Prodrive Technologies SAM2 SAM2 User Manual
Prodrive B.V. SAM2 Users Manual
Users Manual
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Service manual SIGMA AIR MANAGEMENT SYSTEM SAM 2 No.: 901735 00 E Manufacturer: KAESER KOMPRESSOREN SE 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 http://www.kaeser.com /KKW/CSAM 2.00 en IBA-SAM2 /KKW/CSAM 2.00 20140916 091703 Contents No.: 901735 00 E Regarding this document 1.1 Using this document ......................................................................................................... 1.2 Copyright .......................................................................................................................... 1.3 Approvals ......................................................................................................................... 1.4 Software ........................................................................................................................... 1.5 Licensed brands and trademarks ..................................................................................... 1.6 Symbols and labels .......................................................................................................... 1.6.1 Warnings ............................................................................................................. 1.6.2 Potential damage warnings ................................................................................ 1.6.3 Other alerts and their symbols ............................................................................ Technical Specifications 2.1 System information .......................................................................................................... 2.2 Electrical Data .................................................................................................................. 2.3 Versions and Options ....................................................................................................... 2.4 Components within the control cabinet ............................................................................ 2.4.1 I/O modules (SAM 2 and SBU) ........................................................................... 2.4.2 I/O Modules (only SBU) ...................................................................................... 2.4.3 Relay block ......................................................................................................... 2.4.4 SIGMA NETWORK Switch 8 port ....................................................................... 2.4.5 Protocol converter SIGMA NETWORK / PROFIBUS master ............................. 2.4.6 SAM 2 -Terminal ................................................................................................. 2.5 Control cabinet ................................................................................................................. 2.6 Pressure transducer ......................................................................................................... 10 10 11 11 13 14 Safety and Responsibility 3.1 Basic instructions ............................................................................................................. 3.2 Intended use .................................................................................................................... 3.3 Improper use .................................................................................................................... 3.4 User's Responsibilities ..................................................................................................... 3.4.1 Observe statutory and universally accepted regulations .................................... 3.4.2 Qualified personnel ............................................................................................. 3.5 Dangers ............................................................................................................................ 3.5.1 Safely dealing with sources of danger ................................................................ 3.5.2 Safe SAM 2 operation ......................................................................................... 3.6 Warranty ........................................................................................................................... 16 16 16 17 17 17 17 17 18 18 Design and Function 4.1 Overview .......................................................................................................................... 4.2 Operating panel ................................................................................................................ 4.3 Touch screen ................................................................................................................... 4.4 User log-on with RFID ...................................................................................................... 4.5 Main menu ....................................................................................................................... 4.5.1 Menu tree ............................................................................................................ 4.6 Operation and function ..................................................................................................... 4.6.1 Adaptive 3D control ............................................................................................ 4.6.2 Base load sequencing ........................................................................................ 4.6.3 Time control ....................................................................................................... 4.6.4 Power limiting ..................................................................................................... 4.6.5 Air main charging ................................................................................................ 4.6.6 EMERGENCY operation ..................................................................................... 4.6.7 Visualisation at external devices ......................................................................... 20 22 23 24 25 25 26 26 26 26 26 26 26 27 Installation and Operating Conditions 5.1 Environment ..................................................................................................................... 5.2 Installation conditions ....................................................................................................... 28 28 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM Contents ii Installation 6.1 Installation ........................................................................................................................ 6.2 Ensuring safety ................................................................................................................ 6.3 Reporting transport damage ............................................................................................ 6.4 Compressed air supply during installation ....................................................................... 6.4.1 Station with emergency operating mode ............................................................ 6.4.2 Stations without emergency operating mode ..................................................... 6.5 Scope of delivery .............................................................................................................. 6.6 Installing the control cabinet ............................................................................................. 6.7 Identifying the machines .................................................................................................. 6.8 Connecting the pressure transducer ................................................................................ 6.8.1 Mechanical connection ....................................................................................... 6.8.2 Electrical connection ........................................................................................... 6.9 Planning the wiring ........................................................................................................... 6.9.1 SIGMA NETWORK ............................................................................................ 6.9.2 PROFIBUS network ............................................................................................ 6.9.3 Floating contacts ................................................................................................. 6.9.4 Instructions on the electrical installation ............................................................. 6.9.5 Prerequisites and accessories required for connection with SIGMA NETWORK ............................................................................................................................ 6.9.6 Prerequisites and accessories connection with PROFIBUS .............................. 6.9.7 Requirements for connecting with floating relay contacts .................................. 6.10 Laying cables ................................................................................................................... 6.10.1 Creating SIGMA NETWORK ............................................................................. 6.10.2 Creating the PROFIBUS network ....................................................................... 6.10.3 Creating the compressor station via floating relay contacts ............................... 6.11 Connecting lines ............................................................................................................... 6.11.1 Wiring the control cabinet ................................................................................... 6.11.2 Connecting the equipotential bond ..................................................................... 6.11.3 Feeding cables and connecting the screening ................................................... 6.11.4 Laying the cables in the control cabinet ............................................................. 6.11.5 Connecting the cables ........................................................................................ 6.11.6 Installing the control cabinet ............................................................................... 6.12 Setting up the machines ................................................................................................... 6.12.1 Integration with SIGMA NETWORK .................................................................. 6.12.2 Integration with PROFIBUS ............................................................................... 6.12.3 Linking via floating relay contact ......................................................................... Initial Start-up 7.1 Commissioning – overview ............................................................................................... 7.2 Switching on SAM 2 ........................................................................................................ 7.3 Setting the language ........................................................................................................ 7.4 User log-on ....................................................................................................................... 7.4.1 Log on with Equipment Card .............................................................................. 7.4.2 User log-out ........................................................................................................ 7.5 Date and time ................................................................................................................... 7.5.1 Setting the time zone .......................................................................................... 7.5.2 Setting date and time .......................................................................................... 7.6 Setting the Unit settings .................................................................................................. 7.7 Setting up E-Mail ............................................................................................................. 7.7.1 Send options ...................................................................................................... 7.8 Setting up the display ....................................................................................................... 7.9 Setting the Data recording .............................................................................................. 7.10 Periphery .......................................................................................................................... 7.10.1 Starting the SBU ................................................................................................ Service manual SAM 2 29 30 30 30 30 31 31 31 33 33 33 35 35 36 36 37 38 38 39 39 40 40 43 44 45 45 46 46 47 48 48 48 49 49 50 52 52 53 53 54 55 55 55 55 56 57 57 58 59 59 59 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E Contents No.: 901735 00 E 7.11 P+I diagram ..................................................................................................................... 7.11.1 Component types ................................................................................................ 7.11.2 Configuring the components ............................................................................... 7.12 Control ............................................................................................................................. 7.12.1 Setting the Parameter ........................................................................................ 7.12.2 Setting the Pressure parameters ....................................................................... 7.13 Activating SAM 2 ............................................................................................................. 61 64 64 66 67 68 68 Operation 8.1 Switching on and off ......................................................................................................... 8.1.1 Switching the compressed air station on ............................................................ 8.1.2 Switching the compressed air station off ............................................................ 8.2 Help function .................................................................................................................... 8.3 Main menu ....................................................................................................................... 8.3.1 Net pressure station ........................................................................................... 8.3.2 Pressure chart ................................................................................................... 8.3.3 Current values ................................................................................................... 8.3.4 Drag Indicator .................................................................................................... 8.3.5 Station view ........................................................................................................ 70 70 70 70 70 71 72 72 73 73 Fault Recognition and Rectification 9.1 KAESER SERVICE ......................................................................................................... 9.2 Messages ......................................................................................................................... 9.3 Other faults ....................................................................................................................... 75 75 76 10 Maintenance 10.1 Maintenance tasks on electrical equipment ..................................................................... 10.2 Additional buffer battery ................................................................................................... 10.2.1 Danger from batteries ......................................................................................... 10.2.2 Buffer battery life ................................................................................................. 10.2.3 Installing the additional buffer battery ................................................................. 77 77 77 77 78 11 Spares, Operating Materials, Service 11.1 Note the nameplate .......................................................................................................... 11.2 Spare parts ....................................................................................................................... 11.3 KAESER AIR SERVICE .................................................................................................. 11.4 Displaying the software version ....................................................................................... 79 79 79 79 12 Decommissioning, Storage and Transport 12.1 De-commissioning ............................................................................................................ 12.2 Disposal ........................................................................................................................... 80 80 13 Annex 13.1 Anchor holes for the control cabinet ................................................................................. 82 13.2 Machine assignment ........................................................................................................ 82 13.3 SBU (SIGMA NETWORK BUS CONVERTER) ............................................................... 83 13.4 SAM 2 setting values ....................................................................................................... 83 13.4.1 Technician's settings .......................................................................................... 83 13.5 Machine settings .............................................................................................................. 85 13.5.1 Setting the pressure regulation (pressure controller in series with the SAM 2 85 load output) ......................................................................................................... 13.5.2 Pressure range for manual operation ................................................................. 87 13.5.3 System offset for manual mode .......................................................................... 89 13.6 Installation accessories .................................................................................................... 90 13.7 Installing the buffer battery ............................................................................................... 93 13.8 Electrical Diagram ............................................................................................................ 93 13.9 I/O block 6DI&6DOT&4AII with relays .............................................................................. 116 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM iii Contents 13.10 13.11 13.12 13.13 iv Module 6DI – Digital inputs .............................................................................................. Module 6DOT – Digital outputs 24VDC 0.5A ................................................................... Module 4AII – Analogue inputs 0-20mA ........................................................................... Glossary ........................................................................................................................... Service manual SAM 2 123 125 127 129 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E List of Illustrations Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 11 Fig. 12 Fig. 13 Fig. 14 Fig. 15 Fig. 16 Fig. 17 Fig. 18 Fig. 19 Fig. 20 Fig. 21 Fig. 22 Fig. 23 Fig. 24 Fig. 25 Fig. 26 Fig. 27 Fig. 28 Fig. 29 Fig. 30 Fig. 31 Fig. 32 Fig. 33 Fig. 34 Fig. 35 Fig. 36 Fig. 37 No.: 901735 00 E Control cabinet dimensions ........................................................................................................ SAM 2 – Standard design of a compressed air station .............................................................. Operating panel SAM 2 ............................................................................................................. Touch screen menu .................................................................................................................... User management with RFID ..................................................................................................... Open the SAM 2 cover ............................................................................................................... Removing the control cabinet cover ........................................................................................... Pressure transducer position ...................................................................................................... Connecting the screening ........................................................................................................... SIGMA NETWORK design ......................................................................................................... Structure of a PROFIBUS network – SAM 2 with Option E1: PROFIBUS master ..................... Structure of a PROFIBUS network – SBU with Option E1: PROFIBUS master ......................... Configuration of the network with floating relay contacts ........................................................... Strip the isolation from the network cable. ................................................................................. Inserting the network cable conductors ...................................................................................... Positioning the network cable ..................................................................................................... Close the lid of the RJ45 plug. ................................................................................................... Rotating the locking piece to the stop ........................................................................................ Stripping the isolation from the PROFIBUS cable ...................................................................... Connection of an inline plug ....................................................................................................... Installation of a terminating PROFIBUS plug ............................................................................. Remove the wire jumper. ........................................................................................................... Cable glands with and without ferrite suppressors ..................................................................... Connecting the screening ........................................................................................................... LAN conduit screening ............................................................................................................... Laying the cables in the control cabinet ..................................................................................... Installing the control cabinet ....................................................................................................... KAESER Equipment Card .......................................................................................................... RFID reader ................................................................................................................................ Logged on .................................................................................................................................. Setting date and time ................................................................................................................. Block configuration menu ........................................................................................................... I/O block menu ........................................................................................................................... Station editor menu .................................................................................................................... Buffer battery location ................................................................................................................ Buffer battery positions ............................................................................................................... Anchor holes for the SAM 2 control cabinet ............................................................................... Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 13 21 22 23 24 32 32 34 35 36 37 37 38 41 41 42 42 42 43 44 44 45 46 46 47 47 48 54 54 54 56 60 60 62 78 80 82 List of Illustrations vi Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E List of Tables Tab. 1 Tab. 2 Tab. 3 Tab. 4 Tab. 5 Tab. 6 Tab. 7 Tab. 8 Tab. 9 Tab. 10 Tab. 11 Tab. 12 Tab. 13 Tab. 14 Tab. 15 Tab. 16 Tab. 17 Tab. 18 Tab. 19 Tab. 20 Tab. 21 Tab. 22 Tab. 23 Tab. 24 Tab. 25 Tab. 26 Tab. 27 Tab. 28 Tab. 29 Tab. 30 Tab. 31 Tab. 32 Tab. 33 Tab. 34 Tab. 35 Tab. 36 Tab. 37 Tab. 38 Tab. 39 Tab. 40 Tab. 41 Tab. 42 Tab. 43 Tab. 44 Tab. 45 Tab. 46 Tab. 47 Tab. 48 Tab. 49 Tab. 50 Tab. 51 Tab. 52 No.: 901735 00 E Danger levels and their definitions (personal injury) .................................................................. Danger levels and their definition (damage to property) ............................................................ System information ..................................................................................................................... Electrical Data ............................................................................................................................ Versions and Options ................................................................................................................. Technical data, all I/O modules .................................................................................................. Technical data I/O-block and individual modules ....................................................................... Technical data, all I/O modules .................................................................................................. Data, 4AIR module ..................................................................................................................... Data, 4AOI module ..................................................................................................................... Data module 4AIP ...................................................................................................................... Relay block data ......................................................................................................................... Data switch ................................................................................................................................. Data, SNW/DP bus controller ..................................................................................................... Interfaces SAM 2 ....................................................................................................................... RFID ........................................................................................................................................... Display data ................................................................................................................................ Control cabinet data ................................................................................................................... Models I and II pressure transducers ......................................................................................... Pressure transducer model III and vacuum ................................................................................ Operating panel SAM 2 ............................................................................................................. Touch screen menu elements .................................................................................................... Menu tree ................................................................................................................................... Ambient temperatures ................................................................................................................ Storage temperatures ................................................................................................................. Installation overview ................................................................................................................... Standard scope of delivery ......................................................................................................... Maximum cable lengths .............................................................................................................. Required equipment ................................................................................................................... Parameter for bus alarm ............................................................................................................. Commissioning – overview ......................................................................................................... Keys on the SAM 2 operating panel ........................................................................................... Unit settings ............................................................................................................................... E-Mail Send options .................................................................................................................. E-Mail Basic settings ................................................................................................................. Data recording ........................................................................................................................... Block configuration menu ........................................................................................................... Station editor ............................................................................................................................. Component types ....................................................................................................................... Parameters in the configuration menu ....................................................................................... "Commissioning" check list ........................................................................................................ Symbols in View station ............................................................................................................ Other faults ................................................................................................................................. Spare buffer battery .................................................................................................................... Software versions menu ............................................................................................................. Machine assignment .................................................................................................................. SBU ........................................................................................................................................... Technician's settings .................................................................................................................. Recommended settings: Pressure controller in series with SAM 2 "external load control" load output ......................................................................................................................................... Recommended settings: Pressure controller in series with the SAM 2 "Man/Auto and Load/ Idle" load output ......................................................................................................................... Personal settings: Pressure controller in series with SAM 2 load output ................................... Recommended settings: Pressure range for manual operation ................................................. Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 10 10 11 12 12 12 13 14 14 22 23 25 28 28 29 31 38 39 49 52 53 56 57 58 59 61 62 64 65 68 73 76 79 79 82 83 83 85 86 87 87 vii List of Tables Tab. 53 Tab. 54 Tab. 55 Tab. 56 Tab. 57 Tab. 58 Tab. 59 Tab. 60 Tab. 61 Tab. 62 Tab. 63 Tab. 64 Tab. 65 Tab. 66 Tab. 67 Tab. 68 Tab. 69 Tab. 70 Tab. 71 Tab. 72 viii Personal settings: Pressure range for manual operation ........................................................... Personal settings: System offset (manual operation) ................................................................. Communication modules ............................................................................................................ SIGMA NETWORK installation accessories .............................................................................. Pressure transducer ................................................................................................................... Pressure transducer accessories ............................................................................................... SBU types for wall mounting ...................................................................................................... SBU types for installation in machines without SIGMA CONTROL .......................................... PROFIBUS installation accessories ........................................................................................... Load/idle module ........................................................................................................................ RC interference suppressor ....................................................................................................... Installing the buffer battery ......................................................................................................... Sample entry in assignment table I/O block with relays ............................................................. Assignment I/O block – Module 1: X1 DI1.x – 20DI6371 – 6x DI 24VDC ................................... Assignment I/O block – Module 2: X2 DOT2.x – X20DO6322 – 6x relays ................................. Assignment I/O block Modules 3 & 4 – X3 & X4 AII3.x – X20AI4632 – 4x AII 0-20mA 16Bit & X20PD2113 ................................................................................................................................ Assignment Module 6DI – X20DI63716x – DI 24VDC ................................................................ Assignment Module 6DOT – X20DO6322 – 6x DOT 24VDC 0,5A ............................................ Assignment 4AII – X20AI4632 – 4x AII 0-20mA 16Bit & X20PD2113 ........................................ Glossary ..................................................................................................................................... Service manual SAM 2 88 89 90 90 90 90 91 92 92 92 93 93 117 118 119 122 124 126 128 129 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 1 Regarding this document 1.1 Using this document 1 Regarding this document 1.1 Using this document The operating manual contains important information to the entire life cycle of SAM 2 . The operating manual is a component of the product. ➤ Keep the manual in a safe place throughout the life of SAM 2 . ➤ Pass the manual on to the next owner or user of the equipment. ➤ Ensure that any amendments received are inserted in the manual. 1.2 Copyright This operating manual is protected by copyright. Any queries regarding the use or duplication of this documentation should be referred to KAESER. Correct use of information will be fully suppor‐ ted. 1.3 Approvals The product with the SAM 2 type designation has the following approvals: ■ This product is MIC approved. The approval number is: AC-xxxxx. The radio waves used for this product may affect medical devices such as pacemakers. ■ This device complies with part 15 of the FCC rules and with RSS-210 of Industry Canada. The operation is subject to the following two conditions: ■ No.: 901735 00 E ─ (1) this device may not cause harmful interference, and ─ (2) this device must accept any interference received, including interference that may cause undesired operation. This equipment has been tested and found to comply with the limits for a Class B digital de‐ vice, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: ─ Reorient or relocate the receiving antenna. ─ Increase the separation between the equipment and receiver. ─ Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. ─ Consult the dealer or an experienced radio/TV technician for help. Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 1.4 Regarding this document 1.4 Software Software The software used in SAM 2 contains copyright-protected software which is licensed by GNU Gen‐ eral Public License in versions 2 and 3. A copy of these licenses is contained in SAM 2 . Display the licenses by pointing your browser to the "COPYING" file in the root directory of SAM 2 . URL: http://SAM 2 COPYING The licenses can be also found under this address: http://www.gnu.org/licenses/gpl-2.0.txt http://www.gnu.org/licenses/gpl.txt Within three years from receipt of SAM 2 , you may obtain the complete source code by sending a corresponding order to the following address: Technisches Büro Elektrokonstruktion KAESER KOMPRESSOREN SE 96450 Coburg, Postfach 2143 Germany. This offer is made to everybody receiving this information. 1.5 Licensed brands and trademarks All licensed brands and trademarks and brands and trademarks licensed to third parties mentioned in this service manual are subject without restriction to the legislation for the brand and trademark rights concerned and the ownership rights of the licensed owner in each case. The mere mention of a trademark alone does not allow the conclusion to be drawn that a trademark is not protected by the rights of a third party. 1.6 Symbols and labels ➤ Please note the symbols and labels used in this document. 1.6.1 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: Tab. 1 Signal term Meaning Consequences of non-compliance DANGER Will result in death or severe injury Warns of an imminent danger WARNING Warns of a potentially imminent danger May result in death or severe injury CAUTION May result in a moderate physical injury Warns of a potentially dangerous situation Danger levels and their definitions (personal injury) Warning notices preceding a chapter apply to the entire chapter, including all sub-sections. Example: Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 1 Regarding this document 1.6 Symbols and labels DANGER These show the kind of danger and its source. 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. WARNING! These show the kind of danger and its source. 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. 1.6.2 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. Tab. 2 Signal term Meaning Consequences of non-compliance NOTE Damage to property is possible Warns of a potentially dangerous situation Danger levels and their definition (damage to property) Example: NOTICE These show the kind of danger and its source. 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. 1.6.3 Other alerts and their symbols This symbol identifies particularly important information. Material Precondition Here you will find details on special tools, operating materials or spare parts. 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. ➤ 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. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 1 Regarding this document 1.6 Symbols and labels 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. Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 2 Technical Specifications 2.1 System information 2 Technical Specifications 2.1 System information ➤ Enter the system information for SAM 2 in the following table. System information Value Material no. Serial no. Tab. 3 System information The nameplate indicates the material no. and serial no. 2.2 Electrical Data Model SAM 2 – 100-240 V AC SAM 2 – 24 V DC Rated voltage [V] 100–240, 50–60 Hz 24 Rated current [A] 1.25-0.65 2.5 User's fusing [A] 16 Power cable core cross-section [mm2] 3x1.5 Equipotential bond connection [mm2] 1x16 Enclosure protection IP54 (IEC 529) Buffer battery Buffer battery [V]/[Ah] Tab. 4 2.3 3/0.12 Life of buffer battery without power supply [years] Life of buffer battery with power supply [years] 10 Electrical Data Versions and Options SAM 2 is available in diverse variants and options: No.: 901735 00 E ■ In principle, every input and output is freely assignable. ■ The number of inputs and outputs can be increased using SBU (see chapter 4) ■ Details on assignable and assigned inputs and outputs can be found in the circuit dia‐ grams in the annex. Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 2 Technical Specifications 2.4 Components within the control cabinet Model SAM 2-4 SAM 2-8 SAM 2-16 Digital inputs (DI) for floating relay signals Digital relay contact outputs (DOR) (as changeover contacts, 230 V, 3 A) Analog inputs (AII) 0(4)-20 mA Free SIGMA NETWORK -Ports 7/132) Maximum 16 Via SIGMA NETWORK Basic configuration Sequenced machines 13 2) 3) I/O directly to SAM 2 Options E1:PROFIBUS master4) Complete SAM PROFIBUS network can be connected E2: 7 SIGMA NETWORK -Ports. E3: 13 SIGMA NETWORK -Ports 4) E9: Network section control E10: PROFINET IO E11: ModbusTCP 5) 5) E12: PROFIBUS DP 5) Tab. 5 2.4 2.4.1 1) PROFIBUS master only once ( SAM 2 or SBU ). 2) with option E3: 13 SIGMA NETWORK -Ports. 3) Expandable to 16 with SBU , see chapter 4. 4) Either option E1 or E3 possible. 5) Only one communication module possible. Factory-equipped with 7 SIGMA NETWORK ports additional 6 SIGMA NETWORK -Ports. Network section control PROFINET IO communication module Modbus TCP communication module PROFIBUS DP communication module Versions and Options Components within the control cabinet I/O modules (SAM 2 and SBU) The following technical data apply to the I/O block and the individual I/O modules used in SAM 2 and SBU : ■ I/O block 6DI&6DOT&4AII ■ Module 6DI – X20DI6371 ■ Module 6DOT – X20DO6322 ■ Module 4AlI – X20AO2632 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 2 Technical Specifications 2.4 Components within the control cabinet Technical data, all I/O modules Feature Value Connection terminals Push-in terminal Connection diameter Copper wires ■ Wire/single-core [mm ] ■ 0.08-2.5 / AWG 28-14 ■ Flex/fine-core [mm2] ■ 0.25-2.5 / AWG 24-14 ■ Wire end ferrule [mm2] ■ 0.25-1.5 / AWG 24-16 ■ Double wire-end ferrule [mm2] ■ 2x (0.25–0.75) Display elements Tab. 6 Status LEDs Technical data, all I/O modules Technical data I/O-block and individual modules No.: 901735 00 E Feature Value Bus Controller X20BC0087-C01 Bus KAESER SIGMA NETWORK Transfer rate [MBit/s] 10/100 Characteristics Auto crossing (Auto-MDI(X) ), Auto negotiation Connections 2 x SIGMA NETWORK -socket RJ45, 10/100Base-TX Max. length of the line between two compo‐ nents [m] 100 Electrical isolation SIGMA NETWORK -I/Omodule Yes 24 V DC power supply X20PS9400 Power supply [V DC], [A] 24 (−15 % / +20 %), max. 0.7 Potential separation — ■ Supply - internal bus ■ Yes ■ Supply - I/O module ■ No Digital inputs (DI) Module 6DI – X20DI6371 Input voltage [V DC 24 (-15 % / +20 %) Model. Input current at 24 V DC [mA] 3.75 Switching threshold [V DC] Low <5 , High >15 Insulation voltage between channel and bus [Veff] 500 Digital outputs (DOT) Module 6DOT – X20DO6322 Output voltage [V DC] 24 Output current per output maximum (overvolt‐ age and short-circuit proof) [A] 0.5 Output protection Thermal shut-down at overvoltage or short-cir‐ cuit, integrated protection for switching inductive loads Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 2 Technical Specifications 2.4 Components within the control cabinet Digital outputs (DOT) Module 6DOT – X20DO6322 Insulation voltage between channel and bus [Veff] 500 Analogue Inputs (All) Module 4AlI – X20AO2632 Measuring range [mA] 0-20 Resolution [bit] 15 Connection type Active and passive possible (2 conductor and 4 conductor technology) Ohmic resistance (internal) [Ohm] < 400 Input protection Protection against supply voltage wiring Maximum error in 25 °C range from currently measured value [%] 0.08 Maximum error in 25 °C offset from final value of 0.02 measuring range [%] Tab. 7 2.4.2 Distribution 24 VDC Module 6x 24 VDC - X20PD2113 Nominal output voltage [V DC] 24, Ground Output current, total [A] 6.0 Fusing (internal, replaceable) [A], [mm] T6.3, 5x20 Technical data I/O-block and individual modules I/O Modules (only SBU) The following technical data apply to the individual I/O modules used only in SBU : Feature Value Connection terminals Push-in terminal Connection diameter Copper wires ■ Wire/single-core [mm ] ■ 0.08-2.5 / AWG 28-14 ■ Flex/fine-core [mm ] ■ 0.25-2.5 / AWG 24-14 ■ Wire end ferrule [mm2] ■ 0.25-1.5 / AWG 24-16 ■ Double wire-end ferrule [mm2] ■ 2x (0.25–0.75) Display elements Tab. 8 Technical data, all I/O modules 2.4.2.1 Module 4AIR – X20AT4222 Status LEDs Feature Value Analogue inputs for PT100 IEC/EN 60751 Range [ °C ] −200 – +850 Resolution [Bit] 16 Connection type Two-wire and three-wire technology Measuring current [µA] 250 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 2 Technical Specifications 2.4 Components within the control cabinet Feature Value Maximum error in 25 °C range from current measured value [%] 0.037 Maximum error in 25 °C offset from final value of 0.0015 measuring range [%] Isolation voltage input–internal bus [Veff] Tab. 9 Data, 4AIR module 2.4.2.2 Module 4AOI – X20AO2632 500 Feature Value Analogue outputs 0–20 mA Output range [mA] 0-20 Resolution [bit] 15 Max. ohmic resistance [Ohm] 500 Output protection Short-circuit-proof, current-limiting 40 mA Maximum error in 25 °C range from current measured value [%] 0.045 Maximum error in 25 °C offset from final value of 0.025 measuring range [%] Isolation voltage output–internal bus [Veff] Tab. 10 2.4.2.3 Data, 4AOI module Module 4AIP – X20AP3121 Feature Value Voltage, analogue inputs ■ ■ ■ No.: 901735 00 E 500 Nominal voltage phase–phase max. [V AC], ■ [Hz] ■ Nominal voltage phase–N max. [V AC] ■ Maximum overload voltage 480 at 50/60 277 1.5xUN permanent, 2xUN for 1 minute Current, analogue inputs ■ Maximum overload current ■ 8xIN for 0.5s ■ Resistance [mOhm] ■ 500 Measuring accuracy — ■ URMS and IRMS [%] ■ < 0.5 ■ Power [%] ■ < 0.5 Potential separation — ■ Inputs–internal bus ■ Yes ■ Input–input ■ No Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 2 Technical Specifications 2.4 Components within the control cabinet Feature Value Isolation voltage — ■ Inputs–Internal bus [V DC] ■ 5500 ■ Inputs–earth [V DC] ■ 5500 Tab. 11 Data module 4AIP 2.4.3 Relay block The relay block comprises 5 relays ( SAM 2 ) or 6 relays ( SBU ) with the following technical data: Feature Value Connection terminals Push-in terminal Connection diameter Copper wires ■ Wire/single-core [mm ] ■ 0.14-1.5 / AWG 26-16 ■ Flex/fine-core [mm2] ■ 0.14-1.5 / AWG 26-16 ■ Wire end ferrule [mm2] ■ 0.14-1.5 / AWG 26-16 ■ Double wire-end ferrule ■ not possible Stripping length [mm] Display elements Status LED Coil voltage [V DC] 24 Output contact 1 changeover contact ■ Switching voltage [V] ■ 5 (at 100 mA) – 250 V AC/DC ■ Min. switching current [mA] (at 12 V) ■ 10 ■ Max. constant current [A] ■ ■ Switching capacity IEC 60947/DIN VDE 0660 24 V DC13 [A] ■ — 230 V AC15 [A] 10 Inductive loads (e.g., auxiliary contact, solenoid valve) to be connected with RC elements Rated isolation voltage [V AC] 250 Tab. 12 Relay block data 2.4.4 SIGMA NETWORK Switch 8 port Feature Value KAESER SIGMA NETWORK ports Transfer rate [Mbps] 10/100 Transfer mode Store-and-forward switching mode Characteristics Auto crossing (Auto-MDI(X) ), Auto negotiation, Auto sensing Connections RJ45, 10/100Base-TX Max. conduit length between two components [m] 100 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 2 Technical Specifications 2.4 Components within the control cabinet Feature Value Power supply [V DC] 9–48, @ 24 V DC/200 mA Display elements Status LEDs for voltage and every port Tab. 13 Data switch 2.4.5 Protocol converter SIGMA NETWORK / PROFIBUS master Feature Value SIGMA NETWORK — ■ Transfer rate ■ 10/100 ■ Properties 1 ■ Auto crossing ■ Properties 2 ■ Auto negotiation ■ Max. conduit length between two compo‐ nents [m] ■ 100 PROFIBUS DP Master ■ Transfer rate [kBit/s] ■ 187.5 ■ Interface ■ RS486 floating ■ Connections ■ 9-pole SUB-D socket ■ Max. conduit length for the entire bus length ■ [m] Power supply [V DC] 24 +/-25 %, typ. @ 130 mA Display elements Status LED Service interfaces Mini USB, slot for MMC memory card, rotary switch Tab. 14 Data, SNW/DP bus controller 2.4.6 SAM 2 -Terminal 2.4.6.1 Industrial computer 2.4.6.2 800 ■ Industrial computer with Quad core processor ■ 2 GB RAM ■ 16 GB flash memory ■ Buffer battery for real-time clock ■ Voltage and temperature monitoring ■ Update-capable with SD memory card Interfaces The positions of the interfaces X1–X5 are marked on the rear of the SAM 2 terminal. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 11 2 Technical Specifications 2.4 Components within the control cabinet Interface Connection Marking Slot for KAESER communication modules X1 Battery 2) For additional buffer battery X2 SD card Slot for SD/SDHC/SDXC memory card X3 USB 2.0 1) For service purposes only X4 USB 3.0 1) For service purposes only X5 RJ485 socket (10/100Base T) X6 RJ485 socket (1000Base T) X7 Power supply, protected against polarity reversal X8 Equipotential bonding 6.3 mm flat plug X9 Com modules 1) SIGMA NETWORK Ethernet 1 Gb 24 V DC FE Tab. 15 1) Slot/interface covered: Remove the cover if a communication module is installed. 2) Slit covered: Remove the cover if an additional buffer battery is installed (see chapter 10.2). Interfaces SAM 2 Identification with RFID Equipment Card Tab. 16 2.4.6.3 Feature Value Integrated hardware RFID write/read device Hardware (external) KAESER Equipment Card Recognition in maximal distance [m] 0.05 Frequency [MHz] 13.56 RFID Display Feature Value Display model Colour display with touch screen Display resolution [px1)] 1280 x 800 Format 12,1”; 16:10 Background lighting Model LCD; industrial version Touch operation Sensor keys 1) Tab. 17 12 LED Capacitive px ≙ Pixel Display data Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 2.4.6.4 Technical Specifications 2.5 Control cabinet Software SAM 2 terminal: 2.5 ■ Operating system: Linux ■ KAESER controller software ■ KAESER user interface Control cabinet Terminal and control cabinet Fig. 1 Control cabinet dimensions 483 mm 540 mm 380 mm Model SAM 2-4 Material SAM 2-16 15 Enclosure protection No.: 901735 00 E SAM 2-8 Enclosure: Sheet metal, painted RAL 9007 grey Cover: Plastic, RAL 7016, anthracite grey Mass [kg] Tab. 18 80 mm 284 mm IP54 Control cabinet data Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 13 2.6 Technical Specifications 2.6 Pressure transducer Pressure transducer Models I and II pressure transducers Model II Measurement range [bar] 0-1 0–6/10/16/20/32/45 Overload limit [bar] 3.5 double final pressure ≤ 0.5 ≤ 0.5 (0.25 typical) G 1/2 B DIN 16288 Stainless steel G 1/4 A DIN 3852 Stainless steel Viton seals Nominal temperature range [ °C ] –20...+80 –25...+85 Nominal temperature range [K] 253-353 248-358 Fluid temperature range [ °C ] –30...+100 –40...+100 243-373 233-373 –40...+100 –40...+100 233-373 233-373 Temperature influence / 10 K over the range [%] ± 0.2 ± 0.15 Temperature influence / 10 K over the range [%] ± 0.2 ± 0.15 Output signal (two-wire technique) [mA] 4-20 4-20 PG 11 PG 9 Stainless steel Stainless steel Enclosure protection IP 65 IP 65 Tightening torque [Nm] 17-20 17-20 III Vacuum pump 0-16 – – 0-1 32 ≤ 1 (0.5 typical) ≤ 1 (0.5 typical) Air connection, male thread G 1/2 A G 1/2 A Air connection, male thread G 1/8 A G 1/8 A Rated temperature range [ °C ] –25...+85 –25...+85 Rated temperature range [K] 248-358 248-358 Fluid temperature range [ °C ] –30...+125 –30...+125 243-373 243-373 –50...+100 –50...+100 Deviation of characteristic from final value Limit setting [%] Air connection, male thread Fluid temperature range [K] Storage temperature range [ °C ] Storage temperature range [K] Power supply connection (plug to EN 175301-803) Enclosure Tab. 19 Models I and II pressure transducers Pressure transducer model III and vacuum Model Measurement range [bar] Measurement range, absolute [bar] Overload limit [bar] Deviation of characteristic from final value Limit setting [%] Fluid temperature range [K] Storage temperature range [ °C ] 14 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 2 Technical Specifications 2.6 Pressure transducer Model III Vacuum pump 233-373 233-373 Temperature influence / 10 K over the range [%] ± 0.4 ± 0.4 Temperature influence / 10 K over the range [%] ± 0.4 ± 0.4 Output signal (two-wire technique) [mA] 4-20 4-20 Power supply connection (plug to EN 175301-803) PG 9 PG 9 Enclosure brass brass Enclosure protection IP 65 IP 65 Tightening torque [Nm] 17-20 17-20 Storage temperature range [K] Tab. 20 No.: 901735 00 E Pressure transducer model III and vacuum Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 15 3 Safety and Responsibility 3.1 Basic instructions 3 Safety and Responsibility 3.1 Basic instructions DANGER Disregarding these instructions can result in serious injury. ➤ To operate the product SAM 2 safely, read the service manual carefully and take notice of its contents. The product SAM 2 is manufactured to the latest engineering standards and acknowledged safety regulations. Nevertheless, dangers can arise through the operation: ■ danger to life and limb of the operator or third parties, ■ impairments to the SAM 2 and other material assets. ➤ Therefore, observe the following: 3.2 ■ Use the product SAM 2 only if it is in a technically perfect condition and only for the pur‐ pose for which it is intended; observe all safety measures and the instructions in the serv‐ ice manual. ■ In particular, immediately rectify (have rectified) any faults that could be detrimental to safety. Intended use Specified use also includes compliance with the instructions in this manual. The product SAM 2 is intended exclusively for the operation of compressors, blowers and vacuum systems in industrial fields and may only be operated within its associated control cabinet. Any oth‐ er use is considered incorrect. The manufacturer is not liable for any damages that may result from incorrect use. The user alone is liable for any risks incurred. ➤ Comply with the instructions in this operating manual. ➤ Operate the product only within its performance limits and under the permitted ambient condi‐ tions. 3.3 Improper use Specified use also includes compliance with the instructions in this manual. Converting or changing the SAM 2 constitutes improper use. The manufacturer's warranty is made invalid in such cases. Improper usage can cause damage to property and/or (severe) injuries. 1. Use SAM 2 only as intended. 2. Do not use SAM 2 to control other machines or products for which SAM 2 is not intended. 3. Do not allow conversions or changes. 16 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 3.4 3.4.1 Safety and Responsibility 3.4 User's Responsibilities User's Responsibilities 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 equipment. 3.4.2 Qualified personnel These are people who, by virtue of their training, knowledge and experience as well as their knowl‐ edge of relevant regulations can assess the work to be done and recognise the possible dangers involved. Authorised operators possess the following qualifications: ■ are of legal age, ■ are conversant with and adhere to the safety instructions and sections of the service manual relevant to operation, ■ have received adequate training and authorisation to operate electrical and compressed air de‐ vices. Authorised installation and maintenance personnel have the following qualifications: ■ are of legal age, ■ have read, are conversant with and adhere to the safety instructions and sections of the serv‐ ice manual applicable to installation and maintenance, ■ are fully conversant with the safety concepts and regulations of electrical and compressed air engineering, ■ are able to recognise the possible dangers of electrical and compressed air devices and take appropriate measures to safeguard persons and property, ■ have received adequate training and authorisation for the safe installation and maintenance on this equipment. ➤ Ensure that operating, installation and maintenance personnel are qualified and authorised to carry out their tasks. 3.5 Dangers The general safety instructions in this chapter describe possible dangers and how to deal with them. Special safety instructions are found in this service manual at the beginning of each chapter or directly before a task instruction. ➤ Take full heed of all safety instructions. 3.5.1 Safely dealing with sources of danger Electricity ➤ Disconnect the machine from all power supply phases. ➤ Switch off any external power sources. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 17 3 Safety and Responsibility 3.6 Warranty Voltage is still present on the marked terminals (orange or labelled) in the SAM 2 when the power supply is switched off. ➤ Check and ensure that no power is present. ➤ Before switching on again make sure that ■ no maintenance personnel are working, ■ all panels are in place, ■ all access doors are closed. ➤ Allow only qualified electricians or trained personnel under the supervision of a qualified electri‐ cian to carry out work on electrical equipment according to electrical engineering regulations. ➤ Observe all accepted safety regulations and national legislation applicable to all work carried out on the SAM 2 . ➤ Use fusing according to current draw (see chapter 2). ➤ Make electrical connections only with power removed and check regularly for tightness and condition. ➤ Use only electrical cables that are suitable and approved for the surroundings and electrical loads applied. ➤ Before every start-up by the user of machines that are linked to the master controller, make sure there is adequate protection against electric shock from direct or indirect contact and check regularly. 3.5.2 Safe SAM 2 operation Pay attention to the following points to avoid damage to the SAM 2 : ➤ Do not remove any plugs on the SAM 2 while the compressed air system is in operation. ➤ Operate the SAM 2 only when all supplies are connected. 1. WARNING! A short circuit can cause irreversible damage to the PROFIBUS interface. ➤ Avoid short-circuits. 2. Avoid short circuits on the power supply pins in the PROFIBUS interface for PROFIBUS/ SIGMA NETWORK converter. ➤ Never modify, bypass or disable safety devices. ➤ Do not remove or obliterate labels and notices. ➤ Use only spare parts approved by the manufacturer for use in SAM 2 . 3.6 Warranty This service manual does not contain any independent warranty commitment. Our general terms and conditions apply with regard to warranty. Prerequisite for granting warranty is the intended and proper use of the product in compliance with the specific application conditions. In view of the multitude of potential applications, it is the duty of the operator to verify that the prod‐ uct is suitable for the actual application. Furthermore, we do not assume any warranty obligation for damages caused by: 18 ■ the use of unsuitable parts or operating materials, ■ arbitary modifications, Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 3 Safety and Responsibility 3.6 Warranty ■ incorrect maintenance, ■ incorrect repair. Correct maintenance and repair means the use of genuine Kaeser spare parts. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 19 4 Design and Function 4.1 Overview 4 Design and Function 4.1 Overview The SAM 2 is used for the control, regulation and monitoring of stations comprising multiple com‐ pressors, blowers or vacuum machines in a commercial environment. SAM 2 reacts flexibly to fluc‐ tuating compressed air demand and thus reduces energy consumption. The system takes into ac‐ count machine run times and deployment priorities. Important parameters are clearly represented as coloured graphic elements. The high-resolution touch screen enables user-friendly settings. SAM 2 is offered as: ■ SAM 2-4 ■ SAM 2-8 ■ SAM 2-16 They differ in the number of controllable machines (see chapter 2 "Design variants and options"). Using the SBU , you can flexibly expand the number of interfaces. SAM 2 comprises the following components: ■ The central pressure transducer measures the pressure in the air network and passes the val‐ ue to SAM 2 . ■ The processing unit of the SAM 2 decides according to default parameters, which machines are switched to load to keep the pressure in the air main constant. All data are clearly graphi‐ cally represented. You can analyse and archive the data provided. ■ The display and control panel of the touch screen provides information on current pressure and other parameter values and offers various possibilities for individual settings. Compressors with SIGMA CONTROL and SIGMA CONTROL 2 as well as those with conventional controllers can be linked to SAM 2 . 20 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E Fig. 2 Design and Function 4.1 Overview SAM 2 – Standard design of a compressed air station No.: 901735 00 E SAM 2 SIGMA CONTROL 2 SIGMA CONTROL SBU Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM I/O lines to machines and sensors SIGMA NETWORK PROFIBUS Analogue input for pressure transducer 21 Design and Function 4.2 Operating panel 4.2 Operating panel Fig. 3 Operating panel SAM 2 Tab. 21 22 No. Sign Operating element Key illumination Function Description Touch screen — Operation of SAM 2 functions Chapter 4.3 "Touch screen" RFIL write/read — device Log-on with RFID Equipment Card Chapter 4.4 "User log-on" Button remote control Green Activation and deactivation of the remote operation. Button time control Green Switch the clock on or off Button automatic Green Switch the station between man‐ ual and automatic mode. Button station On/Off Green/red Compressed air station activation Chapter 7.2 8.1 (air supply) or Switch on deactivation (ATTENTION: no air "SAM 2" supply!) — Operating panel SAM 2 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 4.3 Design and Function 4.3 Touch screen Touch screen The touch screen menu is arranged as follows: Fig. 4 No.: 901735 00 E Touch screen menu No. Menu element Function Description Device selection list Selection of machines, individually or by groups — Product designation — — SAM 2 model e.g., SAM 2-4 — System status Traffic lights function: green: Operation yellow: Maintenance/warning red: Fault (air supply is endangered!) — Operating mode Display of the set operating mode — Pressure chart Display of current system pressure — Access mode Display of current access mode: Chapter 7.4 "User log-on" ■ — (logged out) ■ Operating ■ Monitoring Status Call up Status menu Chapter 8.3.1 "Main menu" Messages Call up Messages menu Chapter 9.2 "Messages" Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 23 4 Design and Function 4.4 User log-on with RFID No. Menu element Function Description 10 Control Call up Control menu Chapter 7.12 "Control" 11 SAM 2.Logic Logic functions are programmed here 12 Time control Call up Timer menu 13 Process control Call up Control technology menu 14 Start-up Menus for commissioning the compressed air station Chapter 7 "Initial Start-up" 15 Configuration Configuration menus for SAM 2 Chapter 7 "Station" 16 Info Call up Help menu Chapter 8.2 "Help function" 17 KAESER Service Support Call up Contact menu — 18 Display Touch screen display for graphics, messag‐ — es and data 19 Device selection UP/DOWN Device selection list; scrollbar provided for more than 10 devices Tab. 22 4.4 — Touch screen menu elements User log-on with RFID The KAESER Equipment Cards provide various functionalities: ■ Switch between three operating modes: ─ Logged out ─ Monitoring ─ Operating ■ Encryption ensures security ■ Different access levels for the customer (Equipment Card) and Service (Key) The system records which user is when logged on at SAM 2 . You can thus determine who was logged on when specific messages or other events have occurred. Fig. 5 User management with RFID 24 SAM 2 KAESER Equipment Card KAESER Key Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 4.5 Design and Function 4.5 Main menu Main menu The menu has the following sub-menus: ■ "Net pressure station" ■ "Net pressure" ■ "Current values" ■ Total values ■ "Drag Indicator" ■ "View station" If the menu page displayed has several sub-menus, touch one of the tabs to open the correspond‐ ing sub-menu. 4.5.1 Menu tree The menu elements and sub-menus available from the main menu depend in part on the se‐ lected machine or the multiple machines selected at once. Main menu element Sub-menu element Status ■ Chapter 8.3.1 "Overview" ■ Chapter 8.3.5 "View station" ■ Chapter 9.2 "Unacknowledged messages" ■ Chapter 9.2 "Current reports" ■ Chapter 9.2 "Message history" ■ Chapter 7.12 Settings ■ Chapter 7.12 Pressure parameters SAM 2.Logic ■ Chapter "Editor" Time control ■ Chapter Status ■ Chapter Editor ■ Chapter Status ■ Chapter Editor ■ Chapter 7.3 Station ■ Chapter 7.11 "P+I diagram" ■ Chapter 7.10 SIGMA NETWORK ■ Chapter 7.10 PROFIBUS ■ Chapter 7.7 "E-Mail" ■ Chapter 7.6 "Unit settings" ■ Chapter "User management" ■ Chapter 11.4 "Software versions" ■ Chapter 7.5 "Date and time" ■ Chapter 7.9 "Data recording" ■ Chapter 7.3 "Language" Messages Control Process control Start-up Configuration No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 25 4 Design and Function 4.6 Operation and function Main menu element Sub-menu element ■ Tab. 23 4.6 Chapter 7.10 "Peripherals" Menu tree Operation and function SAM 2 has been developed for a multitude of possible applications. Generally, most of the default settings can be kept or have to be changed only slightly. 4.6.1 Adaptive 3D control The adaptive 3D control minimises the energy requirements of the compressed air station by auto‐ matically adapting to the operating conditions. It automatically adapts the selection of the machines to be activated and deactivated as well as the cut-out and cut-in pressures for the selected machines to the current operating conditions of the compressed air station. 4.6.2 Base load sequencing The controller will equally use machine of the same size. The standard for comparison is the num‐ ber of operating hours. The machine with the least number of operating hours is used the most. 4.6.3 Time control The compressed air system can be operated via an integrated timer. There are 32 switching points per week available. 4.6.4 Power limiting If the power limiting function is activated, the system will add machines only to the point where the overall load capacity of the running machines exceeds the specified power limit. The nominal pres‐ sure and the maximum speed are used for calculating the overall load capacity. 4.6.5 Air main charging After the activation of the compressed air station, the air network is charged at the specified net‐ work charging speed. 4.6.6 EMERGENCY operation A compressed air station can run in EMERGENCY operation if each machine has its own system pressure switch or presser control system. This is always the case with KAESER rotary screw compressors. Compressed air systems with rotary blowers or reciprocating compressors may or may not have machines provided with their own system pressure switches. Stations with machines without system pressure switches cannot operate in EMERGENCY mode. These compressed air systems cannot deliver compressed air without SAM 2 . 26 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 4 Design and Function 4.6 Operation and function Compressor stations with EMERGENCY mode (manual mode) EMERGENCY mode can cause large pressure swings in the air main. The connected machines are automatically switched to EMERGENCY mode: ■ When the voltage supply of SAM 2 fails in activated state ■ When the connection to the pressure transducer is interrupted ■ When SAM 2 itself fails The machines then run under their internal pressure regulation, independent of SAM 2 . The ma‐ chines can be manually switched to EMERGENCY operation (manual mode) for test purposes. Compressor stations without EMERGENCY mode (manual mode) No compressed air is delivered without SAM 2 . The output relays switch off: ■ When the voltage supply of SAM 2 fails ■ When the connection to the pressure transducer is interrupted ■ When SAM 2 itself fails This causes the connected machines to switch to idle or off. The compressed air system no longer delivers compressed air. 4.6.7 Visualisation at external devices The user interface of SAM 2 can be represented at an external computer (PC, laptop, tablet). For this purpose, SAM 2 must be connected to the external computer via the Gigabit Ethernet connec‐ tion X7, directly via a network cable or indirectly (network). A web browser is used for the visualisa‐ tion. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 27 5 Installation and Operating Conditions 5.1 Environment 5 Installation and Operating Conditions 5.1 Environment Temperature range Ambient temperatures Tab. 24 Min. ambient temperature Maximum ambient temperature 0 °C 45 °C Ambient temperatures Storage temperatures Tab. 25 Minimum storage temperature Maximum storage temperature −20 °C 70 °C Storage temperatures Comply with permissible ambient temperatures: 1. Check ambient temperature. 2. Adjust equipment location to suitable ambient temperature range. Comply with the specified storage temperature: 1. Check temperature of storage location. 2. Determine the storage location according to a suitable temperature range. 5.2 Installation conditions SAM 2 is designed for the operation in an industrial environment with proprietary supply network separated from the public supply by a transformer or generator. ➤ Install SAM 2 as appropriate. 28 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 6 Installation 6.1 Installation 6 Installation 6.1 Installation Connection Tab. 26 No.: 901735 00 E SIGMA CONTROL and SIGMA CONTROL 2 Conventional Description Ensuring safety Chapter 6.2 "Ensuring safety" Reporting transport dam‐ age Chapter 6.3 "Reporting transport damage" Compressed air supply during installation Chapter 6.4 "Com‐ pressed air supply dur‐ ing installation" Scope of delivery Chapter 6.5 "Scope of delivery" Installing the control cabi‐ net Chapter 6.6 "Installing the control cabinet" Identifying the machines Chapter 6.7 "Identify‐ ing the machines" Connecting the pressure transducer Chapter 6.8 "Connect‐ ing the pressure trans‐ ducer" Planning the wiring Chapter 6.9 "Planning the wiring" Laying cables Chapter 6.10 "Laying cables" Creating SIGMA NETWORK − Chapter 6.10.1 Creat‐ ing "SIGMA NETWORK" Creating the PROFIBUS network − Chapter 6.10.2 "Creat‐ ing the Profibus net‐ work" Setting up the compres‐ sor station via floating re‐ lay contacts − Chapter 6.10.3 "Set‐ ting up the compressor station via floating re‐ lay contacts" Connecting the cables to SAM 2 Chapter 6.11 Connect‐ ing the cables to "SAM 2" Setting up the machines Chapter 6.12 "Setting up the machines" Installation overview Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 29 6.2 Installation 6.2 Ensuring safety Ensuring safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤ Comply with the instructions in chapter 3 Safety and Responsibility . ➤ This product may only be installed by a qualified person. See chapter 3, "Assigning personnel". When 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 authorised electricians. ➤ Switch off and lock out the power supply disconnecting (isolating) device and check that no voltage is present. ➤ Check that there is no voltage on potential-free contacts. 6.3 Reporting transport damage 1. Check the product for visible and hidden transport damage. 2. Immediately notify the carrier and the manufacturer in writing of any damage. 6.4 Compressed air supply during installation ➤ Check the compressor station's EMERGENCY mode characteristics. 6.4.1 ■ Station with emergency operating mode: Chapter 6.4.1 ■ Stations without emergency operating mode: Chapter 6.4.2 Station with emergency operating mode It is possible to install and commission SAM 2 without shutting down the complete air system. DANGER Mortal danger from electric current ➤ The machine must be free of voltage before work commences. 1. Isolate the machine from all sources of voltage. 2. Make sure the machine is voltage-free. 3. Connect the machine to SAM 2 (chapters 6.9 to 6.10). 4. Put the machine back into operation. 5. Repeat steps 1 to 3 for any further machines. 6. Perform the commissioning and setting as detailed in chapter 7. 30 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 6 Installation 6.5 Scope of delivery 7. Do not switch SAM 2 from manual to automatic mode until these settings have been comple‐ ted. SAM 2 subsequently assumes control of the machines. Further information 6.4.2 For EMERGENCY mode, see chapter "EMERGENCY mode". Stations without emergency operating mode SAM 2 is required for the supply of compressed air. The compressed air system is not operational until initial start-up of SAM 2 is completed. ➤ Switch on the compressor station after commissioning SAM 2 . Further information 6.5 For EMERGENCY mode, see chapter "EMERGENCY mode". Scope of delivery This product comprises at least the following components (depending on the selected configura‐ tion, additional components may be provided): Item Material Name 10 SAM2.1 SAM 2 (SAM 2-4, SAM 2-8 or SAM 2-16) 20 "Pressure-dependent" Pressure transducer 30 2x KAESER Equipment Cards 40 Tab. 27 6.6 — This instruction Standard scope of delivery Installing the control cabinet A solid, vibration-free and load-bearing wall is required for the control cabinet. Take the following criteria into consideration when selecting the installation location and the installation of the control cabinet: ■ The mounting aids must be compatible with the type of wall and the weight of the control cabinet (chapter 2). ■ The control cabinet must be fully accessible. ■ Fully opening control cabinet door. ■ A free escape route must be maintained (also with the control cabinet door fully open). ■ Protection from direct sunlight, rain, splashed water or excessive dust build up must be provided. WARNING Overheating from insufficient ventilation ➤ The space between the wall and the rear of SAM 2 must remain clear to support ventila‐ tion! No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 31 Fig. 6 Installation 6.6 Installing the control cabinet Open the SAM 2 cover Control cabinet cover Base plate Cover with SAM 2 terminal Spagnolet Base 1. Carefully unpack the control cabinet. Protect the sensitive surfaces (e.g., cover 5 with touch screen terminal) from damage. 2. Place the entire control cabinet onto a suitable surface 7 (protected from dirt and scratching) with the base plate 2 pointing downward. 3. Use the control cabinet key (two-way key, 3 mm) to unlock the spagnolet 6 at the control cabi‐ net 1 . 4. Open the cover 5 (in arrow direction). 5. Remove the cables which are connected from the modules on the base plate 2 with the termi‐ nal 5 . Fig. 7 Removing the control cabinet cover Control cabinet cover Base plate Flat mushroom-head screw M 6x16, SW4 Flat mushroom-head screw M 6x16, SW4 6. Separate the control cabinet cover 1 (enclosure cover with SAM 2 terminal) from the base plate 2 as follows. 7. First, use the SW4 wrench to unscrew the two screws 3 , then loosen the two screws 4 and carefully lift the control cabinet cover 1 in arrow direction (see Fig. 7). 32 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 6 Installation 6.7 Identifying the machines 8. Place the control cabinet cover 1 onto a suitable surface 7 (protected from dirt and scratch‐ ing). 9. Properly attach the base plate 2 to the wall. A template for the bore holes is provided in the annex (see chapter 13.1). 10. Wire the control cabinet as described in chapter 6.11. 6.7 Identifying the machines Same model machines have to be identified as well, because the internal pressure regulation can be set differently. ➤ Clearly identify or number the machines. The alarm and service messages displayed on SAM 2 can thus be allocated to the correct ma‐ chine. Identification (machine and SAM 2 ) for remote control The machines and SAM 2 must carry a warning notice when they are in remote mode. ■ Warning notice to indicate the machines. ─ ■ "WARNING": This machine is remotely controlled and can start automatically at any time. Warning notices for identification at SAM 2 . ─ Before starting, make sure that no one is working on the machines and that they can be started safely. Place the notices so they are highly visible. 1. Place warning notices on the machine. 2. Attach a warning notice at SAM 2 . 6.8 Precondition Connecting the pressure transducer The connection point is not under pressure. NOTICE Network pressure too high Damage to the pressure transducer ➤ Never connect the pressure transducer to a pressurised network with a maximum pres‐ sure exceeding the nominal pressure of the pressure transducer. 1. Check the maximum working pressure of the compressed air network. 2. Check the nominal pressure of the pressure transducer. 6.8.1 Mechanical connection The "pressure transducer position" graphic (illustration 8) shows the correct position for the trans‐ ducer: No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 33 Fig. 8 Installation 6.8 Connecting the pressure transducer Pressure transducer position 34 SAM 2 Machine 1 Machine 2 Machine 3 Machine 4 Compressed air generation Service manual SAM 2 10 11 12 Air Treatment Air receiver Shut-off valve Pressure transducer connection point Pressure transducer Maine compresses air outlet SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 6 Installation 6.9 Planning the wiring ➤ Note the following when connecting the pressure transducer: 6.8.2 ■ Connect the pressure transducer either to the side or the top of the air receiver so that no condensate can settle. ■ If the pressure transducer is connected to the main collector pipe, fit a small, additional air receiver (item 8 order separately, see chapter 13.6 for the material number). ■ Fit the pressure transducer downstream of the air treatment components because pres‐ sure losses caused by air treatment components or pipework can occur between the ma‐ chine and the point of measurement. ■ The airflow at the point of measurement must not pulsate. ■ Note the installation depth of the pressure transducer. ■ Install a shut-off valve between the air receiver and the pressure transducer. This allows replacement of the pressure transducer without having to vent the air receiver. Ensure that the shut-off valve cannot be closed during operation. ■ A kit of parts for the air connection is available separately (see chapter 13.6 for the materi‐ al number). Electrical connection Avoid signal distortion by uusingg suitable wiring and screening. 1. Use two conductor screened cable with minimum section 0.75 mm2. 2. The pressure transducer must be earthed. ■ Earth by metallic contact with the air receiver or ■ Use a separate equipotential bonding conductor with a minimum cross-section 1 x 10 mm2 (with, for example, an earth clamp (G 3/4) on the transducer housing). 3. Connect SAM 2 and the pressure transducer at the same equipotential bonding conductor. The potential difference between both earthing points must be zero. 4. Connect the conductor screen at the pressure transducer to earth. C0246 Fig. 9 Connecting the screening 5. Feed the conductor through an EMC cable gland into the control cabinet. 6. Maintain a distance of at least 10 cm between the connecting cable and power cables. 6.9 Planning the wiring There are several methods of linking the machines to SAM 2 or SBU : ■ No.: 901735 00 E Using SIGMA NETWORK (for machines with SIGMA CONTROL 2 ), see chapter 6.10.1. Prerequisites: A SIGMA NETWORK port is provided for every machine. Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 35 6.9.1 Installation 6.9 Planning the wiring ■ PROFIBUS (when replacing a SIGMA AIR MANAGER with SAM 2 or for machines with SIGMA CONTROL 2 ), see chapter 6.10.2. Prerequisites: The PROFIBUS master option is available. ■ Using floating relay contacts (for conventional machines without SIGMA CONTROL or SIGMA CONTROL 2 ; see chap‐ ter 6.10.3). Prerequisites: At least one I/O Port DI and DOR is available for every machine. SIGMA NETWORK The SIGMA NETWORK subscribers are linked in a star pattern. All SIGMA NETWORK wires start from SIGMA NETWORK hub installed in SAM 2 or SBU . Fig. 10 SIGMA NETWORK design 6.9.2 SAM 2 SBU with option SIGMA NETWORK ports Machine with SIGMA CONTROL 2 PROFIBUS network PROFIBUS wiring is used when a SIGMA AIR MANAGER is replaced by SAM 2 in machines with SIGMA CONTROL or SIGMA CONTROL 2 with a PROFIBUS communication module. ThePROFIBUS subscribers are connected in series, that is, one after another. SAM 2 or SBU are located at the end of the bus. A terminating resistor can be activated in every PROFIBUS plug. At the start and at the end of the bus cable, this resistor must be set to ON. In all other PROFIBUS plugs within the network, you must set the terminating resistors to OFF. 36 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E Fig. 11 Installation 6.9 Planning the wiring Structure of a PROFIBUS network – SAM 2 with Option E1: PROFIBUS master Fig. 12 PROFIBUS plug with terminating resistor position: ON PROFIBUS plug with terminating resistor position: OFF Structure of a PROFIBUS network – SBU with Option E1: PROFIBUS master 6.9.3 SAM 2 Machine with SIGMA CONTROL or SIGMA CONTROL 2 SAM 2 SBU Machine with SIGMA CONTROL or SIGMA CONTROL 2 PROFIBUS plug with terminating resistor position: ON PROFIBUS plug with terminating resistor position: OFF Floating contacts The connection of conventional machines without SIGMA CONTROL or SIGMA CONTROL 2 via floating contacts is realised in star pattern, that is, each machine is directly connected to SAM 2 or SBU if more I/O conductors are required. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 37 Fig. 13 Installation 6.9 Planning the wiring Configuration of the network with floating relay contacts SAM 2 SBU 6.9.4 Instructions on the electrical installation ■ A supply disconnecting device to EN 60204 must be installed by the user. ■ Do not exceed the following maximal values for the cable lengths: Model Tab. 28 6.9.5 Machine with SIGMA CONTROL or SIGMA CONTROL 2 Machine connected via floating relay con‐ tacts Maximum cable length [m] Remark SIGMA NETWORK 100 Maximum cable length between two SIGMA NETWORK compo‐ nents. Digital transistor outputs 30 Digital relay outputs 100 Digital inputs 30 Analogue inputs 30 screened PROFIBUS 800 Maximum cable length of the en‐ tire PROFIBUS. Maximum cable lengths ■ Use galvanic isolation on cables laid outside the building to ensure increased lightning protec‐ tion (preferably fibre optic cable). ■ See chapter 2 for conductor types and cross-sections and the wiring diagram in chapter 13.8 for cable selection. We recommend to use flexible stranded wires wherever possible. ■ This suppressor is suitable for inductive loads connected to the relay outputs. Prerequisites and accessories required for connection with SIGMA NETWORK Prerequisites: For each SIGMA NETWORK device ( SIGMA CONTROL 2 machine, SBU ) a SIGMA NETWORK port is provided. 38 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 6 Installation 6.9 Planning the wiring The following accessories are required for the construction of a SIGMA NETWORK (see annex for material numbers): 6.9.6 ■ SIGMA NETWORK cable. ■ For SAM 2 : One RJ45 bus connector for every SIGMA NETWORK to be connected. ■ For SBU : One RJ45 bus connector for every SIGMA NETWORK to be connected. ■ For every SIGMA CONTROL 2 machine: LAN RJ45 retrofit kit. Prerequisites and accessories connection with PROFIBUS Prerequisites: PROFIBUS master option When replacing a SIGMA AIR MANAGER with a SAM 2 , you can connect the existing PROFIBUS to SAM 2 without additional equipment. The following accessories are required for the wiring machines to SIGMA CONTROL 2 (see annex for material numbers): 6.9.7 ■ PROFIBUS cable ■ For SAM 2 or SBU : PROFIBUS connector ■ For every machine with SIGMA CONTROL: PROFIBUS plug set for SIGMA CONTROL Requirements for connecting with floating relay contacts Connect a floating output from SAM 2 or SBU in series with the existing pressure regulation (main pressure switch or electronic pressure regulation) of the machine. Avoid overload of the electric supply caused by simultaneous starting of compressors con‐ nected by floating relay contacts. You can stagger the start times by installing a timing relay in some compressors. In stations with EMERGENCY operation, compressors connected via floating relay contacts will start when the compressor pressure is below the compressor's cut-in pressure and one of the following conditions is met: ■ The voltage supply at SAM 2 and the compressor fails and returns simultaneously. ■ The voltage supply at SAM 2 fails but not at the compressor. ■ SAM 2 fails. Required equipment for machines to be connected to SAM 2 SAM 2 design Equipment Up to 4 machines are connected via floating relays contacts to SAM 2 or SBU : SAM 2-4/SAM 2-8 An "external load control" input. An additional "motor running" floating relay contact (normally open) is recom‐ mended. More than 4 machines are connected via floating relays contacts to SAM 2 or SBU : No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 39 6 Installation 6.10 Laying cables SAM 2 design Equipment SAM 2-16 A "manual/automatic mode" / "LOAD/IDLE" control input with a system pres‐ sure switch in manual mode (-B1.1). A "pressure switch in series with SAM 2 ” (-B1) or a pressure switch blow-off protection pressure reliaf valve (-B6). A "motor running" floating relay contact (normally open). A "ON and no alarm" floating relay contact (normally open). Tab. 29 Required equipment If a machine is not prepared for connection to SAM 2 , it can be retrofitted. Documents and parts for the retrofit are available separately. 6.10 Laying cables DANGER Contact with live electric components can cause serious injury or death. ➤ De-energise SAM 2 / SBU and external power sources. 1. Switch off all phases of SAM 2 / SBU and external power sources. 2. Lock against reactivation. 3. Observe all accepted safety regulations and national legislation applicable to all work carried out on the SAM 2 / SBU . 4. Have SAM 2 / SBU connected to the power supply by an authorised and qualified electrician to national legislation and the regulations of the electricity company concerned. The terminals of SAM 2 / SBU must be identified with one of the following alternatives as they may carry voltage even when the power supply is shut off. ■ Orange ■ Label 5. Create the connections to the power supply, the individual machines and the component as detailed in the circuit diagrams. 6.10.1 Creating SIGMA NETWORK 1. Lay SIGMA NETWORK cables. ■ For details to create SIGMA NETWORK , see Fig. 10. ■ For details of the connection at the machine, see the description for "LAN retrofit kit SIGMA CONTROL 2 ". ■ For details of the connection at SAM 2 or SBU , see chapter 6.11. 2. For maximal cable lengths, see chapter 6, "Notes to the electrical installation". 40 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 6.10.1.1 Installation 6.10 Laying cables Installing the RJ45 bus connector To connect to SIGMA NETWORK , you must connect the network subscribers according to the SIGMA NETWORK conduit. ■ Feed the network cable to the SIGMA NETWORK devices on both sides through one EMC screw fitting. ■ Use an RJ45 bus connector at both ends of the network cable. Installing the RJ plug Fig. 14 Strip the isolation from the network cable. Orange Blue Yellow White 18 mm 5 mm 1. Stripping the network cable isolation (see Fig. 14). The RJ45 plug and the network cable can be damaged if unlocked under strain. ➤ Always release strain on the RF45 plug prior to unlocking. 2. Spread the conductors according to the colour coding of the contact element of the RJ45 con‐ nector (see Fig. 14). Fig. 15 Inserting the network cable conductors 3. Insert the conductors into the contact elements up to the end stop. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 41 Fig. 16 Installation 6.10 Laying cables Positioning the network cable 4. Position the network cable as shown (arrows, see Fig. 16). Fig. 17 Close the lid of the RJ45 plug. RJ45 plug lid Rotatable locking piece 5. Close the lid and manually rotate the locking piece clockwise as far as possible. Fig. 18 Rotating the locking piece to the stop 42 RJ45 plug (view from cable end) Screwdriver Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 6 Installation 6.10 Laying cables 6. Insert a screwdriver with 2.5 mm blade width into the bore and rotate the locking piece clock‐ wise up to the end stop. Contact issues with conductor ends after multiple contact creation. ➤ Cut off contacted conductor ends and again strip the conductors. The insulation displacement contacts of the plug may be disconnected and re-contacted up to 10 times. Result 6.10.2 The plug is correctly locked when the opening of the locking piece is facing sideways and the side surfaces are flush with the plug. Creating the PROFIBUS network When replacing a SIGMA AIR MANAGER with a SAM 2 , you can connect the existing PROFIBUS to the SAM 2 . 1. Install PROFIBUS cables. ■ See Fig. 11 for details about the creation of a PROFIBUS network. ■ See the installation instructions for the "PROFIBUS retrofit kit“ for details about the ma‐ chine integration. 2. Switch the terminating resistor 3 (see Fig. 11) at both ends of the PROFIBUS to the ON posi‐ tion. 3. See the wiring diagrams in the annex for cable types, cross-sections and maximum cable lengths. 6.10.2.1 Fig. 19 Connecting the PROFIBUS cable Stripping the isolation from the PROFIBUS cable Green conductor Red conductor 5 mm 13 mm 6 mm 1. Strip the isolation from the PROFIBUS cable as shown. 2. Connect the green conductor 1 to the green terminal “A” of the PROFIBUS plug. 3. Connect the red conductor 2 to the red terminal “B” of the PROFIBUS plug. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 43 6.10.2.2 Installation 6.10 Laying cables Installing the PROFIBUS plug NOTICE Too tight a bend radius can cause a defect in the PROFIBUS cables. ➤ Do not bend the PROFIBUS cable. Subscribers in the middle of a PROFIBUS network: Install the PROFIBUS plug at one of the inline subscribers to the PROFIBUS network: Fig. 20 Connection of an inline plug 1. Connect two PROFIBUS cables (input and output) 2. Set the terminating resistor in the PROFIBUS plug to OFF. Subscribers at the end of the PROFIBUS network Install the PROFIBUS plug at a terminating subscriber and at the SAM 2 : Fig. 21 Installation of a terminating PROFIBUS plug 1. Connect one PROFIBUS cable (input only). 2. Set the terminating resistor in the PROFIBUS plug to ON. 6.10.3 Creating the compressor station via floating relay contacts 1. Use conventional wiring. ■ For details of creating a network with floating relay contacts, see Fig. 13. 2. Directly connect each machine with SAM 2 or SBU . 6.10.3.1 Wiring modifications to the machine Interruptions to the air supply caused by unsuppressed inductive loads connected to the relay outputs of SAM 2 or SBU , such as auxiliary contactors or solenoid valves. 44 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 6 Installation 6.11 Connecting lines 1. Suppress inductive loads with an RC interference suppressor. 2. Connect the interference suppressor in parallel directly at the coil (connections A1–A2). If the connections are inaccessible, in solenoid valves for example, the suppressor can also be con‐ nected to the corresponding terminals on the terminal strip. 3. Use an RC interference suppressor suited to the coil voltage and apparent holding power, see chapter 13.6. Machine with "external load signal" control input KAESER machines from 1990 onwards with terminal 32W: Fig. 22 Remove the wire jumper. ➤ Remove the jumper between the terminals (terminals 32W and 21 or 18) to allow sequencing. Machines without terminal 32W 1. Fit terminal 32W in the terminal strip. 2. Disconnect the conductor A of the mains pressure switch cable connected to terminal 18. 3. Disconnect the conductor A of the mains pressure switch cable connected to terminal 21. 4. Connect the conductor A to terminal 32W. 6.10.3.2 Machine with one control input for "Operating mode Manual/Automatic" / LOAD/IDLE KAESER machines from1990 onwards: If a jumper is connected between the terminals for manual operation [-X1 (W) 20 or 17 and X1 (W) 24 (W)] on the terminal strip for connection of SAM 2 or SBU , then it must be removed. A more precise designation of the terminals is given in the electrical diagrams for the machine. ➤ Remove wire jumper if necessary. 6.11 6.11.1 Precondition Connecting lines Wiring the control cabinet The control cabinet is properly attached to the wall as described in chapter 6.6. The base plate is freely accessible. ➤ Wire the control cabinet as described below. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 45 6.11.2 Installation 6.11 Connecting lines Connecting the equipotential bond 1. Connect the enclosure with a user-supplied equipotential bond at the corresponding equipoten‐ tial bond connection 3 . 2. Keep the connection as short as possible. 3. Use an earth strap or cable with a cross-section of at least 16 mm2. 6.11.3 Fig. 23 Feeding cables and connecting the screening Cable glands with and without ferrite suppressors Metallic cable glands for screened cables (analogue inputs, SIGMA NETWORK , PROFIBUS, cables to the COM module and the user's LAN) Plastic cable glands for unscreened cables (common supply line, digital inputs, digital out‐ puts) Equipotential bond connection (stud) 1. Feed screened cables (analogue inputs, SIGMA NETWORK , PROFIBUS, cables to the COM module and the user's LAN) through the metallic cable glands 1 . Connect the screening as described below. 2. Feed unscreened cables (common supply line, digital inputs, digital outputs) through the plastic cable glands 2 . Connecting the screening At the control cabinet: C0246 Fig. 24 46 Connecting the screening Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 6 Installation 6.11 Connecting lines 1. Strip off the cable insulation by about 1 cm where the cable passes through the cable gland. 2. Push the cable through the metal cable gland on the control cabinet until the stripped section snaps in and contacts the earth clamp in the cable gland. Connecting the screening for the user's LAN Fig. 25 LAN conduit screening 1. Strip off the cable insulation by about 1 cm at the terminal. 2. Ensure electrical contact of the cable screening with the screening clamp. 6.11.4 Fig. 26 Laying the cables in the control cabinet Laying the cables in the control cabinet Cables with voltages up to 24 V (digital inputs, analogue inputs, SIGMA NETWORK , PROFIBUS, cables to the COM module and the user's LAN, relay outputs, if provided) SAM 2 control cabinet Cables with 115/230 V AC voltage (common supply line, relay outputs, if provided) 1. Use cable ties to bundle all 115/230 V AC cables and keep them separate from all other ca‐ bles. 2. Install the bus cables to the SAM 2 terminal so that they will not be kinked by opening and closing the cover. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 47 6.11.5 Installation 6.12 Setting up the machines Connecting the cables 1. Make the connections to terminals and interfaces as detailed in the attached wiring diagram. 2. Connect external sensors according to the wiring diagram in the annex. 3. For installing the RJ45 bus connector, see chapter 6.10.1. 4. For installing the the PROFIBUS plug, see chapter 6.10.2. 6.11.6 Precondition Fig. 27 Installing the control cabinet The base plate of the control cabinet is properly attached to the wall (see chapter 6.6). The control cabinet is fully wired (see chapter 6.11.1). Installing the control cabinet Control cabinet cover Base plate Screw M 6x16, SW4 Screw M 6x16, SW4 SAM 2 terminal Spagnolet 1. Mount the control cabinet cover 1 on the base plate 2 . 2. Install the control cabinet cover 1 , using the four screws 3 and 4 on the base plate 2 . 3. Connect the internal cables leading from the base plate 2 to the SAM 2 terminal 5 . 4. Close the SAM 2 terminal 5 . 5. Lock the spagnolet 6 at the control cabinet cover 1 with the control cabinet key (two-way type, 3 mm). 6.12 Setting up the machines NOTICE Damage to drive motors can occur when the permissible motor starting frequency is excee‐ ded on machines without idle control (piston compressors, blowers). ➤ Set the SAM 2 pressure band to a width which ensures that the switching frequency is not exceeded. ➤ If necessary, increase the capacity of the air receiver. 48 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E Precondition Installation 6.12 Setting up the machines The settings described in this section must be entered in full for every machine to ensure faultless operation. Make sure that the compressed air system remains in operation should the SAM 2 fail. ➤ Carry out settings as detailed in this manual. 6.12.1 Integration with SIGMA NETWORK The prescribed procedure for the setting of SIGMA CONTROL 2 machines is described in the corresponding operating manuals. Only use the current software version for SIGMA CONTROL 2 . Set the IP address of the network subscribers as follows: SAM 2 : IP address = 169.254.100.“Machine number +100“ SAM 2 does not automatically assign the IP addresses to the network users. Either the wrong machine or no machine at is controlled if an incorrect IP address is assigned. 1. Enter system pressure pB (p2 and set as default for "Manual mode pressure". Simultaneous activation of the machines in manual mode ➤ In manual mode, the pressure set point of each machine should be staggered by 0,3 bar to prevent all machines starting together. The stagger time for station operation must be set. Suggestions for these settings are found in the annex (see chapter 13.5.2). 2. Activate and setting up automatic restart after a power failure. 3. Configure the operation at the SIGMA NETWORK . 6.12.2 Integration with PROFIBUS The correct procedure for setting up SIGMA CONTROL machines is described in the corre‐ sponding operating manuals. Note the settings made in the appropriate form in the attachment. Set the slave numbers of the PROFIBUS devices as follows: ■ SIGMA CONTROL Slave No. = Machine number +2 ■ SIGMA CONTROL 2 : Slave No. = Machine number +102 Either the wrong machine or no machine at is controlled if an incorrect slave number is en‐ tered. 1. Enter system pressure pB (p2 and set as default for "Manual mode pressure". Simultaneous activation of the machines in manual mode ➤ In manual mode, the pressure set point of each machine should be staggered by 0,3 bar to prevent all machines starting together. The stagger time for station operation must be set. Suggestions for these settings are found in the annex (see chapter 13.5.2). 2. Activate and setting up automatic restart after a power failure. 3. Configure PROFIBUS operation. The following settings are recommended as parameters for bus alarms: Parameter Value Meaning Start td: No.: 901735 00 E 40.0 s Maximum period that the machine waits for a signal from the PROFIBUS after return of the power supplies. If no signal arrives before the period ends, the machine switches to self-control. Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 49 6 Installation 6.12 Setting up the machines Parameter Value Meaning Tab. 30 Timeout 5.00 s Period after which the machine switches to self-control if a fault occurs in SAM 2 . Restart Auto Restart man. Not at SIGMA CONTROL 2 . After a bus alarm the machine remains under its own internal control until it is connected to the bus again when the «remote» key is pressed. Not at SIGMA CONTROL 2 . The machine automatically connects again when the PROFIBUS runs again af‐ ter a bus alarm. Parameter for bus alarm 4. Repeat steps 1 to 3 for any further machines. 6.12.3 Precondition Linking via floating relay contact The machines are provided with the relay contacts required and they are wired up (see chap‐ ter 6.9.7). ➤ Note the settings made here in the table in the annex (see chapter 13.5) Rotary screw compressors always have an EMERGENCY mode. Piston compressors and blowers may or may not have this facility. 6.12.3.1 Stations with EMERGENCY mode facility ■ In automatic mode, SAM 2 assumes the LOAD / IDLE regulation. ■ In manual mode, the machines run under the control of their own internal pressure regulation. Machine with "External load control" input When the machine is linked, the machine pressure regulation (mains pressure switch (-B1) or elec‐ tronic pressure control) remains in operation. The system automatically runs in emergency mode via these pressure switches if power to the SAM 2 fails or the SAM 2 itself malfunctions, ensuring a further supply of compressed air. ➤ Set the pressure control. Further information For more information about the suggested settings for the pressure control, see Annex, chap‐ ter 13.5.1. Machine with one control input for "Operating mode Manual/Automatic" / LOAD/IDLE A "blow off protection pressure relief valve" pressure switch (-B6) or a "pressure switch in series to the SAM 2 load output" (-B1) is fitted in the machines to prevent one of the following: 50 ■ The machine is overloaded ■ The pressure relief valve responds due to: - switching points set too high - defective master controller - excessive pressure loss between the machine and the pressure transducer of SAM 2 . Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 6 Installation 6.12 Setting up the machines ➤ Set the "pressure switch in series to the SAM 2 load output“ (-B1). See chapter 13.5.1 for rec‐ ommended settings. ➤ Set the "pressure switch for manual operation (-B1.1) in sequence to ensure that the machines cut in after another. See chapter 13.5.2 in the Annex for recommended settings. 6.12.3.2 Stations without emergency mode capability Blowers and reciprocating compressors are not fitted with a pressure switch that could ensure EMERGENCY operation. When these machines are connected, the IDLE switching is controlled by SAM 2 . These stations will stop delivering compressed air if SAM 2 fails. ➤ Take suitable application-specific measures. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 51 7 Initial Start-up 7.1 Commissioning – overview 7 Initial Start-up 7.1 Commissioning – overview SAM 2 has been designed and developed for a number of applications. The settings that can be made are correspondingly varied. When shipped, SAM 2 is preconfigured with a standard configuration. Generally, most of these settings can be used for many applications or need only minor modifications. Thus, not all the steps listed below may be required for the initial start-up. This depends on the applica‐ tion involved. Tab. 31 7.2 Precondition topic Description Switch on SAM 2 Chapter 7.2 Switch on "SAM 2" Setting the Language Chapter 7.3 "Language" User log-on Chapter 7.4 "User log-on" Setting the time zone, date and time Chapter 7.5 "Date and time" Setting the Unit settings Chapter 7.6 "Unit settings" Setting the E-Mail Chapter 7.7 "E-Mail" Setting up the display Chapter 7.8 "Display" Data recording Chapter 7.9 "Data recording" SAM 2 Upgrade Chapter "Upgrade" Peripherals Chapter 7.10 "Peripherals" P+I diagram Chapter 7.11 "P+I diagram" Control Chapter 7.12 "Control" SAM 2.Logic Chapter "SAM 2.Logic" Time control Chapter "Time control" Process control Chapter "Process control" Activating the controller Chapter 7.13 "Activating the controller" Commissioning – overview Switching on SAM 2 Nobody works at the machines. All maintenance doors and removable panels are properly installed, closed and secured. All installation tasks and wiring as described in chapter 6 "Installation" are properly completed. The ambient conditions as described in chapter 5 "Installation and Operating Conditions" are met. 1. NOTICE! There is risk of damage to the compressed air supply through premature changeover to auto‐ matic mode. ➤ Press Automatic mode only when all settings required for commissioning (see chapter 7 "Initial Start-up" ) have been made. 52 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 7 Initial Start-up 7.3 Setting the language 2. Switch on the power supply for SAM 2 at the user's power supply isolating device. SAM 2 starts. The machine is switched on when the "Main menu" appears (after 2 minutes ap‐ proximately). Symbol Tab. 32 Operating element Key illumination Button remote control Green Button time control Green Button automatic Green Button station On/Off Green/red Keys on the SAM 2 operating panel 3. Ensure that SAM 2 is set to Manual mode mode. The 4. If the 7.3 key does not illuminate. key illuminated green, press again this key for the illumination to extinguish. ■ Stations without EMERGENCY operation will not deliver compressed air (see chapter 6.4 "Installation" ). ■ In compressed air systems with EMERGENCY operation capability, the machines run un‐ der their own internal pressure control (see chapter 6.4 "Installation" ). Setting the language You can choose and set the user interface language for the SAM 2 . 1. Press Configuration ➙ Language . The Language menu displays the currently set language. 2. Touch the symbol. The available languages are displayed in a list. 3. Select the desired "Language (country)" combination. SAM 2 loads and automatically displays the selected language. 7.4 User log-on Together with your SAM 2 , you received two KAESER Equipment Cards. They authorise the user to log on to SAM 2 and make or change settings. The KAESER Equipment Cards provide various functionalities: ■ No.: 901735 00 E Switch between three operating modes: ─ Logged out ─ Monitoring ─ Operating ■ Encryption ensures security ■ Different access levels for the customer (Equipment Card) and Service (Key) Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 53 7 Initial Start-up 7.4 User log-on The system records which user is when logged on at SAM 2 . You can thus determine who was logged on when specific messages or other events have occurred. Fig. 28 KAESER Equipment Card KAESER Equipment Card Number on the back of the KAESER Equipment Card 1. Remove the Equipment Card from the plastic sleeve. 2. Record the number shown on the back of the Equipment Card and keep it at a secure location. 7.4.1 Log on with Equipment Card Fig. 29 RFID reader RFID reader ACCESS MODE menu element 1. Hold the Equipment Card 1 directly in front of RFID reader 3 . The log-on data are read. If the system recognises the Equipment Card, it returns a message 5 . The message compri‐ ses information about User name and Access level . Fig. 30 54 Logged on Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 7 Initial Start-up 7.5 Date and time 2. Press Continue 6 to confirm the message. The message window closes. The user is now logged on with Monitoring access level. This shown in the ACCESS MODE 4 menu element. 3. To switch to “ Operating “, repeat this procedure from Step 1. The user is now logged on with Operating access level. This shown in the ACCESS MODE 4 menu element. 7.4.2 User log-out 1. To kog out from the system, hold the Equipment Card 1 directly in front of the RFID reader 3 . If the system recognises the Equipment Card, it returns a message 5 . 2. Press Logout 7 to log out. The access level will automatically return to "Logged out" after 10 minutes without user inter‐ vention. 7.5 Date and time You must set the time zone in which the SAM 2 is operated and the current date and time. This is required to ensure proper functioning of the machine controller, messages, logs and evaluations. Precondition Log on with access level 2: Operating (see chapter 7.4 "User log-on"). ➤ Enter the settings in the sequence described below: 7.5.1 Setting the time zone Set the time zone for the SAM 2 to ensure the timely automatic conversion from standard time to daylight savings time, for example. 1. Press Configuration ➙ Date and time . The Date and time settings menu is displayed. 2. Press the Time zone key. 3. Use the scroll wheel to move up or down to set the time zone. The display value in the centre is saved as the setting. Use the scroll wheel to move up or down to set the time zone for the device. 4. Press OK to apply the set time zone. 7.5.2 Setting date and time 1. Press Configuration ➙ Date and time . The Date and time settings menu is displayed. 2. Press the Current key. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 55 Fig. 31 Initial Start-up 7.6 Setting the Unit settings Setting date and time Day Month Year Hour Minute Scroll wheel Cancel OK 3. You can the scroll wheels 6 up or down to change the setting values for date and time. The display value in the centre is saved as the setting. Use the scroll wheels 6 to set each value for: 1 Day 2 Month 3 Year 4 Hour 5 Minute to the current date and current time. 4. Press OK 8 to apply the set date and time. The display field Current : displays the set date and time for verification 7.6 ■ Regularly (at least once a year) check the time for deviations and adjust, of necessary. ■ The change between daylight savings time and standard time is automatic and follows the rules for the set time zone. Setting the Unit settings You can adjust the units for some parameters in SAM 2 to the standards in the country of installa‐ tion. The system automatically calculates and displays the correct units. Precondition Log on with access level 2: Operating (see chapter 7.4 "User log-on"). 1. Press Configuration ➙ Unit settings . The Unit settings menu displays the currently set units. 56 Parameter Unit settings Pressure bar, psi, M Pa, mbar Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 7 Initial Start-up 7.7 Setting up E-Mail Parameter Unit settings Free air delivery m3/min, CFM Volume m3, cft Power kW, W Specific power kWmin/m3, kWmin/cft Temperature °C, °F The factory-set units depend on the "language" set. Tab. 33 Unit settings symbol in the line of the parameter to be changed. 2. Touch the The available units are displayed in a list. 3. Select the desired unit. SAM 2 saves the selected unit and uses it for all display values referenced. 7.7 Setting up E-Mail You can set up the sending of messages via e-mail in SAM 2 . The E-Mail menu has the following sub-menus: Precondition 7.7.1 ■ Send options ■ Basic settings Log on with access level 2: Operating (see chapter 7.4 "User log-on"). Send options Use the Send options menu to set the parameters required for sending messages via e-mail. 1. Press Configuration ➙ E-Mail . Select the Send options sub-menu. The Send options sub-menu displays the following e-mail parameters: Parameter Meaning Send message Touch the option box Active to set a check mark and activate the e-mail sending of messages. Remove the check mark and e-mail sending is deactivated. Sender's name In this field, enter the name to appear as the sender of e-mails. Touch the input field to display a virtual keyboard. Confirm with Accept to apply the entry. Contact's phone In this field, enter a telephone number under which the system operator can be number reached. This telephone number is indicated with the e-mail. No.: 901735 00 E Repeated send suppression time The repeat lock time specifies the time interval during which a message cannot be resent if the same message has already been sent by e-mail. This prevents multiple sending operations of the same e-mail if a message trigger (e.g., a loose contact) occurs several times in a short period of time. Send-attempt interval In this field, enter the time in seconds to be waited after a failed e-mail sending operation before the system again attempts to send. Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 57 Tab. 34 Initial Start-up 7.8 Setting up the display Parameter Meaning Send-attempt duration Use this setting to specify how long the system is to attempt to e-mail a mes‐ sage. In most cases (but not always), it is advisable to no longer send an old message when its cause has been probably remedied in the interim. E-Mail Send options 2. Enter the required data into the Sender's name and Contact's phone number fields. 3. The factory-set default values of the remaining data must be adjusted only if needed. 4. Select the Basic settings sub-menu. Use this menu to set the e-mail communication parame‐ ters required for sending messages via e-mail. Request the required information from your IT department. The Basic settings sub-menu displays the following e-mail parameters: Tab. 35 Parameter Meaning Sender's e-mail address The e-mail address used by the sender. Receiver's e-mail address The e-mail address of the recipient. You can only enter one e-mail address. SMTP Host The IP address of the SMTP mail server receiving and forwarding the mes‐ sage. SMTP Port The port address of the SMTP mail server receiving and forwarding the message. SMTP user name The log-in user name for logging on to the SMTP mail server. SMTP Password The log-in password for logging on to the SMTP mail server. SMTP Timeout In this field, enter the seconds for SAM 2 to wait for a reply by the SMTP server before cancelling sending. E-Mail Basic settings 5. Enter the required communication parameters into the data fields. All data fields are completed. 6. You can now send a test message to verify the settings. Press Send test E-mail . You have completed the settings upon verification of the successful reception of the test mail. 7. Select the Send options sub-menu. 8. In the Send message field, touch the Active option box. A check mark appears in the option box and e-mail sending is activated. 7.8 Setting up the display You can adjust the display brightness and the time behaviour of the screen saver. Precondition Log on with access level 2: Operating (see chapter 7.4 "User log-on"). 1. Press Configuration ➙ Display. 2. Set brightness and time behaviour. 58 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 7.9 Initial Start-up 7.9 Setting the Data recording Setting the Data recording Use the Data recording menu to set automatic data recording for the SAM 2 . Precondition Log on with access level 2: Operating (see chapter 7.4 "User log-on"). 1. Press Configuration ➙ Data recording . The Data recording menu displays the currently set parameters. Parameter Meaning Data recorder active Touch the Active option box to set a check mark and activate internal data recording. Data to be recorded Touch the Station map to activate data recording for the compressed air station. Touch the System information option box to activate the recording of the SAM 2 system data. These data can be useful when determining the cause of a fault. Tab. 36 Resolution This setting specifies the time between the individual measuring points. Every nth station map Use this setting to specify whether every station map is recorded or only every second, fourth or eighth station map. Current allocation The system displays here information about the current memory allocation in MB and as a percentage value of the data volume internally recorded by SAM 2 . Buffer emptied on This variable displays the time of the last data recording reset for informa‐ tion purposes. Buffer full on This variable displays the time at which the internal data memory was full. The system no longer records data after this time. Data recording 2. If required, change the setting by touching the option box or the available setting values. symbol and selecting the 3. In the Data recorder active field, touch the Active option box. A check mark appears in the op‐ tion box and data recording is activated. 7.10 Periphery The communication between SAM 2 and the connected machines and devices must be configured to ensure proper functioning. ➤ Enter the settings in the sequence described below: 7.10.1 Starting the SBU During the registration process, you can only register one SBU at SAM 2 at any time. If you want to register multiple SBU , you have to do this in sequence. Any SBU not yet registered must remain deactivated. Follow the following sequence to ensure the proper commissioning of the SBU . No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 59 Precondition Initial Start-up 7.10 Periphery All installation tasks and wiring as described in chapter 6 "Installation" are properly completed. The SAM 2 is switched on. SBU is switched off at the supply disconnect device 1. Switch on the supply disconnect device for the SBU . The L/A IF1 LED at the Bus controller of the SBU illuminates green. At the SAM 2 , a pop-up window displays New Bus controller detected. 2. Press the Create new block 4 key. A pop-up window displays New I/O block added Fig. 32 Block configuration menu 3. Press Configure new I/O block. The Block configuration menu opens. Alternatively, you can manually access this menu: Press Start-up ➙ SIGMA NETWORK . Fig. 33 60 I/O block menu Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 7 Initial Start-up 7.11 P+I diagram 4. Select I/O block 66 2 . The Block configuration sub-men displays these parameters: Item No. Parameter Meaning Identification Network location Select the name of the network from the list. Block number Select a SIGMA NETWORK address of the SBU from the list. Description In this field, enter an explanatory name (Compressor station Hall 5, for example) for the SBU . Serial data Material number If possible, the Material number from the SBU is retrieved and displayed here. Alternatively, you can manually enter the Material number . Serial number If possible, the Serial number from the SBU is retrieved and dis‐ played here. Alternatively, you can manually enter the Serial number . Communication IP address Communication status This field displays the current communication status: Tab. 37 Send IP address to block This field displays the IP address currently assigned to SBU . ■ Not connected ■ OK Use this key to transfer changed settings to the Bus controller . Block configuration menu 5. If necessary, add or adjust the settings in the < Block configuration > menu. 6. Press the Send IP address to block key. A message is displayed. 7. Confirm the message. The network configuration for SBU is completed. For the configuration of the I/O block see chapter "I/O block configuration". 8. If you want to register other SBU at the SAM 2 , you must follow the procedure described above from item 1. for every SBU . 7.11 P+I diagram The fundamental configuration of the compressed air station is realised with a visual P&I diagram in SAM 2 . Using a graphical editor, you place, configure and connect the components retrieved from a library in the drawing area. Precondition No.: 901735 00 E Log on with access level 2: Operating (see chapter 7.4 "User log-on"). Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 61 Fig. 34 Initial Start-up 7.11 P+I diagram Station editor menu 1. Press Start-up ➙ P+I diagram . The Station editor menu is displayed. Item No. Tab. 38 Sign Meaning Add component Remove component Connect components Component details Save Enlarge view Reduce view – Drawing area – Component 10 – Connection Station editor 2. Press The Add component menu is displayed. The Component menu is active. 62 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 7 Initial Start-up 7.11 P+I diagram 3. Touch the symbol. The available component types are displayed in a list (see chapter 7.11.1 "Component types)". 4. Add component: Select the required component by touching it. The selected component is copied to the clipboard and the drawing area 8 of the Station Edi‐ tor opens. 5. Touch the drawing area 8 at the desired location. The previously selected component is pasted on the touched position on the drawing area. The placed component is framed by dashed line. This identifies the component as currently inactive. 6. Touch the placed component. The selected component is framed in grey. 7. Touch the symbol. The Details menu opens. Configure the details for the selected component (see chapter 7.11.2 "Configuring the components"). 8. Moving a component: Touch and drag the component (without releasing it) to another position on the drawing area 8 . 9. Delete component: Touch to mark the component to be deleted (the selected component will be framed) and press . The marked component is removed. 10. Add any other components as described above, until all components required for the P&I dia‐ gram are placed on the drawing area and arranged as required. The number of possible compressors is limited by the SAM 2 type available (see chapter 2.3 "Technical Specification" ). However, for the SAM 2-4 and SAM 2-8 types, it can be expan‐ ded by Upgrade (see chapter "Upgrade" ). The P&I diagram flows from left to right. 11. Use the and symbols to enlarge or reduce the view of the drawing area. Touch and drag the drag arrows to move the view into the desire direction. 12. Touch the symbol. The connecting mode is active. The symbol is displayed with a green background. 13. Add connection: Touch the first component to be connected. The selected component is framed in grey. 14. Touch the second component to be connected. A connecting line is drawn between both components. The dashed frame of the first component disappears. This marks this component to be active. 15. Delete connection: Execute the same procedure as described in "Add connection". 16. Add all other connections as described above, until all components of the P&I diagram are connected. 17. Touch to save the completed P&I diagram. The above created P&I diagram of the compressed air station will be used as the valid config‐ uration of SAM 2 for machine control, calculations and display purposes only after it has been saved. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 63 7.11.1 Initial Start-up 7.11 P+I diagram Component types Component type Symbol (example) Compressor Dryer Filter Receiver Valve Sensor Tab. 39 7.11.2 Component types Configuring the components You must properly configure the components shown in the P&I diagram in order for SAM 2 to re‐ ceive the correct parameters for output calculations, network communication and maintenance, for example. Precondition Log on with access level 2: Operating (see chapter 7.4 "User log-on"). The Component mode is active (see chapter 7.11 "P+I diagram" ). At least one component is positioned on the drawing area 8 (see chapter 7.11 "P+I diagram" ). 1. Configuring the component: select the required component by touching it. The selected component is framed in grey. 64 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 7 Initial Start-up 7.11 P+I diagram 2. Touch the symbol. The configuration menu for the selected component is displayed. The items available in the configurations depend on the selected component type. The configuration menu has maximally the following sub-menus: ■ Connection ■ Identification ■ Performance data ■ Maintenance management 3. Select a sub-menu. Parameter Meaning Connection Use this menu to set the fundamental communication options for connect‐ ing the selected component with SAM 2 . Some options are available only for certain components. Number The system automatically assign a unique ID to every component. This en‐ ables the activation of the component via "SAM 2.Logic" for example. Active Touch the option box Active to set a check mark which ensures that the sig‐ nals of the corresponding component will be evaluated by SAM 2 . Connection type Set here the connection type: ■ Controlled: The component is automatically controlled. ■ Monitored+: The component is not automatically controlled and oper‐ ates independently. ■ Monitored: The component is not automatically controlled and operates independently. The component is not taken into account when the com‐ pressed air station is energetically evaluated. ■ Not connected: The component is only displayed in the P&I diagram. Only machines are controlled. Communication me‐ Set here the communication medium: dium ■ SIGMA NETWORK ■ PROFIBUS ■ conventional Only machines are controlled via SIGMA NETWORK or PROFIBUS. Controller type The type of KAESER controller is displayed here: ■ SIGMA CONTROL ■ SIGMA CONTROL 2 IP address The IP address of the component is displayed. PROFIBUS slave address Enter here the PROFIBUS slave address. Definition of conven‐ Use this key to open the menu. tional signals Identification No.: 901735 00 E Service manual SAM 2 In this menu, enter general information about the component to be regis‐ tered. SIGMA AIR MANAGEMENT SYSTEM 65 7 Initial Start-up 7.12 Control Parameter Meaning Description The name of the component within the compressed air station, for example "Compressor 1". Material number The manufacturer's article number for the component. Serial number The manufacturer's serial number for the component. Equipment number The KAESER-specific number. Device type The manufacturer's type designation for the component. Manufacturer The name of the component manufacturer. Performance data Use this menu to enter the basic technical data for the component previous‐ ly registered in the Identification menu. Obtain this information from the nameplate and/or the operating manual. Rated pressure Enter the component's rated pressure in the set unit of pressure. Rated power Enter the component's rated power in the set unit of power. Rated air delivery Enter the component's rated air delivery in the set unit of delivery volume. Idle power Enter the power consumption in IDLE in the set unit of power. Variable speed Touch the option box Active to set a check mark and activate the "Variable speed" option. Add-on dryer Touch the option box Active to set a check mark and activate the "Add-on dryer" option. Speed parameter field Use this key to open the Speed parameter field menu. Add-on dryer techni‐ Use this key to open the Add-on dryer menu. cal data Tab. 40 Copying technical data from the SD card Use this key to open the SC card menu. Maintenance management Set the maintenance options in this menu. Maintenance management via SAM 2 Touch the option box Active to set a check mark and activate the Maintenance management option. SAM 2 now manages the component's maintenance signals in the < Messages > menu. Parameters in the configuration menu 4. Set all required parameters for the selected component in the provided sub-menus as descri‐ bed above. 7.12 Control The Control parameter menu has the following sub-menus: ■ "Parameter" ■ Priority ■ Dynamic Control ■ "Required pressure" 1. Press Control ➙ Settings or Control ➙ Pressure parameters . 66 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 7 Initial Start-up 7.12 Control 2. If the menu page displayed has several sub-menus, touch one of the tabs to open the corre‐ sponding sub-menu. 3. Enter the required parameters in the corresponding fields. 4. If necessary, activate the desired functions by touching the selection box. 7.12.1 Setting the Parameter The fundamental pressure values of the station must be set in the Parameter menu. 7.12.1.1 Pressure range upper limit [pR] You define the pressure margin by setting a pressure value above the required pressure. For example, if you want a required pressure of 7.0 bar and a pressure margin of 0.5 bar,you must specify 7.5 bar as value for the upper pressure margin. 7.12.1.2 Pressure range The pressure margin is the difference resulting from the upper margin limit and the required pres‐ sure. For energetic reasons, select the largest possible pressure margin. Practical values are 0.8–1.2 bar, for example. Lower values for the pressure margin result in more frequent machine motor starts. 7.12.1.3 Required pressure [pREQ] The required pressure is the pressure required by the consumers in the compressed air network (measured with the "pressure transducer"). SAM 2 usually maintains the required pressure with a maximum deviation of 0.1 bar. For energetic reasons, the operating pressure is to be set as low as possible, i.e., not higher as required for the consumers within the compressed air network. A pressure of 1 bar higher than required causes ap‐ proximately 6 % more energy consumption. 7.12.1.4 Maximum pressure Pressure high [ph] is a monitoring function. If the monitoring function is activated, the system is‐ sues a warning message as soon as the mains pressure exceeds the set threshold value for the set time. 7.12.1.5 Minimum pressure Pressure low [pt] is a monitoring function. If the monitoring function is activated, the system issues a warning message as soon as the mains pressure falls below the set threshold value for the set time. The monitoring function is provided in two variants: ■ Δpt: This monitoring function uses a pressure limit relative to the set required pressure. ■ pt: This monitoring function uses a pressure limit which is independent of the required pres‐ sure. You cannot use both variants at the same time. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 67 7.12.2 Initial Start-up 7.13 Activating SAM 2 Setting the Pressure parameters Use this menu to specify the limits within the working pressure may be set ( SAM 2 ) or specified ( Process control ). 7.12.2.1 Maximum required pressure The maximum working pressure represents the upper pressure limit which still ensures safe opera‐ tion for the consumers within the air network. 7.12.2.2 Required pressure minimum The minimum working pressure represents the lower pressure limit which still ensures safe opera‐ tion for the consumers within the air network. 7.12.2.3 Decrease of required pressure You can lower the required pressure by an adjustable amount either manually or by an external signal. 7.13 Precondition Activating SAM 2 Nobody is working on the machine. All access doors on the machines are closed. The ambient conditions for SAM 2 are met as described in chapter 5. "Installation and Operating Conditions" The temperature of the machines is not below +3 °C. All installation tasks and wiring as described in chapter 6 "Installation" are properly completed. There is no bus error. WARNING Risk of injury during an automatic machine start. ➤ Before switching on, make sure that all conditions are met. ➤ Compare the settings for initial start-up of SAM 2 with those listed in the operating man‐ ual. ➤ Use the "Commissioning" check list. Tab. 41 Precondition To be checked Description date and time is set Chapter 7.5 "Date and time" machines are set up Chapter 6.12 "Setting up the machines" Machines are connected Chapter 7.10 "Periphery" Required pressure is set Chapter 7.12 "Control" "Commissioning" check list All points in the "Commissioning" check list are complied with,. ➤ Key "Automatic" Press Result 68 Confirmed? Key "Automatic" Service manual SAM 2 illuminates green. SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 7 Initial Start-up 7.13 Activating SAM 2 SAM 2 assumes control of the compressed air station. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 69 8 Operation 8.1 Switching on and off 8 Operation 8.1 Precondition Switching on and off The ambient conditions are met as described in chapter 5. "Installation and Operating Conditions" All installation tasks and wiring as described in chapter 6 "Installation" are properly completed. Commissioning in accordance with chapter 7 "Initial Start-up" is completed. 8.1.1 Switching the compressed air station on ➤ Press the Result 8.1.2 key. The compressed air station switches on. The key illuminates green. Switching the compressed air station off You can switch off the compressed air delivery for the entire station at SAM 2 . ➤ Press the Result 8.2 key. The compressed air station shuts down and compressed air is no longer delivered. The key illuminates red. Help function SAM 2 features an integrated Help function. A matching description can be displayed for the cur‐ rently displayed menu. 1. Press the key. The matching Help page is displayed. 2. If the Help page is more than one screen page, swipe with your finger up or down. 3. Touching underlined terms opens further Help pages with corresponding descriptions. 4. Use the and keys to browse back and forward in the Help file. 5. Press to open the table of contents. 6. Press to open the glossary. 7. Press to return to the Help page of the current SAM 2 menu. 8. Press again. The Help page is closed and the current SAM 2 menu is again displayed. When you close the currently displayed Help page and again call up the Help function, the page displayed is the same page which you saw before closing the function. If you close the currently displayed Help page 10 minutes after the initial call up, the system displays the initially description matching the menu when you re-call the Help function. 8.3 Main menu The menu has the following sub-menus: 70 ■ Net pressure station ■ Net pressure Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 8 Operation 8.3 Main menu ■ Current values ■ Total values ■ Drag Indicator ■ View station 1. Press Status ➙ Overview or Status ➙ View station . 2. If the menu page displayed has several sub-menus, touch one of the tabs to open the corre‐ sponding sub-menu. 8.3.1 Net pressure station The pressure curve is the visual display of the network pressure progression and set limit values for the entire station or the selected machines. One or more pressure transducers in the network provide the measured values. " " If multiple pres‐ sure transducers are used, the software calculates a weighted mean value. The values are displayed in the previously set units for the set time axis. 8.3.1.1 Net pressure [pN] The system displays the progression curve of the network pressure over the time axis. The values are displayed in the set unit. 8.3.1.2 Required pressure [pREQ] The required pressure is the pressure required by the consumers in the compressed air network (measured with the "pressure transducer"). SAM 2 usually maintains the required pressure with a maximum deviation of 0.1 bar. For energetic reasons, the operating pressure is to be set as low as possible, i.e., not higher as required for the consumers within the compressed air network. A pressure of 1 bar higher than required causes ap‐ proximately 6 % more energy consumption. 8.3.1.3 Pressure range The pressure margin is the difference resulting from the upper margin limit and the required pres‐ sure. For energetic reasons, select the largest possible pressure margin. Practical values are 0.8–1.2 bar, for example. Lower values for the pressure margin result in more frequent machine motor starts. 8.3.1.4 Compressor The machine's name within the station. This name can be set in the P&I diagram menu. 8.3.1.5 Free air delivery Current compressed air volume delivered by the machine. The values are displayed in the set unit. 8.3.1.6 Pi Current compressed air volume generated by the machine. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 71 8 Operation 8.3 Main menu The values are displayed in the set unit. 8.3.1.7 ADT "Airend discharge temperature" of the machine. The values are displayed in the set unit. 8.3.1.8 Operating state Current operating state of machine, for example: 8.3.1.9 ■ READY ■ IDLE ■ LOAD Error state Current fault state of machine, for example: 8.3.2 ■ Fault ■ Warning ■ Communication alarm ■ Local mode Pressure chart This sub-menu page displays the current network pressure as numerical value in large font. This display type enables good legibility from a larger distance. The values are displayed in the set unit. 8.3.3 Current values The display of current measuring values of the entire station or selected machine(s). 8.3.3.1 Power The display of the currently measured power consumption of the entire station or selected ma‐ chine(s). The values are displayed in the set unit. 8.3.3.2 Free air delivery The compressed air volume currently delivered by the entire station or selected machine(s). The values are displayed in the set unit. 8.3.3.3 Specific power This standard value is used as reference value in the assessment of the station's efficiency, The value is calculated from the power consumption per delivery volume. Lower values indicate a high degree of efficiency. 72 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 8.3.3.4 Operation 8.3 Main menu Switch events The number of motor starts of the selected machine within the last 60 minutes. 8.3.3.5 Consumption Calculated current compressed air usage in the air network. The values are displayed in the set unit. 8.3.4 Drag Indicator This sub-menu page records the maximum, mean or minimum pressure values. 8.3.4.1 Maximum pressure The maximum pressure in the network, measured from the reference time set. This value corre‐ sponds to the highest measured pressure in the network and can be used to evaluate the com‐ pressed air quality. The values are displayed in the set unit. 8.3.4.2 Average pressure The mean pressure in the network, calculated since the reference time set. The values are displayed in the set unit. 8.3.4.3 Minimum pressure The minimum pressure in the network, measured from the reference time set. This value corre‐ sponds to the lowest measured pressure in the network and can be used to evaluate the com‐ pressed air quality. The values are displayed in the set unit. 8.3.4.4 RESET The set reference time is reset to the current date and the current time. 8.3.5 Station view Display of the P&I diagram of the compressed air station. The P&I diagram illustrates the structure, operating modes and important data of the station and is updated continuously. Use the and symbols to scale the view and move it by touching and dragging with your finger. The display of the symbols changes with the operating state of the corresponding machine. Sign Meaning Machine in operating mode READY Machine in operating mode IDLE No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 73 8 Operation 8.3 Main menu Sign Meaning Machine in operating mode LOAD Machine has warning messages or service messages Machine has fault messages Tab. 42 74 Symbols in View station Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 9 Fault Recognition and Rectification 9.1 KAESER SERVICE 9 Fault Recognition and Rectification 9.1 KAESER SERVICE The messages valid for SAM 2 are dependent on how the compressor station is equipped. 1. Do not attempt fault rectification measures other than those given in this manual! 2. If the fault cannot be removed by the action suggested: Contact KAESER SERVICE. 9.2 Messages Alarm, service and warning messages are displayed at SAM 2 and stored in the event memory. A pop-up window appearing on top of the current display notifies the user of new messages. New messages are displayed together with the following data: ■ Event : ─ Number of messages: Error ─ Number of messages: Warning ─ Number of messages: Maintenance You must acknowledge the messages. ➤ Press Active reports to open the < Unacknowledged messages > menu. The event memory differentiates between: ■ Unacknowledged messages ■ Current reports ■ Message history storing the last 1000 messages. 1. Press Message . 2. Select a menu option: ■ Unacknowledged messages ■ Current reports ■ Message history The system displays three different event times for individual messages: ■ ─ Event “k”: Message coming ─ Event “q”: Message acknowledged ─ Event “g”: Message gone The following data are shown in addition: ─ Time : Date and time ─ Number : Message number ─ component ─ Message : Message text 3. If the message list is longer than one screen page, swipe with your finger up or down. 4. In the Unacknowledged messages message page, touch an individual message for selection. Press Acknowledge message to acknowledge the message. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 75 9.3 Fault Recognition and Rectification 9.3 Other faults Other faults Fault Possible cause Remedy Operation of the touch screen is difficult and/or re‐ turns errors. The touch screen is dirty. Wipe the touch screen surfaces with a soft cloth (micro-fibre, for example) without any harsh cleaning agent. SAM 2 is incorrectly connected Connect SAM 2 to the equipoten‐ to the equipotential bonding. The tial bonding (see chapter 6.11.2). capacitive touch screen must be earthed to work reliably. Tab. 43 76 Other faults Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 10 Maintenance 10.1 Maintenance tasks on electrical equipment 10 Maintenance 10.1 Maintenance tasks on electrical equipment Maintenance tasks on electrical equipment may only be carried out by the following persons: ■ Specialist personnel, see chapter 3 “Assigning personnel”. ■ Technicians qualified to maintain SAM 2 and service personnel instructed by and under the supervision of such a qualified technician ■ Authorised KAESER service personnel. 1. Check personnel for specialised qualifications. 2. Assign suitable personnel to maintenance tasks. 3. Instruct on correct maintenance procedures in accordance with the operating manual. 4. Document maintenance tasks carried out. Enter completed maintenance tasks in the corresponding lists in the operating manual. 10.2 Additional buffer battery SAM 2 features a permanently installed buffer battery. In the event of a failure, you can install a second buffer battery. This additional buffer battery is switched in parallel to the factory-installed battery and assumes its function. The functionality of this second battery is not impaired by the dis‐ charged factory-installed battery. ➤ Comply with the following instructions. 10.2.1 Danger from batteries WARNING There is danger of acid burns if batteries are overheated or damaged. ➤ Store the battery in a cool and dry place. ➤ Properly dispose of discharged buffer batteries. 10.2.2 Buffer battery life Under normal operating conditions, the buffer battery in SAM 2 has a life of at least 10 years. NOTICE Data loss from discharged buffer battery ➤ Heed warning messages from SAM 2 concerning the buffer battery charge level. ➤ Install the additional buffer battery only when SAM 2 is switched on. In the event of a voltage loss and discharged buffer battery, the internal clock is reset to the date 01.01.1970 after power has returned. ➤ Notice the maximum storage times for unused buffer batteries. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 77 10.2.3 Fig. 35 10 Maintenance 10.2 Additional buffer battery Installing the additional buffer battery Buffer battery location Precondition Slot for additional buffer battery Buffer battery You have a new buffer battery at hand (for article number and type, please see chapter 11). The SAM 2 is switched on. 1. Use a slot-head screwdriver to break off the plastic cover ("Battery X2") at the rear of SAM 2 . 2. Insert the buffer battery 2 into the slot 1 . The positive pole of the buffer battery points to the terminal rear. 3. Insert the buffer battery until you feel resistance. 4. Check and correct, if required, the time zone, date and time (see chapter 7.5). 5. Record the installation date of the buffer battery in the maintenance table in the annex of this operating manual (chapter 13.7). Discharged batteries are hazardous waste. ➤ Dispose of discharged batteries according to national regulations and directives. 78 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 11 Spares, Operating Materials, Service 11.1 Note the nameplate 11 Spares, Operating Materials, Service 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 enquiry and order for spares. 11.2 Spare parts Name Voltage [V] Capacity [Ah] Model 3.0 0.19 CR2032/BR2032 Lithium buffer battery Tab. 44 Spare buffer battery 11.3 KAESER AIR SERVICE KAESER AIR SERVICE offers: ■ Authorised service technicians with KAESER factory training ■ Increased operational reliability ensured by preventive maintenance ■ Energy savings achieved by avoidance of pressure losses ■ optimum conditions for operation of the compressed air system, ■ The security of genuine KAESER spares. ■ Increased legal certainty as all regulations are kept to. ➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement. Your advantage: lower costs and higher compressed air availability. 11.4 Displaying the software version You can display the versions of the various software modules in SAM 2 . ➤ Press Configuration ➙ Software versions . The Software versions menu is displayed. Tab. 45 No.: 901735 00 E Parameter Meaning Software Software name SAM 2 Software versions menu Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 79 12 Decommissioning, Storage and Transport 12.1 De-commissioning 12 Decommissioning, Storage and Transport 12.1 De-commissioning De-commissioning is necessary, for example, under the following circumstances: ■ SAM 2 is (temporarily) not needed. ■ SAM 2 is to be moved to another location. 1. Isolate SAM 2 from all power phases (power supply isolating device). 2. Switch off external power sources. 3. Disconnect SAM 2 from all connections when the device is to be moved to another location. 12.2 Precondition Fig. 36 Disposal SAM 2 is de-commissioned. Buffer battery positions Permanently installed buffer battery Additional buffer battery 1. Disconnect SAM 2 from all connections. 2. Open the control cabinet of the SAM 2 cover (see chapter 6.6). 3. Detach all connections from the SAM 2 terminal. 4. If necessary, use a suitable tool to force the removal of incommoding cover parts. 5. Use a Torx screwdriver to remove the T9 screws at the rear housing panel of the SAM 2 termi‐ nal. 6. Remove the housing panel. 7. Use a suitable tool to remove the permanently installed and any additional buffer battery. 8. Properly dispose of the buffer batteries. 9. Hand the SAM 2 over to an authorised disposal expert. 80 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 12 Decommissioning, Storage and Transport 12.2 Disposal Discharged batteries are hazardous waste. ➤ Dispose of discharged batteries according to national regulations and directives. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 81 13 Annex 13.1 Anchor holes for the control cabinet 13 Annex 13.1 Anchor holes for the control cabinet See instructions in chapter 6.6 Fig. 37 Anchor holes for the SAM 2 control cabinet 13.2 1300 mm 1084 mm 507 mm 180 mm Machine assignment No. Model Machine number Year of manufacture No. in wiring diagram Bus address or number Slave 10 11 12 13 14 15 82 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 13 Annex 13.3 SBU (SIGMA NETWORK BUS CONVERTER) No. Model Machine number Year of manufacture No. in wiring diagram Bus address or number Slave 16 Tab. 46 Machine assignment 13.3 SBU (SIGMA NETWORK BUS CONVERTER) No. Model Material number SIGMA NETWORK address 10 11 12 Tab. 47 SBU 13.4 SAM 2 setting values Save your settings on an SD card after commissioning and any modifications of the default values. Use the following list "Technician settings" to document major modifications. ➤ Save the setting data to the SD card and enter major modifications in the "Technician settings" list. Result 13.4.1 Data backup and the documentation of major modifications simplify the task of external Service Technicians in particular, in determining the cause of problems arising. Technician's settings Technician's settings No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 83 13 Annex 13.4 SAM 2 setting values Technician's settings 84 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 13 Annex 13.5 Machine settings Technician's settings Tab. 48 Technician's settings 13.5 Machine settings 13.5.1 Setting the pressure regulation (pressure controller in series with the SAM 2 load output) See instructions in chapter 6.12.3 Setting suggestion for machines with an "external load control" actuating input [bar] The reference point is the maximum working pressure ➤ Adjust the setting values for the pressure regulation (pressure switch (-B1) or system pressure) as follows: Machine number Cut-in pressure Cut-out pressure Maximum working pressure 1 bar to 2.5 bar: No.: 901735 00 E Machine 1/5 ON − 0.10 OFF + 0.05 Machine 2/6 ON − 0.15 OFF + 0.05 Machine 3/7 ON − 0.20 OFF + 0.05 Machine 4/8 ON − 0.25 OFF + 0.05 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 85 13 Annex 13.5 Machine settings Machine number Cut-in pressure Cut-out pressure Maximum working pressure 2.5 bar to 6 bar: Machine 1/5 ON − 0.2 OFF + 0.2 Machine 2/6 ON − 0.4 OFF + 0.2 Machine 3/7 ON − 0.6 OFF + 0.2 Machine 4/8 ON − 0.8 OFF + 0.2 Maximum working pressure 6 bar to 16 bar: Machine 1/5 ON − 0.4 OFF + 0.3 Machine 2/6 ON − 0.7 OFF + 0.3 Machine 3/7 ON − 1.0 OFF + 0.3 Machine 4/8 ON – 1.3 OFF + 0.3 Maximum working pressure 16 bar to 32 bar: Tab. 49 Machine 1/5 ON − 4.0 OFF + 1.0 Machine 2/6 ON − 5.0 OFF + 1.0 Machine 3/7 ON − 6.0 OFF + 1.0 Machine 4/8 ON − 7.0 OFF + 1.0 Recommended settings: Pressure controller in series with SAM 2 "external load control" load out‐ put Setting suggestion for machines with the "Man/Auto"/ "Load/Idle" operating mode" control input [bar] The reference point is the maximum working pressure ➤ Adjust the setting values for the pressure regulation (pressure switch (-B1) or system pressure) as follows: Machine number Cut-in pressure Cut-out pressure Maximum working pressure 1 bar to 2.5 bar: all ON − 0.10 OFF + 0.05 − 0.2 OFF + 0.2 − 0.4 OFF + 0.3 − 4.0 OFF + 1.0 Maximum working pressure 2.5 bar to 6 bar: all ON Maximum working pressure 6 bar to 16 bar: all ON Maximum working pressure 16 bar to 32 bar: all Tab. 50 86 ON Recommended settings: Pressure controller in series with the SAM 2 "Man/Auto and Load/Idle" load output Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 13 Annex 13.5 Machine settings Personal settings Date/time Switching point ON OFF ON OFF ON OFF Unit Tab. 51 13.5.2 Machine1 [bar] Machine 2 [bar] Machine 3 [bar] Machine 4 [bar] Machine 5 [bar] Machine 6 [bar] Machine 7 [bar] Machine 8 [bar] Machine 9 [bar] Machine 10 [bar] Machine 11 [bar] Machine 12 [bar] Machine 13 [bar] Machine 14 [bar] Machine 15 [bar] Machine 16 [bar] Personal settings: Pressure controller in series with SAM 2 load output Pressure range for manual operation To avoid simultaneous cut-in of machines in manual mode, you must set the system pressure p2 and/or system pressure switch −B1.1. Suggested setting [bar]: Machine number Cut-in pressure Cut-out pressure Maximum working pressure 1 bar: Machine 1/5/9/13 ON 0.93 OFF 1.00 Machine 2/6/10/14 ON 0.91 OFF 0.98 Machine 3/7/11/15 ON 0.89 OFF 0.96 Machine 4/8/12/16 ON 0.87 OFF 0.94 Maximum working pressure 7.5 bar: Machine 1/5/9/13 ON 7.0 OFF 7.5 Machine 2/6/10/14 ON 6.7 OFF 7.2 Machine 3/7/11/15 ON 6.4 OFF 6.9 Machine 4/8/12/16 ON 6.1 OFF 6.6 Maximum working pressure 10 bar: No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 87 13 Annex 13.5 Machine settings Machine number Cut-in pressure Cut-out pressure Machine 1/5/9/13 ON 9.3 OFF 10.0 Machine 2/6/10/14 ON 9.0 OFF 9.7 Machine 3/7/11/15 ON 8.7 OFF 9.4 Machine 4/8/12/16 ON 8.4 OFF 9.1 Maximum working pressure 13 bar: Machine 1/5/9/13 ON 12.3 OFF 13.0 Machine 2/6/10/14 ON 12.0 OFF 12.7 Machine 3/7/11/15 ON 11.7 OFF 12.4 Machine 4/8/12/16 ON 11.4 OFF 12.1 Maximum working pressure 25 bar: Machine 1/5/9/13 ON 22 OFF 25 Machine 2/6/10/14 ON 21 OFF 24 Machine 3/7/11/15 ON 20 OFF 23 Machine 4/8/12/16 ON 19 OFF 22 Maximum working pressure 32 bar: Tab. 52 Machine 1/5/9/13 ON 27 OFF 32 Machine 2/6/10/14 ON 26 OFF 31 Machine 3/7/11/15 ON 25 OFF 30 Machine 4/8/12/16 ON 24 OFF 29 Recommended settings: Pressure range for manual operation Personal settings Date/time Switching point ON OFF ON OFF ON OFF Unit 88 Machine1 [bar] Machine 2 [bar] Machine 3 [bar] Machine 4 [bar] Machine 5 [bar] Machine 6 [bar] Machine 7 [bar] Machine 8 [bar] Machine 9 [bar] Machine 10 [bar] Machine 11 [bar] Machine 12 [bar] Machine 13 [bar] Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 13 Annex 13.5 Machine settings Date/time Switching point ON OFF ON OFF ON OFF Unit Tab. 53 13.5.3 Machine 14 [bar] Machine 15 [bar] Machine 16 [bar] Personal settings: Pressure range for manual operation System offset for manual mode tv = time delay for switching machines on after a power failure Date/time Name Time delay tv [s] tv [s] tv [s] tv [s] tv [s] tv [s] Machine1 Machine 2 Machine 3 Machine 4 Machine 5 Machine 6 Machine 7 Machine 8 Machine 9 Machine 10 Machine 11 Machine 12 Machine 13 Machine 14 Machine 15 Machine 16 Tab. 54 No.: 901735 00 E Personal settings: System offset (manual operation) Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 89 13.6 13 Annex 13.6 Installation accessories Installation accessories Communication modules Name Material number Remarks PROFINET IO retrofit kit 7.5250.01920 PROFIBUS DP-V0 Retro‐ 7.5250.01880 fit Kit Modbus TCP retrofit kit Tab. 55 Communication module with accessories, to be instal‐ led by the user, can be retrofitted. 7.5250.01950 Communication modules SIGMA NETWORK Name Tab. 56 Material number Remarks SIGMA NETWORK cable 7.9679.0 CAT5 2x2x0.64 gr, for indoor installation, PVC coat‐ ing, grey, ∅ 6.5 mm, by the metre RJ45 bus connector 7.7628.1 RJ45 plug, 4 insulation displacement/clamping con‐ tacts, tool-free installation (fast connect) LAN RJ45 retrofit kit 7.5250.01870 RJ45 bus connector, screw fittings, accessories SIGMA NETWORK installation accessories Pressure transducer Tab. 57 Name Material number Pressure range For model I 7.4599.0 0-1 bar For model II 7.3397.1 7.2816.3 7.2817.3 7.4762.0 7.6689.0 7.4773.0 0–6 bar 0–10 bar 0–16 bar 0–20 bar 0–32 bar 0–45 bar For model III 7.7040E3 0-16 bar For vacuum 7.7046.0 0–1 bar (absolute) Pressure transducer Pressure transducer connection parts and line Name Material number Remarks Fitting set straight, elbow G 1/4, G1/2 with shut-off valve and accessories for air receiver connection up to 16 bar 8.0484.10050 up to 45 bar 8.0484.00090 Fitting set G 1/4, G1/2 with shut-off valve and accessories up to 15 bar 90 Service manual SAM 2 1–litre air receiver for connec‐ tion to pipework 204465.0 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E Tab. 58 13 Annex 13.6 Installation accessories Name Material number Remarks Connecting cable for pressure transducer 7.2679.0 Screened, 2x0.75 mm2, for in‐ door installation, PVC sheath, grey, 6 mm diameter Pressure transducer accessories SBU for wall mounting Relay at DO AII (0-20mA, p/a) AO (0-20 mA) AIR (PT100) 1/0 Converter SBU400-1_PT 7.9681.00010 1/0 Converter SBU400-1_FC 7.9681.00020 1/0 Converter SBU400-1_DHS 7.9681.00030 1/0 6x2 Converter SBU400-1_SW 7.9681.02000 7/0 Converter SBU400-1_OLM 7.9681.00040 3/1 Converter SBU400-1_DP 7.9681.01000 1/0 Converter SBU400-1_SWDP 7.9681.03000 7/0 Converter SBU400-2 7.9682.0 1/0 Converter SBU400-3_X 7.9683.0 12 12 12 1/0 Converter SBU400-3_XDP 7.9683.01000 12 12 12 1/0 Converter SBU400-3_XLFC 7.9683.02010 12 12 12 7/0 7.9684.0 36 1/0 7.9684.02000 36 7/0 Converter SBU400-4 Converter SBU400-4_SW No.: 901735 00 E Relay signal dupli‐ cation DO (24 VDC 0.5A) Converter SBU400-1 Isolating amplifiers DI (24 VDC) Material number 7.9681.0 Name Tab. 59 SNW free ports Cu RJ45 / LWL DP master Scope of supply: Sheet steel control cabinet, 100-240 V mains voltage, single phase, 50-60 Hz SBU types for wall mounting Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 91 13 Annex 13.6 Installation accessories SBU for installation in machines without SIGMA CONTROL Relay at DO AII (0-20mA, p/a) AO (0-20 mA) AIR (PT100) 1/0 Converter SBU-1_FC 2) On request 1/0 For star-delta machines 2) For machines with frequency converter Relay signal dupli‐ cation DO (24 VDC 0.5A) 1) Isolating amplifiers DI (24 VDC) On request Material number Converter SBU-1 1) Name Tab. 60 SNW free ports Cu RJ45 / LWL DP master Scope of supply: Retrofit kit, components including installation description SBU types for installation in machines without SIGMA CONTROL Profibus installation parts and line Name Material number Remarks Connecting cable for PROFIBUS 7.4666.0 Screened, 1x2x0.64/2.55, for indoor in‐ stallation, PVC sheath. violet, 8mm di‐ ameter. PROFIBUS connector plug for SIGMA AIR MANAGER 7.4664.20010 35° cable exit PROFIBUS plug set for SIGMA CONTROL 7.5250.00300 (not required for model 16/8) PROFIBUS DP communication module 7.5250.01880 set for SIGMA CONTROL 2 Tab. 61 For PG and M fittings including EMC fit‐ tings. Module, bus connector, fittings PROFIBUS installation accessories Load/idle control module Name 92 Pressure Material number Remarks Module for external 8 bar load/idle control 11 bar (7.7005.1 or 7.7005.2) 15 bar 7.7006.00003 7.7006.00013 7.7006.00023 Digital input for load control via SIGMA AIR MANAGER. For machines with SIGMA CONTROL BASIC (7.7005.1 or 7.7005.2) without frequency converter. SFC module with ex‐ 8 bar ternal load/idle control 7.7706.00033 as 7.7006.00003 but for machines with varia‐ ble frequency drive (SFC) Module for external load/idle control (7.7005.3). 7.7056.00002 7.7056.00012 7.7056.00022 Digital input for load control via SIGMA AIR MANAGER. For machines with SIGMA CONTROL BASIC (7.7005.3) without frequency converter. Service manual SAM 2 8 bar 11 bar 15 bar SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 13 Annex 13.7 Installing the buffer battery Name Pressure Material number Remarks SFC module with ex‐ 8 bar ternal load/idle control Tab. 62 7.7056.00035 as 7.7056.00002 but for machines with fre‐ quency converter (SFC) Load/idle module RC interference suppressor Name Material number Remarks RC interference suppressor 7.2812.1 For suppression of inductive loads connected to the relay out‐ puts of the master controller. Coil voltage: 110–230 V AC/DC Coil retention capacity: 15 VA Tab. 63 RC interference suppressor 13.7 Installing the buffer battery Installing the buffer battery Date/time Name No.: 901735 00 E Tab. 64 Installing the buffer battery 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 93 94 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E No.: 901735 00 E 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 95 96 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E No.: 901735 00 E 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 97 98 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E No.: 901735 00 E 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 99 100 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E No.: 901735 00 E 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 101 102 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E No.: 901735 00 E 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 103 104 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E No.: 901735 00 E 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 105 106 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E No.: 901735 00 E 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 107 108 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E No.: 901735 00 E 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 109 110 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E No.: 901735 00 E 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 111 112 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E No.: 901735 00 E 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 113 114 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E No.: 901735 00 E 13 Annex 13.8 Electrical Diagram Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 115 13.9 13 Annex 13.9 I/O block 6DI&6DOT&4AII with relays I/O block 6DI&6DOT&4AII with relays Enter the wiring information of the actual application into the following tables. 116 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E Tab. 65 No.: 901735 00 E Service manual SAM 2 Relay -K21 AII 3.1 DOT 2.1 SIGMA AIR MANAGEMENT SYSTEM 12 14 W4633 3G 1.5 mm²: SM NC NO Compressor 3 -X3: 19 Compressor 3 -X3: 18 C3 load C3 load I/O block 6DI&6DOT&4AII with relays Internal wiring 13.9 11 W4633 3G 1.5 mm²: BN -K1-X2: 14 A2 1x1 mm²: SM Internal wiring Pressure from air main charging sys‐ tem Internal wiring Internal wiring Motor running K3 Motor running K3 Application Annex CC -K1-X2: 11 DHS -X1:20 DHS -X1:19 -K21: A2 -K21: A1 Compressor 3 -X1:26 Compressor 3 -X1:25 Destination A1 1x1 mm²: SM 11 GND X4 13 W4713 2x1.5 mm² : SW 21 X3 1– 11 W4713 2x1.5 mm² : BN 14 1x1 mm²: SM 11 1x1 mm²: SM +24V X4 X3 1+ GND X2 X2 14 W7625 2x0.75 mm²: 2 +24V X1 11 W7625 2x0.75 mm²: 1 DI 1.1 Line X1 Terminal Input 13 Sample entry in assignment table Sample entry in assignment table I/O block with relays 117 13 Annex 13.9 I/O block 6DI&6DOT&4AII with relays Tab. 66 118 23 26 X1 +24V X1 16 +24V X1 DI 1.6 13 X1 25 +24V X1 DI 1.5 22 X1 15 +24V X1 DI 1.4 12 X1 DI 1.3 24 +24V X1 21 X1 DI 1.2 14 +24V X1 DI 1.1 11 Terminal Input X1 Line Objective Application Module 1: X1 DI1.x Assignment I/O block – Module 1: X1 DI1.x – 20DI6371 – 6x DI 24VDC Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM Relay -K23 12 NC -K21: A2 A2 Wire jumper 11 -K1-X2: 12 -K23: A1 A1 1x1 mm²: SM 15 CC GND X2 12 1x1 mm²: SM 14 NO 12 NC -K21: A2 A2 Wire jumper Internal wiring Internal wiring Internal wiring Internal wiring Internal wiring Internal wiring Internal wiring Internal wiring Internal wiring I/O block 6DI&6DOT&4AII with relays 11 -K1-X2: 21 A1 1x1 mm²: SM 24 -K22: A1 -K1-X2: 14 -K1-X2: 11 -K21: A2 Internal wiring Application 13.9 CC X2 GND X2 21 1x1 mm²: SM 14 NO X2 12 NC 11 CC A2 1x1 mm²: SM A1 1x1 mm²: SM 14 1x1 mm²: SM GND X2 -K21: A1 Objective Annex DOT 2.3 Relay -K22 DOT 2.2 Relay -K21 11 1x1 mm²: SM DOT 2.1 Line X2 Terminal Input 13 Module 2: X2 DOT2.x (wiring when shipped) 119 120 Service manual SAM 2 SBU : Relay -K26 14 NO GND X6 -K1-X2: 23 -K21: A2 A2 Wire jumper SAM 2 : Control cabinet fan SBU : -K26: A1 SAM 2 : Control cabinet fan A1 1x1 mm²: SM 26 SAM 2 : 1x1 mm²: SM 23 1x1 mm²: SM 12 NC 11 -K21: A2 A2 Wire jumper CC -K1-X2: 13 A1 1x1 mm²: SM 16 -K25: A1 Internal wiring Internal wiring Internal wiring Internal wiring Internal wiring Internal wiring Internal wiring Internal wiring Internal wiring Application I/O block 6DI&6DOT&4AII with relays X6 GND X5 13 1x1 mm²: SM 14 NO X5 12 NC 11 -K21: A2 A2 Wire jumper CC -K1-X2: 22 -K24: A1 Objective A1 1x1 mm²: SM 25 22 1x1 mm²: SM 14 Line 13.9 DOT 2.6 X4 GND X4 NO Terminal Annex Relay -K25 DOT 2.5 Relay -K24 DOT 2.4 Input 13 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E Annex 13.9 I/O block 6DI&6DOT&4AII with relays 11 12 14 CC NC NO Input Terminal Line Objective Application 13 Tab. 67 No.: 901735 00 E Assignment I/O block – Module 2: X2 DOT2.x – X20DO6322 – 6x relays Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 121 13 Annex 13.9 I/O block 6DI&6DOT&4AII with relays 122 26 24 14 X3 4– +24V X4 GND X4 24 13 GND X4 X3 23 +24V X4 4+ AII 3.4 16 X3 3– 14 12 GND X4 X3 22 +24V X4 3+ AII 3.3 23 X3 2– 21 X3 2+ +24V X4 AII 3.2 X3 1– 11 21 X3 1+ AII 3.1 GND X4 13 Terminal 11 Tab. 68 Input Line Objective Application Modules 3 & 4: X3 & X4 AII3.x Assignment I/O block Modules 3 & 4 – X3 & X4 AII3.x – X20AI4632 – 4x AII 0-20mA 16Bit & X20PD2113 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 13 Annex 13.10 Module 6DI – Digital inputs 13.10 Module 6DI – Digital inputs Enter the wiring information of the actual application into the following table. If you require more than table, please use this table to create photocopies. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 123 13 Annex 13.10 Module 6DI – Digital inputs Tab. 69 124 23 26 X__ +24V X__ 16 +24V X__ DI __.6 13 X__ 25 +24V X__ DI __.5 22 X__ 15 +24V X__ DI __.4 12 X__ DI __.3 24 +24V X__ 21 X__ DI __.2 14 +24V X__ DI __.1 11 Terminal Input X__ Line Objective Application Module __: X__ DI__.x Assignment Module 6DI – X20DI63716x – DI 24VDC Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 13 Annex 13.11 Module 6DOT – Digital outputs 24VDC 0.5A 13.11 Module 6DOT – Digital outputs 24VDC 0.5A Enter the wiring information of the actual application into the following table. If you require more than table, please use this table to create photocopies. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 125 13 Annex 13.11 Module 6DOT – Digital outputs 24VDC 0.5A Tab. 70 126 23 26 X__ GND X__ 16 GND X__ DOT __.6 6 13 X__ 25 GND X__ DOT __.5 5 22 X__ 15 GND X__ DOT __.4 4 12 X__ DOT __.3 3 24 GND X__ 21 X__ 14 GND X__ DOT __.2 2 11 X__ DOT __.1 1 Input Terminal Line Objective Application Module __: X__ DOT__.x Assignment Module 6DOT – X20DO6322 – 6x DOT 24VDC 0,5A Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 13 Annex 13.12 Module 4AII – Analogue inputs 0-20mA 13.12 Module 4AII – Analogue inputs 0-20mA Enter the wiring information of the actual application into the following table. If you require more than table, please use this table to create photocopies. No.: 901735 00 E Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 127 13 Annex 13.12 Module 4AII – Analogue inputs 0-20mA 128 26 24 14 X__ 4– +24V X__ GND X__ 24 13 GND X__ X__ 23 +24V X__ 4+ AII __.4 16 X__ 3– 14 12 GND X__ X__ 22 +24V X__ 3+ AII __.3 23 X__ 2– 21 X__ 2+ +24V X__ AII __.2 X__ 1– 11 21 X__ 1+ AII __.1 GND X__ 13 Terminal 11 Tab. 71 Input Line Objective Application Module __ & __: X__ & X__ AII __.x Assignment 4AII – X20AI4632 – 4x AII 0-20mA 16Bit & X20PD2113 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 13 Annex 13.13 Glossary 13.13 Glossary Term Meaning "Current reports" Displays a chronologically sorted list of the last messages returned by the system. The newest messages are shown at the top. "Required pressure" The required pressure is the pressure required by the consumers in the compressed air network (measured with the "pressure transducer"). "Operating state" The operating states of compressors are: ■ READY ■ IDLE ■ LOAD "Maximum pressure" Pressure high is a monitoring function. If the monitoring function is activa‐ ted, the system issues a warning message as soon as the mains pressure exceeds the set threshold value. "Minimum pressure" Pressure low is a monitoring function. If the monitoring function is activa‐ ted, the system issues a warning message as soon as the mains pressure falls below the set threshold value. "Air Main Charging Valve" The air main charging system is a component designed for the relief of the compressed air treatment facility when an empty air network is filled. It prevents problems in the components of the compressed air treatment fa‐ cility when compressed air flows at high speed through the components. "Net pressure station" The pressure curve is the visual display of the network pressure progres‐ sion and set limit values for the entire station or the selected machines. "Pressure range" The pressure margin is the difference resulting from the upper margin limit and the required pressure. "Pressure range upper You define the pressure margin by setting a pressure value above the re‐ limit" quired pressure. For example, if you want a required pressure of 7.0 bar and a pressure margin of 0.5 bar,you must specify 7.5 bar as value for the upper pressure margin. "Pressure transducer" Sensor for measuring the pressure (relative, absolute or differential pres‐ sure). The sensor is available for different pressure measuring ranges and converts pressure into an electric signal. "Frequency converter" Device converting fixed mains AC voltage to an AC voltage with changea‐ ble frequency for the speed regulation of three-phase motors. No.: 901735 00 E "Total values" Calculated sum of important measuring data. "Process control" Central control and monitoring station. SAM 2 can be remote controlled via an Ethernet interface. "Free air delivery" The compressed air volume currently delivered by the entire station or se‐ lected machine. "Message history" Chronologically sorted list of the last 1000 messages. "Current values" The display of current measuring values of the entire station or selected machine(s). "Pressure chart" "Mains pressure” as numeric value in large display. This display type ena‐ bles good legibility from a larger distance. Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 129 13 Annex 13.13 Glossary 130 Term Meaning PROFIBUS The Process Field Bus is a standard for fieldbus communication in plant engineering. ThePROFIBUS subscribers are connected in series, that is, one after another. A terminating resistor is required at both ends of the wiring. Pt100 Platinum sensor for temperature measuring. A change in temperature causes a change in the platinum sensor's resistance which can be reliably evaluated. A Pt100 sensor has a 100 Ohm resistance at 0 °C. "Buffer volume" Volume of the air receiver storing the compressed air. A larger buffer vol‐ ume ensures a lower switching frequency of the compressor at equal compressed air consumption. "P&I diagram station" Piping and instrument flow chart in plant and process engineering. The P&I diagram symbolically displays all components required for the station operation, such as: ■ Compressors ■ Blowers ■ Receivers ■ Separators ■ Filters ■ Valves ■ Fan ■ Cooler ■ Pipes ■ Instruments ■ Actuators ■ Sensors ■ Measuring devices "RFID" Radio Frequency IDentification. Touch-less and reliable identification technology. Consists of a reader and a chip card or chip. SAM SIGMA AIR MANAGER. KAESER first generation master controller for the energy-efficient control of compressed air stations with up to 16 com‐ pressors. "SAM 2" SIGMA AIR MANAGER 2. KAESER second generation master controller for the energy-efficient control of compressed air stations with up to 16 compressors. "SAM 2.Logic" Using SAM 2.Logic , you can create programs for the control of machines or devices, similar to a PLC (programmable logic controller). "SBU" The SIGMA NETWORK BUS CONVERTER is an interface expansion for SAM 2 . A SBU is connected via a SIGMA NETWORK conductor with SAM 2 . "Switch events" The number of motor starts of the selected machine within the last 60 mi‐ nutes. "Drag Indicator" Display of maximum, average and minimum pressure values. "SIGMA NETWORK" KAESER-specific network for the machine control. The SIGMA NETWORK subscribers are linked in a star pattern. Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E 13 Annex 13.13 Glossary Tab. 72 No.: 901735 00 E Term Meaning "Specific power" The power in kW required to compress 1 m³ air per minute. This standard value is used as reference value in the assessment of the station's effi‐ ciency, "Station editor" The fundamental configuration of the compressed air station is realised with a visual P&I diagram in SAM 2 . Using a graphical editor, you place, configure and connect the components retrieved from a library in the drawing area. "Unacknowledged messages" New messages not yet acknowledged by the operator. You can highlight individual messages and acknowledge them with Acknowledge message. This action removes the message from the list of unacknowledged mes‐ sages. "Upgrade" Use the Upgrade function to upgrade SAM 2-4 or SAM 2-8 to the next larger type SAM 2-8 or SAM 2-16 when the station is expanded with addi‐ tional compressors. To do so, you require an activation code. "Consumption" Calculated current compressed air usage in the air network. "ADT" Compressed air is heated during the compression process. The airend discharge temperature is the compression temperature at the compressed air outlet, measured directly at the airend. Glossary Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM 131 13 Annex 13.13 Glossary 132 Service manual SAM 2 SIGMA AIR MANAGEMENT SYSTEM No.: 901735 00 E
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