Prodrive Technologies SIGCON2 SoftPLC system User Manual manual
Prodrive B.V. SoftPLC system manual
manual
| Download: |  |
| Mirror Download [FCC.gov] | |
| Document ID | 1412970 |
| Application ID | F/xNv4WuB9dJB6YBQuONiw== |
| Document Description | manual |
| Short Term Confidential | No |
| Permanent Confidential | No |
| Supercede | No |
| Document Type | User Manual |
| Display Format | Adobe Acrobat PDF - pdf |
| Filesize | 120.24kB (1503000 bits) |
| Date Submitted | 2011-02-02 00:00:00 |
| Date Available | 2011-03-01 00:00:00 |
| Creation Date | 2011-01-28 15:58:55 |
| Producing Software | Antenna House PDF Output Library 2.6.0 (Windows) |
| Document Lastmod | 2011-01-28 15:58:55 |
| Document Title | manual |
| Document Creator | AH Formatter V5.2 R1 (5,2,2010,0806) for Windows |
Service Manual Controller SIGMA CONTROL 2 No.: 9_9450 00 USE SCREW FLUID 1.0.x.x /KKW/SSC 2.00 en 01 BA-SIGMA CONTROL-01 /KKW/SSC 2.00 01 20110128 155040 Quick user guide Controller SIGMA CONTROL 2 9_9450 00 USE SCREW FLUID 1.0.x.x Contents 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 9_9450 00 USE Important settings ............................................................................................................. Setting the display language ............................................................................................ Entering a password ........................................................................................................ Adjusting the system set-point pressure .......................................................................... Activating the «Timer» key ............................................................................................... Activating the «Remote control» key ................................................................................ Changing the control mode .............................................................................................. Outputting important operational states of the machine ................................................... Resetting maintenance interval counters ......................................................................... Testing the safety relief valve ........................................................................................... Checking the temperature sensor and overheating shutdown function ........................... Interpreting operation messages ...................................................................................... Interpreting diagnostic messages .................................................................................... Interpreting fault messages .............................................................................................. Interpreting warning messages ........................................................................................ Interpreting system messages ......................................................................................... Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 11 12 13 14 17 19 21 22 27 31 Contents ii Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 1 Important settings 1 Important settings In this chapter, important or often used settings are explained in brief. Detailed information on func‐ tion, configuration, fault removal and important instructions concerning safe operation are found in subsequent chapters. Setting and other work on the machine may only be carried out by the following persons: 9_9450 00 USE ■ persons trained on the machine/controller and persons instructed by and under the su‐ pervision of a specialist, ■ trained technicians, ■ authorized service personnel. Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 2 Setting the display language 2 Setting the display language Precondition The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Press the «UP» or «DOWN» keys until the current language is shown as active line. 88 psi 08:15 176 ° F ········· Deutsch ········· Active line with current language ▶1 xxxxxxxxxx Submenu ▶2 xxxxxxxxxx Submenu ▶3 xxxxxxxxxx Submenu ▶4 xxxxxxxxxx Submenu ▶5 xxxxxxxxxx Submenu ▶6 xxxxxxxxxx Submenu 3. Use the «Enter» key to switch to setting mode. The currently set language flashes. 4. Move to the required language with «UP »or «DOWN». 5. Confirm the setting with «Enter». 6. Press «Escape» repeatedly to return to the main menu. Result The display texts are now in the selected language. Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 3 Entering a password 3 Entering a password Use a supplied Equipment Card to log on at the controller. Fig. 1 RFID reader 24 RFID reader 1. Hold the Equipment Card in front of the RFID reader for a short time (several seconds). The system reads the data and displays your access level. 2. Press «Enter» to confirm the logon. Result Further information 9_9450 00 USE The operating mode is displayed. You are logged on. See chapter 7.2.4 for instructions on logging on to the controller manually. Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 4 Adjusting the system set-point pressure 4 Adjusting the system set-point pressure Precondition Password level 2 is activated. The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Select the < Configuration ➙ Pressure control ➙ Pressure settings > menu. 3. Press «UP» or «DOWN» repeatedly until the switching point pA is displayed as active line: 88 psi 08:15 176 ° F 5.2.2 Pressure settings Current menu ········· Setpoint pressure Parameter to be adjusted pA SP:115 psi ¦ SD: -7.3 psi Active line with current value for pA ¦ SD pB SP: 110 psi ¦ SD: - 5.8 psi Current value for pB ········· System pressure low ☐ 4. Press «Enter» to switch into setting mode. The current value flashes. 5. Use «UP» or «DOWN» to adjust the setting for the switching point pA . 6. Press «Enter» to accept the setting. 7. Press the «Right» key once. 8. Press «Enter» to switch into the setting mode for the switching differential. The current value flashes. 9. Use «UP» or «DOWN» to adjust the setting for the switching differential. 10. Press «Enter» to accept the setting. 11. If necessary, adjust the value for pB in the same way. 12. Press «Escape» repeatedly to return to the main menu. Further information See chapter 7.3 for the adjustment of the machine's pressure parameters. Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 5 Activating the «Timer» key 5 Activating the «Timer» key Activating/deactivating the check box Tab. 1 Precondition Check box Check box for Reset Status ☑ ☒ activated ☐ ☐ deactivated Check box status Password level 2 is activated. The display shows the operating mode. Selecting the Compressor clock menu 1. Press «Enter». The main menu is displayed. 2. Select < Compressor clock >. The display for setting the Compressor clock timing program appears. 88 psi 08:15 176 ° F 6 Compressor clock Current menu Key clock : ☐ Reset: ☐ ········· 01 n.a. 00:00 off Enter switching point 01 (active line) 02 n.a. 00:00 off Enter switching point 02 03 n.a. 00:00 off Enter switching point 03 Entering switching points 1. Press «Enter» to switch into setting mode. The n.a. column flashes in the active line. 2. Use «UP» to specify the settings for the weekdays. 3. Press «Enter» to accept the setting. 4. Press the «Right» key once. 5. Press «Enter» to switch into setting mode. Time column, hours display, 00 : 00 flashes in the active line. 6. Use «UP» to specify the settings for the hours. 7. Press the «Right» key once. Time column, minutes display, 00 : 00 flashes in the active line. 8. Use «UP» to specify the settings for the minutes. 9_9450 00 USE Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 5 Activating the «Timer» key 9. Press «Enter» to accept the settings. The display stops flashing and the time (hours/minutes) is set. 88 psi 08:15 176 ° F Current menu 6 Compressor clock Key clock : ☐ Reset: ☐ ········· 01 Mon-Fri 06:30 on Example for weekdays 02 Mon-Fri 12:00 off Example for time 03 Mon-Fri 13:00 on Example for the action Compressor ON 10. Press the «Right» key once. 11. Press «Enter» to switch into setting mode. The action off / on column flashes. 12. Use «UP» to specify the settings for the Compressor ON action. 13. Press «Enter» to accept the setting. The Compressor ON action is set for the first switching point. 14. Specify further switching points in the same manner. Result Weekdays, time and the Compressor ON / Compressor OFF actions are set for all switching points. Activating the «Timer» key 1. Use «UP» to move to line Key clock . 2. Press «Enter» to switch into setting mode. The check box flashes in the active line. 88 psi 08:15 176 ° F 6 Compressor clock Menu Key clock : ☑ Active line with check box Reset: ☐ Resetting all current switching points ········· 01 Mon-Fri 06:30 on 02 Mon-Fri 12:00 off 03 Mon-Fri 13:00 on 3. Use the «UP» key to activate the check box. 4. Press «Enter» to accept the setting. The «Timer» key is activated. 5. Press «Escape» repeatedly to return to the main menu. 6. Press the «Timer» key. ■ Proceed in the same manner to deactivate the «Timer» key. ■ All defined switching points will be reset simultaneously if you activate the Reset check box. Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 5 Result Further information Activating the «Timer» key The machine runs according to the defined switching points of the timing program. See chapter 7.4 for the Configuration of starting and stopping the machine. See chapter 7.6.2 for the Configuration of load changeover based on a timing program. 9_9450 00 USE Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 6 Activating the «Remote control» key 6 Activating the «Remote control» key Further settings have to be made to allow the machine to be remotely controlled. ➤ Refer to the section "Additional information" in this chapter. Activating/deactivating the check box Tab. 2 Check box Status ☑ activated ☐ deactivated Check box status The following menus are used to activate the «Remote control» key: ■ Menu < Compressor ON > ■ Menu < Load control > The function will be available as soon as the «Remote control» key in one of the menus has been activated. Precondition Password level 2 is activated. The display shows the operating mode. Activating the «Remote control» key in the Compressor ON menu 1. Press «Enter». The main menu is displayed. 2. Select < Configuration ➙ Compressor start ➙ Compressor ON >. 3. Press «DOWN» repeatedly until Key remote is displayed as active line. 4. Press «Enter» to switch into setting mode. The check box for Key remote will flash. 88 psi 08:15 176 ° F 5.4.1 Compressor ON Menu ········· current Key ········· RC DI 1.12 ok ☑ Key remote : ☐ Active line with check box Key clock : ☐ 5. Press «UP». The activated check box is displayed. Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 6 Activating the «Remote control» key 6. Press «Enter» to save the setting. The «Remote control» key is activated and can be used. 88 psi 08:15 176 ° F Menu 5.4.1 Compressor ON ········· current Key ········· RC DI 1.12 ok ☑ Active line with check box Key remote : ☑ Key clock : ☐ 7. Press «Escape» repeatedly to return to the main menu. 8. Press the «Remote control» key to enable Remote mode. Proceed in the same manner to deactivate the «Remote control» key. Activating the «Remote control» key in the Load control menu Precondition Password level 2 is activated. The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Select < Configuration ➙ Pressure control ➙ Load control >. 3. Press «UP» repeatedly until Key remote is displayed as active line. 4. Press «Enter» to switch into setting mode. The check box for Key remote will flash. 88 psi 08:15 176 ° F 5.2.3 Load control Menu local mode pA ········· Remote mode : pA Key remote : ☐ Active line with check box ········· current pA 5. Press «UP». The activated check box is displayed. 9_9450 00 USE Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 6 Activating the «Remote control» key 6. Press «Enter» to accept the setting. The «Remote control» key is activated and can be used. 88 psi 08:15 176 ° F 5.2.3 Load control Menu local mode pA ········· Remote mode : pA Key remote : ☑ Active line with check box ········· current pA 7. Press «Escape» repeatedly to return to the main menu. 8. Press the «Remote control» key to enable Remote mode. Proceed in the same manner to deactivate the «Remote control» key. Further information See chapter 7.4 for the Configuration of starting and stopping the machine. See chapter 7.7 for the Configuration of the load changeover in sequenced mode. 10 Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 7 Changing the control mode 7 Changing the control mode The standard setting of Control Mode depends on the machine type. Precondition Password level 2 is activated. The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Select the < Configuration ➙ Control Mode > menu. 3. Press «UP» repeatedly until local mode is displayed as active line. The Control Mode setting is shown in the active line. 88 psi 08:15 176 ° F 5.3 Control Mode Current menu local mode : DUAL Active line with Control Mode to be adjusted ········· Current control mode current DUAL ········· ▶1 Venting period ········· 4. Press «Enter» to switch into setting mode. DUAL flashes. 88 psi 08:15 176 ° F 5.3 Control Mode Current menu local mode : QUADRO Active line with adjusted Control Mode ········· current QUADRO Current control mode ········· ▶1 Venting period ········· 5. Use «UP» to change the Control Mode QUADRO. 6. Press «Enter» to accept the setting. The new Control Mode QUADRO is shown in the current line. 7. Press «Escape» repeatedly to return to the main menu. Result Further information The Control Mode DUAL has been changed to Control Mode QUADRO. See chapter 4.6 for the functions of the control modes. See chapter 7.5 for the Configuration of the control mode parameters. 9_9450 00 USE Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 11 8 Outputting important operational states of the machine 8 Outputting important operational states of the ma‐ chine Important operational machine states can be assigned via floating relay contacts as a binary signal on the outputs DOR 1.05 – DOR 1.07. Further outputs are optionally available. You can assign ev‐ ery output only once. Precondition Password level 2 is activated. The display shows the operating mode. Configuration ➙ I/O periphery ➙ DO functions menu 1. Press «Enter». The main menu is displayed. 2. Select the < Configuration ➙ I/O periphery ➙ DO functions > menu. Controller ON is displayed in the active line. 3. Select the required message with the «UP» or «DOWN» keys. 88 psi 08:15 176 ° F 5.7.1 DO functions Menu Controller ON DOR 1.05 ok ☑ Active line with Controller ON message Logic + Compressor ON DOR 1.04 ☐ Logic + Motor running DOR 1.07 ok ☑ Logic + Assigning a message to an output 1. Press «Enter» to switch into setting mode. The display flashes. 2. Select a free output with the «UP» or «DOWN» key. 3. Press «Enter» to accept the setting. A message is now sent via the output assigned. 4. Press «Escape» repeatedly to return to the main menu. Further information 12 See chapter 7.9 for Configuration and use of the controller's inputs and outputs. Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 9 Resetting maintenance interval counters 9 Resetting maintenance interval counters Example: Resetting the maintenance interval counter for Oil filter. Precondition Maintenance has been performed. Warning message has been acknowledged. Access level 2 is activated. The display shows the operating mode. Maintenance menu 1. Press «Enter». The main menu is displayed. 2. Select the < Maintenance > menu. The maintenance counter for Oil filter is displayed in the active line. 3. Press «DOWN» once. Reset line is displayed as being active. 4. Press «Enter» to switch into setting mode. The check box for Reset will flash. 88 psi 08:15 176 ° F Menu 4 Maintenance Oil filter 6000 h ¦ 0005 h Maintenance interval ¦ remaining time Active line Reset: ☐ ········· Oil separator 6000 h ¦ 3000 h Reset: ☐ ········· 5. Use the «DOWN» key to deactivate the check box for Reset . 88 psi 08:15 176 ° F Menu 4 Maintenance Oil filter 6000 h ¦ 6000 h Maintenance interval ¦ remaining new time Active line Reset: ☑ ········· Oil separator 6000 h ¦ 3000 h Reset: ☐ ········· 6. Press «Enter» to accept the setting. The check box for Reset is deactivated automatically. Result Further information The remaining time of the new oil filter complies with the defined maintenance interval of 6000 h. See chapter 8.4 for setting the maintenance intervals. See chapter 10 for the maintenance of the controller. 9_9450 00 USE Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 13 10 Testing the safety relief valve 10 Testing the safety relief valve Overview ■ Preparing the test ■ Performing the test ■ Correct conclusion of the test ■ Performing a Reset 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 internal pressure pi is used to describe the following check. Tab. 3 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 air distribution network. 4. Log on to SIGMA CONTROL 2 with password level 2 (see chapter 7.2.4). 5. In operating mode, switch to the main menu with the «Enter» key. 6. Select the < Machine test ➙ TÜV inspection > menu. Safety valve line is displayed as being active. 88 psi 08:15 176 ° F 9.1 TÜV inspection Menu Safety valve: ☐ Active line with check box pRV : 232 psi ¦ pi 0.00 psi Safety relief valve activating pressure (example) Reset: ☐ ········· ADT ⇞ : ☐ Offset : 32 °F ¦ ADT ⇞ 32 °F Performing the test 1. Press «Enter» to switch into setting mode. The check box in the active line flashes. 2. Use the «UP» key to activate the check box. 14 Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 10 Testing the safety relief valve 3. Press «Enter» to accept the setting. The test mode is now activated. The monitoring of internal and network set point pressures is deactivated! 88 psi 08:15 176 ° F 9.1 TÜV inspection Menu Safety valve: ☑ Active line with check box pRV : 232 psi ¦ pi 36 psi Activating pressure safety relief valve ( pRV ) ¦ Inter‐ nal pressure pi ( current ) Reset: ☐ ········· 4. Excessive noise is caused when the safety relief valve blows off! ➤ Close all access doors, replace and secure all removable panels. ➤ Wear hearing protection. 5. 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. 6. Press and hold the «ON» key. The machine switches to load, the machine's internal pressure pi rises. 7. Manually monitor on the display the pressure rise pi during the TÜV inspection. 8. If the internal pressure pi increases to more than 10 % above the correct opening pressure of the safety relief valve, shut down the machine with the «OFF» key. 9. Have the Safety valve replaced immediately. If the alarm message pRV ⇞ appears, the safety relief valve is defective. The permissible internal pressure was exceeded by 29 psi. ➤ Have the safety relief valve replaced immediately. Avoid oil mist: ➤ Release the «ON» key immediately when the safety relief valve responds, in order to pre‐ vent unnecessary oil mist. Correct conclusion of the test 1. Press «Enter» to switch into setting mode. The check box in the active line flashes. 2. Use the «DOWN» key to deactivate the check box. 3. Press «Enter» to accept the setting. The "Safety relief valve" test mode is de-activated and the test is completed. 4. Press «Escape» repeatedly to return to the main menu. 5. Open the shut-off valve from the machine. Result 9_9450 00 USE The machine is ready for operation. Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 15 10 Testing the safety relief valve Resetting If the test is canceled when opening the safety relief valve, the internal pressure pi will indicate the highest measured value. Activate the check box for Reset in order to reset the stored value. ➤ Activate the check box for Reset. Further information 16 See chapter 8.5 to test the safety relief valve. Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 11 Checking the temperature sensor and overheating shutdown function 11 Checking the temperature sensor and overheating shutdown function 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 airend discharge temperature to cause the machine to shut down prematurely. In standard operation, SIGMA CONTROL 2 generates the "overtemperature" fault message when the maximum airend discharge temperature is reached. Since the modified test temperature is 4 °F below the fault message switching point for overtemperature, the system will not generate a fault message in test mode. Overview ■ Shut down the machine and allow to cool down slightly ■ Performing the test ■ Correct conclusion of the test ■ Performing a Reset Performing the test Precondition Machine cooled down by approx. 9 °F 1. Log on to SIGMA CONTROL 2 with access level 2. (see section 7.2.4). 2. In operating mode, switch to the main menu with the «Enter» key. 3. Select the < Machine test ➙ TÜV inspection > menu. Safety valve is displayed in the active line. 4. Press «DOWN» repeatedly until ADT ⇞ is displayed as active line. 5. Press «Enter» to switch into setting mode. The check box in the active line flashes. 88 psi 08:15 164 ° F 9.1 TÜV inspection Menu ········· ADT ⇞ : ☐ Active line Offset : 32 °F ¦ ADT ⇞ 32 °F Reset: ☐ 6. Use the «UP» key to activate the check box. 9_9450 00 USE Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 17 11 Checking the temperature sensor and overheating shutdown function 7. Press «Enter» to accept the setting. The Offset display changes to 95 °F. The ADT ⇞ display changes to 226 °F. The test mode is now activated. 88 psi 08:15 164 ° F 9.1 TÜV inspection Menu ········· ADT ⇞ : ☑ Active line Offset : 95 °F ¦ ADT ⇞ 226 °F Offset ¦ ADT ⇞ in test mode Reset: : ☐ 8. Press the «ON» key to switch the machine to LOAD. The machine switches to LOAD and the airend discharge temperature rises again. The machine will switch off as soon as ADT attains a value of 226 °F. The machine does not shut down? ➤ Abort the test and contact KAESER Service as soon as possible. Correct conclusion of the test 1. Press «Enter» to switch into setting mode. The check box in the active line flashes. 2. Use the «DOWN» key to deactivate the check box. 3. Press «Enter» to accept the setting. The offset is reset to 32 °F. The test mode is de-activated and the test is completed. 4. Press «Escape» repeatedly to return to the main menu. Resetting ADT ⇞ will display the highest measured value if the test for switching off at overtemperature is aborted. Activate the check box for Reset in order to reset the stored value. ➤ Activate the check box for Reset. Further information 18 See chapter 8.6 for testing the temperature sensor. Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 12 Interpreting operation messages 12 Interpreting operation messages The controller will automatically display operation messages informing you about the current opera‐ tional state of the machine. Operating messages are identified with the letter O. The message numbers are not numbered consecutively. Messages 0081 to 0095 are customer-specific and undefined. Complete them with your defined message text and interpretation. Message Meaning 0001 O The machine is regulated by system set point pressure pA. load control pA 0002 O The machine is regulated by system set point pressure pB. load control pB 0003 O The machine is regulated via the remote contactor. load control RC 0004 O The machine is remotely regulated via the bus connection. load control RB 0005 O The machine is switched on and in STANDSTILL operating mode. ready 0006 O The machine is switched on and in IDLE operating mode. IDLE 0007 O The machine is switched on and in LOAD operating mode. ON LOAD 0008 O The machine is switched off. off The power supply is connected. 0009 O The machine is switched on. Compressor ON 0010 O The power supply is connected. Controller ON The controller is powered. 0011 O Cold start release The machine can be switched on although the machine temperature is be‐ low the permissible starting temperature. 0025 O The value for pA is output. The machine can be switched on only as long as the message is displayed. Setpoint pressure pA 0026 O The value for pB is output. Setpoint pressure pB 0027 O Power OFF → ON Request: Switch the power supply off and on. 0028 O Control mode DYNAMIC: DYNAMIC motor T↑ The temperature of the compressor motor is too high. 0081 O 9_9450 00 USE Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 19 12 Interpreting operation messages Message Meaning 0082 O 0083 O 0084 O 0085 O 0086 O 0087 O 0088 O 0089 O 0090 O 0091 O 0092 O 0093 O p-Switch pi 0094 O T-Switch ADT 0095 O p-Switch pN Tab. 4 20 Operational Messages Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 13 Interpreting diagnostic messages 13 Interpreting diagnostic 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 the KAESER service in troubleshooting. 9_9450 00 USE Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 21 14 Interpreting fault messages 14 Interpreting fault messages Fault messages are identified with the letter A. The message numbers are not numbered consecutively. Messages 0081 to 0095 are customer-specific and may differ from the suggested values. Com‐ plete them with your defined message text, possible causes and remedies. Message Possible cause Remedy 0001 A Direction of rotation The compressor drive motor is turning in the wrong direction. Change over phase lines L1 and L2. 0002 A Motor T⇞ Compressor drive motor over‐ heated. Clean the motor. 0003 A pRV ⇞ The activating pressure of the Change the safety relief safety relief valve on the oil sepa‐ valve. rator tank has been exceeded. 0004 A EMERGENCY STOP EMERGENCY STOP control de‐ vice actuated. Unlatch the push-button. 0005 A Oil separator T⇞ Maximum air temperature at the oil separator tank outlet is ex‐ ceeded. Check the line to the trip re‐ lay. 0007 A Mains monitor Fault in main power supply. Have the main power sup‐ ply checked. 0009 A Sigma Control T⇞ Permissible enclosure tempera‐ ture for SIGMA CONTROL 2 ex‐ ceeded. Keep ambient conditions within specified limits. Keep ambient conditions within specified limits. Control cabinet: Check filter mats and fan. 0010 A Blow-off protection ⇞ The activating pressure of the Change the oil separator safety relief valve on the oil sepa‐ cartridge. rator tank has been exceeded. Open the shut-off valve in the venting line. 0011 A Fan M4 I⇞ Overload shut-down of the first fan motor. Investigate cause of shutdown. Reset the overload relay. 0012 A Access doors Door open / interlocked panel re‐ moved while the machine is run‐ ning. Fit and secure all panels and close access doors. 0013 A Motor I⇞ Overload shut-down of the com‐ pressor drive motor. Investigate cause of shutdown. Change the oil separator cartridge. 0014 A Fan M5 I⇞ Overload shut-down of the sec‐ ond fan motor. Investigate cause of shutdown. Reset the overload relay. 22 Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 14 Interpreting fault messages Message Possible cause Remedy 0015 A ADT ⇞ Maximum permissible airend dis‐ Keep ambient conditions charge temperature (ADT) ex‐ within specified limits. ceeded. Clean the cooler. Check the cooling oil level. 0016 A Fan M6 I⇞ Overload shut-down of the third fan motor. Investigate cause of shutdown. Reset the overload relay. 0019 A Internal pressure pi⇟ – – 0021 A Refrigeration dryer T⇟ Refrigeration dryer: Compressed air temperature too low. Contact an authorized KAESER service represen‐ tative. 0022 A Oil separator dp⇞ Oil separator cartridge clogged. Change the oil separator cartridge. 0023 A Motor bearings Drive motor bearings overheated. Re-grease the motor bear‐ ings. 0024 A Water-cooling water shortage Cooling water pressure is too low. Check cooling water supply. 0034 A Mains contactor on? Main contactor does not close. 0035 A Fan M7 I⇞ Overload shut-down of the control Contact an authorized cabinet fan motor. KAESER service represen‐ tative. 0038 A PD T⇟ Package discharge (PD) tempera‐ Contact an authorized ture too low. KAESER service represen‐ tative. 0039 A PD T⇞ Package discharge (PD) tempera‐ Check the cooling oil level. ture too high. Clean the radiator. Check main contactor and wiring. Check the fan motor. 0040 A Mains contactor off? Main contactor does not open. Check main contactor and wiring. 0041 A Mains voltage ⇟ Second power failure. Check power supply volt‐ age. Check the door interlock switch. 0042 A Back pressure stop Back pressure in the oil separator Check venting line. tank caused by defective venting. 0043 A ADT 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. The working pressure does not Check coupling / V-belt. rise above 50 psi within the preset period. 9_9450 00 USE Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 23 14 Interpreting fault messages Message Possible cause Remedy 0045 A Compressor T⇟ Thermostatic valve defective Contact an authorized KAESER service represen‐ tative. 0048 A High-voltage cell Fault in the high voltage cell. Contact an authorized KAESER service represen‐ tative. 0051 A Aggregate A Aggregate A failed. Contact an authorized KAESER service represen‐ tative. 0052 A Aggregate B Aggregate B failed. Contact an authorized KAESER service represen‐ tative. 0056 A RD condensate drain Refrigeration dryer: The condensate drain is defec‐ tive. Refrigeration dryer: Check condensate drain and condensate conduits. 0057 A Model Compressor model uncertain. Contact an authorized KAESER service represen‐ tative. 0058 A Condensate drain The condensate drain is defec‐ tive. Check condensate drain and condensate conduits. 0059 A Back pressure run Drive belt or coupling broken. Drive belt: Replace drive belt. Coupling: Contact an authorized KAESER service represen‐ tative. 0060 A Softstart Fault in the soft start equipment. Contact an authorized KAESER service represen‐ tative. 0061 A Oil separator dT/dt⇞ The rate of rise of the airend dis‐ charge temperature is too fast. Check the cooling oil level. 0062 A Refrigeration dryer p⇞ Refrigeration dryer: Pressure too high in the refriger‐ ant circuit. Safety pressure switch tripped. Clean the refrigerant con‐ denser. Refrigeration dryer: Refrigerant lost; pressure in the refrigerant circuit too low. Inlet pressure switched tripped. Contact an authorized KAESER service represen‐ tative. 0063 A Refrigeration dryer p⇟ Check the fan motor. Maintain operating condi‐ tions. 0081 A 0082 A 0083 A 24 Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 14 Interpreting fault messages Message Possible cause Remedy 0097 A High-voltage cell on? High-voltage cell does not acti‐ vate. Check high-voltage cell and wiring. 0098 A High-voltage cell off? High-voltage cell does not deacti‐ Check high-voltage cell and vate. wiring. 0099 A Mains contactor on? Main contactor does not close. Check main contactor and wiring. 0100 A Mains contactor off? Main contactor does not open. Check main contactor and wiring. 0101 A Motor I⇞ Overload shut-down of the com‐ pressor drive motor. Investigate cause of shutdown. 0084 A 0085 A 0086 A 0087 A 0088 A 0089 A 0090 A 0091 A 0092 A 0093 A p-Switch pi 0094 A T-Switch ADT 0095 A p-Switch pN Change the oil separator cartridge. 0102 A Fan M4 I⇞ Overload shut-down of the first fan motor. Investigate cause of shutdown. Reset the overload relay. 9_9450 00 USE 0200 A Compressor motor USS alarm Frequency converter fault Contact an authorized KAESER service represen‐ tative. 0201 A Compressor motor USS alarm Frequency converter fault Contact an authorized KAESER service represen‐ tative. Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 25 14 Tab. 5 26 Interpreting fault messages Message Possible cause Remedy 0202 A Compressor motor USS alarm Frequency converter fault Contact an authorized KAESER service represen‐ tative. 0205 A Compressor motor USS alarm Communications error Check connection and line path. 0210 A Compressor motor FC Motor overload alarm Frequency converter fault Contact an authorized KAESER service represen‐ tative. 0211 A Compressor motor FC Group alarm Frequency converter fault Contact an authorized KAESER service represen‐ tative. Fault messages and measures Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 15 Interpreting warning messages 15 Interpreting warning messages Warning messages are identified with the letter W. The message numbers are not numbered consecutively. Messages 0081 to 0092 are customer-specific and may differ from the suggested values. Com‐ plete them with your defined message text, possible causes and remedies. Message Possible cause Remedy 0002 W Motor T↑ Drive motor overheating. Clean the motor. 0003 W V-belt tension Belt tension is too low. Re-tension drive belt. 0004 W Oil separator dp↑ The pressure drop across the oil separator cartridge has risen. Change the oil separator cartridge. Keep ambient conditions within specified limits. Oil separator cartridge clogged. 0005 W Start inhibit Too frequent manual on and off switching. Do not exceed the maximum num‐ ber of motor switchings per hour when manual on/off switching. 0007 W Motor bearings Drive motor bearing defective. Contact an authorized KAESER ser‐ vice representative. 0008 W ADT↑ Maximum airend discharge tem‐ perature will soon be reached. Clean the radiator. Check the cooling oil level. Replace the oil filter. Ensure adequate ventilation. Keep surrounding temperature with‐ in recommended limits. 0010 W Buffer battery Data retention battery is almost discharged. Change the battery. 0011 W Oil filter Δp↑ The pressure differential of the oil filter has risen. Change the oil filter. Oil filter clogged. 0012 W Modem problem SIGMA CONTROL 2 does not rec‐ Check the link between the ognize modem. SIGMA CONTROL 2 and the mo‐ dem. 0013 W Air filter dp↑ Air filter clogged. Change the air filter element. 0015 W Bus alarm The bus link from the Profibus DP interface is interrupted. Check bus highway and plug. 0016 W Error: RAM Internal RAM defective. Contact an authorized KAESER ser‐ vice representative. 0017 W Refrigeration dryer T↓ Refrigeration dryer: Compressed air temperature too high. Maintain operating conditions. Clean the refrigerant condenser. Clean the cooler. Install an extractor fan. 9_9450 00 USE Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 27 15 Interpreting warning messages Message Possible cause Remedy 0018 W Refrigeration dryer p↓ Refrigeration dryer: Contact an authorized KAESER ser‐ Refrigerant lost; pressure in the re‐ vice representative. frigerant circuit too low. Inlet pres‐ sure switched tripped. 0025 W Oil separator h⇞ Oil separator cartridge: Change the oil separator cartridge. Maintenance interval has elapsed. 0026 W Oil change h⇞ Cooling oil: Change the cooling oil. Maintenance interval has elapsed. 0027 W Oil filter h⇞ Oil filter: Change the oil filter. Maintenance interval has elapsed. 0028 W Air filter h⇞ Air filter: Change the air filter element. Maintenance interval has elapsed. 0029 W Valve inspection h⇞ Valves: Contact an authorized KAESER ser‐ Maintenance interval has elapsed. vice representative. 0030 W Belt tension/coupling: Carry out a visual inspection. Belt/coupling inspection Maintenance interval has elapsed. Re-tension drive belt. h⇞ 0031 W Motor bearing h⇞ Motor bearing of compressor mo‐ Contact an authorized KAESER ser‐ tor: vice representative. Maintenance interval has elapsed. 0032 W Electric components and installa‐ Inspect and reset the maintenance Electrical equipment h⇞ tion: interval counter. Maintenance interval has elapsed. 0033 W Fan bearing h⇞ Motor bearing of fan motors: Contact an authorized KAESER ser‐ Maintenance interval has elapsed. vice representative. 0034 W PD T↓ Package discharge (PD) tempera‐ Contact an authorized KAESER ser‐ ture too low. vice representative. 0035 W PD T↑ Compressed air discharge temper‐ Clean the radiator. ature too high. Check the cooling oil level. 0036 W Motor starts /h⇞ The permissible number of motor starts was exceeded in the last 60 minutes. Extend the idle period. The permissible number of motor starts was exceeded in the last 24 hours. Extend the idle period. 0038 W Blow-off protection ↑ The safety relief valve's activating pressure will soon be reached. Change the oil separator cartridge. 0041 W Mains voltage ↓ 1. Power failure: The machine is automatically restarted. Check power supply. 0037 W Motor starts /d⇞ 28 Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x Increase the capacity of air receiver. Increase the cross-section of piping between compressor and air receiv‐ er. Increase the capacity of air receiver. Increase the cross-section of piping between compressor and air receiv‐ er. Open the shut-off valve in the vent‐ ing line. Check the door interlock switch. 9_9450 00 USE 15 Interpreting warning messages Message Possible cause Remedy 0043 W External load signal? Ambiguous external load signal: Increased cut-out pressure ex‐ ceeded. Check settings of the external con‐ troller. Take into account pressure drops across filters and dryer. The external load control has not switched to idle (off load). 0044 W Oil T↓ Cooling oil temperature too low. Check temperature switch, line and connection. Check the oil circulation. Increase room temperature. 0046 W System pressure ↓ Network pressure has fallen below Check air demand. the set 'low' value. Check cable runs and sensor con‐ Air consumption too high. nections. Check the 'sys.press. low' warning setting. 0047 W No pressure buildup The compressor cannot build-up to Check for air leaks. working pressure. Check the value for internal pres‐ sure given in themenu against the reading on the oil separator tank pressure gauge. 0048 W Bearing lube h⇞ Re-grease the motor bearings. Re-grease the motor bearings. Maintenance interval has elapsed. 0049 W Annual maintenance Last maintenance was 1 year ago. Carry out the necessary mainte‐ nance and reset the corresponding maintenance interval counter. 0059 W Start T↓↓ The airend temperature is too low Keep ambient conditions within (<14 °F) for the machine to be op‐ specified limits. erated. 0060 W Start T↓ The airend temperature is too low (<35 °F). 0061 W Compressor T↓ The airend discharge temperature Contact an authorized KAESER ser‐ (ADT) did not reach the minimum vice representative. value within the specified time. 0066 W Air filter dp⇡ Initial warning: Air filter clogged. 0068 W Condensate drain The condensate drain is defective. Check the condensate drain and drain line. 0069 W Refrigeration dryer p↑ Refrigeration dryer: Clean the refrigerant condenser. Pressure too high in the refrigerant Check the fan motor. circuit. Maintain operating conditions. Safety pressure switch tripped. 0070 W Refrigeration dryer T↑ Refrigeration dryer: Compressed air temperature too high. Keep ambient conditions within specified limits. Change the air filter element soon. Maintain operating conditions. Clean the refrigerant condenser. Clean the cooler. Install an extractor fan. 9_9450 00 USE Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 29 15 Interpreting warning messages Message Possible cause Remedy 0071 W Oil level ↓ Cooling oil level too low. Replenish the cooling oil. 0072 W RD condensate drain Refrigeration dryer: Check condensate drainage The condensate drain is defective. 0081 W 0082 W 0083 W 0084 W 0085 W 0086 W 0087 W 0088 W 0089 W 0090 W 0091 W 0092 W 0093 W p-Switch pi 0094 W T-Switch ADT 0095 W p-Switch pN Tab. 6 30 Warning messages and remedies Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE 16 Interpreting system messages 16 Interpreting system messages System messages are identified with the letter Y. The message numbers are not numbered consecutively. Tab. 7 9_9450 00 USE Message Possible cause Remedy 0001 Y Hardware watchdog reset System error Contact an authorized KAESER service representative. 0002 Y Internal software error System error Contact an authorized KAESER service representative. 0003 Y Filesystem Read/Write failure System error Contact an authorized KAESER service representative. 0004 Y CPU load too high System error Contact an authorized KAESER service representative. 0005 Y RAM out of memory System error Contact an authorized KAESER service representative. 1000 Y System error RFID error: switch SIGMA CONTROL power supply OFF→ON! Contact an authorized KAESER service representative. System messages and remedies Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 31 16 32 Interpreting system messages Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 9_9450 00 USE Contents No.: 9_9450 00 USE Regarding this Document 1.1 Using this document ......................................................................................................... 1.2 Copyright .......................................................................................................................... 1.2.1 Software .............................................................................................................. 1.3 Updating the SIGMA CONTROL 2 operating manual ...................................................... 1.4 Symbols and labels .......................................................................................................... 1.4.1 Warnings ............................................................................................................. 1.4.2 Potential damage warnings ................................................................................ 1.4.3 Other alerts and their symbols ............................................................................ Technical Data 2.1 SIGMA CONTROL 2 Controller ....................................................................................... 2.1.1 User interface with display, CPU and interfaces ................................................. 2.1.2 Input/output modules .......................................................................................... 2.1.3 Sensors ............................................................................................................... Safety and Responsibility 3.1 Basic instructions ............................................................................................................. 3.2 Specified use .................................................................................................................... 3.3 Improper use .................................................................................................................... Design and Function 4.1 The controller ................................................................................................................... 4.2 Operating panel SIGMA CONTROL 2 ............................................................................ 4.3 Display ............................................................................................................................. 4.3.1 Operating mode .................................................................................................. 4.3.2 Main menu .......................................................................................................... 4.3.3 Setting parameters ............................................................................................. 4.3.4 Activating keys with check boxes ....................................................................... 4.4 Access rights .................................................................................................................... 4.4.1 Secure storage of the RFID Equipment Cards ................................................... 4.5 Menus – overview ............................................................................................................ 4.5.1 Operating mode .................................................................................................. 4.5.2 Menu structure .................................................................................................... 4.6 Operating modes and control modes ............................................................................... 4.6.1 Operating modes ................................................................................................ 4.6.2 Control modes .................................................................................................... 4.6.3 Frequency-controlled drive (SFC) ....................................................................... 4.7 MODULATING control ..................................................................................................... 10 11 13 14 14 15 16 16 16 16 16 17 24 24 25 26 27 Installation and Operating Conditions 5.1 Maintaining ambient conditions ........................................................................................ 5.2 Installation conditions ....................................................................................................... 28 28 Installation 6.1 Reporting Transport Damage ........................................................................................... 6.2 Machine identification ....................................................................................................... 29 29 Initial Start-up 7.1 Outline .............................................................................................................................. 7.2 Configuring the controller ................................................................................................. 7.2.1 Selecting menu options ...................................................................................... 7.2.2 Changing the display language .......................................................................... 7.2.3 Access rights with equipment card ..................................................................... 7.2.4 Access right via manual input ............................................................................. 7.2.5 Creating additional user names .......................................................................... 7.2.6 Checking/setting time and date .......................................................................... 30 30 30 31 31 32 33 34 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x Contents 7.2.7 Setting display formats ....................................................................................... 7.2.8 Setting and activating summer/winter time ......................................................... Pressure parameters of the machine ............................................................................... 7.3.1 Displaying pressure parameters ......................................................................... 7.3.2 Configuring the pressure parameters for compressors ...................................... 7.3.3 Activating/deactivating the «IDLE» key .............................................................. Configuring machine start and stop ................................................................................. 7.4.1 Automatic start/stop in programmed clock mode ................................................ 7.4.2 Setting up the holiday period .............................................................................. 7.4.3 Starting the machine remotely from a control center (remote ON/OFF or remote control function) ...................................................................................... 7.4.4 Activating/deactivating the idle phase (Venting period function) ........................ 7.4.5 Activating/deactivating and adjusting the "automatic restart after a power failure" function ................................................................................................... Activating and setting up the control modes .................................................................... 7.5.1 Selecting a control mode .................................................................................... 7.5.2 Adjusting Idle period of Control Mode DUAL ..................................................... 7.5.3 Adjusting the unloaded and minimum running period in Control Mode QUADRO ........................................................................................................... Configuring the machine for local mode ........................................................................... 7.6.1 Selecting ......................... 7.6.2 Configuring the system pressure set-point changeover using the timer program .............................................................................................................. 7.6.3 Configuring the system pressure set-point changeover using the Timer .......... Configuring the machine for master control ..................................................................... Configuring e-mail ............................................................................................................ Configuring input and output signals ................................................................................ Configuring the compressed air outlet temperature (PD temperature) ............................ Activating remote acknowledgement ............................................................................... Linking to an external pressure transducer ...................................................................... Activating the energy-saving mode for Dryer .................................................................. Commissioning the machine ............................................................................................ 59 61 61 61 61 61 62 62 62 Operation 8.1 Switching on and off ......................................................................................................... 8.1.1 Switching on ....................................................................................................... 8.1.2 Switching off ....................................................................................................... 8.1.3 Switching off in an emergency and switching on again ...................................... 8.2 Acknowledging alarm and warning messages ................................................................. 8.3 Displaying operating data ................................................................................................. 8.3.1 Interpreting operation messages ........................................................................ 8.4 Setting the maintenance interval ...................................................................................... 8.5 Testing the safety relief valve ........................................................................................... 8.6 Checking the temperature sensor and overheating shutdown function ........................... 63 63 63 64 64 65 66 68 68 70 Fault Recognition and Rectification 9.1 Basic instructions ............................................................................................................. 9.2 Interpreting fault messages .............................................................................................. 9.3 Interpreting system messages ......................................................................................... 9.4 Interpreting diagnostic messages .................................................................................... 9.5 Interpreting warning messages ........................................................................................ 73 73 77 78 78 10 Maintenance 10.1 Safety ............................................................................................................................... 83 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.11 7.12 7.13 7.14 ii Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 35 38 38 39 40 43 44 44 47 47 50 51 53 53 54 55 55 56 56 No.: 9_9450 00 USE Contents No.: 9_9450 00 USE 11 Spares, Operating Materials, Service 11.1 Note the nameplate .......................................................................................................... 11.2 KAESER AIR SERVICE .................................................................................................. 11.3 Service Addresses ........................................................................................................... 11.4 Displaying the version number, machine model, material, serial, and equipment numbers ........................................................................................................................... 12 Decommissioning, Storage and Transport 12.1 De-commissioning ............................................................................................................ 12.2 Packing ............................................................................................................................ 12.3 Storage ............................................................................................................................. 12.4 Transporting ..................................................................................................................... 12.5 Disposal ........................................................................................................................... Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 84 84 84 84 85 85 85 85 85 iii Contents iv Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE List of Illustrations Fig. Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 No.: 9_9450 00 USE RFID reader ................................................................................................................................ System structure ........................................................................................................................ Keys – overview ......................................................................................................................... Indicators .................................................................................................................................... RFID sensor field ........................................................................................................................ Pressure rise in frequency-controlled machines ........................................................................ Switching on and off ................................................................................................................... Switching off in an emergency ................................................................................................... Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 10 11 12 13 43 63 64 List of Illustrations vi Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 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 No.: 9_9450 00 USE Danger levels and their definitions (personal injury) .................................................................. Danger levels and their definition (damage to property) ............................................................ User interface ............................................................................................................................. Display data ................................................................................................................................ Interfaces .................................................................................................................................... RFID ........................................................................................................................................... SC2IOM-1 .................................................................................................................................. SC2IOM-2 .................................................................................................................................. SC2IOM-3 .................................................................................................................................. Power supply specifications ....................................................................................................... Cable lengths ............................................................................................................................. Degree of protection, IOM .......................................................................................................... IOM dimensions ......................................................................................................................... Pressure transducer ................................................................................................................... Resistance thermometer ............................................................................................................ Keys ........................................................................................................................................... Indicators .................................................................................................................................... RFID sensor field ........................................................................................................................ Reset check box status .............................................................................................................. Check box status ........................................................................................................................ Menu structure ........................................................................................................................... Menu Status .............................................................................................................................. Menu Configuration ................................................................................................................... Menu Pressure control .............................................................................................................. Menu I/O periphery .................................................................................................................... Menu Communication ............................................................................................................... Menu SIGMA CONTROL 2 ....................................................................................................... Menu Components .................................................................................................................... Energy-efficient control modes ................................................................................................... Machine identification ................................................................................................................. Remote control identification ...................................................................................................... Machine identification ................................................................................................................. Language diversity ..................................................................................................................... Date format ................................................................................................................................. Time formats .............................................................................................................................. Units of pressure ........................................................................................................................ Units of temperature ................................................................................................................... Compressor pressure parameters .............................................................................................. Setting limits for system set-point pressure (* Cut-in pressure min) .......................................... Pressure condition for LOAD ..................................................................................................... Pressure condition for IDLE ...................................................................................................... Example: Activated output .......................................................................................................... Settings for machine start and stop. ........................................................................................... Example of a machine ON/OFF clock program .......................................................................... Local operating mode (local mode) ............................................................................................ Example of system pressure changeover switching points ........................................................ Operational Messages ............................................................................................................... Check box status ........................................................................................................................ Fault messages and measures .................................................................................................. System messages and remedies ............................................................................................... Warning messages and remedies .............................................................................................. 11 12 13 15 16 18 19 20 21 22 23 24 24 25 29 29 29 31 35 36 37 37 38 40 40 40 41 44 45 56 57 66 68 73 77 78 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x vii List of Tables viii Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 1 Regarding this Document 1.1 Using this document 1 Regarding this Document 1.1 Using this document The operating manual contains important information to the entire life cycle of SIGMA CONTROL 2. The operating manual is a component of the product. ➤ Keep the manual in a safe place throughout the life of SIGMA CONTROL 2. ➤ Pass the manual on to the next owner/user of the machine. ➤ Ensure that all amendments received are inserted into the operating manual. 1.2 Copyright This operating manual is protected by copyright. Any queries regarding the use or duplication of this documentation should be referred to KAESER. Correct use of information will be fully support‐ ed. 1.2.1 Software The software used in SIGMA CONTROL 2 contains copyright-protected software which is licensed by GNU General Public License in versions 2 and 3. 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:// / SIGMA CONTROL 2 COPYING The licenses can be also found under this address: http://www.gnu.org/licenses/gpl-2.0.txt http://www.gnu.org/licenses/gpl.txt Within three years from receipt of 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 96450 Coburg, Postfach 2143 Germany This offer is valid for anybody having this information. 1.3 Updating the SIGMA CONTROL 2 operating manual The page http://www.kaeser.com/sc2manual will soon present an updated version of the operating manual in certain languages. Be prepared to provide the part number and the serial number of the machine in which the SIGMA CONTROL 2 is installed. Both numbers can be found on the nameplate of the machine. ➤ Download the operating manual in your language. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 1.4 Regarding this Document 1.4 Symbols and labels Symbols and labels ➤ Please note the symbols and labels used in this document. 1.4.1 Warnings Warning notices indicate dangers that may result in injury when disregarded. Warning notices indicate three levels of danger identified by the corresponding signal word: Tab. 8 Signal term Meaning Consequences of non-compliance DANGER Will result in death or severe injury Warns of an imminent danger WARNING Warns of a potentially imminent danger May result in death or severe injury CAUTION May result in a moderate physical injury Warns of a potentially dangerous situation Danger levels and their definitions (personal injury) Warning notices preceding a chapter apply to the entire chapter, including all sub-sections. Example: The type and source of the imminent danger is shown here! The possible consequences of ignoring a warning are shown here. If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐ jury will occur. ➤ The measures required to protect yourself from danger are shown here. Warning notes referring to a sub-section or the subsequent action are integrated into the procedure and numbered as an action. Example: 1. The type and source of the imminent danger is shown here! The possible consequences of ignoring a warning are shown here. If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe injury may occur. ➤ The measures required to protect yourself from danger are shown here. 2. Always read and comply with warning instructions. 1.4.2 Potential damage warnings Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐ jury. Warning notices for damages are identified by their signal term. Tab. 9 Signal term Meaning Consequences of non-compliance NOTICE Damage to property is possible Warns of a potentially dangerous situation Danger levels and their definition (damage to property) Example: Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 1 Regarding this Document 1.4 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. 1.4.3 Other alerts and their symbols This symbol identifies particularly important information. Material Precondition Here you will find details on special tools, operating materials or spare parts. Here you will find conditional requirements necessary to carry out the task. The conditions relevant to safety shown here will help you to avoid dangerous situations. ➤ This symbol denotes lists of actions comprising one stage of a task. Operating instructions with several steps are numbered in the sequence of the operating steps. 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 No.: 9_9450 00 USE Further subjects are introduced here. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 2 Technical Data 2.1 SIGMA CONTROL 2 Controller 2 Technical Data 2.1 SIGMA CONTROL 2 Controller Industrial computer ■ Internal temperature monitoring ■ Internal undervoltage monitoring ■ 2.1.1 Battery-buffered real-time clock ─ Battery life span more than 10 years ─ Battery replaceable User interface with display, CPU and interfaces User interface Feature Value Material Plastics Width [in] 7.5 Height [in] 5.1 Depth [in] 1.8 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] 24 Current [A] 0.3 Voltage source Tab. 10 Input/output module User interface Display Feature Graphical display [px] Value 255 x 128 Width [in] 3.2 Height [in] 1.6 Maximum number of lines/characters 8/30 Colors Lighting Black/white with gray levels LED backlit px ≙ pixel Tab. 11 Display data Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 2 Technical Data 2.1 SIGMA CONTROL 2 Controller Interfaces Interface Connection Marking RJ 45 socket X1 9-pole SUB-D pins X2 RS485–FC (USS interface) 9-pole SUB-D socket X3 COM modules, slot for communications module Module optional for: Profibus, Modbus, Profinet, Devicenet X4 SD/SDHC card X5 Ethernet 10/100 Base T IO bus SD card, SD card slot The positions of the interfaces X1–X5 are marked on the rear of the controller. Tab. 12 Interfaces Identification with RFID Equipment Card Feature Value Hardware on the SIGMA CONTROL 2 controller RFID write/read device Hardware (external) KAESER Equipment Card Recognition distance [in] Max. 2 Frequency [MHz] 13.56 Tab. 13 RFID 2.1.2 Input/output modules There are three different types of input/output modules with different amounts of inputs and out‐ puts. The actually available number of input/output modules 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. Every input/output module is equipped with: ■ Internal temperature monitoring ■ Internal undervoltage monitoring ■ LED indication of operational status IOM 1 Input/Output No.: 9_9450 00 USE 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 – Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 2 Technical Data 2.1 SIGMA CONTROL 2 Controller Input/Output Analog output current (AOI), 0–20 mA Tab. 14 Input/output module 1 Internal, into the control cabinet available in parallel on both sides External, into the compres‐ sor interior – – – SC2IOM-1 IOM 2 Input/Output Tab. 15 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 – – SC2IOM-2 IOM 3 Input/Output Tab. 16 2.1.2.1 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 – – SC2IOM-3 Power supply specifications Power is provided by the power supply unit within the machine. Feature Value Rated power supply (stabilized) [V DC] 24 Current consumption SIGMA CONTROL 2 with IOM 1 [A] 2,4 Current consumption IOM 2 [A] 2,5 IOM ≙ input/output module Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 2 Technical Data 2.1 SIGMA CONTROL 2 Controller Feature Current consumption IOM 3 [A] Value 1,6 IOM ≙ input/output module Tab. 17 2.1.2.2 Power supply specifications Maximum cable lengths Input/Output Tab. 18 2.1.2.3 Tab. 19 2.1.2.4 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 resistor (DOT) ＜ 100 Cable lengths Input/output modules – degree of protection Feature Value Degree of protection within the machine IP 54 Degree of protection within the control cabinet IP 20 Degree of protection, IOM Input/output modules – dimensions Feature Value Width [in] 4.9 Height [in] 9.8 Depth [in] 1.7 Tab. 20 IOM dimensions 2.1.3 Sensors Pressure transducer Feature Value Output signal [mA] 0/4–20 Connection Tab. 21 Twin cable Pressure transducer Resistance thermometer No.: 9_9450 00 USE Feature Value Sensing resistance (to DIN IEC 751) PT100 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 2 Technical Data 2.1 SIGMA CONTROL 2 Controller Feature Connection Tab. 22 Value Twin cable Resistance thermometer Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 3 Safety and Responsibility 3.1 Basic instructions 3 Safety and Responsibility 3.1 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. 3.2 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 these operating instructions and the machine's service manual. ➤ Operate the machine only within its performance limits and under the permitted ambient condi‐ tions. 3.3 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. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 4 Design and Function 4.1 The controller 4 Design and Function 4.1 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 comprises the following components: ■ ■ Fig. 2 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, and interfaces. ─ Radio Frequency Idenfication (RFID): Identification with the KAESER 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 Input-Output-Module (IOM): Modules with digital and analog inputs and outputs with their own power supply. System structure Machine enclosure Control cabinet SIGMA CONTROL 2 Input/output module IO 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 Function The control and regulating function allows: ■ 10 Automatic changeover of the machine from LOAD to IDLE or STANDSTILL. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 4 Design and Function 4.2 Operating panel SIGMA CONTROL 2 ■ 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). 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 the SIGMA CONTROL 2. The protective function allows: ■ 4.2 Automatic machine shutdown on alarms that may lead to damage to the machine, e.g. overcur‐ rent, overpressure, overtemperature. Operating panel SIGMA CONTROL 2 Keys Fig. 3 Keys – overview Item Name Function «OFF» Switch off the machine. «ON» Switch on the machine. «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. «DOWN» Scrolls down the menu options. Reduces a parameter value. No.: 9_9450 00 USE «Right» Jumps to the right. «Left» Jumps to the left. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 11 4 Design and Function 4.2 Operating panel SIGMA CONTROL 2 Item Name Function Scrolls up the menu options. «UP» Increases a parameter value. «Events and information» Operating mode: Displays the event memory. 10 «Acknowledgement» Acknowledges alarms and warning messages. If permissible: Resets the fault counter (RESET). Tab. 23 11 «LOAD/IDLE» Toggles the compressor between LOAD and IDLE operating modes. 12 «Remote control» Switches remote control on and off. 13 «Shift clock» Switches clock control on and off. Keys Indicators Fig. 4 Indicators Item Name Function 14 Indicator field or dis‐ play Graphic display with 8 lines and 30 characters. 15 Fault Flashes red when an alarm occurs. Lights continuously when acknowledged. 16 Communication Continuous red illumination if a communication connection (Ethernet, USS, COM modules) has a fault. 17 Warning Flashes in yellow in the following events: ■ maintenance work due, ■ Warning message Lights continuously when acknowledged. 12 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 4 Design and Function 4.3 Display Item Name Function 18 Control voltage Lights green when the power supply is switched on. 19 LOAD Lights green when the compressor is running under LOAD. 20 IDLE Lights green when the compressor is running in IDLE. Flashes when the «LOAD/IDLE» toggle key is pressed. Tab. 24 21 Remote control The LED lights when the machine is in remote control. 22 Shift clock The LED lights when the machine is in clock control. 23 Machine ON Lights green when the machine switched on. Indicators RFID sensor field RFID is the abbreviation for “Radio Frequency Indentification” and enables the identification of per‐ sons or objects. Placing a suitable transponder in front of the RFID sensor field of the controller will automatically activate the communication between transponder and SIGMA CONTROL 2 . A suitable transponder is the EQUIPMENT CARD. Two of them have been provided with the ma‐ chine. Typical application: ■ Fig. 5 Users log on to the machine. (no manual input of the password required.) RFID sensor field Item Name Function 24 Tab. 25 Further information 4.3 RFID RFID sensor field for the communication with a suitable RFID transponder. RFID sensor field More information about the use of RFID technology is provided in the SIGMA CONTROL 2 operat‐ ing manual. 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. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 13 4 Design and Function 4.3 Display Pressing «Enter» or one 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. 4.3.1 Operating mode 88 psi 08:15 176 ° F ········· Current operating mode off ········· Key – off ¦ pA – off Operating parameters Run 2500 h ¦ load 2490 h Operating parameters Maintenance in: 500 h Header The header is the topmost line on the display. It is always shown as white text on a black back‐ ground. The following parameters are displayed permanently on the title bar: ■ Working pressure ■ Time ■ Airend discharge temperature Line 3: Operational state Depending on settings, either the current state of the machine or menu text is shown in line 3. Lines 5 and 6: Machine state The following parameters with their current values are displayed in lines 5 and 6: 4.3.2 ■ Remote control yes/no ■ Time control yes/no ■ Pressure control ■ The hours during which the machine was activated ■ The hours during which the machine ran in operating mode LOAD. Main menu 88 psi 14 08:15 176 ° F ········· Deutsch ········· Language ▶1 Status Submenu ▶2 Performance data Submenu (here: active line) ▶3 Operating data Submenu ▶4 Maintenance Submenu ▶5 Configuration Submenu ▶6 Compressor clock Submenu Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 4 Design and Function 4.3 Display 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. Because the access to certain menus is restricted to specific access rights, not all menus may be shown. 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 4.5.2. 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. Further information 4.3.3 For the setting of parameters see chapter 4.3.3. Setting parameters In order to set a parameter in the active line of the selected menu, you must always switch to setting mode. You move to setting mode by: pressing «Enter». The value of the parameter will flash indicating that it can be changed. 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. 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 for 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. No.: 9_9450 00 USE Check boxes for Reset Status ☒ activated Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 15 4 Design and Function 4.4 Access rights Check boxes for Reset Status ☐ deactivated Tab. 26 Reset check box status 4.3.4 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 again «Enter» to save the settings. The display line no longer flashes and the key is activated. Proceed correspondingly to deactivate a key. Tab. 27 4.4 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. Throughout this operating manual, the RFID Equipment Card will be simply called the "Equip‐ ment Card". When the controller is switched on, the lowest level of access (level 0) is activated. You have access to a further level: Level 2. In level 2, you can display and specify further parameters and, for instance, reset the system pres‐ sure or the maintenance counters. The access level will automatically return to level 0 after 10 minutes without any key being pressed. 4.4.1 Secure storage of the RFID Equipment Cards You will receive 2 RFID Equipment Cards with each machine. If both Equipment Cards are misplaced, you can register a new Equipment Card only after entering the user name and the password. A new Equipment Card may registered by an authorized KAESER service representative, subject to a fee, if the user name and the password are lost. 4.5 4.5.1 Menus – overview Operating mode After the machine is switched on, details of the software are displayed, for example, 16 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 4 Design and Function 4.5 Menus – overview Compressor Compressor PN Compressor SN Material number and serial number of the machine Compressor EN Equipment number of the machine SIGMA CONTROL 2 MCS MCS: Main Control System PN: Material number and serial number of the controller SN: Software version Software: Subsequently, the software is loaded and the current operating mode is displayed (example): 88 psi 08:15 176 ° F ········· off Current operating mode ········· Key – off ¦ pA – off Operating parameters Run 2500 h ¦ load 2490 h Operating parameters Maintenance in: 500 h The following parameters are displayed: ■ Operating mode of the machine ■ Information to the «LOAD/IDLE» keys, «Remote control» or «Timer» ■ Value for Setpoint pressure pA ■ Number of operating hours and hours of the machine being in LOAD mode The operations menu provides the most important parameters during the machine's operation. 4.5.2 Menu structure Pressing «Enter» or one the arrow keys opens the main menu. In the main menu, you can: ■ Retrieve displayed information ■ Enter customer-specific settings The menus shown require access level 2. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 17 4 Design and Function 4.5 Menus – overview Main menu Navigation Function/submenu 1 Status ■ 1.1 Messages ─ Status report ─ current Warnings current Alarms ■ 1.2 Statistics ■ 1.3 Current pressure control ■ 1.4 Current operating mode For details of the < Status > menu, see table 29 “Status menu”. 2 Performance data 3 Operating data 4 Maintenance Display of the following Performance data : ■ System pressure pNloc ■ Internal pressure pi ■ ADT ■ Oil separator ■ Starting temperature ■ Motor temperature ■ MCS Temperature ■ First IOM ......... Sixth IOM ■ Load valve ON ■ 3.1 Operating hours Compressor ─ ON LOAD ─ Motor ─ Compressor block ─ SIGMA CONTROL 2 ■ Oil filter ■ Oil separator ■ Oil change ■ Air filter ■ Valve inspection ■ Belt/coupling inspection ■ Bearing lube ■ Motor bearings ■ Fan bearing ■ Electrical equipment 5 Configuration For details of the < Configuration > menu, see table 30 “Configuration menu”. 6 Compressor clock Entering weekdays and times: ■ 18 ─ Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x Switching points 01 ......... 10 No.: 9_9450 00 USE 4 Design and Function 4.5 Menus – overview Navigation Function/submenu 7 User ■ Name Password: ■ Current access level: ■ 8.1 Ethernet ■ 8.2 Com-Module ■ Key remote 8 Communication For details of the < Communication > menu, see table 33 “Communication menu”. 9 Machine test ■ 9.1 TÜV inspection 10 Components ■ 10.1 Compressor motor ─ 10.1.1 Power switching For details of the < Components > menu, see table 35 “Components menu”. Tab. 28 Menu structure 4.5.2.1 Menu: 1 Status Navigation Function/submenu 1.1 Messages ■ 1.1.1 Current messages ■ 1.1.2 Message history 1.2 Statistics 1.3 Current pressure control No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x ─ 1.1.2.1 Compressor messages ─ 1.1.2.2 Diagnostic messages ─ 1.1.2.3 System messages ■ Load overall ■ Pressure actual value pNloc ■ Internal pressure ■ Motor starts ■ Motor starts /d ■ Motor starts /h ■ Motor starts T↓ ■ Last load run ■ Last idle run ■ Last motor OFF ■ Cut-out press. ■ Pressure actual value ■ Setpoint pressure 19 Tab. 29 4.5.2.2 Design and Function 4.5 Menus – overview Navigation Function/submenu 1.4 Current operating mode ■ Compressor ON Load control ■ Control Mode Idle period ■ Acknowledgement Menu Status Menu: 5 Configuration Navigation Function/submenu 5.1 General ■ Model ■ Time ■ Date format ■ Time format ■ Unit of pressure ■ Temperature unit 5.1.1 System information ■ ■ 5.2 Pressure control Compressor ─ Part number ─ Serial number ─ Equipment number SIGMA CONTROL 2 MCS ─ Part number ─ Serial number ─ Software ■ 5.2.1 Pressure sensors ■ 5.2.2 Pressure settings ■ 5.2.3 Load control ■ 5.2.4 Pressure actual value For details of the < Pressure control > menu, see table 31 “Pressure control menu”. 5.3 Control Mode 5.4 Compressor start 20 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x ■ Dryer ■ 5.3.1 Venting period ■ 5.3.3 DUAL ■ 5.3.4 QUADRO ■ Autostart ■ 5.4.1 Compressor ON ■ 5.4.2 Compressor OFF ■ Back pressure No.: 9_9450 00 USE 4 Design and Function 4.5 Menus – overview Navigation Function/submenu 5.5 Acknowledgement ■ Remote mode ■ Key remote ■ current ■ RC ack ■ AIR 1.00 ■ Conductor correction: ■ ADT rise dT/dt ■ 5.6.1 T-Switch ADT ■ 5.7.1 DO functions ■ 5.7.2 Quantities ■ 5.7.3 External messages 5.6 ADT 5.7 I/O periphery For details of the < I/O periphery > menu, see table 32 “I/O periphery menu”. Tab. 30 Menu Configuration Menu: 5.2 Pressure control Navigation Function/submenu 5.2.1 Pressure sensors ■ System pressure pNloc ■ AII 1.00 ■ AOI2.00 ■ Internal pressure pi ■ AII 1.01 ■ AOI2.00 ■ 5.2.1.1 p-Switch pN ■ 5.2.1.2 p-Switch pi ■ pRV ■ Pressure rise ■ Nominal pressure ■ Setpoint pressure pA ■ Setpoint pressure pB ■ System pressure low ■ Cut-in pressure min ■ local mode ■ Remote mode ■ Key remote ■ pA/pB cycle ■ pA/pB RC ■ loc.-loadRC ■ Key idle 5.2.2 Pressure settings 5.2.3 Load control No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 21 Tab. 31 Design and Function 4.5 Menus – overview Navigation Function/submenu 5.2.4 Pressure actual value ■ Pressure actual value pNloc ■ AII 1.02 ■ current pNloc Menu Pressure control Menu: 5.7 I/O periphery Navigation Function/submenu 5.7.1 DO functions ■ Controller ON ■ Compressor ON ■ Motor running ■ IDLE ■ ON LOAD ■ Group alarm ■ Group warning ■ Remote mode ■ Clock active ■ EMERGENCY STOP ■ 5.7.1.1 Clock contact ─ 5.7.2 Quantities 5.7.3 External messages Tab. 32 22 Switching points 01 ......... 10 ■ Display 1 (p), Display 2 (p) ■ Display 3 (T), Display 4 (T) ■ Display 5 (I), Display 6 (I) ■ External message 1 ......... External message 6 Menu I/O periphery Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 4.5.2.3 Design and Function 4.5 Menus – overview Menu: 8 Communication Navigation Function/submenu 8.1 Ethernet ■ ■ 8.1.1 IP configuration ─ IP address ─ Subnet mask ─ Gateway ─ DNS Server 1 ─ DNS Server 2 8.1.2 Connections ─ 8.1.2.1 SIGMA CONTROL 2 For details of the < SIGMA CONTROL 2 > menu, see table 34 “SIGMA CONTROL 2 menu”. ■ ■ 8.2 Com-Module ■ ■ Tab. 33 No.: 9_9450 00 USE 8.1.2 Connections ─ Restart ─ Timeout ─ Cycle time 8.1.3 E-mail ─ active: ─ Compressor number: ─ Sender address: ─ Sender name: ─ Contact telephone: ─ Receiver address: ─ SMTP Server: ─ User name: ─ Port ─ Interval time 8.2.1 PROFIBUS ─ Status Run ─ Start Com-Module: Slave no.: ─ Bus alarm Start td: Timeout: 8.2.2 MODBUS ─ Status Run ─ Start Com-Module: Slave no.: ─ Bus alarm Start td: Timeout: Menu Communication Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 23 4.5.2.4 Tab. 34 4.5.2.5 Tab. 35 4.6 4.6.1 Design and Function 4.6 Operating modes and control modes Menu: 8.1.2.1 SIGMA CONTROL 2 Navigation Function/submenu 8.1.2.1 SIGMA CONTROL 2 ■ Mode: ■ Port ■ Communication partner IP address Menu SIGMA CONTROL 2 Menu: 10 Components Navigation Function/submenu 10.1 Compressor motor ■ 10.1.1 Power switching ─ 10.1.1.1 Star-delta start ─ 10.1.1.2 DOL start ─ 10.1.1.3 High-voltage cell ─ 10.1.1.4 SFC USS Micromaster ─ 10.1.1.5 SFC USS Sinamics Menu Components Operating modes and control modes Operating modes The machine operates in the following modes: Option C1 24 ■ LOAD: The inlet valve is open. The airend delivers compressed air to the distribution network. The drive motor runs under full load. ■ IDLE: The inlet valve is closed. The minimum pressure/check valve shuts off the oil separator from the distribution network. 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 valve. The drive motor runs without load and draws little current. ■ STANDSTILL: The inlet valve is closed. The minimum pressure/check valve shuts off the oil separator from the distribution network. The venting valve is open. The drive motor is stopped. ■ MODULATING CONTROL: With the help of a control valve (the proportional controller) the degree of opening of the inlet valve is steplessly varied in response to the air demand. The airend delivers compressed air to the distribution network. The load and power consumption of the drive motor rises and falls with the air demand. The regulating valve is factory set. The setting should not be changed without consultation with an authorized KAESER service representative. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 4.6.2 Design and Function 4.6 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 of by consumers and maintain system pressure between the set minimum and maximum values. The control mode also rules the degree of energy efficiency of the machine. The machine-dependant venting phase between the LOAD and STANDSTILL operating modes en‐ sures load changes at minimum material stresses. The controller SIGMA CONTROL 2 can operate in the following modes: ■ DUAL ■ QUADRO ■ VARIO ■ CONTINUOUS ■ DYNAMIC Energy-efficient control modes for various applications: Tab. 36 Application Recommended control mode Compressed air station with one machine or several machines with com‐ parable delivery VARIO Machine for peak load in a compressed air station DUAL Machine for intermediate load in a compressed air station VARIO Machine for basic load in a compressed air station QUADRO Energy-efficient control modes The SIGMA CONTROL 2 is factory set to DUAL control mode unless specifically ordered other‐ wise. 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 STANDSTILL. The idling time is factory preset according to the maximum starting frequency of the drive motor. The shorter the idling time setting, the sooner (and more frequently) the drive motor is stopped. QUADRO In contrast to the DUAL regulating mode, the machine will switch from LOAD to STANDSTILL 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 STANDSTILL after passing through IDLE. In this control mode, the controller requires two specified times: The running time and the idle/ standstill time. The shorter these times are set, the sooner (and more frequently) the drive motor is stopped. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 25 4 Design and Function 4.6 Operating modes and control modes VARIO The VARIO mode is based on the DUAL control mode. The difference to DUAL is that the idling time is automatically lengthened or shortened to compensate for higher or lower machine starting frequencies. CONTINUOUS 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. The motor is not stopped, i.e. the machine does not switch to STANDSTILL. DYNAMIC In contrast to the DUAL regulating mode, the machine will switch from LOAD to STANDSTILL in DYNAMIC mode at low drive motor temperature. And from LOAD via IDLE to STANDSTILL at a high drive motor temperature. The lower the drive motor temperature, the sooner (and, therefore, more often and longer) it is stopped. 4.6.3 Frequency-controlled drive (SFC) The frequency converter compares the actual network pressure with a target value and adjusts the speed of the drive motor, and thereby the delivery of the compressor, accordingly. 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 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 idle period has elapsed, the machine switches to STANDSTILL. VARIO/QUADRO/CONTINUOUS: The minimum controllable speed is reached and, depending on the air demand at the time, the ma‐ chine switches either to IDLE or to STANDSTILL. DYNAMIC: The minimum controllable speed is reached and, depending on the air temperature of the drive mo‐ tor, the machine switches either to STANDSTILL or to IDLE. 26 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 4 Design and Function 4.7 MODULATING control If network pressure falls below the set-point: The frequency converter runs the motor up to a speed at which air delivery matches the air de‐ mand. The inlet valve opens and the machine delivers compressed air. The converter varies the speed of the drive motor according to the air demand. The power con‐ sumption of the drive motor rises and falls according to air demand. 4.7 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. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 27 5 Installation and Operating Conditions 5.1 Maintaining ambient conditions 5 Installation and Operating Conditions 5.1 Maintaining ambient conditions ➤ Follow the instructions in the machine's service manual. 5.2 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 operating manual for required conditions. 28 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 6 Installation 6.1 Reporting Transport Damage 6 Installation 6.1 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. 6.2 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. 37 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. 38 Remote control identification Identifying the machine for clock control mode operation ➤ Attach the following notice to warn of remote machine operation (suggestion): Clock control: danger of unexpected starting! ➤ Make sure the power supply disconnecting device is switched off before commencing any work on the machine. Tab. 39 No.: 9_9450 00 USE Machine identification Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 29 7 Initial Start-up 7.1 Outline 7 Initial Start-up 7.1 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. 7.2: Configuring the controller (display format, units, languages, etc.) 7.3: Matching the pressure parameters of the machine and possible modules 7.4: Configuring machine start and stop 7.5: Activating and setting up the control modes 7.6: Configuring the machine for local mode 7.7: Configuring the machine for master control 7.8: Configuring e-mail 7.9: Configuring input and output signals 7.10: Configuring the compressed air outlet temperature 7.11: Activating remote acknowledgement 7.12: Linking to an external pressure transducer 7.13: Activating the energy-saving mode for the refrigeration dryer 7.14: Machine commissioning 7.2 Configuring the controller All controller settings are explained in detail in the following sections. The most common set‐ tings are summarized for experienced users in the front of this manual. ➤ Carry out settings as required: 7.2.1 ■ 7.2.1: Selecting menu options (introduction) ■ 7.2.2: Changing the display language ■ 7.2.4: Entering and displaying passwords ■ 7.2.5: Creating additional user names ■ 7.2.6: Setting up time and date ■ 7.2.7: Setting display formats (date, time, units of pressure and temperature) ■ 7.2.8: Activating summer/winter time ■ 7.3.3: Activating/deactivating the «IDLE» key Selecting menu options All menu options can be selected with the «DOWN», «UP» and «Enter» keys. Example: Selecting the < Configuration ➙ General > menu option Precondition 30 The display shows the operating mode. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7 Initial Start-up 7.2 Configuring the controller 1. Press «Enter». The main menu is displayed. 2. Press the «UP» or «DOWN» key until Configuration is displayed as active line. 3. In order to open the < Configuration > menu, press «Enter» once. 4. Use the «DOWN» or «UP» keys to select a submenu in the < Configuration > menu, < General > or < Pressure control > for instance. 5. Press «UP» repeatedly until General is displayed as active line. 6. Press «Enter». The current menu is the < General > submenu in the < Configuration > menu. 7. Use the «DOWN» or «UP» keys to select a menu option in the < General > submenu, < System information > for instance. 7.2.2 Changing the display language The controller can display text messages in the following languages: Tab. 40 Bulgarian English (USA) Indonesian Norwegian Slovenian Chinese Estonian Italian Polish Spanish Chinese (Taiwan) Finnish Japanese Portuguese Spanish (South-America) Danish French Korean Romanian Czech German French (Canada) Croatian Russian Turkish English Greek Dutch Swedish ... Language diversity Some of the units, as well as clock and date format, will be adjusted according to the language selected. Precondition The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Press «UP» repeatedly until the specified language is displayed as active line. 3. Use the «Enter» key to switch to setting mode. The currently set language flashes. 4. Use the «DOWN» or «UP» keys to select the desired language. 5. Press «Enter» to accept the setting. 6. Press «Escape» repeatedly to return to the main menu. The display texts are now in the selected language. 7.2.3 Access rights with equipment card Use the Equipment Card to quickly and easily check the advanced access rights to the SIGMA CONTROL 2. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 31 7 Initial Start-up 7.2 Configuring the controller Advanced access rights: ■ read additional data ■ change other settings 1. Hold the Equipment Card in front of the controller's reader. (see also chapter 4.2) Your user name and access level will be displayed. 2. Press «Enter» to confirm the access right. The Equipment Card is damaged or lost. ➤ Manually enter the user name and password (see also the following chapter). 7.2.4 Access right via manual input Entering the user name Precondition The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Use «DOWN» to select the menu option. The Name line is displayed as being active. 88 psi 08:15 176 ° F 7 User Menu Name : Citizen4 Active line Password: : **************** Login ········· Current access level: 0 Display access level 0 3. Press «Enter» to switch into setting mode. A column with alphanumeric characters is displayed. 4. Repeatedly press «DOWN» or «UP» until the requested character is displayed. 5. Press the «Right» key. The cursor jumps to the next position. 6. Complete the remaining characters of the name. 7. Press the «Right» key. 8. Press «Enter» to accept the settings. Result The user name is entered in full. Enter current password Precondition The user name has been entered. 1. Press «DOWN» once. The Password line is displayed as being active. 32 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7 Initial Start-up 7.2 Configuring the controller 2. Press «Enter» to switch into setting mode. A column with alphanumeric characters is displayed. 88 psi 08:15 176 ° F Menu 7 User Name : Citizen4 Active line Password: : **************** Login ········· Display access level 0 Current access level: 0 3. Repeatedly press «DOWN» or «UP» until the requested character is displayed. 4. Press the «Right» key. The cursor jumps to the next position. 5. Complete the remaining characters of the password. 6. Press the «Right» key. 7. Press «Enter» to accept the settings. Result The password is entered in full. Logging on Precondition User name and Password are entered. 1. Press «DOWN» once. The Login line is displayed as being active. 2. Press «Enter» to complete the login process. The Login text in the active line switches to Logout. Your current access level is shown as 2 . 88 psi 08:15 176 ° F Menu 7 User Name : Citizen4 Password: : **************** [Logout] Active line ········· Current access level: 2 Display access level 2 3. Press «Escape» repeatedly to return to the main menu. Result 7.2.5 You are logged in with a higher access level. Creating additional user names In order to change passwords or to create new users, you require a PC application (remote HMI). Use the Equipment Card to quickly and easily check the advanced access rights to the SIGMA CONTROL 2. ➤ Preferably use the Equipment Card. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 33 7.2.6 Precondition Initial Start-up 7.2 Configuring the controller Checking/setting time and date Password level 2 is activated. The display shows the operating mode. Checking and setting time ➤ When operating the machine with a timer program, check the time settings at least once a year. 1. Press «Enter». The main menu is displayed. 2. Select the menu < Configuration ➙ General >. 3. Press the «DOWN» key repeatedly until the current time is displayed as active line. 88 psi 08:15 176 ° F Menu 5.1 General ········· Time 06:05:10 08:15:37 Current time ········· 4. Press the «Right» key. 5. Press «Enter» to switch into setting mode. The hours display flashes. 00 : 00 : 00. 6. Use «UP» or «DOWN» to change the hour setting. 7. Press the «Right» key. The minutes display flashes. 00 : 00 : 00. 8. Use «UP» or «DOWN» to change the minute setting. 9. Press the «Right» key. The seconds display flashes. 00 : 00 : 00 . 10. Use «UP» or «DOWN» to change the second setting. 11. Press «Enter» to save the settings. 12. Press «Escape» repeatedly to return to the main menu. Checking/setting the date Precondition 34 Password level 2 is activated, the < Configuration ➙ General > menu is selected (see 7.2.1). Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7 Initial Start-up 7.2 Configuring the controller 1. Press the «DOWN» key repeatedly until the current date is displayed as active line. 88 psi 08:15 176 ° F Menu 5.1 General ········· Time 06:05:10 08:15:37 Current date ········· 2. Press «Enter» to switch into setting mode. The day display flashes. 00 : 00 : 00. 3. Use «UP» or «DOWN» to change the day setting. 4. Press the «Right» key. The month display flashes. 00 : 00 : 00. 5. Use «UP» or «DOWN» to change the month setting. 6. Press the «Right» key. The year display flashes. 00 : 00 : 00 . 7. Use «UP» or «DOWN» to change the year setting. 8. Press «Enter» to save the settings. 9. Press «Escape» repeatedly to return to the main menu. 7.2.7 Setting display formats When setting the language, several display formats will automatically adjust to local usage. Setting the date format Select your preferred format. Tab. 41 Precondition No.: 9_9450 00 USE Format Example: DD.MM.YY 30.07.10 YY-MM-DD 10–07–30 MM/DD/YY 07/30/10 Date format Password level 2 is activated, menu < Configuration ➙ General > is selected (see 7.2.1). Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 35 7 Initial Start-up 7.2 Configuring the controller 1. Press the «DOWN» key repeatedly until Date format is displayed as active line. 88 psi 08:15 176 ° F Menu 5.1 General ········· Current date format Date format DD.MM.YY Time format hh:mm:ss ········· 2. Press «Enter» to switch into setting mode. DD.MM.YY flashes. 3. Change the format with the «DOWN» or «UP» keys. 4. Press «Enter» to save the setting. 5. Press «Escape» repeatedly to return to the main menu. Setting the time format Select your preferred format for the time display: Tab. 42 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 level 2 is activated, menu < Configuration> General > is selected (see 7.2.1). 1. Press the «DOWN» key repeatedly until Time format is displayed as active line. 88 psi 08:15 176 ° F 5.1 General Menu ········· Date format DD.MM.YY Time format hh:mm:ss Current Time format ········· 2. Press «Enter» to switch into setting mode. hh:mm:ss flashes. 3. Change the format with the «DOWN» or «UP» keys. 4. Press «Enter» to save the setting. 5. Press «Escape» repeatedly to return to the main menu. 36 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7 Initial Start-up 7.2 Configuring the controller Setting the pressure display units Select your preferred display of the pressure unit: Tab. 43 Precondition Format Example: bar 5.5 bar hPa 5523 hPa MPa 0.55 MPa psi 80 psi at 5.6 at "Hg 162.9 "Hg Units of pressure Password level 2 is activated, menu < Configuration> General > is selected (see 7.2.1). 1. Press the «DOWN» key repeatedly until Unit of pressure is displayed as active line. 88 psi 08:15 176 ° F 5.1 General Menu ········· Unit of pressure bar Current Unit of pressure Temperature unit °C ········· 2. Press «Enter» to switch into setting mode. The bar parameter flashes. 3. Change the unit with the «DOWN» or «UP» keys. 4. Press «Enter» to save the setting. 5. Press «Escape» repeatedly to return to the main menu. Setting the temperature display units Select your preferred display of the temperature unit: Tab. 44 Precondition No.: 9_9450 00 USE Format Example: °C 46 °C 319 K °F 114 °F Units of temperature Password level 2 is activated, menu < Configuration ➙ General > is selected (see 7.2.1). Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 37 7 Initial Start-up 7.3 Pressure parameters of the machine 1. Press the «DOWN» key repeatedly until Temperature unit is displayed as active line. 88 psi 08:15 176 ° F 5.1 General Menu ········· Unit of pressure bar Temperature unit °C Current Temperature unit ········· 2. Press «Enter» to switch into setting mode. The °C parameter flashes. 3. Change the unit with the «DOWN» or «UP» keys. 4. Press «Enter» to save the setting. 5. Press «Escape» repeatedly to return to the main menu. 7.2.8 Setting and activating summer/winter time The functions for summer/winter time are not yet implemented. ➤ Ignore any corresponding references to chapter 7.2.8 in this manual. 7.3 Pressure parameters of the machine This chapter contains information on the display and configuration of all the machine pressure pa‐ rameters and is divided into the following sections: ■ 7.3.1: Displaying pressure parameters ■ 7.3.2: Configuring the pressure parameters "Display:" means that the parameter will only be shown. "Setting:" means that the parameter can also be changed. Parameter Explanation pRV Display: Activating pressure of the safety relief valve on the oil separator tank pE Pressure increase Setting: 38 ■ pE SP: Switching point pE; upper safety limit for machine maximum pressure; in an external LOAD control, this value is used to switch the machine from LOAD to IDLE. ■ pE SD: Switching differential pE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7 Initial Start-up 7.3 Pressure parameters of the machine Parameter Explanation dpFC Limiting value for machines with frequency-controlled drive (SFC). Setting: ■ dpFC Limit for minimum delivery. If this value is exceeded [Setpoint pressure switching point + dpFC], the compressor switches from LOAD to IDLE. Nominal pressure Display: Setpoint pressure The Setpoint pressure can be regulated to two different values: pA and pB The compressor is designed for this pressure (maximum system pressure setpoint) Setting: ■ Switching point pA or control pressure pA in machines with frequency converter (SFC) ■ Switching point pB or control pressure pB in machines with frequency converter (SFC) System A warning message can be displayed when the limiting value System pressure low pressure low is reached. Setting: ■ BeSD: Switching differential System pressure low, SP: Switching point System pressure low ■ Optional warning message: no message, Warning message displayed or an additional output signal is sent, e.g., to a control centre Cut-in Display: pressure min For design reasons, pressure can only be built up above this value. Tab. 45 Compressor pressure parameters ➤ Parameters correspond to the following specifications 7.3.1 Precondition Displaying pressure parameters Password level 2 is activated. The < Configuration ➙ Pressure control > menu is selected. Opening the menu for pressure parameters 1. Press «DOWN» or «UP» repeatedly until Pressure settings is displayed as active line. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 39 7 Initial Start-up 7.3 Pressure parameters of the machine 2. Press «Enter». The system displays the pressure parameters. 88 psi 08:15 176 ° F 5.2.2 Pressure settings Menu pA SP: 116 psi ¦ SD: - 7 psi Active line pB SP: 110 psi ¦ SD: - 6 psi ········· System pressure low ☐ ↓ < 73 psi ¦ SD: 7 psi ta: 600 s ¦ DOR 1.04 ☐ Displaying compressor parameters 1. Press «DOWN» repeatedly until Setpoint pressure is displayed. 88 psi 08:15 176 ° F 5.2.2 Pressure settings Menu ········· Setpoint pressure Active line pA SP: 116 psi ¦ SD: - 7 psi current Setpoint pressure pA and switching differen‐ tial current Setpoint pressure pB and switching differen‐ tial pB SP: 110 psi ¦ SD: - 6 psi ········· System pressure low ☐ 2. Display further parameters with «UP» and «DOWN». 7.3.2 Configuring the pressure parameters for compressors 7.3.2.1 Adjusting system set-point pressure pA and pB The pressure parameters can only be set within certain limits: Rated machine pressure ≥ SP: pA /pB ≥ minimum cut-in pressure* + switching differential Tab. 46 Setting limits for system set-point pressure (* Cut-in pressure min) The machine switches to LOAD under the following condition: System pressure ≤ SP: pA /pB - switching differential Tab. 47 Pressure condition for LOAD The machine switches to IDLE under the following condition: System pressure = Setpoint pressure Tab. 48 Precondition Pressure condition for IDLE Password level 2 is activated. 1. Select < Configuration ➙ Pressure control ➙ Pressure settings > (see Section 7.3.1) 40 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7 Initial Start-up 7.3 Pressure parameters of the machine 2. Press «UP» or «DOWN» repeatedly until the following is displayed as active line: 88 psi 08:15 176 ° F Menu 5.2.2 Pressure settings ········· Setpoint pressure Active line with current value for Setpoint pressure pA pA SP: 116 psi ¦ SD: - 7 psi pB SP: 110psi ¦ SD: - 6 psi ········· System pressure low ☐ 3. Press «Enter» to switch into setting mode. The 116 psi parameter flashes. 4. Use «UP» or «DOWN» to adjust Setpoint pressure pA. 5. Press «Enter» to accept the setting. 6. Adjust the switching differential in the same way. 7. Adjust the Setpoint pressure pB and the switching differential in the same way, if necessary. 8. Press «Escape» repeatedly to return to the main menu. Result The settings for Setpoint pressure pA and pB are adjusted. 7.3.2.2 Adjusting the value for "System pressure low" If the system pressure falls to the "System pressure low" value, SIGMA CONTROL 2 will display a warning message for the system pressure being too low. The switching differential influences the pressure at which the message can be acknowledged or the optionally activated output will again switch: Message Output 73 psi Message coming active 80 psi Message going Tab. 49 Precondition inactive Example: Activated output Password level 2 is activated. 1. Select < Configuration ➙ Pressure control ➙ Pressure settings > (see Section 7.3.1) 2. Press the «DOWN» key repeatedly until the following is displayed as active line: 88 psi 08:15 176 ° F Menu 5.2.2 Pressure settings ········· System pressure low ☐ ↓ < 73 psi ¦ SD: 7 psi Current value System pressure low ¦ current switch‐ ing differential ta: 600 s ¦ DOR 1.04 ☐ ········· Cut-in pressure min 73 psi No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 41 7 Initial Start-up 7.3 Pressure parameters of the machine 3. Press «Enter» to switch into setting mode. The 73 psi parameter flashes. 4. Use «UP» or «DOWN» to adjust the setting. 5. Press «Enter» to accept the setting. 6. Adjust the switching differential if necessary in the same way. 7. Press «Escape» repeatedly to return to the main menu. 7.3.2.3 Adjusting pressure rise pE The value for pressure rise pE serves as a safety limit value when the machine is externally con‐ trolled. When the system set pressure reaches the value pE (for example, when the external con‐ trol functions incorrectly) the machine switches to IDLE. The warning message External load signal? is triggered. Precondition Password level 2 is activated. 1. Select < Configuration ➙ Pressure control ➙ Pressure settings > (see Section 7.3.1) 2. Press the «DOWN» key repeatedly until the following is displayed as active line: 88 psi 08:15 176 ° F 5.2.2 Pressure settings Menu pRV 232 psi ········· Pressure rise pE SP: 122 psi ¦ SD: - 7 psi Active line with current switching point Pressure rise ¦ current switching differential dpFC : 3 psi ········· 3. Press «Enter» to switch into setting mode. The 122 psi parameter flashes. 4. Use «UP» or «DOWN» to adjust the setting. 5. Press «Enter» to accept the setting. 6. Adjust the switching differential if necessary in the same way. 7. Press «Escape» repeatedly to return to the main menu. 7.3.2.4 Adjusting pressure rise in frequency-controlled machines (SFC) The pressure rise value dpFC is the limit from which the machine switches to IDLE. This value can be between 3 psi and 6 psi. The factory setting is 3 psi. The pressure rise is added to the set-point pressure. In this way, the set-point pressure can be changed without having to adjust the parameter again. Precondition 42 Password level 2 is activated. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE Fig. 6 Initial Start-up 7.3 Pressure parameters of the machine Pressure rise in frequency-controlled machines System pressure IDLE switching point: Setpoint pressure + dpFC Setpoint pressure pA or pB LOAD switching point: (Setpoint pressure + dpFC) - switching dif‐ ferential Pressure rise dpFC System pressure band width 1. Select < Configuration ➙ Pressure control ➙ Pressure settings > (see Section 7.3.1) 2. Press «DOWN» repeatedly until the following is displayed: 88 psi 08:15 176 ° F 5.2.2 Pressure settings Menu Pressure rise pE SP: 122 psi ¦ SD: - 7 psi Pressure increase dpFC : 3 psi Active line with pressure increase value dpFC ········· Nominal pressure 116 psi ········· 3. Press «Enter» to switch into setting mode. 4. Use «UP» or «DOWN» to adjust the setting. 5. Press «Enter» to accept the setting. 6. Press «Escape» repeatedly to return to the main menu. 7.3.3 Activating/deactivating the «IDLE» key In order to prevent unauthorized users from switching the machine to IDLE, you can deactivate the «IDLE» key on the operating panel. Precondition Password level 2 is activated, The < Configuration ➙ Pressure control ➙ Load control > menu is selected (see Section 7.2.1). 1. Press «UP» or «DOWN» repeatedly until «IDLE» key is displayed as active line. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 43 7 Initial Start-up 7.4 Configuring machine start and stop 2. Press «Enter» to switch into setting mode. The check box for «IDLE» key will flash. 88 psi 08:15 176 ° F Menu 5.2.3 Load control pA/pB DO DOR1.04 ☐ ········· load RC Tue1.13 ok ☑ loc.-loadRC Tue1.09 ☑ ········· Active line with check box Key idle : ☑ 3. Press «UP». The deactivated check box is displayed. 4. Press «Enter» to save the setting. The «IDLE» key is de-activated. 88 psi 08:15 176 ° F 5.2.3 Load control Menu pA/pB DO DOR1.04 ☐ ········· load RC Tue1.13 ok ☑ loc.-loadRC Tue1.09 ☑ ········· Key idle : ☐ Active line with deactivated check box 5. Press «Escape» repeatedly to return to the main menu. Result 7.4 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 Automatic start/stop in programmed clock mode No clock (time) program entered 7.4.1 Holidays Not set 7.4.2 Remote start, e.g. from a control center Deactivated 7.4.3 IDLE (venting) Activated 7.4.4 Automatic restart after power failure (after delay period). Activated 7.4.5 Tab. 50 Settings for machine start and stop. 7.4.1 Automatic start/stop in programmed clock mode See Overview ■ 44 If not activated, enter password for level 2. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7.4.1.1 Precondition Initial Start-up 7.4 Configuring machine start and stop ■ Select < Compressor clock >. ■ set/adjust the time program. ■ Activate the «clock» key. Selecting the Compressor clock menu Password level 2 is activated. The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Select < Compressor clock >. The display for setting the Compressor clock timing program appears. 88 psi 08:15 176 ° F 6 Compressor clock Menu Key clock : ☐ The Compressor clock key is activated Reset: ☐ All current switching points are reset ········· Active line 01 n.a. 00:00 off 02 n.a. 00:00 off 03 n.a. 00:00 off 7.4.1.2 Setting the clock program (example) When setting a clock program for the first time, note the switching times on a sheet of paper first. In addition to individual week days, the controller has the following cycles: ■ Mon-Thu ■ Mon-Fri ■ Mon-Sat ■ Mon-Sun ■ Sat-Thu You can also program an OFF time (Shutdown periods) (see Section 7.4.2). Example: ■ Machine ON: Weekdays 6:30 – 17:00, Fridays 6:30 – 15:00. ■ Machine OFF: Sat – Sun and during midday break from 12:00 – 13:00. The following switching points result: No.: 9_9450 00 USE No. Day Time Function Mon-Fri 06:30 ON Mon-Fri 12:00 OFF Mon-Fri 13:00 ON Mon-Thu 17:00 OFF Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 45 Tab. 51 Precondition Initial Start-up 7.4 Configuring machine start and stop No. Day Time Function Fri 15:00 OFF Example of a machine ON/OFF clock program Password level 2 is activated, the «clock» key is activated, the "clock" menu is selected. 1. Press «DOWN» repeatedly until the 01 switching point is displayed as active line. 88 psi 08:15 176 ° F Menu 6 Compressor clock ········· 01 n.a. 00:00 off Active line with 01 switching point 02 n.a. 00:00 off Switching point 02 03 n.a. 00:00 off Switching point 03 04 n.a. 00:00 off Switching point 04 05 n.a. 00:00 off Switching point 05 2. Press «Enter» to switch into setting mode. The n.a. column flashes in the active line. 3. Use «UP» to specify the settings for the weekdays. 4. Press «Enter» to accept the setting. 5. Press the «Right» key once. 6. Press «Enter» to switch into setting mode. Time column, hours display, 00 : 00 flashes in the active line. 7. Use «UP» to specify the settings for the hours. 8. Press the «Right» key once. 9. Time column, minutes display, 00 : 00 flashes in the active line. 10. Use «UP» to specify the settings for the minutes. 11. Press «Enter» to accept the settings. The display stops flashing and the time (hours/minutes) is set. 88 psi 08:15 176 ° F 6 Compressor clock Menu ········· 01 Mon-Fri 06:30 on Switching point 01 is set 02 Mon-Fri 12:00 off Switching point 02 is set 03 Mon-Fri 13:00 on Switching point 03 is set 04 Mon-Thu 17:00 off Switching point 04 is set 05 Fri 15:00 off Switching point 05 is set 12. Press the «Right» key once. The Action off / on column flashes. 13. Press «Enter» to switch into setting mode. 14. Use «UP» to specify the settings for the Compressor ON action. 46 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7 Initial Start-up 7.4 Configuring machine start and stop 15. Press «Enter» to accept the setting. The Compressor ON action is set for the first switching point. 16. Specify further switching points in the same manner. Result Weekdays, time and the Compressor ON / Compressor OFF actions are set for all switching points. 7.4.1.3 Activating the«compressor clock» key 1. Press the «UP» repeatedly until Key clock is displayed as active line. 2. Press «Enter» to switch into setting mode. The check box flashes in the active line. 88 psi 08:15 176 ° F 6 Compressor clock Menu Key clock : ☑ Active line with deactivated check box Reset: ☐ ········· 01 Mon-Fri 06:30 on Switching point 01 02 Mon-Fri 12:00 off Switching point 02 03 Mon-Fri 13:00 on Switching point 03 3. Activate the check box with «UP» and press «Enter». 4. Press «Escape» repeatedly to return to the main menu. The «clock» key is activated and can be used. 5. Press «clock» to enable the operation with a timing program. 7.4.2 Setting up the holiday period The functions for company shutdown are not yet implemented. ➤ Ignore any corresponding references to chapter 7.4.2 in this manual. 7.4.3 Starting the machine remotely from a control center (remote ON/OFF or re‐ mote control function) If the machine is to be started and stopped from a remote control center then the following settings have to be made: Overview No.: 9_9450 00 USE ■ Make the electrical connection (a spare input for the remote contact is shown in the electrical wiring diagram for the machine, preferably DI 1.12). ■ Switch machine start to remote mode. ■ Activate the «remote control» key. ■ If required, activate the «clock» key and configure the clock program (see Section 7.4.1.2) ■ If required, assign the remote contact to another input. ■ Press the «remote control» key. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 47 7.4.3.1 Initial Start-up 7.4 Configuring machine start and stop Switching the machine start to Remote mode Two methods are available to start the machine remotely from a control center: Precondition ■ Method A: Starting the machine with the input signal from the remote control center. ■ Method 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 clock is activated and the actual program sequence is OFF at this point in time. The electrical connection has been made. Password level 2 is activated. The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Select the < Configuration ➙ Compressor start ➙ Compressor ON > menu. 3. Press the «UP» repeatedly until Remote mode is displayed as active line. 4. Press «Enter» to switch into setting mode. Key flashes. 88 psi 08:15 176 ° F Menu 5.4.1 Compressor ON local mode : Key Active line Remote mode : Key ········· current Key ········· RC DI 1.12 ok ☑ 5. Press «DOWN» repeatedly until Key+RC is displayed. 6. Press «Enter» to accept the setting. 88 psi 08:15 176 ° F 5.4.1 Compressor ON Menu local mode : Key Remote mode : Key+RC Active line with Key+RC ········· current Key ········· RC DI 1.12 ok ☑ Result The machine start is set to Remote mode with Key+RC. 7.4.3.2 Activating/deactivating the «remote control» key Precondition The electrical connection has been made. Password level 2 is activated. The display shows the operating mode. 48 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7 Initial Start-up 7.4 Configuring machine start and stop 1. Press «Enter». The main menu is displayed. 2. Select the < Configuration ➙ Compressor start ➙ Compressor ON > menu. 3. Press «DOWN» repeatedly until Key remote is displayed as active line. 4. Press «Enter» to switch into setting mode. The check box for Key remote will flash. 88 psi 08:15 176 ° F Menu 5.4.1 Compressor ON ········· current Key ········· RC DI 1.12 ok ☑ Active line with check box Key remote : ☐ Key clock : ☐ 5. Press «UP». The activated check box is displayed. 6. Confirm the setting with «Enter». 88 psi 08:15 176 ° F 5.4.1 Compressor ON Menu ········· current Key ········· RC DI 1.12 ok ☑ Key remote : ☑ Active line with deactivated check box Key clock : ☐ The clock key is not activated. 7. Press «Escape» repeatedly to return to the main menu. The «remote control» key is activated and can be used. 8. If method B with the clock program is selected, the «clock» key must be activated in the same manner. 7.4.3.3 Assigning another input Inputs already assigned cannot be further assigned. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 49 7 Initial Start-up 7.4 Configuring machine start and stop 1. Press the «DOWN» key repeatedly until the following is displayed as active line: 88 psi 08:15 176 ° F 5.4.1 Compressor ON Menu ········· Remote contact DI 1.12 (default) current Key ········· Active line RC DI 1.12 ok ☑ Key remote : ☑ Key clock : ☐ 2. Press «Enter». An inverse cursor appears. 3. Use the «UP» or «DOWN» keys to select another input and confirm with «Enter». The input has now been assigned. 4. Press the «Remote» 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. 7.4.4 Activating/deactivating the idle phase (Venting period function) After receiving the OFF signal from the remote control center, an additional idling (Venting period function) phase can be activated before the machine is stopped completely. The duration of the idling phase can be timed and/or regulated by internal pressure. Precondition Password level 2 is activated. The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Select the < Configuration ➙ Compressor start ➙ Compressor OFF > menu. The "Venting period" function is displayed in the active line. 3. Press «Enter» to switch into setting mode. The check box for the "Venting period" function will flash. 88 psi 08:15 176 ° F 5.4.2 Compressor OFF Menu Venting period : ☐ Current setting " Venting period " is deactivated 4. Press «UP». The check box for the "Venting period" function is activated. 50 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7 Initial Start-up 7.4 Configuring machine start and stop 5. Press «Enter» to save the setting. The function can be deactivated in the same manner. Result 7.4.5 The "Venting period" function is activated. Activating/deactivating and adjusting the "automatic restart after a power fail‐ ure" function 'Autostart' is activated as standard. To avoid overloading the main power supply through several machines starting simultaneously a delay period determining the restart of each machine can be entered. Overview Precondition ■ If not activated, enter password for level 2 ■ Select the < Configuration ➙ Compressor start > menu. ■ Activate/deactivate the restart function or set the restart delay. Password level 2 is activated. The < Configuration ➙ Compressor start > menu option is selected. 1. Press «Enter». The Compressor start menu is displayed. 88 psi 08:15 176 ° F 5.4 Compressor start Menu ▶1 Compressor ON Active line ▶2 Compressor OFF ········· Automatic restart activated. Autostart : ☑ Target 10 s ¦ Actual 0 s ········· Deactivating/activating automatic restart 1. Press «DOWN» repeatedly until Autostart is displayed as active line. 88 psi 08:15 176 ° F 5.4 Compressor start Menu ▶1 Compressor ON ▶2 Compressor OFF ········· Autostart : ☐ Automatic restart is deactivated Target 10 s ¦ Actual 0 s Set/expiring delay period ········· No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 51 7 Initial Start-up 7.4 Configuring machine start and stop 2. Press «Enter» to switch into setting mode. The check box for the "Autostart" function will flash. 3. Press «UP». The check box for the "Autostart" function is activated. 4. Press «Enter» to accept the setting. Activate the “Autostart” function in the same manner. 5. Press «Escape» repeatedly to return to the main menu. Result Automatic restart after a power failure is now deactivated. Setting up the automatic restart delay period If you operate several machines, it is better to start them in sequence. Time for restart: Use the set times (IDLE to LOAD) of the other machines as base. Precondition Password level 2 is activated. The < Compressor start > menu is selected. 1. Press «DOWN» repeatedly until the delay time for the restart is displayed as active line. 88 psi 08:15 176 ° F Menu 5.4 Compressor start ▶1 Compressor ON ▶2 Compressor OFF ········· Autostart : ☑ automatic restart is activated Target 10 s ¦ Actual 0 s Set/expiring delay period ········· 2. Press «Enter» to switch into setting mode. Target flashes. 3. Change the time using the «DOWN» or «UP» keys. 88 psi 08:15 176 ° F 5.4 Compressor start Menu ▶1 Compressor ON ▶2 Compressor OFF ········· Autostart : ☑ Target 12 s ¦ Actual 0 s Active line ········· 4. Press «Enter» to accept the setting. 5. Press «Escape» repeatedly to return to the main menu. Result 52 You have adjusted the delay tome for the restart after a mains failure from 10 s to 12 s. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7.5 Initial Start-up 7.5 Activating and setting up the control modes Activating and setting up the control modes The controller is provided with various control modes that can bring about different capacity utiliza‐ tion depending on machine application. Chapter 4.6 provides a comprehensive description of all control modes. 7.5.1 Selecting a control mode The following control modes are possible: ■ DUAL ■ QUADRO ■ VARIO ■ DYNAMIC ■ CONTINUOUS The standard setting of Control Mode depends on the machine type. Precondition Password level 2 is activated. The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Select the < Configuration ➙ Control Mode > menu. 3. Press «UP» repeatedly until local mode is displayed as active line. The Control Mode setting is shown in the active line. 88 psi 08:15 176 ° F 5.3 Control Mode Menu local mode : DUAL Active line ········· Current Control Mode current DUAL ········· Menu Venting period ▶1 Venting period ········· 4. Press «Enter» to switch into setting mode. DUAL flashes. 88 psi 08:15 176 ° F 5.3 Control Mode Menu local mode : QUADRO Active line ········· current QUADRO Changed current Control Mode ········· ▶1 Venting period Menu Venting period ········· 5. Use «UP» to adjust Control Mode to the QUADRO setting. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 53 7 Initial Start-up 7.5 Activating and setting up the control modes 6. Press «Enter» to accept the setting. The new Control Mode QUADRO is shown in the current line. 7. Press «Escape» repeatedly to return to the main menu. 7.5.2 Adjusting Idle period of Control Mode DUAL When the Idle period period has elapsed, the machine comes to a STANDSTILL. The shorter the period, the more often the machine will switch from IDLE to STANDSTILL. SIGMA CONTROL 2 will take into account the maximum motor switching capacity. Depending on the machine type, the machine may not fall below a minimum Idle period or standstill time. Precondition Password level 2 is activated. DUAL control mode is selected. The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Select the < Configuration ➙ Control Mode ➙ DUAL > menu. (see section 7.5.1) The Idle period setting is shown in the active line. 88 psi 08:15 176 ° F Menu 5.3.3 DUAL Idle period Active line Target 240 s ¦ Actual 0 s 3. Press «Enter» to switch into setting mode. The current Idle period 240 s flashes. 88 psi 08:15 176 ° F 5.3.3 DUAL Menu Idle period Target 300 s ¦ Actual 0 s Active line with changed Idle period , (example: 300 seconds) 4. Use «UP» to change to the desired Idle period. 5. Press «Enter» to accept the setting. 6. Press «Escape» repeatedly to return to the main menu. 54 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7.5.3 Initial Start-up 7.6 Configuring the machine for local mode Adjusting the unloaded and minimum running period in Control Mode QUADRO When the Min. run period has elapsed, the machine switches from IDLE to STANDSTILL. Depend‐ ing on the setting for Unloaded period, the machine switches from LOAD to IDLE or directly to STANDSTILL. Precondition Password level 2 is activated. QUADRO control mode is selected. The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Select the < Configuration ➙ Control Mode ➙ QUADRO > menu. 3. Press «DOWN» repeatedly until Target is displayed as active line. 88 psi 08:15 176 ° F Menu 5.3.4 QUADRO Min. run period Active line set-point value for Min. run period Target 240 s ¦ Actual 0 s ········· Unloaded period Target 240 s ¦ Actual 100 s 4. Press «Enter» to switch into setting mode. The set-point value 240 s flashes. 88 psi 08:15 176 ° F 5.3.4 QUADRO Menu Min. run period Target 260 s ¦ Actual 0 s Active line with changed set-point value for Min. run period ········· Unloaded period Target 260 s ¦ Actual 100 s Changed set-point value for Unloaded period 5. Use «UP» to change the Min. run period. 6. Press «Enter» to accept the setting. 7. Change the Unloaded period accordingly. 8. Press «Escape» repeatedly to return to the main menu. Further information 7.6 See chapter 4.6 for an overview of the control modes. Configuring the machine for local mode In local mode the machine is regulated with the Setpoint pressure pA or pB. The controller is pro‐ vided with the following modes of operation: No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 55 Tab. 52 Initial Start-up 7.6 Configuring the machine for local mode Operating mode Description See section pA The machine is controlled by Setpoint pressure pA 7.6.3.3 pB The machine is controlled by Setpoint pressure pB pA/pB clock The changeover between pA and pB is regulated by a timer pro‐ gram. pA/pB cycle The changeover between pA and pB is regulated by a programmed 7.6.3 time pulse. 7.6.2 Local operating mode (local mode) ➤ Adapting the Setpoint pressure as described in Section 7.3. Overview 7.6.1 Precondition ■ If not activated, enter password for level 2 ■ Select < Configuration >. ■ Set/adjust the clock program (see Section 7.6.2) or Timer (see Section 7.6.3). ■ Local mode Selecting Password level 2 is activated. 1. In operating mode, switch to the main menu with the «Enter» key. 2. Select < Configuration ➙ Pressure control ➙ Load control >. The < Load control > menu is displayed. 7.6.2 Configuring the system pressure set-point changeover using the timer pro‐ gram Note the configuration sequence: ➤ First, determine the timer program. ➤ Then select the operating mode. Overview ■ If not activated, enter password for level 2 ■ Set the day of the week for the first switching point (delete any existing timer program). ■ Enter Time for the first switching point. ■ Select Setpoint pressure for the first switching point pA or pB ■ Specify any further switching points. ■ Select Operating mode pA/pB clock, see Section 7.6.3.3. When setting a timer program for the first time, note the switching times on a sheet of paper first. In addition to individual week days, the controller has the following cycles: 56 ■ Mon-Thu ■ Mon-Fri Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7 Initial Start-up 7.6 Configuring the machine for local mode ■ Mon-Sat ■ Mon-Sun ■ Sat-Thu Example: ■ Peak load period: weekdays 06:30 – 17:00, Fridays 06:30 – 16:00; ■ Low load period: midday from 12:00 – 13:00 and the remaining period. The clock program is established with the following switching points (maximum 10 switching points available): Tab. 53 No. Weekday Time System set-point pres‐ sure 01 Mon-Fri 06:30 pA on 02 Mon-Fri 12:00 pB on 03 Mon-Fri 13:00 pA on 04 Mon-Thu 17:00 pB on 05 Fri 16:00 pB on Example of system pressure changeover switching points Setting the day of the week for the first switching point Precondition Password level 2 is activated, The < Configuration ➙ Pressure settings ➙ Load control > menu is selected (see Section 7.6.1). 1. Press «DOWN» repeatedly until pA/pB clock is displayed as active line. 2. Press «Enter». The system displays the setting options for the switching points. 88 psi 08:15 176 ° F 5.2.3.1 pA/pB clock Menu ········· 01 n.a. 00:00 pA 02 n.a. 00:00 pA 03 n.a. 00:00 pA 04 n.a. 00:00 pA 05 n.a. 00:00 pA No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 57 7 Initial Start-up 7.6 Configuring the machine for local mode 3. Press «Enter» to switch into setting mode. n.a. flashes in the active line. 88 psi 08:15 176 ° F Menu 5.2.3.1 pA/pB clock ········· 01 Mon-Fri 06:30 pA Active line (settings for weekdays, time, pA) 02 Mon-Fri 12:00 pB (settings for weekdays, time, pB) 03 Mon-Fri 13:00 pA 04 Mon-Thu 17:00 pB 05 Fri 16:00 pB 4. Use «DOWN» or «UP» to set the time and confirm by pressing «Enter». 5. Press the «Right» key once. 6. Press «Enter» once. Time column, hours display, 00 : 00 flashes in the active line. 7. Use «UP» or «DOWN» to change the hour setting. 8. Press the «Right» key once. 9. Time column, minutes display, 00 : 00 flashes in the active line. 10. Use «DOWN» or «UP» to set the minutes and confirm by pressing «Enter». The display stops flashing and the time (hours/minutes) is set. 11. Press the «Right» key once. 12. Press «Enter». Setpoint pressure pA/Setpoint pressure pB flashes. 13. Use «UP» or «DOWN» to change the setting for pA or pB. 14. Specify further switching points in the same manner. Deleting the existing timer program Take the following steps to delete an existing timer program: Precondition Password level 2 is activated. The < Configuration ➙ Pressure settings ➙ Load control > menu is selected. 1. Press «DOWN» repeatedly until pA/pB clock is displayed as active line. 2. Press «Enter». The current timer program is displayed. 3. Press the «UP» repeatedly until Reset is displayed as active line. 88 psi 08:15 176 ° F 5.2.3.1 pA/pB clock Menu Reset: ☐ Active line ········· 01 Mon-Fri 06:30 pA 02 Mon-Fri 12:00 pB 03 Mon-Fri 13:00 pA 04 Mon-Thu 17:00 pB 58 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7 Initial Start-up 7.6 Configuring the machine for local mode 4. Press «Enter» to switch into setting mode. The check box for Reset will flash. 5. Press «UP». The check box is activated. 6. Press «Enter» to accept the settings. Result The timer program is now deleted. Selecting the Operating mode 1. Press the «DOWN» key. 2. Press «Enter» and use the «DOWN» or «UP» key to select pA or pB (not required in this ex‐ ample). 3. Specify any other Switching points in the same manner. The timer program is now created. 4. Select the pA/pB clock operating mode, see Section 7.6.3.3. 5. Press «Escape» repeatedly to return to the main menu. 7.6.3 Configuring the system pressure set-point changeover using the Timer Overview 7.6.3.1 ■ If not activated, enter password for level 2 ■ Delete the old timer configuration, if necessary ■ Set timer periods pA and pB. ■ Select the starting time for pA or pB. ■ Select Operating mode pA/pB cycle, see Section 7.6.3.3. Setting the timer periods pA and pB Note the Configuration sequence. For the Configuration of the timer period, Operating mode pA/pB cycle must be deactivated. ➤ First, configure the Timer, then select the Operating mode, if necessary, select first a dif‐ ferent Operating mode. Precondition Password level 2 is activated. The < Configuration ➙ Pressure control ➙ Load control > menu is selected. 1. Press the «DOWN» repeatedly until the Settings for pA and pB menu section is displayed as active line. 2. Press «Enter» to switch into setting mode. pA flashes. 3. Press the «UP» repeatedly until the desired timer period is displayed as active line. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 59 7 Initial Start-up 7.6 Configuring the machine for local mode 4. Press «Enter» to accept the setting. 88 psi 08:15 176 ° F Menu 5.2.3 Load control pA/pB cycle pA : 10 h – 10 h pB : 18 h – 18 h 1.Start pA ¦ pA : timer period – expiring period (example) 00:00 ········· 5. Set the timer period for pB in the same manner. 6. Press «Enter» to accept the setting. Result The timer period for Setpoint pressure pA and pB is set. 7.6.3.2 Setting the starting time for pA or pB 1. Press the «DOWN» key. 2. Press the «Right» key. 3. Press «Enter» to switch into setting mode. The starting time h flashes. 88 psi 08:15 176 ° F 5.2.3 Load control Menu pA/pB cycle pA : 10 h – 10 h pB : 18 h – 18 h 1.Start pA ¦ 06:30 Starting time for pA (active line) ········· 4. Press «UP» to set the hours. 5. Press the «Right» key. The starting time min flashes. 6. Press «UP» to set the minutes. 7. Press «Enter» to accept the settings. Result The starting time for pA is set. The period is to start with pB. ➤ Press «Enter» and specify 1.Start pB with «UP». 7.6.3.3 Precondition Selecting local mode Password level 2 is activated. The < Configuration ➙ Pressure control ➙ Load control > menu is selected. The timer program or the Timer is set. 1. Press the «UP» repeatedly until local mode is displayed as active line. 60 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 7 Initial Start-up 7.7 Configuring the machine for master control 2. Press «Enter» to switch into setting mode. Operating mode flashes. 88 psi 08:15 176 ° F 5.2.3 Load control Menu local mode pA/pB cycle Active line ········· Remote mode : Key remote : pA ☐ ········· current pA/pB cycle Display of the current operating mode 3. Press the «UP» or «DOWN» key to select the required operating mode (pA, pB, pA/pB clock or pA/pB cycle). 4. Press «Enter» to accept the setting. The actual operating mode is displayed. 5. Press «Escape» repeatedly to return to the main menu. Result 7.7 The timer is fully configured. Configuring the machine for master control The functions for a master control are not yet implemented. ➤ Ignore any corresponding references to chapter 7.7 in this manual. 7.8 Configuring e-mail The functions for the e-mail configuration are not yet implemented. ➤ Ignore any corresponding references to chapter 7.8 in this manual. 7.9 Configuring input and output signals The configuration of input and output signals is not yet implemented. ➤ Ignore any corresponding references to chapter 7.9 in this manual. 7.10 Configuring the compressed air outlet temperature (PD temperature) The functions for the compressed air outlet temperature are not yet implemented. ➤ Ignore any corresponding references to chapter 7.10 in this manual. 7.11 Activating remote acknowledgement The functions for remote acknowledgement are not yet implemented. ➤ Ignore any corresponding references to chapter 7.11 in this manual. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 61 7.12 Initial Start-up 7.12 Linking to an external pressure transducer Linking to an external pressure transducer The functions for the external pressure transducer are not yet implemented. ➤ Ignore any corresponding references to chapter 7.12 in this manual. 7.13 Activating the energy-saving mode for Dryer The functions for the energy-saving mode are not yet implemented. ➤ Ignore any corresponding references to chapter 7.13 in this manual. 7.14 Commissioning the machine The functions for machine commissioning are not yet implemented. ➤ Ignore any corresponding references to chapter 7.14 in this manual. 62 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 8 Operation 8.1 Switching on and off 8 Operation 8.1 Switching on and off Always switch the machine on with the «ON» key and off with the «OFF» key. A power supply disconnecting device has been installed by the user. Fig. 7 Switching on and off 8.1.1 Precondition Machine ON LED (green) «ON» key «OFF» key Control voltage LED (green) 11 19 20 «LOAD/IDLE» toggle key LOAD LED IDLE 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 isolating device. After the controller has carried out a self-test, the green Control voltage LED is lit continuously. 2. Press the «ON »key. The green Machine ON LED is lit continuously. If a power failure occurs, the machine is not prevented from re-starting automatically when power is resumed. It can re-start automatically as soon as power is restored. Result 8.1.2 The compressor motor starts as soon as system pressure is lower than the set point pressure (cutoff pressure). Switching off 1. Press the «LOAD/IDLE »key. The machine switches to IDLE and the IDLE LED flashes. 2. After allowing the machine to IDLE for 20 seconds, Press the «OFF» key. The Machine ON LED extinguishes. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 63 8 Operation 8.2 Acknowledging alarm and warning messages 3. Press the «LOAD/IDLE »key. The warning LED extinguishes. The machine is ready for further operation. The machine can be re-started. 4. Switch off and lock out the power supply disconnecting device. Result 8.1.3 The Control voltage LED extinguishes. The machine is switched off and disconnected from the power supply. Switching off in an emergency and switching on again The EMERGENCY STOP push-button is located below the control panel. Fig. 8 Switching off in an emergency EMERGENCY STOP control device: Switching off ➤ Press the EMERGENCY STOP control device. Result The EMERGENCY STOP button remains latched after actuation. The compressor's pressure system is vented and the machine is prevented from automatically restarting. Switching on Precondition The fault has been rectified 1. Turn the EMERGENCY STOP device in the direction of the arrow to unlatch it. 2. Acknowledge any existing alarm messages. Result 8.2 The machine can now be started again. Acknowledging alarm and warning messages The functions for acknowledging alarm and warning messages are not yet implemented. ➤ Ignore any corresponding references to chapter 8.2 in this manual. 64 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 8.3 Operation 8.3 Displaying operating data Displaying operating data The following information can be called up in the operating data menu option: ■ Operating hours ─ Compressor run: Total machine running time ─ ON LOAD: Machine on-load running time ─ Motor: Motor running time (can be changed) ─ Airend: Airend running time (can be changed) ─ SIGMA CONTROL 2: Controller running time ─ Modulating control valve: Modulating valve operating hours ■ Load valve: Total number of activations ■ Machine power consumption (according to version) Displaying operating data Precondition Password level 2 is activated. 1. In operating mode, switch to the main menu with the «Enter» key. 2. Select < Operating data >. The Operating data menu is displayed. Changing the operating hours The run times of the motor and airend components can be changed if, for example, a component exchange is required. Example: Airend exchange Precondition Password level 2 is activated. 1. Select the < Operating data ➙ Operating hours > menu. The Operating hours menu is displayed. 88 psi 08:15 176 ° F 3.1 Operating hours Menu Compressor 3050 h Active line ON LOAD 3030 h Motor 3050 h Compressor block 3050 h SIGMA CONTROL 2 3050 h 2. Press «DOWN» repeatedly until Compressor block is displayed as active line. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 65 8 Operation 8.3 Displaying operating data 3. Press «Enter» to switch into setting mode. The runtime value 3050 h flashes. 88 psi 08:15 176 ° F 3.1 Operating hours Menu Compressor 3050 h ON LOAD 3030 h Motor 3050 h Compressor block 0 h Active line SIGMA CONTROL 2 3050 h 4. Use «DOWN» or «Up» to set the value for operating hours to zero. 5. Press «Enter» to accept the setting. 6. Press «Escape» repeatedly to return to the main menu. Result 8.3.1 The operating hours for the new airend are set to 0 h . Interpreting operation messages The controller will automatically display operation messages informing you about the current opera‐ tional state of the machine. Operating messages are identified with the letter O. The message numbers are not numbered consecutively. Messages 0081 to 0095 are customer-specific and undefined. Complete them with your defined message text and interpretation. Message Meaning 0001 O The machine is regulated by system set point pressure pA. load control pA 0002 O The machine is regulated by system set point pressure pB. load control pB 0003 O The machine is regulated via the remote contactor. load control RC 0004 O The machine is remotely regulated via the bus connection. load control RB 0005 O The machine is switched on and in STANDSTILL operating mode. ready 0006 O The machine is switched on and in IDLE operating mode. IDLE 0007 O The machine is switched on and in LOAD operating mode. ON LOAD 0008 O The machine is switched off. off The power supply is connected. 0009 O The machine is switched on. Compressor ON 66 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 8 Operation 8.3 Displaying operating data Message Meaning 0010 O The power supply is connected. Controller ON The controller is powered. 0011 O Cold start release The machine can be switched on although the machine temperature is be‐ low the permissible starting temperature. 0025 O The value for pA is output. The machine can be switched on only as long as the message is displayed. Setpoint pressure pA 0026 O The value for pB is output. Setpoint pressure pB 0027 O Power OFF → ON Request: Switch the power supply off and on. 0028 O Control mode DYNAMIC: DYNAMIC motor T↑ The temperature of the compressor motor is too high. 0081 O 0082 O 0083 O 0084 O 0085 O 0086 O 0087 O 0088 O 0089 O 0090 O 0091 O 0092 O 0093 O p-Switch pi No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 67 8 Operation 8.4 Setting the maintenance interval Message Meaning 0094 O T-Switch ADT 0095 O p-Switch pN Tab. 54 8.4 Operational Messages Setting the maintenance interval The functions for setting maintenance intervals are not yet implemented. ➤ Ignore any corresponding references to chapter 8.4 in this manual. 8.5 Testing the safety relief valve Overview ■ Preparing the test ■ Performing the test ■ Correct conclusion of the test ■ Performing a Reset 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 internal pressure pi is used to describe the test below. Tab. 55 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 air distribution network. 4. Log on to SIGMA CONTROL 2 with access level 2 (see chapter 7.2.4). 5. In operating mode, switch to the main menu with the «Enter» key. 68 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 8 Operation 8.5 Testing the safety relief valve 6. Select the < Machine test ➙ TÜV inspection > menu. Safety valve line is displayed as being active. 88 psi 08:15 176 ° F 9.1 TÜV inspection Menu Safety valve: ☐ Active line with check box pRV : 232 psi ¦ pi 0.00psi Safety relief valve activating pressure (example) Reset: ☐ ········· ADT ⇞ : ☐ Offset : 0 °F ¦ ADT ⇞ 0.0 °F Performing the test 1. Press «Enter» to switch into setting mode. The check box flashes in the active line. 2. Use the «UP» key to activate the check box. 3. Press «Enter» to accept the setting. The test mode is now activated. The monitoring of internal and network set point pressures is deactivated! 88 psi 08:15 176 ° F 9.1 TÜV inspection Menu Safety valve: ☑ Active line with check box pRV :232 psi ¦ pi 36 psi Activating pressure safety relief valve ( pRV ) ¦ Inter‐ nal pressure pi ( current ) Reset: ☐ ········· 4. Excessive noise is caused when the safety relief valve blows off! ➤ Close all access doors, replace and secure all removable panels. ➤ Wear hearing protection. 5. 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. 6. Press and hold the «ON» key. The machine switches to load, the machine's internal pressure pi rises. 7. Manually monitor on the display the pressure rise pi during the TÜV inspection. 8. If the internal pressure pi increases to more than 10 % above the correct opening pressure of the safety relief valve, shut down the machine with the «OFF» key and replace the Safety valve. 9. Have the safety relief valve replaced immediately. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 69 8 Operation 8.6 Checking the temperature sensor and overheating shutdown function If the alarm message pRV ⇞ appears, the safety relief valve is defective. The permissible internal pressure was exceeded by 29 psi. ➤ Have the safety relief valve replaced immediately. Avoid oil mist: ➤ Release the «ON» key immediately when the safety relief valve responds, in order to pre‐ vent unnecessary oil mist. Correct conclusion of the test 1. Press «Enter» to switch into setting mode. The check box flashes in the active line. 2. Use the «DOWN» key to deactivate the check box. 3. Press «Enter» to accept the setting. The "Safety relief valve" test mode is de-activated and the test is completed. 4. Press «Escape» repeatedly to return to the main menu. 5. Open the shut-off valve from the machine. Result The machine is ready for operation. Resetting If the test is canceled when opening the safety relief valve, the internal pressure pi will indicate the highest measured value. Activate the check box for Reset in order to reset the stored value. ➤ Activate the check box for Reset . 8.6 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 airend discharge temperature to cause the machine to shut down prematurely. In standard operation, SIGMA CONTROL 2 generates the "overtemperature" fault message when the maximum airend discharge temperature is reached. Since the modified test temperature is 4 F below the fault message switching point for overtemperature, the system will not generate a fault message in test mode. Overview ■ Shut down the machine and allow to cool down slightly ■ Performing the test ■ Correct conclusion of the test ■ Performing a Reset Performing the test Precondition 70 Machine cooled down by approx. 9 °F Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 8 Operation 8.6 Checking the temperature sensor and overheating shutdown function 1. Log on to SIGMA CONTROL 2 with access level 2 (see section 7.2.4). 2. In operating mode, switch to the main menu with the «Enter» key. 3. Select the < Machine test ➙ TÜV inspection > menu. Safety valve is displayed in the active line. 4. Press «DOWN» repeatedly until ADT ⇞ is displayed as active line. 5. Press «Enter» to switch into setting mode. The check box in the active line flashes. 88 psi 08:15 164 ° F Menu 9.1 TÜV inspection ········· Active line ADT ⇞ : ☐ Offset : 0 °F ¦ ADT ⇞ 32 °F Reset: ☐ 6. Use the «UP» key to activate the check box. 7. Press «Enter» to accept the setting. The Offset display changes to 95 °F. The ADT ⇞ display changes to 226°F. The test mode is now activated. 88 psi 08:15 164 ° F 9.1 TÜV inspection Menu ········· ADT ⇞ : ☑ Active line Offset : 95 °F ¦ ADT ⇞ 226 °F Offset ¦ ADT ⇞ in test mode Reset: : ☐ 8. Press the «ON» key to switch the machine to LOAD. The machine switches to LOAD and the airend discharge temperature rises again. The machine will switch off as soon as ADT attains a value of 226°F. The machine does not shut down? ➤ Cancel the test and gave the temperature sensor replaced immediately. Correct conclusion of the test 1. Press «Enter» to switch into setting mode. The check box in the active line flashes. 2. Use the «DOWN» key to deactivate the check box. 3. Press «Enter» to accept the setting. The offset is reset to 32 °F. The test mode is de-activated and the test is completed. 4. Press «Escape» repeatedly to return to the main menu. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 71 8 Operation 8.6 Checking the temperature sensor and overheating shutdown function Resetting ADT ⇞ will display the highest measured value if the test for switching off at overtemperature is aborted. Activate the check box for Reset in order to reset the stored value. ➤ Activate the check box for Reset. 72 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 9 Fault Recognition and Rectification 9.1 Basic instructions 9 Fault Recognition and Rectification 9.1 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: red LED flashes - see chapter 9.2. ■ Fault on the controller: red LED flashes - see chapter 9.3. ■ Warning: yellow LED lights - see chapter 9.5. 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. 9.2 Interpreting fault messages Fault messages are identified with the letter A. The message numbers are not numbered consecutively. Messages 0081 to 0095 are customer-specific and may differ from the suggested values. Com‐ plete them with your defined message text, possible causes and remedies. Message Possible cause Remedy 0001 A Direction of rotation The compressor drive motor is turning in the wrong direction. Change over phase lines L1 and L2. 0002 A Motor T⇞ Compressor drive motor over‐ heated. Clean the motor. 0003 A pRV ⇞ The activating pressure of the Change the safety relief safety relief valve on the oil sepa‐ valve. rator tank has been exceeded. 0004 A EMERGENCY STOP EMERGENCY STOP control de‐ vice actuated. Unlatch the push-button. 0005 A Oil separator T⇞ Maximum air temperature at the oil separator tank outlet is ex‐ ceeded. Check the line to the trip re‐ lay. 0007 A Mains monitor Fault in main power supply. Have the main power sup‐ ply checked. 0009 A Sigma Control T⇞ Permissible enclosure tempera‐ ture for SIGMA CONTROL 2 ex‐ ceeded. Keep ambient conditions within specified limits. 0010 A Blow-off protection ⇞ No.: 9_9450 00 USE Keep ambient conditions within specified limits. Control cabinet: Check filter mats and fan. The activating pressure of the Change the oil separator safety relief valve on the oil sepa‐ cartridge. rator tank has been exceeded. Open the shut-off valve in the venting line. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 73 9 Fault Recognition and Rectification 9.2 Interpreting fault messages Message Possible cause Remedy 0011 A Fan M4 I⇞ Overload shut-down of the first fan motor. Investigate cause of shutdown. Reset the overload relay. 0012 A Access doors Door open / interlocked panel re‐ moved while the machine is run‐ ning. Fit and secure all panels and close access doors. 0013 A Motor I⇞ Overload shut-down of the com‐ pressor drive motor. Investigate cause of shutdown. Change the oil separator cartridge. 0014 A Fan M5 I⇞ Overload shut-down of the sec‐ ond fan motor. Investigate cause of shutdown. Reset the overload relay. 0015 A ADT ⇞ Maximum permissible airend dis‐ Keep ambient conditions charge temperature (ADT) ex‐ within specified limits. ceeded. Clean the cooler. Check the cooling oil level. 0016 A Fan M6 I⇞ Overload shut-down of the third fan motor. Investigate cause of shutdown. Reset the overload relay. 0019 A Internal pressure pi⇟ – – 0021 A Refrigeration dryer T⇟ Refrigeration dryer: Compressed air temperature too low. Contact an authorized KAESER service represen‐ tative. 0022 A Oil separator dp⇞ Oil separator cartridge clogged. Change the oil separator cartridge. 0023 A Motor bearings Drive motor bearings overheated. Re-grease the motor bear‐ ings. 0024 A Water-cooling water shortage Cooling water pressure is too low. Check cooling water supply. 0034 A Mains contactor on? Main contactor does not close. 0035 A Fan M7 I⇞ Overload shut-down of the control Contact an authorized cabinet fan motor. KAESER service represen‐ tative. 0038 A PD T⇟ Package discharge (PD) tempera‐ Contact an authorized ture too low. KAESER service represen‐ tative. 0039 A PD T⇞ Package discharge (PD) tempera‐ Check the cooling oil level. ture too high. Clean the radiator. Check mains contactor and wiring. Check the fan motor. 0040 A Mains contactor off? 74 Main contactor does not open. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x Check main contactor and wiring. No.: 9_9450 00 USE 9 Fault Recognition and Rectification 9.2 Interpreting fault messages Message Possible cause Remedy 0041 A Mains voltage ⇟ Second power failure. Check power supply volt‐ age. Check the door interlock switch. 0042 A Back pressure stop Back pressure in the oil separator Check venting line. tank caused by defective venting. 0043 A ADT 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. The working pressure does not Check coupling / V-belt. rise above 50 psi within the preset period. 0045 A Compressor T⇟ Thermostatic valve defective Contact an authorized KAESER service represen‐ tative. 0048 A High-voltage cell Fault in the high voltage cell. Contact an authorized KAESER service represen‐ tative. 0051 A Aggregate A Aggregate A failed. Contact an authorized KAESER service represen‐ tative. 0052 A Aggregate B Aggregate B failed. Contact an authorized KAESER service represen‐ tative. 0056 A RD condensate drain Refrigeration dryer: The condensate drain is defec‐ tive. Refrigeration dryer: Check condensate drain and condensate conduits. 0057 A Model Compressor model uncertain. Contact an authorized KAESER service represen‐ tative. 0058 A Condensate drain The condensate drain is defec‐ tive. Check condensate drain and condensate conduits. 0059 A Back pressure run Drive belt or coupling broken. Drive belt: Replace drive belt. Coupling: Contact an authorized KAESER service represen‐ tative. No.: 9_9450 00 USE 0060 A Softstart Fault in the soft start equipment. Contact an authorized KAESER service represen‐ tative. 0061 A Oil separator dT/dt⇞ The rate of rise of the airend dis‐ charge temperature is too fast. Check the cooling oil level. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 75 9 Fault Recognition and Rectification 9.2 Interpreting fault messages Message Possible cause Remedy 0062 A Refrigeration dryer p⇞ Refrigeration dryer: Pressure too high in the refriger‐ ant circuit. Safety pressure switch tripped. Clean the refrigerant con‐ denser. Refrigeration dryer: Refrigerant lost; pressure in the refrigerant circuit too low. Inlet pressure switched tripped. Contact an authorized KAESER service represen‐ tative. 0097 A High-voltage cell on? High-voltage cell does not acti‐ vate. Check high-voltage cell and wiring. 0098 A High-voltage cell off? High-voltage cell does not deacti‐ Check high-voltage cell and vate. wiring. 0099 A Mains contactor on? Main contactor does not close. 0063 A Refrigeration dryer p⇟ Check the fan motor. Maintain operating condi‐ tions. 0081 A 0082 A 0083 A 0084 A 0085 A 0086 A 0087 A 0088 A 0089 A 0090 A 0091 A 0092 A 0093 A p-Switch pi 0094 A T-Switch ADT 0095 A p-Switch pN 76 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x Check main contactor and wiring. No.: 9_9450 00 USE 9 Fault Recognition and Rectification 9.3 Interpreting system messages Message Possible cause Remedy 0100 A Mains contactor off? Main contactor does not open. Check maincontactor and wiring. 0101 A Motor I⇞ Overload shut-down of the com‐ pressor drive motor. Investigate cause of shutdown. Change the oil separator cartridge. 0102 A Fan M4 I⇞ Overload shut-down of the first fan motor. Investigate cause of shutdown. Reset the overload relay. Tab. 56 9.3 0200 A Compressor motor USS alarm Frequency converter fault Contact an authorized KAESER service represen‐ tative. 0201 A Compressor motor USS alarm Frequency converter fault Contact an authorized KAESER service represen‐ tative. 0202 A Compressor motor USS alarm Frequency converter fault Contact an authorized KAESER service represen‐ tative. 0205 A Compressor motor USS alarm Communications error Check connection and line path. 0210 A Compressor motor FC Motor overload alarm Frequency converter fault Contact an authorized KAESER service represen‐ tative. 0211 A Compressor motor FC Group alarm Frequency converter fault Contact an authorized KAESER service represen‐ tative. Fault messages and measures Interpreting system messages System messages are identified with the letter Y. The message numbers are not numbered consecutively. No.: 9_9450 00 USE Message Possible cause Remedy 0001 Y Hardware watchdog reset System error Contact an authorized KAESER service representative. 0002 Y Internal software error System error Contact an authorized KAESER service representative. 0003 Y Filesystem Read/Write failure System error Contact an authorized KAESER service representative. 0004 Y CPU load too high System error Contact an authorized KAESER service representative. 0005 Y RAM out of memory System error Contact an authorized KAESER service representative. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 77 9 Fault Recognition and Rectification 9.4 Interpreting diagnostic messages Message Possible cause Remedy 1000 Y System error RFID error: switch SIGMA CONTROL power supply OFF→ON! Tab. 57 9.4 Contact an authorized KAESER service representative. System messages and remedies Interpreting diagnostic 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 the KAESER service representative in troubleshooting. 9.5 Interpreting warning messages Warning messages are identified with the letter W. The message numbers are not numbered consecutively. Messages 0081 to 0092 are customer-specific and may differ from the suggested values. Com‐ plete them with your defined message text, possible causes and remedies. Message Possible cause Remedy 0002 W Motor T↑ Drive motor overheating. Clean the motor. 0003 W V-belt tension Belt tension is too low. Re-tension drive belt. 0004 W Oil separator dp↑ The pressure drop across the oil separator cartridge has risen. Change the oil separator cartridge. Keep ambient conditions within specified limits. Oil separator cartridge clogged. 0005 W Start inhibit Too frequent manual on and off switching. Do not exceed the maximum num‐ ber of motor switchings per hour when manual on/off switching. 0007 W Motor bearings Drive motor bearing defective. Contact an authorized KAESER ser‐ vice representative. 0008 W ADT↑ Maximum airend discharge tem‐ perature will soon be reached. Clean the radiator. Check the cooling oil level. Replace the oil filter. Ensure adequate ventilation. Keep surrounding temperature with‐ in recommended limits. 0010 W Buffer battery Data retention battery is almost discharged. Change the battery. 0011 W Oil filter Δp↑ The pressure differential of the oil filter has risen. Change the oil filter. Oil filter clogged. 78 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 9 Fault Recognition and Rectification 9.5 Interpreting warning messages Message Possible cause Remedy 0012 W Modem problem SIGMA CONTROL 2 does not rec‐ Check the link between the ognize modem. SIGMA CONTROL 2 and the mo‐ dem. 0013 W Air filter dp↑ Air filter clogged. Change the air filter element. 0015 W Bus alarm The bus link from the Profibus DP interface is interrupted. Check bus highway and plug. 0016 W Error: RAM Internal RAM defective. Contact an authorized KAESER ser‐ vice representative. 0017 W Refrigeration dryer T↓ Refrigeration dryer: Compressed air temperature too high. Maintain operating conditions. Clean the refrigerant condenser. Clean the cooler. Install an extractor fan. 0018 W Refrigeration dryer p↓ Refrigeration dryer: Contact an authorized KAESER ser‐ Refrigerant lost; pressure in the re‐ vice representative. frigerant circuit too low. Inlet pres‐ sure switched tripped. 0025 W Oil separator h⇞ Oil separator cartridge: Change the oil separator cartridge. Maintenance interval has elapsed. 0026 W Oil change h⇞ Cooling oil: Change the cooling oil. Maintenance interval has elapsed. 0027 W Oil filter h⇞ Oil filter: Change the oil filter. Maintenance interval has elapsed. 0028 W Air filter h⇞ Air filter: Change the air filter element. Maintenance interval has elapsed. 0029 W Valve inspection h⇞ Valves: Contact an authorized KAESER ser‐ Maintenance interval has elapsed. vice representative. 0030 W Belt tension/coupling: Carry out a visual inspection. Belt/coupling inspection Maintenance interval has elapsed. Re-tension drive belt. h⇞ 0031 W Motor bearing h⇞ Motor bearing of compressor mo‐ Contact an authorized KAESER ser‐ tor: vice representative. Maintenance interval has elapsed. 0032 W Electric components and installa‐ Inspect and reset the maintenance Electrical equipment h⇞ tion: interval counter. Maintenance interval has elapsed. No.: 9_9450 00 USE 0033 W Fan bearing h⇞ Motor bearing of fan motors: Contact an authorized KAESER ser‐ Maintenance interval has elapsed. vice representative. 0034 W PD T↓ Package discharge (PD) tempera‐ Contact an authorized KAESER ser‐ ture too low. vice representative. 0035 W PD T↑ Compressed air discharge temper‐ Clean the radiator. ature too high. Check the cooling oil level. Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 79 9 Fault Recognition and Rectification 9.5 Interpreting warning messages Message Possible cause Remedy 0036 W Motor starts /h⇞ The permissible number of motor starts was exceeded in the last 60 minutes. Extend the idle period. The permissible number of motor starts was exceeded in the last 24 hours. Extend the idle period. 0038 W Blow-off protection ↑ The safety relief valve's activating pressure will soon be reached. Change the oil separator cartridge. 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 ex‐ ceeded. Check settings of the external con‐ troller. Take into account pressure drops across filters and dryer. 0037 W Motor starts /d⇞ Increase the capacity of air receiver. Increase the cross-section of piping between compressor and air receiv‐ er. Increase the capacity of air receiver. Increase the cross-section of piping between compressor and air receiv‐ er. Open the shut-off valve in the vent‐ ing line. Check the door interlock switch. The external load control has not switched to idle (off load). 0044 W Oil T↓ Cooling oil temperature too low. Check temperature switch, line and connection. Check the oil circulation. Increase room temperature. 0046 W System pressure ↓ Network pressure has fallen below Check air demand. the set 'low' value. Check cable runs and sensor con‐ Air consumption too high. nections. Check the 'sys.press. low' warning setting. 80 0047 W No pressure buildup The compressor cannot build-up to Check for air leaks. working pressure. Check the value for internal pres‐ sure given in the menu against the reading on the oil separator tank pressure gauge. 0048 W Bearing lube h⇞ Re-grease the motor bearings. Re-grease the motor bearings. Maintenance interval has elapsed. 0049 W Annual maintenance Last maintenance was 1 year ago. Carry out the necessary mainte‐ nance and reset the corresponding maintenance interval counter. 0059 W Start T↓↓ The airend temperature is too low Keep ambient conditions within (<14 °F) for the machine to be op‐ specified limits. erated. 0060 W Start T↓ The airend temperature is too low (<35 °F). Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x Keep ambient conditions within specified limits. No.: 9_9450 00 USE 9 Fault Recognition and Rectification 9.5 Interpreting warning messages Message Possible cause Remedy 0061 W Compressor T↓ The airend discharge temperature Contact an authorized KAESER ser‐ (ADT) did not reach the minimum vice representative. value within the specified time. 0066 W Air filter dp⇡ Initial warning: Air filter clogged. 0068 W Condensate drain The condensate drain is defective. Check the condensate drain and drain line. 0069 W Refrigeration dryer p↑ Refrigeration dryer: Clean the refrigerant condenser. Pressure too high in the refrigerant Check the fan motor. circuit. Maintain operating conditions. Safety pressure switch tripped. 0070 W Refrigeration dryer T↑ Refrigeration dryer: Compressed air temperature too high. Change the air filter element soon. Maintain operating conditions. Clean the refrigerant condenser. Clean the cooler. Install an extractor fan. 0071 W Oil level ↓ Cooling oil level too low. Replenish the cooling oil. 0072 W RD condensate drain Refrigeration dryer: Check condensate drainage The condensate drain is defective. 0081 W 0082 W 0083 W 0084 W 0085 W 0086 W 0087 W 0088 W 0089 W 0090 W 0091 W 0092 W 0093 W p-Switch pi No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 81 9 Fault Recognition and Rectification 9.5 Interpreting warning messages Message Possible cause Remedy 0094 W T-Switch ADT 0095 W p-Switch pN Tab. 58 82 Warning messages and remedies Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 10 Maintenance 10.1 Safety 10 Maintenance 10.1 Safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of these instructions can result in serious injury. Basic safety instructions Disregarding safety instructions can result in unforeseeable hazards. ➤ Follow the instructions in chapter 3 'Safety and Responsibility'. ➤ Allow maintenance work to be performed by authorized personnel only. ➤ Make sure that no one is working on the machine. ➤ Ensure that all service doors and panels are locked. Working on live components Touching voltage carrying components can result in electric shocks, burns or death. ➤ Work on electrical equipment may only be carried out by authorized electricians. ➤ Switch off and lock out the power supply isolating device and verify the absence of voltage. ➤ Check that there is no voltage on floating relay contacts. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 83 11 Spares, Operating Materials, Service 11.1 Note the nameplate 11 Spares, Operating Materials, Service 11.1 Note the nameplate The nameplate contains all information to identify your machine. This information is essential to us in order to provide you with optimal service. ➤ Please give the information from the nameplate with every inquiry and order for spares. 11.2 KAESER AIR SERVICE KAESER AIR SERVICE offers: ■ authorized service technicians with KAESER factory training, ■ increased operational reliability ensured by preventive maintenance, ■ energy savings achieved by avoidance of 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 11.3 Your advantage: lower costs and higher compressed air availability. Service Addresses Addresses of KAESER representatives are given at the end of this manual. 11.4 Displaying the version number, machine model, material, serial, and equipment numbers 1. In operating mode, switch to the main menu with the «Enter» key. 2. Select the < Configuration ➙ General ➙ System information > menu. The system information is displayed. 88 psi 08:15 176 ° F 5.1.1 System information Menu Compressor Compressor overview Compressor PN *** Compressor SN *** Material number, serial number Compressor EN *** Equipment number SIGMA CONTROL 2 MCS Controller overview SIGMA CONTROL 2 PN: 7.7601P0 SN: 10-34-000- Material number, serial number Software: 0.7.4.1 Software version 3. Press «Escape» repeatedly to return to the main menu. 84 Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE 12 Decommissioning, Storage and Transport 12.1 De-commissioning 12 Decommissioning, Storage and Transport 12.1 De-commissioning ➤ Follow the instructions in the machine's service manual. 12.2 Packing ➤ Follow the instructions in the machine's service manual. 12.3 Storage ➤ Follow the instructions in the machine's service manual. 12.4 Transporting ➤ Follow the instructions in the machine's service manual. 12.5 Disposal ➤ Follow the instructions in the machine's service manual. No.: 9_9450 00 USE Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x 85 86 12 Decommissioning, Storage and Transport 12.5 Disposal Service Manual Controller SIGMA CONTROL 2 SCREW FLUID 1.0.x.x No.: 9_9450 00 USE
Source Exif Data:
File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.6 Linearized : No Create Date : 2011:01:28 15:58:55+01:00 Modify Date : 2011:01:28 15:58:55+01:00 Creator : AH Formatter V5.2 R1 (5,2,2010,0806) for Windows Producer : Antenna House PDF Output Library 2.6.0 (Windows) Trapped : False Page Count : 132 Page Mode : UseOutlinesEXIF Metadata provided by EXIF.tools