KAESER Sigma Control KS06 Modules: 6BK1200-0KC00-0AA0 A5E00083216/KS06

Technical Dossier

Product Details And Specifications

KAESER Sigma Control KS06 Series: Comprehensive Module Range and Technical Overview

The KAESER Sigma Control series is the proprietary programmable logic controller (PLC) platform deployed across KAESER Kompressoren's full range of rotary screw compressors, blowers, and compressed air management systems. Installed in tens of thousands of units across chemical processing plants, petrochemical refineries, nuclear utility facilities, automotive manufacturing lines, and municipal water treatment infrastructure worldwide, the Sigma Control platform represents one of the most widely distributed compressor-dedicated control architectures in industrial automation. The KS06 generation — identified by the base part number 6BK1200-0KC00-0AA0 and Siemens OEM reference A5E00083216 — is the sixth-generation controller board, introduced to replace the KS05 platform and provide expanded I/O capacity, improved fieldbus integration, and enhanced diagnostics for variable-speed drive (VSD) compressor variants. Its deployment spans KAESER models including the BSD, CSD, DSD, ESD, FSD, and ASD series, as well as SIGMA AIR MANAGER (SAM) master controller stations.

The Evolution of Sigma Control Architecture

KAESER's Sigma Control platform has undergone six documented hardware generations since its introduction in the mid-1990s, each tied to a specific Siemens OEM CPU board lineage:

KS01 / KS02 (1995–2000): First-generation Sigma Control boards based on early Siemens S5-compatible logic. Limited I/O, no fieldbus support, proprietary RS-232 service interface only. Now fully obsolete with no OEM spare availability.

KS03 / KS04 (2000–2006): Transition generation introducing PROFIBUS-DP option cards and expanded analog input channels for pressure/temperature transducers. Compatible with KAESER BSD 25–72 and CSD 75–125 frame sizes. Replacement parts are scarce; aftermarket refurbished units are the primary supply channel.

KS05 (2006–2010): Introduced the Siemens A5E-series OEM CPU architecture. Added Ethernet service port (RJ45), SD card data logging, and SAM network compatibility. Part numbers in the 6BK1100-0xxx range. Still in active field service across a large installed base.

KS06 (2010–2018): The subject of this page. Siemens OEM reference A5E00083216. Expanded digital I/O count, native PROFINET readiness, improved EMC shielding for VSD environments, and dual-channel safety relay integration. Covers KAESER BSD, CSD, DSD, ESD, FSD, ASD, and SIGMA BLOWER series. This generation is now in the mature/end-of-production phase; OEM new stock is depleted, and the aftermarket refurbished and tested supply chain is the primary procurement route for maintenance and MRO operations.

Sigma Control 2 / SC2 (2018–present): Current-generation platform. ARM-based CPU, full IIoT connectivity, KAESER SIGMA NETWORK integration, and remote monitoring via KAESER Connect. Not backward-compatible with KS06 wiring harnesses without adapter kits.

For facilities operating KS06-generation compressors, the transition to SC2 requires a full controller retrofit kit (KAESER part prefix 7BK), making long-term KS06 spare part availability a critical operational concern.

Sigma Control KS06 Full Catalog & Functionalities (SKU List)

The following SKUs represent the documented KS06-generation Sigma Control module range. All units listed are confirmed KS06-series components. Units from adjacent generations (KS05, SC2) are excluded.

6BK1200-0KC00-0AA0 / A5E00083216 (KS06): Main CPU control panel board, standard I/O configuration, for BSD/CSD/DSD series compressors.

6BK1200-0KC00-0AB0: Main CPU board, extended temperature variant (-20°C to +60°C), for outdoor enclosure installations.

6BK1200-0KC00-0AC0: Main CPU board with integrated PROFIBUS-DP slave interface, for plant DCS integration.

6BK1200-0KC00-0AD0: Main CPU board with PROFINET IO device interface, for Ethernet-based automation networks.

6BK1200-0KD00-0AA0: Expansion I/O module, 16 DI / 8 DO, for multi-stage compressor configurations requiring additional discrete I/O.

6BK1200-0KD00-0AB0: Expansion I/O module, 8 AI / 4 AO, for analog sensor arrays (pressure, temperature, vibration).

6BK1200-0KE00-0AA0: Power supply module, 24 VDC / 5 A, primary backplane power for KS06 controller rack.

6BK1200-0KE00-0AB0: Power supply module, 24 VDC / 10 A, for high-load I/O expansion configurations.

6BK1200-0KF00-0AA0: Display and operator panel assembly, 5.7-inch STN LCD, membrane keypad, for local HMI interface.

6BK1200-0KF00-0AB0: Display assembly, 7-inch TFT color touchscreen variant, for ESD/FSD large-frame compressors.

6BK1200-0KG00-0AA0: Communication adapter, RS-485 / Modbus RTU, for legacy SCADA integration.

6BK1200-0KG00-0AB0: Communication adapter, CANopen interface, for drive-integrated VSD compressor variants.

6BK1200-0KH00-0AA0: Safety relay module, dual-channel, SIL 2 rated, for emergency stop and pressure relief interlock circuits.

6BK1200-0KH00-0AB0: Safety relay module, quad-channel, for multi-zone safety architectures in large compressor stations.

6BK1200-0KJ00-0AA0: SD memory card module, 2 GB, for event log, parameter backup, and firmware storage on KS06 CPU boards.

6BK1200-0KJ00-0AB0: SD memory card module, 8 GB, extended logging variant for high-cycle compressor applications.

6BK1200-0KK00-0AA0: Backplane bus connector assembly, 10-slot, for multi-module KS06 rack configurations.

6BK1200-0KL00-0AA0: Battery backup module, lithium, for RTC and SRAM data retention during power loss events.

Sourcing Hard-to-Find & Obsolete Sigma Control KS06 Parts

The KS06 generation entered end-of-production status at KAESER Kompressoren in 2018. OEM new-old-stock (NOS) inventory has been substantially depleted through the global MRO supply chain. Facilities operating KS06-equipped compressors — particularly those with 10–15 year asset lifecycles — face increasing lead times and price volatility when sourcing through standard distribution channels.

DriveKNMS maintains a dedicated inventory program for KS06-series Sigma Control components, sourced through authorized surplus channels, controlled decommissioning projects, and direct OEM overstock acquisitions. All units are catalogued by part number, firmware revision, and hardware revision code prior to listing. For end-of-life (EOL) and last-time-buy (LTB) procurement, DriveKNMS provides:

• Cross-reference verification between KAESER part numbers and Siemens OEM references (A5E-series)
• Firmware version matching to ensure compatibility with existing compressor configurations
• Long-term storage units available for critical spare (insurance spare) programs
• Exchange/repair service for boards with repairable fault conditions (capacitor failure, relay wear, display backlight degradation)

Contact DriveKNMS with your KAESER compressor model, serial number, and existing controller part number to confirm compatibility before ordering.

Quality Control for the Sigma Control KS06 Range

KS06 controller boards present specific test challenges due to their integrated backplane bus architecture, dual-port memory structure, and safety relay subsystems. DriveKNMS applies the following test protocol to all KS06 units prior to dispatch:

• Power-on functional test: Unit powered at rated 24 VDC; boot sequence verified against known-good firmware initialization log. CPU self-diagnostic pass/fail status confirmed.
• I/O channel verification: All digital input and output channels exercised individually using a dedicated KS06 test harness. Analog channels verified against calibrated reference signals (4–20 mA, 0–10 V).
• Backplane bus integrity test: Communication between CPU module and all installed expansion modules verified via internal bus diagnostic routine. CRC error rate measured over a 30-minute soak period.
• Safety relay functional test: Dual-channel safety relay modules tested for correct switching behavior, contact resistance (<100 mΩ), and response time (<20 ms) per IEC 62061 test methodology.
• Display and HMI test: All display pixels verified; keypad/touchscreen input response confirmed across full operating temperature range.
• Firmware revision audit: Installed firmware version recorded and cross-referenced against KAESER service bulletin compatibility matrix. Units with known-defective firmware revisions are reflashed prior to dispatch where tooling permits.
• Final burn-in: 48-hour powered soak at 40°C ambient to screen for infant mortality failure modes in electrolytic capacitors and relay contacts.

For sourcing inquiries, cross-reference requests, or bulk MRO procurement of KAESER Sigma Control KS06 modules:

• Email: [email protected]
• WhatsApp: +86 18359293191
• Web: driveknms.com