Prodrive Technologies SC2MCSIO SC2MCSIO RFID User Manual

Prodrive Technologies B.V. SC2MCSIO RFID Users Manual

Users Manual

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User Manual
Controller
SIGMA CONTROL 2
SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
/KKW/SSC 2.08 en Z1 IBA-SIGMA CONTROL FLUID
/KKW/SSC 2.08 Z1
20170413 074810
Contents
No.: 9_9450 07 USE
SIGMA CONTROL 2 Quick installation guide
1.1 Operating elements ..........................................................................................................
1.2 Display elements ..............................................................................................................
1.3 Main menu .......................................................................................................................
1.4 Functions – Overview .......................................................................................................
Regarding this Document
2.1 Using this document .........................................................................................................
2.2 Copyright ..........................................................................................................................
2.2.1
Software ..............................................................................................................
2.3 Approvals .........................................................................................................................
2.4 Updating the user manual ................................................................................................
2.5 Symbols and labels ..........................................................................................................
2.5.1
Warnings .............................................................................................................
2.5.2
Potential damage warnings ................................................................................
2.5.3
Other alerts and their symbols ............................................................................
Technical Data
3.1 SIGMA CONTROL 2 Controller .......................................................................................
3.1.1
Versions and options ..........................................................................................
3.1.2
User interface with display, CPU and interfaces .................................................
3.1.3
Inputs and outputs with MCSIO ..........................................................................
3.1.4
Input/output modules ..........................................................................................
3.1.5
Sensors ...............................................................................................................
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Safety and Responsibility
4.1 Basic instructions .............................................................................................................
4.2 Specified use ....................................................................................................................
4.3 Improper use ....................................................................................................................
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Design and Function
5.1 The controller ...................................................................................................................
5.2 Operating panel ................................................................................................................
5.2.1
Indicating and operating elements ......................................................................
5.2.2
Display elements ................................................................................................
5.2.3
RFID reader ........................................................................................................
5.3 Display ............................................................................................................................
5.3.1
Operating mode ..................................................................................................
5.3.2
Main menu ..........................................................................................................
5.3.3
Setting parameters .............................................................................................
5.3.4
Activating keys with check boxes .......................................................................
5.4 Access rights ....................................................................................................................
5.5 KAESER CONNECT ........................................................................................................
5.6 Menus – overview ............................................................................................................
5.6.1
Operating mode ..................................................................................................
5.6.2
Menu structure ....................................................................................................
5.7 Operating modes and control modes ...............................................................................
5.7.1
Operating modes ................................................................................................
5.7.2
Control modes ....................................................................................................
5.7.3
Frequency-controlled drive (SFC) .......................................................................
5.7.4
MODULATING control ........................................................................................
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Installation and Operating Conditions
6.1 Maintaining ambient conditions ........................................................................................
6.2 Installation conditions .......................................................................................................
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Contents
ii
Installation
7.1 Reporting Transport Damage ...........................................................................................
7.2 Machine identification .......................................................................................................
Initial Start-up
8.1 Outline ..............................................................................................................................
8.2 Configuring the controller .................................................................................................
8.2.1
Selecting menu options ......................................................................................
8.2.2
Setting the language ...........................................................................................
8.2.3
Noting the number of the KAESER Equipment Card .........................................
8.2.4
User log-in with KAESER Equipment Card ........................................................
8.2.5
Generating a password .......................................................................................
8.2.6
Manual user log-in ..............................................................................................
8.2.7
Checking and setting time and date ...................................................................
8.2.8
Set the time zone ................................................................................................
8.2.9
Setting display formats .......................................................................................
8.2.10 Setting the display illumination ...........................................................................
8.2.11 Setting the contrast and the brightness ..............................................................
8.2.12 Activating the remote control ..............................................................................
8.2.13 IP configuration ..................................................................................................
8.2.14 Setting the e-mail function .................................................................................
8.2.15 Configuring the time server ................................................................................
8.3 Using KAESER CONNECT ..............................................................................................
8.3.1
Open KAESER CONNECT .................................................................................
8.3.2
System status menu ...........................................................................................
8.3.3
Graphs menu ......................................................................................................
8.3.4
Messages menu .................................................................................................
8.3.5
I/O display menu .................................................................................................
8.3.6
User management menu ....................................................................................
8.3.7
Settings ...............................................................................................................
8.3.8
Backup menu ......................................................................................................
8.3.9
Closing KAESER CONNECT .............................................................................
8.4 Adjusting the pressure parameters of the machine .........................................................
8.4.1
Displaying pressure parameters .........................................................................
8.4.2
Configuring the pressure parameters .................................................................
8.4.3
Activating/deactivating the «LOAD/IDLE» key ....................................................
8.5 Configuring machine start and stop .................................................................................
8.5.1
Automatic start/stop in timer mode ....................................................................
8.5.2
Setting up the holiday period ..............................................................................
8.5.3
Starting the machine remotely (Remote ON/OFF) .............................................
8.5.4
Activating the remote control .............................................................................
8.5.5
Activating/deactivating the idle period "Venting period" function .......................
8.5.6
Activating/deactivating and adjusting the "Autostart" function ............................
8.6 Activating and adjusting the control modes ......................................................................
8.6.1
Selecting a control mode ....................................................................................
8.6.2
Adjusting the idle time of DUAL control mode ....................................................
8.6.3
Adjusting the minimum running and unloaded period in QUADRO control
mode ...................................................................................................................
8.7 Electronic Thermal Management ....................................................................................
8.7.1
Activating the heat recovery for machine type 2 .................................................
8.7.2
Activating the heat recovery for machine type 3 .................................................
8.7.3
Deactivating heat recovery .................................................................................
8.8 Refrigerated dryer ...........................................................................................................
8.8.1
Setting the operating mode .................................................................................
8.8.2
Output messages ................................................................................................
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Contents
8.9
8.10
8.11
8.12
8.13
8.14
No.: 9_9450 07 USE
8.8.3
Fault in the refrigerated dryer – compressed air quality has priority ...................
8.8.4
Fault in the refrigerated dryer – compressed air quantity has priority .................
Configuring the machine for local mode ..........................................................................
8.9.1
Load control menu ..............................................................................................
8.9.2
Configuring the system setpoint pressure changeover using the clock ..............
8.9.3
Configuring the system setpoint pressure changeover using the timer ..............
Configuring the machine for master control .....................................................................
8.10.1 List of the different master controllers .................................................................
8.10.2 SAM 4.0 mode ...................................................................................................
8.10.3 Configuring PROFIBUS mode (SIGMA AIR MANAGER) ...................................
8.10.4 Configuring the master control of two machines in master/slave operation ......
8.10.5 Configuring master control using the LOAD remote contact (e.g.,
SIGMA AIR MANAGER BASIC) ........................................................................
8.10.6 Configuring the master control with local/LOAD remote contact .......................
8.10.7 Setting the setpoint pressure pre-selection via remote contact .........................
8.10.8 Configuring master control of compressors regulated by pressure switch ........
8.10.9 Examples of time settings for equal overall load ...............................................
Configuring input and output signals ................................................................................
8.11.1 Outputting important operational states of the machine .....................................
8.11.2 Output input signals on the display .....................................................................
8.11.3 Output measured values on the display .............................................................
Activating remote acknowledgement ..............................................................................
8.12.1 Setting the remote acknowledgement function ...................................................
8.12.2 Activating the remote control ..............................................................................
8.12.3 Assigning an input ..............................................................................................
Linking to an external pressure transducer .....................................................................
8.13.1 Pressure control menu ........................................................................................
8.13.2 Assigning an input to an external pressure transducer ......................................
Commissioning the machine ...........................................................................................
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Operation
9.1 Switching on and off .........................................................................................................
9.1.1
Switching on .......................................................................................................
9.1.2
Switching off .......................................................................................................
9.2 Switching off in an emergency and switching on again ....................................................
9.3 Acknowledging alarm and warning messages .................................................................
9.4 Displaying messages ......................................................................................................
9.4.1
Selecting the status menu ..................................................................................
9.5 Displaying the current operating mode ...........................................................................
9.6 Adjusting the working pressure ........................................................................................
9.7 Displaying analog data ....................................................................................................
9.8 Displaying operating data ................................................................................................
9.8.1
Checking the operating hours .............................................................................
9.8.2
Checking the switching cycles ............................................................................
9.9 Displaying the frequency converter settings ...................................................................
9.10 Setting the maintenance interval .....................................................................................
9.11 Checking the safety relief valve ......................................................................................
9.12 Checking the temperature sensor and overheating shutdown function ...........................
9.13 Save data ........................................................................................................................
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Fault Recognition and Rectification
10.1 Basic instructions .............................................................................................................
10.2 Interpreting alarm messages ............................................................................................
10.3 Interpreting warning messages ........................................................................................
10.4 Interpreting operation messages ......................................................................................
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Contents
10.5 Interpreting diagnostic messages ....................................................................................
10.6 Interpreting system messages .........................................................................................
iv
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11
Maintenance
11.1 Changing the buffer battery .............................................................................................. 203
12
Spares, Operating Materials, Service
12.1 Note the nameplate ..........................................................................................................
12.2 KAESER AIR SERVICE ...................................................................................................
12.3 Service Addresses ...........................................................................................................
12.4 Displaying the version number, machine model, part number and serial number ..........
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13
Decommissioning, Storage and Transport
13.1 De-commissioning ............................................................................................................
13.2 Packing ............................................................................................................................
13.3 Storage .............................................................................................................................
13.4 Transporting .....................................................................................................................
13.5 Disposal ...........................................................................................................................
13.5.1 Battery disposal ..................................................................................................
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SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
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
Fig. 38
Fig. 39
Fig. 40
Fig. 41
Fig. 42
No.: 9_9450 07 USE
Operating elements ....................................................................................................................
Display elements ........................................................................................................................
MCS interfaces ...........................................................................................................................
MCSIO interfaces .......................................................................................................................
MCS system design with IOM ....................................................................................................
MCSIO system design ................................................................................................................
Indicating and operating elements .............................................................................................
Display elements ........................................................................................................................
RFID reader ................................................................................................................................
KAESER CONNECT for SIGMA CONTROL 2 ...........................................................................
Back of the KAESER Equipment Card .......................................................................................
User log-in with KAESER Equipment Card ................................................................................
User log-in with KAESER Equipment Card ................................................................................
Manual user log-in ......................................................................................................................
Login window ..............................................................................................................................
KAESER CONNECT for SIGMA CONTROL 2 ...........................................................................
Select language: window ............................................................................................................
System status menu ...................................................................................................................
Main menu ..................................................................................................................................
Graphs (illustration similar) .........................................................................................................
Arrow keys ..................................................................................................................................
Messages ..................................................................................................................................
I/O display (illustration similar) ...................................................................................................
User management menu ............................................................................................................
Log on for write access: window ................................................................................................
User management menu ............................................................................................................
Settings .....................................................................................................................................
Backup menu .............................................................................................................................
PROFIBUS plug wiring ...............................................................................................................
Electrical diagram example with SIGMA AIR MANAGER ..........................................................
Communication interface ............................................................................................................
Inserting the communication module ..........................................................................................
Front plate of the PROFIBUScommunication module ................................................................
Direct connection of two SIGMA CONTROL 2 ...........................................................................
LOAD remote contact .................................................................................................................
Wiring diagram for local/LOAD remote contact: .........................................................................
Machine with pressure switch regulation ....................................................................................
Function diagram ........................................................................................................................
Switching on and off ...................................................................................................................
Switching off in an emergency ...................................................................................................
Acknowledging messages ..........................................................................................................
Battery disposal ..........................................................................................................................
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
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List of Illustrations
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User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
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
Tab. 53
Tab. 54
No.: 9_9450 07 USE
Operating elements ....................................................................................................................
Display elements ........................................................................................................................
Main menu ..................................................................................................................................
Functions – Overview .................................................................................................................
Danger levels and their definition (personal injury) ....................................................................
Danger levels and their definition (damage to property) ............................................................
Formatting options ......................................................................................................................
Versions and options ..................................................................................................................
User interface .............................................................................................................................
Display data ................................................................................................................................
MCS interfaces ...........................................................................................................................
MCSIO interfaces .......................................................................................................................
RFID ...........................................................................................................................................
MCSIO inputs and outputs .........................................................................................................
Cable lengths .............................................................................................................................
IOM 1 ..........................................................................................................................................
IOM 2 ..........................................................................................................................................
IOM 3 ..........................................................................................................................................
Power supply specifications .......................................................................................................
Cable lengths .............................................................................................................................
IOM degree of protection ............................................................................................................
IOM dimensions .........................................................................................................................
Pressure transducer ...................................................................................................................
Resistance thermometer ............................................................................................................
Operating elements ....................................................................................................................
Display elements ........................................................................................................................
RFID reader ................................................................................................................................
Header ........................................................................................................................................
Reset check box status ..............................................................................................................
Check box status ........................................................................................................................
KAESER CONNECT functions ...................................................................................................
Menu structure ..........................................................................................................................
Status menu ...............................................................................................................................
Configuration menu ....................................................................................................................
Pressure control menu ...............................................................................................................
I/O periphery menu .....................................................................................................................
Communication menu ................................................................................................................
Connections menu .....................................................................................................................
Components menu .....................................................................................................................
Power switching menu ...............................................................................................................
Machine identification .................................................................................................................
Remote control identification ......................................................................................................
Machine identification .................................................................................................................
Display languages ......................................................................................................................
Date formats ...............................................................................................................................
Time formats ..............................................................................................................................
Units of pressure ........................................................................................................................
Units of temperature ...................................................................................................................
Display illumination .....................................................................................................................
Network parameters ...................................................................................................................
E-mail parameters ......................................................................................................................
Arrow key functions ....................................................................................................................
Compressor pressure parameters ..............................................................................................
Setting limits for the system setpoint pressure (* Cut-in pressure min) ......................................
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List of Tables
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
Tab. 73
Tab. 74
Tab. 75
Tab. 76
Tab. 77
Tab. 78
Tab. 79
Tab. 80
Tab. 81
Tab. 82
Tab. 83
Tab. 84
Tab. 85
Tab. 86
Tab. 87
Tab. 88
Tab. 89
viii
Pressure condition for LOAD ......................................................................................................
Pressure conditions for IDLE ......................................................................................................
Example: activated output ..........................................................................................................
Displaying and adjusting parameters .........................................................................................
Settings for machine start and stop ............................................................................................
User-defined clock program machine ON/OFF ..........................................................................
Example of a machine ON/OFF clock program ..........................................................................
Autostart delay period ................................................................................................................
Machine type and ETM design ...................................................................................................
Local operating mode (local mode) ............................................................................................
User-defined clock program ......................................................................................................
Example of system pressure changeover switching points ........................................................
Master control – overview ...........................................................................................................
Parameters for monitoring for communication malfunction ........................................................
PROFIBUS DP pin connection ...................................................................................................
Master-slave configuration procedure ........................................................................................
Function diagram ........................................................................................................................
Example for a clock program for equal duty cycling during the day ...........................................
Example for a clock program for equal duty cycling during the week ........................................
Assigned output signals .............................................................................................................
Logic settings .............................................................................................................................
Assigned analog measured values ............................................................................................
Transmitting a pressure transducer value ..................................................................................
Check list for commissioning the machine .................................................................................
Message sequence 1 .................................................................................................................
Message sequence 2 .................................................................................................................
Information of a message ...........................................................................................................
Message abbreviations ..............................................................................................................
Operating mode display .............................................................................................................
Abbreviation of operating modes ................................................................................................
Check box status ........................................................................................................................
Fault messages, possible causes and remedies ........................................................................
Warning messages and remedies ..............................................................................................
Operational messages ...............................................................................................................
System messages and remedies ...............................................................................................
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1
SIGMA CONTROL 2 Quick installation guide
1.1
Operating elements
1 SIGMA CONTROL 2 Quick installation guide
1.1
Operating elements
Fig. 1
Operating elements
Item Description
Tab. 1
No.: 9_9450 07 USE
Function
«Up»
Scrolls up the menu options. Increases a parameter value.
«Left»
Jumps to the left.
Moves the cursor position to the next left field.
«Right»
Jumps to the right.
Moves the cursor position to the next right field.
«Down»
Scrolls down the menu options.
Reduces a parameter value.
«Escape»
Returns to the next higher menu option level.
Exits the edit mode without saving.
«Enter»
Jumps to the selected submenu option.
Exits the edit mode and saves.
«ON»
Switches the machine on.
«OFF»
Switches the machine off.
10
RFID
RFID reader for user log-in with RFID Equipment Card.
11
«Timer control»
Switches the timer control on and off.
12
«Remote control»
Switches the remote control on and off.
13
«LOAD/IDLE»
Toggles between the LOAD and IDLE modes.
19
«Information»
Displays the event memory.
21
«Acknowledgement»
Confirms/acknowledges alarms and warning messages.
If permissible: Resets the fault counter (RESET).
Operating elements
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
1
SIGMA CONTROL 2 Quick installation guide
1.2
Display elements
1.2
Display elements
Fig. 2
Display elements
Item Description
Function
ON
Display illuminates green when the machine switched on.
Display
Graphic display with 8 lines and 30 characters per line.
11
Timer control
Continuous green light when the machine is controlled by the timer.
12
Remote control
Continuous green light when the machine is in remote control.
14
IDLE
Continuous green light when the machine is running in IDLE. Flashes
when the «LOAD/IDLE» toggle key is pressed.
15
LOAD
Continuous green light when the machine is running in LOAD.
16
Controller voltage
Continuous green light when voltage is applied to the controller.
17
Warning
Flashes in yellow in the following events:
■
Maintenance work due
■
Warning message
Continuous yellow light after acknowledgement.
18
Communications
error
Continuous red light to indicate a defective communication connection,
or an external alarm message without machine shutdown.
20
Alarm
Flashes red to indicate a machine alarm.
Continuous red light after acknowledgement.
Tab. 2
Display elements
1.3
Main menu
Press «Up» / «Down» / «Enter» to open the main menu.
Menu No. Menu designation Function
Status
Displays messages, statistics and status information.
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SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
1
SIGMA CONTROL 2 Quick installation guide
1.4
Functions – Overview
Menu No. Menu designation Function
Tab. 3
Performance data Displays measured data of the machine and its components (e.g.,
motors).
Operating data
Displays operating hours, switching cycles and energy data.
Maintenance
Displays maintenance data of the machine and its components.
Configuration
Setting of machine parameters, compressed air system and acces‐
sories.
Compressor clock Setting the timer control.
User
Manual user log-in and password administration.
Communication
Setting the Ethernet interface, COM modules and control center
connection.
Machine test
Safety relief valve and temperature sensor test and shutdown at ex‐
cessive temperature.
10
Components
Display of settings on machine components, e.g. the power switch‐
ing unit.
Main menu
See Chapter 5.6.2 for the complete menu structure.
1.4
No.: 9_9450 07 USE
Functions – Overview
Function
Menu Action steps
No.
Chapter
Setting the contrast
Main Press and hold «Information» – «Up» / «Down».
menu
8.2.11
Setting the brightness
Main Press and hold «Information» – «Left» / «Right».
menu
8.2.11
Setting the language
Main «Enter» – «Up» – «Enter» – «Up» / «Down».
menu
8.2.2
Setting date, time and
time zone
5.1
Identification with
RFID Equipment Card
–
8.2.4
Setting pressure pa‐
rameters
5.2.2 .
8.4
Setting the
«Timer control»
.
8.5.1
Activating the
«Timer control» key
.
8.5.1.3
Activating
«Timer control»
–
Activate the «Timer control» key – Press
«Timer control».
8.5.1.4
.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
8.2.7
Tab. 4
SIGMA CONTROL 2 Quick installation guide
1.4
Functions – Overview
Function
Menu Action steps
No.
Chapter
Activate
the «Remote control»
key
5.2.3 .
8.2.12
Activating the
«Remote control»
–
Activate the «Remote control» key – Press
«Remote control».
8.2.12
Setting the control
mode
5.3
Select .
8.6.1
Setting up the holiday
period
5.4.2 .
8.5.2
Displaying operating
data
.
9.8
Setting the mainte‐
nance interval
.
9.10
Checking the safety re‐ 9.1
lief valve
For the test process, see Chapter.
9.11
High temperature shut‐ 9.1
down test
For the test process, see Chapter.
9.12
5.5
Alarm messages
1.1.1 An alarm message causes the machine to shut down.
10.2
The Alarm LED flashes red. Alarm messages are identi‐
fied with the letter A. Example:
<0002 S k 31/12/2017 13:14:15 Motor temperature ⇞> .
Warning messages
1.1.1 If maintenance work is to be carried out or if the warning 10.3
is displayed before an alarm, the yellow Warning LED
flashes. Warning messages are identified with the let‐
ter W.
Operational messages
1.1.1 Operational messages provide information about the
current operational state of the machine. Operational
messages are identified with the letter O.
Diagnostic messages
1.1.1 A diagnostic message causes the machine to shut
10.5
down. They provide information on the status of the con‐
troller, the connected input and output modules and sup‐
port an authorized KAESER service representative in
troubleshooting. Diagnostic messages are identified with
the letter D.
System messages
1.1.1 A system message causes the machine to shut down.
System messages are identified with the letter Y.
10.4
10.6
Functions – Overview
Settings can be made after log-in with the RFID Equipment Card and password access level
2.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
2
Regarding this Document
2.1
Using this document
2 Regarding this Document
2.1
Using this document
The user manual contains important information to the entire life cycle of SIGMA CONTROL 2.
The user manual is a component of the product.
➤ Keep the user manual in a safe place throughout the life of SIGMA CONTROL 2.
➤ Pass the user manual on to the next owner/user of the machine.
➤ Ensure that all amendments received are inserted into the user manual.
2.2
Copyright
This user 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 supported.
2.2.1
Software
The software used in SIGMA CONTROL 2 contains copyright-protected software packages which
are licensed as Open Source.
A copy of these licenses is contained in SIGMA CONTROL 2.
Display the licenses by pointing your browser to the "COPYING" file in the root directory of
SIGMA CONTROL 2.
URL:
http:// /COPYING
The licenses can also be found under these addresses:
http://www.gnu.org/licenses
http://code.google.com/p/curve25519-donna/
Within three years from receipt of SIGMA CONTROL 2, you may obtain the complete source code
by sending a corresponding order to the following address:
Technical Office Electrical Design
KAESER KOMPRESSOREN SE
96450 Coburg, Postfach 2143
Germany
This offer is valid for anybody having this information.
No.: 9_9450 07 USE
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
2.3
Regarding this Document
2.3
Approvals
Approvals
The product has the following approvals:
■
─
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
■
To assure continued compliance, any changes or modifications not expressly approved by the
party responsible for compliance could void the user's authority to operate this equipment. (Ex‐
ample - use only shielded interface cables when connecting to computer or peripheral devi‐
ces).
■
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions:
■
■
2.4
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 of the
following measures:
─
This device may not cause harmful interference, and
─
This device must accept any interference received, including interference that may cause
undesired operation
This device complies with Industry Canada licence-exempt RSS standard(s). Operation is sub‐
ject to the following two conditions:
─
This device may not cause interference and
─
This device must accept any interference, including interference that may cause undesired
operation of the device
Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio
exempts de licence. L'exploitation est autorisée aux deux conditions suivantes :
─
l'appareil ne doit pas produire de brouillage, et
─
l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le brouil‐
lage est susceptible d'en compromettre le fonctionnement
Updating the user manual
The page http://www.kaeser.com/int-en/manuals/response.aspx of our website provides frequently
updated versions of this user manual.
➤ Download the user manual in your language.
2.5
Symbols and labels
➤ Please note the symbols and labels used in this document.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
2.5.1
Regarding this Document
2.5
Symbols and labels
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. 5
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 definition (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
Example:
The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1.
The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe
injury may occur.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
2.5.2
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. 6
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:
No.: 9_9450 07 USE
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
2
Regarding this Document
2.5
Symbols and labels
The type and source of the imminent danger is shown here!
Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.
2.5.3
Other alerts and their symbols
The meaning of names is emphasized by different formatting. Depending on the font, not all for‐
matting options can be realized.
Tab. 7
Name
Formatting
Example
Operating state
UPPER CASE
LOAD
Item number
...
Open valve 4
Indication
italic
ON LED
Key
« ... »
«ON» key
Menu option
< ... >

Menu path


activated
...
The minutes display flashes. 00:00:00
Formatting options
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.
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.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
3
Technical Data
3.1
SIGMA CONTROL 2 Controller
3 Technical Data
3.1
SIGMA CONTROL 2 Controller
Industrial computer
■
Internal temperature monitoring
■
Internal low voltage monitoring
■
3.1.1
Battery-buffered real-time clock
─
Battery service span more than 10 years
─
Battery replaceable
Versions and options
SIGMA CONTROL 2 is offered in different designs.
Type
Prepared for connection to control center
Connection to control technology not
provided
Option
C3
C48
Compo‐
nents
Main Control System (MCS): Slot for an
optional communication module (to con‐
nect to a control center)
Main Control System Input Output
(MCSIO): Digital and analog inputs and
outputs integrated
Input-Output-Module (IOM): Modules with
digital and analog inputs and outputs.
Tab. 8
3.1.2
Versions and options
User interface with display, CPU and interfaces
User interface
Feature
MCS
Material
MCSIO
Plastics
Width [in.]
7.5
Height [in.]
5.1
Depth [in.]
1.8
2.4
Number of membrane keys
13
Number of LEDs
Degree of protection, control cabinet exterior
IP 54
Degree of protection, control cabinet interior
IP 20
Voltage [V]
Current [A]
Voltage source
Tab. 9
No.: 9_9450 07 USE
24
0.3
2.5
Input/output module
External
User interface
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
3
Technical Data
3.1
SIGMA CONTROL 2 Controller
Display
Feature
Value
Graphical display [px]
255 x 128
Width [in.]
3.2
Height [in.]
1.6
Maximum number of lines/characters
8/30
Colors
Black/white with grey scale
Lighting
LED backlit
px = pixel
Tab. 10
Fig. 3
Display data
MCS interfaces
Identification
Interface
Connection
X1
Ethernet 10/100 Base T
RJ 45 socket
X2
I/O bus
9-pole SUB-D pins
X3
RS485–FC (USS interface)
9-pole SUB-D socket
X4
Com modules,
slot for communications module
Module optional for:
PROFIBUS, PROFINET,
Modbus RTU, Modbus TCP,
DeviceNet
X5
SD card, SD card slot
SD/SDHC card
X6
FG
Functional ground (FG)
The positions of the interfaces X1–X6 are marked on the rear of the controller.
Tab. 11
10
MCS interfaces
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
Fig. 4
Technical Data
3.1
SIGMA CONTROL 2 Controller
MCSIO interfaces
Marking
Interface
Connection
X1
Ethernet 10/100 Base T
RJ 45 socket
X3
RS485–FC (USS interface)
9-pole SUB-D socket
X5
SD card, SD card slot
SD/SDHC card
X6
FG
Functional ground (FG)
X7
24 VDC, DII
Power supply 24 VDC
Digital inputs DII1.00–DII1.05
X8
DII/DOT
Digital inputs DII1.06–DII1.07
Digital outputs DOT1.00–DOT1.01
X9
AII/AIR
Analog input current 0–20 mA,
AII1.00–AII1.01
Analog input resistor AIR1.00–
AIR1.01
X10
DOR
Digital output relay 250 VAC, 4 A
DOR1.00–DOR1.04
The positions of the interfaces X1–X10 are marked on the rear of the controller.
Tab. 12
MCSIO interfaces
Identification with RFID Equipment Card
Feature
Hardware on the SIGMA CONTROL 2 controller
Hardware (external)
Recognition distance [in.]
No.: 9_9450 07 USE
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Value
RFID write/read device
RFID Equipment Card
Max. 2
11
3
Technical Data
3.1
SIGMA CONTROL 2 Controller
Feature
Value
Frequency [MHz]
13.56
Tab. 13
RFID
3.1.3
Inputs and outputs with MCSIO
Integrated inputs and outputs with MCSIO type controller
Input/Output
Tab. 14
3.1.3.1
Number
Digital input (DI), 24 VDC
Digital output transistor (DOT), 24 VDC, 0.5 A
Analog input current (AII), 0–20 mA
Analog input resistor (AIR), PT100
Digital output relay (DOR), 250 VAC, 4 A
MCSIO inputs and outputs
Maximum cable lengths
Input/Output
Cable length [ft.]
Analog input current (AII),
Analog input resistor (AIR)
Analog output current (AOI)
< 100
Digital input (DI),
Digital output relay (DOR)
< 330
Digital output transistor (DOT)
< 100
Tab. 15
Cable lengths
3.1.4
Input/output modules
IOM modules only in combination with the MCS controller type
There are three different types of input/output modules with different numbers of inputs and out‐
puts.
The number of input/output modules actually available depends on the machine type and the avail‐
able options.
Refer to the machine's wiring diagram for the input/output modules installed in your equipment.
The input/output module features:
12
■
Internal temperature monitoring
■
Internal low voltage monitoring
■
LED indication of operational status
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
3
Technical Data
3.1
SIGMA CONTROL 2 Controller
IOM 1
Input/Output
Tab. 16
Input/output module 1
Internal, into
the control
cabinet
Available in
parallel on
both sides
External, into
the compres‐
sor interior
Digital input (DI), 24 VDC
10
Analog input current (AII), 0–20 mA
–
Analog input resistor (AIR), PT100
–
Digital output relay (DOR), 250 VAC, 8 A
–
–
Digital output transistor (DOT), 24 VDC, 0.5 A
–
Analog output current (AOI), 0–20 mA
–
–
–
IOM 1
IOM 2
Input/Output
Tab. 17
Input/output module 2
Internal, into
the control
cabinet
Available in
parallel on
both sides
External, into
the compres‐
sor interior
Digital input (DI), 24 VDC
–
Analog input current (AII), 0–20 mA
–
Analog input resistor (AIR), PT100
–
–
Digital output relay (DOR), 250 VAC, 8 A
–
–
Digital output transistor (DOT), 24 VDC, 0.5 A
–
Analog output current (AOI), 0–20 mA
–
–
IOM 2
IOM 3
Input/Output
Tab. 18
No.: 9_9450 07 USE
Input/output module 3
Internal, into
the control
cabinet
Available in
parallel on
both sides
External, into
the compres‐
sor interior
Digital input (DI), 24 VDC
–
Analog input current (AII), 0–20 mA
–
Analog input resistor (AIR), PT100
–
Digital output relay (DOR), 250 VAC, 8 A
–
–
Digital output transistor (DOT), 24 VDC, 0.5 A
–
Analog output current (AOI), 0–20 mA
–
–
IOM 3
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
13
3.1.4.1
Technical Data
3.1
SIGMA CONTROL 2 Controller
Electrical connection specifications IOM
Power is provided by the power supply unit within the machine.
Feature
Value
Rated power supply (stabilized) [V DC]
24
Current consump‐
tion SIGMA CONTROL 2 with IOM 1 [A]
2.4
Current consumption IOM 2 [A]
2.5
Current consumption IOM 3 [A]
1.6
IOM = Input/Output module
Tab. 19
3.1.4.2
Power supply specifications
Maximum cable lengths
Input/Output
Tab. 20
3.1.4.3
Tab. 21
3.1.4.4
Conductor length [ft.]
Analog input current (AII),
Analog input resistor (AIR)
Analog output current (AOI)
< 100
Digital input (DI),
Digital output relay (DOR)
< 330
Digital output transistor (DOT)
< 100
Cable lengths
Input/output module – degree of protection
Feature
Value
Degree of protection within the machine
IP 54
Degree of protection within the control cabinet
IP 20
IOM degree of protection
Input/output modules – dimensions
Feature
Value
Width [in.]
4.9
Height [in.]
9.8
Depth [in.]
1.7
Tab. 22
IOM dimensions
3.1.5
Sensors
Pressure transducer
14
Feature
Value
Output signal [mA]
0/4–20
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
3
Technical Data
3.1
SIGMA CONTROL 2 Controller
Feature
Connection
Tab. 23
Value
Twin cable
Pressure transducer
Resistance thermometer
Feature
Value
Sensing resistance
PT100
Connection
Tab. 24
No.: 9_9450 07 USE
Twin cable
Resistance thermometer
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
15
4
Safety and Responsibility
4.1
Basic instructions
4 Safety and Responsibility
4.1
Basic instructions
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 ener‐
gy and, if not installed and used in accordance with the instructions, may cause harmful inter‐
ference 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:
➤ Close and lock the door of the equipment properly.
➤ Place the equipment as far as possible from the interfered radio or television receiver.
Changes or modifications not expressly approved by KAESER could void the user's authority
to operate the equipment.
This device complies with Industry Canada licence-exempt RSS standard(s).
Operation is subject to the following two conditions:
■
this device may not cause interference and
■
this device must accept any interference, including interference that may cause unde‐
sired operation of the device
SIGMA CONTROL 2 is manufactured to the latest engineering standards and acknowledged safety
regulations.
The safety regulations of the machine in which SIGMA CONTROL 2 is installed apply.
4.2
Specified use
SIGMA CONTROL 2 is solely intended for the control of machines in which SIGMA CONTROL 2 is
factory-installed. Any other use is considered incorrect. The manufacturer is not liable for any dam‐
ages that may result from incorrect use. The user alone is liable for any risks incurred.
➤ Adhere to the specifications given in this user manual and the machine's operator manual.
➤ Operate the machine only within its performance limits and under the permitted ambient condi‐
tions.
4.3
Improper use
Improper usage can cause damage to property and/or (severe) injuries.
➤ Use SIGMA CONTROL 2 only as intended.
➤ Do not use SIGMA CONTROL 2 to control other machines or products for which
SIGMA CONTROL 2 is not intended.
16
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5
Design and Function
5.1
The controller
5 Design and Function
5.1
The controller
SIGMA CONTROL 2 controls, regulates, monitors, and protects the machine.
All parameters needed to operate KAESER rotary screw compressors can be set and displayed
using the controller. Various user-dependent password mechanisms protect the parameters.
Components
SIGMA CONTROL 2 has the following components:
■
■
■
No.: 9_9450 07 USE
Main Control System (MCS):
─
Industrial PC.
─
Software for the control, regulation, and monitoring of the machine, for the display and mod‐
ification of settings and for communication.
─
User interface with backlit display, touch keys, LEDs, and interfaces.
─
Radio Frequency Idenfication (RFID):
Identification with RFID Equipment Card.
─
Slot for customer interface; optional communications module.
─
SD card slot for SD/SDHC cards:
Manual loading of updates with an SC card, reading or recording process data.
Main Control System Input Output (MCSIO):
─
As with MCS, but with:
─
Integrated digital and analog inputs and outputs.
─
Without slot for customer interface.
Input-Output-Module (IOM):
For SIGMA CONTROL 2 (Prepared for connection to control center): modules with digital and
analog inputs and outputs with autonomous power supply.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
17
Fig. 5
Design and Function
5.1
The controller
MCS system design with IOM
Fig. 6
Machine enclosure
Control cabinet
SIGMA CONTROL 2 (Prepared for con‐
nection to control center)
Input-Output-Module (IOM):
I/O bus
Inputs/outputs in the interior of the control
cabinet
Inputs/outputs in the interior of the com‐
pressor
Inputs/outputs for external sensors
Compressor
MCSIO system design
Machine enclosure
Control cabinet
SIGMA CONTROL 2 (Connection to con‐
trol technology not provided)
Inputs/outputs in the interior of the control
cabinet
Inputs/outputs in the interior of the com‐
pressor
Inputs/outputs for external sensors
Compressor
Function
The control and regulating function allows:
18
■
Automatic changeover of the machine from LOAD to IDLE or READY.
■
Optimum utilization of the drive motor in relation to the user's actual air demand.
■
Automatic restart of the machine after a power failure (can be deactivated).
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5
Design and Function
5.2
Operating panel
The monitoring function allows:
■
Supervision of all maintenance-relevant components via the maintenance interval counters.
■
Display of warning and maintenance messages for due maintenance on the display
of SIGMA CONTROL 2.
The protective function allows:
■
5.2
5.2.1
Fig. 7
Automatic machine shutdown on alarms that may lead to damage to the machine, e.g. high
current, high pressure or high temperature.
Operating panel
Indicating and operating elements
Indicating and operating elements
Item Description
No.: 9_9450 07 USE
Function
«Up»
Scrolls up the menu options. Increases a parameter value.
«Left»
Jumps to the left.
Moves the cursor position to the next left field.
«Right»
Jumps to the right.
Moves the cursor position to the next right field.
«Down»
Scrolls down the menu options.
Reduces a parameter value.
«Escape»
Returns to the next higher menu option level.
Exits the edit mode without saving.
«Enter»
Jumps to the selected menu option.
Exits the edit mode and saves.
«ON»
Switches the machine on.
«OFF»
Switches the machine off.
10
RFID
RFID reader for user log-in with RFID Equipment Card.
11
«Timer control»
Switches the timer control on and off.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
19
5
Design and Function
5.2
Operating panel
Item Description
12
«Remote control»
Switches the remote control on and off.
13
«LOAD/IDLE»
Toggles between the LOAD and IDLE modes.
19
«Information & Events»
Displays the event memory.
21
«Acknowledgement»
Confirms/acknowledges alarms and warning messages.
If permissible: Resets the fault counter (RESET).
Tab. 25
Operating elements
5.2.2
Display elements
Fig. 8
Function
Display elements
Item Description
Function
ON
Continuous green light when the machine switched on.
Display
Graphic display with 8 lines and 30 characters per line.
11
Timer control
Continuous green light when the machine is controlled by the timer.
12
Remote control
Continuous green light when the machine is in remote control.
14
IDLE
Continuous green light when the machine is running in IDLE. Flashes
when the «LOAD/IDLE» toggle key is pressed.
15
LOAD
Continuous green light when the machine is running in LOAD.
16
Controller voltage
Continuous green light when voltage is applied to the controller.
17
Warning
Flashes in yellow in the following events:
■
Maintenance necessary
■
Warning message
Continuous yellow light after acknowledgement.
18
20
Communications
error
Continuous red light to indicate a defective communication connection,
or an external alarm message without machine shutdown.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5
Design and Function
5.3
Display
Item Description
20
Function
Alarm
Tab. 26
Display elements
5.2.3
RFID reader
Flashes red to indicate a machine alarm.
Continuous red light after acknowledgement.
RFID is the abbreviation for “Radio Frequency Identification” and makes possible to identify per‐
sons and objects.
Placing a suitable transponder in front of the RFID reader of the controller will automatically acti‐
vate the communication between transponder and SIGMA CONTROL 2.
A suitable transponder is the RFID Equipment Card. Two of them have been provided with the ma‐
chine.
Typical application:
■
Operators log on at the machine.
(Manual input of the password not required)
The RFID Equipment Cards are carefully packed in a plastic sleeve.
This plastic sleeve is attached to the rear of the controller in the control cabinet.
Fig. 9
RFID reader
Item Description Function
24
Tab. 27
5.3
RFID
RFID reader for the communication with a RFID Equipment Card or RFID Key.
RFID reader
Display
Use the display to read information and to enter data. The display comprises 8 lines, each of 30
characters.
During operation, the display will indicate the operating mode.
Pressing «Enter» or one of the arrow keys opens the main menu. Here, you can set the language
to be used for the display of texts or open the various submenus.
No.: 9_9450 07 USE
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
21
5.3.1
Design and Function
5.3
Display
Operating mode
88psi
08:15AM
176° F
Header
__________________________________
Current operating mode
Load
__________________________________
Key
–
on
¦
pA
–
Operating parameters
on
__________________________________
Run
2500h Load
2490h
Maintenance in
500h
Operating parameters
Maintenance indicator
Header
The header is the topmost line on the display. It is always shown as white text on a black back‐
ground.
Important information and values are displayed in the header.
The displayed data varies depending on the machine type:
Type
Tab. 28
Header, left
Header, center
Header, right
SIGMA CONTROL 2 Working pressure
FLUID
Time
Airend discharge temperature
SIGMA CONTROL 2 Working pressure
DRY
Time
Airend discharge temperature
SIGMA CONTROL 2 Working pressure
VAC
Time
Airend discharge temperature
SIGMA CONTROL 2 Pressure at the com‐
BOOSTER
pressed air inlet p1
Temperature at the Pressure at the compressed
compressed air
air outlet p4
outlet T2
Header
Lines 3 and 5: Operational state
Depending on the settings, either the current state of the machine or a menu text is shown in line 3.
The following parameters with their current values are displayed in line 5:
■
Remote control yes/no
■
Timer control yes/no
■
Pressure control
Lines 7 and 8: Machine state
The following parameters with their current values are displayed in lines 7 and 8:
22
■
The hours during which the machine was activated.
■
The hours during which the machine ran in operating mode LOAD.
■
Remaining working hours of the machine before the next maintenance.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5.3.2
Design and Function
5.3
Display
Main menu
88psi
08:15AM
176° F
Main menu
----------------English US----------------
Language
▶1 Status
Active line
▶2 Performance data
Submenu
▶3 Operating data
Submenu
▶4 Maintenance
Submenu
▶5 Configuration
Submenu
Description
The main menu is the top menu level. You open the individual submenus in the main menu.
A scrollbar appears at the right side of the display if you open a menu with more than 6 lines. It
represents the currently visible portion of the menu. A short scrollbar thus indicates that the opened
menu is very long as only a small portion can be displayed.
The image above provides an example for the appearance of the main menu (without scrollbar).
Numbering
Each menu is numbered.
Not all menus may be displayed because the access to certain menus is restricted by the access
level, and some menus are displayed or hidden due to specific settings or options.
For example, you can recognize subordinate menus in the menu structure by the number preced‐
ing their designation. The menu structure is explained in chapter 5.6.2.
Active line
The active line is always shown as white text on a dark background. Do not confuse this with the
header which is also shown with white lettering on a black background.
Press «Enter» to open a menu in the active line. This opens the selected menu.
Here, you can change parameters.
5.3.3
Setting parameters
In order to set a parameter in the active line of the selected menu, you must always switch to
setting mode.
Changing parameters
Press «Enter». The value of the parameter will flash indicating that it can be changed.
The «Enter» key affects only the active line.
In some lines, you can change more than a single parameter.
In this case, you must first select the specific parameter with the «Left» or «Right» keys.
No.: 9_9450 07 USE
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
23
5
Design and Function
5.4
Access rights
Resetting current parameters
In order to reset current parameters to zero, activate the check box for Reset in the active line of
the display.
First, press «Enter» to switch into setting mode. The check box Reset will flash.
You then press «Up». The check box is activated and flashes.
Press «Enter» to save the settings.
The parameters no longer flash and are reset. The check box for Reset is again deactivated.
Check box Reset
Status
☒
activated
☐
deactivated
Tab. 29
Reset check box status
5.3.4
Activating keys with check boxes
Certain keys of the SIGMA CONTROL 2 are locked by default. Activate the corresponding check
boxes in the active line of the display to unlock these keys.
First, press «Enter» to switch into setting mode. The check box will flash.
You then press «Up». The check box is activated and flashes.
Press «Enter» again to save the settings.
The display line no longer flashes and the key is activated.
Proceed correspondingly to deactivate a key.
Tab. 30
5.4
Check box
Status
☑
activated
☐
deactivated
Check box status
Access rights
Access to the controller is governed by the user name combined with a password.
Users log on using an RFID Equipment Card by default. Alternatively, you can manually enter the
user name and the password.
When the controller is switched on, the lowest level of access (level 0) is activated.
You have access to a further level: Access level 2
Access level 2 allows you to display and adjust further parameters.
The access level will automatically return to level 0 after 10 minutes without any key being pressed.
Secure storage of the RFID Equipment Cards
You will receive 2 RFID Equipment Cards with each machine.
They are stored in a plastic sleeve.
This plastic sleeve is attached at the rear of the controller in the control cabinet.
If you lose both RFID Equipment Cards, you can register a new RFID Equipment Card only after
having entered the user name and the password. A new RFID Equipment Card may be registered
by KAESER service subject to a fee, if the user name and the password are lost.
24
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5.5
Design and Function
5.5
KAESER CONNECT
KAESER CONNECT
Using an Internet-capable device with web browser, you can open a visualization of the controller.
This enables remote checking of, for example, the operating and energy efficiency of your ma‐
chine. For this purpose, you must once generate a password (see Chapter 8.2.5). KAESER
CONNECT does not require additional software to do so. The display language of KAESER
CONNECT can be set independently to the language used with SIGMA CONTROL 2.
Fig. 10
KAESER CONNECT for SIGMA CONTROL 2
KAESER CONNECT functions:
Operating element Meaning
read => write
Switching from read-only to read/write mode
To create users and acknowledge messages
write => read
Switching from read/write to read-only mode
Logout
User log-out
Contact/Service
Displaying the contact information for an authorized KAESER service repre‐
sentative
Select language:
Setting the display language for KAESER CONNECT
System status
Mapping of the local menu
Graphs
■
Pressures and temperatures are displayed in different graphs
■
Graphic representation of the machine status (STOP, IDLE, LOAD) and
RPM along the time axis
■
Current messages
■
Message history (event memory)
Messages
I/O display
No.: 9_9450 07 USE
Assignment of the input/output modules
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
25
5
Design and Function
5.6
Menus – overview
Operating element Meaning
User management ■
Settings
Backup
Tab. 31
Further information
5.6
5.6.1
Creating and activating new user accounts
■
Modifying or deactivating existing user accounts
■
Changing passwords
■
Unit display format
■
Date display format
■
Time display format
Saving the SIGMA CONTROL 2 data to a PC
KAESER CONNECT functions
For opening KAESER CONNECT, login and other procedures, please see chapter 8.3.
Menus – overview
Operating mode
When the machine is switched on, details of the software are displayed, for example:
Compressor
Machine model
PN: SN:
Part number and serial number of the machine
EN:
Equipment number of the machine
SIGMA CONTROL 2 – MCS
MCS: Main Control System
PN: SN:
Part number and serial number of the controller
Software:
Software version
Subsequently, the software is loaded and the current operating mode is displayed, for example:
88psi 08:15AM 176° F
Header
__________________________________
Load
Current operating mode
__________________________________
Key – on ¦ pA – on
Operating parameters
__________________________________
Run 2500h Load 2490h
Operating parameters
Maintenance in 500h
Maintenance indicator
The following parameters are displayed:
26
■
Current operating mode of the machine
■
On the left-hand side of "¦" you can see from where the compressor is switched on (in the illus‐
trated example via the green «ON» key) and what the current status is (in the example "on").
■
On the right-hand side of "¦", you can see the mode of the load control (in the illustrated exam‐
ple, the network nominal pressure pA is active) and the mode of the compressor (in the exam‐
ple it is switched on).
■
Number of operating hours and hours of the machine being in LOAD mode.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5.6.2
Design and Function
5.6
Menus – overview
Menu structure
Press «Enter» or one of the arrow keys to open the main menu.
In the main menu, you can:
■
Retrieve displayed information
■
Enter customer-specific settings
The menus shown require password access level 2.
Main menu
Navigation
Function/Submenu
1 Status
■
Messages
■
Statistics
■
Current pressure control
■
Current operating mode
■
DI/DO status
■
pN/ADT curve
■
pN/n curve 1)
For details of the Status menu, please see ta‐
ble 33.
No.: 9_9450 07 USE
1)
Power switching with frequency converter
3)
SIGMA CONTROL 2 (Prepared for connection to control technology)
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
27
5
Design and Function
5.6
Menus – overview
Navigation
Function/Submenu
2 Performance data
■
■
■
3 Operating data
─
System pressure pNloc
─
Internal pressure pi
─
ADT
─
Oil separator
─
Starting temperature
─
Inlet temperature
─
PD temperature
─
Air filter
Compressor motor
─
Motor temperature (if available)
─
Speed 1)
─
Current 1)
─
UzK 1)
─
Torque 1)
Fan
─
Speed 1)
─
Current 1)
─
UzK 1)
─
Torque 1)
■
Analogue values
■
SIGMA CONTROL 2
■
Operating hours
■
■
28
Compressor
─
Compressor
─
On load
─
Motor
─
Compressor block
─
SIGMA CONTROL 2
─
Partial load valves
Switching cycles
─
Load valve on
─
Mains contactor on
kWh counter
1)
Power switching with frequency converter
3)
SIGMA CONTROL 2 (Prepared for connection to control technology)
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5
Design and Function
5.6
Menus – overview
Navigation
Function/Submenu
4 Maintenance
Oil filter
Oil separator
Oil change
Air filter
Valve inspection
Belt/coupling inspection
Compressor motor
Bearing lube
Bearing change
Fan motor(s)
Bearing lube
Bearing change
Electrical equipment
Annual maintenance due
5 Configuration
For details of the Configuration menu, please
see table 34.
6 Compressor clock
Key clock
Reset
Switching point 01:
Switching point 02:
Switching point 03:
Switching point 04:
Switching point 05:
Switching point 06:
Switching point 07:
Switching point 08:
Switching point 09:
Switching point 10:
7 User
Name
Password
Current access level:
8 Communication
■
Ethernet/SIGMA NETWORK
■
Com-Module 3)
Key remote
For details of the Communication menu, please
see table 37.
9 Machine test
No.: 9_9450 07 USE
■
TÜV inspection
1)
Power switching with frequency converter
3)
SIGMA CONTROL 2 (Prepared for connection to control technology)
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
29
5
Design and Function
5.6
Menus – overview
Navigation
Function/Submenu
10 Components
■
Compressor motor
─
Power switching
For details of the Components menu, please
see table 39.
Tab. 32
5.6.2.1
1)
Power switching with frequency converter
3)
SIGMA CONTROL 2 (Prepared for connection to control technology)
Menu structure
Status menu
Navigation
Function/Submenu
1.1 Messages
■
■
■
Current messages
Message history
─
Compressor messages
─
Diagnostic messages
─
System messages
Address error
─
Incorrect parameterisation in 2)
Status report
current Alarms
current Warnings
1.2 Statistics
Load (hours)
since/Reset:
Load (speed) 1)
since/Reset:
Network actual pressure pNloc
Motor starts
since/Reset:
Motor starts /d
Motor starts /h
Motor starts T↓
Last load run
Last idle run
Last motor off
30
1)
Power switching with frequency converter
2)
Only visible in the event of parameterization error
3)
SIGMA CONTROL 2 (Prepared for connection to control technology)
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5
Design and Function
5.6
Menus – overview
Navigation
Function/Submenu
1.3 Current pressure control
SIGMA CONTROL 2
Cut-out pressure
SP/SD
Network actual pressure
Frequency converter 1)
Setpoint pressure 1)
Actual pressure 1)
Speed nominal value 1)
Speed actual value 1)
Speed limits 1)
1.4 Current operating mode
Compressor on
Load control
Control mode
Idle period
Acknowledgement
Waste heat recovery (if available)
1.5 DI/DO status
1st I/O module
DI/DO display
2nd I/O module
DI/DO display
3rd I/O module
DI/DO display
Tab. 33
No.: 9_9450 07 USE
1.6 pN/ADT curve
Diagram:
Nominal pressure/Discharge temperature
1.7 pN/n curve 1)
Diagram:
Nominal pressure/Speed
1)
Power switching with frequency converter
2)
Only visible in the event of parameterization error
3)
SIGMA CONTROL 2 (Prepared for connection to control technology)
Status menu
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
31
5.6.2.2
Design and Function
5.6
Menus – overview
Configuration menu
Navigation
Function/Submenu
5.1 General
■
System information
─
SIGMA CONTROL 2 MCS 3)
─
Software
─
KAESER:PN/SN
─
Controller manufacturer:PN/SN
─
MFGDT (Manufacturing date)
─
Compressor
─
EN (Equipment number)
─
PN (Part number)
─
SN ( Serial number)
─
I/O modules
─
First IOM
─
Second IOM (if available) 3)
─
FC information 1)
─
Compressor motor
─
Oil-/air cooler fan
─
Oil cooler fan
Model:
Date/time
Time zone
■
Time server
─
active:
─
IP address
Date format
Time format
Pressure unit
Temperature unit
Display lighting
5.2 Pressure control
■
Pressure sensors
■
Pressure settings
■
Load control
■
Network actual pressure
For details of the Pressure control menu, please
see table 35.
32
1)
Power switching with frequency converter
3)
SIGMA CONTROL 2 (Prepared for connection to control technology)
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5
Design and Function
5.6
Menus – overview
Navigation
Function/Submenu
5.3 Control mode
Local mode:
5.4 Compressor start
■
Venting period
■
DUAL
■
QUADRO
■
Partial load valves
■
Compressor on
■
Compressor off
Autostart:
Start inhibit:
Starting temperature
5.5 Acknowledgement
Remote mode:
RC ack
Key remote
5.6 ETM
Waste heat recovery
Local mode:
Remote mode:
current
RC DI
Key remote
5.7 I/O periphery
■
Oil cooler
■
Waste heat recovery
■
DO functions
■
Analogue values
■
External messages
■
Switch
For details of the I/O periphery menu, please
see table 36.
5.8 Timer
on
off
DOR
No.: 9_9450 07 USE
1)
Power switching with frequency converter
3)
SIGMA CONTROL 2 (Prepared for connection to control technology)
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
33
5
Design and Function
5.6
Menus – overview
Navigation
Function/Submenu
5.9 Refrigeration dryer (if available)
Control mode
Compressor ready:
Compressor Clk/RC/RB off:
Temperature ↑
DOR
DOT
Temperature ⇟
DOR
DOT
Safe compressed air supply/Safe compressed
air quality
Error operation without RD
active:
Run time max.:
Reset Alarm:
Tab. 34
1)
Power switching with frequency converter
3)
SIGMA CONTROL 2 (Prepared for connection to control technology)
Configuration menu
Pressure control menu
Navigation
Function/Submenu
5.2.1 Pressure sensors
System pressure pNloc
Internal pressure pi
5.2.2 Pressure settings
pRV (Safety relief valve opening pressure)
Pressure rise
pE SP/SD
ΔpFC 1)
Nominal pressure
Setpoint pressure
pA SP/SD
pB SP/SD
System pressure low
Cut-in pressure min
1)
34
Power switching with frequency converter
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5
Design and Function
5.6
Menus – overview
Navigation
Function/Submenu
5.2.3 Load control
■
pA/pB Clock
(Menu see Remote mode)
Local mode
Remote mode
pA/pB Cycle
pA/pB RC
pA/pB DO
Load RC
loc.-load RC
Key remote
Key idle
5.2.4 Network actual pressure
pNloc (locale network pressure)/FC USS 1)/AII
AII
For sensor error:
Type of message:
Warning
Alarm
1)
Tab. 35
No.: 9_9450 07 USE
Power switching with frequency converter
Pressure control menu
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
35
5
Design and Function
5.6
Menus – overview
I/O periphery menu
Navigation
Function/Submenu
5.7.1 DO functions
Controller on
DOR
DOT
Compressor on
DOR
DOT
Motor running
DOR
DOT
Idle
DOR
DOT
On load
DOR
DOT
Group alarm
DOR
DOT
Group warning
DOR
DOT
Remote mode
DOR
DOT
Clock active
DOR
DOT
■
Clock contact
DOR
DOT
EMERGENCY STOP
DOR
DOT
1)
36
Power switching with frequency converter
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5
Design and Function
5.6
Menus – overview
Navigation
Function/Submenu
5.7.2 Analogue values
■
■
■
■
5.7.3 External messages
1)
No.: 9_9450 07 USE
AnMod (Analog modules)
─
AnMod_p_1
─
AnMod_p_2
─
AnMod_p_3
─
AnMod_p_4
─
AnMod_T_1
─
AnMod_T_2
─
AnMod_T_3
─
AnMod_T_4
─
AnMod_I_1
─
AnMod_I_2
AI (Analog inputs)
─
AI_p_1
─
AI_p_2
─
AI_T_1
─
AI_T_2
─
AI_I_1
─
AI_I_1
AO (Analog outputs)
─
AO_p_1
─
AO_p_2
─
AO_T_1
─
AO_T_2
─
AO_I_1
─
AO_I_2
─
AO_n_1 1)
PD (Process data)
─
PD_p_1
─
PD_p_2
─
PD_T_1
─
PD_T_2
─
PD_I_1
─
PD_I_2
■
External message 1
■
External message 2
■
External message 3
■
External message 4
■
External message 5
■
External message 6
Power switching with frequency converter
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
37
5
Design and Function
5.6
Menus – overview
Navigation
Function/Submenu
5.7.4 Switch
■
System pressure pNloc
■
Internal pressure pi
■
ADT
■
Inlet temperature
■
PD temperature
1)
Tab. 36
5.6.2.3
Power switching with frequency converter
I/O periphery menu
Communication menu
Navigation
Function/Submenu
8.1 Ethernet/SIGMA NETWORK
■
■
IP configuration
─
IP address
─
Subnet mask
─
Gateway
─
DNS Server 1
─
DNS Server 2
─
Restart network
Connections
─
SIGMA CONTROL 2
─
SAM 4.0
Restart
Timeout
Cycle time
For details of the Connections menu, please see
table 38.
■
E-mail
─
active:
Compressor number:
Language:
Repeat cut-off time:
─
Sender address:
Sender name:
Contact telephone:
Receiver address:
─
SMTP Server:
User name:
Password:
─
Port/Timeout
Resend after:
MAC: MAC address
3)
38
SIGMA CONTROL 2 (Prepared for connection to control technology)
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5
Design and Function
5.6
Menus – overview
Navigation
8.2 Com-Module
Function/Submenu
3)
The content of the menu depends on the type of
the communication module identified.
The following KAESER communications mod‐
ules may be used:
3)
Tab. 37
5.6.2.4
■
PROFIBUS
■
Modbus
■
Modbus TCP
■
DeviceNet
■
PROFINET
SIGMA CONTROL 2 (Prepared for connection to control technology)
Communication menu
Connections menu
Navigation
Function/Submenu
8.1.2 Connections
■
■
SIGMA CONTROL 2
─
Status
─
Mode
─
Port
─
Communication partner
─
IP address
─
Communication error
Start td
Timeout
SAM 4.0
─
Status
─
SAM 4.0 active:
Send/receive
Send
─
IP address
─
Port
─
Communication error
Start td
Timeout
Restart
Timeout
Cycle time
Tab. 38
No.: 9_9450 07 USE
Connections menu
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
39
5.6.2.5
Design and Function
5.6
Menus – overview
Components menu
Navigation
Function/Submenu
10.1 Compressor motor
USS status: Run/Error
■
Power switching
─
Star-delta start
─
DOL start
─
High-voltage cell 3)
─
SFC USS 1)
─
Softstart 3)
─
Customer-provided 3)
For details of the Power switching menu, please
see table 40.
Tab. 39
40
1)
Power switching with frequency converter
3)
SIGMA CONTROL 2 (Prepared for connection to control technology)
Components menu
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5.6.2.6
Design and Function
5.6
Menus – overview
Power switching menu
Navigation
Function/Submenu
10.1.1 Power switching
■
■
■
■
■
■
No.: 9_9450 07 USE
Star-delta start
─
Temp. warm start
─
Star time T↑
─
Star time T↓
─
Υ/Δ switching time
─
Overload relay
─
Mains contactor
─
Star contactor
─
Delta contactor
DOL start
─
Run-up period:
─
Overload relay
─
Mains contactor
─
Delta contactor
High-voltage cell 3)
─
Run-up period:
─
Overload relay
─
Mains contactor
SFC USS 1)
USS status: Run/Error
─
Run-up period:
─
Service operation
─
Heavy load monitoring
─
Mains contactor
─
STO channel A
─
STO channel B
Softstart 3)
─
ready
─
Motor running
─
Start-up ended
─
Start
─
Reset
─
Mains contactor
Customer-provided 3)
─
Temp. warm start
─
Run-up period T↑
─
Run-up period T↓
─
ready
─
Mains contactor/Alarm td
─
Redundancy contactor/Alarm td
1)
Power switching with frequency converter
3)
SIGMA CONTROL 2 (Prepared for connection to control technology)
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
41
5
Design and Function
5.7
Operating modes and control modes
10.1.1 Power switching
Tab. 40
5.7
5.7.1
If there is a power switching unit with a frequen‐
cy converter, the further content of the menu is
determined by the type of frequency converter
and the settings available for it.
Power switching menu
Operating modes and control modes
Operating modes
STOP
The machine is connected to the power supply.
The Controller voltage LED lights green.
The machine is switched off. The On LED is extinguished.
READY
The machine has been activated with the «ON» key:
■
The On LED lights green.
■
The drive motor is stopped.
■
The inlet valve is closed.
■
The minimum pressure check valve isolates the oil separator tank from the air system.
■
The venting valve is open.
The compressor motor starts as soon as system pressure is lower than the network nominal pres‐
sure (cut-off pressure).
In addition, timing and/or remote control may affect the start of the motor.
LOAD
The compressor motor runs under load.
■
The inlet valve is open.
■
The airend delivers compressed air to the air system.
IDLE
The compressor motor runs unloaded with low power consumption.
■
The inlet valve is closed.
■
The minimum pressure check valve isolates the oil separator tank from the air system.
■
The venting valve is open.
A small volume of air circulates through the bleed hole in the inlet valve, through the airend and
back to the inlet valve via the venting line.
42
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
5.7.2
Design and Function
5.7
Operating modes and control modes
Control modes
Using the selected control mode, the controller switches the machine between its various opera‐
tional states in order to compensate for air being drawn off by consumers, and to maintain the sys‐
tem pressure between the set minimum and maximum values. The control mode also rules the de‐
gree of energy efficiency of the machine.
The machine-dependant venting phase between the LOAD and READY operating modes ensures
load changes at minimum material stresses.
The controller SIGMA CONTROL 2 can operate in the following modes:
Option C1
■
DUAL
■
QUADRO
■
VARIO
■
CONTINUOUS
■
DYNAMIC
■
MODULATING control
DUAL
In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to
maintain the machine working pressure between the preset minimum and maximum values. When
maximum pressure is reached, the machine switches to IDLE. When the preset idling time has
elapsed, the machine switches to READY.
The idling time is factory preset according to the maximum starting frequency of the compressor
motor. The shorter the idling time setting, the sooner (and more frequently) the drive motor is stop‐
ped.
QUADRO
Unlike the DUAL regulating mode, the machine will switch from LOAD to READY in QUADRO
mode after periods with low compressed air consumption.
After periods with a high compressed air consumption, the machine will switch from LOAD to
READY after passing through IDLE.
In this control mode, the controller requires two specified times: The running time and the idling/
standstill time.
The shorter these times are set, the sooner (and more frequently) the motor is stopped.
VARIO
The VARIO mode is based on the DUAL control mode. Unlike the DUAL regulating mode, the
idling time is automatically lengthened or shortened to compensate for higher or lower machine
starting frequencies.
CONTINUOUS
Unlike the DUAL control mode, the machine is switched back and forth between LOAD and IDLE,
to maintain the machine working pressure between the preset minimum and maximum values.
When maximum pressure is reached, the machine switches to IDLE. However, the machine does
not switch to READY.
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5
Design and Function
5.7
Operating modes and control modes
DYNAMIC
Unlike the DUAL regulating mode, the machine will switch from LOAD to READY in DYNAMIC
mode at low drive motor temperature.
And from LOAD via IDLE to READY at a high drive motor temperature.
The lower the drive motor temperature, the sooner (and, therefore, more often and longer) it is
stopped.
Option C1
MODULATING control
The MODULATING control is an additional mechanical regulation. It continuously changes the de‐
livery volume within the machine's control range.
A control valve, the proportional controller, changes the degree of opening of the inlet valve when
the machine transports compressed air into the air network (LOAD).
The load and power consumption of the drive motor rises and falls with the air demand.
5.7.3
Frequency-controlled drive (SFC)
If the machine runs in LOAD , the frequency converter compares the ACTUAL value with the TAR‐
GET value of the system pressure and regulates, depending on the difference, the speed of the
compressor motor and the airend.
The speed of the airend determines the rate of compressed air delivery and the working pressure.
If air consumption rises, the frequency converter increases motor speed and therefore increases
the volume of air delivered.
If air consumption drops, the converter reduces motor speed and therefore reduces the volume of
air delivered.
The network pressure remains constant – within the control range of the converter – regardless of
fluctuating air demand.
If the network pressure exceeds the TARGET value:
Outside the frequency converter's range of control the machine reverts to the selected control
mode.
DUAL:
The minimum controllable speed is reached and the machine switches to IDLE . The drive motor
runs unloaded with low power consumption.
When the preset idling time has elapsed, the machine switches to READY.
VARIO/QUADRO/CONTINUOUS:
The minimum controllable speed is reached and, depending on the air demand at the time, the ma‐
chine switches either to READY or to IDLE. The machine remains in IDLE at least for the duration
of the venting time, before it switches to READY.
DYNAMIC:
The minimum controllable speed is reached and, depending on the air temperature of the drive mo‐
tor the machine switches either to READY or to IDLE. The machine remains in IDLE at least for the
duration of the venting time, before it switches to READY.
If the network pressure falls below the TARGET value:
The frequency converter runs the motor up to a speed at which air delivery matches the air de‐
mand.
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5
Design and Function
5.7
Operating modes and control modes
The inlet valve opens and the machine delivers compressed air.
The frequency converter varies the speed of the drive motor according to the air demand. The
power consumption of the drive motor rises and falls according to air demand.
5.7.4
MODULATING control
With the help of a mechanical control valve (the proportional controller), the opening and closing of
the inlet valve is continuously varied in relation to the actual air demand. The airend delivers com‐
pressed air to the distribution network.
The load and power consumption of the drive motor rises and falls with the air demand.
To ensure optimal control on large compressors, the control air for the proportional controller is tak‐
en from an external air receiver.
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6
Installation and Operating Conditions
6.1
Maintaining ambient conditions
6 Installation and Operating Conditions
6.1
Maintaining ambient conditions
➤ Follow the instructions in the machine's operator manual.
6.2
Installation conditions
The installation and operating conditions depend the machine into which the controller is installed.
UV radiation!
Direct sunlight (UV radiation) can destroy the display screen.
➤ Do not allow the display screen to be subjected to direct sunlight.
➤ See the machine's operator manual for required conditions.
46
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No.: 9_9450 07 USE
7
Installation
7.1
Reporting Transport Damage
7 Installation
7.1
Reporting Transport Damage
1. Check the machine for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage without delay.
7.2
Machine identification
If the machine is run in sequenced operation its identification as detailed in the installation diagram
is to be taken into account.
Identifying the machine for operation in remote mode.
➤ Attach the following notice to warn of remote machine operation (suggestion):
Remote control: danger of unexpected starting!
➤ Make sure the power supply disconnecting device is switched off before commencing any
work on the machine.
Tab. 41
Machine identification
➤ Label the starting device in the remote control center as follows (suggestions):
Remote control: danger of unexpected starting!
➤ Before starting, make sure that no one is working on the machine and that it can be safely
started.
Tab. 42
Remote control identification
Identifying the machine for clock control mode operation
➤ Attach the following notice to warn of remote machine operation (suggestion):
Clock control: Risk of injury caused by unexpected starting!
➤ Make sure the power supply disconnecting device is switched off before commencing any
work on the machine.
Tab. 43
No.: 9_9450 07 USE
Machine identification
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8
Initial Start-up
8.1
Outline
8 Initial Start-up
8.1
Outline
SIGMA CONTROL 2 was designed and developed for a number of applications. Potential settings
are correspondingly varied.
It is possible that only a few of these settings are needed for the initial start-up. This depends on
the application .
The following sections explain the large number of practical applications, but only one configuration
is relevant for a specific use.
8.2: Configuring the controller (display format, units, languages, etc.)
8.3: Using KAESER CONNECT
8.4: Pressure parameters of the machine
8.5: Machine start and stop
8.6: Control modes
8.7: Electronic Thermal Management
8.8: Refrigerated dryer
8.9: Configuring the machine for local mode
8.10: Configuring the machine for master control operation
8.11: Configuring input and output signals
8.12: Activating remote acknowledgement
8.13: Linking to an external pressure transducer
8.14: Commissioning the machine
8.2
Configuring the controller
The following chapters describe in detail the basic settings for the SIGMA CONTROL 2. The
quick installation guide at the beginning of this operating manual provides an overview of the
essential displays and operating elements, the main menu and important functions.
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8
Initial Start-up
8.2
Configuring the controller
➤ Carry out settings as required:
8.2.1
■
8.2.1: Selecting menu options (introduction)
■
8.2.2: Setting the language
■
8.2.3: Noting number of the KAESER Equipment Card
■
8.2.4: User log-in with RFID Equipment Card
■
8.2.5: Generating a password
■
8.2.6: Manual user log-in
■
8.2.7: Checking and setting time and date
■
8.2.8: Setting the time zone (summer and winter time)
■
8.2.9: Setting display formats (date, time, units of pressure and temperature)
■
8.2.10: Setting the display illumination
■
8.2.11: Setting the contrast and the brightness
■
8.2.12: Activating the remote control
■
8.2.13: IP configuration
■
8.2.14: Configuring the e-mail function
■
8.2.15: Setting the time server
■
8.3.6: Creating a user account
Selecting menu options
All menu options can be selected with the «Down», «Up» and «Enter» keys.
Example: Selecting the < Configuration – General > menu
1. Switch on the machine and wait for SIGMA CONTROL 2 to start.
The operating mode is displayed.
88psi
08:15AM
176° F
Header
__________________________________
Current operating mode
Load
__________________________________
Key
–
on
¦
pA
–
on
Operating parameters
__________________________________
Run
2500h Load
Maintenance
in
No.: 9_9450 07 USE
2490h
Operating parameters
Maintenance indicator
500h
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8
Initial Start-up
8.2
Configuring the controller
2. Press «Enter».
The main menu is displayed.
88psi
08:15AM
176° F
Main menu
----------------English US----------------
Current language
▶1 Status
Submenu
▶2 Performance data
Submenu
▶3 Operating data
Submenu
▶4 Maintenance
Submenu
▶5 Configuration
Active line
3. Use «Up» or «Down» to select the Configuration line.
4. Press «Enter».
The Configuration menu is displayed.
5. Use «Up» or «Down» to select the General line.
6. Press «Enter».
The General menu is displayed.
88psi
08:15AM
176° F
5.1 General
Menu
▶1 System information
Submenu
·········
Model:
Set machine type (SC2 FLUID)
XXXXXX
·········
Date/time
04/13/16
08:15:37AM
Current date and time
7. Use «Up» or «Down» to select a menu item in the General submenu such as System
information.
8. Press «Escape» repeatedly to leave this menu.
8.2.2
Setting the language
The controller can display text messages in the following languages:
Tab. 44
50
Arabic
Estonian
Italian
Norwegian
Spanish
Bulgarian
Finnish
Japanese
Polish
Spanish
(South America)
Chinese
French
Korean
Portuguese
Czech
Danish
French
(Canada)
Croatian
Romanian
Turkish
German
Greek
Latvian
Russian
Hungarian
English
Hebrew
Lithuanian
Swedish
...
English (USA)
Indonesian
Dutch
Slovenian
...
Display languages
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
8
Initial Start-up
8.2
Configuring the controller
Some of the units, as well as clock and date format, will be adjusted according to the lan‐
guage selected. You can manually change these settings (see chapter 8.2.9).
Precondition
The operating mode is displayed.
1. Press «Enter».
The main menu is displayed.
88psi
08:15AM
176° F
Main menu
----------------English US----------------
Current language
▶1 Status
Active line
▶2 Performance data
Submenu
▶3 Operating data
Submenu
▶4 Maintenance
Submenu
▶5 Configuration
Submenu
2. Press the «Up» key.
The currently set language is displayed as the active line.
88psi
08:15AM
176° F
Main menu
----------------English US----------------
Active line with currently set language
▶1 Status
Submenu
▶2 Performance data
Submenu
▶3 Operating data
Submenu
▶4 Maintenance
Submenu
▶5 Configuration
Submenu
3. Press «Enter».
The currently set language flashes.
4. Use «Up» or «Down» to select the desired language.
5. Press «Enter».
Result
8.2.3
The user interface is displayed in the set language.
Noting the number of the KAESER Equipment Card
The number of your KAESER Equipment Card is identical with the user name displayed on
SIGMA CONTROL 2 after you have successfully logged on using your KAESER Equip‐
ment Card.
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Fig. 11
Initial Start-up
8.2
Configuring the controller
Back of the KAESER Equipment Card
Back of the KAESER Equipment Card
Number of the KAESER Equipment Card
1. Note the user name (= number of the KAESER Equipment Card).
2. Keep the note at a secure location.
If your KAESER Equipment Card gets damaged or can no longer be found?
➤ If you know your user name and password, you can manually log on to
SIGMA CONTROL 2 (see chapter 8.2.5).
8.2.4
User log-in with KAESER Equipment Card
Use the KAESER Equipment Card to quickly and easily check the advanced access rights to the
SIGMA CONTROL 2 controller.
Advanced access rights let you:
Fig. 12
52
■
Read additional data
■
Change other settings
User log-in with KAESER Equipment Card
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
8
Initial Start-up
8.2
Configuring the controller
1. Hold the KAESER Equipment Card in front of the RFID reader.
Your user name and access level will be displayed.
88psi
08:15AM
176° F
Log-in successful
Menu
Button to change password
Prompt, whether the password is to be changed
__________________________________
Name:
E00019895
Level:
2. Press «Enter» to confirm the access right.
The access right is confirmed.
The KAESER Equipment Card is damaged or lost?
➤ Manually enter the user name and password, see chapter 8.2.6.
8.2.5
Generating a password
In the event that your KAESER Equipment Card is damaged or lost, you must manually log on to
SIGMA CONTROL 2. A password is also required to use KAESER CONNECT to log on at
SIGMA CONTROL 2 (see chapter 8.3).
Prerequisite for this is that you know your
■
Name
■
Password
You have noted your user name and stored it at a suitable location (see chapter 8.2.3). You now
generate a password at the SIGMA CONTROL 2. Note this generated password as well, and store
it in a suitable location. If your KAESER Equipment Card is damaged or lost, the card won't be nec‐
essary to manually log on to SIGMA CONTROL 2 when you have these two pieces of information.
Precondition
Fig. 13
No.: 9_9450 07 USE
Any menu is displayed
User log-in with KAESER Equipment Card
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8
Initial Start-up
8.2
Configuring the controller
1. Hold the KAESER Equipment Card in front of the controller’s RFID reader.
Users are always logged on with password access level 2.
88psi
08:15AM
176° F
Log-in successful
Menu
Button to change password
Prompt, whether the password is to be changed
__________________________________
Name:
E00019895
Level:
2. Press the «Right» key within five seconds.
The new Password is displayed.
88psi
08:15AM
176° F
Password changed
Menu
__________________________________
Please take note of your new
password:
xFNDQRCnDn
New password
3. Note the new password.
4. Store the password at a suitable location, if it should become necessary to manually log-on
without KAESER Equipment Card.
5. Press «Enter».
The setting is applied.
8.2.6
Manual user log-in
In the event that your KAESER Equipment Card is damaged or lost, you can manually log on to
SIGMA CONTROL 2.
Precondition
The user name (see chapter 8.2.3) and password (see chapter 8.2.5) are known.
The operating mode is displayed.
1. Open the 7 User menu.
2. Use «Up» or «Down» to select the Name line.
3. Press «Enter».
The setting mode is active.
A column with alphanumeric characters is displayed.
The selected character flashes.
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Fig. 14
Initial Start-up
8.2
Configuring the controller
Manual user log-in
4. Select the required character with the «Up» or «Down» keys.
5. Press the «Right» key.
The cursor jumps to the next position of the user name.
6. Enter the remaining characters of the user name in the same manner.
7. Press «Enter».
The user name is entered.
8. Use «Up» or «Down» to select the Password line.
9. Press «Enter».
Enter the remaining letters and digits of the password in the same manner.
The password is case sensitive!
10. Press «Enter».
The password is entered.
11. Use «Up» or «Down» to select the [Login] line.
12. Press «Enter».
Current access level: 2 is displayed.
Result
8.2.7
Precondition
You are now logged on to SIGMA CONTROL 2 with password access level 2, having manually in‐
put your user name and the password.
Checking and setting time and date
Password access level 2 is activated.
Checking and setting time
➤ When operating the machine with a timer program, check the time settings at least once
a year.
➤ You can automatically synchronize date and time using a time server. Manual setting of
the time is no longer required in this case. See chapter 8.2.15.
1. Open the 5.1  menu.
2. Use the «Up» or «Down» keys to select the Date/time line.
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8
Initial Start-up
8.2
Configuring the controller
3. Press the «DOWN» key.
88psi
08:15AM
176° F
Menu
5.1 General
▶1 System information
·········
Model:
Set machine type (SC2 FLUID)
XXXXXX
·········
Date/time
04/13/16
08:15:37AM
Date and time
4. Press the «Right» key.
5. Press «Enter».
The display for hours 00:00:00 flashes.
6. Use «Up» or «Down» to set the hours.
7. Press the «Right» key.
The display for minutes 00:00:00 flashes.
8. Use «Up» or «Down» to set the minutes.
9. Press the «Right» key.
The display for seconds 00:00:00 flashes.
10. Use «Up» or «Down» to set the seconds.
11. Press «Enter» to accept all settings.
The setting is applied.
12. Press «Escape» repeatedly to return to the main menu.
Checking and setting the date
Precondition
Password access level 2 is activated.
1. Open the 5.1  menu.
2. Use the «Up» or «Down» keys to select the Date/time line.
3. Press the «DOWN» key.
88psi
08:15AM
176° F
Menu
5.1 General
▶1 System information
·········
Model:
Set machine type (SC2 FLUID)
XXXXXX
·········
Date/time
04/13/16
08:15:37AM
Date and time
4. Press «Enter».
The display for days 00.00.00 flashes.
5. Use «Up» or «Down» to set the day.
6. Press the «Right» key.
The display for months 00.00.00 flashes.
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8
Initial Start-up
8.2
Configuring the controller
7. Use «Up» or «Down» to set the month.
8. Press the «Right» key.
The display for years 00.00.00 flashes.
9. Use the «Up» or «Down» keys to set the years.
10. Press «Enter».
The setting is applied.
11. Press «Escape» repeatedly to return to the main menu.
8.2.8
Set the time zone
Set the time zone for the SIGMA CONTROL 2 to ensure the timely automatic conversion from win‐
ter time (standard time) to daylight savings time, for example.
Precondition
Password access level 2 is activated.
1. Open the 5.1  menu.
2. Use the «Up» or «Down» keys to select the Date/time line.
3. Press «Down» twice.
88psi
08:15AM
176° F
5.1 General
Menu
Model:
Set machine type (SC2 FLUID)
XXXXXX
·········
Date/time
04/13/16
08:15:37AM
US/Central
Time zone
·········
4. Press «Enter».
The time zone display flashes.
5. Use «Up» or «Down» to set the time zone.
6. Press «Enter».
The setting is applied.
7. Press «Escape» repeatedly to leave this menu.
8.2.9
Setting display formats
When setting the language, the system automatically sets the units and the time and date formats.
You can manually change these settings.
Setting the date format
Select your preferred format:
Tab. 45
No.: 9_9450 07 USE
Format
Example
DD.MM.YY
30.07.16
YY-MM-DD
16–07–30
MM/DD/YY
07/30/16
Date formats
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57
Precondition
Initial Start-up
8.2
Configuring the controller
Password access level 2 is activated.
1. Open the 5.1  menu.
2. Use the «Up» or «Down» keys to select the Date format line.
88psi
08:15AM
176° F
Menu
5.1 General
US/Central
·········
▶2 Time server
·········
Date format
MM/DD/YY
Time format
Date format
hh:mm:ssAM/PM
3. Press «Enter».
The MM/DD/YY display flashes.
4. Use the «Up» or «Down» keys to set the date format.
5. Press «Enter».
The setting is applied.
6. Press «Escape» repeatedly to leave this menu.
Setting the time format
Select your preferred format for the time display:
Tab. 46
Precondition
Format
Example
hh:mm:ss
13:33:45
hh:mm
13:33
hh:mm:ssAM/PM
01:33:45PM
hh:mmAM/PM
01:33PM
Time formats
Password access level 2 is activated.
1. Open the 5.1  menu.
2. Use the «Up» or «Down» keys to select the Time format line.
88psi
08:15AM
176° F
Menu
5.1 General
US/Central
·········
▶2 Time server
·········
Date format
Time format
MM/DD/YY
hh:mm:ssAM/PM
Time format
3. Press «Enter».
The hh:mm:ssAM/PM indication flashes.
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8
Initial Start-up
8.2
Configuring the controller
4. Use the «Up» or «Down» keys to set the time format.
5. Press «Enter».
The setting is applied.
6. Press «Escape» repeatedly to leave this menu.
Setting the pressure display units
Select your preferred display of the pressure unit:
Tab. 47
Precondition
Format
Example
bar
5.5bar
hPa
5523hPa
MPa
0.55MPa
psi
80psi
at
5.6at
Units of pressure
Password access level 2 is activated.
1. Open the 5.1  menu.
2. Use the «Up» or «Down» keys to select the Pressure unit line.
88psi
08:15AM
176° F
Menu
5.1 General
Time
format
hh:mm:ssAM/PM
·········
Pressure unit
psi
Temperature unit
°F
Unit of pressure
Unit of temperature
·········
Display lighting
3. Press «Enter».
The display for the set unit flashes.
4. Use the «Up» or «Down» keys to set the unit.
5. Press «Enter».
The setting is applied.
6. Press «Escape» repeatedly to leave this menu.
Setting the temperature display units
Select your preferred display of the temperature unit:
Tab. 48
No.: 9_9450 07 USE
Format
Example
°C
46°C
319K
°F
114°F
Units of temperature
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59
Precondition
Initial Start-up
8.2
Configuring the controller
Password access level 2 is activated.
1. Open the 5.1  menu.
2. Use the «Up» or «Down» keys to select the Temperature unit line.
88psi
08:15AM
176° F
Menu
5.1 General
Time
format
hh:mm:ssAM/PM
·········
Pressure unit
Unit of pressure
psi
Temperature unit
Unit of temperature
°F
·········
Display lighting
3. Press «Enter».
The display for the set unit flashes.
4. Use the «Up» or «Down» keys to set the unit.
5. Press «Enter».
The setting is applied.
6. Press «Escape» repeatedly to leave this menu.
8.2.10
Setting the display illumination
Select your personal mode for the display illumination:
Mode
Tab. 49
Precondition
Indication
automatic
on
off
Function
The illumination extin‐
guishes after the timeout has elapsed.
Permanent setting
Illumination "on"
Permanent setting
Illumination "off"
Display illumination
Access level 2 is activated.
1. Open the 5.1  menu.
2. Use the «Up» or «Down» keys to select the Display lighting line.
3. Press the «DOWN» key.
The Mode line is displayed.
88psi
08:15AM
176° F
Menu
5.1 General
·········
Pressure unit
psi
Temperature unit
°F
·········
Display lighting
Mode:
60
auto. ¦ Timeout:
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
1min
Active line
No.: 9_9450 07 USE
8
Initial Start-up
8.2
Configuring the controller
4. Press «Enter».
The display for the set mode flashes.
5. Use the «Up» or «Down» keys to set the auto. mode.
6. Press «Enter».
The setting is applied.
7. Press the «Right» key.
8. Set the value for the Timeout in the same manner, e.g. 1 min.
9. Press «Enter».
10. Press «Escape» repeatedly to leave this menu.
Result
8.2.11
The display illumination is set for automatic operation with deactivation following one minute with‐
out user intervention.
Setting the contrast and the brightness
The display settings for contrast and brightness are set to the highest possible values by default.
Change the settings if adverse lighting conditions make it difficult to read the displayed information.
Precondition
The operating mode is displayed.
1. Press and hold the «Information» key.
2. Use «Up» or «Down» to adjust the contrast.
3. Use «Left» or «Right» to adjust the brightness.
Result
8.2.12
The settings for contrast and brightness have been adjusted.
Activating the remote control
The «Remote control» key on the operating panel of the SIGMA CONTROL 2 can be activated or
deactivated. Various menus offer check boxes for this setting.
Precondition
Password access level 2 is activated.
The operating mode is displayed.
1. Open the 8 Communication menu.
2. Use «Up» or «Down» to select the Key remote line.
3. Press «Enter».
The check box Key remote flashes.
88psi
08:15AM
176° F
Menu
8 Communication
▶1 Ethernet/SIGMA NETWORK
▶2 Com-Module
Key remote
No.: 9_9450 07 USE
☐
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Active line with deactivated check box
61
8
Initial Start-up
8.2
Configuring the controller
4. Press the «Up» key.
The check box Key remote is activated.
88psi
08:15AM
176° F
Menu
8 Communication
▶1 Ethernet/SIGMA NETWORK
▶2 Com-Module
Key remote
☑
Active line with activated check box
5. Press «Enter».
The «Remote control» key is activated.
6. Press «Escape» repeatedly to leave this menu.
Proceed in the same manner to deactivate the «Remote control» key.
7. Press the «Remote control» key on the operating panel of SIGMA CONTROL 2.
Result
8.2.13
SIGMA CONTROL 2 Remote control is activated.
IP configuration
For the SIGMA CONTROL 2 to be connected to the network, you must set the IP configuration (for
KAESER CONNECT for example).
If you use SIGMA CONTROL 2 as the master control of two machines, you set other network
parameters in the IP configuration menu (see chapter 8.10.4).
The network parameters for the IP configuration must be specified manually. You cannot use
DHCP for an automatic IP configuration.
Precondition
Password access level 2 is activated.
The network parameters are known. Request the required information from your IT department.
1. SIGMA CONTROL 2 Connect to the network using an Ethernet cable.
2. Select the 8.1.1  menu.
3. Use «Up» or «Down» to select the IP address line.
88psi
08:15AM
176° F
8.1.1 IP configuration
Menu
IP address
Active line, factory setting
Subnet mask
169.254.100.101
255.255.000.000
Gateway
169.254.100.97
DNS Server 1
169,254,100.97
DNS Server 2
169,254,100.97
Restart network
☐
4. Press «Enter» to switch into setting mode.
The first group of numbers of the IP address flashes 169.254.100.101.
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SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
8
Initial Start-up
8.2
Configuring the controller
5. Use «Up» or «Down» to set the first group of numbers of the IP address.
6. Press the «Right» key.
The SECOND group of numbers of the IP address flashes 192.168.100.101.
7. Use «Up» or «Down» to set the second, third and fourth group of numbers of the IP address.
The IP address is correctly set.
8. Press «Enter» to accept the setting.
The setting is applied.
9. Press «Down».
The Subnet mask line is displayed.
10. Set the remaining network parameters as described above:
Parameters
Setting value
IP address
IP address of the interface X1 Ethernet
Subnet mask
Subnet mask of the network
Gateway
Gateway address of the network
DNS Server 1
DNS server 1 address
DNS Server 2
DNS server 2 address
Restart network
Tab. 50
Meaning
–
Activate the changed network parameters
Network parameters
11. Use the «Up» or «Down» keys to select the Restart network line.
88psi
08:15AM
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8.1.1 IP configuration
Menu
IP address
Example address
Subnet mask
192.168.001.010
255.255.255.000
Example address
Gateway
192.168.001.001
Example address
DNS Server 1
008.008.008.008
Example address
DNS Server 2
008.008.004.004
Example address
Restart network
☐
Active line
12. Press «Enter».
The check box Restart network will flash.
13. Press «Up» key.
The check box is activated.
14. Press «Enter».
Result
The network is restarted.
The set network parameters are active.
8.2.14
Setting the e-mail function
SIGMA CONTROL 2 uses e-mail to send information (messages) to an e-mail address.
For this purpose, an Ethernet connection with an SMTP server is required.
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8
Initial Start-up
8.2
Configuring the controller
Setting e-mail parameters
Precondition
Password access level 2 is activated.
IP configuration is set; see chapter 8.2.13
An SMTP server is active in the network.
The e-mail parameters are known. Request the required information from your IT department.
1. Open the 8.1.3  menu.
2. Use the «Up» or «Down» keys to select the active: line.
88psi
08:15AM
176° F
Menu
8.1.3 E-mail
active:
☐
Compressor number:
Language:
Activating/deactivating the e-mail function
English US
Repeat cut-off time:
Setting the language
5min
__________________________________
Sender address:
3. Press «Enter».
The check box active: will flash.
4. Press «Up» key.
The check box is deactivated.
5. Press «Enter».
The e-mail function is deactivated.
6. Set the e-mail parameters as described above:
Parameters
64
Setting Meaning
value
Compressor
number:
This field displays the machine number that appears as the sender of
e-mails. The recipient is thus able to recognize the different machines
sending mails.
Language:
Use this field to define the language for the message texts. This setting
in independent from the language setting in SIGMA CONTROL 2 (see
chapter 8.2.2).
Repeat cut-off
time:
In this field, enter the time in minutes (repeat block time) that the sys‐
tem must wait in order not send multiple recurring messages in short
time intervals.
Sender address:
Enter the e-mail address of the sender in this field.
Sender name:
Enter the name of the sender in this field.
Contact
telephone:
In this field, enter a telephone number under which the system operator
can be reached. This telephone number is sent with each e-mail.
Receiver
address:
The e-mail address of the recipient.
SMTP Server:
IP address of the SMTP server receiving and forwarding the e-mails.
User name:
Log-in user name for logging on to the SMTP server.
Password
Log-in password for logging on to the SMTP server.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
8
Initial Start-up
8.2
Configuring the controller
Parameters
Tab. 51
Setting Meaning
value
Port
Port address of the SMTP server.
Timeout
In this field, enter the seconds for SIGMA CONTROL 2 to wait for a re‐
ply by the SMTP server before e-mail sending is cancelled.
Resend after:
In this field enter, the time in seconds for the system to wait after a
failed e-mail sending operation before it again attempts to send the
mail.
E-mail parameters
7. Activating the e-mail function: Activate the active: check box as described above.
8. Press «Esc» repeatedly to leave this menu.
Result
8.2.15
The e-mail parameters are set and the e-mail function is activated.
Configuring the time server
If SIGMA CONTROL 2 is connected to the network, you can set the access to an SNTP server
available in the Internet or a local Intranet. SIGMA CONTROL 2 then automatically imports the
date and time settings and ensures continuous synchronization of the internal clock with the exter‐
nal time server.
Precondition
Password access level 2 is activated.
IP configuration is set; see chapter 8.2.13.
The time server's IP address is known. Request the required information from your IT department.
1. Open the 5.1.2  menu.
2. Use the «Up» or «Down» keys to select the IP address line.
88psi
08:15AM
176° F
Menu
5.1.2 Time server
active:
IP address
☐
192.053.103.103
Activating/deactivating the time server function
Example address, time server
3. Press «Enter».
The first group of numbers of the IP address flashes 192.053.103.103.
4. Use «Up» or «Down» to set the first group of numbers of the IP address.
5. Press the «Right» key.
The second group of numbers of the IP address flashes 192.053.103.103.
6. Use «Up» or «Down» to set the second, third and fourth group of numbers of the IP address.
The IP address is correctly set.
7. Press «Enter» to accept the setting.
The setting is applied.
8. Use «Up» or «Down» to select the active: line.
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8
Initial Start-up
8.3
Using KAESER CONNECT
9. Press «Enter».
The check box active: will flash.
10. Press «Up» key.
The check box is activated.
88psi
08:15AM
176° F
Menu
5.1.2 Time server
active:
IP address
☑
192.053.103.103
The time server function is activated
Example address, time server
11. Press «Enter».
12. Press «Escape» repeatedly to return to the main menu.
Result
Access to the selected time server is active.
The internal clock of SIGMA CONTROL 2 is permanently synchronized.
8.3
Using KAESER CONNECT
Using an Internet-capable device with web browser, you can use KAESER CONNECT to remotely
display these SIGMA CONTROL 2 menus:
■
System status
■
Graphs
■
Messages
■
I/O display
■
User management
■
Settings
■
Backup
■
Data recording
Thus, KAESER CONNECT provides an excellent option for an easy and quick check of the econo‐
my and energy efficiency of your machines.
The following functions are not available with KAESER CONNECT:
■
Remotely starting the machine
■
Remotely setting parameters
For KAESER CONNECT to be able to use the Internet-capable device, it must be registered
in the same network as SIGMA CONTROL 2.
To be able to use KAESER CONNECT, the browser installed on the Internet-capable device
must be able to display HTML5 content. For security reasons, we strongly recommend to use
only up-to-date browser versions.
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No.: 9_9450 07 USE
8.3.1
Precondition
Initial Start-up
8.3
Using KAESER CONNECT
Open KAESER CONNECT
The user name (see chapter 8.2.3) and password (see chapter 8.2.5) are known.
The IP address of your controller is known, see chapters 8.2.13 and 8.10.4.
1. Use an Ethernet cable to connect SIGMA CONTROL 2 to the Internet-capable device or net‐
work.
2. In the web browser, enter the controller's IP address.
The Login window is displayed.
Fig. 15
Login window
3. Enter your user name in the User name: field.
4. Enter your password in the Password: field.
5. Click Login.
KAESER CONNECT for SIGMA CONTROL 2 is displayed.
Fig. 16
No.: 9_9450 07 USE
KAESER CONNECT for SIGMA CONTROL 2
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
67
8
Initial Start-up
8.3
Using KAESER CONNECT
6. Click the arrow key 1 to open Select language:.
The Select language: window is displayed.
Fig. 17
Select language: window
«Arrow key» Select language:
Select language: window
Select a language
Selected language
7. Select the required language 3 .
Result
8.3.2
Precondition
Fig. 18
KAESER CONNECT is displayed in the selected language.
System status menu
KAESER CONNECT for SIGMA CONTROL 2 is displayed.
System status menu
1. Click the System status menu element.
The System status menu is displayed
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SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
Fig. 19
Initial Start-up
8.3
Using KAESER CONNECT
Main menu
2. Click in the SIGMA CONTROL 2 display.
The Main menu is displayed.
3. Click the numbered lines.
The system displays the corresponding sub-menus.
4. Press ESC repeatedly to leave this menu.
8.3.3
Graphs menu
When starting the Graphs menu, the recorded data from the last 60 minutes are loaded. The last
20 minutes are displayed in a graph. The system updates the graph every ten seconds whilst the
current time is displayed.
If an SD card is provided in the X5 SD card slot, you can retrieve and display the automaticallyrecorded machine data for any time in the past.
Moving the mouse pointer across the graph calls up a ruler. The time selected with the ruler and
the associated values are displayed in the legend above the graph. When the ruler is hidden, the
time and associated values are displayed at the right edge of the graph.
The graph content depends on the machine type.
The Speed display is implemented only for machines with frequency converter.
Precondition
KAESER CONNECT for SIGMA CONTROL 2 is displayed.
1. Click the Graphs menu element.
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69
Fig. 20
Initial Start-up
8.3
Using KAESER CONNECT
Graphs (illustration similar)
2. Check the displayed data.
8.3.3.1
Zoom function
Use the Zoom function to enlarge significant curve developments:
Highlight a specific area within the graph by drawing a rectangle with the mouse pointer pressed.
The selected area will be enlarged as soon as the mouse pointer is released.
Fig. 21
Tab. 52
70
Arrow keys
Item Description
Function
«Start»
Display the oldest data in the cache memory or load the data from the previ‐
ous 20 minutes from the SD card
«Scroll left»
Shift the display area by 1/3 to the left
«Zoom-out» Time range is enlarged
«Scroll right» Shift the display area by 1/3 to the right
«End»
Display of newest data
«Refresh»
Load and display the entered machine data from start time to end time
Arrow key functions
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
8
Initial Start-up
8.3
Using KAESER CONNECT
1. Click the «Start» 1 arrow key.
The oldest data in the cache memory or the data of the last 20 minutes are loaded form the SD
card and displayed
2. Click the «Scroll right» 4 arrow key.
The display area is shifted to the right by 1/3.
3. With the mouse button pressed, draw a rectangle around the selected area.
4. Release the mouse button.
The selected area is enlarged (zoom-in function).
5. Click the «Zoom-out» 3 arrow key.
The time range is enlarged (zoom-out function).
8.3.3.2
Displaying past machine data
You can display the automatically-recorded machine data for any time in the past.
Precondition
An SD card with sufficient free memory is inserted in the X5 SD card slot
The SD card was inserted for the entire operating time of the machine.
The SIGMA CONTROL 2 data recorder function is activated.
1. Enter the date and time for the start time in the required time period in Start:.
2. Enter the date and time for the end time in the required time period in End:.
3. Click 6 .
The machine data for the specified time interval are loaded and displayed.
8.3.4
Messages menu
The following messages are shown:
Precondition
No.: 9_9450 07 USE
■
Current messages
■
Compressor messages
■
System messages
■
Diagnostic messages
KAESER CONNECT for SIGMA CONTROL 2 is displayed.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
71
Fig. 22
Initial Start-up
8.3
Using KAESER CONNECT
Messages
1. Open the Messages menu.
The Messages menu is displayed.
2. Click the required message type.
3. Check messages.
8.3.5
I/O display menu
The measured values of the analog inputs and the states of the digital inputs and outputs are dis‐
played in the I/O display menu. Depending on the machine options, you may select from further
IOM module tabs.
Precondition
72
KAESER CONNECT for SIGMA CONTROL 2 is displayed.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
Fig. 23
Initial Start-up
8.3
Using KAESER CONNECT
I/O display (illustration similar)
➤ Click the I/O display menu element.
The current measured data and states of the input/output modules are displayed.
8.3.6
User management menu
Use the User management menu to create additional user accounts for other employees.
In order to be able to create user accounts, you must activate the write mode. The system will
prompt you to enter and confirm your user name and your password. Subsequently, the write
mode is activated (see Chapter 8.2.5).
The write mode is granted only to one person at a time.
If a second user attempts to log on in write mode, he will be refused by the system.
The system will return an error message.
String length for personally created user names and passwords:
Precondition
■
User name: 6 to 16 characters, the second character must not be a number
■
Password: 6 to 16 characters
The generated password is available.
KAESER CONNECT for SIGMA CONTROL 2 is displayed.
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Fig. 24
Initial Start-up
8.3
Using KAESER CONNECT
User management menu
1. Select the User management menu element.
2. Click read => write to activate the read/write mode.
The Log on for write access: window is displayed.
Fig. 25
Log on for write access: window
3. Enter your user name in the User name: field.
4. Enter your password in the Password: field.
5. Click OK.
The User management menu is displayed.
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No.: 9_9450 07 USE
Fig. 26
Initial Start-up
8.3
Using KAESER CONNECT
User management menu
6. Enter a new user name in the User name: field.
7. Enter a new password in the Password: field.
8. Re-enter the same new password in the Repeat password: field.
9. Set Level 2 in the Access level: field.
10. Set the State: option in the Enabled field.
11. Click Add.
The new user name has been added to the user list.
Result
A new user account has been created and activated.
Editing a user account
You can edit existing user accounts:
■
Changing the password
■
Changing the access level
■
Changing the status
Example: Change the password for an existing user account.
Precondition
The User management menu is displayed.
Write mode is activated.
1. Click the required user account in the list.
2. Enter a new password in the Password: field.
3. Re-enter the same new password in the Repeat password: field.
4. Click Update user.
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Result
8.3.7
Initial Start-up
8.3
Using KAESER CONNECT
The password for the existing user account is changed.
Settings
Settings via KAESER CONNECT apply only to your PC and your Browser.
The following settings are available.
Fig. 27
■
Units
■
Date format
■
Time format
Settings
Converting units to US values:
Precondition
KAESER CONNECT for SIGMA CONTROL 2 is displayed.
1. Select the Settings menu.
2. Click the arrow key for the unit of pressure.
A selection list of units of pressure is displayed.
3. Select the desired unit.
4. Click the arrow key for the unit of temperature.
A selection list of units of temperature is displayed.
5. Select the desired unit.
6. Set additional units and date and time formats.
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SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
8.3.8
Initial Start-up
8.3
Using KAESER CONNECT
Backup menu
The Backup menu allows you to download data from SIGMA CONTROL 2 to the Internet-capable
device.
The following backup types are available:
Precondition
■
Backup all
■
Log files
■
Settings
■
User information
KAESER CONNECT for SIGMA CONTROL 2 is displayed.
1. Click the Backup menu element.
Fig. 28
Backup menu
2. Set the required backup type in the Select source: option.
3. Click Backup.
Result
8.3.9
The data are downloaded to the Internet-capable device.
Closing KAESER CONNECT
In order to close KAESER CONNECTfor SIGMA CONTROL 2, click Logout in the header.
➤ Click Logout.
The system displays a message confirming the successful logout.
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8.4
Initial Start-up
8.4
Adjusting the pressure parameters of the machine
Adjusting the pressure parameters of the machine
This section contains instructions for how to display and adjust the pressure parameters of the ma‐
chine.
The section is divided into the following sections:
■
8.4.1: Displaying pressure parameters
■
8.4.2: Configuring the pressure parameters
"Display" means that the parameter will only be shown.
"Setting" means that the parameter can also be changed.
Parameters
Explanation
pRV
Display:
Activating pressure of the safety relief valve on the oil separator tank.
pE
Pressure increase.
Setting:
ΔpFC
■
pE SP: Switching point for pressure increase; upper safety limit for machine
maximum pressure; in an external LOAD control, this value is used to switch
the machine from LOAD to IDLE in the event of a fault.
■
pE SD: Switching differential of pressure increase.
Limiting value for machines with frequency-controlled drive (SFC).
Setting:
■
dp FC: Limit of the lowest delivery quantity. When the value [switching point
system setpoint pressure +dp FC] is exceeded, the compressor switches from
LOAD to IDLE.
Nominal
pressure
Display:
Setpoint
pressure
Setpoint pressure can be regulated to two values: pA and pB.
System
pressure low
The compressor is designed for this pressure (maximum system pressure set‐
point).
Setting:
■
Switching point pA or control pressure pA in machines with frequency convert‐
er (SFC).
■
Switching point pB or control pressure pB in machines with frequency convert‐
er (SFC).
A warning message is displayed when the limit value for the system pressure is
reached.
Setting:
78
■
SD: Switching differential for system pressure low.
↓: Switching point for system pressure low.
■
Option: Configure the output signal.
Warning message displayed or an additional output signal is sent, e.g., to a
control center.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
Tab. 53
Initial Start-up
8.4
Adjusting the pressure parameters of the machine
Parameters
Explanation
Cut-in
pressure min
Display:
For design reasons, pressure can only be built up above this value.
Compressor pressure parameters
➤ Parameters correspond to the following specifications.
8.4.1
Precondition
Displaying pressure parameters
Password access level 2 is activated.
Opening the menu for pressure parameters
1. Open the 5.2.2  menu.
2. Press «Enter».
The Pressure settings menu is displayed.
88psi
08:15AM
176° F
Menu
5.2.2 Pressure settings
Setpoint pressure
Active line
pA SP: 116psi ¦ SD:
−7.3psi
pB SP: 109psi ¦ SD:
−5.8 psi
·········
System pressure low
☐
↓ < 72.5psi ¦ SD:
7.2psi
Displaying further parameters
1. Use the «Up» or «Down» keys to select the Cut-in pressure min line.
88psi
08:15AM
176° F
Menu
5.2.2 Pressure settings
System pressure low
☐
↓ < 72.5psi ¦ SD:
7.2psi
ta:
DOR1.03
600s
☐ ¦ Logic:
__________________________________
Cut-in pressure min
72.5psi
Active line
2. Display further parameters with the «Up» and «Down» keys.
8.4.2
Configuring the pressure parameters
8.4.2.1
Adjusting the system setpoint pressure: pA and pB
The pressure parameters can only be set within certain limits:
Rated machine pressure ≥ SP: pA pB / ≥ Min. cut-in pressure* + switching differential
Tab. 54
No.: 9_9450 07 USE
Setting limits for the system setpoint pressure (* Cut-in pressure min)
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8
Initial Start-up
8.4
Adjusting the pressure parameters of the machine
The machine switches to LOAD under the following condition:
System pressure ≤ SP: pA /pB - switching differential
Tab. 55
Pressure condition for LOAD
The machine switches to IDLE under the following conditions:
System pressure = System setpoint pressure
Tab. 56
Precondition
Pressure conditions for IDLE
Password access level 2 is activated.
1. Select the 5.2.2  menu.
2. Use «Up» or «Down» to select the pASP line.
88psi
08:15AM
176° F
Menu
5.2.2 Pressure settings
·········
Setpoint pressure
pA SP: 116psi ¦ SD:
−7.3psi
pB SP: 109psi ¦ SD:
−5.8 psi
Active line with current value for system setpoint
pressure pA
·········
System pressure low
☐
3. Press «Enter».
The setting mode is active.
4. Use «Up» or «Down» to adjust the pA SP value.
5. Press «Enter» to accept the setting.
The setting is applied.
6. Adjust the SD switching differential in the same way.
7. Adjust the pB SP and the SD switching differential in the same manner, if necessary.
8. Press «Escape» repeatedly to return to the main menu.
Result
The settings for the system setpoint pressure pA and pB are adjusted.
8.4.2.2
Adjusting the value for "System pressure low"
If the system pressure falls to the System pressure lowvalue, SIGMA CONTROL 2 will display a
warning message for the system pressure being too low.
Be generous when setting the time value for the display of the warning message.
If the time interval is set too short, the system will display a warning message despite the machine
delivering compressed air and approaching the preset value for the system setpoint pressure.
The switching differential influences the pressure level at which the message can be acknowledged
or the optionally activated output can switch again:
Message
Output
72.5 psi message appears
Active
80.0 psi message disappears
Tab. 57
80
Inactive
Example: activated output
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
Precondition
Initial Start-up
8.4
Adjusting the pressure parameters of the machine
Password access level 2 is activated.
1. Select the 5.2.2  menu.
2. Use «Up» or «Down» to select the ↓< line.
88psi
08:15AM
176° F
Menu
5.2.2 Pressure settings
·········
System pressure low
↓ < 72.5psi ¦ SD:
☐
ta:
DOR1.03
Current system pressure low point
7.2psi
600s
☐ ¦ Logic:
__________________________________
3. Press «Enter» to switch into setting mode.
The setting mode is active.
4. Use «Up» or «Down» to adjust the value for System pressure low.
5. Press «Enter» to accept the setting.
The setting is applied.
6. Adjust the SD switching differential in the same way, if necessary.
7. Press «Escape» repeatedly to leave this menu.
8.4.2.3
Adjusting the SD switching differential of the pressure increase
The value for pressure rise pE SP serves as a safety limit value when the machine is externally
controlled. When the system setpoint pressure reaches the value pE SP (for example, when the
external control functions incorrectly) the machine switches to IDLE. The warning message
External load signal? is displayed.
The parameter for pE SP pressure increase is preset and cannot be changed. You can, however,
adjust the SD switching differential.
Displaying and adjusting the pressure increase parameters:
Pressure increase
Display parameters
Setting parameters
Switching point pE SP
–
Switching differential SD
x = fitted, − = not fitted
Tab. 58
Precondition
Displaying and adjusting parameters
Password access level 2 is activated.
1. Select the 5.2.2  menu.
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8
Initial Start-up
8.4
Adjusting the pressure parameters of the machine
2. Use «Up» or «Down» to select the pESP line.
88psi
08:15AM
176° F
Menu
5.2.2 Pressure settings
pRV:
232psi
__________________________________
Pressure rise
pE SP:
122psi ¦ SD:
ΔpFC:
Active line
−8.7psi
2.9psi
·········
3. Press «Enter» to switch into setting mode.
The setting mode is active.
4. Use «UP» or «DOWN» to adjust the required value for SD.
5. Press «Enter» to accept the setting.
The setting is applied.
6. Press «Escape» repeatedly to return to the main menu.
8.4.3
Activating/deactivating the «LOAD/IDLE» key
In order to prevent unauthorized users from switching the machine to IDLE, you can deactivate the
«LOAD/IDLE» key on the SIGMA CONTROL 2 operating panel.
Precondition
Password access level 2 is activated.
1. Select the 5.2.3  menu.
2. Use «Up» or «Down» to select the Key idle line.
3. Press «Enter» to switch into setting mode.
The check box Key idle will flash.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
Logic :
loc.-load RC
DI1.07
☑
Logic :
·········
Key remote:
Key idle:
☐
☑
Active line with activated check box
4. Press the «Up» key.
The deactivated check box is displayed.
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8
Initial Start-up
8.5
Configuring machine start and stop
5. Press «Enter» to save the setting.
The «IDLE» key is deactivated.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
Logic :
loc.-load RC
DI1.07
☑
Logic :
·········
Key remote:
Key idle:
☐
☐
Active line with deactivated check box
6. Press «Escape» repeatedly to return to the main menu.
Result
8.5
Thus, it is ensured that unauthorized users can press the «IDLE» key without the machine switch‐
ing to IDLE.
Configuring machine start and stop
➤ In addition to manually starting the machine locally, you have the following alternatives:
Function
State on delivery, setting
See
Automatic start/stop in timer mode
No clock (time) program set
8.5.1
Holidays
Not set
8.5.2
Remote start, e.g. from a control center
Deactivated
8.5.3
"Venting" function
Activated
8.5.5
"Autostart" function
Activated
8.5.6
Tab. 59
Settings for machine start and stop
8.5.1
Automatic start/stop in timer mode
Overview
8.5.1.1
Precondition
No.: 9_9450 07 USE
■
Selecting the Compressor clock menu
■
Setting/adjusting the time program
■
Activating the «Clock» key
■
Activating timer control
Compressor clock
Password access level 2 is activated.
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SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
83
8
Initial Start-up
8.5
Configuring machine start and stop
1. Open the 6 Compressor clock menu.
The Compressor clock menu is displayed.
88psi
08:15AM
176° F
Menu
6 Compressor clock
Key clock
:☐
The Timer control key is activated
Reset
:☐
All current switching points are reset
·········
01
n.a.
00:00AM
off
02
n.a.
00:00AM
off
03
n.a.
00:00AM
off
Active line
User-defined clock program:
No.:
Day
Time
Function
01
02
03
04
05
06
07
08
09
10
Tab. 60
User-defined clock program machine ON/OFF
8.5.1.2
Setting/adjusting the clock program (example)
When setting a clock program for the first time, note the switching times on the "User-defined
clock program" table.
In addition to individual weekdays, the controller has the following cycles:
■
Mon-Thu
■
Mon-Fri
■
Mon-Sat
■
Mon-Sun
■
Sat-Thu
You can also program an OFF time (plant vacation shutdown, for example) (see Sec‐
tion 8.5.2).
Example
84
■
Machine ON: On weekdays 06:30AM – 05:00PM, Fridays 06:30AM – 03:00PM
■
Machine OFF: Sat – Sun and during midday break 12:00PM – 01:00PM
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
8
Initial Start-up
8.5
Configuring machine start and stop
The following switching points result:
Tab. 61
Precondition
No.:
Day
Time
Function
01
Mon-Fri
06:30AM
on
02
Mon-Fri
12:00PM
off
03
Mon-Fri
01:00PM
on
04
Mon-Thu
05:00PM
off
05
Fri
03:00PM
off
Example of a machine ON/OFF clock program
Password access level 2 is activated.
1. Select the 6Compressor clock menu.
2. Use «Up» or «Down» to select the 01 line.
88psi
08:15AM
176° F
Menu
6 Compressor clock
·········
01
n.a.
00:00AM
off
Active line with switching point 01
02
n.a.
00:00AM
off
Switching point 02
03
n.a.
00:00AM
off
Switching point 03
04
n.a.
00:00AM
off
Switching point 04
05
n.a.
00:00AM
off
Switching point 05
3. Press «Enter» to switch into setting mode.
The n.a. column flashes in the active line.
4. Use the «Up» or «Down» keys to specify the settings for the weekdays.
5. Press «Enter» to accept the setting.
The setting is applied.
6. Press the «Right» key.
7. Press «Enter» to switch into setting mode.
The column time, display for hours, 00:00 flashes in the active line.
8. Use «Up» or «Down» to specify the settings for the hours.
9. Press the «Right» key.
10. The column time, display for minutes, 00:00 flashes in the active line.
11. Use «Up» or «Down» to specify the settings for the minutes.
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8
Initial Start-up
8.5
Configuring machine start and stop
12. Press «Enter» to accept the setting.
The setting is applied.
88psi
08:15AM
176° F
Menu
6 Compressor clock
·········
01
Mon-Fri
06:30AM
on
Switching point 01 is set
02
Mon-Fri
12:00PM
off
Switching point 02 is set
03
Mon-Fri
01:00PM
on
Switching point 03 is set
04
Mon-Thu
05:00PM
off
Switching point 04 is set
05
Fri
03:00PM
off
Switching point 05 is set
13. Press the «Right» key.
14. Press «Enter» to switch into setting mode.
The on/off indicator flashes.
15. Use «Up» or «Down» to specify the settings for the action Compressor On.
16. Press «Enter» to accept the setting.
The setting is applied.
The action Compressor ON is set for the first switching point.
17. Specify further switching points in the same manner.
Result
Weekdays, time and the Compressor ON/Compressor OFF actions are set for all switching points
of the user-defined clock program.
8.5.1.3
Activating the «Timer control» key
1. Use «Up» or «Down» to select the Key clock line.
2. Press «Enter» to switch into setting mode.
The check box Key clock flashes in the active line.
88psi
08:15AM
176° F
Menu
6 Compressor clock
Key clock
:☑
Reset
:☐
Active line with deactivated check box
·········
01
Mon-Fri
06:30AM
on
Switching point 01
02
Mon-Fri
12:00PM
off
Switching point 02
03
Mon-Fri
01:00PM
on
Switching point 03
3. Press the «Up» key to activate the check box.
The check box is activated.
4. Press «Enter» to accept the setting.
The setting is applied.
5. Press «Escape» repeatedly to return to the main menu.
Result
86
The «Timer control» key is activated.
The activated key «Timer control» can be used for activating the timer control.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
8.5.1.4
Precondition
Initial Start-up
8.5
Configuring machine start and stop
Activating timer control
The «Timer control» key is activated; see chapter 8.5.1.3.
➤ Press the «Timer control» key on the SIGMA CONTROL 2 operating panel to activate the time
control.
Result
The Timer control LED on the operating panel of the SIGMA CONTROL 2 signalizes with green
continuous light that the machine is operated with activated timer control.
The timer control of SIGMA CONTROL 2 switches the machine according to the defined switching
points of the timer program.
8.5.2
Setting up the holiday period
In addition to the fixed cycles of a timing program or timer, you can also specify a longer lasting
standstill time. For example, you may specify a standstill period for vacation shutdown by defining
the following:
Precondition
Password access level 2 is activated.
1. Select the 5.4.2  menu.
2. Use «Up» or «Down» to select the Start line.
88psi
08:15AM
176° F
Menu
5.4.2 Compressor off
·········
Holidays :
☐
Start
01/01/16
Active line
00:00AM
End
01/01/16
03:00AM
3. Press «Enter» to switch into setting mode.
The display for days 00.00.00 flashes.
4. Use «Up» or «Down» to set the day.
5. Press the «Right» key.
The display for months 00.00.00 flashes.
6. Use «Up» or «Down» to set the month.
7. Press the «Right» key.
The display for years 00.00.00 flashes.
8. Use the «Up» or «Down» keys to set the year.
9. Press «Enter» to accept the setting.
The setting is applied.
10. Press «Down».
11. Press «Enter» to switch into setting mode.
The display for hours 00:00:00 flashes.
12. Use «Up» or «Down» to set the hours.
13. Press the «Right» key.
The display for minutes 00:00:00 flashes.
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8
Initial Start-up
8.5
Configuring machine start and stop
14. Use «Up» or «Down» to set the minutes.
15. Press «Enter» to accept the setting.
The date and time for the start of the company shutdown are set.
16. Adjust the date and time for the end of the company shutdown in the same manner.
88psi
08:15AM
176° F
Menu
5.4.2 Compressor off
·········
Holidays :
☐
Start
12/23/16
05:00PM
End
01/04/17
06:30AM
Date for start
Time for start
Date for end
Time for end
17. Use «Up» or «Down» to select the Holidays line.
88psi
08:15AM
176° F
Menu
5.4.2 Compressor off
·········
Holidays :
Active line
☐
Start
12/23/16
05:00PM
End
01/04/17
06:30AM
18. Press «Enter» to switch into setting mode.
The check box Holidays will flash.
19. Press the «UP» key to activate the check box.
The check box is activated.
88psi
08:15AM
176° F
Menu
5.4.2 Compressor off
·········
Holidays :
☑
Start
12/23/16
05:00PM
End
01/04/17
06:30AM
Active line with activated check box
Date for start
Time for start
Date for end
Time for end
20. Press «Enter» to accept the setting.
Result
8.5.3
In this example, a company shutdown (standstill time) for the time between 12/23/16 / 05:00PM
until 01/04/17 / 06:30AM has been set for the machine.
Starting the machine remotely (Remote ON/OFF)
If the machine is to be started and stopped remotely, the following settings have to be set:
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8
Initial Start-up
8.5
Configuring machine start and stop
Overview
8.5.3.1
■
Making the electrical connection (a spare input for the remote contact can be found in the elec‐
trical wiring diagram for the machine, DI 1.07 being preferred).
■
Switching machine start to remote mode.
■
Activating the «Remote control» key.
■
Activating the «Timer control» key and configuring the clock program (see chapter 8.5.1.2), if
necessary.
■
Assigning a different input for the remote contact RC, if required.
■
Pressing the «Remote control» key.
Switching machine start to Remote mode
Two methods are available to start the machine remotely from a control center:
Precondition
■
Variant A: Starting the machine with the input signal from the remote control center.
■
Variant B: Starting the machine from the remote control center in addition to a configured
ON/OFF clock program.
The machine can be started from the remote control center even though the timer control is
activated and the ON/OFF program has selected OFF at this point in time.
The electrical connection has been made.
Password access level 2 is activated.
The operating mode is displayed.
1. Open the 5.4.1  menu.
2. Use «Up» or «Down» to select the Remote mode line.
3. Press the «DOWN» key.
4. Press «Enter» to switch into setting mode.
The currently active operating mode flashes.
88psi
08:15AM
176° F
Menu
5.4.1 Compressor on
Local mode:
Key
Remote mode:
Active line
Key
__________________________________
RC
DI1.07
ok ☑
5. Use «Up» or «Down» to set the Key + remote contact input.
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8
Initial Start-up
8.5
Configuring machine start and stop
6. Press «Enter» to accept the setting.
The setting is applied.
88psi
08:15AM
176° F
Menu
5.4.1 Compressor on
Local mode:
Key
Remote mode:
Key + remote contact
Active line
__________________________________
RC
DI1.07
ok ☑
Result
The machine start is set to Remote mode Key + remote contact.
8.5.3.2
Assigning another input
Inputs already assigned cannot be further assigned.
1. Use «Up» or «Down» to select the RC line.
88psi
08:15AM
176° F
Menu
5.4.1 Compressor on
__________________________________
RC
DI1.07
ok ☑
Logic :
Remote contact DI 1.07 (default)
·········
Key remote
:☑
Key clock
:☐
2. Press «Enter» to switch into setting mode.
The display for the currently set input flashes.
3. Select another input with the «Up» or «Down» keys.
4. Press «Enter» to accept the setting.
The input has now been assigned.
5. Press the «Remote control» key to enable the machine to be started from the remote control
center.
If an input is rejected it means it is already assigned.
➤ Select a different input.
8.5.4
Activating the remote control
➤ Activating remote control, see chapter 8.2.12.
Result
90
SIGMA CONTROL 2 remote control is activated.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
8.5.5
Initial Start-up
8.5
Configuring machine start and stop
Activating/deactivating the idle period "Venting period" function
Prior to the machine's transition from the operating modes LOAD to READY you can also activate
an IDLE period ("Venting period" function). The duration of the IDLING period can be timed and/or
regulated by internal pressure. The machine-dependent venting period between the LOAD and
READY operating modes ensures load changes at minimum material stresses and is therefore ac‐
tivated at the factory (default setting). If this function is not required, you can deactivate it.
Precondition
Password access level 2 is activated.
1. Open the 5.4.2  menu.
2. Use «Up» or «Down» to select the Start line.
88psi
08:15AM
176° F
Menu
5.4.2 Compressor off
Venting period :
☑
Factory setting: "Venting period” activated
·········
Holidays :
☐
Start
01/01/16
00:00AM
End
01/01/16
3. Press «Enter» to switch into setting mode.
The check box Venting period will flash.
4. Press the «UP» key.
The check box is deactivated.
88psi
08:15AM
176° F
Menu
5.4.2 Compressor off
Venting period :
☐
·········
Holidays :
☐
Start
01/01/16
00:00AM
End
Active line with deactivated check box
Date for start
Time for start
Date for end
Time for end
01/01/16
5. Press «Enter» to accept the setting.
The setting is applied.
Apart from the discontinuation of the pressure or load requirement, venting of the machine is also
executed when the «OFF» key is pressed.
Press the «OFF» key twice to immediately shut the machine off.
➤ Press the «OFF» key twice.
Result
8.5.6
The machine is switched off without venting (IDLE time).
Activating/deactivating and adjusting the "Autostart" function
The Autostart: function is activated (default setting).
To avoid overloading the power supply through several machines starting simultaneously, a delay
period determining the restart of each machine can be entered.
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91
Precondition
Initial Start-up
8.5
Configuring machine start and stop
Password access level 2 is activated.
1. Select the 5.4  menu.
2. Press «Enter».
The Compressor start menu is displayed.
88psi
08:15AM
176° F
5.4 Compressor start
Menu
▶1 Compressor on
Active line
▶2 Compressor off
·········
Autostart:
Target
Autostart activated
☑
10 s ¦ Actual
·········
Setting up the Autostart delay period
If you operate several machines, it is better to start them in sequence.
Use the "Delay time for Autostart" table to plan the time-delayed machine start. In the "Start
period" column, enter for each individual machine the real time required for the first possible
LOAD. Cumulatively add these values in the "Delay time" column. Enter the value of the de‐
lay time of each machine in the corresponding controller.
The first machine may start immediately and does not require a delay time.
Machine number
Start time [sec]
Delay time [sec]
––
––
10
11
12
13
14
15
16
Tab. 62
Precondition
92
Autostart delay period
Password access level 2 is activated.
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SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
8
Initial Start-up
8.5
Configuring machine start and stop
1. Select the 5.4 Compressor start menu.
2. Use «Up» or «Down» to select the Target line.
88psi
08:15AM
176° F
Menu
5.4 Compressor start
▶1 Compressor on
▶2 Compressor off
·········
Autostart:
Target
Autostart is activated
☑
10 s ¦ Actual
Set/expiring delay time
·········
3. Press «Enter» to switch into setting mode.
The Target display flashes.
4. Use «Up» or «Down» to set the time delay in seconds.
88psi
08:15AM
176° F
Menu
5.4 Compressor start
▶1 Compressor on
▶2 Compressor off
·········
Autostart:
Target
☑
12 s ¦ Actual
Active line
·········
5. Press «Enter» to accept the setting.
The setting is applied.
6. Press «Escape» repeatedly to return to the main menu.
Result
The delay time for an Autostart after a power failure has been adjusted from 10 s to 12 s.
Deactivate/activate the Autostart function
1. Use «Up» or «Down» to select the Autostart: line.
88psi
08:15AM
176° F
Menu
5.4 Compressor start
▶1 Compressor on
▶2 Compressor off
·········
Autostart:
Target
Autostart deactivated
☐
10 s ¦ Actual
Set/expiring delay time
·········
2. Press «Enter» to switch into setting mode.
The check box Autostart: will flash.
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8
Initial Start-up
8.6
Activating and adjusting the control modes
3. Press the «Up» key.
The check box Autostart: is deactivated.
4. Press «Enter» to accept the setting.
The Autostart: function can be activated in the same manner.
The setting is applied.
5. Press «Escape» repeatedly to return to the main menu.
Result
8.6
Autostart after a power failure is deactivated.
Activating and adjusting the control modes
The controller is provided with various control modes that can bring about different capacity utiliza‐
tion depending on machine application. Chapter 5.7 provides a comprehensive description of all
control modes.
8.6.1
Selecting a control mode
The following control modes are possible:
Precondition
■
DUAL
■
QUADRO
■
VARIO
■
DYNAMIC
■
Continuous
■
The standard setting of the control mode depends on the machine type.
■
The machine-dependant venting period between the LOAD and READY operating modes
ensures load changes at minimum material stresses.
Password access level 2 is activated.
1. Select the 5.3  menu.
2. Use «Up» or «Down» to select the Local mode line.
88psi
08:15AM
176° F
5.3 Control mode
Menu
Local mode:
Active line
DUAL
__________________________________
▶1 Venting period
Venting period menu
·········
▶2 DUAL
3. Press «Down».
The currently set control mode is displayed.
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No.: 9_9450 07 USE
8
Initial Start-up
8.6
Activating and adjusting the control modes
4. Press «Enter» to switch into setting mode.
The currently active control mode flashes.
88psi
08:15AM
176° F
Menu
5.3 Control mode
Local mode:
Active line
DUAL
__________________________________
Venting period menu
▶1 Venting period
·········
▶2 DUAL
5. Use «Up» or «Down» to set the control mode.
6. Press «Enter» to accept the setting.
The setting is applied.
7. Press «Escape» repeatedly to return to the main menu.
8.6.2
Adjusting the idle time of DUAL control mode
The machine is READY when the specified idle time has elapsed.
The shorter the period, the more often the machine will switch from IDLE to READY.
SIGMA CONTROL 2 will take into account the maximum motor switching capacity.
Depending on the machine type, the machine's motor may not fall below a minimum idling or
standstill time.
Precondition
Password access level 2 is activated.
The DUAL control mode is set.
The operating mode is displayed.
1. Select the 5.3.2  menu.
88psi
08:15AM
176° F
Menu
5.3.2 DUAL
Idle period
Target
No.: 9_9450 07 USE
240 s ¦ Actual
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
0s
Active line
95
8
Initial Start-up
8.6
Activating and adjusting the control modes
2. Use «Up» or «Down» to select the Target line.
88psi
08:15AM
176° F
Menu
5.3.2 DUAL
Idle period
Target
300 s ¦ Actual
0s
Active line with increased idle time, (example:
300 seconds)
3. Press «Enter» to switch into setting mode.
The seconds display flashes.
4. Use «Up» or «Down» to set the seconds.
5. Press «Enter» to accept the setting.
The setting is applied.
6. Press «Escape» repeatedly to return to the main menu.
8.6.3
Adjusting the minimum running and unloaded period in QUADRO control
mode
When the minimum running period has elapsed, the machine switches from IDLE to READY. De‐
pending on the setting for the unloaded period, the machine switches from LOAD to IDLE or direct‐
ly to READY.
Precondition
Password access level 2 is activated.
The QUADRO control mode is set.
1. Select the 5.3.3  menu.
88psi
08:15AM
176° F
Menu
5.3.3 QUADRO
Min. run period
Target
240 s ¦ Actual
0s
Active line setpoint value for minimum run time
·········
Unloaded period
Target
0s
240 s ¦ Actual
10
2. Use the «Up» or «Down» keys to select the Min. run period line.
3. Press the «DOWN» key.
4. Press «Enter».
The seconds display flashes.
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Initial Start-up
8.7
Electronic Thermal Management
5. Use «Up» or «Down» to set the seconds.
88psi
08:15AM
176° F
Menu
5.3.3 QUADRO
Min. run period
Target
260 s ¦ Actual
0s
Active line with changed setpoint value for minimum
run time
0s
Changed setpoint value for unloaded period
·········
Unloaded period
Target
260 s ¦ Actual
6. Press «Enter» to accept the setting.
The setting is applied.
7. Adjust the target value for the Unloaded period switching differential in the same way, if neces‐
sary.
8. Press «Escape» repeatedly to return to the main menu.
Further information
8.7
See chapter 5.7 for an overview of the control modes.
Electronic Thermal Management
The design of the electronic thermal management (ETM) is determined by your machine's design.
Model
Tab. 63
Electronic thermal management (ETM)
Machine type 1
Without heat recovery
Machine type 2
Heat recovery without electrically controlled valve
Machine type 3
Heat recovery with adjustable airend discharge temperature for the
regulator of the electrically controlled heat recovery valve
Machine type and ETM design
Note:
■
The machine runs with increased airend discharge temperature when heat recover is set to ac‐
tive.
■
An increased airend discharge temperature causes poor efficiency of the compressed air gen‐
eration.
1. Check whether your machine is fitted with an electronic thermal management.
2. Check whether the setpoint value of the airend discharge temperature for the regulator of the
electrically controlled heat recovery valve can be adjusted.
3. Set the heat recovery to "active" if you can use the machine's exhaust heat.
4. Set the heat recovery to "inactive" if you cannot use the machine's exhaust heat.
8.7.1
Activating the heat recovery for machine type 2
The heat recovery can be set for local operation, as well as for remote operation. In remote opera‐
tion, the heat recovery can be controlled by means of a load remote contact.
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8
Initial Start-up
8.7
Electronic Thermal Management
Example: Heat recovery for machines in "remote operation".
Precondition
Password access level 2 is activated.
1. Select the 5.6  menu.
2. Use the «Up» or «Down» keys to select the Remote mode: line.
88psi
08:15AM
176° F
Menu
5.6 ETM
Waste heat recovery
Local mode:
inactive
Remote mode:
current
inactive
Active line
inactive
Status of heat recovery
3. Press the «DOWN» key.
4. Press «Enter» to switch into setting mode.
The currently active operating mode flashes.
5. Use «Up» or «Down» key to set the active option.
6. Press «Enter» to accept the setting.
The setting is applied.
88psi
08:15AM
176° F
Menu
5.6 ETM
Waste heat recovery
Local mode:
inactive
Remote mode:
current
active
Active line
active
Status of heat recovery
7. If a load remote contact controls the remote control, set the remote contact option.
88psi
08:15AM
176° F
Menu
5.6 ETM
Remote mode:
remote contact
current
active
__________________________________
RC
DI1.07
ok ☑
Key remote:
Active line
☑
8. Subsequently, set the requested digital input DI in line RC and activate the corresponding
check box.
9. Activate the «Remote control» key (see chapter 8.2.12).
Result
98
The heat recovery system in "remote operation" has been activated.
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No.: 9_9450 07 USE
8
Initial Start-up
8.7
Electronic Thermal Management
The «Remote control» key is activated.
No other settings are required.
The current status for the heat recovery is displayed in the current line.
8.7.2
Activating the heat recovery for machine type 3
Example: Heat recovery with adjustable setpoint value for the airend discharge temperature
for the regulator of the electrically controlled heat recovery valve for machines in "local opera‐
tion".
Precondition
Password access level 2 is activated.
1. Select the 5.6  menu.
2. Use the «Up» or «Down» keys to select the Local mode: line.
88psi
08:15AM
176° F
Menu
5.6 ETM
Waste heat recovery
Local mode:
inactive
Active line
Remote mode:
inactive
current
inactive
Status of heat recovery
3. Press the «DOWN» key.
4. Press «Enter» to switch into setting mode.
The currently active operating mode flashes.
5. Use «Up» or «Down» key to set the active option.
6. Press «Enter» to accept the setting.
The setting is applied.
88psi
08:15AM
176° F
Menu
5.6 ETM
Waste heat recovery
Local mode:
active
Active line
Remote mode:
inactive
current
Result
Further information
No.: 9_9450 07 USE
active
Status of heat recovery
The heat recovery system has been activated.
The setpoint value for the airend discharge temperature for the regulator of the electrically control‐
led heat recovery valve can be set manually; see chapter 8.7.2.1.
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8.7.2.1
Initial Start-up
8.7
Electronic Thermal Management
Setting the setpoint value for the airend discharge temperature
The airend discharge temperature and the water outlet temperature are related. To increase
the value for the water outlet temperature, you must increase the setpoint value for the airend
discharge temperature.
Maximum setting = 198 °F.
The specific value of the discharge temperature depends on the respective application for the
heat recovery at the customer's.
Precondition
Password access level 2 is activated.
1. Select the 5.6  menu.
2. Use the «Up» or «Down» keys to select the ADT controller line.
88psi
08:15AM
176° F
Menu
5.6 ETM
·········
Oil cooler
ADT controller
ΔT:
176 °F
Active line
·········
▶1 Oil cooler
Indication
▶2 ADT controller
Indication
3. Press «Enter» to switch into setting mode.
The setting mode is active.
4. Use «Up» or «Down» to set the setpoint for the ADT controller.
88psi
08:15AM
176° F
Menu
5.6 ETM
·········
Oil cooler
ADT controller
ΔT:
194 °F
Active line
·········
▶1 Oil cooler
Indication
▶2 ADT controller
Indication
5. Press «Enter» to accept the setting.
The setting is applied.
Result
8.7.3
The setpoint value of the airend discharge temperature for the regulator of the electrically control‐
led heat recovery valve is set.
Deactivating heat recovery
If the heat recovery is set to inactive, you have improved efficiency in compressed air genera‐
tion.
➤ Set the heat recovery to "inactive" if you cannot use the machine's exhaust heat.
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8.8
Initial Start-up
8.8
Refrigerated dryer
Refrigerated dryer
Overview:
■
Setting the operating mode
■
Output messages
■
Procedures following a fault of the refrigerated dryer:
─
■
The quality of the compressed air has priority:
Immediately contact an authorized KAESER service representative.
Procedures following a fault of the refrigerated dryer:
─
Compressed air quality has priority:
Activate fault mode without refrigerated dryer.
➤ It is mandatory to follow the procedures indicated according to the priorities established for the
compressed air quality or compressed air quantity!
8.8.1
Setting the operating mode
The CONTINUOUS or TIMER modes can be activated for the refrigerated dryer.
If the TIMER setting is used, the refrigerated dryer is shut down under timing control whenever
compressed air is not required.
The operating temperature in the refrigerated dryer is kept constant within narrow limits under this
method of control by cycling the refrigerant circulation.
Precondition
Password access level 2 is activated.
1. Select the 5.9  menu.
2. Use the «Up» or «Down» keys to select the Compressor ready: line.
3. Press the «DOWN» key.
88psi
08:15AM
176° F
Menu
5.9 Refrigeration dryer
Control mode
Compressor ready:
Continuous
Active line
Compressor Clk/RC/RB off:
off
·········
4. Press «Enter» to switch into setting mode.
The currently active operating mode flashes.
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8
Initial Start-up
8.8
Refrigerated dryer
5. Use «Up» or «Down» to set the Timer operating mode.
88psi
08:15AM
176° F
Menu
5.9 Refrigeration dryer
Control mode
Compressor ready:
Active line
Timer
Compressor Clk/RC/RB off:
off
·········
6. Press «Enter» to accept the setting.
The setting is applied.
7. Press «Escape» repeatedly to leave this menu.
Result
8.8.2
The CONTINUOUS operating mode has been switched to the TIMER operating mode.
Output messages
If required, you can activate messages regarding the operating temperature of the refrigerated dry‐
er as a binary signal.
You can assign to DOR or DOT.
If you have correctly parameterized, ok will be displayed.
Precondition
Password access level 2 is activated.
1. Select the 5.9  menu.
2. Use «Up» or «Down» to select the Temperature line.
88psi
08:15AM
176° F
5.9 Refrigeration dryer
Menu
Temperature ↑
Active line, temperature high
DOR1.07
☐ ¦ Logic
DOT1.01
☐ ¦ Logic
DOR1.03
☐ ¦ Logic
DOT2.01
☐ ¦ Logic
Temperature⇟
3. Press the «DOWN» key.
4. Press «Enter» to switch into setting mode.
The setting mode is active.
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8
Initial Start-up
8.8
Refrigerated dryer
5. Select a free input DOR with the «Up» or «Down» key.
88psi
08:15AM
176° F
5.9 Refrigeration dryer
Menu
Temperature↑
Temperature high
DOR1.05
☐ ¦ Logic
DOT1.01
☐ ¦ Logic
DOR1.03
☐ ¦ Logic
DOT2.01
☐ ¦ Logic
Active line, example: DOR selected
Temperature⇟
6. Press «Enter» .
The setting is applied.
7. Press the «Right» key.
8. Press «Enter».
The setting mode is active.
9. Press «UP».
88psi
08:15AM
176° F
5.9 Refrigeration dryer
Menu
Temperature↑
Temperature high
DOR1.05
ok ☑ ¦ Logic
DOT1.01
☐ ¦ Logic
Active line
Temperature low
Temperature⇟
DOR1.03
☐ ¦ Logic
DOT2.01
☐ ¦ Logic
10. Press «Enter».
ok is displayed as the active line.
11. Set the Temperature ⇟ message if necessary in the same way.
Upon activation of the check box, err is displayed.
➤ The parameterization is incorrect.
➤ Deactivate the check box.
➤ Assign another and/or free output.
8.8.3
Fault in the refrigerated dryer – compressed air quality has priority
After a fault occurs in the refrigerated dryer, the SIGMA CONTROL 2 shuts the machine down.
No compressed air is delivered.
Because compressed air quality (dried compressed air) is crucial, you must contact an authorized
KAESER service representative immediately.
Precondition
The operator decides: Compressed air quality has a higher priority than the compressed air quanti‐
ty.
1. Keep machine shut down because the required compressed air quality is no longer delivered.
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8
Initial Start-up
8.8
Refrigerated dryer
2. Immediately contact an authorized KAESER service representative.
An authorized KAESER service representative eliminates the fault and executes a reset.
The machine is ready for the delivery of high-quality, dried compressed air.
8.8.4
Fault in the refrigerated dryer – compressed air quantity has priority
Higher residual humidity in the compressed air!
Higher residual humidity in the compressed air encourages corrosion.
➤ Carefully assess a "Fault mode without refrigerated dryer" in respect to the further use of
the compressed air.
After a fault occurs in the refrigerated dryer, the SIGMA CONTROL 2 shuts the machine down.
In order to ensure compressed air delivery for a defined period of time, the operator can activate
the Error operation without RD function. The quality of the compressed air (dried compressed air)
is compromised in this case. The 0069 Error operation without RD
→ Call service! warning message is displayed. The 0069 warning message remains active for the
entire time of operation in fault mode.
Precondition
The operator decides: Compressed air quantity has a higher priority than the compressed air quali‐
ty.
Password access level 2 is activated.
1. Open the 5.9  menu.
2. Use the «Up» or «Down» keys to select the Error operation without RD line.
3. Press the «DOWN» key.
88psi
08:15AM
176° F
Menu
5.9 Refrigeration dryer
·········
Safe compressed air quality
·········
Error operation without RD
active:
Run time max.:
☐
8h
Active line
Running time (fixed)
4. Press «Enter» to switch into setting mode.
The setting mode is active.
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8
Initial Start-up
8.9
Configuring the machine for local mode
5. Press «Up» key.
The check box is activated.
88psi
08:15AM
176° F
Menu
5.9 Refrigeration dryer
·········
Safe compressed air quality
·········
Error operation without RD
active:
☑
Run time max.:
8h
Active line
Running time (fixed)
6. Press «Enter» to accept the setting.
The setting is applied.
Result
"Fault mode without refrigerated dryer" function is activated.
The compressor provides compressed air for connected consumers.
The compressed air delivered in this mode contains a higher residual humidity because the func‐
tion of the refrigerated dryer is defective.
8.9
Configuring the machine for local mode
In local mode, the machine is regulated with the system setpoint pressure pA or pB. The controller
is equipped with the following modes of operation:
Tab. 64
Operating
mode
Description
See
chapter
pA
The machine is controlled by the system setpoint pressure pA.
8.9.3.3
pB
The machine is controlled by the system setpoint pressure pB.
pA/pB Clock
The changeover between the pA and pB system setpoint pressures
is regulated by a clock program.
pA/pB Cycle
The changeover between the pA and pB system setpoint pressure is 8.9.3
regulated by a programmed time pulse.
8.9.2
Local operating mode (local mode)
➤ Adjusting the system setpoint pressure as described in chapter 8.4.
Overview
8.9.1
Precondition
■
Open the Configuration menu
■
Setting the clock program (see chapter 8.9.2)
or Setting the timer (see chapter 8.9.3)
■
Setting local operating mode
Load control menu
Password access level 2 is activated.
1. Select the 5.2.3  menu.
The Load control menu is displayed.
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8.9.2
Initial Start-up
8.9
Configuring the machine for local mode
Configuring the system setpoint pressure changeover using the clock
Note the configuration sequence:
➤ First, determine the clock program.
➤ Then select the operating mode.
Overview
■
Deleting an existing clock program
■
Entering the weekday for the first switching point
■
Entering the time of the first switching point
■
Configuring the system setpoint pressure for the first switching point pA or pB
■
Setting up any further switching points
■
Setting the operating mode pA/pB Clock: see chapter 8.9.3.3
User-defined clock program
No.:
Day
Time
System setpoint
pressure
01
02
03
04
05
06
07
08
09
10
Tab. 65
User-defined clock program
When setting a clock program for the first time, note first the switching times on the "Userdefined clock program" table for example.
In addition to individual weekdays, the controller has the following cycles:
■
Mon-Thu
■
Mon-Fri
■
Mon-Sat
■
Mon-Sun
■
Sat-Thu
Example
■
Peak load period: On weekdays from 06:30AM–05:00PM, Fridays 06:30AM–03:00PM
■
Low load period: Midday from 12:00PM–01:00PM and the remaining period.
The clock program is established with the following switching points (maximum 10 switching points
available):
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Tab. 66
Initial Start-up
8.9
Configuring the machine for local mode
No.:
Weekday
Time
System setpoint pres‐
sure
01
Mon-Fri
06:30AM
pA on
02
Mon-Fri
12:00PM
pB on
03
Mon-Fri
01:00PM
pA on
04
Mon-Thu
05:00PM
pB on
05
Fri
03:00PM
pB on
Example of system pressure changeover switching points
Deleting an existing clock program
Take the following steps to delete an existing clock program:
Precondition
Password access level 2 is activated.
1. Open the 5.2.3  menu.
2. Use «Up» or «Down» to select the pA/pB Clock line.
3. Press «Enter».
The Clock program menu is displayed.
4. Use «Up» or «Down» to select the Reset line.
88psi
08:15AM
176° F
Menu
5.2.3.1 pA/pB Clock
Reset
:☐
Active line
·········
01
Mon-Fri
06:30AM
pA
02
Mon-Fri
12:00PM
pB
03
Mon-Fri
01:00PM
pA
04
Mon-Thu
05:00PM
pB
5. Press «Enter» to switch into setting mode.
The check box Reset: will flash.
6. Press «UP».
The check box is activated.
7. Press «Enter» to accept the settings.
The clock program is now deleted.
Setting the switching point
Precondition
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Password access level 2 is activated.
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8
Initial Start-up
8.9
Configuring the machine for local mode
1. Open the 5.2.3.1  menu.
The Clock program menu is displayed.
88psi
08:15AM
176° F
Menu
5.2.3.1 pA/pB Clock
Reset
:☐
·········
01
n.a.
00:00AM
pA
02
n.a.
00:00AM
pA
03
n.a.
00:00AM
pA
04
n.a.
00:00AM
pA
2. Press «Enter» to switch into setting mode.
The display for the set operating mode flashes.
88psi
08:15AM
176° F
Menu
5.2.3.1 pA/pB Clock
Reset
:☐
·········
01
Mon-Fri
06:30AM
pA
Settings for weekdays, time, pA
02
Mon-Fri
12:00PM
pB
Settings for weekdays, time, pB
03
Mon-Fri
01:00PM
pA
04
Mon-Thu
05:00PM
pB
3. Use «Up» or «Down» to set the weekdays.
4. Press «Enter» to accept the setting.
The setting is applied.
5. Press the «Right» arrow.
6. Press «Enter».
The display for hours, 00:00 flashes.
7. Use «Up» or «Down» to set the hours.
8. Press the «Right» key.
9. The display for minutes, 00:00 flashes.
10. Use «Up» or «Down» to set the minutes.
11. Press «Enter».
The setting is applied.
12. Press the «Right» arrow.
13. Press «Enter».
The pA/pBindication flashes.
14. Use «Up» or «Down» to set pA or pB.
15. Press «Enter».
The setting is applied.
16. Set the other switching points in the same manner.
The clock program is now finished.
17. Setting the operating mode pA/pB Clock: see chapter 8.9.3.3
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8.9.3
Initial Start-up
8.9
Configuring the machine for local mode
Configuring the system setpoint pressure changeover using the timer
Overview
8.9.3.1
■
Deleting the old timer configuration, if necessary
■
Setting timer periods pA and pB
■
Setting starting time for pA or pB
■
Setting the operating mode pA/pB Cycle: See chapter 8.9.3.3
Setting timer periods pA and pB
Keep to the order of the configuration. The pA/pB Cycle operating mode must not be activa‐
ted when configuring the timer period.
➤ Configure the timer first and then select the operating mode or select another operating
mode first.
Precondition
Password access level 2 is activated.
1. Open the 5.2.3  menu.
2. Use «Up» or «Down» to select the pA/pB Cycle line.
3. Press the «DOWN» key.
The pA line is displayed.
4. Press «Enter» to switch into setting mode.
The display for the cycle duration in hours, 00 flashes.
5. Use «Up» or «Down» to set the hours.
6. Press «Enter» to accept the setting.
The setting is applied.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
▶1 pA/pB Clock
·········
pA/pB Cycle
pA: 10 h – 10 h pB: 18 h – 18 h
1.Start pA ¦
Active line, manually set setpoint value – automati‐
cally elapsing value (example)
00:00
·········
7. Press the «Right» arrow.
8. Set the cycle duration for pB in the same manner.
9. Press «Enter».
The timer period for the system setpoint pressure pA and pB is set.
8.9.3.2
Setting the starting time for pA or pB
1. Use «Up» or «Down» to select the 1.Start pA line.
2. Press the «Right» arrow.
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8
Initial Start-up
8.9
Configuring the machine for local mode
3. Press «Enter» to switch into setting mode.
The display for hours, 00:00 flashes.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
▶1 pA/pB Clock
·········
pA/pB Cycle
pA: 10 h – 10 h pB: 18 h – 18 h
1.Start pA ¦
06:30AM
Active line, starting time
·········
4. Use «Up» or «Down» to set the hours.
5. Press the «Right» key.
The display for minutes, 00 :00 flashes.
6. Use «Up» or «Down» to set the minutes.
7. Press «Enter» to accept the settings.
Result
The starting time for pA is set.
The cycle is set to start with pB.
➤ Press «Enter» and specify 1.Start pB with «UP».
8.9.3.3
Precondition
Setting local mode
Password access level 2 is activated.
The timing program or timer is set up.
1. Open the 5.2.3  menu.
2. Use «Up» or «Down» to select the Local mode line.
3. Press «Enter» to switch into setting mode.
The display for the set operating mode flashes.
88psi
08:15AM
176° F
5.2.3 Load control
Menu
Local mode:
Active line
pA/pB Cycle
Remote mode:
pB
__________________________________
▶1 pA/pB Clock
·········
pA/pB Cycle
4. Use «Up» or «Down» to set the required operating mode (pA, pB, pA/pB Clock, pA/pB Cycle).
5. Press «Enter» to accept the setting.
The setting is applied.
6. Press «Esc» repeatedly to leave this menu.
Result
110
The timer is fully configured.
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8.10
8.10.1
Initial Start-up
8.10
Configuring the machine for master control
Configuring the machine for master control
List of the different master controllers
The machine controller is equipped with several methods of working under other controllers.
Method
Description
Section
Master control with SAM 4.0.
You must modify the settings in SIGMA
CONTROL 2 for the operation via
SIGMA NETWORK using the KAESER
SIGMA AIR MANAGER 4.0.
8.10.2
Master control via PROFIBUS
(only available with SIGMA
CONTROL 2 - requires an additional
module).
The controller (and therefore the compressor) re‐ 8.10.3
ceives the instruction LOAD, IDLE or local opera‐
tion via the PROFIBUS Master (e. g.
SIGMA AIR MANAGER). The system setpoint
pressures pA and pB are irrelevant for the LOAD/
IDLE signals.
Master control of two compressors
The two SIGMA CONTROL 2 controllers operate 8.10.4
with SIGMA CONTROL 2 via Ethernet as master and slave. The slave receives the
interface.
command to switch between the two system set‐
point pressures pA and pB from the master.
Master control via LOAD remote con‐ LOAD remote contact:
8.10.5
tact.
An input signal from a superordinate controller
switches the machine to LOAD or IDLE. The set‐
Master control via a LOAD remote
contact is another method of control‐ point pressure settings pA and pB have no rele‐
vance.
ling the machine externally.
There are two possibilities:
Local/LOAD remote contact:
Using two inputs, a master controller (e.g.
MVS 8000) switches the machine between
LOAD/IDLE and local operation.
8.10.6
Setpoint pressure preselection.
pA/pB remote contact:
An input contact provides the signal to switch
from the system setpoint pressure pA to pB.
8.10.7
Master control of machines regulated On machines with the same FAD,
8.10.8.1
by pressure switch.
SIGMA CONTROL 2 controls the pressure switch
via a floating relay output.
On machines supplying an unequal FAD, the
pressure ranges are matched to each other.
Tab. 67
Further information
8.10.2
8.10.8.2
Master control – overview
Examples of timing programs for equal machine loading are given in section 8.10.9.
SAM 4.0 mode
You must modify the settings in SIGMA CONTROL 2 for the operation via SIGMA NETWORK us‐
ing, for example, the KAESER SIGMA AIR MANAGER 4.0 (SAM 4.0).
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Precondition
Initial Start-up
8.10
Configuring the machine for master control
SIGMA CONTROL 2 is connected to SAM 4.0 via SIGMA NETWORK and ready for operation (see
the SAM 4.0 operating manual in the chapter “Installation”)
System pressure pB is set as the pressure for the “SAM 4.0 manual mode".
Password access level 2 is activated.
The remote control is activated (see chapter 8.2.12)
Setting the IP configuration
1. Open the 8.1.1  menu.
2. Use «Up» or «Down» to select the IP address line.
88psi
08:15AM
176° F
Header
8.1.1 IP configuration
Menu
IP address
Active line
169.254.100.103
Subnet mask
255.255.000.000
Gateway
169.254.100.97
DNS Server 1
169,254,100.97
DNS Server 2
169,254,100.97
Restart network
☐
3. Set the IP address for SIGMA CONTROL 2 using the following pattern:
169.254.100.(SAM 4.0 machine number +102)
(for the setting see chapter 8.2.13).
Setting the SAM 4.0 mode
The IP address for SAM 4.0 has been set on SIGMA CONTROL 2 at the factory:
169.254.100.100 and must not be changed. The same applies to Port 2000.
1. Open the 8.1.2.2 
menu.
2. Use «Up» or «Down» to select the SAM 4.0active line.
88psi
08:15AM
176° F
Header
Menu
8.1.2.2 SAM 4.0
Status
Counter 0
No error
__________________________________
SAM 4.0 active :
☑
Active line
Send
IP address
169.254.100.100
3. Press «Enter» to switch into setting mode.
The SAM 4.0 active check box flashes.
4. Press the «UP» key.
The check box is activated.
5. Press «Enter» to accept the setting.
The setting is applied.
6. Press the «DOWN» key.
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8
Initial Start-up
8.10
Configuring the machine for master control
7. Press «Enter» to switch into setting mode.
The currently active operating mode flashes.
8. Use «Up» or «Down» to set the Send/receive value.
88psi
08:15AM
176° F
Header
Menu
8.1.2.2 SAM 4.0
Status
Counter 0
No error
__________________________________
SAM 4.0 active :
☑
Active line
Send/receive
IP address
169.254.100.100
9. Press «Enter» to accept the setting.
The setting is applied.
10. Use «Up» or «Down» to select the Starttd line.
88psi
08:15AM
176° F
Header
Menu
8.1.2.2 SAM 4.0
IP address
169.254.100.100
Port
2000
__________________________________
Communication error
Start td
☑
Active line
15s
Timeout :
5s
☑
11. Press «Enter» to switch into setting mode.
The setting mode is active.
12. Use «Up» or «Down» to set the Start td value to 30 s.
88psi
08:15AM
176° F
Menu
8.1.2.2 SAM 4.0
IP address
Port
Header
169.254.100.100
2000
__________________________________
Communication error
Start td
Timeout :
☑
Active line
30s
5s
☑
13. Press «Enter» to accept the setting.
The setting is applied.
Result
SIGMA CONTROL 2 communicates with SAM 4.0 via SIGMA NETWORK.
The communication is working smoothly when neither SIGMA CONTROL 2 nor SAM 4.0 report any
communication fault.
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8.10.2.1
Initial Start-up
8.10
Configuring the machine for master control
Reaction in the event of a communication malfunction
After switching on the power supply, monitoring for communication malfunctions is suppressed for
a period of time which can be defined by means of the Start td parameter. The setting depends on
the time passing at the bus master between return of power and start of communication via the
bus.
For the communication with SAM 4.0, the value of Start td must be set to 30 s.
SIGMA CONTROL 2 can monitor the bus communication at user level. For this purpose, the bus
master reads a value ("toggle bit") that changes with every bus cycle and returns it without change.
SIGMA CONTROL 2 returns a communication malfunction if the value does not change for a time
longer than set (Timeout).
Monitoring for communication malfunction can be activated if needed. For this purpose, the
Send/receive option must be set for the data exchange. Activate the Communication error
check box to enable monitoring for communication malfunctions.
88psi
08:15AM
176° F
Menu
8.1.2.2 SAM 4.0
IP address
Port
Header
169.254.100.100
2000
__________________________________
Communication error
Start td
Timeout :
Active line
☑
30s
5s
☑
Settings for connection to SAM 4.0.
Parameters
Factory setting
Check box Communication error
Check box ☑ activated 1)
Start td
30 s
Timeout
5s
Check box Timeout
Check box ☑ activated
1)
Tab. 68
8.10.3
Set value
Prerequisite: The Send/receive option has been set.
Parameters for monitoring for communication malfunction
Configuring PROFIBUS mode (SIGMA AIR MANAGER)
Only possible with SIGMA CONTROL 2 (prepared for connection to control center)
Overview:
Precondition
114
■
Establishing the electrical connection
■
Setting the remote operating mode pB
■
Configuring the PROFIBUS interface
■
Activating the «Remote control» key
Retrofit kit PROFIBUS required
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Initial Start-up
8.10
Configuring the machine for master control
Establishing the electrical connection
Tab. 69
Pin
Assignment
Spare
Spare
PROFIBUS connection B
TTL signal RTS
Ground
+5 V for bus terminal
Spare
PROFIBUS connection A
Spare
PROFIBUS DP pin connection
Interface plug wiring
Fig. 29
PROFIBUS plug wiring
No.: 9_9450 07 USE
Terminal 1A
Terminal 1B
Terminal 2A
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SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Terminal 2B
Slide switch, terminating resistor
115
8
Initial Start-up
8.10
Configuring the machine for master control
Electrical diagram example with SIGMA AIR MANAGER
Fig. 30
116
Electrical diagram example with SIGMA AIR MANAGER
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Initial Start-up
8.10
Configuring the machine for master control
1. Connect the bus subscribers one after the other according to the pin assignment below.
2. Connect the screening to the plug housings at both ends.
3. Set the terminating resistor in the plug to ON for the first and last subscribers to the
PROFIBUS .
Result
8.10.3.1
The terminals for the remaining bus conduit (2A/2B) are switched off.
Inserting the communication module
The SIGMA CONTROL 2 communication interface is sealed with a plastic cover when shipped
from the factory. Before you can insert the communication module in the X4 interface, you must
remove the plastic cover from the SIGMA CONTROL 2 . The designation of the interfaces is provi‐
ded on the rear of the SIGMA CONTROL 2.
Material
Small screwdriver
Torx screwdriver, size 9
Precondition
The machine is disconnected from the power supply.
The absence of voltage has been verified.
➤ Work with caution.
Removing the plastic cover
Fig. 31
Communication interface
Designation of the interfaces
Rear side of the SIGMA CONTROL 2 con‐
troller
Ethernet interface X1
IO BUS X2
RS485–FC (USS interface) X3
Communication interface X4 (customer in‐
terface)
Plastic cover
Fin
Communication interface X4 without plastic
cover
1. Place the screwdriver next to the fin.
2. Insert the tip into the slot between the plastic cover and the enclosure of the
SIGMA CONTROL 2.
3. Press the screwdriver down until the fin breaks.
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Initial Start-up
8.10
Configuring the machine for master control
4. Break the other fins in the same manner.
5. Remove the plastic cover 7 .
Inserting and fixing the communication module
Align the communication module until both cable connectors are at the same height.
Precondition
Fig. 32
The plastic cover is removed.
Inserting the communication module
Bay, interface X4
Cable connector, interface X4
Guiding plate
Recess, module bay
Cable connector, communication module
Communication module
Front plate
1. Align the communication module 6 .
2. Insert the communication module into the bay of interface X4 1 until it latches (see Fig. 32).
The module is correctly installed when its front plate 7 is seated solidly in the recess of the
module bay 4 .
3. Use the Torx T9 screwdriver to screw in the fixing screws.
8.10.3.2
Activating operation via PROFIBUS
Overview:
Precondition
■
Activating the communications module
■
Setting the slave address
■
Setting reaction for a communication malfunction
■
Activating the remote control
The communication module is plugged and screwed into the X4 interface.
The electrical connection to the bus master is made.
The machine's power supply is activated.
The machine is parametrized as a slave in the bus master.
The bus master is operational.
Fig. 33
Front plate of the PROFIBUScommunication module
118
PROFIBUS communication module
Operation LED
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Status LED
PROFIBUSinterface
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Initial Start-up
8.10
Configuring the machine for master control
➤ Proceed as shown.
Activating the communications module
1. Select the 8.2  menu.
The Com-Module menu is displayed
2. Use «Up» or «Down» to select the Com-Moduleactive line.
3. Press «Enter» to switch into setting mode.
The Com-Module active check box flashes.
88psi 08:15AM 176° F
8.2 Com-Module
Menu
Com-Module deactivated
__________________________________
Type None
Send/receive
Com-Module active : ☐
Active line
Reset : ☐
4. Press the «Up» key.
The check box is activated.
5. Press «Enter» to accept the setting.
The communication module is activated.
88psi 08:15AM 176° F
8.2 Com-Module
Menu
No error
__________________________________
Type PROFIBUS
Send/receive
Com-Module active : ☑
Active line
Reset : ☐
6. Press «Escape» repeatedly to return to the main menu.
Setting the slave address
You only need to set the slave address for the communication with the
SIGMA AIR MANAGER.
The other parameters do not require adjustment. When connected to a
SIGMA AIR MANAGER, the slave address is determined as follows:
Compressor number used at SIGMA AIR MANAGER +102.
Precondition
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Password access level 2 is activated.
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8
Initial Start-up
8.10
Configuring the machine for master control
1. Select the 8.2  menu.
The Com-Module menu is displayed
88psi 08:15AM 176° F
8.2 Com-Module
Menu
Send/receive
Com-Module active : ☑
Active line
Reset : ☐
SlaveNo.: 103
·········
Communication error : ☑
2. Use «Up» or «Down» to select the SlaveNo. line.
88psi 08:15AM 176° F
8.2 Com-Module
Menu
Send/receive
Com-Module active : ☑
Reset : ☐
SlaveNo.: 103
Active line
·········
Communication error : ☑
3. Press «Enter» to switch into setting mode.
The display for the slave address flashes.
4. Use «Up» or «Down» to set the slave address 104.
5. Press «Enter» to accept the setting.
The setting is applied.
88psi 08:15AM 176° F
8.2 Com-Module
Menu
Send/receive
Com-Module active : ☑
Reset : ☐
SlaveNo.: 104
Active line
·········
Communication error : ☑
Result
Monitoring for communication malfunction is active.
Slave address 104 is set.
Setting reaction for a PROFIBUS communication malfunction
Exchange of data with a PROFIBUS connection takes place in fixed cycles. The PROFIBUScon‐
nection can be monitored with the help of the cycle time:
The bus connection is considered to be interrupted if no data is exchanged between the bus mas‐
ter and the controller (as bus subscriber) after expiry of a set time period (time-out).
Time-out monitoring is activated. You may neither adjust nor deactivate time-out for
SIGMA AIR MANAGER.
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Initial Start-up
8.10
Configuring the machine for master control
After switching on the power supply, the communication malfunction can be suppressed tem‐
porarily.
Monitoring for communication malfunction can be deactivated if needed. For this purpose, the
Send option must be selected for the data exchange.
■
Settings for SIGMA AIR MANAGER without SIGMA AIR CONTROL PLUS
─
■
Start: 30 seconds
Settings for SIGMA AIR MANAGER with SIGMA AIR CONTROL PLUS
─
Start: 40 seconds
1. Use «Up» or «Down» to select the Communication error line.
2. Press «Enter» to switch into setting mode.
The check box Communication error will flash.
88psi 08:15AM 176° F
8.2 Com-Module
Menu
Reset : ☐
SlaveNo.: 104
·········
Communication error : ☐
Active line
Start td: 30 s
Timeout : 5 s ☑
3. Press the «Up» key.
The check box is activated.
The monitoring for communication malfunctions is active.
4. Use «Up» or «Down» to select the Starttd line.
88psi 08:15AM 176° F
Com-Module active : ☑
Reset : ☐
SlaveNo.: 104
·········
Communication error : ☑
Monitoring for communication malfunctions is active
Start td: 30 s
Active line
Timeout : 5 s ☑
5. Press «Enter» to switch into setting mode.
The 00 seconds display flashes.
6. Use «Up» or «Down» to set the seconds.
7. Press «Enter» to accept the setting.
The setting is applied.
Activating the remote control
➤ Activate remote control see chapter 8.2.12.
Result
SIGMA CONTROL 2 remote control is activated.
The bus master now remotely controls the SIGMA CONTROL 2.
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8.10.4
Initial Start-up
8.10
Configuring the machine for master control
Configuring the master control of two machines in master/slave operation
Two machines with SIGMA CONTROL 2 work as master/slave in the same air network. The mas‐
ter controls the machine configured as a slave and provides the signal for the pA and pB setpoint
pressures.
Example: Two machines with different delivery quantities
Local operating mode of the master: Local mode pA/pB Clock.
■
Toggles between system pressure setpoints pA and pB by a clock program.
■
At peak load times, pressure is regulated to system setpoint pressure pA .
During periods of low air demand, pressure is regulated to system setpoint pressure pB (e. g.
at weekends).
■
The machine with the lesser air delivery is the slave.
In times with lower air demand, the machine with the smaller delivery is used more frequently.
Example: Two machines with equal delivery quantities
■
Local operating mode of the master: Local mode pA/pB Cycle.
(Toggles between system pressure setpoints pA and pB target pressure by a clock).
The timer ensures even loading of both machines. The system pressure setpoints are set the
same for both machines.
■
During timer period 1, the master regulates to pA and signals the slave for pB.
During timer period 2, the master regulates to pB and signals the slave to pA.
If two machines with SIGMA CONTROL 2 are to work in master-slave mode, their controllers
must have the same software version.
➤ Follow the configuration steps as described in table 70:
Controller Procedure
Chapter
Both
Making the electrical connection
8.10.4.1
Both
Set the system pressure setpoints for both, pA and pB. The pressure 8.10.4.2 and
for switching points pA and pB is measured directly at the compressor. 8.10.4.3
Pressure losses in the network do not need to be taken into account.
Master
Either set up switching times for the clock program
8.10.4.2
Or, set switching times for the clock
8.10.4.2
Master
Set the type of LOAD control (clock program or clock) in local mode
8.10.4.2
Slave
Set remote mode pA/pB SC2
8.10.4.3
Slave
Activate the «Remote control» key
8.10.4.3
Both
Set IP addresses for Ethernet
8.10.4.2 and
8.10.4.3
Both
Activate controller as master or slave
8.10.4.2 and
8.10.4.3
Tab. 70
Master-slave configuration procedure
8.10.4.1
Making the electrical connection
You need the following accessories to create the network connection with SIGMA NETWORK or
Ethernet:
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Initial Start-up
8.10
Configuring the machine for master control
■
SIGMA NETWORK cable (7.9679.0) or Ethernet cable with a maximum connection length of
328 ft. each.
■
For each machine with SIGMA CONTROL 2:
─
■
Retrofit kit LAN RJ45 (7.5250.01870)
For connecting the machines to a network (LAN) or switch:
─
2x RJ45 plug (7.7628.1)
➤ Make the electrical connection according to the local condition. For more information, see the
installation manual for the Retrofit kit LAN RJ45 (7.5250.01870)
Installing the Ethernet cable
Use a cross-link Ethernet cable for the direct connection of two machines.
Fig. 34
Direct connection of two SIGMA CONTROL 2
Controller machine 1 (Master mode)
Ethernet interface X1
Ethernet cable, cross-link
Controller machine 2 (Slave mode)
Ethernet interface X1
➤ Install the Ethernet cable between the two machines.
For connecting the machines to a network (LAN) or switch (when using KAESER CONNECT for
example).
➤ Install the Ethernet cable from each machine to the LAN connection or switch.
Connecting the Ethernet cable with the machine
For each machine:
1. Insert the Ethernet cable into the machine and the machine's control cabinet, using an EMC
connection.
2. Feed the Ethernet cable through the cable ducts to SIGMA CONTROL 2. Use the wiring path
in the 24V range (blue wiring) of the ducts.
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Initial Start-up
8.10
Configuring the machine for master control
3. Install the Ethernet bus plug at the cable end.
4. Push the bus plug into the Ethernet interface X1 of the SIGMA CONTROL 2 until it latches.
For connecting the machines to a network (LAN) or switch
Connect the Ethernet cable for each machine to the LAN connection or switch.
1. Install the Ethernet bus plug to the cable end.
2. Push the bus plug into the LAN socket until it latches.
8.10.4.2
Precondition
Configure the controller of machine 1 as master
The electrical connection is made.
Password access level 2 is activated.
Setting the switching points pA and pB
1. Select the 5.2.2  menu.
The pA line is displayed.
2. Press «Enter» to switch into setting mode.
The value for pA flashes.
88psi
08:15AM
176° F
Menu
5.2.2 Pressure settings
Setpoint pressure
pA SP: 123psi ¦ SD:
−7.3psi
pB SP: 119psi ¦ SD:
−7.3 psi
Active line
·········
System pressure low
↓< 72.5psi ¦ SD:
☐
7.2psi
3. Use «Up» or «Down» to set the pA value.
4. Press «Enter» to accept the setting.
The setting is applied.
5. Press «Down».
The pB line is displayed.
6. Adjust the value for pB in the same manner, If necessary,
Setting the times
SIGMA CONTROL 2 provides the following options for selecting times:
■
1: Clock program
■
2: Timer
1. Decide your desired method.
2. Follow the instructions below for the settings required.
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Initial Start-up
8.10
Configuring the machine for master control
Alternative 1: Setting the clock program
Precondition
The electrical connection is made.
Password access level 2 is activated.
➤ Setting the target pressure change with a clock program; see chapter 8.9.2.
Alternative 2: Setting the timer
Precondition
The electrical connection is made.
Password access level 2 is activated.
1. Setting clock periods pA and pB see chapter 8.9.3.1
2. Setting the starting time for pA or pB; see chapter 8.9.3.2.
Master IP configuration
If the controllers of both machines are linked directly, they must be given different IP addresses.
Example:
Precondition
■
IP address of the machine 1 controller (Master mode): 169.254.100.101
■
IP address of the machine 2 controller (Slave): 169.254.100.102
The electrical connection is made.
Password access level 2 is activated.
1. IP address set for the master: For instructions, see chapter 8.2.13, IP address for the above
example.
The IP address of machine 1 (master) is set correctly.
2. Open the 8.1.2.1  menu.
3. Use «Up» or «Down» to select the Mode line.
4. Press «Enter» to switch into setting mode.
The setting mode is active.
88psi
08:15AM
176° F
8.1.2.1 SIGMA CONTROL 2
Status
Run
0 ¦Error
Header
Menu
__________________________________
Mode
Port
Master
Active line
2.001
·········
Communication partner
5. Use «Up» or «Down» to set Machine 1 Master operating mode.
6. Press «Enter» to accept the setting.
The setting is applied.
7. Use «Up» or «Down» to select the IP address line.
8. Press «Enter» to switch into setting mode.
The setting mode is active.
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Initial Start-up
8.10
Configuring the machine for master control
9. Set the IP address of the communication partner (slave, see above example).
10. Press «Enter» to accept the setting.
The IP address of machine 2 (slave) is set correctly.
The setting is applied.
Result
8.10.4.3
Precondition
The controller of machine 1 is set as master.
Configuring the machine 2 controller as slave
The electrical connection is made.
Password access level 2 is activated.
Setting the switching points pA and pB
1. Open the 5.2.2  menu.
The pA line is displayed.
2. Press «Enter» to switch into setting mode.
The value for pA flashes.
88psi
08:15AM
176° F
Menu
5.2.2 Pressure settings
Setpoint pressure
pA SP: 123psi ¦ SD:
−7.3psi
pB SP: 119psi ¦ SD:
−7.3 psi
Active line
·········
System pressure low
↓< 72.5psi ¦ SD:
☐
7.2psi
3. Use «Up» or «Down» to set the pA value.
4. Press «Enter» to accept the setting.
The setting is applied.
5. Press «Down».
The pB line is displayed.
6. If necessary, adjust the value for the pB switching differential in the same manner.
Activating the remote control
➤ Activating Remote control see chapter 8.2.12.
Result
SIGMA CONTROL 2 Remote control is activated.
Setting the remote operating mode
Precondition
The electrical connection is made.
Password access level 2 is activated.
1. Open the 5.2.3  menu.
2. Use «Up» or «Down» to select the Remote mode line.
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Initial Start-up
8.10
Configuring the machine for master control
3. Press «Enter» to switch into setting mode.
The setting mode is active.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
Local mode:
pA/pB Cycle
Remote mode:
pA/pB SC2
Active line, current operating mode
__________________________________
▶1 pA/pB Clock
·········
pA/pB Cycle
4. Use «Up» or «Down» to set the pA/pB SC2 input.
5. Press «Enter» to accept the setting.
The setting is applied.
Specifying machine 2 with Slave IP address
If the controllers of both machines are linked directly, they must be given different IP addresses.
Example:
Precondition
■
IP address of the machine 1 controller (Master mode): 169.254.100.101
■
IP address of the machine 1 controller (Slave mode): 169.254.100.102
The electrical connection is made.
Password access level 2 is activated.
1. IP address set for the master: For instructions, see chapter 8.2.13, IP address for the above
example.
The IP address of machine 2 (slave) is set correctly.
2. Open the 8.1.2.1  menu.
3. Use «Up» or «Down» to select the Mode line.
4. Press «Enter» to switch into setting mode.
The setting mode is active.
5. Use «Up» or «Down» to set Machine 2 Slave operating mode.
6. Press «Enter» to accept the setting.
The setting is applied.
7. Use «Up» or «Down» to select the IP address line.
8. Press «Enter» to switch into setting mode.
The setting mode is active.
9. Set the IP address of the communication partner (master, see above example).
10. Press «Enter» to accept the setting.
The setting is applied.
Result
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The controller of machine 2 is set as slave.
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8.10.5
Initial Start-up
8.10
Configuring the machine for master control
Configuring master control using the LOAD remote contact (e.g.,
SIGMA AIR MANAGER BASIC)
Overview
■
Making the electrical connection for LOAD remote contact
■
Setting the LOAD remote contact operating mode and assigning the input
■
Adjusting the pressure increase pE, if necessary
■
Activating the «Remote control» key
➤ Configure master control as described below.
8.10.5.1
Making the electrical connection for LOAD remote contact (excerpt)
Machine (example)
Fig. 35
LOAD remote contact
Electrical connection DI 1.12
LOAD remote contact open (IDLE)
Electrical connection DI 1.12
LOAD remote contact closed (LOAD)
SIGMA AIR MANAGER BASIC contacts
➤ Establish the electrical connection for DI 1.12 according to the diagram.
8.10.5.2
Precondition
Setting the LOAD remote contact operating mode and assigning the input for LOAD remote contact
Password access level 2 is activated.
Setting the LOAD remote contact operating mode
1. Select the 5.2.3  menu.
2. Use «Up» or «Down» to select the Remote mode line.
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Initial Start-up
8.10
Configuring the machine for master control
3. Press «Enter» to switch into setting mode.
The currently active operating mode Remote mode flashes.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
Local mode:
pA/pB Cycle
Remote mode:
Active line
Load RC
__________________________________
▶1 pA/pB Clock
·········
pA/pB Cycle
4. Use «Up» or «Down» to set the Load RC input.
5. Press «Enter» to accept the setting.
The LOAD remote contact operating mode is set.
Assigning the input for LOAD remote contact
The input for the LOAD remote contact is pre-assigned.
Setting is only necessary if you deliberately want to use a different input.
1. Use «Up» or «Down» to select the Load RC line.
2. Press «Enter» to switch into setting mode.
The DI display flashes.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
pA/pB DO
DOR1.03
☐
Logic :
·········
Load RC
DI1.13
ok ☑
Logic :
loc.-load RC
DI1.09
Active line; standard DI 1.13
☐
3. Use «Up» or «Down» to select the input for the LOAD remote contact.
4. Press «Enter» to accept the setting.
The setting is applied.
5. Press the «Right» arrow.
6. Press «Enter».
The check box Load RC will flash.
7. Press «Up» key.
The check box is activated.
8. Press «Enter».
ok is displayed to the left of the check box.
The operating mode is set.
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8.10.5.3
Initial Start-up
8.10
Configuring the machine for master control
Setting the SD switching differential of the pressure increase
➤ Set the SD switching differential of the pressure increase as described in chapter 8.4.2.3.
Further information
8.10.5.4
Detailed information on the pressure parameters is provided in chapter 8.4.2.
Activating the remote control
➤ Activate remote control see chapter 8.2.12.
Result
8.10.6
SIGMA CONTROL 2 remote control is activated.
Configuring the master control with local/LOAD remote contact
Overview
■
Making the electrical connection
■
Setting the local/LOAD remote contact operating mode and assigning the input
■
Setting local operating mode, if necessary
■
Activating the «Remote control» key
➤ Configure master control as described below.
8.10.6.1
Making the electrical connection
Use the input “Controller On for the "alarm machine X" message (DOR1.03) to prevent line
breaks!
➤ Wire the "motor running” and "Controller on” (DOR1.03) messages from the compressor
to the MVS 8000.
130
■
Contact A open: SIGMA CONTROL 2controls with pB system setpoint pressure.
■
Contact A closed: SIGMA CONTROL 2 controls via external LOAD mode contact.
■
DI 1.13: LOAD/IDLE external.
■
DI 1.09: LOAD control – switchover local/LOAD remote contact.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
Fig. 36
Initial Start-up
8.10
Configuring the machine for master control
Wiring diagram for local/LOAD remote contact:
Changeover between automatic and manual modes
LOAD/IDLE contact
➤ Make the electrical connection according to the diagram.
8.10.6.2
Precondition
Setting the local/LOAD remote contact operating mode and assigning the input
Password access level 2 is activated.
Setting local/LOAD remote contact operating mode
1. Select the 5.2.3  menu.
2. Use «Up» or «Down» to select the Remote mode line.
3. Press «Enter».
The currently active operating mode Remote mode flashes.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
Local mode:
Remote mode:
pA/pB Cycle
loc.-load RC
Active line
__________________________________
▶1 pA/pB Clock
·········
pA/pB Cycle
4. Use «Up» or «Down» to set the loc.-load RC input.
5. Press «Enter».
The local/LOAD remote contact operating mode is set.
Assigning an input for the local/LOAD remote contact for switching the pressure control
1. Use «Up» or «Down» to select the loc.-load RC line.
No.: 9_9450 07 USE
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8
Initial Start-up
8.10
Configuring the machine for master control
2. Press «Enter».
The DI display flashes.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
pA/pB DO
DOR1.03
☐
Logic :
No input assigned
·········
Load RC
loc.-load RC
DI1.13
ok ☑
Logic :
DI1.09
☑
Active line
3. Use «Up» or «Down» to select a new input for local/LOAD remote contact.
4. Press «Enter».
The input for local/LOAD remote contact is assigned.
8.10.6.3
Setting local operating mode pB
The pB system setpoint pressure is normally set for local operation.
➤ When setting the pB system setpoint pressure, bear in mind that, under certain circum‐
stances, more than one compressor may be operating in local mode (see section 8.4 for
adjusting the system setpoint pressure).
Precondition
Password access level 2 is activated.
1. Select the 5.2.3  menu.
2. Use «Up» or «Down» to select the Local mode line.
3. Press «Enter» to switch into setting mode.
The operating mode display flashes.
88psi
08:15AM
176° F
5.2.3 Load control
Menu
Local mode :
Active line, current operating mode
pB
Remote mode:
loc.-load RC
__________________________________
▶1 pA/pB Clock
·········
pA/pB Cycle
4. Use «Up» or «Down» to set the pB input.
5. Press «Enter» to accept the setting.
The setting is applied.
6. Adjust the pB system setpoint pressure, if necessary (see section 8.4).
The local operating mode pB is set.
8.10.6.4
Activating the remote control
➤ Activate remote control see chapter 8.2.12.
Result
132
SIGMA CONTROL 2 remote control is activated.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
8.10.6.5
Precondition
Initial Start-up
8.10
Configuring the machine for master control
Assigning an input for the LOAD remote contact for switching the pressure control
Password access level 2 is activated.
1. Open the 5.2.3  menu.
2. Use «Up» or «Down» to select the Load RC line.
3. Press «Enter» to switch into setting mode.
The DI display flashes.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
pA/pB RC
pA/pB DO
DI1.05
☐
Logic :
DOR1.04
☐
Logic :
·········
Load RC
DI1.13
ok ☑
Active line
4. Use «Up» or «Down» to select the input for the LOAD remote contact.
5. Press «Enter» to accept the setting.
The input for LOAD remote contact is assigned.
8.10.7
Setting the setpoint pressure pre-selection via remote contact
The signal to changeover from setpoint pressure pA to setpoint pressure pB comes from an input
contact. If there is a signal at the input then system pressure is regulated on setpoint pressure pB.
Overview
■
Setting up remote contact mode pA/pB
■
Assigning the remote contact input
■
Activating the remote control
➤ Configure the setpoint pressure pre-selection as described.
8.10.7.1
Precondition
Setting up remote contact mode pA/pB
The electrical connection is made.
Password access level 2 is activated.
1. Open the 5.2.3  menu.
2. Use «Up» or «Down» to select the Remote mode line.
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Initial Start-up
8.10
Configuring the machine for master control
3. Press «Enter».
The currently active operating mode flashes.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
Local mode:
pB
Remote mode :
Active line
pA/pB RC
__________________________________
▶1 pA/pB Clock
·········
pA/pB Cycle
4. Use «Up» or «Down» to set the pA/pB RC input.
5. Press «Enter».
Result
8.10.7.2
The pA/pB RC operating mode is set.
Assigning the remote contact input
A spare input can be found in the machine circuit diagram.
1. Use «Up» or «Down» to select the pA/pB RC line.
2. Press «Enter».
The DI display flashes.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
pA/pB RC
pA/pB DO
DI1.05
☑
Logic :
DOR1.04
☐
Logic :
Active line
·········
Load RC
DI1.13
ok ☑
3. Use «Up »or «Down» to set the DI input.
4. Press «Enter».
Result
8.10.7.3
The input for remote contact has now been assigned.
Activating the remote control
➤ Activating the remote control see chapter 8.2.12.
Result
8.10.8
SIGMA CONTROL 2 remote control is activated.
Configuring master control of compressors regulated by pressure switch
➤ Configure the master control as described below.
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8.10.8.1
Initial Start-up
8.10
Configuring the machine for master control
Configuring master control via floating relay contact
Requirement:
A machine with SIGMA CONTROL 2 (e.g. series BSD) and a conventional machine without
SIGMA CONTROL 2 of the same capacity are to run in sequence as base load or peak load ma‐
chines.
Proposal:
■
Set/adjust the clock program or clock on SIGMA CONTROL 2.
■
Select local mode with time control pA/pB Clock or clock pA/pB Cycle.
■
Set the system setpoint pressures pA and pB analogous to the required values. They must be
identical to the pressure switch settings on the machine without SIGMA CONTROL 2.
■
To make the system setpoint pressure changeover between the two machines possible, a
floating relay contact must be assigned to the selected local operating mode. An auxiliary con‐
tactor can be energized via this contact to activate the pressure switches for pA and pB on the
compressor without SIGMA CONTROL 2. See the example wiring diagram below.
Overview
■
Making the electrical connection
■
Setting the system setpoint pressure pA and pB.
■
Setting operating mode in local operating mode
■
Assigning the floating relay contact
■
Setting local operating mode
Making the electrical connection
No.: 9_9450 07 USE
■
Contact A open: SIGMA CONTROL 2 controls with system setpoint pressure pB
■
Contact A closed: SIGMA CONTROL 2 controls with system setpoint pressure pA
■
B 1.1: Pressure switch for system setpoint pressure pB
■
B 1.2: Pressure switch for system setpoint pressure pA
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8
Initial Start-up
8.10
Configuring the machine for master control
-K3
A1
A2
07-S0629
Fig. 37
Machine with pressure switch regulation
floating relay contact SIGMA CONTROL 2
➤ Make the electrical connection according to the diagram.
Setting the system setpoint pressure pA and pB.
Precondition
Password access level 2 is activated.
The electrical connection is made.
1. Select the <5.2.2 – Pressure control – Pressure settings> menu (see chapter 8.4.1).
2. Use «Up» or «Down» to select the pASP line.
3. Press «Enter» to switch into setting mode.
The setting mode is active.
The Setpoint pressure pAdisplay flashes.
88psi
08:15AM
176° F
Menu
5.2.2 Pressure settings
Setpoint pressure
pA SP: 123psi ¦ SD:
−7.3psi
pB SP: 119psi ¦ SD:
−7.3 psi
Active line
·········
System pressure low
↓< 72.5psi ¦ SD:
☐
7.2psi
4. Use «Up» or «Down» to set the value for pA.
5. Press «Enter» to accept the setting.
The setting is applied.
6. Adjust the value for the SD switching differential in the same way, if necessary.
7. Adjust the value for pB/SD in the same manner, if necessary.
8. Press «Esc» repeatedly to leave this menu.
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8
Initial Start-up
8.10
Configuring the machine for master control
Configuring local mode
➤ Set the clock program or clock as described in section 8.9.
Assigning the floating relay contact (activate)
Precondition
Password access level 2 is activated.
The electrical connection made (select spare contact from the machine's electrical diagram).
1. Select the 5.2.3  menu.
2. Use «Up» or «Down» to select the pA/pB DO line.
88psi
08:15AM
176° F
Menu
5.2.3 Load control
pA/pB RC
DI1.10
☐
Logic :
pA/pB DO
DOR1.03
☐
Logic :
Active line, no output assigned
·········
Load RC
DI1.03
ok ☑
3. Press «Enter» .
The setting mode is active.
4. Use «Up» or «Down» to set the required output.
5. Press «Enter».
The setting is applied.
Result
This output can now be used for the changeover between the two pressure switches.
Setting local mode
Precondition
Password access level 2 is activated.
1. Select the 5.2.3  menu.
2. Use «Up» or «Down» to select the Local mode line.
88psi
08:15AM
176° F
5.2.3 Load control
Menu
Local mode:
Active line, current operating mode
pA
Remote mode:
pA
__________________________________
▶1 pA/pB Clock
·········
pA/pB Cycle
3. Press «Enter» to switch into setting mode.
The setting mode is active.
4. Use «Up» or «Down» to set the pA/pB Clock or pA/pB Cycle operating mode.
5. Press «Enter» to accept the setting.
The setting is applied.
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8.10.8.2
Initial Start-up
8.10
Configuring the machine for master control
Configuring the master control without an electrical connection
Requirement:
A high-capacity machine with SIGMA CONTROL 2 (e. g. BSD) is to work as base load machine. A
second machine (e.g., SK) without SIGMA CONTROL 2 is to supply air in times of low demand.
Proposal:
■
Select the system setpoint pressures pA and pB of the BSD machine for the switching point of
the SK machine's pressure switch to be in between. When pB is activated for the periods of
low demand, the SK machine automatically functions as the base load machine.
■
Set the required values for a clock program on SIGMA CONTROL 2.
■
Select local mode pA/pB SC2Clk.
■
Activate the compressor timer.
Function diagram
Tab. 71
138
Period t1–t7: high compressed air demand
Period t8–t14: low compressed air demand
t1
t8:
Air demand rises.
System pressure pNloc drops.
Air demand rises.
System pressure pNloc drops.
t2
t9:
BSD switches to LOAD.
SK switches to LOAD.
t3:
t10:
System setpoint pressure pA reached.
BSD switches to IDLE.
System setpoint pressure pB reached.
SK switches to IDLE.
t4:
t11:
BSD switches to LOAD.
Air demand not covered.
BSD switches to LOAD.
Air demand not covered.
t5:
t12:
SK also switches to LOAD.
System pressure pNloc begins to rise.
SK switches to LOAD.
System pressure pNloc begins to rise.
t6:
t13:
SK switches to IDLE.
SK switches to IDLE.
t7:
t14:
BSD switches to IDLE.
BSD switches to IDLE.
Function diagram
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
Fig. 38
Initial Start-up
8.10
Configuring the machine for master control
Function diagram
SD
Switching differential
Pressure
Time
Setting the system setpoint pressure pA and pB
Precondition
Password access level 2 is activated.
1. Select the <5.2.2 – Pressure control – Pressure settings> menu (see chapter 8.4.1).
2. Use «Up» or «Down» to select the pASP line.
88psi
08:15AM
176° F
Menu
5.2.2 Pressure settings
Setpoint pressure
pA SP: 123psi ¦ SD:
−7.3psi
pB SP: 119psi ¦ SD:
−7.3 psi
Active line
·········
System pressure low
↓< 72.5psi ¦ SD:
☐
7.2psi
3. Press «Enter» to switch into setting mode.
The pA display flashes.
4. Use «Up» or «Down» to set the pA value.
5. Press «Enter» to accept the setting.
The setting is applied.
6. If necessary, adjust the value for SD/ in the same manner.
7. If necessary, adjust the value for pB/SD in the same manner.
8. Press «Esc» repeatedly to leave this menu.
Configuring the clock program
➤ Configure the clock program as described in chapter 8.9.2.
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8.10.9
Initial Start-up
8.10
Configuring the machine for master control
Examples of time settings for equal overall load
Requirement:
Two machines of the same capacity are to be equally loaded. Versions A, B and C describe the
different possibilities of achieving this requirement.
A detailed description for configuring a clock or timing program can be found in Chapter 8.9.
Variant A: Daily switch between system setpoint pressure pA and system setpoint pressure pB af‐
ter 24 hours
The compressors start with a system setpoint pressure pB at 0:00 hours. A timer triggers the
switch between system setpoint pressure pA and system setpoint pressure pB (local operating
mode: pA/pB Cycle local mode).
Precondition
The setpoint pressure pA/pB is configured the same for both machines.
➤ Establish a cycle with the following switching points:
■
Cycle time pA: 24 h
■
Cycle time pB: 24 h
■
Start pB: 00:00AM
Variant B: Equal duty cycle during the day
A timer triggers the switch between system setpoint pressure pA and system setpoint pressure pB
(local operating mode pA/pB Clock.
Precondition
The system setpoint pressure pA/pB is configured the same for both machines.
➤ The clock program is set up using the following switching points:
Tab. 72
No.:
Weekday
Time
Network nominal pressure
01
Mon-Sun
00:00AM
pA On
02
Mon-Sun
06:30AM
pB On
03
Mon-Sun
12:00PM
pA On
04
Mon-Sun
05:00PM
pB On
Example for a clock program for equal duty cycling during the day
Variant C: Equal duty cycle during the week
A timer triggers the switch between system setpoint pressure pA and system setpoint pressure pB
(local operating mode: pA/pB SC2Clk).
Precondition
The system setpoint pressure pA/pB is configured the same for both machines.
➤ The clock program is set up using the following switching points:
140
No.:
Weekday
Time
Network nominal pressure
01
Mon
00:00AM
pA On
02
Mon
09:00PM
pB On
03
Tue
05:00PM
pA On
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
8
Initial Start-up
8.11
Configuring input and output signals
No.:
Weekday
Time
Network nominal pressure
04
Wed
03:00PM
pB On
05
Thu
12:00PM
pA On
06
Fri
09:00AM
pB On
07
Sat
06:30AM
pA On
08
Sun
03:00AM
pB On
Tab. 73
Example for a clock program for equal duty cycling during the week
8.11
Configuring input and output signals
The controller's analog and digital inputs and outputs can be used for customized messages and/or
other functions.
This chapter deals with the various options in the following sections:
■
8.11.1: Outputting operational states of machine on digital outputs
■
8.11.2: Outputting input signals on the display
■
8.11.3: Outputting measured values on the display
The controller only allows assignment of spare inputs and outputs.
If an occupied input or output is assigned this will be rejected by the controller.
When delivered from the factory, the outputs DO0.3 to DO0.5 are available for assignment.
Further spare outputs can be found in the machine circuit diagram.
➤ Configure the inputs and outputs as described in the following.
8.11.1
Outputting important operational states of the machine
Important operational machine states can be made available as digital signals via floating contacts.
Each output can be assigned only once.
The following messages can be output:
Tab. 74
No.: 9_9450 07 USE
Message
Explanation
Controller on
Controller is powered up
Compressor on
The machine is switched on
Motor running
Compressor motor running
IDLE
The machine is running in IDLE mode
ON LOAD
The machine is running in LOAD mode
Group alarm
Fault has occurred
Group warning
Warning message has appeared
Remote mode
Remote mode is activated
Clock active
Clock is activated
Clock contact
The clock contact is closed
EMERGENCY STOP
The EMERGENCY STOP push button has been pressed
Output
Assigned output signals
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8.11.1.1
Initial Start-up
8.11
Configuring input and output signals
DO functions menu
The requested message can be assigned to a free digital output (DOR orDOT).
Precondition
Password access level 2 is activated.
1. Select the 5.7.1  menu.
A list of available messages and their assigned outputs is displayed.
88psi
08:15AM
176° F
5.7.1 DO functions
Menu
Controller on
Active line
DOR1.05
☐ ¦ Logic :
DOT1.02
☐ ¦ Logic :
DOR1.03
☐ ¦ Logic :
DOT1.02
☐ ¦ Logic :
Compressor on
8.11.1.2
Assigning a message to an output
1. Select the required message with the «Up» or «Down» keys.
2. Press the «Down» key once.
Output DOR has been selected.
3. Press «Down» twice.
Output DOT has been selected.
4. Press «Enter».
The output of the selected message flashes.
88psi
08:15AM
176° F
Menu
5.7.1 DO functions
Controller on
DOR1.05 ok
☑ ¦ Logic :
DOT1.02
☐ ¦ Logic :
DOR1.03
☐ ¦ Logic :
DOT1.02
☐ ¦ Logic :
Active line with assigned output
Compressor on
5. Select a free output with the «Up» or «Down» key.
6. Press «Enter».
The setting is applied.
7. Press the «Right» key.
8. Press «Enter».
The check box will flash.
9. Press «Up» key.
The check box associated to the output is activated.
10. Press «Enter».
If the message is correctly assigned to the output and activated, ok is displayed.
11. If necessary, set the Logic option.
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Result
Initial Start-up
8.11
Configuring input and output signals
A message about the operational state is now sent via the assigned output.
You are missing an organized display of assigned output signals?
➤ Enter the selected output in table 74.
8.11.2
Output input signals on the display
As well as the defined fault and warning messages there are 6 additional freely selectable input
signals that can be used to display messages. A list of the alarm and warning messages is provi‐
ded in chapters 10.2 and 10.3. Information on spare inputs is given in the machine circuit diagram.
An input signal can be classified as either an alarm, a warning or an operational message. To sup‐
press any possible contact bounce or similar problems, the input signal can be delayed by an ad‐
justable period. This ensures that the signal must be apparent for a minimum period before it can
be processed as a message.
If an input signal is classified as an alarm, the controller goes into the alarm state and shuts
down the machine.
Overview
Use the External messages menu for specifying the settings.
8.11.2.1
Precondition
■
Entering the message text
■
Assigning and activate the input
■
Setting the time delay
■
Setting the logic
■
Assigning and activate the output
■
Selecting the message type
■
Activating the message.
External messages menu
The electrical connection has been made.
Access level 2 is activated.
1. Open the 5.7.3  menu.
The External messages menu is displayed
88psi
08:15AM
176° F
5.7.3 External messages
Menu
▶1 External message 1
Active line with external message No. 1
▶2 External message 2
▶3 External message 3
▶4 External message 4
▶5 External message 5
▶6 External message 6
8.11.2.2
Entering the message text
In the below example we select External message 1.
1. Use «Up» or «Down» to select the External message 1 line.
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Initial Start-up
8.11
Configuring input and output signals
2. Press «Enter».
The External message 1 menu is displayed.
88psi
08:15AM
176° F
5.7.3.1 External message 1
Menu
External message 1
Active line, message text
DI1.11
No input assigned
td:
☐
0 s ¦ Logic
DOR1.04
☐
Warning
☑
Logic
Message type (operational, alarm, warning)
3. Press «Enter».
The cursor is located at the first character of the message text.
A column with alphanumeric characters is displayed.
The selected character flashes.
4. Select the required character with the «Up» or «Down» keys.
5. Press the «Right» key.
The cursor jumps to the next position of the message text.
6. Enter the remaining characters of the message text in the same manner.
7. Press «Enter».
The message text has been entered.
8. Press «Enter».
The setting is applied.
8.11.2.3
Assigning and activating the input
1. Use «Up» or «Down» to select the DI line.
2. Press «Enter».
The display for the currently set input flashes.
3. Use «Up» or «Down» to select the input.
4. Press «Enter».
The setting is applied.
88psi
08:15AM
176° F
5.7.3.1 External message 1
Menu
External message 1
Message name
DI1.14
The output has been selected
td:
☐
0 s ¦ Logic
DOR1.04
☑
Warning
☑
Logic
Example: Warning message type
5. Press the «Right» arrow.
6. Press «Enter».
The check box assigned to the input flashes.
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8
Initial Start-up
8.11
Configuring input and output signals
7. Press «Up» key.
The check box is activated.
88psi
08:15AM
176° F
5.7.3.1 External message 1
Menu
External message 1
Message name
DI1.14
Active line, Input is selected and activated
ok ☑
td:
0 s ¦ Logic
DOR1.04
☑
Warning
☑
Logic
Example: Warning message type
8. Press «Enter».
ok is displayed.
The input is assigned and activated.
8.11.2.4
Setting the time delay
The delay time can be set in the range between 0 and 600 seconds. The delay is counted
down from 600 in 1 second increments with the «DOWN» key and counted upwards from
zero in 1 second increments with the «UP» key.
1. Use «Up» or «Down» to select the td line.
2. Press «Enter».
The td delay time flashes.
88psi
08:15AM
176° F
5.7.3.1 External message 1
Menu
External message 1
Message name
DI1.14
td:
ok ☑
0 s ¦ Logic
DOR1.04
☐
Warning
☑
Active line, set time delay td
3. Use «Up» or «Down» to set the time delay in seconds.
4. Press «Enter».
Result
8.11.2.5
The td delay time has been set.
Setting the logic
Possible logic settings
Message at
Tab. 75
Sign
24 V
0V
Logic settings
1. Use «Up» or «Down» to select the td line.
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Initial Start-up
8.11
Configuring input and output signals
2. Press the «Right» arrow.
3. Press «Enter».
The control field Logic flashes.
4. Use «UP» or «Down» to set the desired behavior, see table 75.
88psi
08:15AM
176° F
5.7.3.1 External message 1
Menu
External message 1
Message name
DI1.14
td:
ok ☑
0 s ¦ Logic
DOR1.04
☐
Warning
☑
Active line, set logic control field
Example: Warning message type
5. Press «Enter».
Result
8.11.2.6
For messages at 24 V, the logic is set with the + symbol.
Setting the message type
1. Select the message type line with the «Up» and «Down» keys.
2. Press «Enter».
The display for the message type flashes.
3. Use «Up» or «Down» to set the message type.
88psi
08:15AM
176° F
5.7.3.1 External message 1
Menu
External message 1
Message name
DI1.14
td:
ok ☑
0 s ¦ Logic
DOR1.04
☐
Warning
☑
Logic
Example: Warning message type
4. Press «Enter».
The message type is set.
8.11.2.7
Assigning and activating the output
1. Use «Up» or «Down» to select the DOR line.
2. Press «Enter».
The DOR display flashes.
3. Select the output with the «Up» and «Down» keys.
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8
Initial Start-up
8.11
Configuring input and output signals
4. Press «Enter» .
The setting is applied.
88psi
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176° F
5.7.3.1 External message 1
Menu
External message 1
Message name
DI1.14
td:
ok ☑
0 s ¦ Logic
Logic
DOR1.01
☑
Active line, output is selected and activated
Warning
☑
Example: Warning message type
5. Press the «Right» arrow.
6. Press «Enter».
The check box assigned to the output flashes.
7. Press «Up» key.
The check box is activated.
8. Press «Enter».
The output is assigned and activated.
Result
8.11.3
The signal at the DI digital input is available as External message 1 and as output signal at the
selected DOR output.
Output measured values on the display
For analog measured values you can define customized messages.
The message can be classified as either a fault, a warning or an operational message.
If exceeding the switching point is classified as a fault, the controller goes into the fault state
when the signal continues and shuts down the machine.
The following messages can be output:
No.: 9_9450 07 USE
Message
Explanation
AnMod_p_1
Customized monitoring of the pressure value p1
AnMod_p_2
Customized monitoring of the pressure value p2
AnMod_p_3
Customized monitoring of the pressure value p3
AnMod_p_4
Customized monitoring of the pressure value p4
AnMod_T_1
Customized monitoring of the temperature value T1
AnMod_T_2
Customized monitoring of the temperature value T2
AnMod_T_3
Customized monitoring of the temperature value T3
AnMod_T_4
Customized monitoring of the temperature value T4
AnMod_I_1
Customized monitoring of the current value I1
AnMod_I_2
Customized monitoring of the current value I2
T-Switch inlet
temperature
Customized monitoring of the intake temperature
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Measured Output
value
147
Tab. 76
Initial Start-up
8.11
Configuring input and output signals
Message
Explanation
Measured Output
value
p-Switch pi
Customized monitoring of internal pressure pi in the oil sep‐
arator tank
T-Switch ADT
Customized monitoring of the airend discharge temperature
ADT
p-Switch pN
Customized monitoring of local network pressure pNloc at
compressor output
T-Switch PDT
Customized monitoring of the compressed air discharge
temperature
Assigned analog measured values
Overview
Use the Analogue values or Switch menus for specifying the settings.
■
Entering the message text
■
Selecting and activating measured value
■
Setting the time delay
■
Setting the logic
■
Selecting the message type
■
Assigning and activating the output
Below, the settings are displayed based on an example in the Analogue values menu. Use the
Switch menu analogously for specifying the settings.
8.11.3.1
Precondition
Analogue values menu
The electrical connection has been made.
Password access level 2 is activated.
1. Open the 2.4  menu.
The Analogue values menu is displayed.
88psi
8.11.3.2
08:15AM
176° F
2.4 Analogue values
Menu
▶1 AnMod
Analog modules
▶2 AI
Analog inputs
▶3 AO
Analog outputs
▶4 PD
Process Data
Entering the message text
In the following example, a message from the analog module is defined by pressure value p1.
1. Use «Up» or «Down» to select the AnMod line.
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Initial Start-up
8.11
Configuring input and output signals
2. Press «Enter».
The 5.7.2.1 AnMod menu is displayed.
88psi
08:15AM
176° F
5.7.2.1 AnMod
Menu
▶1 AnMod_p_1
AnMod_p_1 measured value
▶2 AnMod_p_2
▶3 AnMod_p_3
▶4 AnMod_p_4
▶5 AnMod_T_1
▶6 AnMod_T_2
3. Use «Up» or «Down» to select the AnMod_p_1 line.
4. Press «Enter».
The 5.7.2.1.1 AnMod_p_1 menu is displayed.
88psi
08:15AM
176° F
Menu
5.7.2.1.1 AnMod_p_1
AnMod_p_1 Title
0.0 psi
pNloc
☐
Message text
Analog measured value
·········
SP:
116psi ¦ SD:
−7.3psi
td:
0s
Switching point (SP) and switching differential (SD)
Time delay (td)
·········
5. Press «Enter».
The cursor is located at the first character of the message text.
A column with alphanumeric characters is displayed.
The selected character flashes.
6. Select the required character with the «Up» or «Down» keys.
7. Press the «Right» key.
The cursor jumps to the next position of the message text.
8. Enter the remaining characters of the message text in the same manner.
9. Press «Enter».
The message text has been entered.
10. Press «Enter».
The setting is applied.
8.11.3.3
Selecting and activating measured value
1. Press the «DOWN» key.
2. Press «Enter».
The display for the currently set measured value flashes.
3. Use «Up» or «Down» to select the measured value.
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8
Initial Start-up
8.11
Configuring input and output signals
4. Press «Enter».
88psi
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Menu
5.7.2.1.1 AnMod_p_1
AnMod_p_1 Title
0.0 psi
pNloc
☐
Message text
Selected analog measured value
·········
SP:
116psi ¦ SD:
−7.3psi
td:
0s
Switching point (SP) and switching differential (SD)
Time delay (td)
·········
5. Press the «Right» key.
6. Press «Enter».
The check box assigned to the input flashes.
7. Press «Up» key.
The check box is activated.
88psi
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Menu
5.7.2.1.1 AnMod_p_1
AnMod_p_1 Title
0.0 psi
pNloc
☑
Message text
Selected analog measured value, activated
·········
SP:
116psi ¦ SD:
−7.3psi
td:
0s
Switching point (SP) and switching differential (SD)
Time delay (td)
·········
8. Press «Enter».
The measured value is assigned and activated.
8.11.3.4
Setting the switching point and switching differential
1. Use «Up» or «Down» to select the SP line.
88psi
08:15AM
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Menu
5.7.2.1.1 AnMod_p_1
AnMod_p_1 Title
0.0 psi
pNloc
☑
Message text
Selected analog measured value
·········
SP:
116psi ¦ SD:
−7.3psi
td:
0s
Switching point (SP) and switching differential (SD)
Time delay (td)
·········
2. Press «Enter».
The display for the current value of the switching point flashes.
3. Use «Up» or «Down» to set the SP value.
4. Press «Enter».
The setting is applied.
5. If necessary, adjust the value for SD in the same manner.
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Result
8.11.3.5
Initial Start-up
8.11
Configuring input and output signals
The threshold value for the SP switching point and the SD switching differential are set.
Setting the time delay
The period can be set between 0 and 600 seconds. The delay is counted down from 600 with
the «DOWN» key and counted upwards from zero in 0.01 second increments with the «UP»
key.
1. Use «Up» or «Down» to select the td line.
2. Press «Enter».
The td delay time flashes.
88psi
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Menu
5.7.2.1.1 AnMod_p_1
AnMod_p_1 Title
0.0 psi
pNloc
☑
Message text
selected analog measured value
·········
SP:
116psi ¦ SD:
−7.3psi
td:
0s
Switching point (SP) and switching differential (SD)
Time delay (td)
·········
3. Use «Up» or «Down» to set the time delay in seconds.
4. Press «Enter».
Result
8.11.3.6
The td delay time has been set.
Setting the message type
1. Select the message type line with the «Up» and «Down» keys.
2. Press «Enter».
The display for the message type flashes.
3. Use «Up» or «Down» to set the message type.
88psi
08:15AM
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Menu
5.7.2.1.1 AnMod_p_1
td:
0s
Time delay (td)
·········
Warning
☐
Set message type, in the example: Warning
·········
DOR1.02
☐ ¦ Logic:
DOR1.03
☐ ¦ Logic:
4. Press «Enter».
5. Press the «Right» arrow.
6. Press «Enter».
The check box assigned to the message type flashes.
7. Press «Up» key.
The check box is activated.
8. Press «Enter».
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Result
8.11.3.7
Initial Start-up
8.12
Activating remote acknowledgement
The message type is set and activated.
Assigning and activating the output
By triggering the message one or two digital DOR outputs can be switched.
1. Use «Up» or «Down» to select the DOR line.
2. Press «Enter».
The DOR display flashes.
3. Use «Up» or «Down» to select the output.
4. Press «Enter».
The setting is applied.
88psi
08:15AM
176° F
Menu
5.7.2.1.1 AnMod_p_1
td:
0s
Time delay (td)
·········
Warning
☑
Set message type, in the example: Warning
·········
DOR1.02
☐ ¦ Logic:
DOR1.03
☐ ¦ Logic:
Active line (DOR output)
5. Press the «Right» arrow.
6. Press «Enter».
The check box assigned to the output flashes.
7. Press «Up» key.
The check box is activated.
8. Press «Enter».
The output is assigned and activated.
9. Press the «Right» arrow.
10. Press «Enter».
The control field Logic flashes.
11. Use «UP» or «Down» to set the desired behavior, see table 75.
12. Press «Enter».
Result
For messages at 24 V, the logic is set with the + symbol.
Result
The pNloc measured value at the analog AnMod_p_1 input is available as a message and as out‐
put signal at the selected DOR output.
8.12
Activating remote acknowledgement
When warning or alarm messages are routed to a remote control center via an output it makes
sense to have these messages acknowledged by the control center.
Acknowledging the message without correcting the cause, however, can lead to machine
damage.
Safety-relevant "EMERGENCY STOP push button" and "Maintenance door limit switch" mes‐
sages cannot be acknowledged remotely.
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8
Initial Start-up
8.12
Activating remote acknowledgement
The following conditions must be fulfilled:
■
The remote control of the compressor is set (see chapter 8.5.3 Controlling machine from a re‐
mote location)
■
Remote control is activated (see chapter 8.2.12 Activating remote control)
■
A controller input has been assigned for the acknowledgement signal.
Overview
■
Selecting the  menu
■
Setting the "Remote acknowledgement" function
■
Activating the remote control
■
Assigning an input
■
Press the «Remote control» key
Machine damage can result from acknowledging a fault message without remedying its
cause!
➤ Find the failure cause.
➤ Decide to acknowledge or not.
8.12.1
Precondition
Setting the remote acknowledgement function
Password access level 2 is activated.
1. Open the 5.5  menu.
2. Use the «Up» or «Down» keys to select the Remote mode line.
3. Press the «DOWN» key.
4. Press «Enter» to switch into setting mode.
The currently active operating mode flashes.
5. Use «Up» or «Down» to set the Key + remote contact input.
88psi
08:15AM
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Menu
5.5 Acknowledgement
Remote mode:
Active line with "Key + remote contact" setting
Key + remote contact
__________________________________
RC ack
DI1.11
☐
Key remote
☑
6. Press «Enter» to accept the setting.
The setting is applied.
Result
8.12.2
The Remote acknowledgement function is set.
Activating the remote control
➤ Activating remote control see chapter 8.2.12.
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Result
8.12.3
Initial Start-up
8.12
Activating remote acknowledgement
SIGMA CONTROL 2 remote control is activated.
Assigning an input
1. Use «Up» or «Down» to select the RCack line.
88psi
08:15AM
176° F
Menu
5.5 Acknowledgement
Remote mode:
Key + remote contact
__________________________________
RC ack
DI1.11
☐
Key remote
Active line
☑
2. Press «Enter».
The DI display flashes.
3. Use «Up» or «Down» to set the input.
4. Press «Enter» to accept the setting.
The input has now been assigned.
5. Press the «Right» arrow.
6. Press «Enter» to switch into setting mode.
The check box assigned to the input flashes.
7. Press the «Up» key.
The check box is activated.
8. Press «Enter» to accept the setting.
The input is assigned and activated.
88psi
08:15AM
176° F
Menu
5.5 Acknowledgement
Remote mode:
Key + remote contact
__________________________________
RC ack
DI1.13 ok
☑
Key remote
Active line, input for remote contact assigned and
activated
☑
9. Press the «Remote control» key to enable remote acknowledgement.
Result
154
Should a message occur, it can now be acknowledged from a control center.
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8.13
Initial Start-up
8.13
Linking to an external pressure transducer
Linking to an external pressure transducer
If the air system is operated with an air receiver, the pressure in the receiver can be regulated by
an external pressure transducer.
Transmitting a pressure transducer value
Assignment to an input
Assign AII
The external pressure transducer is connected to
SIGMA CONTROL 2.
Pressure transducer characteristics:
Tab. 77
■
4–20 mA
■
0–232 psi
Transmitting a pressure transducer value
The controller processes the options in the following sequence:
■
Pressure according to the assigned external transducer
■
The local system pressure transducer (pNloc) remains active
Overview
Example: The external pressure transducer is connected to SIGMA CONTROL 2.
8.13.1
Precondition
■
Select the  menu.
■
Assigning an input
Pressure control menu
Password access level 2 is activated.
1. Select the 5.2.4 < Configuration – Pressure control – Network actual pressure> menu.
The Network actual pressure menu is displayed.
88psi
08:15AM
176° F
5.2.4 Network actual pressure
Menu
pNloc
Active line (local pressure transducer)
AII1.01
88.0psi
☐
0.0psi
For sensor error:
Alarm
8.13.2
Assigning an input to an external pressure transducer
1. Press «Enter» to switch into setting mode.
The pNloc indication flashes.
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8
Initial Start-up
8.14
Commissioning the machine
2. Use «Up »or «Down» to set the AII input.
88psi
08:15AM
176° F
5.2.4 Network actual pressure
AII
88.0psi
AII1.01
☐
Active line (external pressure transducer)
0.0psi
For sensor error:
Alarm
3. Press «Enter» to accept the setting.
The AII input is set.
4. Press «Down».
The line for activating the input is displayed.
5. Press the «Right» key.
6. Press «Enter» to switch into setting mode.
The check box assigned to the input flashes.
88psi
08:15AM
176° F
5.2.4 Network actual pressure
AII
AII1.01
88.0psi
ok ☑
88.0psi
Active line
For sensor error:
Alarm
7. Press «UP».
The check box is activated.
ok is displayed.
8. Press «Enter» to accept the setting.
The setting is applied.
Result
8.14
Tab. 78
156
The input for the external transducer is now activated.
Commissioning the machine
Checking the controller settings
Section
➤ Language correctly set?
8.2.2
➤ Date and time correct?
8.2.7
➤ Display format correctly set?
8.2.9
➤ System pressure setpoint correctly set?
8.4
Complied?
Check list for commissioning the machine
User Manual Controller
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No.: 9_9450 07 USE
8
Initial Start-up
8.14
Commissioning the machine
1. Check and confirm all the items in the checklist before commissioning the machine.
When power is applied to the machine the controller boots and carries out a self test.
The display and the Controller on LED illuminate.
88psi
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Header
__________________________________
Current operating mode
Load
__________________________________
Key
–
on
¦
pA
–
Operating parameters
on
__________________________________
Run
2500h Load
2490h
Maintenance in
500h
Operating parameters
Maintenance indicator
2. Continue the commissioning process as described in chapter "Commissioning" of the ma‐
chine's operating manual.
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9
Operation
9.1
Switching on and off
9 Operation
9.1
Switching on and off
Always switch the machine on with the «ON» key and off with the «OFF» key.
Precondition
Fig. 39
A power supply disconnecting device has been installed by the user.
Switching on and off
13
9.1.1
Precondition
«ON» key
«OFF» key
«Load/Idle» toggle key
14
15
16
IDLE LED
LOAD LED
Controller voltage LED
Switching on
No personnel are working on the machine.
All access doors and panels are closed and secure.
1. Switch on the power supply disconnecting device.
2. Switch on the machine and wait for SIGMA CONTROL 2 to start.
The Controller voltage LED 16 lights green.
3. Press the «On» 7 key.
The On LED lights green.
If a power failure occurs, the machine is not prevented from restarting automatically when
power is resumed.
It can restart automatically as soon as power is restored (see chapter 8.5).
Result
158
The compressor motor starts as soon as system pressure is lower than the setpoint pressure (cut‐
off pressure).
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No.: 9_9450 07 USE
9.1.2
Operation
9.2
Switching off in an emergency and switching on again
Switching off
1. Press the «OFF» key.
The machine switches to IDLE and the IDLE LED flashes. The SIGMA CONTROL 2 dis‐
playsStopping. The ON LED extinguishes as soon as the automatic shut-off action is comple‐
ted.
2. Switch off and lock out the power supply disconnecting device.
Result
The Controller voltage LED extinguishes. The machine is switched off and disconnected from the
power supply.
In rare cases, if you need to shut the machine down immediately and cannot wait until the
automatic shutdown process is finished:
➤ Press «OFF» once again.
9.2
Switching off in an emergency and switching on again
The EMERGENCY STOP push button is located below the control panel.
Fig. 40
Switching off in an emergency
22
EMERGENCY STOP push button
Switching off
➤ Press the EMERGENCY STOP push button.
Result
The EMERGENCY STOP push button remains latched after actuation.
The compressor's pressure system is vented and the machine is prevented from automatically re‐
starting.
Switching on
Precondition
The fault has been rectified
1. Turn the EMERGENCY STOP push button in the direction of the arrow to unlatch it.
2. Acknowledge any existing alarm messages.
Result
No.: 9_9450 07 USE
The machine can now be started again.
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9.3
Operation
9.3
Acknowledging alarm and warning messages
Acknowledging alarm and warning messages
Messages are displayed on the "new value" principle: You can acknowledge warning or fault mes‐
sages immediately after Message coming or Message going. However, warning and fault messag‐
es can be acknowledged only following a successful elimination of the corresponding fault.
Message sequence 1
Message coming
Message acknowledged
Indication
LED flashes
LED illuminates
Message going
Tab. 79
LED off
Message sequence 1
Message sequence 2
Indication
Message coming
LED flashes
Message going
LED flashes
Message acknowledged
Tab. 80
Fig. 41
LED off
Message sequence 2
Acknowledging messages
17
20
21
Warning LED (yellow)
Alarm LED (red)
Key «Acknowledge»
Alarm message
An alarm message shuts the machine down automatically.
The red Alarm LED flashes.
Precondition
The fault has been rectified
➤ Press «Ack» to acknowledge the fault message.
Alarm LED extinguishes. The machine is again ready for operation.
If the machine has been stopped with the EMERGENCY STOP push button.
➤ First turn the EMERGENCY STOP push button in the direction of the arrow to unlatch it.
➤ Then acknowledge the alarm message.
Further information
160
A list of possible alarm messages occurring during operation are shown in chapter 10.2.
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No.: 9_9450 07 USE
9
Operation
9.4
Displaying messages
Warning message
If maintenance work is to be carried out or if the warning is displayed before an alarm, the yel‐
low warning LED flashes.
Precondition
The danger of an alarm is eliminated.
Maintenance has been carried out
➤ Press «Ack» to acknowledge the warning message.
The Maintenance LED extinguishes. The machine is again ready for operation.
Further information
9.4
A list of possible warning messages occurring during operation are shown in chapter 10.3.
Displaying messages
The following information can be accessed in the 1.1  menu:
■
■
■
Current messages
─
Last alarm
─
Last warning
─
Number of currently registered alarms and/or warnings
Message history: The last 1000 events, these include alarm and warning messages
─
Compressor messages
─
Diagnostic messages
─
System messages
Address error: Display of incorrect parameterization in menu X
The information (message) is shown in three lines of the display.
Line
Submenu/Segment/Text
Selected submenu:
Tab. 81
■
Compressor messages
■
Diagnostic messages
■
System messages
Segment:
■
Message number
■
Message type
■
Message status
■
Message date
■
Message time
Text:
■
Message text
■
–
Information of a message
Message type and status are shown abbreviated.
No.: 9_9450 07 USE
Segment
Indication
Meaning
Message number
0059 (example)
Message 0059
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9
Operation
9.4
Displaying messages
Segment
Indication
Meaning
Message type
Warning/service message
Alarm message
Message has come
Message gone
Message acknowledged (reset)
Date
04/13/16 (example)
Date
Time
08:15:37AM (example)
Time
Message status
Tab. 82
Message abbreviations
9.4.1
Selecting the status menu
1. Open the 1.1  menu.
The Messages menu is displayed
The number of current alarms and warnings is displayed in the two bottom lines.
88psi
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1.1 Messages
Menu
▶1 Current messages
Active line
▶2 Message history
Status report
01:00 ☐
__________________________________
current
Alarms
Warnings
Number of currently registered alarms
Number of currently registered warnings
Displaying the last alarm or warning
1. Open the 1.1.1  menu.
The third line displays the last alarm or warning message.
88psi
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1.1.1 Current messages
Menu
0300 W c 04/16/16 01:32:49PM
Last message
SD card write error
0015 W a 04/16/16 01:06:43PM
Second to last message
Com-Module communication error
0034 O c 04/13/16 08:15:37AM
E-mail send unsuccessful!
2. Press «Esc» repeatedly to leave this menu.
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9
Operation
9.5
Displaying the current operating mode
Displaying the message history
1. Select the 1.1.2  menu.
The Message history menu is displayed.
88psi
08:15AM
176° F
1.1.2 Message history
Menu
▶1 Compressor messages
Active line with submenu: Compressor messages
▶2 Diagnostic messages
Diagnostic messages
▶3 System messages
System messages
2. Press «Enter».
The 1.1.2.1 Compressor messages menu is displayed.
The third line displays the last alarm or warning message.
88psi
08:15AM
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1.1.2.1 Compressor messages
Menu
0300 W c 04/16/16 01:32:49PM
Last message
SD card write error
Message text for message 0300
0015 W a 04/16/16 01:06:43PM
Com-Module communication error
Message text for message 0015
0034 O c 04/13/16 08:15:37AM
E-mail send unsuccessful!
Message text for message 0034
3. Press «Esc» repeatedly to leave this menu.
9.5
Displaying the current operating mode
The operating mode is displayed in 2 segments (example):
Tab. 83
No.: 9_9450 07 USE
On/off switching via
Load control via
Key
pA
Operating mode display
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9
Operation
9.6
Adjusting the working pressure
1. Select the 1.4  menu.
The Current operating mode menu is displayed.
88psi
08:15AM
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1.4 Current operating mode
Menu
Compressor on
Active line
Key
Load control
pA
·········
Control mode
Abbreviation of operating modes
Segment
Indication
On/off switching via Key
Meaning
«ON» key on the control panel of SIGMA CONTROL 2
Key + clock
Cycle Control
Key + remote
contact
Remote contact (external LOAD signal)
Key + remote bus Remote bus (external bus signal)
LOAD control via
Tab. 84
9.6
pA
System setpoint pressurepA
pB
System setpoint pressurepB
pA/pB Clock
System setpoint pressure via time control
pA/pB Cycle
System setpoint pressure via timer
pA/pB SC2
System setpoint pressure via 2 machines working in mas‐
ter-slave mode
pA/pB RC
System setpoint pressure via remote contact
pA/pB RB
System setpoint pressure via remote bus
Load RC
LOAD remote contact (external LOAD signal)
Load RB
Remote bus (external bus signal)
loc.-load RC
Local/LOAD remote contact
Abbreviation of operating modes
Adjusting the working pressure
➤ Adjust the pressure parameter to suit the compressor and application.
Further information
9.7
A detailed explanation of all pressure parameter settings is given in chapter 8.4.
Displaying analog data
The Performance data menu provides the following information:
■
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9
Operation
9.8
Displaying operating data
■
Compressor motor
■
Fan
■
Analogue values
■
SIGMA CONTROL 2
Displaying analog data
Precondition
Password access level 2 is activated.
The operating mode is displayed.
1. Open the 2 Performance data menu.
A list of the components is displayed.
88psi
08:15AM
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2 Performance data
Menu
▶1 Compressor
Active line
▶2 Compressor motor
▶3 Fan
▶4 Analogue values
▶5 SIGMA CONTROL 2
2. If necessary, repeatedly press «Up» or «Down» to select the required component.
3. Press «Enter» access compressor measurement data.
The system displays the measurement data for the compressor.
88psi
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Menu
2.1 Compressor
System pressure pNloc
88.0 psi
Local System pressure pNloc
·········
ADT
176°F
Airend discharge temperature
dT/dt
0.0°F/s
Rise of airend discharge temperature
·········
Oil separator
9.8
Δp
0.0psi
Differential pressure, oil separator cartridge
Displaying operating data
The following information can be called up in the Operating data menu:
■
No.: 9_9450 07 USE
Operating hours
─
Compressor: Total machine running time
─
On load: Machine running time in LOAD mode
─
Motor: Motor running time (can be changed)
─
Compressor block: Airend running time (can be changed)
─
SIGMA CONTROL 2: Controller running time
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9
Operation
9.8
Displaying operating data
■
■
Switching cycles
─
Load valve on
─
Mains contactor on (adjustable)
kWh counter
➤ Reset the run times after replacing the airend or the compressor motor.
➤ Reset the main contactor switching cycle counter after replacing the main contactor.
9.8.1
Checking the operating hours
Displaying the operating hours
Precondition
Password access level 2 is activated.
1. Open the 3 Operating data menu.
88psi
08:15AM
176° F
3 Operating data
Menu
▶1 Operating hours
Active line
▶2 Switching cycles
▶3 kWh counter
Changing the operating hours
The running times of the compressor motor and airend can be adjusted. This may be required after
a replacement, for example.
Precondition
Password access level 2 is activated.
1. Open the 3.1  menu.
88psi
08:15AM
176° F
Menu
3.1 Operating hours
Compressor
3050 h
On load
3030 h
Motor
3050 h
Compressor block
3050 h
SIGMA CONTROL 2
3050 h
Active line
2. Use «Up» or «Down» to select the Compressor block line.
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Operation
9.8
Displaying operating data
3. Press «Enter».
The display of the running time flashes.
88psi
08:15AM
176° F
Menu
3.1 Operating hours
Compressor
3050 h
On load
3030 h
Motor
3050 h
Compressor block
SIGMA CONTROL 2
0h
Active line
3050 h
4. Use «Down» or «Up» key to set the value for operating hours to zero.
5. Press «Enter».
The setting is applied.
6. Press «Esc» repeatedly to leave this menu.
Result
9.8.2
The operating hours for the new airend are set to 0 h.
Checking the switching cycles
The system monitors the usage times of safety-relevant components to ensure the proper
condition of all safety-relevant functions. Depending on the component, the usage time may
be defined by run time or switching cycles. For the main contactor, the usage time is defined
by the maximum permissible number of switching cycles.
The main contactor switching cycle counter in SIGMA CONTROL 2 records the number of
switching cycles and generates a warning message when the maximum permissible number
of switching cycles is exceeded.
When this warning message is generated, the safety-relevant function is no longer ensured.
The main contactor must be replaced!
➤ Comply with all instructions.
Displaying the switching cycles
Precondition
Password access level 2 is activated.
1. Select the 3.2  menu.
2. Compare the maximum permissible number of switching cycles with the value displayed by the
switching cycle counter.
88psi
08:15AM
176° F
Menu
3.2 Switching cycles
Load valve on
Active line
·········
Mains contactor on
max:
1100000 ¦
10227
Reset:
Result
No.: 9_9450 07 USE
Maximum value/switching cycle timer
☐
The safety-relevant function is ensured.
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9
Operation
9.9
Displaying the frequency converter settings
The maximum permissible number of switching cycles have not exceeded.
The main contactor can still be used.
The safety-relevant function is not ensured.
The maximum permissible number of switching cycles have exceeded.
➤ Have the main contactor replaced.
Replacing the main contactor
If the displayed value of the main contactor exceeds the maximum permissible number of
switching cycles, SIGMA CONTROL 2 generates the warning message 0024 Mains contactor
operations ⇞.
The main contactor must be replaced.
➤ Have the main contactor replaced by an authorized KAESER service representative.
Resetting the main contactor switching cycle counter
➤ Have the main contactor replaced by an authorized KAESER service representative.
9.9
Precondition
Displaying the frequency converter settings
The machine is fitted with the frequency converter option (example).
The operating mode is displayed.
1. Select the 10.1.1  menu.
2. Use «Up» or «Down» to select the Local operating mode: line.
In the two lines underneath Local operating mode:, the source for the speed setting and the
setting values for the minimal and maximum speed are shown.
88psi
08:15AM
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10.1.1 Power switching
▶4 SFC USS
▶5 Softstart
▶6 Customer-provided
Local operating mode:
Speed sensor All
nMin =
0/min ¦ nMax =
Speed setting
0/min
3. Press «Escape» repeatedly to return to the main menu.
9.10
Setting the maintenance interval
Maintenance tasks are tasks to be completed to ensure the functionality of a technical instal‐
lation.
Time interval established by the manufacturer at which end a maintenance task must be
completed.
Example: Changing the oil change service interval.
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Precondition
Operation
9.10
Setting the maintenance interval
Password access level 2 is activated.
The operating mode is displayed.
Unauthorized extended maintenance intervals
Progressing damage to the machine up to functional incapacity.
➤ Observe the maintenance intervals of the manufacturer.
Selecting menu maintenance
1. Open the 4 Maintenance menu.
2. Use «Up» or «Down» to select the Oil change line.
88psi
08:15AM
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4 Maintenance
Active line, Description maintenance interval
Oil change
3000 h ¦
0150 h Reset:
☐
Preset interval 3000 h
·········
Air filter
3000 h ¦
0150 h Reset:
☐
·········
3. Press the «DOWN» key.
The maintenance interval for oil change is displayed as active line.
88psi
08:15AM
176° F
4 Maintenance
Maintenance interval description
Oil change
4000 h ¦
0150 h Reset:
☐
Active line, factory-defined interval
·········
Air filter
3000 h ¦
0150 h Reset:
☐
·········
4. Press «Enter».
The setting mode is active.
5. Use «Up» or «Down» to set the value for new value for the maintenance interval.
Keep the «Up» key pressed to change the maintenance interval in increments of 10, 100 or
1000.
6. Press «Enter».
The setting is applied.
7. Press «Escape» repeatedly to return to the main menu.
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9.11
Operation
9.11
Checking the safety relief valve
Checking the safety relief valve
Overview
■
Preparing the inspection
■
Performing the inspection
■
Correct conclusion of the test
■
Resetting
When the check mode is activated, monitoring of internal pressure (blow-off protection - if
provided) and regulation of network pressure are deactivated.
The measured value of the pi pressure value is used to describe the following check:
Tab. 85
Check box
Status
☑
activated
☐
deactivated
Check box status
Danger of injury from pressurized components!
➤ Perform the following actions in the sequence provided.
Preparing the test
1. Note the activating pressure of the safety relief valve from the machine's nameplate.
2. Press the «OFF» key to shut down the machine.
3. Close the user's shut-off valve between the machine and the pressure system.
4. Log on with password access level 2.
5. Open the 9.1  menu.
88psi
08:15AM
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Menu
9.1 TÜV inspection
Safety valve:
pRV:
Active line with check box
☐
232psi ¦ pi ⇞
Reset
Safety relief valve activating pressure (example)
0.0psi
☐
·········
ADT ⇞
Offset
32°F ¦ ADT
⇞
☐
32.0°F
Performing the test successfully
1. Use «Up» or «Down» to select the Safety valve: line.
2. Press «Enter».
The check box Safety valve: will flash.
3. Press «Up» key.
The check box is activated.
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Operation
9.11
Checking the safety relief valve
4. Press «Enter».
The test mode is now activated.
88psi
08:15AM
176° F
Menu
9.1 TÜV inspection
Safety valve:
pRV:
Active line with check box
☑
232psi ¦ pi ⇞
Reset
36.0psi
Safety relief valve activating pressure
☐
·········
ADT ⇞
Offset
5.
32°F ¦ ADT
⇞
☐
32.0°F
Risk of hearing damage when safety relief valve blows off!
➤ Close all access doors, replace and secure all removable panels.
➤ Always wear ear protection.
6.
Risk of burns due to released cooling oil and compressed air when blowing off
the safety relief valve!
➤ Close all access doors, replace and secure all removable panels.
➤ Wear eye protection.
7. Press the «ON» key. After the motor start is completed, keep the «LOAD/IDLE» key pressed.
Otherwise, the machine remains in IDLE and is stopped after two minutes.
The machine switches to LOAD and the machine's pi pressure rises.
8. Monitor on the display the pi pressure rise during the TÜV check.
9. If the pi pressure increases to 10 % above the set pressure of the safety relief valve, immedi‐
ately release the «LOAD/IDLE» key.
10. Shut down the machine with the «OFF» key and immediately replace the safety relief valve.
If the alarm message pRV ⇞ appears, the safety relief valve is defective. pi pressure has ex‐
ceeded the set pressure of the safety relief valve by 29.0 psi.
➤ Have the safety relief valve replaced.
Avoid oil mist:
➤ Release the «LOAD/IDLE» key immediately when the safety relief valve responds, in or‐
der to prevent unnecessary oil mist.
Correct conclusion of the test
1. Press «Enter» to switch into setting mode.
The check box Safety valve: in the active line flashes.
2. Press the «DOWN» key to deactivate the box.
The check box is deactivated.
3. Press «Enter».
The test mode is deactivated and the test is completed.
4. Press «Escape» repeatedly to return to the main menu.
5. Open the user's shut-off valve between the machine and the air distribution network.
Result
No.: 9_9450 07 USE
The machine is ready for operation.
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9
Operation
9.12
Checking the temperature sensor and overheating shutdown function
Resetting
If the test is cancelled when opening the safety relief valve, SIGMA CONTROL 2 will indicate the
highest measured value as internal pressure.
To reset the saved value, activate the Reset check box.
➤ Activate the Reset check box.
9.12
Checking the temperature sensor and overheating shutdown func‐
tion
The machine should shut down if the airend discharge temperature (ADT) reaches a maximum of
230°F.
SIGMA CONTROL 2 will simulate a higher temperature for checking this function.
For this purpose, SIGMA CONTROL 2 automatically determines an offset value to be displayed.
During the test mode, this offset is added to the actual compressor discharge temperature to cause
the machine to shut down prematurely.
No warning message is generated. However, the corresponding fault message "0015Airend
discharge temperature ADT ⇞" switches off the machine once the maximum discharge tempera‐
ture has been reached.
Overview
■
Allow the machine to warm up, then shut it down and allow it to cool down slightly
■
Performing the test
■
Correct conclusion of the test
■
Resetting
Performing the test
The offset value of 95°F displayed in activated test mode refers to the example discharge
temperature of 163°F as shown in the header of the display.
Precondition
Allow the machine to warm up. Shut down the machine as soon as the discharge temperature has
stabilized.
Machine has cooled down by approximately 41°F (from discharge temperature of warmed up ma‐
chine).
Password access level 2 is activated.
1. Open the 9.1  menu.
2. Use the «Up» or «Down» keys to select the ADT line.
88psi
08:15AM
176° F
Menu
9.1 TÜV inspection
Safety valve:
pRV:
☐
232psi ¦ pi ⇞
Safety relief valve activating pressure (example)
0.0psi
Reset
☐
·········
ADT ⇞
Offset
172
32°F ¦ ADT
⇞
☐
Active line with check box
32.0°F
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9
Operation
9.12
Checking the temperature sensor and overheating shutdown function
3. Press «Enter».
The ADT ⇞ check box flashes.
4. Press «Up» key.
The check box is activated.
5. Press «Enter».
The Offset display changes to 95°F.
The ADT ⇞ display changes to 226°F.
The test mode is now activated.
88psi
08:15AM
16 3° F
Menu
9.1 TÜV inspection
Safety valve:
pRV:
☐
232psi ¦ pi ⇞
Safety relief valve activating pressure (example)
0.0psi
Reset
☐
·········
ADT ⇞
Offset
95°F ¦ ADT
⇞
☑
Active line with check box
226°F
6. Press the «ON» key.
The machine is running in LOAD.
The discharge temperature increases again.
The machine will switch off as soon as the discharge temperature attains a value of 230°F.
The machine does not shut down?
➤ Abort the test and contact an authorized KAESER service representative soon as possi‐
ble.
Correct conclusion of the test
1. Press «Enter» to switch into setting mode.
The setting mode is active.
The check box flashes in line ADT ⇞.
2. Press the «DOWN» key.
The check box is deactivated.
3. Press «Enter» to accept the setting.
The offset is reset to 32°F.
Result
The test mode is deactivated and the test is completed.
Resetting
SIGMA CONTROL 2 will display the highest measured value if the test for switching off at high
temperature is aborted.
Activate the Reset check box in order to reset the stored value.
➤ Activate the Reset check box.
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9.13
Operation
9.13
Save data
Save data
SIGMA CONTROL 2 settings can be backed up to an SD card.
Precondition
An SD card with compatible file system (FAT32) and minimum 50 MB free memory is plugged into
the SD card slot X5 of SIGMA CONTROL 2
The write protection of the SD card has been deactivated.
Password access level 2 is activated.
1. Open the 5.10  menu.
2. Use «Up» or «Down» to select the Language: line.
88psi
08:15AM
176° F
5.10 Save data
Language:
Header
Menu
en_US English
Active line
·········
Save data
:☐
3. Press «Enter» to switch into setting mode.
The display for the set language flashes.
4. Use «Up» or «Down» to select the desired language.
5. Press «Enter» to accept the setting.
The setting is applied.
6. Use «Up» or «Down» to select the Save data line.
88psi
08:15AM
176° F
Menu
5.10 Save data
Language:
Header
en_US English
·········
Save data
:☑
Active line
7. Press «Enter».
The check box Save data will flash.
8. Press «Up» key.
The check box is activated.
9. Press «Enter».
A security query is displayed.
10. Press «Enter».
Result
174
The settings are saved on the SD card.
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10
Fault Recognition and Rectification
10.1
Basic instructions
10 Fault Recognition and Rectification
10.1
Basic instructions
The following tables are intended to assist in locating faults.
SIGMA CONTROL 2 will indicate three types of faults:
■
Fault on the machine:
The red LED flashes, the machine is shut down, see chapters 10.2 and 10.5.
■
Fault on the controller:
The machine is shut down, see chapter 10.6.
■
Warning:
The yellow LED illuminates, the machine is not shut down, see chapter 10.3.
The messages valid for your machine are dependent on the controller and individual equipment.
1. Do not attempt fault rectification measures other than those given in this manual!
2. In all other cases:
Have the fault rectified by an authorized KAESER service representative.
10.2
Interpreting alarm messages
If an input signal is classified as an alarm, the controller will display the fault upon the signal's
arrival.
Consequences:
■
The red LED flashes:
■
The controller switches the machine off.
Alarm messages are identified with the letter A.
The message numbers are not numbered consecutively.
Meanings of designation of fault messaged within this table with "%d".
1)
Messages 0073–0078 and 0081–0096 are customer-specific and may differ from the suggested
values.
Complete them with your defined message text, possible causes and remedies. (see chapter 8.11).
Message
Possible cause
Remedy
0001 A
Direction of rotation
The compressor drive motor is
turning in the wrong direction.
Changeover phase lines L1 and L2.
0002 A
Motor temperature ⇞
Compressor drive motor overhea‐ Keep ambient conditions within
ted.
specified limits.
Check the cooling air supply.
Clean the motor.
No.: 9_9450 07 USE
0003 A
pRV ⇞
The activating pressure of the
Change the safety relief valve.
safety relief valve on the oil sepa‐
rator tank has been exceeded.
0004 A
EMERGENCY STOP
EMERGENCY STOP push button Unlatch the push button.
actuated.
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10
Fault Recognition and Rectification
10.2
Interpreting alarm messages
Message
Possible cause
0005 A
Oil separator
Temperature ⇞
Maximum air temperature at the Check the line to the trip relay.
oil separator tank outlet is excee‐ Check the oil separator cartridge
ded.
for damage.
0007 A
Power supply monitor
Fault in main power supply.
0008 A
Diagnostics group alarm
A diagnostic message has occur‐ For more details, see the text of the
red.
diagnostic message.
0010 A
Blow-off protection ⇞
The activating pressure of the
Change the oil separator cartridge.
safety relief valve on the oil sepa‐ Open the shut-off valve in the vent‐
rator tank has been exceeded.
ing line.
0011 A
Oil-/air cooler fan
Overcurrent
Overload shutdown of the fan mo‐ Investigate cause of shutdown.
tor.
Reset the overload protection relay.
0012 A
Access doors
Door open / interlocked panel re‐ Fit and secure all panels and close
moved while the machine is run‐ access doors.
ning.
0013 A
Compressor motor
overcurrent
Overload shutdown of the com‐
pressor drive motor.
0014 A
Overload shutdown of the oil
Oil cooler fan overcurrent cooler fan motor.
0015 A
Airend discharge
temperature ADT ⇞
Remedy
Have the main power supply
checked.
Investigate cause of shutdown.
Change the oil separator cartridge.
Investigate cause of shutdown.
Reset the overload protection relay.
Maximum permissible airend dis‐ Keep ambient conditions within
charge temperature (ADT) excee‐ specified limits.
ded.
Clean the cooler.
Check the cooling oil level.
0016 A
Air cooler - Fan
Overcurrent
Overload shutdown of the air
cooler fan motor.
Investigate cause of shutdown.
0017 A
Safety shutdown ADT
Maximum permissible airend dis‐ Keep ambient conditions within
charge temperature (ADT) excee‐ specified limits.
ded.
Clean the cooler.
Reset the overload protection relay.
Check the cooling oil level.
176
0018 A
Interior fan Overcurrent
Overload shutdown of the air
cooler fan motor.
Investigate cause of shutdown.
0019 A
Internal pressure pi ⇟
Inlet valve defective.
Contact an authorized KAESER
service representative.
0021 A
Refrigeration dryer T ⇟
Refrigerated dryer:
Compressed air temperature too
low.
Contact an authorized KAESER
service representative.
0022 A
Oil separator Δp ⇞
Oil separator cartridge clogged.
Change the oil separator cartridge.
0033 A
Oil pressure ⇟
Oil level too low.
Check the cooling oil level.
Reset the overload protection relay.
Defective oil pump (provided only If necessary, request that an au‐
in vacuum machines).
thorized KAESER service repre‐
sentative replaces the oil pump.
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10
Fault Recognition and Rectification
10.2
Interpreting alarm messages
Message
Possible cause
Remedy
0034 A
Mains contactor on?
Main contactor of the compressor Check main contactor and wiring.
motor does not open.
0035 A
Cabinet fan I ⇞
Overload shutdown of the control Contact an authorized KAESER
cabinet fan motor.
service representative.
0038 A
PD temperature ⇟
Package discharge (PD) temper‐ Contact an authorized KAESER
ature too low.
service representative.
0039 A
PD temperature ⇞
Package discharge (PD) temper‐ Check the cooling oil level.
ature too high.
Clean the cooler.
Check the fan motor.
0040 A
Mains contactor off?
Main contactor of the compressor Check main contactor and wiring.
motor does not deactivate.
0041 A
Mains voltage ⇟
Second power failure.
0042 A
Back pressure stop
Back pressure in the oil separator Check venting line.
tank caused by defective venting.
0043 A
Airend discharge
temperature ADT rise
dT/dt⇞
The rate of rise of the airend dis‐
charge temperature (ADT) is too
fast.
Check the cooling oil level.
0044 A
No pressure buildup
The machine does not produce
compressed air.
Check the machine for leaks.
Check power supply voltage.
Checking the door interlock switch.
Check coupling and V-belt.
The working pressure does not
Contact an authorized KAESER
rise above 50 psi within the speci‐ service representative.
fied time period.
The machine does not enter
LOAD mode.
Minimum pressure check valve
defective.
0048 A
High-voltage cell
No.: 9_9450 07 USE
Fault in the high voltage cell.
Contact an authorized KAESER
service representative.
0050 A
Power switching module not
Customer-provided power ready or defective.
element
Check power switching module.
0051 A
Aggregate A
Aggregate A failed.
Contact an authorized KAESER
service representative.
0052 A
Aggregate B
Aggregate B failed.
Contact an authorized KAESER
service representative.
0056 A
RD condensate drain
Refrigerated dryer:
Condensate drain defective.
Refrigerated dryer:
Check the condensate drain and
conduits.
0057 A
Model?
Compressor model uncertain.
Contact an authorized KAESER
service representative.
0058 A
Condensate drain
Condensate drain defective.
Check the condensate drain and
conduits.
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10
Fault Recognition and Rectification
10.2
Interpreting alarm messages
Message
Possible cause
Remedy
0059 A
Back pressure run
Drive belt or coupling broken.
Drive belts:
Replace drive belt.
Coupling:
Contact an authorized KAESER
service representative.
0060 A
Softstart
Fault in the soft start equipment.
Contact an authorized KAESER
service representative.
0062 A
Refrigeration dryer p ⇞
Refrigerated dryer:
Pressure too high in refrigerant
circuit.
Safety pressure switch tripped.
Clean the refrigerant condenser.
0063 A
Refrigeration dryer p ⇟
Refrigerated dryer:
Refrigerant lost; pressure in the
refrigerant circuit too low.
Inlet pressure switched tripped.
Contact an authorized KAESER
service representative.
0064 A
Refrigeration dryer
compressor motor
temperature ⇞
Permissible ambient tempera‐
tures exceeded.
Condenser cooling insufficient.
Compressed air inlet temperature
is too high.
Low refrigerant level.
Check and lower ambient tempera‐
tures.
Clean the condenser.
Check the fan.
Check compressed air cooling at
the compressor.
Clean the compressor cooler.
Check the fan motor.
Maintain operating conditions.
Contact an authorized KAESER
service representative.
178
0067 A
SC2 <=> SC2
communication error
The electrical connection is inter‐ Check the electrical connection.
rupted.
Check the IP configuration.
IP configuration incorrect.
0073 A
External message 1
1)
0074 A
External message 2
1)
0075 A
External message 3
1)
0076 A
External message 4
1)
0077 A
External message 5
1)
0078 A
External message 6
1)
0081 A
AnMod_p_1
1)
0082 A
AnMod_p_2
1)
0083 A
AnMod_p_3
1)
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10
Fault Recognition and Rectification
10.2
Interpreting alarm messages
Message
Possible cause
0084 A
AnMod_p_4
1)
Remedy
0085 A
AnMod_T_1
1)
0086 A
AnMod_T_2
1)
0087 A
AnMod_T_3
1)
0088A
AnMod_T_4
1)
0089A
AnMod_I_1
1)
0090 A
AnMod_I_2
1)
0092 A
T-Switch inlet
temperature
1)
0093 A
p-Switch pi
1)
0094 A
T-Switch ADT
1)
0095 A
p-Switch pN
1)
0096 A
T-Switch PDT
1)
0100 A
Star contactor on?
Star contactor of the compressor Check star contactor and wiring.
motor does not activate.
0101 A
Star contactor off?
Star contactor of the compressor Check star contactor and wiring.
motor does not deactivate.
0102 A
Delta contactor on?
Delta contactor of the compressor Check delta contactor and wiring.
motor does not activate.
0103 A
Delta contactor off?
Delta contactor of the compressor Check delta contactor and wiring.
motor does not deactivate.
0104 A
High-voltage cell on?
High-voltage cell does not acti‐
vate.
0105 A
High-voltage cell off?
High-voltage cell does not deacti‐ Contact an authorized KAESER
vate.
service representative.
0106 A
Softstarter DI%.2d
closed?
Soft start device does not acti‐
vate.
Contact an authorized KAESER
service representative.
Contact an authorized KAESER
service representative.
0107 A
Soft start device does not deacti‐ Contact an authorized KAESER
Softstarter DI%.2d open? vate.
service representative.
0108 A
Softstarter DI%.2d
closed?
No.: 9_9450 07 USE
Run-up of the soft start device is
not completed.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Contact an authorized KAESER
service representative.
179
10
Fault Recognition and Rectification
10.2
Interpreting alarm messages
Message
Possible cause
Remedy
0109 A
Run-down of the soft start device Contact an authorized KAESER
Softstarter DI%.2d open? is not completed.
service representative.
180
0111 A
Oil-/air cooler fan Mains
contactor on?
Main contactor of the fan motor
does not activate.
Check main contactor and wiring.
0112 A
Oil-/air cooler fan Mains
contactor off?
Main contactor of the fan motor
does not deactivate.
Check main contactor and wiring.
0113 A
Oil-/air cooler fan Speed
↓ on?
Main contactor of the fan motor
does not activate.
Check main contactor and wiring.
0114 A
Oil-/air cooler fan Speed
↓ off?
Main contactor of the fan motor
does not deactivate.
Check main contactor and wiring.
0115 A
Oil-/air cooler fan Speed
↑ on?
Main contactor of the fan motor
does not activate.
Check main contactor and wiring.
0116 A
Oil-/air cooler fan Speed
↑ off?
Main contactor of the fan motor
does not deactivate.
Check main contactor and wiring.
0121 A
Oil cooler fan Mains
contactor on?
Main contactor of the fan motor
does not activate.
Check main contactor and wiring.
0122 A
Oil cooler fan Mains
contactor off?
Main contactor of the fan motor
does not deactivate.
Check main contactor and wiring.
0131 A
Air cooler - Fan Mains
contactor on?
Main contactor of the fan motor
does not activate.
Check main contactor and wiring.
0132 A
Air cooler - Fan Mains
contactor off?
Main contactor of the fan motor
does not deactivate.
Check main contactor and wiring.
0141 A
Interior fan Mains
contactor on?
Main contactor of the fan motor
does not activate.
Check main contactor and wiring.
0142 A
Interior fan Mains
contactor off?
Main contactor of the fan motor
does not deactivate.
Check main contactor and wiring.
0150 A
Redundancy contactor
on?
Redundancy contactor does not
activate.
Check redundancy contactor and
wiring.
0151 A
Redundancy contactor
off?
Redundancy contactor does not
deactivate.
Check redundancy contactor and
wiring.
0200 A
Compressor motor USS
alarm
Frequency converter fault.
Contact an authorized KAESER
service representative.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
No.: 9_9450 07 USE
10
Fault Recognition and Rectification
10.2
Interpreting alarm messages
Message
Possible cause
Remedy
0201 A
Compressor motor USS
alarm
Frequency converter fault.
Contact an authorized KAESER
service representative.
0202 A
Compressor motor USS
alarm
Frequency converter fault.
Contact an authorized KAESER
service representative.
0203 A
Compressor motor FC
PKW failure P%d.E%d
Frequency converter fault.
Contact an authorized KAESER
service representative.
0204 A
Compressor motor FC
PKW failure P%d.E%d
Frequency converter fault.
Contact an authorized KAESER
service representative.
0205 A
Compressor motor FC
PKW failure P%d.E%d
Frequency converter fault.
Contact an authorized KAESER
service representative.
0206 A
USS bus communication
error %d
Fault caused by software driver.
Contact an authorized Kaeser serv‐
ice representative.
0207 A
USS bus communication
error %d
Fault caused by software driver.
Contact an authorized KAESER
service representative.
0208 A
USS bus communication
error %d
Fault caused by software driver.
Contact an authorized KAESER
service representative.
0210 A
Compressor motor FC
Over temperature alarm
Compressor motor temperature
too high.
Keep ambient conditions within
specified limits.
0211 A
Compressor motor FC
Alarm %d
Fault message of the frequency
converter with message number
(here: 50).
Contact an authorized KAESER
service representative.
0212 A
Compressor motor FC
AI2 error
Speed sensor of the frequency
converter (here: AI2).
Contact an authorized KAESER
service representative.
0220 A
Compressor motor FC
Motor overload alarm
Compressor motor overload.
Contact an authorized KAESER
service representative.
0221 A
Compressor motor FC
Alarm %d
Fault message of the frequency
converter with message number
(here: 50).
Contact an authorized KAESER
service representative.
0230 A
Compressor motor FC
Motor overload alarm
Compressor motor overload.
Contact an authorized KAESER
service representative.
0231 A
Compressor motor FC
Alarm %d
Fault message of the frequency
converter with message number
(here: 50).
Contact an authorized KAESER
service representative.
Cooler maintenance.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
181
182
10
Fault Recognition and Rectification
10.2
Interpreting alarm messages
Message
Possible cause
Remedy
0232 A
Compressor motor FC
AI1 error
Speed sensor of the frequency
converter (here: AI1).
Contact an authorized KAESER
service representative.
0240 A
Compressor motor USS
alarm
Fault caused by software driver.
Contact an authorized KAESER
service representative.
0241 A
Compressor motor FC
PKW failure P%d.E%d
Frequency converter fault.
Contact an authorized KAESER
service representative.
0242 A
USS bus communication
error %d
Fault caused by software driver.
Contact an authorized KAESER
service representative.
0243 A
Compressor motor FC
Alarm %d
Fault message of the frequency
converter with message number
(here: 50).
Contact an authorized KAESER
service representative.
0244 A
Compressor motor FC
activation failed
Frequency converter incorrectly
activated.
Contact an authorized KAESER
service representative.
0245 A
Compressor motor FC
run-up time exceeded
Minimum speed not reached with Check the set value.
a defined time (can be set).
Contact an authorized KAESER
service representative.
0246 A
Compressor motor FC
nMin undershot
Below minimum speed by a spe‐ Check the set value.
cific speed (can be set) for a spe‐ Contact an authorized KAESER
cific time (can be set).
service representative.
0247 A
Compressor motor FC:
STO function inactive
Parametrization error.
Contact an authorized KAESER
service representative.
0248 A
Parametrization error.
Compressor motor FC off
- STO?
Contact an authorized KAESER
service representative.
0251 A
Oil-/air cooler fan USS
alarm
Fault caused by software driver.
Contact an authorized KAESER
service representative.
0252 A
Oil-/air cooler fan FC
PKW failure P%d.E%d
Frequency converter fault.
Contact an authorized KAESER
service representative.
0253 A
Oil-/air cooler fan FC
PKW failure P%d.E%d
Frequency converter fault.
Contact an authorized KAESER
service representative.
0254 A
USS bus communication
error %d
Fault caused by software driver.
Contact an authorized KAESER
service representative.
0255 A
USS bus communication
error %d
Fault caused by software driver.
Contact an authorized KAESER
service representative.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
10
Fault Recognition and Rectification
10.2
Interpreting alarm messages
Message
Possible cause
Remedy
0260 A
Oil-/air cooler fan FC
Motor overload alarm
Fan motor overload.
Contact an authorized KAESER
service representative.
0261 A
Oil-/air cooler fan FC
Alarm %d
Fault message of the frequency Contact an authorized KAESER
converter with message number. service representative.
0270 A
Oil-/air cooler fan FC
Motor overload alarm
Fan motor overload.
Contact an authorized KAESER
service representative.
0271 A
Oil-/air cooler fan FC
Alarm %d
Fault message of the frequency
converter with message number
(here: 50).
Contact an authorized KAESER
service representative.
0280 A
Oil-/air cooler fan USS
alarm
Fault caused by software driver.
Contact an authorized KAESER
service representative.
0281 A
Oil-/air cooler fan FC
PKW failure P%d.E%d
Frequency converter fault.
Contact an authorized KAESER
service representative.
0282 A
Oil-/air cooler fan USS
error %d
Fault caused by software driver.
Contact an authorized KAESER
service representative.
0283 A
Oil-/air cooler fan FC
Alarm %d
Fault message of the frequency
converter with message number
(here: 50).
Contact an authorized KAESER
service representative.
0284 A
Oil-/air cooler fan FC
activation failed
Fan frequency converter incor‐
rectly activated.
Contact an authorized KAESER
service representative.
0287 A
Oil-/air cooler fan FC:
STO function inactive
Frequency converter parametriz‐ Check frequency converter para‐
ing incorrect.
metrizing.
Contact an authorized KAESER
service representative.
0288 A
Frequency converter parametriz‐ Check frequency converter para‐
Oil-/air cooler fan FC off - ing incorrect.
metrizing.
STO?
Contact an authorized KAESER
service representative.
No.: 9_9450 07 USE
0301 A
Oil cooler fan USS alarm
Frequency converter fault.
Contact an authorized KAESER
service representative.
0303 A
Oil cooler fan FC PKW
failure P%d.E%d
Frequency converter fault.
Contact an authorized KAESER
service representative.
0305 A
USS bus communication
error %d
Fault caused by software driver.
Contact an authorized KAESER
service representative.
0320 A
Oil cooler fan FC Motor
overload alarm
Fan motor overload.
Contact an authorized KAESER
service representative.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
183
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
Message
Possible cause
Remedy
0321 A
Oil cooler fan FC
Alarm %d
Fault message of the frequency
converter with message number
(here: 50).
Contact an authorized KAESER
service representative.
0330 A
Oil cooler fan USS alarm
Frequency converter fault.
Contact an authorized KAESER
service representative.
0331 A
Oil cooler fan FC PKW
failure P%d.E%d
Frequency converter fault.
Contact an authorized KAESER
service representative.
0332 A
USS bus communication
error %d
Fault caused by software driver.
Contact an authorized KAESER
service representative.
0333 A
Oil cooler fan FC
Alarm %d
Fault message of the frequency Contact an authorized KAESER
converter with message number. service representative.
0334 A
Oil cooler fan FC
activation failed
Fan frequency converter incor‐
rectly activated.
0337 A
Oil cooler fan FC: STO
function inactive
Frequency converter parametriz‐ Check frequency converter para‐
ing incorrect.
metrizing.
0338 A
Oil cooler fan FC off STO?
Frequency converter parametriz‐ Check frequency converter para‐
ing incorrect.
metrizing.
0500 A
I/O parameterisation
incorrect in module %d!
An I/O address has been as‐
signed more than once.
Contact an authorized KAESER
service representative.
Contact an authorized KAESER
service representative.
Contact an authorized KAESER
service representative.
Tab. 86
Fault messages, possible causes and remedies
10.3
Interpreting warning messages
Display and correct the incorrect
parameters in the 1.1.3Address
error menu.
If an input signal is classified as a warning, the controller will display the warning upon the
signal's arrival.
Consequences:
■
The yellow LED flashes.
■
The controller does not switch off the machine.
Warning messages are identified with the letter W.
The message numbers are not numbered consecutively.
In this table, you will see "%d" for a variable value, e.g. a number, duration or I/O address.
184
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
1)
Messages 0073–0078 and 0081–0096 are customer-specific and may differ from the suggested
values.
Complete them in the table below with your defined message text, possible causes and remedies
(see chapter 8.11).
Message
Possible cause
Remedy
0001 W
Equipment number
incomplete
Equipment number entered incompletely
or not at all.
Contact an authorized
KAESER service representa‐
tive.
0002 W
Motor temperature ↑
Drive motor overheating.
Keep ambient conditions with‐
in specified limits.
Check the cooling air supply.
Clean the motor.
0004 W
Oil separator Δp ↑
Increased differential pressure of the oil
separator cartridge.
Change the oil separator car‐
tridge.
Oil separator cartridge clogged.
0008 W
Airend discharge
temperature ADT ↑
Maximum airend discharge temperature
will soon be reached.
Clean the cooler.
Check the cooling oil level.
Replace the oil filter element.
Ensure adequate ventilation.
Keep surrounding tempera‐
ture within recommended lim‐
its.
0011 W
Oil filter Δp ↑
Increased pressure differential of the oil
filter.
Change the oil filter.
Oil filter clogged.
0013 W
Air filter Δp ↑
Air filter clogged.
Change the air filter.
0015 W
Com-Module
communication error
The bus link via PROFIBUS interface is
interrupted.
Check bus lines and plug.
0021 W
Refrigerated dryer:
Refrigeration dryer T ⇟ Compressed air temperature too low.
Keep ambient conditions with‐
in specified limits.
Contact an authorized
KAESER service representa‐
tive.
No.: 9_9450 07 USE
0024 W
Mains contactor
operations ⇞
The maximum permissible number of
switching cycles has been exceeded.
Have the main contactor re‐
placed by an authorized
KAESER service representa‐
tive.
0025 W
Oil separator h ⇞
Oil separator cartridge:
Maintenance interval has elapsed.
Change the oil separator car‐
tridge.
0026 W
Oil change h ⇞
Cooling oil:
Maintenance interval has elapsed.
Change the cooling oil.
0027 W
Oil filter h ⇞
Oil filter:
Maintenance interval has elapsed.
Change the oil filter.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
185
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
Message
Possible cause
Remedy
0028 W
Air filter h ⇞
Air filter:
Maintenance interval has elapsed.
Change the air filter.
0029 W
Valve inspection h ⇞
Valves:
Maintenance interval has elapsed.
Contact an authorized
KAESER service representa‐
tive.
0030 W
Belt tension/coupling:
Belt/coupling inspection Maintenance interval has elapsed.
h⇞
Carry out a visual inspection.
0031 W
Motor bearing h ⇞
Motor bearing of compressor motor:
Maintenance interval has elapsed.
Contact an authorized
KAESER service representa‐
tive.
0032 W
Electrical equipment h
⇞
Electric components and electrical instal‐ Inspect and reset the mainte‐
lation:
nance interval counter.
Maintenance interval has elapsed.
0033 W
Fan bearing h ⇞
Motor bearing of fan motors:
Maintenance interval has elapsed.
0034 W
PD temperature ↓
Package discharge (PD) temperature too Contact an authorized
low.
KAESER service representa‐
tive.
0035 W
PD temperature ↑
Compressed air discharge temperature
too high.
Clean the cooler.
0036 W
Motor starts/h ⇞
The permissible number of motor starts
was exceeded in the last 60 minutes.
Extend the idle period.
Tension the drive belt.
Contact an authorized
KAESER service representa‐
tive.
Check the cooling oil level.
Increase the capacity of the
air receiver.
Increase the cross-section of
piping between compressor
and air receiver.
0037 W
Motor starts/d ⇞
The permissible number of motor starts
was exceeded in the last 24 hours.
Extend the idle period.
Increase the capacity of the
air receiver.
Increase the cross-section of
piping between compressor
and air receiver.
0038 W
Blow-off protection ↑
The safety relief valve's activating pres‐
sure will soon be reached.
Change the oil separator car‐
tridge.
Open the shut-off valve in the
venting line.
0041 W
Mains voltage ↓
1. Power failure:
The machine is automatically restarted.
Check power supply.
0043 W
External load signal?
Ambiguous external load signal:
Increased cut-out pressure exceeded.
Check settings of the external
controller. Take into account
pressure drops across filters
and dryer.
The external load control has not switch‐
ed to IDLE.
186
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
Message
Possible cause
Remedy
0044 W
Oil temperature ↓
Cooling oil temperature too low.
Check temperature switch,
line and connection.
Check the oil circuit.
Increase room temperature.
0045 W
DO test active
Test operation for the manual actuation of Switch the power supply off
individual outputs is active.
and on again.
0046 W
System pressure ↓
System pressure has fallen below the set Check air demand.
system pressure low' value.
Check cable runs and sensor
Air consumption too high.
connections.
Check the system pressure
low' warning value.
0047 W
No pressure buildup
The machine does not produce com‐
pressed air.
Check the machine for leaks.
The working pressure does not rise
above 50 psi bar within the pre-set time
period.
Contact an authorized
KAESER service representa‐
tive.
The machine does not enter LOAD mode
Check coupling and V-belt.
Minimum pressure check valve defective.
0048 W
Bearing lube h ⇞
Re-grease the motor bearings.
Maintenance interval has elapsed.
Re-grease the motor bear‐
ings.
0049 W
Annual maintenance
Last maintenance was 1 year ago.
Carry out the necessary main‐
tenance and reset the corre‐
sponding maintenance inter‐
val counter.
0050 W
Fan bearing lube h ⇞
Maintenance interval has elapsed.
Re-grease the fan bearing.
0051 W
Double aggregate
emergency operation!
Last maintenance was 1 year ago.
Carry out the necessary main‐
tenance and reset the corre‐
sponding maintenance inter‐
val counter.
0053 W
Condensate drain 2
Condensate drain defective.
Check the condensate drain
and condensate lines.
Too much condensate.
Line interrupted.
No.: 9_9450 07 USE
Check the lines.
Condensate cannot be drained.
Check EcoDrain.
0058 W
SC2 <=> SC2
communication error
The electrical connection is interrupted.
IP configuration incorrect
Check the electrical connec‐
tions.
Check the IP configuration.
0059 W
Start temperature ↓↓
The airend temperature is too low (<
−50°F) for the machine to be operated.
Keep ambient conditions with‐
in specified limits.
0060 W
Start temperature ↓
The airend temperature is too low
(<+35°F).
Keep ambient conditions with‐
in specified limits.
0061 W
Compressor T ↓
The airend discharge temperature (ADT) Contact an authorized
did not reach the minimum value within
KAESER service representa‐
the specified time.
tive.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Check inlet conditions.
187
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
Message
Possible cause
Remedy
0062 W
Refrigerated dryer:
Clean the refrigerant con‐
Refrigeration dryer p ⇞ Pressure too high in the refrigerant circuit. denser.
Safety pressure switch tripped.
Check the fan motor.
Maintain operating conditions.
0063 W
Refrigerated dryer:
Refrigeration dryer p ⇟ Refrigerant lost; pressure in the refriger‐
ant circuit too low. Inlet pressure switch
tripped.
Contact an authorized
KAESER service representa‐
tive.
0064 W
Refrigeration dryer
compressor motor
temperature ⇞
Check and lower ambient
temperatures.
Clean the condenser.
Check the fan.
Check compressed air cooling
at the compressor.
Clean the compressor cooler.
Permissible ambient temperatures excee‐
ded.
Condenser cooling insufficient
Compressed air inlet temperature is too
high.
Low refrigerant level.
Contact an authorized
KAESER service representa‐
tive.
0065 W
Refrigeration dryer
external shut-off
Low room temperature.
Risk that refrigerated dryer freezes.
Keep ambient conditions with‐
in specified limits.
0067 W
System pressure ↑
System pressure is above the "system
pressure high" value.
Check cable runs and sensor
connections.
Refrigerated dryer has automatically been Check temperature sensor.
deactivated.
Check the "system pressure
high" warning setting.
0068 W
Condensate drain
Condensate drain defective.
Too much condensate.
Line interrupted.
Condensate cannot be drained.
Check the condensate drain
and condensate lines.
Check the lines.
Check EcoDrain.
Check inlet conditions.
0069 W
Refrigerated dryer defective.
Immediately contact an au‐
Error operation without Compressed air supply with non-dried air thorized KAESER service rep‐
RD → Call service!
is activated.
resentative.
0070 W
Refrigerated dryer:
Refrigeration dryer T ↑ Compressed air temperature too high.
Maintain operating conditions.
Clean the refrigerant con‐
denser.
Clean the cooler.
Install an extractor fan.
188
0071 W
Oil level ↓
Cooling oil level too low.
Top off the cooling oil.
0072 W
RD condensate drain
Refrigerated dryer:
Condensate drain defective.
Check the condensate drain.
0073 W
External message 1
1)
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
No.: 9_9450 07 USE
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
Message
Possible cause
0074 W
External message 2
1)
0075 W
External message 3
1)
0076 W
External message 4
1)
0077 W
External message 5
1)
0078 W
External message 6
1)
0081 W
AnMod_p_1
1)
0082 W
AnMod_p_2
1)
0083 W
AnMod_p_3
1)
0084 W
AnMod_p_4
1)
0085 W
AnMod_T_1
1)
0086 W
AnMod_T_2
1)
0087 W
AnMod_T_3
1)
0088 W
AnMod_T_4
1)
0089 W
AnMod_I_1
1)
0090 W
AnMod_I_2
1)
0092 W
T-Switch inlet
temperature
1)
0093 W
p-Switch pi
1)
0094 W
T-Switch ADT
1)
0095 W
p-Switch pN
1)
0096 W
T-Switch PDT
1)
0097 W
SAM 4.0
communication error
Bus link via SIGMA NETWORK interrup‐
ted.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Remedy
Check bus lines and plug.
189
190
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
Message
Possible cause
Remedy
0200 W
Compressor motor FC
Service mode active
Frequency converter in service mode.
Terminate service mode.
0201 W
Compressor motor FC
Service mode active
Frequency converter in service mode.
Terminate service mode.
0202 W
Compressor motor FC
Service mode active
Frequency converter in service mode.
Terminate service mode.
0203 W
Compressor motor FC
Service mode active
Frequency converter in service mode.
Terminate service mode.
0210 W
Compressor motor FC
AI1 error
Pressure transducer of the frequency
converter defective.
Contact an authorized
KAESER service representa‐
tive.
0230 W
Compressor motor FC
AI0 error
Pressure transducer of the frequency
converter defective.
Contact an authorized
KAESER service representa‐
tive.
0231 W
Compressor motor FC
Alarm %d
Malfunction at compressor motor or its
frequency converter.
Contact an authorized
KAESER service representa‐
tive.
0240 W
Compressor motor FC
test shut-off required
Run time of the frequency converter since Temporarily fully disconnect
last shutdown too large.
the machine from the power
supply. (Required for the safe‐
ty functions.)
0243 W
Compressor motor FC
Alarm %d
Malfunction at compressor motor or its
frequency converter.
Contact an authorized
KAESER service representa‐
tive.
0251 W
Oil-/air cooler fan FC
Service mode active
Frequency converter in service mode.
Terminate service mode.
0253 W
Oil cooler fan FC
Service mode active
Frequency converter in service mode.
Terminate service mode.
0254 W
Oil cooler fan FC
Service mode active
Frequency converter in service mode.
Terminate service mode.
0255 W
Oil-/air cooler fan FC
Service mode active
Frequency converter in service mode.
Terminate service mode.
0260 W
Oil-/air cooler fan FC
Alarm %d
Fault in fan frequency converter.
Acknowledge message.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Contact an authorized
KAESER service representa‐
tive.
No.: 9_9450 07 USE
No.: 9_9450 07 USE
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
Message
Possible cause
Remedy
0261 W
Oil-/air cooler fan FC
Alarm %d
Fault in fan frequency converter.
Acknowledge message.
0262 W
Oil cooler fan FC
Alarm %d
Fault in fan frequency converter.
0263 W
Oil cooler fan FC
Alarm %d
Fault in fan frequency converter.
0300 W
SD card write error
Write protection activated?
Contact an authorized
KAESER service representa‐
tive.
Acknowledge message.
Contact an authorized
KAESER service representa‐
tive.
Acknowledge message.
Contact an authorized
KAESER service representa‐
tive.
Memory card defective.
Deactivate the write protec‐
tion.
Use a new memory card.
0866 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
0867 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
0868 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
0869 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
0872 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
0873 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
0874 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
0875 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
0878 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
0879 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
191
192
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
Message
Possible cause
0880 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
0881 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
0884 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put faulty.
0885 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
0886 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
0887 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1034 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
1035 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1036 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1037 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1040 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
1041 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1042 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1043 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1046 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Remedy
No.: 9_9450 07 USE
No.: 9_9450 07 USE
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
Message
Possible cause
1047 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1048 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1049 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1052 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put faulty.
1053 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1054 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1055 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1202 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
1203 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1204 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1205 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1208 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
1209 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1210 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1211 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Remedy
193
194
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
Message
Possible cause
1214 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put faulty.
1215W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1216 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1217 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1220 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put faulty.
1221 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1222 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1223 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1370 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put faulty.
1371 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1372 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1373 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1376 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put faulty.
1377 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1378 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Remedy
No.: 9_9450 07 USE
No.: 9_9450 07 USE
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
Message
Possible cause
1379 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1382 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put faulty.
1383 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1384 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1385 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1388 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
1389 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1390 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1391 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1538 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
1539 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1540 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1541 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1544 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
1545 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Remedy
195
196
10
Fault Recognition and Rectification
10.3
Interpreting warning messages
Message
Possible cause
1546 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1547 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1550 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put faulty.
1551 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1552 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1553 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1556 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
1557 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1558 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1559 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1706 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
1707 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1708 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1709 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1712 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Remedy
No.: 9_9450 07 USE
10
Fault Recognition and Rectification
10.4
Interpreting operation messages
Message
Possible cause
1713 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1714 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1715 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1718 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
1719 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1720 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1721 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
1724 W
AII%d.0%d - error
power supply
Power supply for ext. sensor at analog in‐ Check the power supply.
put defective.
1725 W
AII%d.0%d - overload
fault
Overload in signal for ext. sensor at ana‐ Contact an authorized
log input defective.
KAESER service representa‐
tive.
1726 W
AII%d.0%d - open
circuit
No continuity in line for ext. sensor at an‐ Check cable runs and sensor
alog input.
connections.
1727 W
AII%d.0%d - shortcircuit
Short circuit in line for ext. sensor at ana‐ Check cable runs and sensor
log input.
connections.
Tab. 87
Warning messages and remedies
10.4
Interpreting operation messages
Remedy
The controller will automatically display operation messages informing you about the current opera‐
tional state of the machine.
Operating messages are identified with the letter O.
The message numbers are not numbered consecutively.
In this table, you will see "%d" for a variable value, e.g. a number, duration or I/O address.
No.: 9_9450 07 USE
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
197
10
Fault Recognition and Rectification
10.4
Interpreting operation messages
1)
Messages 0073–0078 and 0081–0096 are customer-specific and undefined.
Complete them in the table below with your defined message text and interpretation (see also
chapter 8.11).
Message
Meaning
0001 O
Delayed start (%ds) active
Total duration until the machine is ready to start after power
has been restored or after a communication error to the mas‐
ter controller (e.g. SAM 4.0) or after switching on the SAM
manual mode.
0009 O
The machine is switched on.
Compressor on
0010 O
The controller is switched on with the «ON» key.
Controller on
0011 O
Cold start release
0027 O
Power OFF → ON
0028 O
The machine can be switched on although the machine tem‐
perature is below the permissible starting temperature.
The machine can be switched on only as long as the mes‐
sage is displayed.
Request:
Switch the power supply off and on.
DYNAMIC motor temperature ↑
Control mode DYNAMIC:
The temperature of the compressor motor is too high.
0030 O
Main power supply returned after main failure.
Voltage restored
0033 O
Machine report sent by e-mail.
Machine report
0034 O
No e-mail sending of machine information.
E-mail send unsuccessful!
0073 O
1)
External message 1
0074 O
1)
External message 2
0075 O
1)
External message 3
0076 O
1)
External message 4
0077 O
1)
External message 5
0078 O
1)
External message 6
0081 O
1)
AnMod_p_1
0082 O
1)
AnMod_p_2
198
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
10
Fault Recognition and Rectification
10.4
Interpreting operation messages
Message
Meaning
0083 O
1)
AnMod_p_3
0084 O
1)
AnMod_p_4
0085 O
1)
AnMod_T_1
0086 O
1)
AnMod_T_2
0087 O
1)
AnMod_T_3
0088 O
1)
AnMod_T_4
0089 O
1)
AnMod_I_1
0090 O
1)
AnMod_I_2
0092 O
1)
T-Switch inlet temperature
0093 O
1)
p-Switch pi
0094 O
1)
T-Switch ADT
0095 O
1)
p-Switch pN
0096 O
1)
T-Switch PDT
0200 O
IOSlot1 Undervoltage error %d
0201 O
IOSlot2 Undervoltage error %d
0202 O
IOSlot3 Undervoltage error %d
0203 O
IOSlot4 Undervoltage error %d
0204 O
IOSlot5 Undervoltage error %d
0205 O
The internal voltage monitoring reports low voltage fault IO‐
Slot1 (in the example 50 times).
The internal voltage monitoring reports low voltage fault IO‐
Slot2 (in the example 50 times).
The internal voltage monitoring reports low voltage fault IO‐
Slot3 (in the example 50 times).
The internal voltage monitoring reports low voltage fault IO‐
Slot4 (in the example 50 times).
The internal voltage monitoring reports low voltage fault IO‐
Slot5 (in the example 50 times).
IOSlot6 Undervoltage error %d
The internal voltage monitoring reports low voltage fault IO‐
Slot6 (in the example 50 times).
0300 O
Service information.
Cycle-exact data recording active
No.: 9_9450 07 USE
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199
10
Fault Recognition and Rectification
10.4
Interpreting operation messages
Message
Meaning
0301 O
Service information.
FEZ-Prozessabbild aktiv
0500 O
Service information.
Safety shutdown "IOMDiagnosis()"
0501 O
Service information.
Safety shutdown "Safeguard()"
0550 O
Short-term overload fault without shutdown occurred at ADT.
ADT channel error "currleak"
detected
0551 O
Short-term overload fault without shutdown occurred at ADT.
ADT channel error "channel open"
detected
0850 O
IOM bus fault.
IOSlot%d - bus error
0867 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
0873 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
0879 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
0885 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1000 O
2 RFID Equipment Cards
successfully registered
1018 O
You successfully registered 2 KAESER RFID Equipment
Cards at the controller.
IOM bus fault.
IOSlot%d - bus error
1035 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1041 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1047 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1053 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1186 O
IOM bus fault.
IOSlot%d - bus error
1203 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1209 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
200
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
10
Fault Recognition and Rectification
10.5
Interpreting diagnostic messages
Message
Meaning
1215 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1221 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1354 O
IOM bus fault.
IOSlot%d - bus error
1371 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1377 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1383 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1389 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1522 O
IOM bus fault.
IOSlot%d - bus error
1539 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1545 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1551 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1557 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1690 O
IOM bus fault.
IOSlot%d - bus error
1707 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1713 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1719 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
1725 O
Short-term overload fault without shutdown occurred at All.
AII%d.0%d - overload fault
Tab. 88
Operational messages
10.5
Interpreting diagnostic messages
A diagnostic message causes the machine to shut down.
No.: 9_9450 07 USE
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
201
10
Fault Recognition and Rectification
10.6
Interpreting system messages
Diagnostic messages are identified with the letter D.
They provide information on the status of the controller, the connected input and output modules,
and support KAESER service with troubleshooting.
10.6
Interpreting system messages
A system message causes the machine to shut down. Contact an authorized KAESER serv‐
ice representative.
System messages are identified with the letter Y.
The message numbers are not numbered consecutively.
Tab. 89
202
Message
Possible cause Remedy
0001 Y
Hardware watchdog reset
System error
Contact an authorized KAESER service representa‐
tive.
0002 Y
Internal software error
System error
Contact an authorized KAESER service representa‐
tive.
0003 Y
Filesystem Read/Write
failure
System error
Contact an authorized KAESER service representa‐
tive.
0004 Y
CPU load too high
System error
Contact an authorized KAESER service representa‐
tive.
0005 Y
RAM out of memory
System error
Contact an authorized KAESER service representa‐
tive.
1000 Y
System error
RFID error: switch SIGMA
CONTROL power supply
OFF → ON!
Contact an authorized KAESER service representa‐
tive.
System messages and remedies
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
11
Maintenance
11.1
Changing the buffer battery
11 Maintenance
11.1
Changing the buffer battery
When SIGMA CONTROL 2 displays a warning message indicating that the integrated buffer bat‐
tery has discharged and requires replacement, please contact an authorized KAESER service rep‐
resentative.
No.: 9_9450 07 USE
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
203
12
Spares, Operating Materials, Service
12.1
Note the nameplate
12 Spares, Operating Materials, Service
12.1
Note the nameplate
The nameplate contains all information to identify your machine. This information is essential to us
in order to provide you with optimal service.
➤ Please give the information from the nameplate with every inquiry and order for spare parts.
12.2
KAESER AIR SERVICE
KAESER AIR SERVICE offers:
■
authorized KAESER service representatives 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 spare parts,
■
increased legal certainty as all regulations are kept to.
➤ Why not sign a KAESER AIR SERVICE maintenance agreement!
Result
12.3
Your advantage:
lower costs and higher compressed air availability.
Service Addresses
Addresses of KAESER representatives are given at the end of this manual.
12.4
Displaying the version number, machine model, part number and
serial number
1. Open the 5.1.1  menu.
88psi
08:15AM
176° F
5.1.1 System information
Menu
▶1 SIGMA CONTROL 2 MCS
Active line
▶2 Compressor
▶3 I/O modules
204
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE
12
Spares, Operating Materials, Service
12.4
Displaying the version number, machine model, part number and serial number
2. Press «Enter».
The system information is displayed.
88psi
08:15AM
176° F
5.1.1.1 SIGMA CONTROL 2 MCS
Menu
Software fluid_4.0.X
Software version
·········
KAESER
PN
7.7601.0
SN
123456
Part number
Serial number
·········
3. Press «Up» or «Down» repeatedly to display further information.
88psi
08:15AM
176° F
5.1.1.1 SIGMA CONTROL 2 MCS
SN
Menu
123456
·········
Manufacturer
Prodrive
PN
6309.1000.7900
SN
10.34.000.961
MFGDT
No.: 9_9450 07 USE
2016/08
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
Part number
Serial number
Manufacturing date
205
13
Decommissioning, Storage and Transport
13.1
De-commissioning
13 Decommissioning, Storage and Transport
13.1
De-commissioning
➤ Follow the instructions in the machine's operator manual.
13.2
Packing
➤ Follow the instructions in the machine's operator manual.
13.3
Storage
➤ Follow the instructions in the machine's operator manual.
13.4
Transporting
➤ Follow the instructions in the machine's operator manual.
13.5
Precondition
Disposal
SIGMA CONTROL 2 is decommissioned.
1. Disconnect SIGMA CONTROL 2 from all connections.
2. If necessary, use a tool to forcefully remove the rear enclosure panel.
3. Use a suitable tool to remove the internally installed buffer battery.
4. Properly dispose of the buffer batteries.
5. Hand the SIGMA CONTROL 2 over to an authorized disposal expert.
13.5.1
Battery disposal
Batteries contain substances that are harmful to living beings and the environment. For this reason,
batteries must not be disposed of with unsorted residential waste. They must be disposed of in ac‐
cordance with local environmental regulations. This procedure facilitates the handling and recycling
of batteries.
Fig. 42
Battery disposal
Do not dispose of batteries with residential waste
Battery contains lead (if applicable)
➤ Dispose of batteries in accordance with local environmental regulations.
206
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.0.X
No.: 9_9450 07 USE

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