3 Improper use

The machine draws not only from the vacuum network but also surrounding air. The following ap‐
plies not only to the vacuum network but also the surroundings in which the machine operates.

3.4 User's responsibilities
➤ The machine must not be allowed to draw in gas or vapor with the following characteristics:
■ toxic
■ acidic
■ flammable
■ explosive
■ radioactive
■ containing solvents
■ containing toxins
■ containing ammonia
■ contain oil residues
■ Substances causing gumming
■ containing residues of chemical waste, coatings or faeces.
■ containing NaCL compounds
■ containing biological substances or organisms hazardous to people or the environment,
e.g.:
─ UN 2814 (infectious to humans)
─ UN 2900 (infectious to animals)
─ UN 3291 (medicinal waste)
➤ Use hot cooling air for heating purposes only if there is no risk to the health of humans or ani‐
mals. If necessary, hot cooling air should be treated by suitable means.
➤ Do not operate the machine in areas in which specific requirements with regard to explosion
protection are in force.
3.4 User's responsibilities

3.4.1 Observe statutory and universally accepted regulations
This is, for example, nationally applied European directives and/or valid national legislation, safety
and accident prevention regulations.
➤ Observe relevant statutory and accepted regulations during installation, operation, and mainte‐
nance of the machine.
3.4.2 Qualified personnel

These are personnel who, by virtue of their training, knowledge, and experience as well as their
knowledge of relevant regulations can assess the work to be done and recognize the possible dan‐
gers involved.
Authorized operators possess the following qualifications:

■ are of legal age,
■ are familiar with and adhere to the safety instructions and sections of the operator manual rele‐
vant to operation,
■ have received adequate training and authorization to operate electrical, vacuum, and com‐
pressed air devices.
Authorised installation and maintenance personnel have the following qualifications:

■ are of legal age,

3.5 Dangers
■ must have read, be familiar with, and adhere to the safety instructions and sections of the op‐
erator manual applicable to installation and maintenance,
■ must be fully familiar with the safety concepts and regulations of electrical, vacuum, and com‐
pressed air technology,
■ must be able to recognize the possible dangers of electrical, compressed air, and vacuum
technology and take appropriate measures to safeguard persons and property,
■ have received adequate training in and authorization for the safe installation and maintenance
of this machine.
➤ Ensure that personnel entrusted with operation, installation, and maintenance are qualified and
authorized to carry out their tasks.
3.4.3 Adherence to inspection schedules and accident prevention regulations

➤ The machine is subject to local inspection schedules.
3.5 Dangers
Basic instructions
The following describes the various forms of danger that can occur during machine operation.
Basic safety instructions are found in this operator manual at the beginning of each chapter in the
section entitled “Safety”.
Warning instructions are found before a potentially dangerous task.
3.5.1 Safely dealing with sources of danger

The following describes the various forms of danger that can occur during machine operation.
Electricity
➤ Touching voltage carrying components can result in electric shocks, burns or death!
➤ Allow only qualified and authorized electricians or trained personnel under the supervision of a
qualified and authorized electrician to carry out work on electrical equipment according to elec‐
trical engineering regulations.
➤ Before commissioning or recommissioning the machine, the user must make sure there is ade‐
quate protection against electric shock from direct or indirect contact.
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply disconnecting device and verify the absence of any
voltage.
➤ Switch off any external power sources.
These could be connections to floating relay contacts or electrical machine heating, for exam‐
ple.
➤ Use fuses corresponding to machine power.
➤ Check regularly that all electrical connections are tight and in proper condition.
Quality of the discharge air from the oil separator tank
The quality of the discharge air and any substances it may contain depends on the quality of the air
drawn from the vacuum network.

3.5 Dangers
➤ Never breath in discharge air.

➤ Lead discharge air outdoors to a point far from any persons.
Spring force
Springs under tension or compression store energy. Uncontrolled release of this energy can cause
serious injury or death.
Safety relief valves and inlet valves are powerfully spring-loaded.
➤ Do not open or dismantle any valves.
Rotating components
Touching the fan while the machine is running can result in serious injury.
➤ Do not open the enclosure while the machine is switched on.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of any
voltage.
➤ Wear close-fitting clothes and a hair net if necessary.
➤ Make sure that all covers and safety guards are in place and secured before starting.
Temperature
Surfaces can reach temperatures above 212°F. Touching hot components may cause injuries.
➤ Avoid contact with hot components.
Some examples of hot components are:
■ Flange connections to the air exhaust from the oil separator tank and pipes and compo‐
nents connected to it
■ Oil and pressure lines
■ The airend
■ The cooler
■ The oil separator tank
■ Motors
■ Machine heaters
➤ Wear protective clothing.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapors or parts of the machine.
Noise
The enclosure absorbs the machine noise to a tolerable level. This function will be effective only if
the enclosure is closed.
➤ Operate the machine only with intact sound insulation.
➤ Wear hearing protection if necessary.
Operating fluids/materials
The used operating fluids and materials can cause adverse health effects. Suitable safety meas‐
ures must be taken in order to prevent injuries.
➤ Strictly forbid fire, open flame and smoking.
➤ Follow safety regulations when dealing with oils, lubricants and chemical substances.

3.5 Dangers
➤ Avoid contact with skin and eyes.

➤ Do not inhale oil mist or vapor.
➤ Do not eat or drink while handling cooling and lubricating fluids.
➤ Keep suitable fire extinguishing agents ready for use.
➤ Use only KAESER approved operating materials.
Unsuitable spare parts
Unsuitable spare parts compromise the safety of the machine.

➤ Use only spare parts approved by the manufacturer for use in this machine.
Unsuitable spare parts compromise the safety of the machine.
➤ Use only genuine KAESER replacement parts on pressure components.
Conversion or modification of the machine
Modifications, additions to and conversions of the machine or the controller can result in unpredict‐
able dangers.
➤ Do not permit conversion or modification of the machine as this can compromise function and
safe working.
3.5.2 Safe machine operation

The following is information supporting you in the safe handling of the machine during individual
product life phases.
Personal protective equipment
When working on the machine you may be exposed to dangers that can result in accidents with
severe adverse health effects.
➤ Wear protective clothing as necessary.
Suitable protective clothing includes:
■ Safety work wear
■ Protective gloves
■ Safety boots
■ Eye protection
■ Ear protection
Transporting
The weight and size of the machine require safety measures during its transport to prevent acci‐
dents.
➤ Use suitable lifting gear that conforms to local safety regulations.
➤ Allow transportation only by personnel trained in the safe movement of loads.
➤ Attach lifting gear only to suitable lifting points.
➤ Be aware of the center of gravity to avoid tipping.
➤ Make sure the danger zone is clear of personnel.
➤ Do not step onto machine components to climb up the machine.

3.5 Dangers
Positioning
A suitable installation location for the machine prevents accidents and faults.
➤ Install the machine in a suitable compressor room.
➤ If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain and
splashing water.
➤ Do not operate in areas in which specific requirements regarding explosion protection are in
force.
➤ Ensure adequate ventilation.
➤ Ensure that required ambient conditions are maintained.
➤ Place the machine in such a manner that the working conditions in its environment are not im‐
paired.
➤ Do not position the machine in warm cooling outlet air from other machines.
➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
Commissioning, operation and maintenance
During commissioning, operation and maintenance you may be exposed to dangers resulting from,
e.g., pressure and temperature. Careless actions can cause accidents with severe adverse effects
for your health.
➤ Allow maintenance work to be carried out only by authorized personnel.
➤ Wear close-fitting, flame-resistant clothing. Wear protective clothing as necessary.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of any
voltage.
➤ Depressurize all pressurized components and enclosures.
➤ Allow the machine to cool down.
➤ Do not open the cabinet while the machine is switched on.
➤ Use only spare parts approved by KAESER for use in this machine.
➤ Carry out regular inspections for visible damages:
of safety devices,
of EMERGENCY STOP push button,
of any components requiring monitoring.
➤ Do not leave any loose components, tools or cleaning rags on or in the machine.
➤ Components removed from the machine can still be dangerous.
Do not attempt to open or destroy any components taken from the machine.
Decommissioning, storage and disposal
Improper handling of old operating fluids and components represent a danger for the environment.
➤ Drain off fluids and dispose of them according to environmental regulations.
These include, for example, compressor oil and cooling water.
➤ Dispose of the machine in accordance with local environmental regulations.
3.5.3 Organizational Measures

➤ Designate personnel and their responsibilities.

3.6 Safety devices
➤ Give clear instructions on reporting faults and damage to the machine.

➤ Give instructions on fire reporting and fire-fighting measures.
3.5.4 Danger areas

The table gives information on areas dangerous to personnel.
Only authorized personnel may enter these areas.
Function Danger area Authorized personnel

Transport Within a 10 ft. radius of the machine. Installation personnel for trans‐
porting preparation.
No personnel during transport.
Beneath the lifted machine. No personnel!
Installation Within the machine. Installation personnel
Within 3 ft. radius of the machine and its power
supply cables.
Operation Within a 3 ft. radius of the machine. Operating personnel
Within a 16 ft. radius of the end of the air dis‐ No personnel!
charge pipe from the oil separator tank.
Maintenance Within the machine. Maintenance personnel
Within a 3 ft. radius of the machine.
Tab. 21 Danger areas
3.6 Safety devices

Various safety devices ensure safe working with the machine.
➤ Do not change, bypass or disable safety devices.
➤ Regularly check safety devices for their correct function.
➤ Do not remove or obliterate labels and notices.
➤ Ensure that labels and notices are clearly legible.
Further information More information on safety devices is contained in chapter 4, section 4.2.2.
3.7 Working life of safety functions

Pursuant to ISO 13849-1:2008, Category and Performance Level (PL) of the machine's safety
functions have been analyzed and assessed:
Safety function Category Performance Level
Safety shut-down at high temperature 2 c
EMERGENCY STOP push button 1 c
Safety shutdown when opening the machine 1 c
Tab. 22 Category and Performance Level

3.8 Safety Signs
The safety-relevant components of the safety devices are designed for a working life of 20 years.
The working life starts with original machine commissioning, and is not extended by times during
which the machine is not in use.
The following components are affected:

■ Resistance thermometer (PT100 sensor for measuring the compression discharge tempera‐
ture)
■ EMERGENCY STOP push button
■ Main contactor
■ Door interlock switch
1. The components of the safety functions must be replaced by an authorized KAESER service
representative after a service life of 20 years.
2. Have an authorized KAESER service representative check the reliability of the safety func‐
tions.
3.8 Safety Signs

The diagram shows the positions of safety signs on the machine. The table lists the various safety
signs used and their meanings.
Fig. 3 Location of safety signs
Item Symbol Meaning

8 Danger of fatal injury from touching electrically live components!
➤ Switch off and lock out the supply disconnecting device and check that no volt‐
age is present.
9 Personal injury or damage to the machine by incorrect operation!
➤ Read and understand the operator manual and all safety signs before switching
on this machine.
Machine starts automatically!
Severe injury could result from rotating components, electrical voltage and air pres‐
sure.
➤ Isolate from the power supply and lock out before opening any machine enclo‐
sure or guard.

3.9 Emergency situations
Item Symbol Meaning

10 Severe injury could result from touching the belt drive or fan blade!
➤ Operate the machine only with fully closed safety guards, access doors and
panels.
➤ Isolate from the power supply and lock out before opening any machine enclo‐
sure or guard.
11 Injury and/or contamination can result from breathing exhaust air!
➤ Never breathe exhaust air.
13 Hot surface can cause burns!

➤ Let the machine cool down.
➤ Wear long-sleeved garments (not synthetics such as polyester) and protective
gloves.
16 Wrong cooling oil level can cause machine defects or rising oil consumption (oil
• • ••
• •• •
content for pure air)!
➤ Check the oil level regularly and top up as necessary.
25 Ear damage and burns can result from loud noise and/or oil mist when the safety
relief valve opens!
➤ Wear ear protection and protective clothing.
➤ Close all access doors and cover panels.
27 Risk of electric shock!
If the interrupter has tripped current-carrying components of the controller should
be examined and replaced if damaged to reduce the risk of fire or electric shock.
28 Risk of electric shock!
To maintain over-current short-circuit, and ground-fault protection, the manufactur‐
er's instructions for setting the interrupter must be followed to reduce the risk of fire
or electric shock.
29 Danger of personal injury or machine damage from incorrect removal, as the belt
pulley is fixed under stress to the conical end of the shaft.
➤ Secure the pulley against falling.
➤ Allow only a trained person with the correct tools to remove the pulley.
Tab. 23 Safety Signs
3.9 Emergency situations

3.9.1 Correct fire fighting
Suitable measures
Calm and prudent action can safe lives in the event of a fire.
➤ Keep calm.
➤ Give the alarm.
➤ Shut off supply lines if possible.
Main disconnecting device (all poles)
Cooling water (if present)
Heat recovery (if present)

3.10 Warranty
➤ Warn and move endangered personnel to safety.

➤ Help incapacitated persons.
➤ Close the doors.
➤ When trained accordingly: Attempt to extinguish the fire.
Extinguishing substances
➤ Suitable extinguishing media:

Foam
Carbon dioxide
Sand or soil
➤ Unsuitable extinguishing media:
Strong jet of water
3.9.2 Treating injuries from handling cooling oil

Eye contact
Cooling oil can cause irritation.

➤ Rinse open eyes thoroughly for a few minutes under running water.
➤ Seek medical help if irritation persists.
Skin contact
Cooling oil may irritate after prolonged contact.

➤ Wash thoroughly with skin cleaner, then with soap and water.
➤ Contaminated clothing should be dry-cleaned before reuse.
Inhalation
Cooling oil mist may make breathing difficult.

➤ Clear air passages of oil mist.
➤ Seek medical help if difficulty with respiration continues.
Ingestion
➤ Wash out the mouth immediately.

➤ Do not induce vomiting.
➤ Seek medical aid.
3.10 Warranty
This operator manual contains no independent warranty commitment. Our general terms and con‐
ditions of business apply with regard to warranty.
A condition of our warranty is that the machine is used for the purpose for which it is intended un‐
der the conditions specified.
Due to the multitude applications for which the machine is suitable the obligation lies with the user
to determine its suitability for his specific application.

3.11 Environment protection
In addition, we accept no warranty obligation for:

■ the use of unsuitable parts or operating materials,
■ unauthorized modifications,
■ incorrect maintenance,
■ incorrect repair.
Correct maintenance and repair includes the use of original spare parts and operating materials.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.
3.11 Environment protection

➤ Observe relevant national and local regulations!
The operation of this machine may cause dangers for the environment.
The quality of the discharge air from the oil separator tank is largely dependent on the composition
of the medium in the vacuum network.
The discharge air can be oily. The user may install an oil vapor separator to reduce the oil content
of the discharge air.
➤ Make sure that no substance is released to the atmosphere that is damaging to animals, hu‐
mans, or the environment.
➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐
ment protection regulations.
➤ Do not allow cooling oil to escape into the environment or into the sewage system.

4.1 Enclosure

4.1 Enclosure
Fig. 4 Enclosure overview

1 Control cabinet door
2 Latch
3 Machine access doors
The enclosure, when closed, serves various functions:

■ Sound insulation
■ Protection against contact with components
■ Cooling air flow
The enclosure is not suitable for the following uses:

■ Walking on, standing or sitting on.
■ As resting place or storage of any kind of load.
Safe and reliable operation is only assured with the enclosure closed.
Doors open outwards. Access to the machine is further protected by a grill. The upper grill has a
fixing hook. Using this hook, the grill is mounted in the upper door and secured against involuntary
closing.
To open it, the latches must be loosened with the key supplied.

4.2 Machine function
4.2 Machine function
Fig. 5 Machine overview

1 Inlet valve 4 Oil cooler
2 Airend 5 Oil separator tank
3 Compressor motor 6 Drive belt
Gas is drawn out of the vacuum network via the vacuum filter in which it is cleaned. The vacuum
filter is designed for dry contaminants.
The gas is then compressed in the airend 2 .
The airend is driven by an electric motor 3 .
Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between the ro‐
tors themselves and between them and the airend casing. This direct cooling in the compression
chamber ensures a very low airend discharge temperature.
Depending on the pressure conditions in the vacuum network, a defined volume of surrounding air
is drawn into the airend through the gas ballast air filter.
Cooling oil recovered from the compressed gas in the oil separator tank 5 gives up its heat in the
oil cooler 4 . The oil then flows through the oil filter and back to the point of injection. A thermostat‐
ic valve maintains optimum cooling oil temperature.
The compressed medium is extracted to the exterior with the pressure adjusting to the atmospheric
pressure level.
4.2.1 Floating relay contacts

Floating relay contacts are provided for the transfer of signals and messages.
Information on location, loading capacity and type of message or signal is found in the electrical
diagram.
If the floating relay contacts are connected to an external voltage source, voltage may be
present even when the machine is isolated from the power supply.
4.2.2 Safety devices

The following safety devices are provided and must not be modified or disabled:
■ EMERGENCY STOP push button:
Shuts down the machine immediately. The motor remains stopped. The pressure system is
vented.

4.3 Operating panel SIGMA CONTROL 2
■ Safety relief valve:

The safety relief valve protects the machine from excessive pressure. This is factory set.
■ Resistance thermometer:
Monitoring the airend discharge temperature protects the vacuum system from impermissible
temperature rises.
■ Door interlock switch:
The machine will stop automatically if a safety interlocked door or panel is opened or removed.
■ Enclosures and covers for moving parts and electrical connections:
These protect against accidental contact.

Keys
Fig. 6 Keys - overview
Position Name Function

1 «OFF» Switches the machine off.
2 «ON» Switches the machine on.
3 «Escape» Returns to the next higher menu option level.
Exits the edit mode without saving.
4 «Enter» Jumps to the selected menu option.
Exits the edit mode and saves.
5 «Down» Scrolls down the menu options.
Reduces a parameter value.
6 «Right» Jumps to the right.
Moves the cursor position to the next right field.
7 «Left» Jumps to the left.
Moves the cursor position to the next left field.


8 «Up» Scrolls up the menu options.
Increases a parameter value.
9 «Events and information» Operating mode:
Displays the event memory.
10 «Acknowledgement» Acknowledges alarms and warning messages.
If permissible: Resets the fault counter (RESET).
11 «LOAD/IDLE» Toggles between the LOAD and IDLE operating modes.
12 «Remote control» Switches the remote control on and off.
13 «Shift clock» Switches clock control on and off.
Tab. 24 Keys
Indicators
Fig. 7 Indicators – overview

14 Indicator field or dis‐ Graphic display with 8 lines and 30 characters per line.
play
15 Fault Flashes red when an alarm occurs.
Lights continuously when acknowledged.
16 Communication Continuous red light to indicate a faulty communication connec‐
tion, or an external fault message without machine shut-down.
17 Warning Flashes yellow for the following events:
■ Maintenance work due
■ Warning message
Continuous yellow light after acknowledgement.


18 Control voltage Continuous green light when voltage is applied to the controller.
19 LOAD Continuous green light when the machine is running in LOAD.
20 IDLE Continuous green light when the machine is running in IDLE.
Flashes when the «LOAD/IDLE» toggle key is pressed.
21 Remote control Continuous green light when the machine is in remote control.
22 Shift clock Continuous green light when the machine is controlled by the timer
(clock).
23 ON Continuous green light when the machine switched on.
Tab. 25 Indicators
RFID sensor field
RFID is the abbreviation for “Radio Frequency Identification” and enables the identification of per‐
sons or objects.
Placing a suitable transponder in front of the RFID reader of the controller will automatically acti‐
vate the communication between transponder and SIGMA CONTROL 2.
A suitable transponder is the KAESER RFID EQUIPMENT CARD. Two of them have been provi‐
ded with the machine.
Typical application:
■ Users log on to the machine.
(no manual input of the password required.)
Fig. 8 RFID sensor field

24 RFID RFID sensor field for the communication with a suitable RFID transponder
Tab. 26 RFID sensor field
Further information More information about the use of RFID technology is provided in the SIGMA CONTROL 2 operat‐
ing manual.

4.4 Operating modes and control modes
4.4 Operating modes and control modes

4.4.1 Operating modes
STOP
The machine is connected to the power supply.

The Controller voltage LED lights green.
The machine is switched off. The Machine ON LED is extinguished.
READY
The machine has been activated with «ON»:

■ The Machine ON LED lights green.
■ The drive motor is stopped.
■ The inlet valve is closed.
The compressor motor starts as soon as system pressure in the vacuum network is higher than the
setpoint pressure (cut-off pressure).
In addition, timer and/or remote control may affect the start of the motor.
LOAD
The compressor motor runs under load.

■ The inlet valve is open.
■ The airend sucks the conveying medium from the vacuum network.
IDLE
The compressor motor runs unloaded with low power consumption.

■ The inlet valve is closed.
■ The machine draws in surrounding air through the gas ballast air filter.
4.4.2 Control modes

Using the selected control mode, the controller switches the drive motor between the operating
modes to maintain the pressure in the vacuum network between the set cut-in and cut-out pres‐
sures.
The machine-dependant venting phase between the LOAD and READY operating modes ensures
load changes at minimum material stresses.
The controller SIGMA CONTROL 2 can operate in the following modes:

■ DUAL
■ VARIO
■ CONTINUOUS
■ MODULATING control
The SIGMA CONTROL 2 controller is factory set to DUAL control mode unless specifically ordered
otherwise.

4.5 Options
DUAL
In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to
maintain the machine working pressure between the preset pressure limits. When maximum vac‐
uum is reached, the machine switches to IDLE. When the preset idling time has elapsed, the ma‐
chine switches to READY.
The idling time is factory preset according to the maximum starting frequency of the compressor
motor. The shorter the idling time setting, the sooner (and more frequently) the drive motor is stop‐
ped.
VARIO
The VARIO mode is based on the DUAL control mode. Unlike the DUAL regulating mode, the
idling time is automatically lengthened or shortened to compensate for higher or lower machine
starting frequencies.
CONTINUOUS
In the CONTINUOUS control mode, the machine is switched back and forth between LOAD and
IDLE to maintain the machine working pressure between the preset pressure limits. When maxi‐
mum vacuum is reached, the machine switches to IDLE. However, the machine does not switch to
READY mode.
MODULATING control
The MODULATING control is an additional mechanical regulation. It smoothly modifies the intake
capacity in LOAD mode within the machine's regulating range
A control valve, the vacuum controller, changes the degree of opening of the inlet valve when the
machine takes the medium from the vacuum network.
The load and power consumption of the compressor motor rises and falls with the intake capacity.
4.5 Options
The options available for your machine are described below.
4.5.1 Option H1
Machine mountings
These mountings allow the machine to be anchored firmly to the floor.
Fig. 9 Machine mountings
4.5.2 Option H17

Super sound-proofing
The machine enclosure is provided with additional sound proofing. This make the machine particu‐
larly quiet.

5.1 Ensuring safety

5.1 Ensuring safety
The conditions in which the machine is installed and operated have a decisive effect on safety.
Warning instructions are located before a potentially dangerous task.
Disregard of warning instructions can cause serious injuries!
Complying with safety warnings
Disregard of safety warnings can cause unforeseeable dangers!

➤ Strictly forbid fire, open flame and smoking.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapors or parts of the machine.
➤ Do not store inflammable material in the vicinity of the machine.
➤ The machine is not explosion-proof!
Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
➤ Ensure sufficient and suitable lighting such that the display can be read and work carried out
comfortably and safely.
➤ Ensure that required ambient conditions are maintained.
5.2 Installation conditions

5.2.1 Determining location and clearances
The machine is intended for installation in an appropriate machine room. Information on distances
from walls and ventilation is given below.
The distances quoted are recommended distances and ensure unhindered access to all ma‐
chine parts.
➤ Please consult KAESER if you cannot comply with these recommendations.
Precondition The floor must be level, firm and capable of bearing the weight of the machine.

Fig. 10 Recommended machine placement and dimensions [inches]

A Exhaust fan C Air discharge line from the oil separator
B Exhaust air duct tank
Z Air inlet aperture
1. Ambient temperature too low!

Frozen condensate and highly viscous cooling oil can cause damage when starting the ma‐
chine.
➤ Make sure that the temperature of the machine is at least +37°F before starting.
➤ Heat the machine room adequately or install an auxiliary heater.
2. Ensure adequate lighting so that all work on the machine can be carried out without danger or
hindrance.
3. Ensure that the indicators can be read without glare and that the controller display cannot be
damaged by direct sunlight (UV radiation).
4. Ensure that all intake and exhaust apertures of the enclosure remain opened.
5. If installed outdoors, the machine must be protected from frost, direct sunlight, dust and rain.
5.2.2 Ensuring adequate ventilation

Adequate ventilation of the machine room has several tasks:
■ It prevents subatmospheric pressure in the machine room.
■ It evacuates the exhaust heat of the machine and thus ensures the required operating condi‐
tions.
➤ Consult with KAESER if you cannot ensure the conditions for an adequate ventilation of
the machine room.
1. Ensure that the volume of air flowing into the machine room is at least equivalent to that being
removed from it by the machine and exhaust fan.
2. Make sure that the machine and exhaust fan can only operate when the inlet aperture is ac‐
tually open.

3. Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely
through the room.
4. Ensure clean air in order to support the proper functioning of the machine.
5.2.3 Exhaust duct design

At the cooling air inlet and exhaust, the machine can only overcome the air resistance resulting
from the duct design. Any additional air resistance will reduce airflow and deteriorate machine cool‐
ing.
➤ Consult an authorized KAESER service representative before deciding on:
■ Design of the exhaust air ducting
■ Transition between the machine and the exhaust air duct
■ Length of the ducting
■ Number of duct bends
■ Design of flaps or shutters
Further information Further information on the design of exhaust air ducts can be found in chapter 13.2.

6 Installation
6.1 Ensuring safety
6 Installation
6.1 Ensuring safety
Follow the instructions below for safe installation.

➤ Follow the instructions in chapter 3 “Safety and Responsibility”.
➤ Installation work may only be carried out by authorized personnel.
➤ Make sure that no one is working on the machine.
➤ Ensure that all service doors and panels are locked.
Working on live components
Touching voltage carrying components can result in electric shocks, burns or death.
➤ Work on electrical equipment may only be carried out by authorized electricians.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of volt‐
age.
➤ Check that there is no voltage on floating relay contacts.
Working on the vacuum system
➤ Vent all components and volumes under vacuum to atmospheric pressure.

Working on the drive system
Touching the fan wheel, the coupling or the belt drive while the machine is switched on can result
in serious injury.
age.
Further information Details of authorized personnel are found in chapter 3.4.2.

Details of dangers and their avoidance are found in chapter 3.5.
6.2 Reporting Transport Damage

1. Check the machine for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage without delay.

6 Installation
6.3 Connecting to the vacuum network
6.3 Connecting to the vacuum network

The vacuum filter that protects the machine from dry contaminants can only hold a limited amount
of dirt. If condensate finds its way into the vacuum filter it ceases to function.
➤ If the intake medium is highly contaminated or moist, the user is advised to install a high
capacity filter and/or a water separator.
KAESER can offer advice in this respect.
Precondition Vacuum network is vented.
Fig. 11 Connecting to the vacuum network

1 Axial compensator or flexible pressure line
2 Shut-off valve
1. A shut-off valve must be installed by the user in the connection line.

2. Make the connection to the vacuum network with an axial compensator or hose.
6.4 Air discharge line from the oil separator tank

The discharge air from the oil separator tank can reach temperatures of up to 212°F and con‐
tains cooling oil vapors and, possibly, other noxious substances.
➤ Install a dedicated pipeline to lead discharge air outdoors.
➤ Lay the pipeline in such a way that any condensate forming will not flow back to the oil
separator tank.
➤ Any components outside the machine that are within normal reach and that can reach
temperatures >140°F should be screened or fitted with warning signs.
Precondition The machine is switched off.
Fig. 12 Connecting the air discharge line

1 Axial compensator or hose
1. Make the connection to the air discharge line with an axial compensator or hose.

6 Installation
6.5 Connecting the power supply
2. Lead the air discharge pipeline outdoors and hang a sign where it passes through an outside
wall.
Noxious discharge air from the oil separator tank!

➤ Do not breath in the discharge air.
➤ Keep away at least 16 ft.
Tab. 27 Discharge air line marking
Collect condensate in a suitable receptacle and dispose of according to local environment

regulations.
6.5 Connecting the power supply

Tri-voltage machines are not wired ready for operation!
All other machines are readily set up for a single supply voltage.
Tri-voltage machines can be set up to one of the following supply voltages:

■ 208V
■ 230V
■ 460V
Precondition The power supply disconnecting device is switched off,

The device is locked in the off position,
The absence of any voltage has been verified.
1. The power supply must only be connected by authorized installation personnel or an author‐
ized electrician.
2. Carry out safety measures as stipulated in relevant regulations. In addition, observe the regula‐
tions of the local electricity supplier.
3. Test the overcurrent protection cut-out to ensure that the time it takes to disconnect in re‐
sponse to a fault is within the permitted limit.
4. Select supply cable conductor diameters and fusing in accordance with local regulations.
5. The user must provide the machine with a lockable power supply disconnecting device.
This could be, for example, a load disconnect switch with fused input. If a circuit breaker is
used it must be suitable for the motor starting characteristics.
6. Check that the tappings on the control voltage transformer are connected according to the
power supply voltage.
If not, change the tappings to suit the power supply voltage.
7. Danger of fatal injury from electric shock!
➤ Switch off and lock out the power supply disconnecting device and verify the absence of
any voltage.
8. If necessary: Set up the machine for the correct power supply voltage as described in chap‐
ter 6.5.1.
9. Connect the machine to the power supply.
Further information The electrical diagram 13.3 contains further details for electrical connection.

6 Installation
6.6 Options
6.5.1 Setting up main voltage connection for a Tri-voltage machine

Machine set up for [V] 208 230 460
Machine may be modified 230 208 208
[V] 460 460 230
Tab. 28 Voltage selection
The following parts have to be considered for making the set up:
■ Motor connection terminals in the motor terminal board
■ Drive motor overload protection relay
■ Control transformer
Material The required jumpers (also known as “bridges” or “links”) are provided in the control cabinet.
Precondition A check has been made to ensure no voltage is present.
Setting up the motor connection
➤ Connect the motor in accordance with the electrical diagram.
Adjusting the overload protection relay
➤ Check the overload protection relay setting.
Supply voltage BSV 80 BSV 100

208V, 3-ph, 60Hz [A] 56 68
230V, 3-ph, 60Hz [A] 52 64
460V, 3-ph, 60Hz [A] 26 32
Tab. 29 Overload protection relay settings.
Connecting the control transformer
➤ Open the control cabinet and connect the control transformer in accordance with the electrical
diagram.
6.6 Options
6.6.1 Option H1
Anchoring the machine
➤ Use appropriate fixing bolts to anchor the machine.
Further information Details of the fixing holes are contained in the dimensional drawing in chapter 13.2.

7 Initial Start-up
7.1 Ensuring safety
7 Initial Start-up
7.1 Ensuring safety
Here you will find instructions for a safe commissioning of the machine.
Disregard of safety notes can cause unforeseeable dangers!

➤ Commissioning tasks may only be carried out by authorized personnel!
➤ Make sure that no personnel are working on the machine.
➤ Ensure that all service doors and panels are locked.
age.
➤ Vent all components and chambers under vacuum to atmospheric pressure.

in serious injury.
age.

7.2 Instructions to be observed before commissioning or re-commis‐

sioning
Incorrect or improper commissioning can cause injury to persons and damage to the machine.

7 Initial Start-up
7.3 Checking installation and operating conditions
➤ Commissioning may only be carried out by authorized installation and service personnel who
have been trained on this machine.
Special measures for re-commissioning after storage
Storage period Remedy

longer than:
3 months ➤ Manually fill the airend with cooling oil.
12 months ➤ Change the oil filter.
➤ Change the oil separator cartridge.
➤ Change the cooling oil.
➤ Have the motor bearings checked by an authorized KAESER service repre‐
sentative.
36 months ➤ Have the overall technical condition checked by an authorized
KAESER service representative.
Tab. 30 Re-commissioning after storage
7.3 Checking installation and operating conditions

➤ Check and confirm all the items in the checklist before initially starting the machine.
To be checked see Confirmed?

chapter
➤ Are the operators completely familiar with safety regulations? –
➤ Have all the positioning conditions been fulfilled? 5
➤ Is a user's lockable power supply disconnecting device installed? 6.5
➤ Are the tolerance limits of the power supply voltage within the per‐ 13.3
missible tolerance limits of the rated voltage (machine)?
(See nameplate in the control cabinet)
➤ Are the power supply cable conductor cross-sections and fuse rat‐ 2.15
ings adequate?
➤ Is the drive motor overload protection switch set according to the 7.4
power supply voltage?
➤ Have all electrical connections been checked for tightness? –
➤ Has the inspection been repeated after 50 operating hours following
the initial commissioning?
➤ Is the user's shut-off valve between the machine and the vacuum 6.3
network installed?
➤ Has the drive belt tension been checked? 10.8
➤ Is there sufficient cooling oil in the separator tank? 10.12
➤ Is there sufficient cooling oil in the airend? 7.5
➤ Is the machine firmly anchored to the floor? 6.6.1
(Option H1)
➤ Are door interlock switches aligned and their function checked? 7.9

7 Initial Start-up
7.4 Setting the overload protection relay
To be checked see Confirmed?

chapter
➤ Are all access doors closed and latched and all removable panels in –
place and secured?
Tab. 31 Installation conditions checklist
7.4 Setting the overload protection relay

Electrical diagram 13.3 gives the location of the overload relay.
With direct online starting, the phase current is fed via the overload relay. This phase current is
0.58-times the rated motor current.
To prevent the overload relay being triggered by voltage fluctuations, temperature influences or
component tolerances, the setting can be higher than the arithmetical phase current.
➤ Check the settings of the overload relay.
The overload relay shuts the machine down despite being correctly set?
➤ Contact an authorized KAESER service representative.
7.5 Filling cooling oil in the airend

Fill the airend manually with cooling oil before initial start-up and after a shutdown period of more
than 3 months.
A label showing the type of oil used is found near the oil separator tank filling port.
➤ Use the same type of oil.
Material 1 qt Cooling oil
Precondition The power supply disconnecting device is switched off.

The disconnecting device is locked off.
A check has been made that no voltage is present.
Fig. 13 Inlet valve oil filling port

1 Filler plug
2 Inlet valve
1. Unscrew the filler plug from the inlet valve.

2. Pour the stipulated amount of cooling oil into the airend and replace the filler plug.
3. Turn the rotors manually by means of the belt pulley to distribute the oil.

7 Initial Start-up
7.6 Starting the machine for the first time
7.6 Starting the machine for the first time

Precondition No personnel are working on the machine,
all access doors are closed,
all removable panels are in place and secured.
1. Open the shut-off valve to the vacuum network.

2. Switch on the power supply disconnecting device.
After the controller has carried out a self-test, the green Controller voltage LED lights continu‐
ously.
3. If necessary:
Change the display language as described in chapter 7.8.
4. Press the «ON» key.
The compressor motor runs up and after a short time the machine switches to LOAD and
sucks the medium from the vacuum network.
➤ Watch for any faults occurring in the first hour of operation.
➤ After the first 50 operating hours, check all electrical connections and tighten where nec‐
essary.
Does the machine stop when the compressor motor rotates in the wrong direction?
➤ Switch off and lock out the power supply disconnecting device and check that no voltage
is present.
➤ Change the machine supply phases L1 and L2.
➤ Acknowledge any existing alarm messages and switches the machine on again.
7.7 Setting the setpoint pressure

The setpoint pressure pA is factory set to the value stated in the customer's order.
Adjusting to individual operating conditions is not necessary when commissioning the machine.
The machine may not switch more than once per minute between LOAD and IDLE.
To improve the switching frequency:
➤ Increase buffer volume by increasing the cross-section of the pipeline to the receiver.
➤ Set the setpoint pressure as described in the SIGMA CONTROL 2 operating manual.
7.8 Setting the display language

The controller can display text messages in several languages.
You can set the language for texts on the display. This setting will be retained even when the ma‐
chine is switched off.
1. In operating mode, switch to the main menu with the «Return» key.

7 Initial Start-up
7.9 Checking the door interlock switch
2. Press the «UP» or «DOWN» keys until the current language is shown as active line (inverse):
88 psig 176 ° F
–––––––– Deutsch –––––––– Current language (active line)
▶1 xxxxxxxxxx Submenu
3. Use the «Return» key to switch to setting mode.

The language display flashes.
4. Move to the required language with «UP »or «DOWN».
5. Confirm the setting with the «Enter» key.
Result The display texts are now in the selected language.
Further information Detailed information can be found in the SIGMA CONTROL 2 operating manual.
7.9 Checking the door interlock switch

The interlock switch stops the machine as soon as the front-left access door is opened.
Check the interlock switch function when commissioning or recommissioning the machine.
The door interlock switch is an important safety device.
The machine may only be operated with a correctly functioning interlock switch.
Fig. 14 Location of the door interlock switch

1 Door interlock switch 5 Frame
2 Door 6 Safety screen door
3 Switch actuator 7 Protective sleeves
4 Screw 8 Clamping nut
1. Open the access door 2 while the machine is running.

The machine shuts down automatically. The controller displays an alarm message.

7 Initial Start-up
7.10 Setting the control mode
2. Close the door and acknowledge the alarm.

If the switch actuator is not correctly aligned, unintentional shutdown of the machine may oc‐
cur.
➤ Loosen the screw 4 and position the actuator 3 so that it slides easily into the door
switch. Re-tighten the screw.
The machine does not shut down?
➤ Have the interlock switch checked by an authorized KAESER service representative.

Other control modes are available according to the setting of the shut-off valve 5 .
Shut-off valve Control modes
Closed DUAL
VARIO
CONTINUOUS
Open Additional MODULATING control in LOAD
Tab. 32 Control modes
Fig. 15 Setting the control mode

1 Inlet valve 5 Shut-off valve
2 Adjusting screw A Shut-off valve (closed)
3 Nut B Shut-off valve (open)
4 Vacuum controller
7.10.1 DUAL
1. Set control mode DUAL at SIGMA CONTROL 2.

2. Close the shut-off valve 5 .
Result The SIGMA CONTROL 2 regulates the machine in the DUAL mode between LOAD, IDLE, and
READY.

7 Initial Start-up
7.10.2 VARIO

2. Set control mode VARIO at the SIGMA CONTROL 2.
Result The SIGMA CONTROL 2 regulates the machine in the VARIO mode between LOAD, IDLE, and
READY.
7.10.3 CONTINUOUS

2. Set control mode DURCHLAUF at the SIGMA CONTROL 2.
Result The SIGMA CONTROL 2 regulates the machine in the CONTINUOUS mode between LOAD and
IDLE.
7.10.4 MODULATING control

The vacuum regulator is factory set.
In the event of changed operating condition, the vacuum regulator may require to be set differently
(see chapter 7.10.5).
The regulating range begins at 7.25 psi (absolute)
1. If required: Set control mode MODULATING at the SIGMA CONTROL 2.

2. Open the shut-off valve 5 .
Result The intake capacity of the machine changes smoothly in LOAD. The regulating mode set at the
SIGMA CONTROL 2 controls the switch between the different operating modes.
7.10.5 MODULATING control: Setting the vacuum regulator

1. Loosen the nut 3 and turn the adjusting screw 2 on the vacuum regulator 4 about 10 turns
counterclockwise.
The vacuum regulator is inoperable.
2. Switch on the machine.
The machine switches to LOAD. Pressure in the vacuum network begins to fall.
3. As soon as the pressure reaches the required level:
turn the adjusting screw 2 clockwise.
When the pressure becomes constant, the vacuum regulator holds it there.
4. Use the adjusting screw until the pressure stabilizes at the required value.
5. Tighten the nut 3 to prevent any further movement of the adjusting screw.
Result The vacuum regulator is now set.

8 Operation
8.1 Switching on and off
8 Operation
8.1 Switching on and off
Always switch the machine on with the «ON» key and off with the «OFF» key.
A power supply disconnecting device must be installed by the user.
Fig. 16 Switching on and off

1 Machine ON LED 11 «LOAD/IDLE» toggle key
2 «ON» key 19 LOAD LED
3 «OFF» key 20 IDLE LED
8 Controller voltage LED
8.1.1 Switching on
Precondition No personnel are working on the machine.
All access doors and panels are closed and secure.
1. Switch on the power supply disconnecting device.

The Controller voltage LED lights green continuously.
2. Press the «ON» key.
The Machine ON LED lights green continuously.
If a power failure occurs, the machine is not prevented from restarting automatically when
power is resumed.
It can restart automatically as soon as power is restored.
Result The compressor motor starts as soon as system pressure is higher than the set point pressure
(cut-off pressure).
8.1.2 Switching off

1. Press the «OFF» key.
The Machine ON LED extinguishes.
2. Switch off and lock out the power supply disconnecting device.

8 Operation
8.2 Switching off in an emergency and switching on again
Result The Controller voltage LED extinguishes. The machine is switched off and disconnected from the
power supply.
8.2 Switching off in an emergency and switching on again

The EMERGENCY STOP push button is located below the control panel.
Fig. 17 Switching off in an emergency

9 EMERGENCY STOP push button
Switching off
➤ Press the EMERGENCY STOP push button.
Result The EMERGENCY STOP push button remains latched after actuation.
The compressor's pressure system is vented and the machine is prevented from automatically re-
starting.
Switching on
Precondition The fault has been rectified
1. Turn the EMERGENCY STOP push button in the direction of the arrow to unlatch it.
2. Acknowledge any existing alarm messages.
Result The machine can now be started again.
8.3 Switching on and off from a remote control center

Precondition A link to the remote control center exists.

8 Operation
8.4 Using the timer for switching on and off
Fig. 18 Switching on and off from a remote control center

1 «Remote control» key
2 Remote control LED
1. Attach an easily seen notice to the machine that warns of remote operation.
Remote control: Risk of injury caused by unexpected starting!

➤ Make sure that the power supply disconnecting device is switched off before commencing any
work on the machine.
Tab. 33 Machine identification
2. Label the starting device in the remote control center as follows:
Remote control: Risk of injury caused by unexpected starting!

➤ Before starting, make sure that no one is working on the machine and that it can be safely
started.
Tab. 34 Remote control center identification
3. Press the «Remote control» key.

The Remote control LED lights. The machine can be remotely controlled.
8.4 Using the timer for switching on and off

Precondition The clock is programmed.

8 Operation
8.5 Interpreting operation messages
Fig. 19 Using the timer for switching on and off

1 «Timer» key
2 Timer LED
1. Attach an easily seen notice to the machine that warns of time-controlled operation:
Timer control: Risk of injury caused by unexpected starting!

➤ Make sure that the power supply disconnecting device is switched off before commencing any
work on the machine.
Tab. 35 Machine identification
2. Press the «Timer» key.

The Timer LED lights. The timer switches the machine on and off.
8.5 Interpreting operation messages

The controller will automatically display operation messages informing you about the current opera‐
tional state of the machine.
Operating messages are identified with the letter B.
Further information Detailed information can be found in the SIGMA CONTROL 2 operating manual.
8.6 Acknowledging alarm and warning messages

Messages are displayed on the "new value" principle:
■ Message coming: LED flashes
■ Message acknowledged: LED illuminates
■ Message going: LED off
or
■ Message coming: LED flashes

■ Message going: LED flashes
■ Message acknowledged: LED off

8 Operation
8.6 Acknowledging alarm and warning messages
Fig. 20 Acknowledging messages

10 LED Warning (yellow)
11 LED Alarm (red)
12 Key «Acknowledge»
Alarm message
An alarm shuts the machine down automatically. The red alarm LED flashes.
The system displays the appropriate message.
Precondition The fault has been rectified.
➤ Acknowledge the message with the «acknowledge» key.

The Fault LED extinguishes.
The machine is again ready for operation.
If the machine was switched off with the EMERGENCY STOP button:
➤ Unlatch the EMERGENCY STOP button (turn in direction of the arrow) before acknowl‐
edging the alarm message.
Further information Please refer to the SIGMA CONTROL 2 operating manual for a list of possible fault messages dur‐
ing operation.
Warning message
If maintenance work is to be carried out or if a warning is displayed before an alarm, the yel‐
low warning LED flashes.
The system displays the appropriate message.
Precondition The danger of an alarm is passed,

maintenance has been carried out.
➤ Acknowledge the message with the «Acknowledge» key.

The warning LED extinguishes.
Further information A list of possible alarm messages occurring during operation can be found in the service manual
SIGMA CONTROL 2 .


There are 3 types of fault:
■ Warning:
─ Warning messagesW
■ Fault (with indication):
─ Alarm messagesS
─ System messages Y
─ Diagnostic messages D
■ Other faults (without indication): See chapter 9.2
The messages valid for your machine are dependent on how the individual machine is equipped.
1. Do not attempt fault rectification measures other than those given in this manual!
2. In all other cases:
Have the fault rectified by an authorized KAESER SERVICE representative.
Further information Detailed information for the various messages can be found in the user manual
SIGMA CONTROL 2.
9.2 Other faults

Fault Possible cause Remedy
Machine runs but produces no Inlet valve not opening or only Call an authorized KAESER
vacuum. opening partially. service representative.
Vacuum regulator defective. Call an authorized KAESER
service representative.
Incorrect setting of the shut-off Check the setting of the shut-off
valve on the vacuum regulator. valve on the vacuum regulator.
Vacuum requirement greater Shut down consumer(s).
than the capacity of the ma‐
chine.
Vacuum filter contaminated. Maintain vacuum filter.
Control air filter and/or control Replace the control air filter.
nozzle clogged. Clean the control nozzle.
Machine switches between Idle period too short. Reset the idle period.
LOAD and IDLE more than Suction rate of the machine too Install a larger vacuum buffer or
once per minute. high. increase the cross-section of
the suction line.
Auxiliary valve defective. Call an authorized KAESER

9.2 Other faults
Fault Possible cause Remedy

Cooling oil leaking into the ma‐ Hose coupling or maintenance Remove coupling or mainte‐
chine interior. hose still plugged into the nance hose.
quick-release coupling on the
oil separator tank.
Oil cooler leaking. Call an authorized KAESER
Leaking pipe joints. Tighten pipe joints.
Replace seals.
Oil sight glass defective. Tighten all fittings.
Replace the oil sight glass.
Cooling oil consumption too Unsuitable oil is being used. Use SIGMA FLUID cooling oil.
high. Oil separator cartridge split. Change the oil separator car‐
tridge.
Oil level in the oil separator Drain off oil until the correct lev‐
tank too high. el is reached.
Oil return line clogged. Check dirt trap strainer in the oil
return line.
Airend discharge temperature Ambient temperature too high. Keep ambient conditions within
too high. specified limits.
Cooler clogged. Clean the cooler.
Oil level in the oil separator Top off the oil until the correct
tank too low. level is reached.
Combination valve defective. Call an authorized KAESER
Oil pump defective. Call an authorized KAESER
Overload protection relay trips Incorrect setting. Check setting.
out. The pressure drop over the dis‐ Limit the pressure drop to
charge air pipeline is too high. 2.9 psi.
Oil pump defective. Call an authorized KAESER
Drive motor defective. Call an authorized KAESER
Airend defective. Call an authorized KAESER
Ambient temperature too high. Keep ambient conditions within
specified limits.
Tab. 36 Other faults and remedies

10 Maintenance
10.1 Ensuring safety
10 Maintenance
10.1 Ensuring safety
Follow the instructions below to ensure safe machine maintenance.

➤ Maintenance work may only be carried out by authorized personnel.
➤ Use one of the safety signs below to advise others that the machine is currently being serv‐
iced:
Sign Meaning
Don't activate the machine.
Warning:
The machine is being serviced.
Tab. 37 Advise others that the machine is being serviced.
➤ Before switching on, make sure that no personnel are working on the machine and all access
doors and panels are closed.
age.
➤ Vent all components and volumes under vacuum to atmospheric pressure.

in serious injury.

10 Maintenance
10.2 Following the maintenance plan
age.


10.2.1 Logging maintenance work
The maintenance intervals given are those recommended for KAESER original components
with average operating conditions.
➤ In adverse conditions, perform maintenance work at shorter intervals.
Adverse conditions are, e.g.:

■ high temperatures
■ much dust
■ high number of load changes
■ low load
➤ Adjust the maintenance intervals with regard to local installation and operating condi‐
tions.
➤ Document all maintenance and service work.
This enables the frequency of individual maintenance tasks and deviations from our recom‐
mendations to be determined.
Further information A prepared list is provided in chapter 10.18.
10.2.2 Resetting maintenance interval counters

According to the way a machine is equipped, sensors and/or maintenance interval counters moni‐
tor the operational state of important functional devices. Required maintenance work is shown on
SIGMA CONTROL 2.
Precondition Maintenance performed and

maintenance message acknowledged.
➤ Reset the maintenance interval counter as described in the SIGMA CONTROL 2 operating
manual.
10.2.3 Regular maintenance tasks

The table below lists maintenance tasks required.

10 Maintenance
➤ Take note of the controller's service messages and carry out tasks punctually, taking ambient
and operating conditions into account.
Interval Maintenance task See chapter

Weekly Check the cooling oil level. 10.12
Check the filter mat. 10.4
Up to 500 h Check the drive belts and their tension. 10.8
Up to 1 000 h Clean the cooler. 10.3
Up to 3 000 h Change the gas ballast air filter. 10.5
Change the air filter inlet valve. 10.6
Clean the regulator nozzle.
Display: Change the vacuum filter. 10.6
SIGMA CONTROL 2 Change the air filter inlet valve.
Clean the regulator nozzle.
Drive motor maintenance. 10.7
Display: Change the oil filter. 10.16
SIGMA CONTROL 2 Change the oil separator cartridge. 10.17
At least annually
Varies, see table 39 Change the cooling oil. 10.15
Annually Check the safety relief valve. 10.9
Check the overheating safety shutdown function. 10.10
Check safety shutdown when opening the machine. 7.9
Test the EMERGENCY STOP push button. 10.11
Check the cooler for leaks. 10.3
Check that all electrical connections are tight. –
h = operating hours
Tab. 38 Regular maintenance tasks
10.2.4 Cooling oil change interval

Duty cycles and ambient conditions are important factors influencing the number and length of the
oil change intervals.
An authorized KAESER service representative will support you in determining appropriate in‐
tervals and provide information on the possibilities of oil analysis.
➤ Observe national regulations regarding the use of cooling oil in oil-injected rotary screw com‐
pressors.

10 Maintenance
10.3 Cooler maintenance
➤ Check operating conditions and adjust intervals as necessary; log the results in table 39 for fu‐
ture reference.
Maximum permissible oil change interval

[operating hours/years]
SIGMA FLUID Favorable operating Unfavorable operating My operating condi‐
conditions* conditions tions
S-460 3000**/2 2000/1
S-570 3000**/2 2000/1
* Cool to moderate ambient temperatures, low humidity, high duty cycle
** Change intervals of >6000 operating hours are not permissible without an oil analysis.
Tab. 39 Cooling oil change intervals
10.2.5 Regular service tasks

The table below lists necessary service tasks.
➤ Have an authorized KAESER service representative carry out service tasks.
➤ Have service tasks carried out punctually, taking ambient and operating conditions into ac‐
count.
Interval Service task

Display: Service valves.
SIGMA CONTROL 2
Display: Compressor drive motor:
SIGMA CONTROL 2 Check and/or replace the motor bearings.
At least every 4 years.
Up to 36 000 h, Have the plastic pipes and hose lines replaced.
At least every 6 years.
At least after 20 years. Replace safety-relevant components of the safety functions.
h = operating hours
Tab. 40 Regular service tasks

Regular cooler cleaning ensures proper machine temperature control. The frequency is mainly de‐
pendent on local operating conditions.
A leaking cooler results in loss of cooling oil and compressed gas .

the device is locked off,
the absence of any voltage has been verified.
The machine has cooled down.

10 Maintenance
Fig. 21 Cooler maintenance

1 Combination valve with oil filter 4 Hex-head screw
2 Cooler 5 Fixing screw
3 Fan casing 9 Hose coupling
1. Check the cooler regularly for clogging.

2. Clean the cooler as required and check for leaks.
10.3.1 Checking the cooler for clogging

The cooler clogs with dirt mostly on the inside.
➤ Open the enclosure and check the cooler for clogging.
10.3.2 Checking the cooler for leaks

➤ Carry out visual inspection: Did cooling oil escape?
Is the cooler leaking?
➤ Have the defective cooler repaired immediately by an authorized KAESER service repre‐
sentative.
10.3.3 Cleaning the cooler

The cooler can be cleaned with a compressed air blast, water or steam. The cooler must be re‐
moved from the machine for cleaning.
Do not use sharp objects to clean the cooler. It could cause damage.
Avoid creating clouds of dust.
Material Steam or compressed air blast

Cleaning cloths
Breathing mask (if necessary)
Removing the cooler
Precondition The machine is vented to atmospheric pressure.
1. Close the user's shut-off valve between the machine and the vacuum network.

10 Maintenance
10.4 Filter mat maintenance
2. Open the doors and protective grill and remove the left panel.
3. Unscrew the combination valve 1 from the cooler 2 , lift slightly, and catch escaping oil with a
cloth.
4. Remove the hex-head screws 4 and push the fan casing 3 back towards the motor.
5. Remove the fixing screws 5 and take out the cooler.
Cleaning the cooler and refitting
Precondition All cooler openings sealed.

A suitable cleaning place is available equipped with an oil separator.
1. Danger of injury from compressed air blast or water or steam jet!

➤ Never direct compressed air, water or steam jets at any person.
➤ Wear eye protection.
2. Clean the cooler with a jet of compressed air, water or steam.
3. Refit the cooler and secure with the fixing screws 5 .
4. Slide the fan casing 3 onto the cooler and fix with the hex-head screws 4 .
5. Fit the combination valve 1 to the cooler 2 .
Check the cooler for leaks
1. Close the enclosure.

2. Open the user's shut-off valve between the machine and the vacuum network.
3. Switch the machine on.
4. After a few minutes of operation, stop the machine and check for leaks.
Is the cooler leaking?
➤ Have the defective cooler repaired immediately by an authorized KAESER service repre‐
sentative.
10.4 Filter mat maintenance

Material Warm water with household detergent.
Spare parts (as required).
Precondition The power supply disconnecting device is switched off.

The disconnecting device is locked off.
A check has been made that no voltage is present.

10 Maintenance
10.5 Changing the gas ballast air filter
Fig. 22 Filter mat maintenance

1 Filter mat
2 Mounting frame
1. Open the snap fasteners (turn the cross-head with a screwdriver counter-clockwise by 90°)
and remove the mounting frame.
2. Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash with lukewarm
water and household detergent.
3. Fit the mounting frame, insert the snap fasteners and press to latch.
The filter mat can no longer be cleaned or has already been cleaned 5 times?
➤ Replace the filter mat.
10.5 Changing the gas ballast air filter

All sealing surfaces are matched to each other. The use of an unsuitable air filter element can per‐
mit dirt to ingress into the airend and cause damage to the machine.
When the gas ballast air filter is changed, the air filter on the inlet valve should be changed at the
same time.
➤ Do not clean the filter element. A damaged filter cartridge can permit dirt to enter the vac‐
uum block and cause damage to the machine.
Material Spare parts

Cleaning cloths

The user's shut-off valve between the machine and the vacuum network is closed.

10 Maintenance
10.6 Changing the vacuum filter
Fig. 23 Changing the gas ballast air filter

1 Gas ballast air filter 3 Dust bowl
2 Snap fastener 4 Filter cartridge
1. Open the snap fastener 2 and remove the dust bowl 3 with filter cartridge 4 .
2. Clean all parts and housing sealing surfaces.
3. Insert the new cartridge 4 in the housing.
4. Secure the dust bowl 3 to the filter housing with the snap fastener 2 .
5. Unscrew the air filter at the inlet valve and clean the control nozzle (see chapter 10.6).
6. Install a new air filter at the inlet valve.
7. Switch on the power supply and reset the maintenance interval counter.
10.6 Changing the vacuum filter

All sealing surfaces are matched to each other. The use of an unsuitable air filter element can per‐
mit dirt to ingress into the system and cause damage to the machine.
Always change the inlet air filter along with the vacuum filter.
➤ Do not clean the filter element.

Cleaning cloths

the disconnecting device is locked off,
The user's shut-off valve between the machine and the vacuum network is closed.

10 Maintenance
10.7 Drive motor maintenance
Fig. 24 Changing the vacuum filter

1 Vacuum filter 5 Prepared hose line
2 Snap fastener 6 Air filter
3 Dust bowl 7 Inlet valve
4 Filter element 8 Regulator nozzle
1. Undo the hose line 5 .

The vacuum filter is vented to atmospheric pressure.
2. Open the snap fastener 2 and remove the dust bowl 3 with filter element 4 .
3. Clean all parts and housing sealing surfaces.
4. Insert the new element 4 in the housing.
5. Secure the dust bowl 3 to the filter housing with the snap fastener 2 .
6. Reattach the hose line 5 .
7. Remove the air filter 6 from the inlet valve 7 and clean the regulator nozzle 8 .
8. Install a new air filter 6 at the inlet valve 7 and reinstall the regulator nozzle 8 .
Dispose of the filter in accordance with local environmental protection regulations.
10.7 Drive motor maintenance

The drive motor bearings are permanently greased. Re-greasing is not necessary.
➤ Have the motor bearings replaced by an authorized KAESER service representative.
10.8 Drive belt maintenance

Material Spare parts (if required)

The disconnecting device is locked off,
The absence of voltage has been verified,
The machine has cooled down.

10 Maintenance
10.8 Drive belt maintenance
Touching the moving drive belt may result in severe bruising or even loss of limb or extremi‐
ties.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of
voltage.
Fig. 25 Drive belt maintenance

1 Adjusting nut
2 Locking nut
3 Marker pin (shown as: belt tensioning required)
Checking the belt tension and adjustment
The tensioning device uses spring force to apply correct tension to the belts.
Adjust the tension when the marker pin reaches the top end of the elongated hole.
1. Loosen the locking nut 2 .
2. Use the adjusting nut 1 to adjust the spring tension until the marker pin reaches the lower end
of the elongated hole.
3. Tighten the locking nut 2 .
Visually check for damages.
1. Turn the pulley by hand so that all of the belt can be inspected for damage.
2. In case of damage: Replace the drive belt immediately.
Changing the belt
1. Loosen the locking nut 2 .

2. Turn adjusting nut 1 to loosen the tension on the belts until they can be removed from the pul‐
ley.
3. Install the new set of belts and use the adjusting nut 1 to adjust tension until the marker pin
reaches the lower end of the elongated hole.
4. Tighten the locking nut 2 .

10 Maintenance
10.9 Checking the safety relief valve
10.9 Checking the safety relief valve

In order to check the safety relief valve, the machine's working pressure is raised above the acti‐
vating pressure of the valve.
➤ Never operate the machine without a correctly functioning safety relief valve!
Danger of injury from released cooling oil or loud noise!

➤ Wear ear and eye protection.
➤ Abort the test if the working pressure rises approximately 10% above the activating
pressure of the valve.
Fig. 26 Check the safety relief valve

1 Oil separator tank A Shut-off valve (closed)
2 Hose coupling B Shut-off valve (open)
4 Plug-in nozzle 6 Maintenance hose
5 Shut-off valve

10 Maintenance
10.10 Checking the overheating safety shutdown function
Checking the safety relief valve with the aid of Checking the safety relief valve using external
machine pressure pressure
The machine is switched off. The power supply disconnecting device is
1. Fit a pressure gauge to the hose coupling 2 switched off,
on the oil separator tank. the device is locked off,
the absence of any voltage has been verified,
2. Use suitable material to seal the end of the
discharge air line from the oil separator an external source of compressed air is availa‐
tank. ble.
3. Read the activating pressure on the valve. 1. Fit a pressure gauge to the hose coupling 2
(the activating pressure is usually to be on the oil separator tank.
found at the end of the part identification) 2. Use suitable material to seal the end of the
4. Start the machine and observe pressure discharge air line from the oil separator
build up on the gauge. tank.
5. Stop the machine as soon as the safety re‐ 3. Read the activating pressure on the valve.
lief valve blows off or working pressure rises (the activating pressure is usually to be
to 10% above the activating pressure of the found at the end of the part identification)
valve. 4. With the shut-off valve closed, insert the
6. Remove the pressure gauge from the hose male hose fitting 4 into the hose coupling
coupling. on the oil separator tank cover.
7. If necessary, vent the oil separator tank and 5. Connect the maintenance hose to the exter‐
replace the defective relief valve. nal air supply.
8. Re-open the end of the discharge air line. 6. Open the shut-off valve 5 and close it again
as soon as the safety relief valve blows off
or working pressure rises to 10% above the
activating pressure of the relief valve 5 .
7. Remove the shut-off valve and the male
hose fitting from the hose coupling.
8. If necessary, vent the oil separator tank and
replace the defective relief valve.
9. Re-open the end of the discharge air line.
10.10 Checking the overheating safety shutdown function

The machine should shut down if the airend discharge temperature reaches a maximum of 230 °F.
➤ Check the safety shutdown function as described in the SIGMA CONTROL 2 operating man‐
ual.
The machine does not shut down?
➤ Have the safety shutdown function checked by an authorized KAESER SERVICE repre‐
sentative.

10 Maintenance
10.11 Testing the EMERGENCY STOP push button
10.11 Testing the EMERGENCY STOP push button
Fig. 27 Testing the EMERGENCY STOP push button

9 EMERGENCY STOP push button
Precondition The compressor motor is running.
1. Press the EMERGENCY STOP push button.

The compressor motor stops, the pressure system is vented, and the machine is prevented
from automatically restarting.
The compressor motor does not stop?
The safety function of the EMERGENCY STOP push button is no longer ensured.
➤ Shut down the machine immediately and call an authorized KAESER SERVICE repre‐
sentative.
2. Turn the EMERGENCY STOP push button in the direction of the arrow to unlatch it.
3. Acknowledge the alarm message.
10.12 Checking the cooling oil level

Precondition The machine has been shut down for at least 5 minutes.

10 Maintenance
10.13 Venting the machine
Fig. 28 Checking the cooling oil level

1 Oil separator tank
2 Maximum oil level
3 Minimum oil level
➤ Read out cooling oil level.
Result As soon as the minimum level is reached: Replenish the cooling oil.
10.13 Venting the machine

Venting takes place in three stages:
■ Isolate the compressor from the vacuum network
■ Vent the vacuum filter
■ Vent the oil separator tank
The machine must be isolated from the vacuum network and completely vented before un‐
dertaking any work on the pressure system. All components and chambers must be at at‐
mospheric pressure.
The oil circulation vents automatically as soon as the machine is stopped.
Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.


10 Maintenance
10.14 Replenishing cooling oil
Fig. 29 Venting the machine

1 Oil separator tank 5 Shut-off valve
2 Hose coupling A Shut-off valve: closed
3 Hose line B Shut-off valve: open
4 Male hose fitting 6 Maintenance hose
Isolating the compressor from the vacuum network
➤ Close the user's shut-off valve between the machine and the vacuum network.
If the user has not provided a shut-off valve, the complete vacuum network must be vented.
Venting the vacuum filter
➤ Undo the hose line 3 .

The vacuum filter is vented to atmosphere.
Venting the oil separator tank
1. Escaping oil mist is damaging to health.

➤ Do not inhale oil mist.
2. With the shut-off valve closed, insert the male hose fitting 4 into the hose coupling 2 .
3. Slowly open the shut-off valve 5 to release pressure.

Before commencing any work on the machine, it must be isolated from the vacuum network
and vented to atmospheric pressure.

10 Maintenance
Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath

the absence of voltage has been verified.
1. Vent the machine as described in section 10.14.1.

2. Fill with cooling oil and test run as described in section 10.14.2.
10.14.1 Venting the machine

Pressure equalization takes place in 3 steps:
■ Isolate the compressor from the vacuum network
■ Vent the vacuum filter
■ Vent the oil separator tank
Material The maintenance hose with hose coupling and shut-off valve needed for pressure equalization is
stowed beneath the oil separator tank.

Escaping oil mist is damaging to health!

➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.

10 Maintenance
Fig. 30 Venting the machine to atmospheric

1 Oil separator tank 5 Shut-off valve
2 Hose coupling A Shut-off valve (closed)
3 Hose line B Shut-off valve (open)
Isolating the compressor from the vacuum network
➤ Close the user's shut-off valve between the machine and the vacuum network.
If the user has not provided a shut-off valve, the complete vacuum network must be vented.
Venting the vacuum filter
➤ Undo the hose line 3 .

The vacuum filter is vented to atmosphere.
Venting the oil separator tank
1. Escaping oil mist is damaging to health!

➤ Do not inhale oil mist.
3. Slowly open the shut-off valve 5 to release pressure.
10.14.2 Topping off with cooling oil and trial run

Replenish cooling oil
A sticker on the oil separator tank specifies the type of oil used.

10 Maintenance
Fig. 31 Replenish cooling oil

1 Oil separator tank B Shut-off valve (open)
2 Hose coupling 6 Maintenance hose
3 Oil filler port with plug 7 Oil level maximum
4 Male hose fitting 8 Oil level minimum
5 Shut-off valve 9 Shut-off valve
A Shut-off valve (closed) 10 Hose coupling
1. The machine could be damaged by unsuitable oil!

➤ Never mix different types of oil.
➤ Never top up with a different type of oil to that already used in the machine.
2. Slowly unscrew the filler plug 3 .
3. Top up to bring the oil to the correct level.
4. Replace the filler plug's sealing ring if necessary and screw the plug into the filler neck.
Starting the machine and performing a trial run
1. Close all access doors, replace and secure all removable panels.
3. After about 10 minutes of operation, check the cooling oil level again and top off if necessary.
4. Switch off the machine and check for leaks.

10 Maintenance
10.15 Changing the cooling oil

Drain the oil from the oil separator tank and oil cooler completely. Always change the oil filter
and oil separator cartridge when changing the oil.
■ Oil separator tank

■ Oil cooler
■ Compressor block
Always change the oil filter and oil separator cartridge when changing the oil.
An electric pump assists in draining the oil. It must be suitable for the type cooling oil used
and the temperature.
➤ Follow the electric pump's operating instructions.
Material Cooling oil

Cooling oil receptacle
The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
Electric pump
Hose for draining the cooling oil

the absence of voltage has been verified.
The machine is vented to atmospheric pressure.
There is risk of burns from hot components and oil!

➤ Wear long-sleeved clothing and protective gloves.

10 Maintenance
Fig. 32 Changing the cooling oil, oil separator tank

1 Oil separator tank B Shut-off valve: open
2 Hose coupling 6 Maintenance hose
3 Oil filler port with plug 7 Maximum oil level
4 Male hose fitting 8 Minimum oil level
5 Shut-off valve 9 Shut-off valve (oil drain)
A Shut-off valve: closed 10 Hose coupling (oil drain)
Draining the oil from the separator tank
Contact an authorized KAESER service representative if condensate is detected in the cool‐

ing oil.
It is necessary to adapt the airend discharge temperature to individual ambient conditions.
1. Have an oil receptacle ready.
3. Connect one end of the maintenance hose to the electric pump and insert and fix the other end
in the cooling oil receptacle.
4. Open the shut-off valve 9 .
5. Slowly open the shut-off valve 5 in the maintenance hose, switch on the pump and allow oil to
drain completely.
6. Close the shut-off valve 9 and unplug the male hose fitting.
➤ Dispose of used oil in accordance with environment protection regulations.

10 Maintenance
10.16 Changing the oil filter
Draining the oil from the cooler
Fig. 33 Draining the oil from the cooler

1 Oil cooler A Shut-off valve closed
2 Hose coupling (oil drainage) B Shut-off valve open
4 Shut-off valve
1. Have an oil receptacle ready.

3. Connect one end of the maintenance hose to the electric pump and insert and fix the other end
in the cooling oil receptacle.
4. Slowly open the shut-off valve 4 , switch on the pump and allow oil to drain completely.
5. Close the shut-off valve 4 and unplug the male hose fitting.
➤ Dispose of used oil in accordance with environment protection regulations.
Filling with cooling oil
1. Slowly unscrew the filler plug 3 (see illustration 32).

2. Fill with cooling oil.
3. Check the filler plug and ring seal for damage and screw the plug back in again.
Start the machine and carry out a trial run
4. Start the machine and check the oil level again after about 10 minutes, topping off if necessary.
5. Switch off the machine and visually check for leaks.
10.16 Changing the oil filter


10 Maintenance
10.17 Changing the oil separator cartridge

Cleaning cloths
Cooling oil receptacle

There is risk of burns from hot components and oil!

➤ Wear long-sleeved clothing and protective gloves.
Fig. 34 Changing the oil filter

1 Oil filter
2 Direction to unscrew
Changing the oil filter
1. Unscrew the oil filter counterclockwise, catch oil spillage and dispose of in accordance with en‐
vironmental protection regulations.
2. Lightly oil the new filter's gasket.
3. Turn the oil filter clockwise by hand to tighten.
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
Starting the machine and carrying out a trial run
4. After about 10 minutes of operation, check the cooling oil level and top off if necessary.
5. Switch off the machine and visually check for leaks.

The oil separator cartridge cannot be cleaned.

10 Maintenance
The life of the oil separator cartridge is influenced by:

■ contamination in the conveying medium,
■ and adherence to the changing intervals for:
─ Cooling oil
─ Oil filter
─ Vacuum filter
─ Gas ballast air filter

Cleaning cloths

Fig. 35 Changing the oil separator cartridge

1 Pipe clamp 6 Cover
2 Self-locking nut 7 Sight glass in the oil return line
3 Fixing crew 8 Metal clip
4 Dirt trap 9 Gasket
5 Screw fitting 10 Oil separator cartridge
Changing the oil separator cartridge
1. Unscrew the self-locking nut 2 and remove the pipe clamp 1 .

2. Loosen the fitting 6 and remove the component carefully with its connection.
3. Remove the cover fixing screws 3 and carefully remove the cover 6 .

10 Maintenance
4. Remove the old oil separator cartridge 10 together with the gaskets 9 and dispose of accord‐
ing to applicable environmental protection regulations.
5. Clean all sealing faces.
If the gaskets have metal clips, these must not be removed.
6. Insert the new oil separator cartridge with gaskets and screw down the cover.
7. Renew the O-ring and strainer in the dirt trap 5 .
8. Replace the oil pump dirt trap 4 strainer and gasket.
9. Reassemble in reverse order.
10. Replace and tighten all fittings.
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
Starting the machine and carrying out a trial run
4. After about 10 minutes of operation, switch off the machine and check for leaks.

10 Maintenance
10.18 Documenting maintenance and service work
10.18 Documenting maintenance and service work

Equipment number:
➤ Enter maintenance and service work carried out in the checklist below.
Date Maintenance task carried out Operating hours Signature
Tab. 41 Logged maintenance tasks

11.1 Note the nameplate

11.1 Note the nameplate
The nameplate contains all information to identify your machine. This information is essential to us
in order to provide you with optimal service.
➤ Please give the information from the nameplate with every inquiry and order for spare parts.
11.2 Ordering consumable parts and operating fluids/materials

KAESER consumable parts and operating materials are original KAESER products. They are spe‐
cifically selected for use in KAESER machines.
Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐
chine or impair its proper function.
Damage to the machine can also result in personal injury.
There is risk of personal injury or damage to the machine resulting from the use of unsuita‐
ble spare parts or operating fluids/materials.
➤ Use only original parts and operating fluids/materials.
➤ Have an authorized KAESER service representative carry out regular maintenance.
Machine
Name Number
Gas ballast air filter 1250
Filter mat 1050
Vacuum filter 1300
Oil filter 1200
Oil separator cartridge 1450
Cooling oil 1600
Drive belt 1800
Inlet valve air filter 1400
Tab. 42 Consumable parts
11.3 KAESER AIR SERVICE

KAESER AIR SERVICE offers:
■ Authorized service technicians with KAESER factory training
■ Increased operational reliability ensured by preventive maintenance
■ Energy savings achieved by avoidance of leakages
■ Optimum conditions for operation of the vacuum station
■ The security of genuine KAESER spare parts
■ Increased legal certainty as all regulations are kept to

11.4 Completing the Declaration of Decontamination
➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement.

Your advantage:
Lower costs and higher vacuum availability.
11.4 Completing the Declaration of Decontamination

Every company (user) is responsible for the health and safety of its employees. This obligation in‐
cludes personnel completing service work at the user or principal.
Before repair and/or service of the machine is commenced, the user must provide a completed and
signed declaration of contamination.
1. Contact an authorized KAESER service representative and request the Declaration of Decon‐
tamination form.
2. Affix a copy of the Declaration of Decontamination to the outside of the packaging.
11.5 Service Addresses

Addresses of KAESER representatives are given at the end of this manual.
11.6 Spare parts for service and repair

With the help of this parts list you can plan your material requirement according to operating condi‐
tions and order the spare parts you need.
➤ Make sure that any service or repair tasks not described in this manual are carried out by
an authorized KAESER service representative.



12.1 Decommissioning

12.1 Decommissioning
Decommissioning is necessary, for example, under the following circumstances:
■ The machine is temporarily not needed.
■ The machine is to be moved to another location.
■ The machine is to be scrapped.
Temporary decommissioning
Precondition The machine can be started at regular intervals.
➤ Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protec‐
tion against corrosion.
Long-term decommissioning
Precondition Immediately prior to decommissioning, run the machine under LOAD for at least 30 minutes.
The power supply disconnecting device is switched off,
The machine is fully vented.
1. Allow the machine to completely cool down.

2. Disconnect all air and electrical connections.
12.2 Packing
A wooden crate is required for overland transport to protect the machine from mechanical damage.
Other measures must be taken for the transport of machines by sea or air. Please contact an au‐
thorized KAESER SERVICE representative for more information.
Material Desiccant
Plastic sheeting
Wooden crate
Precondition The machine is decommissioned.

The machine is dry and cooled down.
1. Place sufficient desiccant silica gel or desiccant clay in the machine.

2. Wrap the machine fully in plastic sheeting.
3. Protect the machine in a wooden crate against mechanical damages.
12.3 Storage
Moisture can lead to corrosion, particularly on the surfaces of the airend and in the oil separator
tank.
Frozen moisture can damage components, valve diaphragms and gaskets.

12.4 Transport
The following measures also apply to machines not yet commissioned.

Please consult with KAESER if you have questions to the appropriate storage and commis‐
sioning.
1. Moisture and frost can damage the machine!

➤ Prevent ingress of moisture and formation of condensation.
➤ Maintain a storage temperature of >32 °F.
2. Store the machine in a dry, frost-proof room.
12.4 Transport
12.4.1 Safety
Weight and center of gravity determine the most suitable method of transportation. The center of
gravity is shown in the drawing in chapter 13.2.
There could be danger from the residue of medium that has been drawn in by the machine.
➤ Hand over with the machine for transporting a Declaration of Decontamination so that the
recipient is aware of any danger.
Please contact an authorized KAESER service representative for the form.
Precondition Transport only by forklift truck or lifting gear only by personnel trained in the safe transportation of
loads.
➤ Make sure the danger area is clear of personnel.
12.4.2 Transport with a forklift truck

Precondition The forks are fully under the machine.
Fig. 36 Transport with a forklift truck
➤ Drive the forks completely under the machine or palette and lift carefully.
12.4.3 Transport with a crane

Suitable lifting gear ensures correct transportation.
The lifting slings must be fed under the machine.
The slings may not bear on the side of the machine enclosure.
Examples of unsuitable fixing points:

■ Pipe sockets

12.5 Disposal
■ Flanges
■ Attached components such as cyclone separators, condensate drains or filters.
■ Rain protection covers
Precondition The lifting gear complies with local safety regulations.

No pressure should bear on the sides of the machine cabinet.
Fig. 37 Transport with a crane

1 Lifting gear
2 Slings
1. The machine can be damaged by incorrect attachment of the lifting gear!

➤ Do not attach the lifting gear to any of the machine components.
2. Use the lifting gear correctly and lift the machine carefully.
12.5 Disposal
When disposing of a machine, drain out all liquids and remove used filters.
The disposal company must be fully informed of the degree of contamination of any noxious sub‐
stances to be found in the machine.
Precondition The machine is decommissioned.
1. Completely drain the cooling oil from the machine.

2. Remove used filters and the oil separator cartridge.
3. Fill out the Declaration of Contamination and hand the machine over to an authorized disposal
company.
➤ Components and filters contaminated with noxious substances must be disposed of in
accordance with local environmental protection regulations.

12.6 Battery disposal
12.6 Battery disposal

Batteries contain substances that are harmful to living beings and the environment. For this reason,
batteries must not be disposed of with unsorted residential waste. They must be disposed of in ac‐
cordance with local environmental regulations. This procedure facilitates the handling and recycling
of batteries.
Fig. 38 Battery disposal

1 Do not dispose of batteries with residential waste
2 Battery contains lead (if applicable)
➤ Dispose of batteries in accordance with local environmental regulations.

13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram)
13 Annex

13 Annex

13 Annex

13 Annex
13.2 Dimensional Drawing

13 Annex

13 Annex
13.3 Electrical Diagrams

13.3.1 Electrical diagram 1 of 2

1 2 3 4 5 6 7 8
9_5773 32 USE
Wiring Diagram
Vacuum-unit ASV, BSV, CSV
air cooled and water cooled
13
13.3
380V±10% 3ph 60Hz

575V±10% 3ph 60Hz
Annex
BSV SIGMA CONTROL 2

Power supply:
Electrical Diagrams
WYE system with center point solidly grounded

ATTENTION !!!
The document gives collective information on
power supply voltages and frequencies for all machines.
The voltage and frequency and local conditions under

manufacturer: KAESER COMPRESSORS
which any particular machine may be used
are given on the nameplate of the machine 96450 COBURG
and in the accompanying service manual.
GERMANY
The drawings remain our exclusive property. They are entrusted

only for the agreed purpose. Copies or any other reproductions,
including storage, treatment and dissemination by use of
electronic systems must not be made for any other than the
agreed purpose. Neither originals nor reproductions must be
forwarded or otherwise made accessible to third parties.
c Datum 09.03.2017 USE cover page =

b Bearbeiter Sitter +
a Geprüft Büchner
Vacuum-unit page 1
A Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS DSV-U3002.00 1 Bl.
89
90
Lfd. Nr. Benennung Zeichnungsnummer (Kunde) Zeichnungsnummer (Hersteller) Blatt Anlagenkennzeichen
No. Name Drawing No. (customer) Drawing No. (manufacturer) Page Unit designation
1 cover page DSV-U3002.00 1
2 list of contents ZSV-U3002.00 1
3 general instructions USV-U3002.00 1
4 electrical equipment identification USV-U3002.00 2
5 electrical component parts list USV-U3002.00 3
13
13.3

11 wiring diagram power supply/power unit SSV-U3002.00 1
12 wiring diagram control SSV-U3002.00 2
13 wiring diagram control voltage tapping SSV-U3002.00 3
14 wiring diagram power supply unit SSV-U3002.00 4
Annex
15 wiring diagram IO-module/configuration SSV-U3002.00 5

16 wiring diagram sensors/actuators SSV-U3002.00 6
BSV SIGMA CONTROL 2

17 wiring diagram volt-free contacts SSV-U3002.00 7
18 wiring diagram inputs/outputs SSV-U3002.00 8
19 wiring diagram digital outputs SSV-U3002.00 9
Electrical Diagrams
20 wiring diagram transformer diagrams SSV-U3002.00 10

21 wiring diagram Handling: Terminals SSV-U3002.00 11
22 wiring diagram Feed line connection SSV-U3002.00 12
23 terminal connection terminal strip -X0,-X11 KSV-U3002.00 1
24 lay-out control panel ASV-U3002.00 1

c Datum 09.03.2017 list of contents =
a Geprüft Büchner
Vacuum-unit page 1
B Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS ZSV-U3002.00 1 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
9_5773 32 USE
general instructions control cabinet wiring for non-designated conductors
ATTENTION !!!
primary circuits ungrounded: black, UL-Style 1015, CSA-TEW
Install supplies, grounding and shock protection
primary circuits grounded: grey, UL-Style 1015, CSA-TEW
to local safety regulations.
control voltage AC 115V ungrounded: red, 18AWG UL-Style 1015, CSA-TEW
Do not make or break
live plug-in connectors. control voltage AC 115V grounded: white, 18AWG UL-Style 1015, CSA-TEW
13
13.3
control voltage DC ungrounded: blue, 18AWG UL-Style 1015, CSA-TEW

control voltage DC grounded: white/blue, 18AWG UL-Style 1015, CSA-TEW
external voltage: orange, 16AWG UL-Style 1015, CSA-TEW
measuring circuits: violet, 18AWG UL-Style 1015, CSA-TEW
Annex
ground conductor: green/yellow, UL-Style 1015, CSA-TEW
BSV SIGMA CONTROL 2

Electrical Diagrams

c Datum 09.03.2017 general instructions =
a Geprüft Büchner
Vacuum-unit page 1
C Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS USV-U3002.00 8 Bl.
91
92
1 2 3 4 5 6 7 8
electrical equipment identification
general components control sensors/actuators

-B25 overload relay, -K20 Main Control System SC2MCS -B1 pressure transducer,
13
13.3
compressor motor -X1 Ethernet air main pressure absolutley

-1FU,-2FU primary control fuse -X2 IO-Bus -B2 safety air pressure switch-direction of rotation
-3FU secondary control fuse -X3 RS485-FC (USS) -B3 high oil filter pressure
-M1 compressor motor -X4 communication module (Bus) (only BSV, CSV)
-Q1 main contactor -X5 SD card slot -B4 pressure transducer,
-S1 EMERGENCY STOP pushbutton -X6 ground connection package internal pressure absolutley
Annex
-S5 door safety interlock switch (only BSV, CSV)

-T11 control transformer -K21 IO-module SC2IOM-1 -B5 differential pressure switch oil separator
BSV SIGMA CONTROL 2

-T21 power unit (only BSV, CSV)
inside
-B8 pressure switch oil pressure
-X1 IO-Bus, input
-B40 temperature probe
-X2 IO-Bus, output
Electrical Diagrams
airend discharge temperature

-X3,-X8 digital inputs
-X4 power supply unit, digital outputs -K1 control valve
-X5,-X9 Relay outputs
-X6 analog input, 4-20mA
-X7 analog input, Pt100

external
-X11...-X13 analog inputs, 4-20mA
-X14...-X17 analog inputs, Pt100
-X18...-X29 digital inputs
-X30...-X32 digital outputs
terminal strips
-X0 terminal strip, power supply
-X11 terminal strip, control
c Datum 09.03.2017 electrical equipment identification =

a Geprüft Büchner
Vacuum-unit page 2
9_5773 32 USE
13 Annex
3
electrical component parts list
Bl. 8
page
model ASV 40
machine power supply 380 V ±10 %, 60 Hz 575 V ±10 %, 60 Hz
USV-U3002.00
motor -M1 10 hp 10 hp
=
+
diagram 1, Sht. 1 diagram 1, Sht. 1
supply terminals -X0:U1/V1/W1 7.3149.02000 7.3149.02000
Wieland WKFN16D1/2/35 WKFN16D1/2/35
Stripped length 16 mm 16 mm
Handling fig. 2, Sht. 11 fig. 2, Sht. 11
-X0:GRD 7.3149.02020 7.3149.02020
Wieland WKFN16D1/2/SL/35 WKFN16D1/2/SL/35
supply connection fig. 10, Sht. 12 fig. 10, Sht. 12
SC2 MCS
terminal strip -X0 7.6836.00640 Wieland 7.6836.00640 Wieland
contactor -Q1 7.8740.00400 7.8740.00390
3RT2035-1AK60 3RT2028-1AK60
auxiliary switch 7.8740.05010 7.8740.05010
3RH2911-1HA11 3RH2911-1HA11
interference suppressor 7.8740.05150 7.8740.05140
Siemens 3RT2936-1CC00 3RT2926-1CC00
overload relay -B25 7.8741.00090 7.8741.00070
3RB3036-1UB0 (12.5-50 A) 3RB3026-1QB0 (6-25 A)

setting: 16 A setting: 10 A
NEC 430.32(C) incremental NEC 430.32(C) incremental
Siemens setting: 18 A setting: 12 A
Vacuum-unit
fuses -1FU/-2FU 7.3316.1 7.3312.1
Gould ATQR 1 1/2 (1.5 A, 600 V) ATQR 1 1/4 (1.25 A, 600 V)
fuses -3FU 7.3313.1 7.3313.1
fuse socket -1FU...-3FU 7.3320.00060 7.3320.00060
Wöhner AMBUS EASYSWITCH AMBUS EASYSWITCH
transformer -T11 7.2239.20080 7.2237.1
USTE250 (250 VA) B0204028 (320 VA)
Block diagram 2, Sht. 10 diagram 1, Sht. 10
power supply -T21 7.7605P0 7.7605P0
Prodrive PSDC24/2.5 PSDC24/2.5
Ursprung:
connection -W11 10 AWG black 10 AWG black
600 V, 90°C 600 V, 90°C
connection -W11.1/.2/.3/.4 6 AWG green/yellow 6 AWG green/yellow
600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
cables -W19.1/.2 4G10 AWG 4G10 AWG
600 V, 90°C 600 V, 90°C
Ersatz für:
compressor control -K20 7.7601.0 7.7601.0
Prodrive SIGMA CONTROL 2 MCS SIGMA CONTROL 2 MCS
IO-module -K21 7.7602.1 7.7602.1
Prodrive SIGMA CONTROL 2 IOM-1 SIGMA CONTROL 2 IOM-1
EMERGENCY STOP pushbutton -S1 7.3217.0 / QRUV 7.3217.0 / QRUV
auxiliary contact Schlegel 7.3218.0 / MHTOO 7.3218.0 / MHTOO
control cabinet KAESER 7.5461.3 7.5461.3
control panel KAESER 207184.1 207184.1
Ersatz durch:
09.03.2017
Büchner
Bearbeiter Sitter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

13 Annex
4
Bl. 8
page
model ASV 60
USV-U3002.00
=
+
Wieland WKFN16D1/2/35 WKFN16D1/2/35
-X0:GRD 7.3149.02020 7.3149.02020
Wieland WKFN16D1/2/SL/35 WKFN16D1/2/SL/35
SC2 MCS
contactor -Q1 7.8740.00400 7.8740.00400
3RT2035-1AK60 3RT2035-1AK60
3RH2911-1HA11 3RH2911-1HA11
overload relay -B25 7.8741.00090 7.8741.00090
3RB3036-1UB0 (12.5-50 A) 3RB3036-1UB0 (12.5-50 A)

Vacuum-unit
fuses -1FU/-2FU 7.3316.1 7.3312.1
fuses -3FU 7.3313.1 7.3313.1
fuse socket -1FU...-3FU 7.3320.00060 7.3320.00060
transformer -T11 7.2239.20080 7.2237.1
USTE250 (250 VA) B0204028 (320 VA)
Ursprung:
600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
cables -W19.1/.2 1x10 AWG 1x10 AWG
600 V, 90°C 600 V, 90°C
Ersatz für:
IO-module -K21 7.7602.1 7.7602.1
Ersatz durch:
09.03.2017
Büchner
Bearbeiter Sitter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

13 Annex
5
Bl. 8
page
model BSV 80
USV-U3002.00
=
+
Siemens 3RV2935-5E 3RV2935-5E
Torque 6 Nm 6 Nm
-X0:PE 7.3291.00010 7.3291.00010
Wieland WKN35SL/U WKN35SL/U
Torque 3 Nm 3 Nm
SC2 MCS
contactor -Q1 7.8740.00410 7.8740.00400
3RT2036-1AK60 3RT2035-1AK60
3RH2911-1HA11 3RH2911-1HA11
overload relay -B25 7.8741.00090 7.8741.00090
3RB3036-1UB0 (12.5-50 A) 3RB3036-1UB0 (12.5-50 A)

fuses -1FU/-2FU 7.3316.1 7.3312.1
Vacuum-unit
fuses -3FU 7.3313.1 7.3313.1
fuse socket -1FU...-3FU 7.3320.00060 7.3320.00060
transformer -T11 7.2239.20080 7.2237.1
USTE250 (250 VA) B0204028 (320 VA)
Ursprung:
600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
IO-module -K21 7.7602.1 7.7602.1
Ersatz für:
Ersatz durch:
09.03.2017
Büchner
Bearbeiter Sitter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

13 Annex
6
Bl. 8
page
model BSV 100
USV-U3002.00
=
+
Siemens 3RV2935-5E 3RV2935-5E
Torque 6 Nm 6 Nm
-X0:PE 7.3291.00010 7.3291.00010
Torque 3 Nm 3 Nm
SC2 MCS
contactor -Q1 7.8740.00420 7.8740.00410
3RT2037-1AK60 3RT2036-1AK60
3RH2911-1HA11 3RH2911-1HA11
overload relay -B25 7.8741.00090 7.8741.00090
3RB3036-1UB0 (12.5-50 A) 3RB3036-1UB0 (12.5-50 A)

fuses -1FU/-2FU 7.3316.1 7.3312.1
Vacuum-unit
fuses -3FU 7.3313.1 7.3313.1
fuse socket -1FU...-3FU 7.3320.00060 7.3320.00060
transformer -T11 7.2239.20080 7.2237.1
USTE250 (250 VA) B0204028 (320 VA)
Ursprung:
600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
IO-module -K21 7.7602.1 7.7602.1
Ersatz für:
Ersatz durch:
09.03.2017
Büchner
Bearbeiter Sitter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

13 Annex
7
Bl. 8
page
model CSV 125
USV-U3002.00
=
+
supply terminals -X0:U1/V1/W1 3x 7.3140.05360 3x 7.3140.05360
Siemens 3RA2943-3L 3RA2943-3L
Torque 10 Nm 10 Nm
-X0:PE 7.3149.01660 7.3291.00010
Torque 6 Nm 3 Nm
SC2 MCS
contactor -Q1 7.8740.00450 7.8740.00440
3RT2046-1AK60 3RT2045-1AK60
3RH2911-1HA11 3RH2911-1HA11
overload relay -B25 7.8741.00140 7.8741.00140
3RB3046-1XB0 (32-115 A) 3RB3046-1XB0 (32-115 A)
setting: ___ setting: ___

Siemens setting: ___ setting: ___
fuses -1FU/-2FU 7.3316.1 7.3312.1
Vacuum-unit
fuses -3FU 7.3313.1 7.3313.1
fuse socket -1FU...-3FU 7.3320.00060 7.3320.00060
transformer -T11 7.2239.20080 7.2237.1
USTE250 (250 VA) B0204028 (320 VA)
Ursprung:
600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
IO-module -K21 7.7602.1 7.7602.1
Ersatz für:
Ersatz durch:
09.03.2017
Büchner
Bearbeiter Sitter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

13 Annex
8
Bl. 8
page
model CSV 150
USV-U3002.00
=
+
supply terminals -X0:U1/V1/W1 3x 7.3140.05360 3x 7.3140.05360
Siemens 3RA2943-3L 3RA2943-3L
Torque 10 Nm 10 Nm
-X0:PE 7.3149.01660 7.3291.00010
Torque 6 Nm 3 Nm
SC2 MCS
contactor -Q1 7.8740.00450 7.8740.00440
3RT2046-1AK60 3RT2045-1AK60
3RH2911-1HA11 3RH2911-1HA11
overload relay -B25 7.8741.00140 7.8741.00140
3RB3046-1XB0 (32-115 A) 3RB3046-1XB0 (32-115 A)
setting: ___ setting: 40 A

Siemens setting: ___ setting: 45 A
fuses -1FU/-2FU 7.3316.1 7.3312.1
Vacuum-unit
fuses -3FU 7.3313.1 7.3313.1
fuse socket -1FU...-3FU 7.3320.00060 7.3320.00060
transformer -T11 7.2239.20080 7.2237.1
USTE250 (250 VA) B0204028 (320 VA)
Ursprung:
600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
IO-module -K21 7.7602.1 7.7602.1
Ersatz für:
Ersatz durch:
09.03.2017
Büchner
Bearbeiter Sitter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

1 2 3 4 5 6 7 8
L1
/3.1
L2
9_5773 32 USE
/3.1
L3
-X0 GRD1-X11 GRD2 GRD
GRD2
GRD2
GRD3
-W11 -X0 -W11 -X0 -W11.1 14AWG
-W11.2
**** **** **** green/yellow
****
600V 90°C
1
3
5
1
3
5
-Q1 -Q1
control panel
13
control panel unit frame /2.5 /2.5

13.3
2
4
6
2
4
6
-W11.3
****
1
3
5
97
95
1
3
5
97
95
-B25 -B25
Annex
unit frame oil separator **** ****
2
4
6
2
4
6
98
98
BSV SIGMA CONTROL 2

/2.4 96
/2.4 96
-W11.4
****
Electrical Diagrams
-W19.1
unit frame pivoting motor base ****
U1
V1
W1
GRD1
-X0
****
Feed line connection -W19.1 -W19.2

For field wiring:
see page 12 **** ****
Use 75°C copper
conductors only! -W19.1
****
U
V
W
GRD
GRD
W1 V2
main disconnect,
M V1 M U2
fuse supplied
3~ U1 3~ W2
by user
diagram 1 -M1
-M1 diagram 2
**** ****
Motor terminal board
L1 L2 L3 GRD U1 V1 W1
supply line cross-section and W2 U2 V2

fusing see operating manual **** performance-related components,
see: electrical component parts list
Function: compressor motor

Group of function: input voltage power unit
c Datum 09.03.2017 wiring diagram =
a Geprüft Büchner
Vacuum-unit page 1
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: power supply/power unit SC2 MCS SSV-U3002.00 12 Bl.
99
100
1 2 3 4 5 6 7 8
95
21
-B25 -Q1
/1.4 5
96
22
Int. Int. Int.
7
6
10
X3 X3 X3
13
13.3
-K21 -K21 -K21

/5.3
DI_PA /5.3
DI 1.01 /5.3
DI 1.02
overload relay answerback signal

compressor motor main contactor
Annex
main contactor
BSV SIGMA CONTROL 2

-K21 DOR 1.00
/5.3 COM
Electrical Diagrams
7
X5
Int.

A1
-Q1
A2
L02
/3.1
1 2
/1.4
3 4
/1.4
5 6
/1.4
13 14
21 22
5
31 32
/7.4
43 44
/7.5
Function:
Group of function: direct on line start
a Geprüft Büchner
Vacuum-unit page 2
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: control SC2 MCS SSV-U3002.00 12 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
L1 -X11 1 -X11 2 L01
9_5773 32 USE
/1.8 /4.1
L2
1
/1.8 -W72
-W18
11
22
-S5
****
21
-1FU -2FU -3FU
12
door safety interlock switch
**** **** ****
2
-W72
Class CC Class CC Class CC
4
-X11
14AWG black
13
1
13.3
-W71
600V 90°C -W102
11
21
14AWG green/yellow -S1
600V 90°C
22
-T11
12
EMERGENCY STOP
1
2
Annex
-W101
2
-W71
**** 2x18AWG
control panel
5
115V -X11 600V 90°C
BSV SIGMA CONTROL 2

Int. Ext.
9
8
1
2
3
X3 X29
.
-K21 DI_PA DI -K21 DI_PA DI
model-specific
Electrical Diagrams
electrical diagram /5.3 DI 1.00 /5.3 DI 1.07

see page 10 connection EMERGENCY STOP door safety interlock switch
s.b.c.
10VA
. -K21 DOR COM

/5.3 COM
.
9
8
X5
Int.
GRD2
-X11
L02 -X11 03 -X11 02 -X11 01 L02

/2.7 /4.1
16AWG green/yellow
600V 90°C
GRD1
-X11
.
For Field Wiring:
**** performance-related components, Use Copper Conductors Only!
see: electrical component parts list Connect Control Device Only!
Function: 115V/1ph/60Hz door safety interlock switch/EMERGENCY STOP

Group of function: control voltage tapping Consumer external safety chain
a Geprüft Büchner
Vacuum-unit page 3
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: control voltage tapping SC2 MCS SSV-U3002.00 12 Bl.
101
102
1 2 3 4 5 6 7 8
L01 -X11 1 L01

/3.8
L02 01 L02
/3.8
-K20
MCS
X5
12AWG green/yellow
14AWG green/yellow
SD card
600V 90°C
13
600V 90°C
13.3
X6
option COM-Module RS485-FC Ethernet IO-Bus

control panel control cabinet door X4 X3 X1 X2
Annex
BSV SIGMA CONTROL 2

-W81
3x2x0,22mm²
Electrical Diagrams
screened
-T21
1)
-K21 X1

100- + I/O-BUS
/5.3 X4
240V~ +
L1 3 L+
-
24V= 2 L-
IOM 1
N -
1 FE
2,5A -
16AWG green/yellow
short circuit proof I/O-BUS
600V 90°C 14AWG green/yellow
X2
600V 90°C
GRD1
-X11
control panel
1) Reset: Switch off L1 for 3 minutes
Function: 24V DC
Group of function: control voltage
a Geprüft Büchner
Vacuum-unit page 4
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: power supply unit SC2 MCS SSV-U3002.00 12 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
9_5773 32 USE
-K21 IOM1 inside
11 1
DI_PA AII_PA
10 2
/2.3 DI_PA AII 1.02
X6
9 3
/3.6 DI_PA AII_GND
8
13
/3.6 DI 1.00
13.3
7
/2.4 DI 1.01 1
AIR 1.03
6
X7
/2.5 DI 1.02 2
X3
AIR 1.03 -K21
5
DI 1.03
4 IOM1 external
DI 1.04 1
3 DI_PB
Annex
DI 1.05 2
2 DI_PB /6.2 AII 1.00 X11 X22 DI 1.00
DI 1.06 3
1 DI_PB /6.3 AII 1.01 X12 X23 DI 1.01
BSV SIGMA CONTROL 2

DI 1.07 4
DI_PB AII 1.02 X13 X24 DI 1.02
8 5
DOT 1.01 DI_PB /6.4 AIR 1.00 X14 X25 DI 1.03
7
Electrical Diagrams
6
M24 DI_PB AIR 1.01 X15 X26 DI 1.04 /6.5
X8
6 7
DOT 1.02 DI 1.08 AIR 1.02 X16 X27 DI 1.05
5 8
M24 DI 1.09 AIR 1.03 X17 X28 DI 1.06 /6.6
X4
4 9
FE DI 1.10 DI 1.08 X18 X29 DI 1.07 /3.7
3 24V 10
/4.6 L+ DI 1.11 DI 1.09 X19 X30 DOT 1.00 /6.2

2 11
/4.6 0V L- DI 1.12 /6.7 DI 1.14 X20 X31 DOT 1.01
1 12
/4.6 FE DI 1.13 /6.8 DI 1.15 X21 X32 DOT 1.02
9 1
/3.6 DOR COM DOR 1.05
8 2
/3.6 DOR COM DOR COM
7 3
/2.5 DOR 1.00
6 4
DOR 1.01 DOR 1.06
5 5
X9
DOR 1.02 DOR COM
X5
4 6
DOR 1.03
3 7
DOR 1.07
2 8
DOR COM DOR COM
1 9
DOR 1.04
Function:
Group of function:
a Geprüft Büchner
Vacuum-unit page 5
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: IO-module/configuration SC2 MCS SSV-U3002.00 12 Bl.
103
104
1 2 3 4 5 6 7 8
only BSV, CSV only BSV, CSV only BSV, CSV

-B1 -B4 -B40
P P
1
1
1
1
-B8 -B5 -B3 -B2
4...20mA 4...20mA
Pt100 P P P P
2
2
2
4
- + - +
1 bar 0,8 bar Δp 1,5 bar 1,0 bar
2
1
2
1
1
2
13
13.3
-W115 -W116 -W117 -W110 -W106 -W105 -W104
Ext. Ext. Ext. Ext. Ext. Ext. Ext.

Annex
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
X11 X12 X14 X26 X28 X20 X21

-K21 AII AII_PA GND -K21 AII AII_PA GND -K21 AIR_A Shield AIR_B -K21 DI_PA DI -K21 DI_PA DI -K21 DI_PB DI -K21 DI_PB DI
BSV SIGMA CONTROL 2

/5.3 AII 1.00 /5.3 AII 1.01 /5.3 AIR 1.00 /5.3 DI 1.04 /5.3 DI 1.06 /5.3 DI 1.14 /5.3 DI 1.15
air main pressure package internal pressure airend discharge temperature oil pressure oil separator oil filter direction of rotation
Electrical Diagrams
control valve

-K21 DOT 1.00
/5.3 DOT M24
1
2
3
X30
Ext.
-W113
1(+)
2(-)
1
2
-K1
Function:
Group of function:
a Geprüft Büchner
Vacuum-unit page 6
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: sensors/actuators SC2 MCS SSV-U3002.00 12 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
9_5773 32 USE
13
13.3
volt-free contacts
User's connection
Annex
BSV SIGMA CONTROL 2

31
43
-Q1 -Q1
/2.5 /2.5
Electrical Diagrams
32
44
15
16
17
-X11 -X11 -X11

max. 250V AC/24V DC, 3A
For Field Wiring:

Use Copper Conductors Only!
Connect Control Device Only!
all non-designated conductors,

16AWG orange
Function: compressor motor running

Group of function: volt-free contacts
a Geprüft Büchner
Vacuum-unit page 7
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: volt-free contacts SC2 MCS SSV-U3002.00 12 Bl.
105
106
1 2 3 4 5 6 7 8
possible connections for AII 1.02
** pre-allocated Inputs/outputs for use by others 4-wire connection

*** available for use 2-wire connection
example connections L+ L-
?
?
only ASV 4...20mA 4...20mA
Pt100
out - + -
13
13.3
Annex
Int. Int. Int. Int. Int. Int. Int.
BSV SIGMA CONTROL 2

5
3
2
1
2
3
1
2
3
1
2
11
X3 X3 X3 X3 X6 X6 X7
-K21 -K21 -K21 -K21 -K21 AII_PA AII GND -K21 AII_PA AII GND -K21 AIR_A AIR_B
DI_PA DI 1.03 DI 1.05 DI 1.06
Electrical Diagrams
AII 1.02 AII 1.02 AIR 1.03

*** *** *** 4-20mA 4-20mA, 18V DC Pt100
Ri = 200Ω Ri = 200Ω
analog inputs, User's connection

max. cable length 30m

Int. Int. Int. Int. Int. Int.
1
7
2
8
3
9
4
5
6
10
11
12
X8 X8 X8 X8 X8 X8
-K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI
DI 1.08 DI 1.09 DI 1.10 DI 1.11 DI 1.12 DI 1.13
*** *** *** *** Remote ON/OFF ** load/idling ** For Field Wiring:
digital inputs, User's connection
18V DC/7mA
Function:
Group of function: digital inputs analog inputs
a Geprüft Büchner
Vacuum-unit page 8
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: inputs/outputs SC2 MCS SSV-U3002.00 12 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
9_5773 32 USE
Inputs/outputs for use by others
digital output, User's connection digital output, User's connection

max. 250V AC/24V DC, 1A 24V DC/0,3A
13
13.3
max. cable length 100m max. cable length 30m
*** control ON ** FAILURE ** motor running ** *** ***

-K21 DOR 1.04 -K21 DOR 1.05 -K21 DOR 1.06 -K21 DOR 1.07 -K21 DOT 1.01 -K21 DOT 1.02
DOT M24 DOT M24
8
6
Annex
2
1
2
1
5
4
8
7
7
5
X5 X9 X9 X9 X4 X4
BSV SIGMA CONTROL 2

Electrical Diagrams

For Field Wiring:
** pre-allocated Connect Control Device Only!
*** available for use
Function:
Group of function: digital outputs
a Geprüft Büchner
Vacuum-unit page 9
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: digital outputs SC2 MCS SSV-U3002.00 12 Bl.
107
108
1 2 3 4 5 6 7 8
diagram 1
L2
L1
primary primary
-T11 575V
1
2
575V
3
4
13
13.3
115V
control panel
secondary
L02
-3FU
Annex
BSV SIGMA CONTROL 2

Electrical Diagrams
primary
diagram 2
L1
L2
380V
-T11
1
31
32
33
34
35
36
37
38
2

primary
380V
0
0
control panel
115V
115V
115V
L02
-3FU
secondary

a Geprüft Büchner
Vacuum-unit page 10
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: transformer diagrams SC2 MCS SSV-U3002.00 12 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
fig. 1: Handling: Control line terminal
9_5773 32 USE
13
13.3
Annex
BSV SIGMA CONTROL 2

Electrical Diagrams
fig. 2: Handling: Supply terminal

a Geprüft Büchner
Vacuum-unit page 11
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Handling: Terminals SC2 MCS SSV-U3002.00 12 Bl.
109
110
1 2 3 4 5 6 7 8
fig. 10: Feed line connection fig. 11: Feed line connection fig. 12: Feed line connection
13
13.3
Annex
BSV SIGMA CONTROL 2

Electrical Diagrams

a Geprüft Büchner
Vacuum-unit page 12
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Feed line connection SC2 MCS SSV-U3002.00 12 Bl.
9_5773 32 USE
9_5773 32 USE
cable-no.
-W72 2x1mm² 500V 70°C 1 2
1)
1)
1)
.
.
0
9
N
L1
11
12
43
32
44
connection
inside
destination
13
name of device
control panel
-T21
-T21
-S5
-T11
-S5
-K21-X5
-T21
.
control panel
-Q1
-Q1
-Q1
13.3
location
/1.2
/1.4
/1.6
/3.4
/3.4
/3.5
/3.2
/3.2
/3.5
/3.5
/4.3
/3.2
/3.4
/1.8
/7.4
/7.4
/7.5
jumper wire
Annex
terminal legend
total 3 terminals
total 16 terminals
terminal strip
link
BSV SIGMA CONTROL 2

terminal strip: -X0
terminal strip: -X11
terminal-no.
GRD1
GRD2
GRD3
1
01
2
02
3
03
4
5
GRD1
GRD1
GRD2
GRD2
15
16
17
18
.
.
.
Electrical Diagrams
11
12
A2
connection
GRD
GRD
external
destination
name of device
supply
-M1
-M1
-3FU
-Q1
-S1
-S1

-W71 2x18AWG 600V 90°C 1 2
-s.b.c. *
cable-no.
* supply line cross-section volt-free contacts, User's connection
see operating manual 1) compressor motor running
s.b.c. = supplied by customer GNYE = green/yellow
c Datum 09.03.2017 terminal connection =

a Geprüft Büchner
Vacuum-unit page 1
H Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: terminal strip -X0,-X11 SC2 MCS KSV-U3002.00 1 Bl.
111
112
1 2 3 4 5 6 7 8
series ASV series BSV series CSV

460 460
380
-T11 -T11
-T11
13
13.3
115V~ 115V~
115V~
-X11 -T21 -X11 -T21

-X11 -T21
Annex
115V~ -K21 115V~ -K21

-K21
IOM 1 IOM 1
115V~ IOM 1
24V=
BSV SIGMA CONTROL 2

115V~
-1FU
-2FU
-3FU
-1FU
-2FU
-3FU
24V=
24V=
115V~
115V~
732
Electrical Diagrams
-1FU
-2FU
-3FU
859
115V~ 115V~
962
962
115V~
1099
1167

115V~ 115V~
V1
U1
W1
-X0
GRD
-Q1
GRD
-X0
-X0
-B25
GRD
-X0
-X0
GRD
GRD
GRD
GRD
-Q1 -Q1
365
-B25
-B25
The components are performance-related

445 445
and not shown to scale.
c Datum 09.03.2017 lay-out =

a Geprüft Büchner
Vacuum-unit page 1
I Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: control panel SC2 MCS ASV-U3002.00 1 Bl.
9_5773 32 USE
13 Annex
13.3.2 Electrical diagram 2 of 2

114
1 2 3 4 5 6 7 8
Wiring Diagram
ATTENTION !!!
The unit is non-functional when delivered.
Vacuum-unit ASV, BSV, CSV
Before connecting the electrical supply,
air cooled and water cooled
13
please follow the advice contained

13.3
in the 'Installation' chapter and

the wiring diagram of the service manual.
208V±10% 3ph 60Hz 230V±10% 3ph 60Hz
460V±10% 3ph 60Hz
Annex
Tri-Voltage
BSV SIGMA CONTROL 2

Power supply:
Electrical Diagrams
WYE system with center point solidly grounded

ATTENTION !!!
The document gives collective information on
power supply voltages and frequencies for all machines.
The voltage and frequency and local conditions under

manufacturer: KAESER COMPRESSORS
which any particular machine may be used
are given on the nameplate of the machine 96450 COBURG
and in the accompanying service manual.
GERMANY
The drawings remain our exclusive property. They are entrusted

only for the agreed purpose. Copies or any other reproductions,
including storage, treatment and dissemination by use of
electronic systems must not be made for any other than the
agreed purpose. Neither originals nor reproductions must be
forwarded or otherwise made accessible to third parties.
c Datum 09.03.2017 USE cover page =

a Geprüft Büchner
Vacuum-unit page 1
A Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS DSV-U3003.00 1 Bl.
9_5773 32 USE
Lfd. Nr. Benennung Zeichnungsnummer (Kunde) Zeichnungsnummer (Hersteller) Blatt Anlagenkennzeichen
No. Name Drawing No. (customer) Drawing No. (manufacturer) Page Unit designation
9_5773 32 USE
1 cover page DSV-U3003.00 1
2 list of contents ZSV-U3003.00 1
3 general instructions USV-U3003.00 1
4 electrical equipment identification USV-U3003.00 2
7 wiring diagram power supply/power unit SSV-U3003.00 1
8 wiring diagram power unit SSV-U3003.00 2
13
13.3
9 wiring diagram control SSV-U3003.00 3

10 wiring diagram control voltage tapping SSV-U3003.00 4
11 wiring diagram power supply unit SSV-U3003.00 5
12 wiring diagram IO-module/configuration SSV-U3003.00 6
13 wiring diagram sensors/actuators SSV-U3003.00 7
14 wiring diagram volt-free contacts SSV-U3003.00 8
Annex
15 wiring diagram inputs/outputs SSV-U3003.00 9

16 wiring diagram digital outputs SSV-U3003.00 10
BSV SIGMA CONTROL 2

17 wiring diagram transformer diagrams SSV-U3003.00 11
18 wiring diagram Handling: Terminals SSV-U3003.00 12
Electrical Diagrams

21 terminal connection terminal strip -X0,-X1,-X11 KSV-U3003.00 1
22 lay-out control panel ASV ASV-U3003.00 1
23 lay-out control panel BSV ASV-U3003.00 2
24 lay-out control panel CSV ASV-U3003.00 3

c Datum 09.03.2017 list of contents =
a Geprüft Büchner
Vacuum-unit page 1
B Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS ZSV-U3003.00 1 Bl.
115
116
1 2 3 4 5 6 7 8
general instructions control cabinet wiring for non-designated conductors

ATTENTION !!!
primary circuits ungrounded: black, UL-Style 1015, CSA-TEW
Install supplies, grounding and shock protection
primary circuits grounded: grey, UL-Style 1015, CSA-TEW
to local safety regulations.
control voltage AC 115V ungrounded: red, 18AWG UL-Style 1015, CSA-TEW
Do not make or break
live plug-in connectors. control voltage AC 115V grounded: white, 18AWG UL-Style 1015, CSA-TEW
13
13.3
control voltage DC ungrounded: blue, 18AWG UL-Style 1015, CSA-TEW

control voltage DC grounded: white/blue, 18AWG UL-Style 1015, CSA-TEW
external voltage: orange, 16AWG UL-Style 1015, CSA-TEW
measuring circuits: violet, 18AWG UL-Style 1015, CSA-TEW
Annex
ground conductor: green/yellow, UL-Style 1015, CSA-TEW
BSV SIGMA CONTROL 2

Electrical Diagrams

c Datum 09.03.2017 general instructions =
a Geprüft Büchner
Vacuum-unit page 1
9_5773 32 USE
1 2 3 4 5 6 7 8
9_5773 32 USE
electrical equipment identification
general components control sensors/actuators

-B25 overload relay, -K20 Main Control System SC2MCS -B1 pressure transducer,
13
13.3
compressor motor -X1 Ethernet air main pressure absolutley

-1FU,-2FU primary control fuse -X2 IO-Bus -B2 safety air pressure switch-direction of rotation
-3FU secondary control fuse -X3 RS485-FC (USS) -B3 high oil filter pressure
-M1 compressor motor -X4 communication module (Bus) (only BSV, CSV)
-Q1 main contactor -X5 SD card slot -B4 pressure transducer,
-S1 EMERGENCY STOP pushbutton -X6 ground connection package internal pressure absolutley
Annex
-S5 door safety interlock switch (only BSV, CSV)

-T11 control transformer -K21 IO-module SC2IOM-1 -B5 differential pressure switch oil separator
BSV SIGMA CONTROL 2

-T21 power unit (only BSV, CSV)
inside
-B8 pressure switch oil pressure
-X1 IO-Bus, input
-B40 temperature probe
-X2 IO-Bus, output
Electrical Diagrams
airend discharge temperature

-X3,-X8 digital inputs
-X4 power supply unit, digital outputs -K1 control valve
-X5,-X9 Relay outputs
-X6 analog input, 4-20mA
-X7 analog input, Pt100

external
-X11...-X13 analog inputs, 4-20mA
-X14...-X17 analog inputs, Pt100
-X18...-X29 digital inputs
-X30...-X32 digital outputs
terminal strips
-X0 terminal strip, power supply
-X1 terminal strip, motor
-X11 terminal strip, control
c Datum 09.03.2017 electrical equipment identification =

a Geprüft Büchner
Vacuum-unit page 2
117
13 Annex
3
Bl. 4
page
model ASV 40 ASV 60 BSV 80 BSV 100
machine power supply 208 V ±10 %, 60 Hz 208 V ±10 %, 60 Hz 208 V ±10 %, 60 Hz 208 V ±10 %, 60 Hz
TRI-VOLTAGE 230 V ±10 %, 60 Hz 230 V ±10 %, 60 Hz 230 V ±10 %, 60 Hz 230 V ±10 %, 60 Hz
USV-U3003.00
460 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz
=
+
motor -M1 10 hp 15 hp 20 hp 25 hp
diagram 1, Sht. 1 (208+ 230 V) diagram 3, Sht. 2 (208+ 230 V) diagram 1, Sht. 1 (208+ 230 V) diagram 1, Sht. 1 (208+ 230 V)
diagram 2, Sht. 1 (460 V) diagram 4, Sht. 2 (460 V) diagram 2, Sht. 1 (460 V) diagram 2, Sht. 1 (460 V)
supply terminals -X0:U1/V1/W1 7.3149.02000 7.3140.05070 3x 7.3140.05360 3x 7.3140.05360
Wieland WKFN16D1/2/35 3RV2935-5E 3RA2943-3L 3RA2943-3L
Torque --- 6 Nm 10 Nm 10 Nm
Stripped length 16 mm 25 mm 25 mm 25 mm
Handling fig. 2, Sht. 12 --- --- ---
-X0:GRD 7.3149.02020 7.3291.00010 7.3291.00010 7.3291.00010
SC2 MCS
Wieland WKFN16D1/2/SL/35 WKN35SL/U WKN35SL/U WKN35SL/U
Torque --- 3 Nm 3 Nm 3 Nm
Stripped length 16 mm 20 mm 20 mm 20 mm
Handling fig. 2, Sht. 12 --- --- ---
supply connection fig. 10, Sht. 13 fig. 11, Sht. 13 fig. 12, Sht. 14 fig. 12, Sht. 14
terminal strip -X0 7.6836.00640 Wieland --- --- ---
terminal strip -X1 --- 6x 7.3149.01960 --- ---
WKFN10D1/2/35
7.3149.02190
Wieland WKFN10SL/35
Handling --- fig. 2, Sht. 12 --- ---

terminal strip -X11 7.6836.00600 Wieland 7.6836.00600 Wieland 7.6836.00390 Wieland 7.6836.00390 Wieland
Handling fig. 1, Sht. 12 fig. 1, Sht. 12 fig. 1, Sht. 12 fig. 1, Sht. 12
contactor -Q1 7.8740.00410 7.8740.00420 7.8740.00440 7.8740.00460
Vacuum-unit
3RT2036-1AK60 3RT2037-1AK60 3RT2045-1AK60 3RT2047-1AK60
auxiliary switch 7.8740.05010 7.8740.05010 7.8740.05010 7.8740.05010
3RH2911-1HA11 3RH2911-1HA11 3RH2911-1HA11 3RH2911-1HA11
interference suppressor 7.8740.05150 7.8740.05150 7.8740.05170 7.8740.05170
Siemens 3RT2936-1CC00 3RT2936-1CC00 3RT2946-1CC00 3RT2946-1CC00
overload relay -B25 7.8741.00090 7.8741.00090 7.8741.00100 7.8741.00100
3RB3036-1UB0 (12,5-50 A) 3RB3036-1UB0 (12,5-50 A) 3RB3036-1WB0 (20-80 A) 3RB3036-1WB0 (20-80 A)
setting: 27 A (208 V) setting: 38 A (208 V) setting: 51 A (208 V) setting: 62 A (208 V)
NEC 430.32(C) incremental NEC 430.32(C) incremental NEC 430.32(C) incremental NEC 430.32(C) incremental
Ursprung:
adapter --- --- 7.8741.05020 7.8741.05020
Siemens 3RU2936-3AA01 3RU2936-3AA01
fuses -1FU/-2FU/-3FU 7.3313.1 7.3313.1 7.3313.1 7.3313.1
Gould ATQR 2 1/2 (2,5 A, 600 V) ATQR 2 1/2 (2,5 A, 600 V) ATQR 2 1/2 (2,5 A, 600 V) ATQR 2 1/2 (2,5 A, 600 V)
fuse socket -1FU/-2FU/-3FU 7.3320.00060 7.3320.00060 7.3320.00060 7.3320.00060
Ersatz für:
Wöhner AMBUS EASYSWITCH AMBUS EASYSWITCH AMBUS EASYSWITCH AMBUS EASYSWITCH
transformer -T11 7.7569.0 7.7569.0 7.7569.0 7.7569.0
Block B0601024 (250 VA) B0601024 (250 VA) B0601024 (250 VA) B0601024 (250 VA)
power supply -T21 7.7605P0 7.7605P0 7.7605P0 7.7605P0
Prodrive PSDC24/2.5 PSDC24/2.5 PSDC24/2.5 PSDC24/2.5
connection -W11 8 AWG black --- --- ---
600 V, 90°C
connection -W11.1/.2/.3/.4 6 AWG green/yellow 6 AWG green/yellow 4 AWG green/yellow 4 AWG green/yellow
Ersatz durch:
600 V, 90°C 600 V, 90°C 600 V, 90°C 600 V, 90°C

connection -W12 --- --- 4 AWG black 4 AWG black
600 V, 90°C 600 V, 90°C
connection -W15.1/.2 --- 8 AWG black --- ---
600 V, 90°C
09.03.2017
connection -W18 10 AWG black 10 AWG black 8 AWG black 8 AWG black
Büchner
Sitter
600 V, 90°C 600 V, 90°C 600 V, 90°C 600 V, 90°C

cables -W19.1/.2 4G10 AWG 1x10 AWG 1x6 AWG 1x6 AWG
Bearbeiter
600 V, 90°C 600 V, 120°C 600 V, 90°C 600 V, 90°C

Geprüft
Datum
Norm
compressor control -K20 7.7601.0 7.7601.0 7.7601.0 7.7601.0

Prodrive SIGMA CONTROL 2 MCS SIGMA CONTROL 2 MCS SIGMA CONTROL 2 MCS SIGMA CONTROL 2 MCS
Name
IO-module -K21 7.7602.1 7.7602.1 7.7602.1 7.7602.1

Prodrive SIGMA CONTROL 2 IOM-1 SIGMA CONTROL 2 IOM-1 SIGMA CONTROL 2 IOM-1 SIGMA CONTROL 2 IOM-1
EMERGENCY STOP pushbutton -S1 7.3217.0 / QRUV 7.3217.0 / QRUV 7.3217.0 / QRUV 7.3217.0 / QRUV
Datum
auxiliary contact Schlegel 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO
control cabinet KAESER 7.5461.3 7.5461.3 7.5455.3 7.5455.3
control panel KAESER 207184.1 207184.1 206100.1 206100.1
C Änderung
b
a
c

13 Annex
4
Bl. 4
page
model CSV 125 CSV 150
TRI-VOLTAGE 230 V ±10 %, 60 Hz 230 V ±10 %, 60 Hz
USV-U3003.00
460 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz
=
+
diagram 1, Sht. 1 (208+ 230 V) diagram 1, Sht. 1 (208+ 230 V)
diagram 2, Sht. 1 (460 V) diagram 2, Sht. 1 (460 V)
Wieland WKN70/U WKN70/U
Torque 6 Nm 6 Nm
-X0:GRD 7.3149.01660 7.3149.01660
SC2 MCS
Torque 6 Nm 6 Nm
contactor -Q1 7.3140.02150 7.3140.02150
3RT1055-6AF36 3RT1055-6AF36
overload relay -B25 7.8741.00140 7.8741.00140

3RB3046-1XB0 (32-115 A) 3RB3046-1XB0 (32-115 A)
setting: 77 A (208 V) setting: 105 A (208 V)
Vacuum-unit
adapter 7.8741.05030 7.8741.05030
Siemens 3RU2946-3AA01 3RU2946-3AA01
fuses -1FU/-2FU/-3FU 7.3313.1 7.3313.1
Gould ATQR 2 1/2 (2,5 A, 600 V) ATQR 2 1/2 (2,5 A, 600 V)
fuse socket -1FU/-2FU/-3FU 7.3320.00060 7.3320.00060
Ursprung:
transformer -T11 7.7569.0 7.7569.0
Block B0601024 (250 VA) B0601024 (250 VA)
600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
Ersatz für:
600 V, 90°C 600 V, 90°C
connection -W15.1/.2 --- ---

600 V, 90°C 600 V, 90°C
600 V, 90°C 600 V, 90°C
Ersatz durch:

IO-module -K21 7.7602.1 7.7602.1
09.03.2017

Büchner
Sitter

Bearbeiter
Geprüft
Datum
Norm
C Änderung Name
Datum
b
a
c

120
1 2 3 4 5 6 7 8
L1
/4.1
L2
/4.1
L3
-X0 GRD1-X11 GRD2 GRD
GRD2
GRD3
-X0 -W11.1 14AWG
-W11.2 -W11
**** green/yellow
**** ****
600V 90°C
1
3
5
-Q1
control panel
13
control panel unit frame /3.5

13.3
2
4
6
-W11.3 -W12
**** ****
1
3
5
97
95
-B25
Annex
unit frame oil separator ****
2
4
6
98
BSV SIGMA CONTROL 2

/3.4 96
-W11.4
**** ATTENTION !!! Motor terminal board
component -B25
Electrical Diagrams
diagram 1 diagram 2
low voltage high voltage
Adjust the setting
unit frame pivoting motor base -B25:4 -B25:2 -B25:6 -B25:4 -B25:2 -B25:6
depending on
U4 V4 W4 U4 V4 W4
the mains voltage
U1
V1
W1
GRD1
-X0
**** U2 V2 W2 U2 V2 W2
Feed line connection

For field wiring:
see page 13 + 14
Use 75°C copper U3 V3 W3 U3 V3 W3
conductors only!
-W19.1 -W19.2 U1 V1 W1 U1 V1 W1
**** **** -B25:6 -B25:4 -B25:2 -B25:6 -B25:4 -B25:2
GRD
W1 V4
main disconnect,
V1 M U4 ATTENTION !!! component -M1
fuse supplied
U1 3~ W4
by user
Make connections
-M1 in the terminal box to suit the motor
****
L1 L2 L3 GRD
supply line cross-section and

fusing see operating manual **** performance-related components,

Group of function: input voltage power unit
a Geprüft Büchner
Vacuum-unit page 1
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: power supply/power unit SC2 MCS SSV-U3003.00 14 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
L1 L1 L1 L1
L2 L2 L2 L2
9_5773 32 USE
L3 L3 L3 L3
GRD -X1 GRD1 GRD GRD -X1. GRD1 GRD
-W11 -W11
**** ****
1
3
5
1
3
5
-Q1 -Q1
13
/3.5 /3.5
13.3
2
4
6
2
4
6
-W12 -W12
**** ****
ATTENTION !!! ATTENTION !!!
1
3
5
97
95
1
3
5
97
95
component -B25 -B25 component -B25 -B25
Annex
**** ****
2
4
6
2
4
6
98
98
Adjust the setting Adjust the setting
BSV SIGMA CONTROL 2

depending on depending on
/3.4 96
/3.4 96
the mains voltage the mains voltage
Electrical Diagrams
-W15.1 -W15.2 -W15.1 -W15.2

**** **** **** ****
-X1 -X1 -X1. -X1.
4 4
5 5
6 6
7 7
8 8
9 9
4 4
5 5
6 6
7 7
8 8
9 9

-W19.1 -W19.2 -W19.1 -W19.2
**** **** **** ****
GRD
GRD
W3 V4 W3 V4
W1 V2 ATTENTION !!! W1 V2
component -M1, -X1
V3 U4 V3 U4
M Check the correct M
V1 U2 V1 U2
3~ connection of 3~
U3 W4 the motor according U3 W4
to the mains voltage
U1 -M1 W2 U1 -M1 W2
**** ****
-X1. 3
diagram 3
2
1
**** performance-related components,

diagram 4

Group of function: power unit
a Geprüft Büchner
Vacuum-unit page 2
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: power unit SC2 MCS SSV-U3003.00 14 Bl.
121
122
1 2 3 4 5 6 7 8
95
21
-B25 -Q1
/1.4 5
96
22
Int. Int. Int.
7
6
10
X3 X3 X3
13
13.3
-K21 -K21 -K21

/6.3
DI_PA /6.3
DI 1.01 /6.3
DI 1.02
overload relay answerback signal

compressor motor main contactor
Annex
main contactor
BSV SIGMA CONTROL 2

-K21 DOR 1.00
/6.3 COM
Electrical Diagrams
7
X5
Int.

A1
-Q1
A2
L02
/4.1
1 2
/1.4
3 4
/1.4
5 6
/1.4
13 14
21 22
5
31 32
/8.4
43 44
/8.5
Function:
Group of function: direct on line start
a Geprüft Büchner
Vacuum-unit page 3
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: control SC2 MCS SSV-U3003.00 14 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
L1 -X11 1 -X11 2 L01
9_5773 32 USE
/1.8 /5.1
L2
1
/1.8 -W72
-W18
11
22
-S5
****
21
-1FU -2FU -3FU
12
door safety interlock switch
2,5A 2,5A 2,5A
2
-W72
Class CC Class CC Class CC
4
-X11
14AWG black
13
1
13.3
-W71
600V 90°C -W102
11
21
14AWG green/yellow -S1
600V 90°C
22
-T11
12
EMERGENCY STOP
1
2
Annex
-W101
2
-W71
**** 2x18AWG
control panel
5
115V -X11 600V 90°C
BSV SIGMA CONTROL 2

Int. Ext.
9
8
1
2
3
X3 X29
.
ATTENTION !!! component -T11
-K21 DI_PA DI -K21 DI_PA DI
Check the correct connection model-specific
Electrical Diagrams
of the transformer according electrical diagram /6.3 DI 1.00 /6.3 DI 1.07

to the mains voltage see page 11 connection EMERGENCY STOP door safety interlock switch
s.b.c.
10VA
. -K21 DOR COM

/6.3 COM
.
9
8
X5
Int.
GRD2
-X11
L02 -X11 03 -X11 02 -X11 01 L02

/3.7 /5.1
16AWG green/yellow
600V 90°C
GRD1
-X11
.
For Field Wiring:
**** performance-related components, Use Copper Conductors Only!
see: electrical component parts list Connect Control Device Only!
Function: 115V/1ph/60Hz door safety interlock switch/EMERGENCY STOP

Group of function: control voltage tapping Consumer external safety chain
a Geprüft Büchner
Vacuum-unit page 4
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: control voltage tapping SC2 MCS SSV-U3003.00 14 Bl.
123
124
1 2 3 4 5 6 7 8
L01 -X11 1 L01

/4.8
L02 01 L02
/4.8
-K20
MCS
X5
12AWG green/yellow
14AWG green/yellow
SD card
600V 90°C
13
600V 90°C
13.3
X6
option COM-Module RS485-FC Ethernet IO-Bus

control panel control cabinet door X4 X3 X1 X2
Annex
BSV SIGMA CONTROL 2

-W81
3x2x0,22mm²
Electrical Diagrams
screened
-T21
1)
-K21 X1

100- + I/O-BUS
/6.3 X4
240V~ +
L1 3 L+
-
24V= 2 L-
IOM 1
N -
1 FE
2,5A -
16AWG green/yellow
short circuit proof I/O-BUS
600V 90°C 14AWG green/yellow
X2
600V 90°C
GRD1
-X11
control panel
1) Reset: Switch off L1 for 3 minutes
Function: 24V DC
Group of function: control voltage
a Geprüft Büchner
Vacuum-unit page 5
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: power supply unit SC2 MCS SSV-U3003.00 14 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
9_5773 32 USE
-K21 IOM1 inside
11 1
DI_PA AII_PA
10 2
/3.3 DI_PA AII 1.02
X6
9 3
/4.6 DI_PA AII_GND
8
13
/4.6 DI 1.00
13.3
7
/3.4 DI 1.01 1
AIR 1.03
6
X7
/3.5 DI 1.02 2
X3
AIR 1.03 -K21
5
DI 1.03
4 IOM1 external
DI 1.04 1
3 DI_PB
Annex
DI 1.05 2
2 DI_PB /7.2 AII 1.00 X11 X22 DI 1.00
DI 1.06 3
1 DI_PB /7.3 AII 1.01 X12 X23 DI 1.01
BSV SIGMA CONTROL 2

DI 1.07 4
DI_PB AII 1.02 X13 X24 DI 1.02
8 5
DOT 1.01 DI_PB /7.4 AIR 1.00 X14 X25 DI 1.03
7
Electrical Diagrams
6
M24 DI_PB AIR 1.01 X15 X26 DI 1.04 /7.5
X8
6 7
DOT 1.02 DI 1.08 AIR 1.02 X16 X27 DI 1.05
5 8
M24 DI 1.09 AIR 1.03 X17 X28 DI 1.06 /7.6
X4
4 9
FE DI 1.10 DI 1.08 X18 X29 DI 1.07 /4.7
3 24V 10
/5.6 L+ DI 1.11 DI 1.09 X19 X30 DOT 1.00 /7.2

2 11
/5.6 0V L- DI 1.12 /7.7 DI 1.14 X20 X31 DOT 1.01
1 12
/5.6 FE DI 1.13 /7.8 DI 1.15 X21 X32 DOT 1.02
9 1
/4.6 DOR COM DOR 1.05
8 2
/4.6 DOR COM DOR COM
7 3
/3.5 DOR 1.00
6 4
DOR 1.01 DOR 1.06
5 5
X9
DOR 1.02 DOR COM
X5
4 6
DOR 1.03
3 7
DOR 1.07
2 8
DOR COM DOR COM
1 9
DOR 1.04
Function:
Group of function:
a Geprüft Büchner
Vacuum-unit page 6
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: IO-module/configuration SC2 MCS SSV-U3003.00 14 Bl.
125
126
1 2 3 4 5 6 7 8
only BSV, CSV only BSV, CSV only BSV, CSV

-B1 -B4 -B40
P P
1
1
1
1
-B8 -B5 -B3 -B2
4...20mA 4...20mA
Pt100 P P P P
2
2
2
4
- + - +
1 bar 0,8 bar Δp 1,5 bar 1,0 bar
2
1
2
1
1
2
13
13.3
-W115 -W116 -W117 -W110 -W106 -W105 -W104
Ext. Ext. Ext. Ext. Ext. Ext. Ext.

Annex
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
X11 X12 X14 X26 X28 X20 X21

-K21 AII AII_PA GND -K21 AII AII_PA GND -K21 AIR_A Shield AIR_B -K21 DI_PA DI -K21 DI_PA DI -K21 DI_PB DI -K21 DI_PB DI
BSV SIGMA CONTROL 2

/6.3 AII 1.00 /6.3 AII 1.01 /6.3 AIR 1.00 /6.3 DI 1.04 /6.3 DI 1.06 /6.3 DI 1.14 /6.3 DI 1.15
air main pressure package internal pressure airend discharge temperature oil pressure oil separator oil filter direction of rotation
Electrical Diagrams
control valve

-K21 DOT 1.00
/6.3 DOT M24
1
2
3
X30
Ext.
-W113
1(+)
2(-)
1
2
-K1
Function:
Group of function:
a Geprüft Büchner
Vacuum-unit page 7
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: sensors/actuators SC2 MCS SSV-U3003.00 14 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
9_5773 32 USE
13
13.3
volt-free contacts
User's connection
Annex
BSV SIGMA CONTROL 2

31
43
-Q1 -Q1
/3.5 /3.5
Electrical Diagrams
32
44
15
16
17
-X11 -X11 -X11

max. 250V AC/24V DC, 3A
For Field Wiring:

all non-designated conductors,

16AWG orange
Function: compressor motor running

Group of function: volt-free contacts
a Geprüft Büchner
Vacuum-unit page 8
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: volt-free contacts SC2 MCS SSV-U3003.00 14 Bl.
127
128
1 2 3 4 5 6 7 8
possible connections for AII 1.02
** pre-allocated Inputs/outputs for use by others 4-wire connection

*** available for use 2-wire connection
example connections L+ L-
?
?
only ASV 4...20mA 4...20mA
Pt100
out - + -
13
13.3
Annex
Int. Int. Int. Int. Int. Int. Int.
BSV SIGMA CONTROL 2

5
3
2
1
2
3
1
2
3
1
2
11
X3 X3 X3 X3 X6 X6 X7
-K21 -K21 -K21 -K21 -K21 AII_PA AII GND -K21 AII_PA AII GND -K21 AIR_A AIR_B
DI_PA DI 1.03 DI 1.05 DI 1.06
Electrical Diagrams
AII 1.02 AII 1.02 AIR 1.03

*** *** *** 4-20mA 4-20mA, 18V DC Pt100
Ri = 200Ω Ri = 200Ω
analog inputs, User's connection


1
7
2
8
3
9
4
5
6
10
11
12
X8 X8 X8 X8 X8 X8
-K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI
DI 1.08 DI 1.09 DI 1.10 DI 1.11 DI 1.12 DI 1.13
*** *** *** *** Remote ON/OFF ** load/idling ** For Field Wiring:
digital inputs, User's connection
18V DC/7mA
Function:
Group of function: digital inputs analog inputs
a Geprüft Büchner
Vacuum-unit page 9
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: inputs/outputs SC2 MCS SSV-U3003.00 14 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
9_5773 32 USE
Inputs/outputs for use by others
digital output, User's connection digital output, User's connection

max. 250V AC/24V DC, 1A 24V DC/0,3A
13
13.3
max. cable length 100m max. cable length 30m
*** control ON ** FAILURE ** motor running ** *** ***

-K21 DOR 1.04 -K21 DOR 1.05 -K21 DOR 1.06 -K21 DOR 1.07 -K21 DOT 1.01 -K21 DOT 1.02
DOT M24 DOT M24
8
6
Annex
2
1
2
1
5
4
8
7
7
5
X5 X9 X9 X9 X4 X4
BSV SIGMA CONTROL 2

Electrical Diagrams

For Field Wiring:
** pre-allocated Connect Control Device Only!
*** available for use
Function:
Group of function: digital outputs
a Geprüft Büchner
Vacuum-unit page 10
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: digital outputs SC2 MCS SSV-U3003.00 14 Bl.
129
130
1 2 3 4 5 6 7 8
status on delivery ATTENTION !!!

The transformer is
L1
L2
-1FU
-2FU
not connected (nc) correctly
on the primary side.
13
0
13.3
nc
Therefore the compressor
208V
230V
460V
-T11 is non-functional at the
status on delivery !
Connect the line L2 to the
Annex
0
115V
control panel correct transformer terminal
according to the mains voltage.
BSV SIGMA CONTROL 2

L02
-3FU
Electrical Diagrams

diagram 1 diagram 2 diagram 3
208V 230V 460V
L1
L2
L1
L2
L1
L2
-1FU
-2FU
-1FU
-2FU
-1FU
-2FU
0
0
0
nc
nc
nc
208V
230V
460V
208V
230V
460V
208V
230V
460V
-T11 -T11 -T11
0
115V
0
115V
0
115V
control panel control panel control panel
L02
-3FU
L02
-3FU
L02
-3FU

a Geprüft Büchner
Vacuum-unit page 11
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: transformer diagrams SC2 MCS SSV-U3003.00 14 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
fig. 1: Handling: Control line terminal
9_5773 32 USE
13
13.3
Annex
BSV SIGMA CONTROL 2

Electrical Diagrams
fig. 2: Handling: Supply terminal

a Geprüft Büchner
Vacuum-unit page 12
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Handling: Terminals SC2 MCS SSV-U3003.00 14 Bl.
131
132
1 2 3 4 5 6 7 8
fig. 10: Feed line connection fig. 11: Feed line connection
13
13.3
Annex
BSV SIGMA CONTROL 2

Electrical Diagrams

a Geprüft Büchner
Vacuum-unit page 13
9_5773 32 USE
1 2 3 4 5 6 7 8
fig. 12: Feed line connection fig. 13: Feed line connection
9_5773 32 USE
13
13.3
Annex
BSV SIGMA CONTROL 2

Electrical Diagrams

a Geprüft Büchner
Vacuum-unit page 14
133
c
a
b
destination destination
cable-no. terminal strip cable-no.
external inside
H Änderung
*
link
-s.b.c. *
location
connection
connection
jumper wire
terminal-no.
Datum
name of device
name of device
terminal legend
Name
see operating manual
-W72 2x1mm² 500V 70°C
-W71 2x18AWG 600V 90°C
supply line cross-section
s.b.c. = supplied by customer
Norm
Datum
Geprüft
Bearbeiter
terminal strip: -X0

total 6 terminals
Sitter
Büchner
A) supply U1 /1.2 -Q1 1

09.03.2017
A) supply V1 /1.2 -Q1 3

A) supply W1 /1.2 -Q1 5
supply GRD1 /1.2 -control panel
-M1 GRD GRD2 /1.5
-M1 GRD GRD3 /1.5
Ersatz durch:
terminal strip: -X1

total 16 terminals
-M1 GRD GRD1 /2.3
1 /2.2
A) only CSV 125/CSV150
2 /2.2
3 /2.2
Ersatz für: -M1 W1 4 /2.2 -M1 W3
-B25 2 4 /2.2
-M1 V1 5 /2.2 -M1 V3
-B25 4 5 /2.2
-M1 U1 6 /2.2 -M1 U3
-B25 6 6 /2.2
-M1 V4 7 /2.3 -M1 V2
-B25 2 7 /2.3
-M1 U4 8 /2.4 -M1 U2
Ursprung:
-B25 4 8 /2.4
-M1 W4 9 /2.4 -M1 W2
-B25 6 9 /2.4
terminal strip: -X1.
total 16 terminals
-M1 GRD GRD1 /2.7
-M1 U3 1 /2.7 -M1 U2
-M1 V3 2 /2.7 -M1 V2
-M1 W3 3 /2.7 -M1 W2
-M1 W1 4 /2.6
Vacuum-unit
-B25 2 4 /2.6
terminal connection
-M1 V1 5 /2.6
-B25 4 5 /2.6
terminal strip -X0,-X1,-X11

-M1 U1 6 /2.6
-B25 6 6 /2.6
-M1 V4 7 /2.7
-B25 2 7 /2.7
-M1 U4 8 /2.7
-B25 4 8 /2.7
-M1 W4 9 /2.7
-B25 6 9 /2.7
terminal strip: -X11
total 16 terminals
SC2 MCS
1) compressor motor running
. 1 /4.4 -T21 L1
. 01 /4.4 -T21 N
volt-free contacts, User's connection

1
-3FU 2 /4.5 -S5 11

-Q1 A2 02 /4.2 -T11 0
3
03 /4.2 .
2
-S1 11 4 /4.5 -S5 12
1 2
-S1 12 5 /4.5 -K21-X5 9
GRD1 /5.3 -T21 -
GRD1 /4.2 .
+
=
. GRD2 /4.4 .
KSV-U3003.00
GRD2 /1.7 control panel
15 /8.4 -Q1 43 1)
16 /8.4 -Q1 32 1)
17 /8.5 -Q1 44 1)
GNYE = green/yellow
18
page
1
1
Bl.
Electrical Diagrams 13.3
Annex 13
1 2 3 4 5 6 7 8
series ASV 40 series ASV 60
9_5773 32 USE
380 380
-T11 -T11
13
13.3
115V~ 115V~
-X11 -T21 -X11 -T21

Annex
-K21 -K21
115V~ IOM 1 115V~ IOM 1
24V=
24V=
BSV SIGMA CONTROL 2

115V~
115V~
732
732
Electrical Diagrams
-1FU
-2FU
-3FU
-1FU
-2FU
-3FU
859
859
115V~ 115V~

-X0
V1
U1
W1
-X0
-X1
-X0
GRD
GRD
GRD
-Q1 -Q1
GRD
-B25 -B25
365 365


a Geprüft Büchner
Vacuum-unit page 1
I Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: control panel ASV SC2 MCS ASV-U3003.00 3 Bl.
135
136
1 2 3 4 5 6 7 8
series BSV
460
-T11
13
13.3
115V~
-X11 -T21
Annex
115V~ -K21
IOM 1
BSV SIGMA CONTROL 2

-1FU
-2FU
-3FU
24V=
115V~
Electrical Diagrams
115V~
962
1099

115V~
-X0
-X0
GRD
GRD
-B25 -Q1

445

a Geprüft Büchner
Vacuum-unit page 2
I Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: control panel BSV SC2 MCS ASV-U3003.00 3 Bl.
9_5773 32 USE
1 2 3 4 5 6 7 8
series CSV
9_5773 32 USE
460
-T11
13
13.3
115V~
-X11 -T21
Annex
115V~ -K21
IOM 1
BSV SIGMA CONTROL 2

-1FU
-2FU
-3FU
24V=
115V~
Electrical Diagrams
115V~
962
1167

-Q1
-X0
GRD
GRD
GRD
-B25
445

a Geprüft Büchner
Vacuum-unit page 3
I Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: control panel CSV SC2 MCS ASV-U3003.00 3 Bl.
137
13 Annex


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Operator Manual

Rotary screw vacuum pump

BSV SIGMA CONTROL 2

1 Regarding this Document

Operator Manual Rotary screw vacuum pump

4.4 Operating modes and control modes ............................................................................... 27

Operator Manual Rotary screw vacuum pump

10.2 Following the maintenance plan ....................................................................................... 51

Operator Manual Rotary screw vacuum pump

Operator Manual Rotary screw vacuum pump

Operator Manual Rotary screw vacuum pump

Operator Manual Rotary screw vacuum pump

Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1

Operator Manual Rotary screw vacuum pump

Operator Manual Rotary screw vacuum pump

1 Regarding this Document

1.2 Further documents

Missing documents can be requested from KAESER.

1.4 Symbols and labels

Tab. 1 Danger levels and their definition (personal injury)

Operator Manual Rotary screw vacuum pump

The type and source of the imminent danger is shown here!

1.4.2 Potential damage warnings

Warning notices for damages are identified by their signal term.

Tab. 2 Danger levels and their definition (damage to property)

The type and source of the imminent danger is shown here!

➤ Carefully read and fully comply with warnings against damages.

1.4.3 Other alerts and their symbols

Operator Manual Rotary screw vacuum pump

Further information Further subjects are introduced here.

Operator Manual Rotary screw vacuum pump

The nameplate is located on the outside of the machine:

Option Option code Available?

BSV 80 BSV 100

Tab. 5 Machine weight

Operator Manual Rotary screw vacuum pump

2.5 Ambient conditions

Tab. 7 Ambient conditions

BSV 80 BSV 100

Operator Manual Rotary screw vacuum pump

2.8 Inlet conditions

Tab. 10 Inlet conditions

2.9 Suction rate

Tab. 11 Suction rate [cfm]

2.10 Cooling Oil Recommendation

2.10.1 Basic Information

Operator Manual Rotary screw vacuum pump

2.10.2 KAESER Lubricants

2.11 Cooling oil charge

Tab. 12 Cooling oil charge quantity

2.12 Motors and power

BSV 80 BSV 100

Tab. 13 Compressor motor

Operator Manual Rotary screw vacuum pump

2.13 Noise emission

BSV 80 BSV 100

Tab. 14 Noise emission

Option H17 Noise emission [dB(A)]

BSV 80 BSV 100

Tab. 15 Noise emission, super silenced

2.14 Power Supply

Fig. 1 Three-phase star (wye); 4 wire; center point solidly grounded

Operator Manual Rotary screw vacuum pump

Fig. 2 Three-phase star (wye); 3 wire; center point solidly grounded