1. Kaeser Rotary Screw Vacuum Packages
ASV / BSV / CSV
Kaeser’s rotary screw compressors feature our sigma profile airend along with our industrial computer –Sigma Control. Our vacuum units are designed and engineered to provide optimum efficiency and lower energy costs for the life of the equipment.

2. What is Vacuum? Vacuum is defined as the absence of matter
A vacuum is created when air or a gas is reduced in pressure below the ambient pressure.
Vacuum systems are specified in terms of vacuum level and flow volume.
The terms may be expressed differently depending on the industry.
Vacuum is the physical opposite of compression.
When compressing air, we cram more air molecules into the space that air molecules naturally want to occupy and pressure increases.
A vacuum is created when we remove air or gas molecules from a space and reduce the pressure below the natural ambient pressure. A complete vacuum exists when a given volume has no molecules of anything in it. This is impossible on Earth, and even in space there are molecules floating around. The best we can do is create a partial vacuum. By creating a partial vacuum we create a differential pressure which can be harnessed for a variety of uses.
A vacuum unit is categorized by the level of vacuum the unit can reach and the flow (CFM) of the unit.
Different terms and units of measure are used by many companies and industries to express these levels of vacuum. As an example in the USA we use PSI as a measure of pressure where other countries use BAR. The same can be said for vacuum. We will explain these units of measure in future slides.
Definitions of rough, medium, and high vacuum are not absolute, so be sure you know what the customer’s specific vacuum level needs are.

3. Vacuum Pressure Terms Hg - inches of mercury
Torr - millimeters of mercury
psi - pounds per square inch
Can be absolute or gauge
Just as pressure may be expressed in psig, psia, bar and torr, vacuum levels can be expressed in several terms. The terms for measuring vacuum very from application to application. Ultimately vacuum is vacuum no matter what unit of measure you are using but knowing what the unit is and its parameters is always important information to know.
Hg is inches of mercury
TORR is millimeters of mercury
PSI is pounds per square inch
These readings can be either absolute or gauge
Absolute reading is the actual pressure at the point of measurement. Absolute vacuum is zero and ambient would be 14.7 at ambient conditions at sea level. Gauge is what the gauge would actually read. Reading 14.7 psi at sea level and going down to zero at absolute vacuum.
On Kaeser Sigma controlled units the vacuum that is shown on the screen is absolute vacuum. The controller reads actual vacuum at whatever elevation you are at and displays this reading. At sea level it is generally accepted the ambient pressure is 14.7 psi which equals 29.9 inches Hg Thus the closer the unit gets to absolute vacuum the Sigma control will read closer to zero. Zero being absolute vacuum. Or the absence of pressure.
Absolute - actual pressure at any given measuring point
Gauge - pressure gauge will read zero at ambient conditions

4. Vacuum Pressure Terms
% of vacuum - percentage of vacuum 0 % = Ambient % = Absolute vacuum
Note:
As the level of vacuum increases absolute pressure decreases
% of vacuum is a measure of the vacuum compared to absolute vacuum
0 % vacuum = ambient pressure
100 % vacuum = absolute vacuum
On Kaeser Sigma controlled units the vacuum that is shown on the screen is absolute vacuum. The controller reads actual vacuum at whatever elevation you are at and displays this reading. At sea level it is generally accepted the ambient pressure is 14.7 psi which equals 29.9 inches Hg Thus the closer the unit gets to absolute vacuum the Sigma control will read closer to zero. Zero being absolute vacuum. Or the absence of pressure.
Kaeser vacuum units display vacuum level in absolute pressure
At sea level the Sigma Control will read 14.7 psi (varies with ambient conditions)

5. Flow Terms cfm – cubic feet per minute Volumetric air flow rate
acfm – actual cubic feet per minute
CFM and ACFM are a measurement of air volume that moves through the pump. This can be measured in cfm which is the amount of air that moves through the pump. acfm is the actual volume of air at a specific point with certain conditions at that point.
Flow rate of air at a certain point at a certain condition at that point

6. Rotary Screw Vacuum Packages
Rotary Screw Vacuum Packages and Flows
Rotary Screw Vacuum Packages
Model
Type
Motor (hp)
Flow (acfm)
ASV 40
Rotary Screw
10 hp
168
ASV 60
15 hp
242
BSV 80
20 hp
296
BSV 100
25 hp
367
CSV 125
30 hp
453
CSV 150
40 hp
555
Note:
The data on the curve is based on 29.92”Hg Absolute discharge pressure
Inlet air temperature of 68º F
60 Hz motor operation. As a premiere rotary screw compressor manufacturer, it may seem like a short step to produce rotary screw vacuum packages. After all, all you have to do is hook up the intake of the compressor to the air line, and presto: you have a vacuum unit.
Well… not quite.
Like compressors, Kaeser takes their production of rotary screw vacuum units quite seriously. In addition to many of the typical compressor features, like…
1) Sigma profile airends,
2) TEFC Motors,
3) Full voltage starters
4) Completely pre-piped and pre-wired
Kaeser's vacuum units add…
5) Filtered gas ballast: Allows clean air to flow through airend during peak levels of vacuum to prevent moisture from accumulating in the airend.
6) Dedicated oil pump: Keeps oil flowing to all components under all vacuum levels.
7) Heavy-duty air intake filter: Prevents solid contaminants from entering airend.
8) Full-synthetic lubricant: Ensures long oil life under continuous operating conditions.
9) Switch able modulation: For constant vacuum applications.

7. Rotary Screw Vacuum Features
Sigma profile airend
The features and benefits of the rotary screw vacuum packages are for the most part the same as for the rotary screw compressor. With that in mind, we will only expound on the features that are unique to the rotary screw vacuum units. The airend is the sigma profile. The airend has oversized bearings to ensure a long service life. Added to the airend is a fluid pump that is needed to circulate the fluid through the oil circuit. This fluid pump is driven directly off the rear of the female rotor. Since the unit operates under a vacuum there is the need for a mechanical pump for fluid circulation to assure proper lubrication and cooling of the airend at all vacuum levels. With the oil pump connected directly to the airend it eliminates the need for and additional motor and reduced maintenance. The standard oil shipped in our Kaeser vacuum screw units is Sigma S460. The pneumatic inlet valve is activated by a solenoid control valve, and full-flow /idle switching is controlled by a vacuum transducer. The wide doors and removable panels with key locks make maintenance easy to perform.

8. Rotary Screw Vacuum Features
Sigma profile airend
TEFC motor with class F insulation
The TEFC electric motor is Epact compliant and features class F insulation and a 1.15 service factor. These motors ensure great efficiency during operation and years of reliable service. Cooling for the motor and the package is provided by a cooling fan that is attached directly to the motor shaft. A Direct On Line (DOL) start system is used on our vacuum screw units and comes complete with a full-voltage magnetic starter and 115v-1-60 control voltage transformer.

9. Rotary Screw Vacuum Features
Sigma profile airend
TEFC motor with class F insulation
V-belt drive with automatic tensioning device
The only thing of note on the V-belts on the vacuum package is that the single ribbed belt we talked about on the rotary screw compressors is not used on the vacuum packages. This particular model uses 6 individual belts. As in our other belt drive units we provide an automatic belt tensioning devise to maintain proper belt tension and provides optimum power transfer and long belt life.

10. Rotary Screw Vacuum Features
Sigma profile airend
TEFC motor with class F insulation
V-belt drive with automatic tensioning device
Sigma Control™
To control the unit we have our reliable Sigma Control. The controller is a PC-based control system with Intel processor. The Sigma Control is used to monitor all control and safety functions and also tracks maintenance schedules along with capturing all messages, alarms and warnings. The control system can be switched from Dual control to Modulation to optimize the operation of the customers system to provide maximum flexibility to meet changing demands or applications.
In dual control the time delay before the unit idles out can be adjusted and automatic restart after power failure is standard on all units.

11. Rotary Screw Vacuum Features
Sigma profile airend
TEFC motor with class F insulation
V-belt drive with automatic tensioning device
Sigma Control™
Full enclosure to reduce sound levels
Dear to Kaeser’s heart is how quiet our units run. Vacuum screws are no different. To accomplish this we use a full enclosure with a solid steel floor. The full enclosure keeps the sounds of the unit to a minimum. The steel floor helps keep the noise inside the cabinet which is especially important when the unit is placed on a mezzanine or a steel grating. The anti-vibration pads these units stand on also help keep the unit quiet and helps keep vibration to a minimum. The enclosure features a durable powder coated finish. Also the additional vibration proofing of the Motor, Airend, and separator tank are standard features. This additional vibration proofing helps to keep the unit running smoothly and quietly.

12. Rotary Screw Vacuum Features
Sigma profile airend
TEFC motor with class F insulation
V-belt drive with automatic tensioning device
Sigma Control™
Full enclosure to reduce sound levels
Oil pump driven by the female rotor for positive instant lubrication
Since a vacuum unit does not create pressure in the sump there is no way to circulate the oil thru-out the system. For this reason Kaeser rotary screw vacuum compressors use an oil pump driven directly off the female rotor. This direct drive of the oil pump assures that the airend will be positively and instantly lubricated.

13. Rotary Screw Vacuum Features
USER CONNECTION
40 micron pre-filter mat
Externally mounted suction filter for vacuum line connection
The inlet filter is mounted on the outside of the unit. This filter is used to filter any material that might be drawn into the vacuum line at the point of use. Periodic maintenance of this filter is very important.
Because the filter is mounted on the outside of the unit, maintenance of the filter is a snap. Remember that you have to relieve the vacuum from the system before you will be able to service the filter.
The system vacuum line is connected directly to the suction inlet filter.

14. Rotary Screw Vacuum Features
40 micron pre-filter mat
Externally mounted suction filter for vacuum line connection
Unit comes completely piped and wired (internally)
The unit will come completely piped and ready to connect the system piping. All you have to do is connect the filter housing and connect the system to the filter.
Also the unit will come completely wired and ready to have the incoming power leads connected. Connect up the power leads. Do a compete check of the unit to make sure everything is ready to go. Then follow the steps we suggest for a safe start-up of a unit and you are ready to use the unit.

15. Rotary Screw Vacuum Features
40 micron pre-filter mat
Externally mounted suction filter for vacuum line connection
Unit comes completely piped and wired (internally)
Thermostatically controlled fluid circuit
Three-stage fluid separation
The temperature of our Rotary Screw Vacuum unit is controlled by a thermostatically controlled combination valve. This combination valve monitors the temperature of the oil and sends it through the cooler as the temp rises.
As in all our screw compressors we use a three stage fluid separation system. The first fluid separation is done when the air and fluid enter the separator tank and is given a spin. The centrifugal force separates a bulk of the fluid from the air. From there the separator has a two stage filter separation media. Also featured are two fluid level sight glasses, a drain valve, and drain hose to quickly and easily check and change to fluid.

16. Rotary Screw Vacuum Features
Gas ballast air injection system keeps moisture from condensing in the separator
Silencer
Check valve
Air filter
All of our vacuum packages have a gas ballast air make-up system. This system allows air to leak into the discharge side of the vacuum pump to absorb any moisture in the vacuum pumps discharge. This is done to prevent moisture from condensing in the separator . The airend turns and draws air from the system into the rotors. As the rotors continue to turn the inlet port is sealed off from the intake trapping a volume of vacuum in the rotors flutes. Continuing to turn a port in the middle of the air end is opened. This port is open to ambient air (Higher pressure air) through a filter, silencer, and check valve. This ambient air being at a higher pressure than the vacuum is forced into the rotors. Along with the air we inject hot oil into this air stream. The hot oil helps to heat the air which in turn allows this air to absorb any moisture that is draw into the unit from the system. The air being hot absorbs the moisture and carries it out of the unit before it can condense in the separator tank.
As we know from the compressor world when you compress air we need to raise the temperature to allow the air to hold all the moisture and not let it condense in the unit. The same is true with a vacuum. We are actually compressing the air from a very low vacuum to the much higher ambient pressure. Due to this compression we need to inject hot air to absorb the moisture that can be present in the system. This works very good in systems where the vacuum is used to draw air in from a very humid process.
Injected air absorbs any moisture that might be drawn into the airend
Air injection line

17. Accessories Vacuum receiver tank Outlet Store volume Inlet
Sight glass
Baffle plate
Discharge pump for liquids
Inlet
Outlet
Store volume
Maintain vacuum levels
Here are some accessories typically needed in a vacuum system.
This diagram shows a vacuum receiver. Note that a discharge pump is required to remove liquids/contaminants being drawn from the point of use. A regular drain trap will not work.
Another reason to have a receiver tank is to knock-out bulk liquids and solids.
Any liquid that is drawn into the the receiver tank will collect on the bottom of the tank to be discharged by a vacuum discharge pump.
Knock-out bulk liquids and solids

18. Accessories Inlet Scrubbers/Knockout Pots Captures oil fog, mist
Protect vacuum unit from solids
The Inlet scrubber or Knockout Pot remove both liquid and particulate contaminants to protect the airend and inlet filter. It captures oil fog and mist to reduce oil that might have an effect on the airend. It uses a demister pad to collect the bulk of the liquids and then a dry filter for finer filtering. An external pump is needed to remove liquids from the sump.
Available in several grades microns, 2 microns down to 0.3 microns (special applications)

19. Accessories
Discharge Demisters - remove entrained oil from pump exhaust
The oil demister traps oil aerosols and prevents their release into the atmosphere. This is an option offered by Kaeser. FYI, NFPA 99C requires that the exhaust air be vented outside.

20. System Configurations
Duplex System
- Each unit sized for 100% duty cycle
Vacuum systems can and do need back up just as compressed air systems do. They can be sequenced and we offer a vacuum sequencer.
This and the next couple slides show some options for meeting the backup requirements and fluctuating demand of the customer.
Here we have 100% redundancy. Since either unit can carry the load.

21. System Configurations
Triplex System
- Each unit sized for 50% duty cycle
This system offers energy savings for applications with fluctuating demand while still offering a back up machine.
50%
50%
50%
100%

22. Process System
Some installations require the use of a “Knockout Pot” to remove heavy concentrations of contaminants from the air stream prior to the inlet filter.

23. Industrial System Schematic
Here is a schematic for a typical industrial installation.
The vacuum receiver serves the same purposes as in a compressed air installation: storage and a collection point for liquids. Unlike a compressed air system, the receiver needs a pump to get the liquids out. A compressed air drain trap will not work.
Demisters are mounted on the outlet side to remove oil from the exhaust air.

24. Hospital System Schematic
This is a typical hospital installation. The principle difference between this and the installation on the previous slide is the addition of an alarm.
The alarm is independent of the vacuum screw. It should be installed to sense vacuum at the receiver. This is one important element of NFPA 99C. Backup units and sequencing are also important for medical applications. Also, the demisters must be vented outdoors.
Many hospitals and their insurance companies demand that their vacuum (and compressed air) systems comply with NFPA 99C codes. There is no such thing as an “NFPA 99C approved” vacuum pump! Don’t let your customers be fooled by our competitors into thinking that their pump is “approved.” The NFPA 99C codes apply to the overall system rather than the vacuum pump. The key to NFPA 99C approval is expertise in installation. The distributor must know the code or get assistance from someone who does.
Kaeser can provide you with information on the NFPA 99C requirements.

25. Installation Unit must be mounted on a flat and level surface
Adhere to the minimum clearances around the unit
Provide for proper ventilation of the compressor room
To properly install a vacuum unit you need to provide a level and flat surface for the unit to sit on. The foundation must be able to carry the weight of the unit.
When placing the unit in a compressor room be sure and provide ample space around the unit to allow for maintenance work and doors to swing open. It would be wise to take into consideration how you would manage changing an airend or motor in the event of a failure. A little planning at this time might save many hours trying to install an airend or motor.
As in all units it is imperative that the room the units is in has proper ventilation. Not only is it important to provide plenty of cool air to enter the room but you must also have a method of venting the hot air from the unit. Remember that the compressed air from a vacuum unit can contain oil vapor which will condense when vented to atmosphere. In most cases you will need to vent this air outside and provide a mist eliminator to collect this oil vapor.
The connection to the system needs to have either a flex connector or an axial compensator. This will eliminate vibration transfers and protect the connection to the unit.
Connect to system with a flex hose or axial compensator

26. Installation Verify proper incoming voltage Verify proper wire size
Verify proper fuse size
dual element – time delay (preferred)
Installation of a Vacuum unit is the same as connecting to any Kaeser screw compressor. The first thing to do is Verify the incoming voltage is the correct voltage for your unit. If it is not correct you might be able to rewire the vacuum unit or possibly a transformer will be needed.
Before hooking up the wires you will need to verify the incoming wire size is correct. Along with that check the fuse or breaker size is correct. Remember this is a DOL start system so size the fuses accordingly. Use a dual element-time delay fuse.
After all this is verified you are ready to connect the power wires to the vacuum unit.
Connect incoming power leads

27. Start-Up Verify the unit is properly installed
Check oil level and top off if needed
Now that we have the unit all hooked up and ready to operate it is a good time to verify that everything is properly installed and ready to go. It is always good to give it the once over to make sure nothing was missed.
Before starting the unit you need to check the oil level. This is done through the sight glasses. It should be ½ way up in the top sight glass.
Check the belts and verify they are at the proper tension. The pin should be at or near the bottom of the slot.
The first time you start a unit it is important to make sure the airend is flooded with oil. It takes some time after the unit to start for the pump to pick up the oil and pressurize the system. We want to make sure the airend does not run dry for the few seconds before oil is injected into the airend. To flood the airend you need to remove the inlet valve and pour oil directly into the airend.
We are now getting closer to being able to actually start the unit.
Check belts for proper tension
Pour oil in airend and rotate to lubricate bearings and rotors

28. Start-Up Verify the overload is set properly
Bump motor and verify proper airend rotation
Follow safe start-up procedure
Verify proper operation
Before you start the unit you should look at the overload setting and verify it is set properly for the voltage you are operating at.
First push the E-stop button
Now you are ready to supply power to the unit.
Next thing to do is bump the unit and verify the airend is rotating in the proper direction. Now we are ready to start the unit.
Follow our guide lines for doing a safe start of the unit. Part of this should be to check to make sure the door safety switch is operating properly. Once it is running you open the door and the unit should shut down.
Now that it is running and put under a load you should verify the operating parameters and fill out the start-up form. This form is for your records and a copy should be sent to Kaeser After Sales Service for their approval of the installation. This copy will be attached to the EMR of the unit for future reference if needed.
When the unit is operating properly and you about to turn the unit over to the customer it is a great time teach them how to operate the unit. Show them how the sigma control monitors the pressure and how the unit tracks the maintenance schedule.
This will take you right into the importance of regular maintenance.
Fill out start-up sheet and send a copy to After Sales Service
Explain operation and the importance of regular maintenance to the customer

29. Maintenance Lock out / tag out - before doing any service
Perform regular maintenance according to service manual
Before doing and maintenance work on a unit you should always lock out/ tag out the power supply. Failure to do this could result in personal injury.
All maintenance should be done on a regular basis. The owner’s service manual will give a detailed schedule to follow for regular maintenance.
The important thing to remember is the oil needs to be changed every hours of operation. If they do not reach these hours the oil should be changed at least annually. Remember as we have stated previously it is a good idea to have a liquid pump available to remove the oil from the separator tank.
Change oil at 2000 to 3000 hours or annually whichever comes first
Use a fluid pump to drain oil from separator tank

30. As you can see our Kaeser Rotary Screw packages are a well engineered complete package. They are designed to give many years of trouble free service with a team at Kaeser standing behind the unit in the event you need technical assistance.
Built for a lifetime™