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Service manual - Kaeser Kompressoren

1. Check box Check box for reset Status Z x activated deactivated Tab 1 Check box status Precondition Password level 2 is activated The display shows the operating mode Select the clock compressor menu 1 Press Enter The main menu is displayed 2 Select lt Compressor clock gt The display for setting the Compressor clock timing program appears 88 5 psi 08 15 176 F 6 Compressor clock Menu Key clock Reset 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 Use UP to specify the settings for the weekdays Press Enter to accept the setting Press the Right key once OV a Press Enter to switch into setting mode Column time hours display 00 00 flashes in the active line D Use UP to specify the settings for the hours 7 Press the Right key once Column time hours display 00 00 flashes in the active line 8 Use UP to specify the settings for the minutes Quick user guide Controller 6 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02 USE TO Naya 6 Activating the clock key COMPRESSORS 9 Press Enter to accept the settings The display stops flashing and the time hours minutes is set
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3. Service manual Controller 64 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 7 Initial Start up 7 5 Configuring machine start and stop Press the UP key The activated check box is displayed Press Enter to save the setting 88 5 psi 08 15 176 F 5 4 1 Compressor on Menu Local mode Key Remote mode Key RC RC DI 1 12 ok a Key remote 4 Active line with deactivated check box Key clock The Clock key is not activated Press Escape repeatedly to return to the main menu The Remote control key is activated and can be used If method B with the timer program is selected the Clock key must be activated in the same manner 7 5 3 3 Assigning another input O e 9_9450 02USE Inputs already assigned cannot be further assigned Press the DOWN key repeatedly until the following is displayed as active line 88 5 psi 08 15 176 F 5 4 1 Compressor on Menu Local mode Key Remote mode Key RC RC DI 1 12 ok m Remote contact DI 1 12 preset Key remote m Key clock Press Enter to switch into setting mode Display for input flashes Select another input with the UP or DOWN keys Press Enter to accept the setting The input has now been assigned Press the Remote control key to enable the machine to be started from the remote control centre If an input is rejected it means
4. 88 5 psi 08 15 176 F 6 Compressor clock Current menu 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 For example compressor ON action 10 Press the Right key once 11 Press Enter to switch into setting mode Column action on offflashes 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 clock key 1 Use UP key to change to line Key clock 2 Press Enter to switch into setting mode The check box flashes in the active line 88 5 psi 08 15 176 F 6 Compressor clock Menu 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 Press Enter to accept the setting The clock key is activated Press Escape repeatedly to return to the main menu Press the clock key O m Proceed in the same manner to deactivate the clock key m All defined switching points will be reset simultaneously if you activate the reset check box Quick user guide Controller 9_9450 02 USE SIGMA CONTROL 2 SCR
5. 2 Press Enter The current clock program is displayed 3 Press the UP repeatedly until Resetis displayed as active line 88 5 psi 08 15 176 F 5 2 3 1 pA pB Clock Menu pene 01 Mon Fri 06 30 pA 02 Mon Fri 12 00 pB 03 Mon Fri 13 00 pA 04 Mon Thu 17 00 pB 4 Press Enter to switch into setting mode Check box reset flashes 5 Press UP The check box is activated 6 Press Enter to accept the settings The clock program is now deleted Select 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 Setup the remaining switching points in the same way The clock program is now finished Select the pA pB Clock operating mode see Section 7 7 3 3 5 Press Escape repeatedly to return to the main menu Configuring the system pressure setpoint changeover using the timer Overview Enter password level 2 Delete the old clock configuration if necessary m Setting the clock periods pA and pB m Select the starting time for pA or pB m Select the pA pB Cycle operating mode see Section 7 7 3 3 Setting the clock periods pA and pB Keep to the order of the configuration The operating mode pA pB Cycle must not be activat ed when configuring the timer period gt Configure the timer first and then select the operating mode or select another operating mode first Password level 2 is activ
6. current pA pB Cycle Display of the current operating mode 3 Press UP or AB to select the desired local operating mode pA pB Clock or pA pB Cycle 4 Press Enter to accept the operating mode The display of the current operating mode switches to the new operating mode 7 8 5 6 Slave Setting remote mode Precondition Access level 2 is activated The lt Configuration gt Pressure control gt Load control gt menu is selected 1 Press UP or DOWN repeatedly until Remote mode is displayed as the active line Service manual Controller 92 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 initial Start up erol INEL ES 7 8 Configuring the machine for master control 2 Press Enter to switch into setting mode The Remote operation display flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu Local mode pA Remote mode pA pB SC2 Active line Key remote current pA pB Cycle 3 Use UP to select the following operating mode pA pB SC2 4 Press Enter to accept the setting Result Remote operation is set to pA pB SC2 operating mode 7 8 5 7 Slave Activating deactivating the Remote control key O Activating deactivating the check box I Check box Check boxes for Reset Status Z x activated deactivated Tab 60 Check box status Precondition Password level 2 is activated The lt Configuration gt Pressure control g
7. EMERGENCY STOP push button actuated Maximum air temperature at the oil separator tank outlet is exceeded Fault in main power supply Permissible enclosure temperature for SIGMA CONTROL 2 exceeded The activating pressure of the safe ty relief valve on the oil separator tank has been exceeded Overload shut down of the first fan motor Door open interlocked panel re moved while the machine is run ning Overload shut down of the com pressor drive motor Overload shut down of the second fan motor SIGMA CONTROL 2 SCREW FLUID 1 0 2 x L1 and L2 Clean the motor Keep ambient conditions within specified limits Change the safety relief valve Unlatch the push button Check the line to the trip relay Have the main power supply checked Keep ambient conditions within specified limits Control cabinet Check filter mats and fan Change the oil separator cartridge Open the shut off valve in the venting line Investigate cause of shut down Reset the overload relay Fit and secure all panels and close access doors Investigate cause of shut down Change the oil separator cartridge Investigate cause of shut down Reset the overload relay 23 COMPRESSORS 24 15 Interpreting fault messages Message 0015 A Airend discharge temperature ADT 0016 A Oil air cooler fan Overcurrent 0019 A Internal pressure pi 0021 A Refrigeration dr
8. The setpoint pressure pA pB is configured the same for both machines gt The clock program is set up using the following switching points No Weekday Time System set point pressure 01 Mon Sun 00 00 pA On 02 Mon Sun 06 00 pB On Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 113 COMPRESSORS Tab 63 Precondition Tab 64 7 9 114 7 initial Start up 7 9 Configuring email No Weekday Time System set point pressure 03 Mon Sun 12 00 pA On 04 Mon Sun 18 00 pB On Example for a clock program for equal duty cycling during the day Variant C Equal duty cycle during the week A timer triggers the switch between system set point pressure pA and system set point pressure pB local operating mode pA pB SC2 Clk The setpoint pressure pA pB is configured the same for both machines gt The clock program is set up using the following switching points No Weekday Time System set point pressure 01 Mon 00 00 pA On 02 Mon 21 00 pB On 03 Tue 18 00 pA On 04 Wed 15 00 pB On 05 Thu 12 00 pA On 06 Fri 09 00 pB On 07 Sat 06 00 pA On 08 Sun 03 00 pB On Example for a clock program for equal duty cycling during the week Configuring email SIGMA CONTROL 2 uses email to send information messages to an email address For this purpose an Ethernet connection with an SMTP server is required Overview m Select the menu lt Communication gt Ethernet gt m Configure and activate the email function
9. 7 11 4 7 initial Start up 7 11 Activating remote acknowledgement The remote acknowledgement is now set Activating the remote control key 1 Press DOWN once Key remote is displayed in the active line 2 Press Enter to switch into setting mode The check box for Key remote will flash 3 Press the UP key 88 5 psi 08 15 176 F 5 5 Acknowledgement Menu Remote mode Key RC Active line with activated check box for remote key RC ack DI 1 11 4 Press Enter to accept the setting The remote key is now activated Assigning an input 1 Press DOWN repeatedly until the active line is displayed 88 5 psi 08 15 176 F 5 5 Acknowledgement Menu Remote mode Key RC Key remote m RC ack DI 1 11 0 Active line 2 Press Enter DI flashes 3 Use the UP key to select the required input 4 Press Enter to accept the setting The input has now been assigned 5 Press the Right key 6 Press Enter to switch into setting mode Check box for analog input flashes 7 Press the UP key Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 127 KAESER COMPRESSORS 128 Result 7 12 7 12 1 Precondition 7 Initial Start up 7 12 Linking to an external pressure transducer 8 Press Enter to accept the setting Display ok appears the input is assigned and activated 88 5 psi 08 15 176 F 5 5 Acknowledgement M
10. The SIGMA CONTROL 2 and the I O modules are maintenance free Use basic safety instructions and safety instructions for working on live components Service manual Controller 9_9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 155 KAESER 11 Spares Operating Materials Service ere ViR 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 gt Please give the information from the nameplate with every inquiry and order for spares 11 2 KAESER AIR SERVICE KAESER AIR SERVICE offers m authorized KAESER service representatives with KAESER factory training m increased operational reliability ensured by preventive maintenance m energy savings achieved by avoidance of pressure losses optimum conditions for operation of the compressed air system m the security of genuine KAESER spare parts m increased legal certainty as all regulations are kept to gt Why not sign a KAESER AIR SERVICE maintenance agreement Result Your advantage lower costs and higher compressed air availability 11 3 Service Addresses Addresses of KAESER representatives are given at the end of this manual 11 4 Displaying the version number machine model part number and serial number 1 In operating mode switch to the main menu with the Enter key 2 Select
11. 0063 A Refrigeration dryer p 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 0097 A High voltage cell on 0098 A High voltage cell off Service manual Controller Possible cause The rate of rise of the airend dis charge temperature is too fast Refrigerated dryer Pressure too high in the refrigerant circuit Safety pressure switch tripped Refrigerated dryer Refrigerant lost pressure in the re frigerant circuit too low Inlet pres sure switched tripped High voltage cell does not activate High voltage cell does not deacti vate SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Remedy Check the cooling oil lev el Clean the refrigerant condenser Check the fan motor Maintain operating condi tions Contact an authorized KAESER service repre sentative Check high voltage cell and wiring Check high voltage cell and wiring 9_9450 02USE KAESER COMPRESSORS 9_9450 02USE Tab 72 9 3 9 Fault Recognition and Rectification 9 3 Interpreting system messages Message 0099 A Mains contactor on 0100 A Mains contactor off 0101 A Compressor motor Overcurrent 0102 A Oil air cooler fan Overcurrent 0200 A Compressor motor USS alarm 0201 A Compressor motor USS alarm 0202 A Compressor motor USS alarm 0205 A Compressor moto
12. Access level 2 is activated 07 S0104 Pressure rise in frequency controlled machines 1 System pressure LOAD switching point 2 IDLE switching point System setpoint pressure dpFC System setpoint pressure dpFC switching differential System setpoint pressure pA or pB Pressure rise dpFC 6 System pressure band width 1 Select lt Configuration gt Pressure control gt Pressure settings gt see Section 7 4 1 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 57 KAESER COMPRESSORS 7 4 3 Precondition 58 7 initial Start up 7 4 Adjusting the pressure parameters of the machine 2 Keep pressing the DOWN key until the following is displayed 88 5 psi 08 15 176 F 5 2 2 Pressure settings Menu Pressure rise pE SP 122 psi SD 7 3 psi Pressure increases ApFC 0 2 bar Active line with pressure rise 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 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 Password level 2 is activated The lt Configuration gt Pressure control gt Load control gt menu is selected see Section 7 2 1 1 2 Press UP or DOWN repeate
13. Adjust the times for start and end hours and minutes of the vacation shut down in the same manner described in chapter 7 5 1 2 timing program for the times of the switching points You have set a standstill time 23 12 12 07 01 13 for your machine Starting the machine remotely Remote ON OFF If the machine is to be started and stopped remotely the following settings have to be set Overview Make the electrical connection a spare input for the remote contact is to be found in the elec trical wiring diagram for the machine DI 1 0 being preferred m Switch machine start to remote mode Press the Remote key f necessary activate the Clock key and configure the clock program see section7 5 1 2 f required assign the remote contact to another input Press the Remote key Switch machine start to Remote mode Two methods are available to start the machine remotely 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 program has selected compressor 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 lt Co
14. Maintenance interval has elapsed 0027 W Oil filter Oil filter h Maintenance interval has elapsed 0028 W Air filter Air filter h Maintenance interval has elapsed 0029 W Valves Valve inspection h Maintenance interval has elapsed 0030 W Belt tension coupling Belt coupling inspectionh Maintenance interval has elapsed 0031 W Motor bearing of compressor Motor bearings h motor Maintenance interval has elapsed 0032 W Electric components and instal Electrical equipment h lation Maintenance interval has elapsed 0033 W Motor bearing of fan motors Fan bearings h Maintenance interval has elapsed 0034 W Package discharge PD tem PD temperature J perature too low 0035 W Compressed air discharge tem PD temperature t perature too high Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Remedy Check bus highway and plug Maintain operating conditions Clean the refrigerant condenser Clean the cooler Install a ventilation fan Contact an authorized KAESER service representative Change the oil separator cartridge Change the cooling oil Change the oil filter Change the air filter element Contact an authorized KAESER service representative Carry out a visual inspection Re tension drive belts Contact an authorized KAESER service representative Inspect and reset the maintenance interval counter Contact an authorized KAESER service representati
15. Remedy Check settings of the external con troller Take into account pressure drops across filters and dryer Check temperature switch line and connection Check the oil circulation Increase room temperature Check air demand Check cable runs and sensor con nections Check the sys press low warn ing setting Check for air leaks Check the value for internal pres sure given in the lt analog data gt menu against the reading on the oil separator tank pressure gauge Re grease the motor bearings Carry out the necessary mainte nance and reset the corresponding maintenance interval counter Keep ambient conditions within specified limits Keep ambient conditions within specified limits Contact an authorized KAESER service representative Change the air filter element soon Check the condensate drain and drain line Clean the refrigerant condenser Check the fan motor Maintain operating conditions Maintain operating conditions Clean the refrigerant condenser Clean the cooler Install a ventilation fan 9_9450 02 USE g 16 Interpreting warning messages COMPRESSORS 9_9450 02 USE Message 0071 Oil level 4 0072 RD condensate drain 0081 0082 0083 0084 0085 0086 0087 0088 0089 0090 0091 0092 0093 p Switch pi 0094 T Switch ADT 0095 p Switch pN WwW WwW W W W W W W Possible cause Remedy
16. SIGMA AIR MANAGER or VESIS The system set point pressures pA and pB are irrelevant for the LOAD IDLE signals Master control of two compressors with 2 The SIGMA CONTROL 2 controllers operate 7 8 4 SIGMA CONTROL 2 via Ethernet inter as master and slave The slave receive the face command to switch between the two system set point pressures pA and pB from the master Examples of a master control of two 2 The SIGMA CONTROL 2 controllers operate 7 8 5 compressors with SIGMA CONTROL 2 as master and slave The slave receives the via Ethernet interface command to switch between the two system set point pressures pA and pB from the master Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 77 KAESER 7 initial Start up ezel i iNES 7 8 Configuring the machine for master control Master controller type Description Section Master control via LOAD remote con LOAD remote contact 7 8 6 tact An input signal from a superordinate controller Master control via a remote LOAD con SWitches the machine to LOAD or IDLE The tact is another method of controlling the Setpoint pressure settings pA and pB have no machine externally There are two possi elevance bilities Local LOAD remote contact 7 8 7 Using two inputs a master controller e g MVS 8000 switches the machine between LOAD IDLE and local operation Set point pressure pre selection pA pB remote contact 7 8 8 An input contact provides the signal to swit
17. Service manual Controller 9 9450 0O2USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 79 Initial Start up KAESER Ri COMPRESSORS Configuring the machine for master control 7 8 Wiring possibilities for master control excerpt Wys Bunsanayspunqian yangpuey ayals savayen WYS lt Z TOMLNO VWOIS krem uejds yaisuagn Ny zjessJ 343p Zjesy Bunsapuy uaylayyabowssniysuy PEL SeEe eee uejdyne wosys el FEREENA YaDVNV Waly YWIS qns o x0 jod 6 Jep uaylaxyGousGunpuiqe Waaa UOA aula snu meys Gunpulqian snqyjoug auaqababue aig nix ozy Z 1041N0J VWOIS ozy ozy Z 1041N07 Z 1041N0J VWIIS VWOIS g Jossasdwoy ozy Z 1041N07 VWIIS ozy ozy ozy Z 1041N07 Z 1041LN0J Z 10Y4LNOI VWOIS VWOIS VWOIS L sossaidwoy 9 sossaudwoy g Jossasdwoy 4 Jossaudwoy g sossaidwoy Z sossaudwoy Z 1041N0J VWOIS Jossaudwoy 0102 60 2 uaBajian nz sp sneq puts jaqey aly ysiajisnejeiualag e ing ssnjyisuy ZUWOLXL OOZLM Jawwnujagey d paqey S 6 h eM MARRE 2wws LXE OOOLM N ZUWSL OX2Z OLZLM 2 a 3 Ey 2 k s 2 vuoz yanupuuay 0 olg Z TOYLNOI YWIS HU L Jossaidwoy sn ua layya1boussnjyasuy 07 S0624 Fig 22 Electrical diagram example with SIGMA AIR MANAGER Controller Service manual 9_9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x
18. Set interval and suppress repeats Select menu 1 Select the menu lt Communication gt Ethernet gt Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 initial Start up erol Tst t t 10 7 9 Configuring email 2 Press DOWN twice E mailsubmenu line is displayed as being active 88 5 psi 08 15 176 F 8 1 Ethernet Menu gt 1 IP configuration gt 2 Connections gt 3 E mail Active line submenu email Configure and activate the email function Precondition Password level 2 is activated E mail submenu is displayed as being active 1 Press Enter The display shows Email function as the active line 2 Press Enter to switch into setting mode The check box for the email function flashes 3 Press UP to deactivate the email function 4 Press Enter to accept the setting The email function is deactivated 88 5 psi 08 15 176 F 8 1 3 E mail Menu active O Active line deactivate activate email function Compressor number 1 Language Deutsch Setting the language Sender address status kaeser mdex de 5 Set Compressor number Language m Sender address m Sender s name Telephone number of contact person m Recipient address SMTP server Username Password Reactivate the email function Press Escape repeatedly to return to the main menu Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 115 KAESER
19. Setting local operating mode pB Set point pressure pB is normally set for local operation gt When setting the system set point pressure pB keep in mind that under certain circum stances more than one compressor may be operating in local mode see section 7 4 for adjusting set point pressure Password level 2 is activated The lt Configuration gt Pressure control gt Load control gt menu is selected 1 Press UP repeatedly until Loca mode is displayed as the active line Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 101 KAESER 7 initial Start up erel i iNES 7 8 Configuring the machine for master control 2 Press Enter to switch into setting mode Setpoint pressure flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu Local mode pB Active line current operating mode Remote mode loc load RC Key remote current pB 3 Use UP to select the pB operating mode 4 Press Enter to accept the setting 5 Adjust the set point pressure pB if necessary see section 7 4 Result The local operating mode pB is set 7 8 7 4 Activating the Remote control key Precondition Password level 2 is activated The lt Configuration gt Pressure control gt Load control gt menu is selected 1 Press UP or DOWN repeatedly until Key remote is displayed as the active line 2 Press Enter to switch into setting mode The check box for the Remote contro
20. Similar to the creation of new user accounts you can also update existing user accounts m Changing the password m Changing the access level m Changing the status For example shown here how to change a password Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER COMPRESSORS Precondition Result 7 3 5 Fig 17 Precondition 9_9450 02USE 7 Initial Start up 7 3 Using KAESER CONNECT The system displays the lt User administration gt menu Write mode is activated Click on the existing user account Enter the new password Confirm the new password Click Update 9 Po NS The existing user account has been updated Settings Settings via KAESER CONNECT apply only to your PC and your Browser The following settings are available m Units Date format Time format SIGMA CONTROL 2 1 SK25 read gt write Logout Contact Service KOMPRESSOREN 2 Settings Pressure unit bar B 3 Temperature unit C ad System status Delivery quantity m3 min v Graphs Volume for delivery quantity m3 MA Messages Buffer volume m3 Vv User management 1 Settings Date format MM DD YY M Backup Time format HH mm ss AM PM VI 97 c1378 Settings lt Settings gt menu Unit of pressure Unit of temperature Converting units to US values KAESER CONNECT for SIGMA CONTROL 2 is displayed 1 Select the lt Settings gt menu T
21. Target 260 s Actual 0 s Active line with changed setpoint value for minimum run time Unloaded period Target 260 s Actual 100 s Changed setpoint value for the standstill period Press the UP key to adjust the minimum run time Press Enter to accept the setting Change the standstill period accordingly O NOD Press Escape repeatedly to return to the main menu 7 6 4 Setting the refrigerated dryer control modes Precondition Password level 2 is activated Menu option lt Control mode gt is selected 1 Press UP repeatedly until Refrigeration dryer is displayed as the active line Control mode timer is set up as standard I Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 71 KAESER 7 initial Start up ote liE ES 7 7 Configuring the machine for local mode 2 Check if the control mode timer is set up 88 5 psi 08 15 176 F 5 3 Control mode Menu gt 2 DUAL gt 3 QUADRO Further information See chapter 4 7 for an overview of the control modes 7 7 Configuring the machine for local mode In local mode the machine is regulated with the pA or pB The controller is provided with the follow ing modes of operation Operating mode Description See section pA The machine is controlled by system pressure setpoint pA 7 7 3 3 pB The machine is controlled by system pressure setpoint pB pA pB Clock The changeover between pA and pB is regulated by a clock pro 7 7 2 gram pA pB
22. The machine switches to LOAD under the following condition System pressure lt SP pA pB switching differential Tab 50 Pressure condition for LOAD The machine switches to IDLE under the following condition System pressure setpoint pressure Tab 51 Pressure condition for IDLE Precondition Access level 2 is activated 1 Select lt Configuration gt Pressure control gt Pressure settings gt see Section 7 4 1 2 Press UP or DOWN repeatedly until the following is displayed as the active line 88 5 psi 08 15 176 F 5 2 2 Pressure settings Menu Setpoint pressure pA SP 116 psi SD 7 3 psi Active line with current value for system setpoint pressure pA pB SP 110 psi SD 5 8 psi System pressure low Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 55 KAESER COMPRESSORS 56 Result 7 4 2 2 Tab 52 Precondition 7 4 2 3 7 initial Start up 7 4 Adjusting the pressure parameters of the machine 3 Press Enter to switch into setting mode The 776 psi parameter flashes Use UP or DOWN to adjust the system setpoint pressure pA Press Enter to accept the setting Adjust the switching differential in the same way Adjust the pB and the switching differential in the same manner if necessary OO EN O 400 Press Escape repeatedly to return to the main menu The settings for the system setpoint pressure pA and pB are ad
23. Cooling oil level too low Replenish the cooling oil Refrigerated dryer Check the condensate drain The condensate drain is defec tive Tab 6 Warning messages and remedies Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 31 KAESER 17 Interpreting system messages COMPRESSORS 17 Interpreting system messages System messages are identified with the letter Y The message numbers are not numbered consecutively Message Possible cause Remedy 0001 Y System error Contact an authorized KAESER service Hardware watchdog reset representative 0002 Y System error Contact an authorized KAESER service Internal software error representative 0003 Y System error Contact an authorized KAESER service Filesystem Read Write failure representative 0004 Y System error Contact an authorized KAESER service CPU load too high representative 0005 Y System error Contact an authorized KAESER service RAM out of memory representative 1000 Y System error Contact an authorized KAESER service RFID error switch SIGMA representative CONTROL power supply OFF gt ON Tab 7 System messages and remedies Quick user guide Controller 32 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02 USE KAESER Contents COMPRESSORS 1 Regarding this Document 1 1 Using this document 2 c2 cc2e eecie ene ee hele i ee ee 122 COPYnQht c32 c teen tego aa aaa pettus Biol be Bh Gh eb oe Be ohh ele ae ne a aae 121 Software
24. 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 5 psi 08 15 176 F 7 User Menu Name Citizen4 Password a kkkkkkkkkkkkkkkk Logout Active line Current access level 2 Display access level 2 3 Press Escape repeatedly to return to the main menu You are logged in with a higher access level Checking setting time and date Password level 2 is activated The display shows the operating mode Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER 7 initial Start up ote Tst t t 10 7 2 Configuring the controller Checking setting the time gt When operating the machine with a timer program check the time settings at least once a year _ o 1 Press Enter The main menu is displayed 2 Select the menu lt Configuration gt General gt 3 Press the DOWN key repeatedly until the current time is displayed as the active line 88 5 psi 08 15 176 F 5 1 General Menu gt 1 System information Date time 13 04 11 08 15 37 Current time Press the Right key 5 Press Enter to switch into setting mode The hours display flashes 00 00 00 Use UP or DOWN to change the hour setting Press the Right key The minutes display flashes 00 00 00 8 Use UP or DOWN to
25. Enter The main menu is displayed Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 35 KAESER COMPRESSORS 36 7 2 2 Tab 41 Precondition 7 2 3 7 initial Start up 7 2 Configuring the controller 2 Press the UP or DOWN key until Configuration is displayed as the active line 3 In order to open the lt Configuration gt menu press Enter once 4 Use the DOWN or UP keys to select a submenu in the lt Configuration gt menu lt General gt or lt Pressure control gt for example 5 Press UP repeatedly until Generalis displayed as the active line 6 Press Enter The current menu is the submenu lt General gt in the menu lt Configuration gt 7 With the DOWN or UP keys you can select the menu option lt General gt for example lt System information gt Changing the display language The controller can display text messages in the following languages Arabian Estonian Italian Norwegian Spanish Bulgarian Finnish Japanese Polish Spanish South America Chinese French Korean Portuguese Czech Danish French Croatian Romanian Turkish Canada German Greek Latvian Russian English GB Hebrew Lithuanian Swedish English Indonesian Dutch Slovenian USA Display language Some of the units as well as clock and date format will be adjusted according to the language selected The display shows the operating mode 1 Press Enter
26. Enter to switch into setting mode Check box flashes 88 5 psi 08 15 176 F 5 2 4 Network actual pressure FC USS 55 psi Active line external transducer All 1 02 ok m 90 psi Press the UP key Press Enter to accept the setting The input for the external transducer is now activated Commissioning the machine Checking the controller settings Section Confirmed gt Language correctly set 7 2 2 gt Date and time correct 7 2 5 gt Display format correctly set 7 2 6 gt System pressure set point correctly set 7 4 Checklist of installation conditions 1 Cover all points in the checklist before starting the machine When power is applied to the machine the controller boots and carries out a self test The display and LED controller power light up The time the current system pressure and the airend discharge temperature are then dis played in the first line 88 5 psi 08 15 122 F Run 0h Load 0h Maintenance in 2000 h Press the LOAD IDLE key Run up time too short A run up time that is too short can damage the machine gt Press the lt ON gt key and let the machine run for at least 1 minute in IDLE to allow sufficient oll to enter the pressure system Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 Initial Start up erol IERES 7 13 Commissioning the machine 4 Press the ON key 5 Press the LOAD IDLE key Result The machine swi
27. F 5 7 3 1 External message 1 Menu External message 1 DI 1 11 ok 4 Active line set time delay DOR 1 04 Alarm 3 Select the required delay time with the UP key 4 Press Enter to accept the setting The delay time is set Set logic Possible logic settings Message at Symbol 24V OV 7 Logic 1 Press the Right key once 2 Press Enter to switch into the logic setting mode The ogic display flashes 3 Use UP to set the desired behavior see table 66 88 5 psi 08 15 176 F 5 7 3 1 External message 1 Menu External message 1 DI 1 11 ok td 1 s Logic Active line set logic DOR 1 04 Alarm 7 For example Fault message type 4 Press Enter to accept the setting For messages at 24 V the logic is with the symbol Assign and activate the output 1 Press DOWN repeatedly until Output is displayed as the active line 2 Press Enter to switch into setting mode The Output display flashes 3 Select the output with the UP or DOWN keys Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE 7 10 3 7 Result 7 11 7 initial Start up 7 11 Activating remote acknowledgement 4 Press Enter to accept the setting 88 5 psi 08 15 176 F 5 7 3 1 External message 1 Menu External message 1 Message name DI 1 11 ok
28. Maintain operating conditions Refrigeration dryer T 4 Compressed air temperature too Clean the refrigerant condenser high Clean the cooler Install a ventilation fan Contact an authorized KAESER service representative 0018 W Refrigeration dryer p 4 Refrigerated dryer Refrigerant lost pressure in the refrigerant circuit too low Inlet pressure switched tripped 0025 W Oil separator cartridge Change the oil separator cartridge Oil separator h Maintenance interval has elapsed 0026 W Cooling oil Change the cooling oil Oil change h Maintenance interval has elapsed 0027 W Oil filter Change the oil filter Oil filter h Maintenance interval has elapsed Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02 USE COMPRESSORS 9_9450 02 USE 16 Interpreting warning messages Message 0028 W Air filter h 0029 W Valve inspection h 0030 W Belt coupling inspection h 0031 W Motor bearings h 0032 W Electrical equipment h 0033 W Fan bearings h 0034 W PD temperature 4 0035 W PD temperature t 0036 W Motor starts h 0037 W Motor starts d 0038 W Blow off protection 0041 W Mains voltage Quick user guide Controller Possible cause Air filter Maintenance interval has elapsed Valves Maintenance interval has elapsed Belt tension coupling Maintenance interval has elapsed Motor bearing of compressor motor Mainten
29. T V inspection gt menu The safety relief valve is displayed as the active line 4 Press DOWN repeatedly until A rend discharge temperature ADT is displayed as active line 5 Press Enter to switch into setting mode The check box in the active line flashes 88 5 psi 08 15 isi Fallen airend discharge temperature ADT 9 1 TUV inspection Menu NE EEE AE EET E a Active line Offset 0 F ADT 0 0 F Reset 6 Use the UP key to activate the check box Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02 USE TO Nata 12 Checking the temperature sensor and overheating shutdown COMPRESSORS function 7 e Press Enter to accept the setting The Offsetdisplay changes to 95 F The Airend discharge temperature ADT display changes to 226 F The test mode is now activated 88 5 psi 08 15 163 F 9 1 TUV inspection Menu NCCC eee MCU meyg Active line t i A Offset 95 F ADT 226 F Offset airend discharge temperature in test mode Reset 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 the airend discharge temperature attains a value of 226 F The machine does not shut down gt Abort the test and contact KAESER Service as soon as possible Correct conclusion of the test 1 Press Enter to switch i
30. You may also activate the Venting period function by pressing the OFF key on the controller gt Press the OFF key The Venting period function is activated Press the OFF key twice to immediately shut the machine off gt Press the OFF key twice The machine is switched off without venting idle time Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 Initial Start up ote Tst t t 10 7 5 Configuring machine start and stop 7 5 5 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 If not activated enter password for level 2 m Select the lt Configuration gt Compressor start gt menu Activate deactivate the restart function or set the restart delay Precondition Password level 2 is activated The lt Configuration gt Compressor start gt menu option is selected 1 Press Enter The Compressor start menu is displayed 88 5 psi 08 15 176 F 5 4 Compressor start Menu gt 1 Compressor on Active line gt 2 Compressor off Autostart z Automatic restart activated Target 10 s Actual 0 s Deactivating activating automatic restart 1 Press DOWN repeatedly until Autost
31. td 1 s Logic Logic Output is selected and activated Alarm 4 For example Fault message type 5 Press the Right key 6 Press Enter to switch into setting mode Check box flashes 7 Press UP key to activate the check box 8 Press Enter to accept the setting ok is displayed The output is assigned and activated Select the message type operational alarm warning 1 Press DOWN once until message type is displayed as the active line 2 Press Enter to switch into setting mode The display of message type flashes 3 Use UP to select the corresponding message type 88 5 psi 08 15 176 F 5 7 3 1 External message 1 Menu External message 1 Message name DI 1 11 ok 4 td 1s Logic Logic DOR 1 04 ok m 4 Press Enter to accept the setting The input signal is available as external message 1 and or as output Activating remote acknowledgement When warning or alarm messages are routed to a remote control center via an output it makes sense to have these messages acknowledged by the control center Acknowledging the message without correcting the cause however can lead to machine damage The following conditions must be fulfilled The remote acknowledgement and remote key are activated A controller input has been assigned for the acknowledgement signal Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 125 KAESER 7 initi
32. 08 15 176 F 5 1 General Menu Time format hh mm ss Pressure unit bar Temperature unit C Current unit of temperature Display lighting Press Enter to switch into setting mode The C parameter flashes Change the unit with the DOWN or UP key Press Enter to save the setting Press Escape repeatedly to return to the main menu Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE Tab 46 Precondition Result 7 2 7 7 3 7 initial Start up 7 3 Using KAESER CONNECT Setting the display illumination Select your personal mode for the display illumination Mode 1 2 Display automatic ON Function The illumination extin Permanent setting guishes after the Illumination on timeout has elapsed Display illumination Password level 2 is activated Menu lt Configuration gt General gt is selected see 7 2 1 1 Press DOWN repeatedly until Display lighting is displayed 2 Press DOWN once until Mode is displayed as the active line 88 5 psi 08 15 176 F 5 1 General Menu Pressure unit bar Temperature unit C Display lighting Mode on Timeout 1 min Active line 3 Press Enter to switch into setting mode The on display flashes Use UP to select the auto mode Press Enter to save the setting Enter the setting for 7imeout in the same manner Press Enter to save the setting 00 TA
33. 1 Status menu Navigation 1 1 Messages 1 2 Statistics 1 3 Current pressure control Service manual Controller 9_9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Function submenu m Ethernet COM module Activating deactivating the Remote control key For details of the lt Communication gt menu see table 33 Menu Communication m T V check m Compressor drive motor Power switching For details of the lt Components gt menu see ta ble 35 Menu Components Function submenu m Current messages m Message history event memory Compressor messages Diagnostic messages System messages m Address error Status report Current warnings Current faults Overall load Actual system pressure pNloc Internal pressure Total number of motor starts Motor starts per day Motor starts per hour Total number of motor starts below mini mum temperature m Last load run Last idle run Last motor OFF SIGMA CONTROL 2 Cut out pressure Actual system pressure 21 KAESER 4 Design and Function ore 2 4 e 10 2t 4 6 Menus overview Navigation Function submenu 1 4 Current operating mode Compressor ON Load control Regulating mode Idle time Acknowledgement 1 5 DI DO display m First I O module DI DO indicator Second I O module DI DO indicator Third I O module DI DO indicator m Fourth I O module DI DO indicator m Fifth I O m
34. 13 00 The following switching points result No a A OO N gt Day Mon Fri Mon Fri Mon Fri Mon Thu Fri Tab 54 Example of a machine ON OFF timer program Precondition Password level 2 is activated the Clock key is activated the clock menu is selected Service manual Controller 60 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Time 06 30 12 00 13 00 17 00 15 00 Function ON OFF ON OFF OFF 9_9450 02USE KAESER COMPRESSORS 9_9450 02USE Result 7 initial Start up 7 5 Configuring machine start and stop 1 Press DOWN repeatedly until the 07 switching pointis displayed as the active line 88 5 psi 08 15 176 F 6 Compressor clock Menu Active line with switching point 01 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 The column time display for hours 00 OO in the active line flashes 7 Use UP to specify the settings for the hours 8 Press the Right key once 9 The column time display for minutes 00 OO in the active line flashes 10 Use UP to specify the settings for the minutes 11 Press Enter to accept
35. 5 Press Escape repeatedly to return to the main menu The Clock key is activated and can be used 6 Press Clock to enable the operation with a timing program 7 5 2 Setting up the holiday period In addition to the fixed cycles of a timing program or timer you can also specify a longer lasting standstill time For example you may specify a standstill period for vacation shut down by defining the following Precondition The display shows the operating mode 1 Press Enter The main menu is displayed 2 Select lt Configuration gt Compressor start gt Compressor off gt 3 Press DOWN repeatedly until Ho idays is displayed as active line 88 5 psi 08 15 176 F 5 4 2 Compressor off Menu Venting period ae Start 23 12 12 00 00 End 07 01 13 4 Press Enter to switch into setting mode The check box flashes Service manual Controller 62 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE O I Result 7 5 3 7 5 3 1 Precondition 7 Initial Start up 7 5 Configuring machine start and stop 5 Press the UP key 88 5 psi 08 15 176 F 5 4 2 Compressor off Menu Venting period O Holidays 4 Active line with deactivated check box Start 23 12 12 00 00 Time for start End 07 01 13 6 Press Enter to accept the setting You may manually adjust the start and end of vacation shut down date in the setting mode
36. 5 2 3 1 pA pB Clock Menu Reset 01 Mon Fri 00 00 pB Active line First switching point set weekdays 02 Mon Fri 00 00 pB Weekday Second switching point 03 n a 00 00 pB 04 n a 00 00 pB 11 Enter the weekdays for the second switching point in the same manner The weekdays for the first two switching points are set Set the time for the first two switching points 1 Press the UP key repeatedly until the switching point 01 is displayed as the active line 2 Press the Right key once 3 Press Enter to switch into setting mode The column time display for hours 00 OO in the active line flashes Use UP to specify the settings for the hours 5 Press the Right key once The column time display for minutes 0C OO in the active line flashes 6 Use UP to specify the settings for the minutes Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 111 KAESER COMPRESSORS 112 Result Result Precondition 7 initial Start up 7 8 Configuring the machine for master control 7 Press Enter to accept the settings The display stops flashing and the time hours minutes is set 88 5 psi 08 15 176 F 5 2 3 1 pA pB Clock Weekday setting Reset v 01 Mon Fri 06 30 pB Active line time first switching point 02 Mon Fri 17 00 pB Time second switching point 03 n a 00 00 pB 04 n a 00 00 pB 8 Enter the time for the second switching point in the same manner The times for
37. Cycle The changeover between pA and pB is regulated by a programmed 7 7 3 time pulse Tab 55 Local operating mode local mode gt Adjusting system pressure setpoint as described in section 7 4 Overview Enter password level 2 m Select lt Configuration gt m Set adjust the clock program see Section 7 7 2 or Set adjust the timer see Section 7 7 3 Local mode 7 7 1 Select menu lt configuration gt Pressure control gt Load control Precondition Password level 2 is activated 1 In operating mode switch to the main menu with the Enter key 2 Select lt Configuration gt Pressure control gt Load control gt The lt Load control gt menu is displayed Service manual Controller 72 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE 7 7 2 o Tab 56 Precondition 7 initial Start up 7 7 Configuring the machine for local mode Configuring the system pressure set point changeover using the clock Note the configuration sequence gt First determine the clock program gt Then select the operating mode Overview If not activated enter password for level 2 m Set the day of the week for the first switching point delete any existing clock program Entering the time of the first switching point m Select the system setpoint pressure for the first switching point pA or pB m Specify any further switching points m Select the pA pB Clock op
38. Functions gt Password level 2 is activated Assign a message to an output Slect menu lt Configuration I O Peripherie Access level 2 is activated 1 In operating mode switch to the main menu with the Return key 2 Select lt Configuration gt I O periphery gt DO functions gt A list of available messages and their assigned outputs is displayed 88 5 psi 08 15 176 F 5 7 1 DO functions Menu eeg Logic Compressor on DOR 1 04 ok m Logic Motor running DOR 1 07 ok m Logic Assign a message to an output 1 Select the required message with the DOWN key Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 117 KAESER COMPRESSORS 118 7 10 2 7 initial Start up 7 10 Configuring input and output signals 2 Press Enter to switch into setting mode The Display of the chosen indication flashes 88 5 psi 08 15 176 F 5 7 1 DO functions Menu Controller on DOR 1 02 ok 4 active line with assigned output Logic Compressor on DOR 1 04 ok m Logic Motor running DOR 1 07 ok m Logic Select a free output with the UP or DOWN key Press Enter to accept the setting Press the Right key Press Enter to switch into setting mode Activate the check box Press Enter to accept the setting ONAAR YW If necessary set Logic The system now uses the assigned output to send a message You are missing an o
39. KAESER foto INELE 7 10 Configuring input and output signals 7 8 Use the UP and DOWN keys to select characters from the character set in order to assign the unit to the sensor signal 88 5 psi 08 15 176 F 5 7 2 5 Display 5 I Menu Flow rate 01 The line for sensor designation All 1 02 O 0 m3 h Unit of measure 20mA 10000 4mA 0 AOI2 00 0 0 0 mA 20mA 16000mmmmm 4mA mmmmm Press Enter to accept the setting Result Editing sensor designation and unit of measure 7 10 2 3 Allocate analog input 1 2 Press left twice until A 7 02is displayed Press Enter to switch into setting mode Display for analog input flashes Select A 7 03 with the UP key Press Enter to accept the setting 88 5 psi 08 15 176 F 5 7 2 5 Display 5 I Menu Flow rate 01 The line for sensor designation All 1 03 0 0 m h Active line 20mA 10000 4mA 0 AOI2 00 0 0 0 mA 20mA 16000mmmmm 4mA mmmmm Press the Right key once Press Enter to switch into setting mode Check box for analog input flashes Activate the check box for All 1 03 88 5 psi 08 15 176 F 5 7 2 5 Display 5 I Menu Flow rate 01 The line for sensor designation All 1 03 ok Z 123 m3 h Active line the signal value is displayed 20mA 10000 4mA 0 AOI2 00 0 0 0 mA 20mA 16000mmmmm 4mA mmmmm Service manual Controller 120 SIGMA CONTROL 2 SCREW FLUID 1 0 2
40. KOMPRESSOREN 96450 Coburg Postfach 2143 Germany This offer is valid for anybody having this information Updating the operating manual The page lt Atto www kaeser com sc2manual gt of our website provides frequently updated ver sions of this operating manual 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 gt Download the operating manual in your language Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 1 COMPRESSORS 1 4 1 4 1 Tab 8 1 4 2 Tab 9 1 Regarding this Document 1 4 Symbols and labels Symbols and labels gt Please note the symbols and labels used in this document 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 Signal term Meaning Consequences of non compliance DANGER Warns of an imminent danger Will result in death or severe injury WARNING Warns of a potentially imminent danger May result in death or severe injury CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury Danger levels and their definitions personal injury Warning notices preceding a chapter apply to the entire chapter including all sub sections Example A DANGER The type and source of the imminent da
41. OOM es Press Escape repeatedly to return to the main menu 3 OFF Permanent setting Illumination off The display illumination is set for automatic operation with deactivation after one minute without user intervention Setting and activating summer winter time The system automatically switches between summer and winter time Using KAESER CONNECT Using a PC with web browser KAESER CONNECT enables you to view the following of the SIGMA CONTROL 2 m System status Graphs Messages Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 43 COMPRESSORS ji 7 3 1 Precondition Fig 8 44 7 initial Start up 7 3 Using KAESER CONNECT m User administration m Settings m Data backup Thus KAESER CONNECT provides an excellent option for an easy and quick check of the energy efficiency of your compressors The following functions are not available with KAESER CONNECT m Remotely starting the machine m Remotely changing parameters Displaying the system status KAESER CONNECT for SIGMA CONTROL 2 is displayed 1 Select the lt System status gt menu The system displays the status information SIGMA CONTROL 2 1 SK25 read gt write Logout Contact Service KOMPRESSOREN System status 1 System status Graphs 6 8 bar 11 47AM Messages WEN Me lonosd S User management x on Load Settings Run 52th Load 520h Backup 21h e 2 SIGMA CONTROL 2 07 C1380 Status dis
42. Operation 8 6 Displaying operating data 2 Select lt Operating data gt The menu Operating data is displayed 88 5 psi 08 15 176 F 3 Operating data Menu gt 1 Operating hours Active line gt 2 kWh counter Load valve ON 383 Total number of activations 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 Password level 2 is activated 1 Select the lt Operating data gt Operating hours gt menu The menu Operating hours is displayed 88 5 psi 08 15 176 F 3 1 Operating hours Menu Aeee 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 the active line 3 Press Enter to switch into setting mode The runtime value 3050 h flashes 88 5 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 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 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 137 KAESER COMPRESSORS 138 Result 8 6 1 8 Operation 8 6 Displaying operating data The operating hours for the new airend have been set to 0 Interpreting oper
43. R 21 Configura OA MeN Li i d a e a e ae e ae a he Niel 23 Pressure controlimenu genske e eee eee i 24 I O Periphery mMenu entinen eaae anes acres aa toca aeaa a EAEn 25 Communication MENU sinense a a eee 26 GOnnections MENU E E AA EE TE E E E E EEE E ects aie ts og 28 Components Menu niinen aside Sh eed ea ea ed ee dee 28 POWGRr SWITCHING MENU nianiar wee ketal cer eget arte cu aaaea ees aae aoa cig econ edocs 29 Energy efficient Control modes cccccccccceeeeeeeeeeeeeeeeeeeaeeeeeeaneeeeeeaeeeeeseaeeseesaaeeeeeeaeeeeeseneeeetees 30 Machines mtifiCatlony a ethos Bd Saad he tee hah todd e se east ad Tat kt 34 Remote control identification cccccecccceeeecceeeeeeceeeeeeeeeeeeeaaeeeeecaeeeeeseaeeeeesaeeesecneeeeeesneeeeeeaees 34 Machine identification Se otter teteeey teed oA etree tenth aed thie 34 Display languag espin noreo teed ald eae eee eee eee 36 Dat EINAN TEN ESEE P E E AE EE eathicas EE ah EEE EE ode NE ours Sellen t athe sie 40 Time formats eree ate ease tye ee ee ee ee 41 Units of pr ssSute insanni a ee teste a a hae a n e e a 41 Units of temperature 2sic2 22ceetee sc eies edited needle eis deg eee i ea aeara oi 42 Display WMUMIMAUON esnie hee cthe sae et ceded atiec het adeedt sada ge cadet daca aaa aian aie ged digs ndda aed ped de 43 Arrow keys and fUNCtiONS n os a a a a E aa 47 Compressor pressure parameters cccccceeecceeeeeeceeeeeeeeeeeseaeeeeeeeceeeeesaeeeeeseeeeeecneeeseeeeeeteenee
44. SCREW FLUID 1 0 2 x 21 KAESER 14 Interpreting diagnostic messages COMPRESSORS 14 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 Quick user guide Controller 22 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02 USE COMPRESSORS 15 9_9450 02 USE 15 Interpreting fault messages Interpreting fault messages Alarm 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 0001 A Direction of rotation 0002 A Motor temperature 0003 A pRV 0004 A EMERGENCY STOP 0005 A Oil separator Temperature 0007 A Mains monitor 0009 A SIGMA CONTROL 2 T 0010 A Blow off protection 0011 A Oil air cooler fan Overcurrent 0012 A Access doors 0013 A Compressor motor Overcurrent 0014 A Oil air cooler fan Overcurrent Quick user guide Controller Possible cause Remedy The compressor drive motor is turn Change over phase lines ing in the wrong direction Compressor drive motor overheat ed The activating pressure of the pres sure relief valve on the oil separator tank has been exceeded
45. Start up 7 8 Configuring the machine for master control The weekday is set for the first switching point Setting the time for the first switching point 1 Press the Right key 2 Press Enter to switch into setting mode The display for hours 00 00 flashes 3 Press UP repeatedly until the hours are set 4 Press the Right key The display for minutes 00 00 flashes 5 Press UP repeatedly until the minutes are set 88 5 psi 08 15 176 F 5 2 3 1 pA pB Clock Menu Reset 01 Mon Fri 06 15 pA Active line current start time 02 n a 00 00 pA 03 n a 00 00 pA 04 n a 00 00 pA 6 Press Enter to accept the settings The start time is set for the first switching point Setting the system pressure for the first switching point 1 Press the Right key 2 Press Enter to switch into setting mode The display for the system setpoint pressure flashes System setpoint pressure pA or system setpoint pressure pB 3 Press the UP or DOWN key to select the required system setpoint pressure System set point pressure pA or system setpoint pressure pB 4 Setup the remaining switching points in the same way The clock program is now finished 5 Select operating mode pA pB Clock see chapter 7 8 5 5 6 Press Escape repeatedly to return to the main menu Master Configuring the system pressure setpoint changeover using the timer Keep to the order of the configuration 1 C
46. The main menu is displayed Press the UP key once The specified language is displayed as the active line Use the Enter key to switch to setting mode The currently set language flashes Use the DOWN or UP keys to select the desired language Press Enter to accept the setting Press Escape repeatedly to return to the main menu The display texts are now in the selected language Access rights with equipment card Use the Equipment Card to quickly and easily check the advanced access rights to the SIGMA CONTROL 2 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER COMPRESSORS 7 2 4 Precondition Result Precondition 9_9450 02USE 7 Initial Start up 7 2 Configuring the controller Advanced access rights m read additional data m 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 gt Manually enter the user name and password see also the following chapter Access right via manual input Entering the user name The display shows the operating mode 1 Press Enter The main menu is displayed 2 Use the DOWN key to select the lt User gt menu option The Name line is displayed as being active 88 5 psi 08 15 176 F 7 User Menu Name Citizen4 A
47. aaa aea Eaa aa oae aen aa a iaaa a a aaea eieiei 11 MdicatO Sa oa E RE E nas ak E a e E od O A A S 12 REID Sensor Thelde si 2 fect Meseucthede a o e a a e a A e a 13 KAESER CONNECT for SIGMA CONTROL 2 ccceccccceeeeeceeeeeeeeeeeceeeeeeceeeeeeeeeneeesesneeeeeesaees 17 FIG AGE seccticsas ETE EAE E A E TEA NEE EEEE seh fede gik E ES eet tka Rat dete ot fade 18 Status display saracia ela ee 44 Main MENi e enea terse a ati dareee teem peaa tapout terri Manta deol aa hy tevunt 45 Status menu with SUDMENUS cceccccceeeeeceeeeeeceeeeeeneeeeeseneeeeeseaeeeeeeaaeeeeseaeeeeeseaeeseesneeeeteneeeess 45 Pressure temperature graphs cc ccceeceeeeeeeeneeeeeeeeeeeeeaaeeeeeeeeeeenaaeeeeeeeeeeeeaaaaaaaaeeeeeeeeeeenneaeeeeeeeees 46 ATROW KO YS spies adie Retest tla Sid aes a Oeste dad a dec ta ed 47 Messages ia rania e neinean tent teaser dec orl Ales ster cables aetna Aide teehee mites nid Os 48 User administration Menu si 2tcrs cesteeeeesneents nii E E a i A ti R 49 Log On to write WINGOW sorient te ae eia aa naaa ei ae aata e aeaa ei ieia ait 49 Creating a NEW USET iisi ae Se de ed eee teed 50 SENGS os eters teeter wetter tact ls Maa thi he aca ee dea he iat Sh Hho byl calle tarct ee aa fl Ot dare tarot 51 Data BACKUP iienaa aa a Ne Suede sleet tes eaten ue 52 laere le CI EOE EE E E EEE EAE E ESE EEE chal qidsdaca die bad Migubadh oie bad ie tits seach gies 53 Pressure rise in frequency controlled machines ccc e
48. 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 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 31 KAESER COMPRESSORS 32 4 8 4 Design and Function 4 8 MODULATING control 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 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 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 distribut
49. failure fUNCUON zs SecA eee Aare dee A a ee ace Activating and setting up the Control modes cceeeceeeeeeeeeeeneeeeeeeeeeeennaeeeeeeeeeneennaaeeees 68 7 6 1 Selecting a control mode ccceceeeceeeeeneeeeeeeeeeeeeseneeeeeseaeeeeeseaeeeteeeaeeeeesneeeess 69 7 6 2 Adjusting the idle time of DUAL Mode ccecesecceeeeeeeeeeeeeeeeeeeeeeteneeeeeeenees 70 7 6 3 Adjusting the unloaded and minimum running period in QUADRO control 70 MOC ve seit E tee ee acter dee dee TEE 7 6 4 Setting the refrigerated dryer control modes ccccccceeeeeeeeeeeeeeeeeeeeeeeeeteneees 71 Configuring the machine for local mode cceeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeseeeeeeesnaees 72 7 7 1 Select menu lt configuration gt Pressure control gt Load control 0 72 7 7 2 Configuring the system pressure set point changeover using the clock 73 7 7 3 Configuring the system pressure setpoint changeover using the timer 75 Configuring the machine for master Control cc c cccceeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeenaees 77 7 8 1 List of the various master Controllers cccccceececeeeeceeeeeeeceeeeeeeeeeeteteeeeesnees 77 7 8 2 Configuring Profibus mode SIGMA AIR MANAGER or VESIS aaaeeeaa 78 7 8 3 Configuring the Profibus interface without SIGMA AIR MANAGER VESIS 84 7 8 4 Examples for master control of two machines using the Ethernet interfac
50. for master control 2 Press UP repeatedly until Loca mode is displayed as the active line 3 Press Enter to switch into setting mode The Local operation display flashes 88 5 psi 176 F 5 2 3 Load control Menu Local mode pA Active line current local operating mode Remote mode pA Key remote gt 1 pA pB Clock 4 Use UP or DOWN to set pA pB Clock or pA pB Cycle operating mode 5 Press Enter to accept the operating mode The actual operating mode is displayed 7 8 9 2 Configuring sequencing mode without an electrical connection Requirement A high capacity machine with SIGMA CONTROL 2 e g BSD is to work as base load machine A second machine e g SK without SIGMA CONTROL 2 is to supply air in times of low demand Proposal m Select the system set point pressures pA and pB of the BSD machine for the switching point of the SK machine s pressure switch to be in between When pB is activated for the periods of low demand the SK machine automatically functions as the base load machine m Set the required values for a clock program on SIGMA CONTROL 2 m Select local mode pA pB SC2 Clk Activate the compressor timer Function diagram Time period t1 t7 high compressed air demand Time period t8 t14 low compressed air demand t1 Air demand rises System pressure pNloc drops t2 BSD switches to LOAD t3 Setpoint pressure pA reached BSD switches to IDLE
51. gt The protective measures against the damages are shown here gt Carefully read and fully comply with warnings against damages 1 4 3 Other alerts and their symbols O I Material Here you will find details on special tools operating materials or spare parts This symbol identifies particularly important information Precondition 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 gt 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 6 gt as is a solution a This symbol identifies important information or measures regarding the protection of the envi ronment Further information Further subjects are introduced here Service manual Controller 9 9450 0O2USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 3 COMPRESSORS 2 1 Tab 10 Tab 11 2 Technical Data 2 1 SIGMA CONTROL 2 Controller Technical Data SIGMA CONTROL 2 Controller Industrial computer Internal temperature monitoring Internal undervoltage monitoring Battery buffered real time clock Battery life span more than 10 years Battery replaceable User interface with display CPU and i
52. gt is displayed as active line 88 5 psi 08 15 176 F 5 2 3 Load control Menu Local mode pA Remote mode pA pB SC2 Key remote m 1 pA pB Clock Active line 2 Press Enter The lt pA pB Clock gt menu is displayed 3 If you want to delete an existing clock program press UP until Reset is displayed as the active line 4 Press Enter to switch into setting mode The check box will flash Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER COMPRESSORS 9_9450 02USE Result 7 Initial Start up 7 8 Configuring the machine for master control 5 Press UP The check box is activated 88 5 psi 08 15 176 F 5 2 3 1 pA pB Clock Menu Reset m Active line delete existing clock program 01 n a 00 00 pA First switching point deleted 02 n a 00 00 pA Second switching point deleted 03 n a 00 00 pA Third switching point deleted 04 n a 00 00 pA Fourth switching point deleted 6 Press Enter to accept the setting You have deleted the existing clock program All switching points are reset to pA The Reset check box is deactivated automatically 7 Press the DOWN key repeatedly until the switching point 01 is displayed as the active line 8 Press Enter to switch into setting mode The Weekdays column flashes 9 Press UP repeatedly until Mon Fri appears 10 Press Enter to accept the setting 88 5 psi 08 15 176 F
53. if the user name and the password are lost Checking the machine status with KAESER CONNECT Using a PC with web browser you can call up a visualization of your machine s controller and thus check the energy efficiency of the machine KAESER CONNECT does not require additional and expensive special software applications KAESER CONNECT selectively visualizes the current sta tus of your controller in your country s language Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS Fig 6 Further information 9_9450 02USE 4 Design and Function 4 5 Checking the machine status with KAESER CONNECT KAESER SIGMA CONTROL 2 1 SK25 read gt write Logout Contact Service KOMPRESSOREN gt Select language English GB v 2 System status 3 Graphs 4 Messages 5 User management 6 Settings 7 Backup PN exon i SN 1063 EN 4234033 MCS PN 7 7601P0 MCS SN x xx xx MCS SW 1 0 1 1 04 C1371 KAESER CONNECT for SIGMA CONTROL 2 Choice of language User administration 2 System status 6 Settings 3 Graphs Data backup Messages KAESER CONNECT functions System status Mapping of the local menu Graphs Graphic representation of the main pressure and airend discharge temperature along the time axis Graphic representation of the compressor status OFF IDLE LOAD and RPM along the time axis Messages Current messages Mes
54. in order to reset the stored value gt Activate the check box See chapter 8 8 to test the safety relief valve Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 17 COMPRESSORS 12 Precondition 18 12 Checking the temperature sensor and overheating shutdown function 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 is added to the actual airend discharge temperature to cause the ma chine 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 m Shut down the machine and allow to cool down slightly Performing the test m Correct conclusion of the test Resetting Performing the test Machine cooled down by approximately 40 F 1 Log onto SIGMA CONTROL 2 with password level 2 see section 7 2 4 2 In operating mode switch to the main menu with the Enter key 3 Select the lt Machine test gt
55. 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 Check box Status z 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 O after 10 minutes without any key being pressed Secure storage of the RFID Equipment Cards You will receive 2 RFID Equipment Cards with each machine 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
56. input assigned td 0 s Logic Logic DOR 1 04 Warning 7 Message type operational alarm warning 7 10 3 3 Assign and activate the input 1 Press DOWN repeatedly until Input is displayed as active line 2 Press Enter to switch into setting mode The display of the input flashes 3 Select the input with the UP or DOWN keys 4 Press Enter to accept the setting 88 5 psi 08 15 176 F 5 7 3 1 External message 1 Menu External message 1 Message name Input is selected and activated td O s Logic Logic DOR 1 04 Alarm amp For example Fault message type 5 Press the Right key 6 Press Enter to switch into setting mode Check box flashes 7 Press UP key to activate the check box 8 Press Enter to accept the setting ok is displayed The input is assigned and activated 7 10 3 4 Set the time delay O The delay can be set between 0 01 and 600 seconds The delay is counted down from 600 with the DOWN key and counted upwards from zero in 0 01 second increments with the UP key 1 Press DOWN once Service manual Controller 9_9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 123 KAESER COMPRESSORS 124 Result 7 10 3 5 Tab 66 7 10 3 6 7 initial Start up 7 10 Configuring input and output signals 2 Press Enter to switch into the setting mode for the time delay The delay time display flashes 88 5 psi 08 15 176
57. into account Identifying the machine for operation in remote mode gt Attach the following notice to warn of remote machine operation suggestion A WARNING Remote control danger of unexpected starting gt Make sure the power supply disconnecting device is switched off before commencing any work on the machine Machine identification gt Label the starting device in the remote control center as follows suggestions A WARNING Remote control danger of unexpected starting gt Before starting make sure that no one is working on the machine and that it can be safely started Remote control identification Identifying the machine for clock control mode operation gt Attach the following notice to warn of remote machine operation suggestion A WARNING Clock control danger of unexpected starting gt Make sure the power supply disconnecting device is switched off before commencing any work on the machine Machine identification Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE 7 1 _ o 7 2 1 Precondition 7 Initial Start up 7 1 Outline Initial Start up 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
58. m For each machine with SIGMA CONTROL 2 Ethernet connector set For connecting the machines to a network LAN 2 Ethernet connection plugs gt Make the electrical connections as shown in the table below Installing the Ethernet cable For direct connection of the two machines Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 87 KAESER COMPRESSORS 88 7 8 5 2 Precondition Further information 7 8 5 3 O I 7 initial Start up 7 8 Configuring the machine for master control gt Install the Ethernet cable between the two machines For connecting the machines to a network LAN gt Install the Ethernet cable from each machine to the next LAN connection Connecting the Ethernet cable with the machine For each machine 1 Insert the Ethernet cable into the machine and the machine s control cabinet using an EMC connection 2 Lead the Ethernet cable through the cable ducts to SIGMA CONTROL 2 Use the wiring path in the 24V range blue wiring of the ducts 3 Install the Ethernet bus plug at the cable end 4 Push the bus plug into the Ethernet interfacee X1 of the SIGMA CONTROL 2 until it latches For connecting the machines to a network LAN Connect the Ethernet cable for each machine to the LAN connection 1 Install the Ethernet bus plug at the cable end 2 Push the bus plug into the LAN socket X1 until it latches Both Adjusting system setpoint pressure pA and pB
59. produces no com pressed air The working pressure does not rise above 50 psi within a default peri od Thermostatic valve defective Fault in the high voltage cell Aggregate A failed Aggregate B failed Refrigerated dryer The condensate drain is defective Compressor model uncertain The condensate drain is defective Drive belts or coupling broken Fault in the soft start equipment SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Remedy Check main contactor and wiring Check power supply volt age Check the door interlock switch Check venting line Check the cooling oil lev el Check the machine for leaks Check coupling V belts Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative Refrigerated dryer Check condensate drain and condensate con duits Contact an authorized KAESER service repre sentative Check condensate drain and condensate con duits Drive belt Replace drive belts Coupling Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative 147 KAESER COMPRESSORS 148 9 Fault Recognition and Rectification 9 2 Interpreting fault messages Message 0061 A Oil separator rise dT dt 0062 A Refrigeration dryer p
60. 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 Using the KAESER CONNECT 7 4 Matching the pressure parameters of the machine and possible modules 7 5 Configuring machine start and stop 7 6 Activating and setting up the control modes 7 7 Configuring the machine for local mode 7 8 Configuring the machine for master control 7 9 Configuring email 7 10 Configuring input and output signals 7 11 Activating remote acknowledgement 7 12 Linking to an external pressure transducer 7 13 Machine commissioning 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 gt Carry out settings as required m 7 2 1 Selecting menu options introduction m 7 2 2 Changing the display language m 7 2 4 Entering and displaying passwords m 7 2 5 Setting up time and date 7 2 6 Setting up display formats date time units of pressure and temperature m 7 2 7 Activating summer winter time m 7 3 4 Creating additional user accounts Selecting menu options All menu options can be selected with the DOWN UP and Enter keys Example Selecting the lt Configuration gt General gt menu option The display shows the operating mode 1 Press
61. slave is set Port 2001 Communication partner IP address 010 000 003 001 IP address 5 Press Enter to accept the setting Service manual Controller 96 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE Result 7 8 6 7 initial Start up 7 8 Configuring the machine for master control Press DOWN repeatedly until P address is displayed as the active line Press Enter to switch into setting mode 88 5 psi 08 15 176 F 8 1 2 1 SIGMA CONTROL 2 Mode Slave Port 2001 Communication partner IP address 169 254 100 101 IP address of communication partner master 8 Use UP or DOWN to set the IP address of Machine 1 9 Press Enter to accept the setting 10 Switch off the control voltage and then switch back on The system automatically saves the settings independently of the voltage Configuring master control using the LOAD remote contact e g SIGMA AIR MANAGER BASIC Overview Making the electrical connection for LOAD remote contact m Setting the LOAD remote contact operating mode and assigning the input Adjusting the pressure increase pE if necessary m Activating the Remote control key gt Configure master control as described below Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 97 KAESER COMPRESSORS 7 8 6 1 Fig 23 7 8 6 2 Precondition Result 98 7 initial Start up 7 8 Configuring the machine fo
62. speed ADT Ap oil separator m Starting temp Temperature MCS Main Control System Temperature first I O module Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 19 KAESER 4 Design and Function ore 2 4 e 10 2t 4 6 Menus overview Navigation 3 Operating data 4 Maintenance 5 Configuration 6 Compressor clock 7 User Service manual Controller 20 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Function submenu Operating hours Compressor On load Engine Airend SIGMA CONTROL 2 kWh counter Active Countpulse m kWh m Reset Load valve ON Oil filter Oil separator Oil change m Air filter Valve inspection Belts coupling inspection Bearing lubrication Motor bearings m Electrical equipment m Annual maintenance For details of the lt configuration gt menu see ta ble 30 Menu Configuration Activate deactivate compressor timer Delete reset the existing clock program Enter weekdays and times m Switching point 01 m Switching point 02 m Switching point 03 m Switching point 04 m Switching point 05 m Switching point 06 m Switching point 07 m Switching point 08 m Switching point 09 m Switching point 10 Name Password m Current access level 9_9450 02USE TO Nata 4 Design and Function oO 0st EA 4 6 Menus overview Navigation 8 Communication 9 Machine test 10 Components Tab 28 Menu structure 4 6 2
63. 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 dling time has elapsed the machine switches to STANDSTILL The dling time is factory preset according to the maximum starting frequency of the drive motor The shorter the d ing time setting the sooner and more frequently the drive motor is stopped Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE 4 7 3 _ o 4 Design and Function 4 7 Operating modes and control modes 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 VARIO The VARIO mode is based on the DUAL control mode The difference to DUAL is that t
64. switch 29 COMPRESSORS 30 16 Interpreting warning messages Message 0043 W External load signal 0044 W Oil temperature 4 0046 W System pressure 4 0047 W No pressure buildup 0048 W Bearing lube h 0049 W Annual maintenance 0059 W Start temperature 4 0060 W Start temperature 0061 W Compressor T 4 0066 W Air filter Ap 0068 W Condensate drain 0069 W Refrigeration dryer p 0070 W Refrigeration dryer T t Quick user guide Controller Possible cause Ambiguous external load signal Increased cut out pressure ex ceeded The external load control has not switched to idle off load Cooling oil temperature too low Network pressure has fallen be low the set low value Air consumption too high The compressor cannot build up to working pressure Re grease the motor bearings Maintenance interval has elapsed Last maintenance was 1 year ago The airend temperature is too low lt 14 F for the machine to be operated The airend temperature is too low lt 36 F The airend discharge tempera ture ADT did not reach the min imum value within the specified time Initial warning Air filter clogged The condensate drain is defec tive Refrigerated dryer Pressure too high in the refriger ant circuit Safety pressure switch tripped Refrigerated dryer Compressed air temperature too high SIGMA CONTROL 2 SCREW FLUID 1 0 2 x
65. the lt Configuration gt General gt System information gt menu 88 5 psi 08 15 176 F 5 1 1 System information Menu gt 2 Compressor gt 3 IO modules Service manual Controller 156 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 11 Spares Operating Materials Service eol Viini 11 4 Displaying the version number machine model part number and serial number 3 Press Enter to open the submenu The system information is displayed 88 5 psi 08 15 176 F 5 1 1 1 SIGMA CONTROL 2 MCS Menu egal Kaeser PN 7 7601 0 Part number SN X xx xx Serial number 4 Keep pressing the DOWN key to display further settings 88 5 psi 08 15 176 F 5 1 1 1 SIGMA CONTROL 2 MCS Menu SN xX XX XX Prodrive Manufacturer PN 6309 1000 7900 Part number SN 10 34 000 961 Serial number MFGDT 2010 08 Date of manufacture Service manual Controller 9_9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 157 COMPRESSORS 158 12 12 1 12 2 12 3 12 4 12 5 12 Decommissioning Storage and Transport 12 1 De commissioning Decommissioning Storage and Transport De commissioning gt Follow the instructions in the machine s service manual Packing gt Follow the instructions in the machine s service manual Storage gt Follow the instructions in the machine s service manual Transporting gt Follow the instructions in the machine s service manual Disposal gt Follow the instructions in the ma
66. the active line 88 5 psi 08 15 176 F 5 2 3 1 pA pB Clock Menu 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 Column time hours display 00 OO flashes in the active line 7 Use UP or DOWN to change the hour setting 8 Press the Right key once 9 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 display pA 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 clock program Take the following steps to delete an existing clock program Password level 2 is activated The lt Configuration gt Pressure settings gt Load control gt menu is selected 1 Press DOWN repeatedly until 0A 0B Clock is displayed as active line Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE Result 7 7 3 7 7 3 1 O I Precondition 7 initial Start up 7 7 Configuring the machine for local mode
67. the first two switching points are set Select the system set point pressure pA or pB for the first two switching points 1 Press the UP key repeatedly until the switching point 01 is displayed as the active line 2 Press the Right key once The column for system set point pressure pA or pB is displayed 3 Press Enter to switch into setting mode The column for the system set point pressure flashes 4 Use UP to specify the settings for the system set point pressure pA or pB 5 Press Enter to accept the settings 88 5 psi 08 15 176 F 5 2 3 1 pA pB Clock Weekday setting Reset m Precise start time 01 Mon Fri 06 30 pA System pressure for the first switching point 02 Mon Fri 17 00 pB System pressure for the second switching point 03 n a 00 00 pB 04 n a 00 00 pB 6 Enter the system set point pressure for the second switching point in the same manner 7 Press Escape repeatedly to return to the main menu Select the system set point pressure pA or system set point pressure pB for the first two switching points Set local mode Access level 2 is activated 1 Select the lt Configuration gt Pressure settings gt Load control gt menu The Local mode mode is displayed as being active Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE COMPRESSORS 9_9450 02USE Result 7 8 10 o Precondition Precondition 7 initial Start up 7 8 Configuring t
68. 0 4 Off 2000 415pm 4 20pm 4 25pm 4 30pm Start 08 15 2011 04 12 37 pm End 08 15 2011 04 33 29 pm Pressure temperature graphs lt Graphs gt menu Speed Network pressure Machine status Airend discharge temperature ADT N Check pressure activity Check airend discharge temperature w Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER COMPRESSORS 9_9450 02USE 7 3 2 1 Fig 12 Tab 47 7 3 3 Precondition 7 initial Start up 7 3 Using KAESER CONNECT Zoom and arrow key functions Use the Zoom function to enlarge significant curve developments Highlight a specific area within the graph by drawing a rectangle with the mouse pointer pressed The selected area will be enlarged as soon as the mouse pointer is released SIS AIL 1 3 5 07 C1391 Arrow keys Position Name Function 1 Start Display of oldest data 2 Scroll left Shift the display area to the left 3 Zoom out Time range is enlarged 4 Scroll right Shift the display area to the right 5 End Display of newest data Arrow keys and functions 1 Click the Start 1 arrow key The oldest data are displayed 2 Click the Scroll right 4 arrow key The display area is shifted to the right by 1 3 3 Draw a rectangle with the mouse pointer pressed Release the mouse pointer The selected are is enlarged zoom in function 5 Click t
69. 02USE COMPRESSORS 9_9450 02USE 1 1 1 2 1 2 1 1 3 1 Regarding this Document 1 1 Using this document Regarding this Document 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 gt Keep the manual in a safe place throughout the life of SIGMA CONTROL 2 gt Pass the manual on to the next owner user of the machine gt Ensure that all amendments received are inserted into the operating manual 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 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 lt Hostname gt 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
70. 1 0 2 x 99 KAESER COMPRESSORS 100 7 8 7 7 8 7 1 Fig 24 7 8 7 2 Precondition 7 initial Start up 7 8 Configuring the machine for master control 4 Press Enter to accept the setting The Remote control key is activated and can be used 5 Press the Remote control key to enable remote mode Configuring the master control with local LOAD remote contact Overview Making the electrical connections m Setting the local LOAD remote contact operating mode and assigning the input m Configuring the local operating mode if necessary Activating the Remote control key gt Configuring master control as described below Making the electrical connections Use the input Controller On for the alarm machine X message DOR 1 03 to prevent line breaks gt Wire the motor running and control on DOR 1 03 messages from the compressor to the MVS 8000 m Contact A open SIGMA CONTROL 2 controls with system set point pressurepB m Contact A closed SIGMA CONTROL 2 controls using a remote contact input m DI 1 13 LOAD IDLE external DI 1 09 LOAD control switchover local remote LOAD contact 07 S0628 Wiring diagram for local LOAD remote contact Changeover between automatic and manual modes LOAD IDLE contact gt Make the electrical connection according to the diagram Setting the local LOAD remote contact operating mode and assigning the input Password level 2 is act
71. 133 KAESER COMPRESSORS 8 3 Tab 68 134 8 Operation 8 3 Displaying the current operating mode Displaying the current operating mode The operating mode is displayed in 4 segments example On off switching via Machine state LOAD control via State of the LOAD control Key on pA Idle Operating mode display 1 In operating mode switch to the main menu with the Enter key 2 Select lt Status gt The lt Status gt menu is displayed 3 Press the DOWN key repeatedly until lt Current operating mode gt is displayed as the active line 88 5 psi 08 15 176 F 1 Status Menu gt 1 Messages gt 2 Statistics gt 3 Current pressure control gt 4 Current operating mode Active line gt 5 DI DO display 4 Press Enter Submenu lt Current operating mode gt is displayed 88 5 psi 08 15 176 F 1 4 Current operating mode Menu Compressor on Key Active line Load control pA Control mode DUAL Idle period Remains 140 s Abbreviation of operating modes Segment Display Meaning On off switching via Key ON key on the control panel Clock Internal timer RC Remote contact external LOAD signal RB Remote bus external bus signal cRC Clock or remote contact external LOAD signal Holidays Holidays see chapter 7 5 2 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS Tab 69 8 4 Further information 9_9450 02USE 8 5 Precondition 8 Operat
72. 2 5 Display 5 I Menu Flow rate 01 The line for sensor designation All 1 03 ok m 12 m3 h Measured value after calibration 20mA 50 4mA 0 Signal top range signal bottom range AOI2 00 0 0 0 mA 20mA 16000mmmmm 4mA mmmmm 6 Set the value for the bottom range 4 mA to zero accordingly The measured value adjusts to the calibration The signal value from the sensor can now be displayed in the lt performance data gt menu see chapter 8 5 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 121 KAESER COMPRESSORS 122 7 10 3 o 7 10 3 1 Precondition 7 10 3 2 7 initial Start up 7 10 Configuring input and output signals Display additional binary input signals As well as the defined alarm and warning messages there are 6 further freely selectable input sig nals that can be used to display messages A list of the defined alarm and warning messages is provided in chapters 9 2 and 9 5 Information on spare inputs is given in the machine circuit dia gram An input signal can be classified as either an alarm service or an operational message To sup press any possible contact bounce or similar problems the input signal can be delayed by an ad justable period This ensures that the signal must be apparent for a minimum period before it can be processed as a message If an input signal is classified as an alarm the controller enters the alarm state and shuts down the machine when th
73. 2 work as master slave in the same air network The mas ter controls the machine configured as a slave and provides the signal for the system pressure set point Example 2 machines with different delivery quantities Local operating mode of the master Local mode pA pB Clock Toggled between setpoints pA and pB by a clock program At peak load times pressure is regulated to system setpoint pressure pA During periods of low air demand pressure is regulated to system setpoint pB e g at week ends The machine with the lesser air delivery is the slave In times with lower air demand the machine with the smaller delivery is used more frequently Example 2 machines with equal delivery quantities Local operating mode of the master Local mode pA pB Cycle Switching between system setpoint pressure pA and pB using a timer The timer ensures even loading of both machines The system pressure setpoints are set the same for both machines During timer period 1 the master regulates to pA and signals the slave for pB During timer period 2 the master regulates to pB and signals the slave for pA If two machines SIGMA CONTROL 2 are to work in master slave mode their controllers must have the same software version gt Follow the configuration steps as described in table 59 Making the electrical connections Prepare the following for the Ethernet connection Ethernet cable 328 ft maximum depending on connection
74. 5 176 F 8 1 Ethernet Menu Fiep eunyan 2 Connections gt 3 E mail 2 Press Enter P adaress line is displayed as being active 88 5 psi 08 15 176 F 8 1 1 IP configuration Menu Subnet mask 255 255 000 000 Gateway 000 000 000 000 DNS Server 1 000 000 000 000 DNS Server 2 000 000 000 000 Restart network 3 Press Enter to switch into setting mode 4 Use UP or DOWN to set the IP address of at least one machine Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 initial Start up erol INEL ES 7 8 Configuring the machine for master control Specify the controller of machine 1 as master Precondition The menu lt Communication gt Ethernet gt Connections gt is selected 1 Press Enter The lt SIGMA CONTROL 2 gt menu is displayed as being active 2 Press Enter The Status line is displayed as being active 88 5 psi 08 15 176 F 8 1 2 1 SIGMA CONTROL 2 Menu Status Run 0 Error 0 Active line Mode n a Port 2001 Communication partner 3 Press DOWN repeatedly until Mode is displayed as active line 88 5 psi 08 15 176 F 8 1 2 1 SIGMA CONTROL 2 Menu Status Run 0 Error 0 Ae Port 2001 Communication partner 4 Press Enter to switch into setting mode n a flashes 5 Press UP to set the lt Master gt mode 88 5 psi 08 15 176 F 8 1 2 1 SIGMA CONTROL 2 Menu Mode Master Active line Port 2001 Communicati
75. 50 02 USE Adjusting the system setpoint pressure Access level 2 is activated The display shows the operating mode 1 NO Oe 8 9 Press Enter The main menu is displayed Select the lt Configuration gt Pressure control gt Pressure settings gt menu Switching point pA is displayed in the active line 88 5 psi 08 15 176 F 5 2 2 Pressure settings Current menu Setpoint pressure Parameter to be adjusted Active line settings for switching point pA pB SP 112 psi SD 7 3 psi Settings for switching point pB System pressure low 4 lt 73 psi SD 7 3 psi Press Enter to switch into setting mode The current value flashes Use UP or DOWN to adjust the setting for the switching point pA Press Enter to accept the setting Press the Right key once Press Enter to switch into the setting mode for the switching differential The current value flashes Use UP or DOWN to adjust the setting for the switching differential Press Enter to accept the setting 10 If necessary adjust the value for switching point pB in the same way 11 Press Escape repeatedly to return to the main menu See chapter 7 4 for the adjustment of the machine s pressure parameters Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x KAESER 6 Activating the clock key COMPRESSORS 6 Activating the clock key Activating deactivating the check box o
76. 80 KAESER COMPRESSORS Result O j Precondition Further information 9_9450 02USE 7 8 2 1 7 initial Start up 7 8 Configuring the machine for master control 1 Connect the bus subscribers one after the other according to the pin assignment below 2 Connect the screening to the plug housings at both ends 3 Switch in the terminating resistor in the plugs of the first and last subscribers to the Profibus The terminals for the remaining bus conduit 2A 2B are switched off Setting the remote operating mode pB When automatic mode is changed to manual mode at the sequencer SIGMA CONTROL 2 changes to the set remote mode In such cases it is preferable to set the operating mode to Remote mode pB gt Where more than one machine is involved make sure that the system set point pres sure pB is set for local operation Password level 2 is activated Menu lt Configuration gt Pressure control gt Load control gt is selected 1 Press DOWN repeatedly until Remote mode is displayed as the active line 2 Press Enter to switch into setting mode Operating mode flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu Local mode pA Remote mode pB Active line Key remote Z gt 1 pA pB Clock 3 Set operating mode pB with the UP or DOWN key 4 Press Enter to accept the setting The remote mode pB is set 5 Adjust the set point pressure pB if necessary See chapter 7 4 f
77. COMPRESSORS 116 Result Precondition Result 7 10 o 7 initial Start up 7 10 Configuring input and output signals Further setting options m SMTP port m Timeout m nterval repeats The email functions are configured and activated Suppress repeat messages setting an interval To suppress messages repeating at short intervals a period of 0 900 minutes can be set during which a repeat of the same message is suppressed i e is not sent Password level 2 is activated E mail submenu is displayed as being active 1 Press Enter 2 Press DOWN repeatedly until nferva is displayed as the active line 3 Press Enter to switch into setting mode The value for the time of suppression flashes 88 5 psi 08 15 176 F 8 1 3 E mail Menu Password Port 25 Timeout 10 s Interval 5 min Active line 4 Use the UP or DOWN keys to set the desired duration of suppression 5 Press Enter to accept the setting 6 Press Escape repeatedly to return to the main menu Suppression interval is set Configuring input and output signals The controller s binary and analog inputs and outputs can be used for other requirements This chapter deals with the various options in the following sections 7 10 1 Outputting important operational states of the compressors m 7 10 2 Display of analog input values 7 10 3 Displaying additional binary input signals The controller only allows
78. CREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 initial Start up ote IERES 7 12 Linking to an external pressure transducer 2 Select the lt Configuration gt Pressure control gt menu lt Pressure settings gt sub menu line is displayed as being active 88 5 psi 08 15 176 F 5 2 Pressure control Menu gt 1 Pressure sensors pees gt 3 Load control gt 4 Network actual pressure 3 Press DOWN twice lt Network actual pressure gt submenu is displayed as being active 4 Press Enter The menu lt Network actual pressure gt is displayed 88 5 psi 08 15 176 F 5 2 4 Network actual pressure Menu Active line local transducer All O 0 0 psi 7 12 2 Allocating the input to an external transducer 1 Press Enter to switch into setting mode pPNloc flashes 2 Press the UP key once Message FC USS is displayed 88 5 psi 08 15 176 F 5 2 4 Network actual pressure FC USS 55 psi Active line external transducer All O 0 0 psi 3 Press Enter to accept the setting Input FC USS Measured values via the frequency controller is shown in the display 4 Press DOWN once Line for input activation is shown in the display 5 Press the Right key Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 129 KAESER COMPRESSORS 130 Result 7 13 Tab 67 7 Initial Start up 7 13 Commissioning the machine 6 7 8 Press
79. Close the user s shut off valve between the machine and the air distribution network 4 Logon 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 6 Select the lt Machine test gt T V inspection gt menu Safety relief valve is displayed as an active line 88 5 psi 08 15 176 F 9 1 TUV inspection Menu Safety valve O Active line with check box pRV 232 psi pi O psi Relief valve activating pressure example Reset Performing the test 1 Press Enter The check box flashes in the active line 2 Use the UP key to activate the check box Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x COMPRESSORS 16 o Result 11 Safety relief valve checking Press Enter to accept the setting The test mode is now activated The monitoring of internal and network set point pressures is deactivated 88 5 psi 08 15 176 F 9 1 TUV inspection Menu Safety valve Active line with check box pRV 232 psi pi 36 psi Safety relief valve activating pressure Reset Excessive noise is caused when the safety relief valve blows off gt Close all access doors replace and secure all removable panels gt Wear hearing protection Risk of burns due to released cooling oil and compressed air when blowing off the safety relief valve gt Close all access doors replace and secure all removable panels gt We
80. Compressor ON Motor running IDLE LOAD Group fault Group warning Remote operation Timer active EMERGENCY OFF m Timer contact enter timing program Configure display of measured values Display 1 p Display 2 p Display 3 T Display 4 T Display 5 l Display 6 I Configure display of external messages External message 1 External message 2 External message 3 External message 4 External message 5 External message 6 Configuring the switching points for pressure and temperature m System pressure pNloc m nternal pressure pi Airend discharge temperature ADT m nlet temperature m Package discharge temperature PDT 25 KAESER 4 Design and Function ore 254 t e 10 2t 4 6 Menus overview 4 6 2 3 Communication menu Navigation Function submenu 8 1 Ethernet P configuration IP address Subnet mask Gateway DNS Server 1 DNS Server 2 Restart network m Connections SIGMA CONTROL 2 Restart Timeout Cycle time For details of the lt connections gt menu see ta ble 34 Menu Connections Email Activate deactivate email Compressor number Language Sender address Sender name Telephone number contact person Recipient address SMTP server User name Port Interval Service manual Controller 26 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE Design and Function KAESER 4 COMPRESSORS B33 Menus over
81. Contact an authorized KAESER service repre sentative 27 COMPRESSORS 16 28 16 Interpreting warning messages 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 0002 W Motor temperature t Possible cause Drive motor overheating Remedy Clean the motor Keep ambient conditions within specified limits 0004 W Oil separator Ap t The pressure drop across the oil Change the oil separator cartridge separator cartridge has risen Oil separator cartridge clogged 0007 W Drive motor bearing defective Contact an authorized KAESER Motor bearings service representative 0008 W Maximum airend discharge tem Clean the cooler Airend discharge temperature ADT perature will soon be reached Check the cooling oil level Replace the oil filter Ensure adequate ventilation Keep surrounding temperature within recommended limits 0011 W The pressure differential of the Change the oil filter Oil filter Ap t oil filter has risen Oil filter clogged 0013 W Air filter clogged Change the air filter element Air filter Ap t 0015 W The bus link from the Profibus Check bus highway and plug Bus alarm DP interface is interrupted 0017 W Refrigerated dryer
82. DOT Cable lengths Input output modules degree of protection Feature Degree of protection within the machine Degree of protection within the control cabinet Degree of protection IOM Input output modules dimensions Feature Width in Height in Depth in IOM dimensions Sensors Pressure transducer Feature Output signal mA Connection Pressure transducer Resistance thermometer Feature Sensing resistance to DIN IEC 751 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Value 1 6 Conductor length ft lt 100 lt 330 lt 100 Value IP 54 IP 20 Value 4 9 9 8 1 7 Value 0 4 20 Twin cable Value PT100 KAESER 2 Technical Data COMPRESSORS 2 1 SIGMA CONTROL 2 Controller Feature Value Connection Twin cable Tab 22 Resistance thermometer Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER COMPRESSORS 9_9450 02USE 3 3 1 I 3 2 3 3 3 Safety and Responsibility 3 1 Basic instructions Safety and Responsibility 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 accor
83. ESSORS viii Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab 55 56 57 58 59 60 61 62 63 64 65 66 67 List of Tables Example SWitChingPOlnts piorra snaa naiaiaee aeaaeae iee Eaa aaa a aaisa eaa aaa 110 Example for a clock program for equal duty cycling during the day ccceeeeeeeeeeetteeees 113 Example for a clock program for equal duty cycling during the week ccceeeeeeeeteees 114 Assigned Output signalS ic2ccicnidheihiedi Ad a a S a a aata nS 117 LOGIC 25 2 a e e Alero tacouth Mine hte tne cunt iad A tao cat Mas ohe tarcaat Ahab tee cal Alans bite 3 124 Checklist of installation conditions ccccceceeeeeeceeeeeeeeeeeeeeeeeeeecaeeeeeeaeeeeeecaeeeeseceeeeeesneeeeeseaees 130 Operating mode diS lay a e e a T a e a rae e eae ae e aaae Ea ae ai 134 Possible operating MOd6S i iisa e eis Me ed eek ee 134 Operational Messages sespe dee Palaces aces fe tars ete area tarred ete 138 Check box Stats sinici Ee dea 141 Fault messages and remedies ccccceeesseeeeceeeeeeeseneeeeeeeeeeeseteaeeeeeeeeeeessesaeseaeeesseessseeeaeeeeeeeess 145 System messages and remedies ccccccceeeeeceeeeeeceeeeeeeeeeeeeeceeeeeeaeeeeeeeaeeseeseeeeeseceeeeeeneeeeeees 149 Warning messages and remedies ccccceceeeeeesseecceeeeeeeseeeeeeeeeeeeeesseeeeeeeeeeenessneeeseeeeeseesesaees 150 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450
84. EW FLUID 1 0 2 x KAESER 6 Activating the clock key COMPRESSORS Result The machine runs according to the defined switching points of the clock program Further information See chapter 7 5 for configuration of starting and stopping the machine See chapter 7 7 2 for configuration of load changeover based on a clock program Quick user guide Controller 8 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02 USE TAN aya Activating the lt Remote control gt key COMPRESSORS 7 Activating the lt Remote control gt key Further settings have to be made to allow the machine to be remotely controlled o gt Refer to the section Additional information in this chapter Activating deactivating the check box Check box Status Z activated deactivated Tab 2 Check box status The following menus are used to activate the Remote control key m Menu lt Compressor ON gt m Menu lt Load control gt 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 lt Configuration gt Compressor start gt Compressor on gt 3 Press DOWN repeatedly until Key remote is displayed as active line 4 Press Enter to switch into setting mode T
85. Enter to switch into setting mode Display for remote mode flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu Remote mode pA pB RC Active line current operating mode Key remote 3 Use the UP key to select operating mode pA pB RC 4 Press Enter to accept the setting Operating mode pA pB remote contact is selected Assigning the remote contact input A spare input can be found in the machine circuit diagram 1 Press UP repeatedly until 0A oB RC is displayed as the active line 2 Press Enter to switch into setting mode DI flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu pA pB RC DI 1 05 ok Active line pA pB DO DOR 1 04 Load RC DI 1 13 ok a loc load RC DI 1 09 ok m No input assigned 3 Use the UP key to select input pA pB RC 4 Press Enter to accept the setting The input for remote contact has now been assigned Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER COMPRESSORS 9_9450 02USE 7 8 8 3 Precondition Result 7 8 9 7 8 9 1 7 initial Start up 7 8 Configuring the machine for master control Activating the remote control key Password level 2 is activated Menu lt Configuration gt Pressure control gt Load control gt is selected 1 Press UP repeatedly until Key remote is displayed as the active line 2 Press Enter to switch into setting mode Check box fl
86. L 2 operat ing manual Display In the display level information can be read and data entered The display comprises 8 lines each of 30 characters During operation the display will indicate the operating mode Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 13 KAESER COMPRESSORS 14 4 3 1 4 3 2 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 Operating mode 88 5 psi 08 15 176 F ah a Current operating mode e ek oS Da Operating parameters Run 2500h Load 2490h 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 m Working pressure Time Airend discharge temperature ADT 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 Remote control yes no Time control yes no Pressure control m The hours during which the machine was activated m The hours during which the machine ran in operating mode LOAD Main menu 88 5 psi 08 15 176 F m Deutsch lt Language gt 1 Status Sub
87. Menu Setpoint pressure pB SP 119 psi SD 7 3 psi System pressure low 4 lt 73 psi SD 7 3 psi Use UP or DOWN to adjust the value Press Enter to accept the setting Adjust the switching differential pA in the same manner If necessary adjust the value for pB in the same way OOF aE ee Press Escape repeatedly to return to the main menu Configuring local mode gt Set the clock program or timer as described in section 7 7 Assigning the potential free contact activate Access level 2 is activated the electrical connection made select spare contact from the machine s electrical diagram 1 Select lt Configuration gt Pressure control gt Load control gt 2 Press the DOWN key repeatedly until the following is displayed as active line 88 5 psi 08 15 176 F 5 2 3 Load control Menu pA pB RC DI 1 10 pA pB DO DOR 1 03 O Active line no output assigned 3 Press Enter to switch into setting mode Output display flashes Use DOWN or UP to select the required output DOR 5 Press Enter to accept the setting This output can now be used for the changeover between the two pressure switches Set local mode Password level 2 is activated 1 Select the lt Configuration gt Pressure control gt Load control gt menu Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 107 KAESER COMPRESSORS 108 7 initial Start up 7 8 Configuring the machine
88. Oil air cooler fan Overcurrent 0012 A Access doors 0013 A Compressor motor Overcurrent 0014 A Oil air cooler fan Overcurrent 0015 A Airend discharge temperature ADT 0016 A Oil air cooler fan Overcurrent 0019 A Internal pressure pi 0021 A Refrigeration dryer T 0022 A Oil separator Ap 0023 A Motor bearings 0024 A Water cooling water shortage 0034 A Mains contactor on 0035 A Cabinet fan 0038 A PD temperature 0039 A PD temperature Service manual Controller Interpreting fault messages Possible cause Overload shut down of the first fan motor Door open interlocked panel re moved while the machine is run ning Overload shut down of the com pressor drive motor Overload shut down of the second fan motor Maximum permissible airend dis charge temperature ADT exceed ed Overload shut down of the third fan motor Refrigerated dryer Compressed air temperature too low Oil separator cartridge clogged Drive motor bearings overheated Cooling water pressure is too low Main contactor does not close Overload shut down of the control cabinet fan motor Package discharge PD tempera ture too low Package discharge PD tempera ture too high SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Remedy Investigate cause of shut down Reset the overload relay Fit and secure all panels and close access doors Investigate cause of shut dow
89. Password level 2 is activated The lt Configuration gt Pressure control gt Pressure settings gt menu is selected 1 Press Enter to switch into setting mode The display of switching point pA flashes Adjust the value with the UP or DOWN key Press Enter to accept the setting Adjust the switching differential for the system setpoint pressure pA in the same manner Adjust the values for pB in the same manner OP Oy ons SD Press Escape repeatedly to return to the main menu Further information on setting up the pressure parameters is found in chapter 7 4 Master Configuring the system pressure setpoint changeover using the clock Keep to the order of the configuration 1 Set clock program 2 Select operating mode When a clock program is first set up note the start times for the system pressure setpoints on a sheet of paper first In addition to individual week days the controller has the following cycles available Mon Thu m Mon Fri Mon Sat Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS Further information Precondition Result 9_9450 02USE 7 Initial Start up 7 8 Configuring the machine for master control Mon Sun Sat Thu gt Record the start times for the system setpoint pressure The example given in chapter 7 7 2 describes the settings for a clock program in more detail Overview Deleting the exis
90. Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE IKKW SSC 2 02 en 01 BA SIGMA CONTROL FLUID IKKW SSC 2 02 01 20120530 132122 Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02 USE AON 4 9 Contents COMPRESSORS 9_9450 02 USE COP ON Nos IMporta t SOUUNGS 32 cee cesvesocese aiaa che ues seek decent de chy aaen ia eS aaae Ea eaa aa Eaa 1 Setting the contrast and the brightness c ccceeeesceeeeeeeeeeeeeeceeeeeeeeeeeeceeeeeeesneeeeesnaees 2 Setting the display language ccccccceeeeecceeeeeceeeeeeeeeeeeeeeeeeeeeaeeeeeceeseeeseeeeeesteneeeeeesaees 3 Entering a password iesise Na ee see edi 4 Adjusting the system setpoint pressure eee eceeceeeeeeeeeeeeeeneeeeeeeeeeenenaeeeeeeeeeeeeeeeeaea 5 Activating the clock Key ccccccccccccccccceeceeeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeetegs 6 Activating the lt Remote Control gt Key cccccccccccccceeeeeeeeceeeeeeeeeeeeeeeeeseeeeeeseseeaeeeeeeeaaees 9 Changing the control mode cccccecceeeeeeceeeeeeeeeeeeeeeeeeeeceeeeeeenaeeeeeeeaeeeeesneeeeessneeeesseaees 12 Outputting important operational states of the machine cceccceeeeeeeeeeeeseeeeeeteees 13 Resetting maintenance interval counters cccceeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeaaeeeeeeeeeeeaee 14 Safety relief valve CHECKING 2 ccecccceeeeeeeeeeee
91. T To close KAESER CONNECT for SIGMA CONTROL 2 click Logout 3 in the header Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 initial Start up eol VIIES 7 4 Adjusting the pressure parameters of the machine SIGMA CONTROL 2 1 SK25 read gt write Logout Contact Service KOMPRESSOREN 1 2 3 4 07 C1384 Fig 19 Header Machine designation Logout Activation Write mode Contact KAESER Service gt Click Logout The logout message is displayed Result You have closed KAESER CONNECT for SIGMA CONTROL 2 7 4 Adjusting the pressure parameters of the machine This section contains instructions for how to display and adjust the pressure parameters of the ma chine The section is divided into the following sections 7 4 1 Displaying pressure parameters 7 4 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 pressure relief valve on the oil separator tank pE Pressure increases Setting m pE SP Switching point for pressure increase upper safety limit for machine maximum pressure in an external LOAD control this value is used to switch the machine from LOAD to IDLE in the event of a fault pE SD Switching differential of pressure increase ApFC Limiting value for machines with frequency controlled drive SFC Setti
92. Work 2 s ce 22 Ae ee es a aa ees Fae ak eS es cee eae ees aes 155 11 Spares Operating Materials Service 11 1 Note the nameplate ccccccceeescceeeeeceeeeeeeeeeeeseaeeeeeaaeeeeecaaeeeseaeeeeesaeeesesaeeeeeteeeeeesenees 156 11 2 KAESER AIR SERVICE ieser Adie ated eh edie eel ae 156 11 3 Service Addresses sicrie ear e aee aa a aeaa aa e aae a 156 11 4 Displaying the version number machine model part number and serial number 156 12 Decommissioning Storage and Transport 12 1 De COMMISSIONING E 158 W222 RACKING E E E E EE A E A oo Se Ses et ek ey acct eee eda 158 12 3 Storage s 2 cees eve a Ea esate ces begs esate est esate sc ease dtes see eaa eaaa E des teen EEn 158 12 4 gt SPAMS POMING EE E T aatiee vane leseestdensadleiy cep ee vadleiy teehee cba alone shgeley 158 42 5 Disposal 22 2 02 05 cet eek es eee aie aera ae ete ae ee a ee ae tl te oe 158 Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Ul COMPRESSORS Contents Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE COMPRESSORS 9_9450 02USE Fi Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig g ANOARWN List of Illustrations REID MGA OF iniiao ga a o aae aa eae aa detay paaa e ea eaS Ra 4 System Structure jrin a aa a a E a a aae 10 Keys OV VIO Waa oa aaa
93. al Start up erel IREEN Eg 7 11 Activating remote acknowledgement Overview m Enter password level 2 m Select the lt Configuration gt Acknowledgement gt menu m Setting the remote acknowledgement function m Activating the remote key m Assigning an input m Press the remote key A CAUTION Machine damage can result from acknowledging a fault message without remedying its cause gt Find the fault and then decide to acknowledge or not 7 11 1 Selecting menu lt Configuration gt Acknowledgement gt Precondition Access level 2 is activated 1 In operating mode switch to the main menu with the Enter key 2 Select the lt Configuration gt Acknowledgement gt menu Remote mode line is displayed as being active 88 5 psi 08 15 176 F 5 5 Acknowledgement Menu Remote mode Key Active line with selecting key Key remote Remote key deactivated RC ack DI 1 11 7 11 2 Setting the remote acknowledgement function 1 Press Enter to switch into setting mode Key flashes 2 Press the UP key Key RCis displayed 88 5 psi 08 15 176 F 5 5 Acknowledgement Menu Remote mode Key RC Active line with selecting key remote contact Key remote RC ack DI 1 11 3 Press Enter to accept the setting Service manual Controller 126 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE Result 7 11 3 Result
94. 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 Tei aid WESTH Z Fig 2 System structure 1 Machine enclosure 6 Inputs outputs in the interior of the control Control cabinet cabinet SIGMA CONTROL 2 Inputs outputs in the interior of the com Input output module pressor IO bus Inputs outputs for external sensors 9 Compressor Function The control and regulating function allows Automatic changeover of the machine from LOAD to IDLE or STANDSTILL Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE COMPRESSORS 9_9450 02USE 4 2 4 Design and Function 4 2 Operating panel SIGMA CONTROL 2 m 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 m 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 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 6 04 S0118 Fig 3 Keys overview Item Name Function 1 OFF Switch off the machine 2 ON Swi
95. ance interval has elapsed Electric components and installa tion Maintenance interval has elapsed Motor bearing of fan motors Maintenance interval has elapsed Package discharge PD temper ature too low Compressed air discharge tem perature too high The permissible number of motor starts was exceeded in the last 60 minutes The permissible number of motor starts was exceeded in the last 24 hours The activating pressure of the safety relief valve will soon be reached 1 Power failure The machine is automatically re started SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Remedy Change the air filter element Contact an authorized KAESER service representative Carry out a visual inspection Re tension drive belts Contact an authorized KAESER service representative Inspect and reset the maintenance interval counter Contact an authorized KAESER service representative Contact an authorized KAESER service representative Clean the cooler Check the cooling oil level Extend the idle period Increase the capacity of air receiv er Increase the cross section of pip ing between compressor and air receiver Extend the idle period Increase the capacity of air receiv er Increase the cross section of pip ing between compressor and air receiver Change the oil separator cartridge Open the shut off valve in the venting line Check power supply Check the door interlock
96. ancel r 9 07 C1383 Log on to write window Log on to write window OK User name esc key Password 3 Enter your own user name 4 Enter your own password 5 Click OK Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 49 COMPRESSORS Initial Start up KAESER KOMPRESSOREN Using KAESER CONNECT SIGMA CONTROL 2 1 SK25 User management read gt write Logout Contact Service Result 50 User list System status Customer4 N Graphs Customer5 Messages Customer6 1 User management Customer7 Settings Backup Vv Show inactive users User account 2 User name Customer8 3 Password dekik 4 Repeat password aaan 5 Access level 2 Vv 6 User type Customer Vv 7 State Enabled Vv 8 Add Update user o9 O 389 Fig 16 Creating a new user lt User administration gt menu 6 User type New user name Status Password Add key Confirm the password 9 Update key Access level 6 Enter the new user name 2 7 Enter the new password 3 8 Confirm the new password 4 Select access level 2 5 10 Select user type Customer 6 11 Select status Activated 7 12 Click Add 8 The new user name has been added to the user list A new user account has been created and activated Updating user accounts
97. anual Controller Possible cause The airend temperature is too low lt 35 F The airend discharge tempera ture ADT did not reach the minimum value within the speci fied time Initial warning Air filter clogged The condensate drain is defec tive Refrigerated dryer Pressure too high in the refrig erant circuit Safety pressure switch tripped Refrigerated dryer Compressed air temperature too high Cooling oil level too low Refrigerated dryer The condensate drain is defec tive SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Remedy Keep ambient conditions within specified limits Contact an authorized KAESER service representative Change the air filter element soon Check the condensate drain and drain line Clean the refrigerant condenser Check the fan motor Maintain operating conditions Maintain operating conditions Clean the refrigerant condenser Clean the cooler Install a ventilation fan Replenish the cooling oil Check the condensate drain 153 KAESER 9 Fault Recognition and Rectification erel INER Eg 9 5 Interpreting warning messages Message Possible cause Remedy 0092 W 0093 W p Switch pi 0094 W T Switch ADT 0095 W p Switch pN Tab 74 Warning messages and remedies Service manual Controller 154 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE TO Nata 10 Maintenance ore idiin 10 1 Maintenance Work 10 Maintenance 10 1 Maintenance Work
98. ar eye protection Press and hold the ON key The machine switches to load the machine s internal pressure pi rises Monitor on the display the pressure rise pi during the check 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 relief valve If the alarm message PAV appears the safety relief valve is defective The permissible internal pressure was exceeded by 30 psi gt Have the safety relief valve replaced Avoid oil mist gt 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 Use the DOWN key to deactivate the check box Press Enter to accept the setting The test mode is deactivated and the test is completed Press Escape repeatedly to return to the main menu Open the shut off valve from the machine The machine is ready for operation Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02 USE COMPRESSORS Further information 9_9450 02 USE 11 Safety relief valve checking Resetting If the test is canceled when opening the safety relief valve SIGMA CONTROL 2 will indicate the highest measured value as internal pressure Activate the check box for reset
99. artis displayed as the active line 88 5 psi 08 15 176 F 5 4 Compressor start Menu gt 1 Compressor on gt 2 Compressor off Autostart O Automatic restart is deactivated Target 10 s Actual 0 s Set expiring delay period 2 Press Enter to switch into setting mode The check box for the Autostart function will flash 3 Press the UP key The check box for the Autostart function is deactivated Service manual Controller 9_9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 67 KAESER 7 initial Start up erol i inih Eg 7 6 Activating and setting up the control modes 4 Press Enter to accept the setting O 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 O If you operate several machines it is better to start them in sequence ial Time for restart Use the set times IDLE to LOAD of the other machines as base Precondition Password level 2 is activated The lt Compressor start gt menu is selected 1 Press DOWN repeatedly until the delay time for the restart is displayed as the active line 88 5 psi 08 15 176 F 5 4 Compressor start Menu gt 1 Compressor on gt 2 Compressor off Autostart 7 Automatic restart is activated Target 10 s Actual 0 s Set expiring delay period 2 Press Enter to sw
100. ase room temperature 0046 W Network pressure has fallen be Check air demand System pressure 4 low the set low value Check cable runs and sensor con Air consumption too high nections Check the sys press low warning setting 0047 W The compressor cannot build Check for air leaks No pressure buildup up to working pressure Check the value for internal pres sure given in the lt ana log data gt menu against the reading on the oil separator tank pressure gauge 0048 W Re grease the motor bearings Re grease the motor bearings Bearing lube h Maintenance interval has elapsed 0049 W Last maintenance was 1 year Carry out the necessary mainte Annual maintenance ago nance and reset the corresponding maintenance interval counter 0059 W The airend temperature is too Keep ambient conditions within Start temperature 4 low lt 14 F for the machine to specified limits be operated Service manual Controller 152 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE 9 Fault Recognition and Rectification 9 5 Interpreting warning messages Message 0060 W Start temperature 0061 W Compressor T 0066 W Air filter Ap 0068 W Condensate drain 0069 W Refrigeration dryer p t 0070 W Refrigeration dryer T 0071 W Oil level 4 0072 W RD condensate drain 0081 W 0082 W 0083 W 0084 W 0085 W 0086 W 0087 W 0088 W 0089 W 0090 W 0091 W Service m
101. ashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu Remote mode pA pB RC poe current pB 3 Use the UP key to activate the check box 4 Press Enter to accept the setting The remote control key can be used 5 Press the remote control key to enable remote mode The operating mode is now configured Configuring master control of compressors regulated by pressure switch gt Configure master control as previously described Configuring master control via floating relay contact Requirement A machine with SIGMA CONTROL 2 e g series BSD and a conventional machine without SIGMA CONTROL 2 of the same capacity are to run in sequence as base load or peak load ma chines Proposal Set adjust the clock program or timer on SIGMA CONTROL 2 m Select local mode with clock program pA pB Clock or timer pA pB Cycle Set system setpoint pressures pA and pB in the same way They must be identical to the pres sure switch settings on the machine without SIGMA CONTROL 2 To make the pA pB set point changeover between the two machines possible the local operat ing mode selected has to be assigned a floating relay contact An auxiliary contactor can be energized via this contact to activate the pressure switches for pA and pB on the compressor without SIGMA CONTROL 2 See example wiring diagram below Overview Establish the electrical connections Set setpoint pressures pA and pB Configure adjust l
102. assignment of spare inputs and outputs If an occupied input or output is assigned this will be rejected by the controller When delivered from the factory the outputs DOO 3 to DOO 5 are available for assignment Further spare outputs can be found in the machine circuit diagram gt Configure the inputs and outputs as described in the following Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE 7 10 1 Tab 65 7 10 1 1 Precondition 7 10 1 2 7 initial Start up 7 10 Configuring input and output signals Outputting important operational states of the machine Important operational machine states can be made available as a binary signal via volt free con tacts Each output can be assigned only once The following messages can be returned Message Explanation Outlet Controller on Controller is powered up Compressor on The machine is switched on Motor running Compressor motor running IDLE The machine runs in the IDLE operating mode ON LOAD The machine runs in the LOAD operating mode Group alarm Fault has occurred Group warning Warning message has appeared Remote mode Remote mode is activated Clock active The clock is activated Clock contact The clock contact is closed EMERGENCY STOP The EMERGENCY STOP switch is operated Assigned output signals Overview The configuration is entered in menu lt Configuration gt I O Peripherie gt DO
103. ated The lt Configuration gt Pressure control gt Load control gt menu is selected Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 15 KAESER COMPRESSORS Result 7 7 3 2 Result fe 76 7 initial Start up 7 7 Configuring the machine for local mode 1 Keep pressing the DOWN key until settings pA I pB appears in the 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 4 Press Enter to accept the setting 88 5 psi 08 15 176 F 5 2 3 Load control Menu pA pB Cycle active line timer period expiring period example 1 Start pA 00 00 5 Set the timer period for pB in the same manner 6 Press Enter to accept the setting Timer period for the setpoint pressure pA and pB is set Setting the starting time for pA or pB 1 2 3 Press the DOWN key Press the Right key Press Enter to switch into setting mode The starting time flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu pA pB Cycle pA 10 h 10hpB 18h 18h 1 StartpA 06 30 active line starting time Press UP to set the hours Press the Right key The starting time min flashes Press UP to set the minutes Press Enter to accept the settings The starting time for pA is set The period is to start with pB gt Press the Enter key and set first start pB w
104. ation 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 0001 O Load control pA 0002 O Load control pB 0003 O Load control RC 0004 O Load control RB 0005 O ready 0006 O Idle 0007 O On load 0008 O off 0009 O Compressor on 0010 O Controller on 0011 O Cold start release 0025 O Setpoint pressure pA 0026 O Setpoint pressure pB 0027 O Power OFF gt ON 0028 O Meaning The machine is regulated by system set point pressure pA The machine is regulated by system set point pressure pB The machine is regulated via the remote contactor The machine is remotely regulated via the bus connection The machine is switched on and in STANDSTILL operating mode The machine is switched on and in IDLE operating mode The machine is switched on and in LOAD operating mode The machine is switched off The power supply is connected The machine is switched on The power supply is connected The controller is powered The machine can be switched on although the machine tempera ture is below the permissible starting temperature The machine can be switched on only as long a
105. ay DUAL flashes 88 5 psi 08 15 176 F 5 3 Control mode Current menu Local mode QUADRO Active line with adjusted control mode 3 DUAL 4 QUADRO Use UP key to select the control mode QUADRO Press Enter to accept the setting Press Escape repeatedly to return to the main menu The regulating mode DUAL has been switched to QUADRO See chapter 4 7 for the functions of the control modes See chapter 7 6 for changing the parameters of the control modes Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02 USE TO Nata 9 Outputting important operational states of the machine COMPRESSORS Precondition Further information 9_9450 02 USE 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 also available as options You can as sign every output only once Password level 2 is activated The display shows the operating mode Menu configuration gt I O Periphery gt DO Functions 1 Press Enter The main menu is displayed 2 Select the lt Configuration gt I O periphery gt DO functions gt menu Controller on is displayed in the active line 3 Select the required message with the UP or DOWN key 88 5 psi 08 15 176 F 5 7 1 DO functions Menu DOR 1 05 J Logic Compressor on DOR 1 04 0 Logic Mo
106. be able to create user accounts you must activate the write mode 2 The system will prompt you enter and confirm your user name and your password Subsequently the m User name 6 to 16 characters the second character must not be a number m Password 6 to 16 characters Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed 1 Select the lt User administration gt menu The system displays the lt User administration gt menu Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE COMPRESSORS 9_9450 02USE Fig 14 Fig 15 Initial Start up Using KAESER CONNECT SIGMA CONTROL 2 1 SK25 read gt write Logout Contact Service KOMPRESSOREN 7 ser managemen 3 U g t TR 2 User list System status Customer4 A Graphs Customer5 Messages Customer6 1 User management Customer7 Settings Backup v Show inactive users A User account User name 4 Password Repeat password Access level 2 v User type Customer Vv State Enabled Vv Add Update user 07 C1373 User administration menu lt User administration gt menu User list Activate write mode User account 2 Activate the write mode 2 The Log on to write window opens 1 Log on for write acces 2 User name Customer4 3 Password ekeke dedede dede 4 OK C
107. ccceeeeeeeeeeeeceeeeeeeeeeeeeeeeeeeseaeeeteeneeees 57 Profibus plug WINING nease ege eee Geert ee ee teil a ee A 79 Electrical diagram example with SIGMA AIR MANAGER 2 ceeeceeeeeeeeeeeeeeeeeeeeeeneeeeeesnees 80 LOAD remote Contact 3222 c3 c2capedesssactensdt fed atete Hie asics thes a es a dh See Node peh te eat ae 98 Wiring diagram for local LOAD remote contact ccececccceeeeeeeeeeeceeeeeeeeeeeeeeeeeeeeeeeeeseaeeeetees 100 Machine with pressure switch regulation cee ecceeneeeeeeeeeeeeeeeeeeeeeeeeeeeeaaeeeeeeeeeeeeeaaeeaeeeeeeeeess 106 FUNGHON diagramen aa a el a E a Aa E N RAA 109 SWITCHING ON ANG Ko n e PE E E E E E EEE EE E ot 8d 132 Switching off in an emergency ceececceeeeeeceeeeeeeeeeeeeeeeeeeecaeeceecaeeeeeeaaeeeeceaeeesecseeeesssneeeeeeeaees 133 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x V ON 3N List of Illustrations COMPRESSORS Service manual Controller VI SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAES COMPRESSORS 9_9450 02USE Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab Tab ANOARWDN List of Tables Danger levels and their definitions personal injury
108. ceeeeeeneeeeesaaeeeeesaeeeeeseaeeeeeseneeeeseneeeees 47 7 3 4 Creating additional user ACCOUNTS cceeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeneeeeteeneeeeeenaees 48 03 5 Settings 2 ch se ee a Se E a a a 51 7 3 6 Performing a data backup cccceececeeeeeeeeeeeeceeeeeeeeeeeeeneeseeseeeseseeeeeeeneeeeeees 52 7 3 7 Closing KAESER CONNECT ccccccceceeeecceeeeeeeeeeeeeeeeeeeeaeeeeeseeeeeessneeeeeseaees 52 Adjusting the pressure parameters of the machine ccceeeceeeeeeeeeeeeeeeeeeeeeeeeteees 53 7 4 1 Displaying pressure parameters cccccececceeeeeeceeeeeeeeeeeeeeceeeeeseeeeeseneeeeeseaees 54 7 4 2 Configuring the pressure parameters for COMPIeSSOIS c ccceeeeeeeeeeeeees 55 7 4 3 Activating deactivating the IDLE key cccccecsccecceeeesessteeeeeeeesssessteeeeeeeeess 58 Configuring machine start ANd Stop ccceeeeeceeeeeceeeeeeeeeeeeceeeeceeneeeeeseaeeeeeeneeeeeeneeees 59 7 5 1 Automatic start stop in programmed clock mode ccececeeeeeeeeeeeeeeeeeeteees 59 7 5 2 Setting up the holiday period ccccceceeccceeceeeeceeeeeeeeeeeeeeeeeeeeeeeeseseeeeeseneeeees 62 7 5 3 Starting the machine remotely Remote ON OFF ccceeeeceeeeeteeeeeeeeees 63 7 5 4 Activating deactivating the idle phase Venting period function 00 66 7 5 5 Activating deactivating and adjusting the Automatic restart after a power 67
109. ch from the set point pressure pA to pB Master control of compressors regulated On machines with the same FAD 7 8 9 1 by pressure switch SIGMA CONTROL 2 controls the pressure There are two possibilities of linking to a SWitch via a floating relay output machine regulated by pressure switch On machines supplying an unequal FAD the 7 8 9 2 pressure ranges are matched to each other Tab 57 Master control overview Further information Examples of clock programs for equal machine loading are given in section 7 8 10 7 8 2 Configuring Profibus mode SIGMA AIR MANAGER or VESIS Overview Profibus DP VO interface retrofit kit is necessary m Make the electrical connections Set the remote operating mode pB m Configure the Profibus interface Activate the remote control key Precondition Profibus DP VO interface retrofit kit is required Making the electrical connections pe 5 Connections Spare Spare Profibus connection B TTL signal RTS Ground 5 V for bus terminal Spare Profibus connection A O ON OO AON gt Spare Tab 58 Profibus DP pin connection Service manual Controller 78 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 0O2USE KAESER 7 initial Start up erol INEL ES 7 8 Configuring the machine for master control Wiring the interface plug 07 C0623 Fig 21 Profibus plug wiring Terminal 1A Terminal 2B Terminal 1B Slide switch terminating resistor Terminal 2A
110. 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 Password level 2 is activated the lt Configuration gt General gt menu is selected see chapter 7 2 1 1 Press the DOWN key repeatedly until the current date is displayed as the active line 88 5 psi 08 15 176 F 5 1 General Menu gt 1 System information Date time 13 04 11 08 15 37 Current date Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 39 KAESER COMPRESSORS 40 7 2 6 Tab 42 Precondition 7 initial Start up 7 2 Configuring the controller 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 Setting display formats When setting the language several display formats will automatically adjust to local usage Setting the date format Select your pref
111. chine s service manual Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE
112. ck box for reset 88 5 psi 08 15 176 F 4 Maintenance Menu Oil filter 6000 h 6000 h Maintenance interval remaining new time Reset Active line Oil separator 6000 h 3000 h Reset 6 Press Enter to accept the setting The check box for reset is deactivated automatically The remaining time of the new oil filter complies with the defined maintenance interval of 3000 h or 6000 h dependant on machine model See chapter 8 7 for setting the maintenance intervals See chapter 10 for the maintenance of the controller Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02 USE COMPRESSORS 9_9450 02 USE 11 o Tab 3 11 Safety relief valve checking Safety relief valve checking Overview m Preparing the test m Performing the test m Correct conclusion of the test m Resetting When the check mode is activated monitoring of internal pressure blow off protection if provided and regulation of network pressure are deactivated The measured value of internal pressure pi is used to describe the following check Check box Status A activated deactivated Check box status A WARNING Danger of injury from pressurized components gt 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
113. ctivate High voltage cell does not deacti vate Main contactor does not close Main contactor does not open Overload shut down of the com pressor drive motor Overload shut down of the first fan motor SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Remedy Check high voltage cell and wiring Check high voltage cell and wiring Check main contactor and wiring Check main contactor and wiring Investigate cause of shut down Change the oil separator cartridge Investigate cause of shut down Reset the overload relay 9_9450 02 USE COMPRESSORS 15 Interpreting fault messages Message 0200 A Compressor motor USS alarm 0201 A Compressor motor USS alarm 0202 A Compressor motor USS alarm 0205 A Compressor motor USS alarm 0210 A Compressor motor FC Motor overload alarm 0211 A Compressor motor FC Motor overload alarm Tab 5 Fault messages and remedies 9_9450 02 USE Quick user guide Controller Possible cause Frequency converter fault Frequency converter fault Frequency converter fault Communications error Frequency converter fault Frequency converter fault SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Remedy Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative Check connection and line path Contact an authorized KAESER service repre sentative
114. ctive line Password 2 Yene Login Current access level 0 Display access level 0 3 Press Enter to switch into setting mode A column with alphanumeric characters is displayed 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 The user name is entered in full Enter current password The user name has been entered 1 Press DOWN once The Password line is displayed as being active Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 37 KAESER COMPRESSORS 38 Result Precondition Result 7 2 5 Precondition 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 5 psi 08 15 176 F 7 User Menu Name Citizen4 Password kkk kkk k kkk kkk kkk Active line Login Current access level 0 Display 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 The password is entered in full Logging on User name and password are entered 1 Press
115. d service personnel Quick user guide Controller 9_9450 02 USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 1 KAESER 2 Setting the contrast and the brightness COMPRESSORS 2 Setting the contrast and the brightness The display settings for contrast and brightness are set to the highest possible values by default Change the settings if adverse lighting conditions make it difficult to read the displayed information Optimizing the contrast settings Press and hold the Information key Atthe same time press the Left or Right key Optimizing the brightness settings Press and hold the Information key Atthe same time press the UP or DOWN key Precondition The display shows the operating mode 1 Press Enter The main menu is displayed 2 Press and hold the Information key 88 5 psi 08 15 Main menu gt 1 XXXXXXXXXX gt 2 XXXXXXXXXX gt 3 XXXXXXXXXX gt A XXXXXXXXXX gt 5 XXXXXXXXXX Active line with current language Submenu Submenu Submenu Submenu Submenu 3 Press UP or DOWN to adjust the contrast 4 Press Left or Right to adjust the brightness Result The settings for contrast and brightness have been adjusted Quick user guide Controller 2 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02 USE T Vaya y 3 Setting the display language COMPRESSORS Precondition 9_9450 02 USE Result 3 Setting the display language 1 The di
116. dance 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 gt Close and lock the door of the equipment properly gt 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 m this device may not cause interference and m 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 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 incurr
117. delta start Temperature warm start Star time at warm start Star time at cold start Star Delta changeover time Overload relays Mains contactor Star contactor Delta contactor Direct start Acceleration time Overload relays Mains contactor m High voltage cell Acceleration time ready Mains contactor SFC USS Micromaster Service mode Mains contactor m SFC USS Sinamics Service mode Mains contactor Tab 36 Power switching menu 4 7 Operating modes and control modes 4 7 1 Operating modes The machine operates in the following modes 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 Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 29 KAESER COMPRESSORS 30 Option C1 4 7 2 Tab 37 4 Design and Function 4 7 Operating modes and control modes STANDSTILL The inlet valve is closed The minimum pressure check valve shuts off the oil separator from the distribution network The venti
118. dly until DLE key is displayed as the active line Press Enter to switch into setting mode The check box for IDLE key will flash 88 5 psi 08 15 176 F 5 2 3 Load control Menu pA pB DO DOR1 04 Load RC DI1 13 ok 4 loc load RC DI1 09 Key idle m Active line with check box Press the UP key The deactivated check box is displayed Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER 7 Initial Start up ote Tst t F 10 7 5 Configuring machine start and stop 4 Press Enter to save the setting The IDLE key is deactivated 88 5 psi 08 15 176 F 5 2 3 Load control Menu pA pB DO DOR1 04 Load RC DI1 13 ok Z loc load RC DI1 09 rs Key idle O Active line with deactivated check box 5 Press Escape repeatedly to return to the main menu Result Thus it is ensured that unauthorized users can press the IDLE key without the machine switch ing to IDLE 7 5 Configuring machine start and stop gt In addition to manually starting the machine locally you have the following alternatives Function State on delivery setting See Automatic start stop in programmed clock mode No clock time program entered 7 5 1 Holidays Not set 7 5 2 Remote start e g from a control centre Deactivated 7 5 3 IDLE venting Activated 7 5 4 Automatic restart after power failure after delay period Activa
119. dryer Refrigerant lost pressure in the re frigerant circuit too low Inlet pres sure switched tripped SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Remedy Check the machine for leaks Check coupling V belts Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative Refrigerated dryer Check condensate drain and condensate con duits Contact an authorized KAESER service repre sentative Check condensate drain and condensate con duits Drive belt Replace drive belts Coupling Contact an authorized KAESER service repre sentative Check the cooling oil lev el Clean the refrigerant condenser Check the fan motor Maintain operating condi tions Contact an authorized KAESER service repre sentative 25 COMPRESSORS 26 15 Interpreting fault messages Message 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 0097 A High voltage cell on 0098 A High voltage cell off 0099 A Mains contactor on 0100 A Mains contactor off 0101 A Compressor motor Overcurrent 0102 A Oil air cooler fan Overcurrent Quick user guide Controller Possible cause High voltage cell does not a
120. e 86 master slave operation ccceceececeeeeeeceeeeeeeceeeeecaeeeeeceeeeeeeeeeeeseseeeeteeeeeetees 7 8 5 Examples for master control using the Ethernet interface master slave 87 OPSratlOn EAE SEE EE eh E EE E E E E stent Rem eae needa 7 8 6 Configuring master control using the LOAD remote contact e g 97 SIGMA AIR MANAGER BASIC ccceeeeceeeeeeeeeeeeeeeeeeeecaeeeeeeseeeeeeeenneeeetees 7 8 7 Configuring the master control with local LOAD remote contact 0 100 7 8 8 Configuring setpoint pressure pre selection via remote contact 0000 103 7 8 9 Configuring master control of compressors regulated by pressure switch 105 7 8 10 Examples of time settings for equal overall load ccccccceeeeeceeeeeeeeeeeeeeeees 113 Configuring email sssini an ween eects esos e tenes dseeeeiedeneecled 114 Configuring input and output Signals cceccecceeeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeetseeeetees 116 7 10 1 Outputting important operational states of the machine ceeeeeeees 117 7 10 2 Display analog input values c ccceceecceeeeeeeeeeeeeeeeeeeeeeeeeeceeeeeeeseeeeeteneeeeeseaees 118 7 10 3 Display additional binary input Signals cceeeecceceeeeeeeeeeeeeeeeeeeeeeeeeneeees 122 Activating remote acknowledgement ccceeeeeseeeeceeeeeeeeeeeeeeeeeeeeeeeeeenaneeeeeeeeeseenaaeeees 125 7 11 1 Selecting menu lt Configura
121. e communication with the II SIGMA AIR MANAGER The other parameters do not require adjustment When connected to a SIGMA AIR MANAGER the slave address is determined as follows Compressor number used at SIGMA AIR MANAGER 102 1 Press the DOWN key repeatedly until S ave is displayed as the active line Service manual Controller 82 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 initial Start up erol INEL ES 7 8 Configuring the machine for master control 2 Press Enter to switch into setting mode Slave flashes 88 5 psi 08 15 176 F 8 2 1 Profibus Menu Status Run 0 Error 4 Com Module Start Slave No 103 Active line current slave address assigned Bus alarm Start td 15 s 3 Set the slave address with UP or DOWN 4 Press Enter to accept the setting Result The slave address is assigned Setting the suppression time for bus alarm Exchange of data with a Profibus connection takes place in three fixed cycles The Profibus con nection can be monitored with the help of the cycle time The bus connection is considered to be interrupted if no data is exchanged between the bus mas ter and the controller as bus subscriber after expiry of a set time period timeout Timeout monitoring is activated You may neither adjust nor deactivate timeout for SIGMA AIR MANAGER 1 Press the DOWN key repeatedly until Start fd is displayed as the active line O After switching on
122. e repre sentative Contact an authorized KAESER service repre sentative Contact an authorized KAESER service Contact an authorized KAESER service Contact an authorized KAESER service Contact an authorized KAESER service 149 KAESER COMPRESSORS 150 Tab 73 9 4 9 5 9 Fault Recognition and Rectification 9 4 Interpreting diagnostic messages Message Possible cause Remedy 0005 Y System error Contact an authorized KAESER service RAM out of memory representative 1000 Y System error Contact an authorized KAESER service RFID error switch SIGMA representative CONTROL power supply OFF gt ON 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 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 Drive motor overheating Clean the motor Motor temperature t Keep ambient conditions within specified limits 0004 W The pressure drop across the Change the oil separator cartridge Oil separator Ap t
123. e signal is received Overview Use the lt Configuration gt I O Periphery gt External messages gt menu for the configuration Enter the message text Assign and activate the input m Set the time delay m Set logic Assign and activate the output m Select the message type operational alarm warning Activate the message Select the lt External messages gt menu Access level 2 is activated The electrical connections are made 1 In operating mode switch to the main menu with the Return key 2 Select lt Configuration gt I O periphery gt External messages gt see Section 7 10 1 1 The External messages menu is displayed 88 5 psi 08 15 176 F 5 7 3 External messages Menu Active line with external message No 1 gt 2 External message 2 gt 3 External message 3 gt 4 External message 4 gt 5 External message 5 gt 6 External message 6 Enter the message text External message 7 is shown as example 1 Press Enter External message 7 is displayed as active line 2 Press Enter to switch into setting mode The display of the character set flashes Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 initial Start up foto Tat t t 10 7 10 Configuring input and output signals 3 Enter the individual message text 4 Press Enter to accept the setting 88 5 psi 08 15 176 F 5 7 3 1 External message 1 Menu DI 1 11 No
124. eceeeeeeaeeeeeeeeeeeeeeaeeeeeccaeeeeecneeeeessneeeeeseaees 15 Checking the temperature sensor and overheating shutdown function e 18 Interpreting Operation MESSAGES ccceeeeceeeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeaaaeeeeeeeeeeeeaaaeeeeeeeeeeeaaa 20 Interpreting diagnostic MESSAGES ccceceeeeeeeeeeeeneeeeeeeeeeeeeaeeeeeeeeeeeeeeeeeaaeeeeeeeseeeenaaeeees 22 Interpreting fault MESSAGES ccceeeeeeceeeeeceeeeeeeeeeeeeeeeeeecaeeeeeecaeeeeeseaeeeeeeseeeeessneeeeeenaees 23 Interpreting warning Messages cccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaaeeeeeeeeeeeeeaeeeeeeeseneeaea 28 Interpreting system messages cccceeeeeeeeseseeeeeeeeeteeseseeeeeeeeeeeesseeeeeeeeeteestsceeeaeeeeeeens 32 Quick user guide Controller f SIGMA CONTROL 2 SCREW FLUID 1 0 2 x l COMPRESSORS Contents Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02 USE r Vi34 4 1 Important settings COMPRESSORS 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 O Setting and other work on the machine may only be carried out by the following persons m persons trained on the machine controller and persons instructed by and under the su pervision of a specialist m trained technicians m authorize
125. ections Activating the Remote control key Precondition Password level 2 is activated The lt Communication gt menu is selected 1 Press DOWN repeatedly until Key remote is displayed as the active line 2 Press Enter The check box for the Remote control key will flash 88 5 psi 08 15 176 F 8 Communication Menu gt 1 Ethernet 2 Com Module ey 3 Use the UP key to activate the check box 4 Press Enter to accept the setting The remote control function is activated and can be used 5 Press the Remote control key to enable remote mode 7 8 3 Configuring the Profibus interface without SIGMA AIR MANAGER VESIS O Contact KAESER Service for information on configuring the interface if Profibus is to be used Service manual Controller 84 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER 7 initial Start up erol IREL ES 7 8 Configuring the machine for master control Overview m Selecting a Profibus interface m Assigning the slave address m f necessary setting suppression time for bus fault m Activating the communications module m Assigning an output contact for the bus alarm message take a spare contact from the electri cal diagram Precondition Communications module from Profibus DP VO retrofit kit is installed The electrical connection to the bus master has been made Password level 2 is activated The required data has been provided by KAESER The display shows the op
126. ed gt Adhere to the specifications given in these operating instructions and the machine s service manual gt Operate the machine only within its performance limits and under the permitted ambient condi tions Improper use Improper usage can cause damage to property and or severe injuries gt Use SIGMA CONTROL 2 only as intended gt Do not use SIGMA CONTROL 2 to control other machines or products for which SIGMA CONTROL 2 is not intended Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 KAESER COMPRESSORS 10 4 1 4 Design and Function 4 1 The controller Design and Function 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 m 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
127. ed Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS Tab 24 Fig 5 Tab 25 Further information 9_9450 02USE 4 3 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 DLE Lights green when the compressor is running in IDLE Flashes when the LOAD IDLE toggle key is pressed 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 m Users log on to the machine no manual input of the password required O 04 S1102 RFID sensor field Item Name Function 24 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 CONTRO
128. eeeaeeeeeeeeeeeeeaaaeeeeeeeeeeeeaaeeeeeeeeeeeaaa 6 2 Machine identification sae rerea aere are a a r aeaaea A e ae ae r a Naa aa Initial Start up TA FOUN iie a e ee 7 2 Configuring the controller ccccccceccceeeeeceeeeeeeeeeeeeeeeeeeecaeeeesecaeeeeesaeeesesneeeeseeneeeeeesaees 7 2 1 Selecting menu options ececceeeeecceeeeeeeeeeeceeeeeeeeeeeeeeeeeeesaeeeeeeeeeeeeesseeeeeenaees 7 2 2 Changing the display language ccccseceeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeesneeeeeenaees 7 2 3 Access rights with equipment card 00 cceeeeeeee cere eeeneeeeeeeeeteeeeaeeeeeeeeeeeeeaee 7 2 4 Access right via manual input cece cece ee eeeeeeeeaeeeeeeeeeeeeeeaaeeeeeeeeeeeenaeeeees 7 2 5 Checking setting time and date Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x OUO NNN A NAAA COMPRESSORS Contents 7 3 7 4 7 5 7 6 7 7 7 8 7 9 7 10 7 2 6 Setting display formats ccccccccceeeeececeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeseeeeeseeneeeeesaees 40 7 2 7 Setting and activating summer winter time cc cccceeeeeeeeeeeeeeeeeeeteeeteenees 43 Using KAESER CONNEC Tarta a ar e a eae ae ea eea aa e a ea a eaaa aaa 43 7 3 1 Displaying the system status cccccceececceeeeeceeeeeeeeeeeeseeeeeeeeeeeeeseneeeeeeeseneeees 44 3 2 Display graph Sker e a a a alae hate eh a tant an 45 7 3 3 Displaying MESSAGES cceeeccceeeeeceeeeeee
129. eeeeeeeeseeeeteees 4 3 4 Activating keys with Check DOXES cc ccceeeeeeeeeeeeceeeeeeeeeeeeeeeeeeeeseeeeeeneeeetees AA ACCESS O lA E A Alec teeta ee tce et aveca tate seep rasasusatshastegsagaiacesardcduasauaiodd E cg aa 4 4 1 Secure storage of the RFID Equipment Cards ccccecceeeeeeeeeeeeeeeeeteeeees 4 5 Checking the machine status with KAESER CONNECT cceeeeeceeeeeeeeeeeeeeseeeees 4 6 Menus OV6RVIOW 2 asione eane Sadie bated ae inde cotta Geohadeb teas teens Pesta lertedtiet iae oats aeai edn 4 6 1 Operating MOde ara a a a a raaa Ea raaa aE Ee A r AE Aa Ee AE a AE EEEE 46 2 MeOnuiStructure cc ccccivhechcedh settee E aa E r a aa e bia eens Aho Lg 4 7 Operating modes and control modes ccceeecceeeeeeeeeeeeeeeeeeeeeeeeeeecaeeeeeseaeeeeesneeeeenenees ATA Operating MOdeS ea ar a Bante ck eee a aae a ate dik atte bah r a r a 7 A EP E Control MOdGS PAE E E ct ees suas r ee ee aes 4 7 3 Frequency controlled drive SFC ccccccccceceececeeeeeeeeeeeeeeeeeseeeeeeeeseeeeeesneeeees 4 8 MODULATING Control 00 ccccecccceeeccceeeeeeceeeeeeeeeeeecaeeeeeeaeeseecaeeeeseeaeeeeeseeeeeessneeeeseeesaees Installation and Operating Conditions 5 1 Maintaining ambient conditions ccccccceeeececeeeeceeeeeeeeeeeeeeeeeeeecaeeeeseaeeeeeseeeeeeneeeeeees 5 2 Installation Conditions minra a T T E E Installation 6 1 Reporting Transport Damage cccccceeeeeeeeeeeeeeeeeeeeee
130. elief valve gt Close all access doors replace and secure all removable panels gt Wear eye protection 6 Press and hold the ON key The machine switches to load the machine s internal pressure pi rises 7 Monitor on the display the pressure rise pi during the check 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 relief valve If the alarm message PAV appears the safety relief valve is defective The permissible internal pressure was exceeded by 30 psi gt Have the safety relief valve replaced Avoid oil mist gt 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 test mode is deactivated and the test is completed 4 Press Escape repeatedly to return to the main menu 5 Open the shut off valve from the machine The machine is ready for operation Resetting If the test is canceled when opening the safety relief valve SIGMA CONTROL 2 will indicate the highest measured value as internal pressure Activate the check box for reset in order to reset the stored value gt Activate the chec
131. enu Remote mode Key RC Key remote m RC ack DI 1 13 ok Active line input for Load RC is assigned and acti vated 9 Press the remote key to enable remote acknowledgement Should a warning message occur it can now be acknowledged from a remote control center Linking to an external pressure transducer If the air system is operated with an air receiver the pressure in the receiver can be regulated by an external pressure transducer The sensor output can be linked in the following ways Via a Profibus link from a master controller An input does not have to be assigned m Via the USS protocol from a pressure transducer linked to the frequency converter assigned to input FC USS Via a pressure transducer connected to SIGMA CONTROL assignment of an analog input re quired Characteristics 4 20 mA 0 232 psi 0 14 5 psi a for Vacuum The controller processes the options in the following sequence Profibus value m Pressure according to the assigned external transducer System pressure pNloc the local system pressure transducer remains activated Overview Enter password level 2 m Select the lt Configuration gt Pressure control gt menu m Assigning an input Selecting menu lt Configuration gt Pressure control gt Access level 2 is activated 1 In operating mode switch to the main menu with the Enter key Service manual Controller SIGMA CONTROL 2 S
132. erating mode Selecting a Profibus interface Press Enter Press DOWN repeatedly until lt Communication gt is displayed as the active line Press Enter Press the DOWN key Menu lt Com Module gt is displayed as the active line 88 5 psi 08 15 176 F 8 Communication Menu gt 1 Ethernet gt 2 Com Module Active line Key remote PQ Nios 5 Press Enter Profibus line is displayed as being active 88 5 psi 08 15 176 F 8 2 Com Module Menu gt 1 Profibus Active line gt 2 Modbus gt 3 Modbus TCP gt 4 DeviceNet 6 Press Enter Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 85 KAESER COMPRESSORS 86 0 Result 7 8 4 7 initial Start up 7 8 Configuring the machine for master control Assigning the slave address The permissible address length is between 3 and 126 characters For configuring the Profibus interface without SIGMA AIR MANAGER or VESIS the rule compressor number 102 does NOT apply 1 Press the DOWN key repeatedly until S ave is displayed as the active line 2 Press Enter to switch into setting mode The slave display flashes 88 5 psi 08 15 176 F 8 2 1 Profibus Menu Status Run 0 Error 4 Com Module Start Slave No 103 Active line current slave address assigned Bus alarm Start td 15s 3 Set the slave address with UP or DOWN 4 Press Enter to accept the settin
133. erating mode see Section 7 7 3 3 When setting a clock program for the first time note the switching times on a sheet of paper first n addition to individual week days the controller has the following cycles Mon Thu m Mon Fri Mon Sat Mon Sun m Sat Thu Example m Peak load period weekdays 06 30 17 00 Fridays 06 30 16 00 m 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 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 Password level 2 is activated The lt Configuration gt Pressure settings gt Load control gt menu is selected see Section 7 7 1 1 Press DOWN repeatedly until 0A oB Clock is displayed as the active line Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 73 KAESER COMPRESSORS 74 Precondition 7 initial Start up 7 7 Configuring the machine for local mode 2 Press Enter The system displays the setting options for the switching points 5 2 3 1 pA pB Clock Menu 02 n a 00 00 pA 03 n a 00 00 pA 04 n a 00 00 pA 05 n a 00 00 pA 3 Press Enter to switch into setting mode n a flashes in
134. erred format Format Example DD MM YY 30 07 10 YY MM DD 10 07 30 MM DD YY 07 30 10 Date formats Password level 2 is activated Menu lt Configuration gt General gt is selected see 7 2 1 1 Press the DOWN key repeatedly until Date format is displayed as the active line 88 5 psi 08 15 176 F 5 1 General Menu Date time 13 04 11 08 15 37 Europe Berlin Date format DD MM YY Current date format 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 key 4 Press Enter to save the setting 5 Press Escape repeatedly to return to the main menu Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER COMPRESSORS Tab 43 Precondition Tab 44 Precondition 9_9450 02USE 7 Initial Start up 7 2 Configuring the controller Setting the time format Select your preferred format for the time display 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 lt Configuration gt General gt is selected see 7 2 1 1 Press the DOWN key repeatedly until 7ime formatis displayed as the active line 88 5 psi 08 15 176 F 5 1 General Menu Date time 13 04 11 08 15 37 Europe Berlin Date format DD MM YY Time format hh mm ss Current time format 2 Press Enter to switch into settin
135. g The slave address is assigned Further steps Proceed with the further configuration as outlined in section 7 8 2 1 gt f required also set the suppression time for the bus alarm Examples for master control of two machines using the Ethernet interface master slave operation Configuration procedure Controller Procedure Chapter Both Establish the electrical connections 7 8 5 1 Both Set system pressure set points pA and pB The pressure for switching points 7 8 5 2 p and pB is measured directly at the compressor Pressure losses in the net work do not need to be taken into account master Either set up switching times for the clock program 7 8 5 3 or set switching times for the timer 7 8 5 4 master Set the type of LOAD control clock program or timer in local mode 7 8 5 5 slave Set remote mode pA pB SC2 7 8 5 6 slave Activating the remote control key 7 8 5 7 Both Set IP addresses for Ethernet 7 8 5 8 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE Tab 59 7 8 5 o 7 8 5 1 7 Initial Start up 7 8 Configuring the machine for master control Controller Procedure Chapter Both Activate master or slave 7 8 5 8 Master slave configuration procedure gt Proceed with the configuration as described below Examples for master control using the Ethernet interface master slave opera tion Two machines with SIGMA CONTROL
136. g mode hh mm ss flashes 3 Change the format with the DOWN or UP key Press Enter to save the setting 5 Press Escape repeatedly to return to the main menu Setting the pressure display units Select your preferred display of the pressure units 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 lt Configuration gt General gt is selected see 7 2 1 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 41 KAESER COMPRESSORS 42 Tab 45 Precondition 7 initial Start up 7 2 Configuring the controller 1 Press the DOWN key repeatedly until Pressure unitis displayed as the active line 88 5 psi 08 15 176 F 5 1 General Menu Time format hh mm ss Temperature unit C Display lighting 2 Press Enter to switch into setting mode The bar parameter flashes 3 Change the unit with the DOWN or UP key 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 units Format Example C 46 C K 319 K oF 114 F Units of temperature Password level 2 is activated Menu lt Configuration gt General gt is selected see 7 2 1 1 Press the DOWN key repeatedly until 7emperature unit is displayed as the active line 88 5 psi
137. gt menu is selected Call up the menu for pressure parameters 1 Press DOWN or UP repeatedly until Pressure settings is displayed as the active line 2 Press Enter The system displays the pressure parameters 88 5 psi 08 15 176 F 5 2 2 Pressure settings Menu pA SP 116 psi SD 7 3 psi Active line pB SP 110 psi SD 5 8 psi System pressure low 4 lt 73 psi SD 7 3 psi ta 600 s DOR 1 04 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER 7 initial Start up erol VIIES 7 4 Adjusting the pressure parameters of the machine Displaying compressor parameters 1 Press DOWN repeatedly until Setpoint pressure is displayed 88 5 psi 08 15 176 F 5 2 2 Pressure settings Menu Setpoint pressure Active line pA SP 116 psi SD 7 3 psi Current system setpoint pressure pA and switching differential pB SP 110 psi SD 5 8 psi Current system setpoint pressure pB and switching differential System pressure low 2 Displaying further parameters with the UP and DOWN keys 7 4 2 Configuring the pressure parameters for compressors 7 4 2 1 Adjust the system setpoint pressure pA and pB The pressure parameters can only be set within certain limits Rated machine pressure gt SP pA pB gt minimum cut in pressure switching differential Tab 49 Setting limits for system setpoint pressure Cut in pressure min
138. he Zoom out 3 arrow key Time range is enlarged zoom out function Displaying messages The following messages are shown m Current messages m Compressor messages m System messages Diagnostic messages KAESER CONNECT for SIGMA CONTROL 2 is displayed 1 Open menu lt Messages gt Menu lt Messages gt is displayed Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 47 KAESER 7 initial Start up fore Vidinio 7 3 Using KAESER CONNECT 48 KAESER SIGMA CONTROL 2 1 SK25 read gt write Logout Contact Service 7 Messages 2 Current Compressor System Diagnosis System status Current Messages Graphs Date Time State Message Message type ID 1 Messages User management 08 08 11 16 35 33 PM a Belt coupling inspection h Warning message 30 Settings Backup Fig 13 Messages 1 Menu lt Messages gt 2 Current messages 3 Compressor messages 2 Check messages 7 3 4 Creating additional user accounts System messages Diagnostic messages 07 C1381 Use the lt User administration gt menu to create additional user accounts for other employees jo write mode is activated The write mode is granted only to one person at a time If a second user attempts to log on in write mode he will be refused by the system The system will return an error message Length for personally created user names and passwords In order to
139. he d ing 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 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
140. he check box for Remote control key will flash 88 5 psi 08 15 176 F 5 4 1 Compressor on Menu Local mode Key Remote mode Key RC DI 1 12 Key clock 5 Press the UP key The activated check box is displayed Quick user guide Controller 9 9450 02 USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Te Naya y 7 Activating the lt Remote control gt key COMPRESSORS 10 i Precondition Press Enter to save the setting The Remote control key is activated and can be used 88 5 psi 08 15 176 F 5 4 1 Compressor on Menu Local mode Key Remote mode Key RC DI 1 12 Key clock Press Escape repeatedly to return to the main menu 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 Password level 2 is activated The display shows the operating mode 1 Press Enter The main menu is displayed Select lt Configuration gt Pressure control gt Load control gt Press UP repeatedly until Key remote is displayed as active line Press Enter to switch into setting mode The check box for Remote control key will flash 88 5 psi 08 15 176 F 5 2 3 Load control Menu Local mode pA Remote mode pA gt 1 pA pB Clock Press the UP key The activated check box is displayed Quick user gu
141. he machine for master control 2 Press Enter to switch into setting mode The Local operation display flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu Local mode pA pB Clock Active line es Current local mode Remote mode pA pB SC2 Key remote gt 1 pA pB Clock 3 Press UP repeatedly until Loca mode pA oB Clock appears 4 Press Enter to accept the setting The current local mode pA pB Clock is set Examples of time settings for equal overall load Requirement Two machines of the same capacity are to be equally loaded Versions A B and C describe the different possibilities of achieving this requirement A detailed description for configuring a clock or timer program can be found in chapter 7 7 Variant A Daily switch between system set point pressure pA and system set point pressure pB after 24 hours The compressors start with a system set point pressure pB at 00 00 hours A timer triggers the switch between system set point pressurepA and system set point pressure pB local operating mode Local mode pA pB Cycle The setpoint pressure pA pB is configured the same for both machines gt Establish a cycle with the following switching points m Cycle time pA 24 h m Cycle time pB 24 h m Start pB 01 00 00 Variant B Equal duty cycle during the day A timer triggers the switch between system set point pressure pA and system set point pressure pB local operating mode pA pB Clock
142. he system displays the lt Settings gt menu 2 Click the arrow key for the unit of pressure A selection list of units of pressure is displayed 3 Select the desired unit Click the arrow key for the unit of temperature A selection list of units of temperature is displayed Select the desired unit Set additional units and date and time formats Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 51 COMPRESSORS 7 3 6 Precondition Fig 18 Result 7 3 7 52 7 initial Start up 7 3 Using KAESER CONNECT Performing a data backup In order to use KAESER CONNECT to easily back up data from the SIGMA CONTROL 2 to your own PC use the lt Data backup gt menu You can choose to either perform a full backup or partial backups m Full Log files m Settings User data KAESER CONNECT for SIGMA CONTROL 2 is displayed 1 Open the lt Data backup gt menu The system displays the lt Dala backup gt menu KAESER SIGMA CONTROL 2 1 SK25 read gt write Logout Contact Service Backup x a a A 2 lUlUltCGS A ee Select source Backup all a 3 Backup all Back System status Log files Settings Graphs User information Messages User management Settings 1 Backup 07 C1382 Data backup 1 lt Data backup gt menu 2 Selection 3 Data backup key 2 Select 2 3 Click the Data backup 3 key Data is saved to your PC Closing KAESER CONNEC
143. hree 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 m nternal temperature monitoring m nternal undervoltage monitoring m LED indication of operational status IOM 1 Input Output Input output module 1 Internal into available in External into the control parallelon the compres cabinet both sides sor interior Digital input DI 24 VDC 4 10 2 Analog input current All 0 20 mA 1 2 Analog input resistor AIR PT100 1 3 Digital output relay DOR 250 VAC 8A 8 Digital output transistor DOT 24 VDC 0 5 A 2 1 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 5 COMPRESSORS Tab 14 Tab 15 Tab 16 2 1 2 1 2 Technical Data 2 1 SIGMA CONTROL 2 Controller Input Output Analog output current AOI 0 20 mA SC2IOM 1 IOM 2 Input Output Digital input DI 24 VDC Analog input current All 0 20 mA Analog input resistor AIR PT100 Digital output relay DOR 250 VAC 8A Digital output transistor DOT 24 VDC 0 5 A Analog output current AOI 0 20 mA SC2IOM 2 IOM 3 Input Output Digital input DI 24 VDC Analog input current All 0 20 mA Analog input resistor AIR PT100 Digita
144. ide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02 USE T N aya Activating the lt Remote control gt key COMPRESSORS 6 Press Enter to accept the setting The Remote control key is activated and can be used 88 5 psi 08 15 176 F 5 2 3 Load control Menu Local mode pA Remote mode pA gt 1 pA pB Clock Press Escape repeatedly to return to the main menu Press the Remote control key to enable remote mode O Proceed in the same manner to deactivate the Remote control key I Further information See chapter 7 5 for configuration of starting and stopping the machine See chapter 7 8 for configuration of load changeover under master control Quick user guide Controller 9 9450 02 USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 11 Te VaSa4 9 8 Changing the control mode COMPRESSORS O I Precondition Result Further information 12 Changing the control mode The standard setting of the control mode depends on the machine type Access level 2 is activated The display shows the operating mode 1 4 5 6 Press Enter The main menu is displayed Select the lt Configuration gt Control mode gt menu Local mode is displayed as an active line 88 5 psi 08 15 176 F 5 3 Control mode Current menu Local mode DUAL Active line with control mode to be adjusted gt 3 DUAL gt 4 QUADRO Press Enter to switch into setting mode The control mode displ
145. ing this menu the recorded data from the last 60 minutes is loaded The last 20 minutes are displayed in a graph The system updates the graph every ten seconds while the current time is displayed Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 45 KAESER COMPRESSORS 46 O Precondition Fig 11 7 initial Start up 7 3 Using KAESER CONNECT Moving the mouse pointer across the graph calls up a ruler The time selected with the ruler and the associated values are displayed in the legend above the graph When the ruler is hidden the time and associated values are display at the right edge of the graph The following graphs can be displayed Network pressure Airend discharge temperature m Machine status OFF IDLE LOAD m Speed The display of the speed is implemented only for machines with frequency converter SFC models KAESER CONNECT for SIGMA CONTROL 2 is displayed 1 Select the lt Graphs gt menu The system displays graphs KAESER KOMPRESSOREN SIGMA CONTROL 2 1 SK25 read gt write Logout Contact Service Graphs E System pressure pN 7 6 bar 2 E Airend discharge temperature ADT 82 5 C m Compressor status Load E Speed n 2378 min System status 1 Graphs pN bar Messages User management gt Settings a Backup 4 15 4 20 4 25 4 30 on 5 m 7 m m m Load k i poy 4000 jin 3500 54 Idle 3000 n 250
146. iod Menu venting period 2 DUAL gt 3 QUADRO 3 Press Enter to switch into setting mode The control mode display DUAL flashes 88 5 psi 08 15 176 F 5 3 Control mode Menu Local mode QUADRO Active line 1 Venting period Menu venting period 2 DUAL gt 3 QUADRO 4 Use UP to change the regulating mode to QUADRO Press Enter to accept the setting Press Escape repeatedly to return to the main menu Service manual Controller 9_9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 69 KAESER COMPRESSORS 70 7 6 2 Precondition 7 6 3 7 initial Start up 7 6 Activating and setting up the control modes Adjusting the idle time of DUAL mode The machine comes to a STANDSTILL when the specified idle period has elapsed 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 idling time or standstill time Password level 2 is activated Control mode is selected The display shows the operating mode 1 Press Enter The main menu is displayed 2 Select the lt Configuration gt Control mode gt DUAL gt menu see section 7 6 1 The idling time setting is shown in the active line 88 5 psi 08 15 176 F 5 3 2 DUAL Menu Idle period Target 240 s Actual 0s Active line 3 Press Enter to switch into se
147. ion KAESER 8 COMPRESSORS BR x3 Displaying operating data 2 Select the lt Performance data gt menu A list of Performance data is displayed 88 5 psi 08 15 176 F 2 Performance data Menu System pressure pNloc 88 psi Local System pressure pNloc ADT T 176 F Airend discharge temperature dT dt 32 F s Increase airend discharge temperature Oil separator Ap 32 psi Oil separator differential pressure 3 Keep pressing the DOWN key to display further Performance data settings 88 5 psi 08 15 176 F 2 Performance data Menu Starting temperature 32 F Motor temperature MCS T 97 F Controller temperature Main Control System First IOM T 32 F Temperature first 1 O module 4 Press Escape repeatedly to return to the main menu 8 6 Displaying operating data The following information can be called up in the lt operating data gt menu option lt Operating hours gt Compressor Total machine running time Load run 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 Load valve Total number of activations Displaying operating data Precondition Password level 2 is activated 1 In operating mode switch to the main menu with the Enter key Service manual Controller 136 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE Precondition 8
148. ion 8 4 Adjusting working pressure Segment Display Meaning Machine state ON Switched on OFF Switched off Alm Alarm There is a fault registered LOAD control via pA System setpoint pressure pA pB System setpoint pressure pB pE Raised system pressure pE at a dubious LOAD signal RC Remote contact external LOAD signal RB Remote bus external bus signal State of the LOAD control Idle IDLE Load LOAD Ready Drive motor off and machine ready to operate Drive motor started with air demand Off Drive motor is off Possible operating modes Adjusting working pressure gt Adjust the pressure parameter to suit the compressor and application A detailed explanation of all pressure parameter settings is given in chapter 7 4 Displaying analog data The following information can be called up in the lt Performance data gt menu option Local system pressure Discharge temperature Rate of rise of the airend discharge temperature Oil separator differential pressure Motor starting temperature Temperature SIGMA CONTROL 2 MCS Temperature first I O module The data for actual pressure can be displayed in lt Configuration gt Pressure control gt Network actual pressure gt Displaying analog data Password level 2 is activated The display shows the operating mode 1 In operating mode switch to the main menu with the Enter key Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 135 Operat
149. ion 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 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE T a44 9 5 Installation and Operating Conditions erol LENN Eg 5 1 Maintaining ambient conditions 5 Installation and Operating Conditions 5 1 Maintaining ambient conditions gt 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 NOTICE UV radiation Direct sunlight UV radiation can destroy the display screen gt Do not allow the display screen to be subjected to direct sunlight gt See the machine s operating manual for required conditions Service manual Controller 9 9450 0O2USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 33 KAESER COMPRESSORS 6 1 6 2 Tab 38 Tab 39 Tab 40 34 6 Installation 6 1 Reporting Transport Damage Installation 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 Machine identification If the machine is run in sequenced operation its identification as detailed in the installation diagram is to be taken
150. isplayed 88 5 psi 08 15 176 F 5 2 3 Load control Menu pA 10h 10h pB 18h 18h 1 Start pA 08 15 Active line starting time with pA example Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 91 KAESER 7 initial Start up erel i iNES 7 8 Configuring the machine for master control 4 Press the Right key The display for minutes 00 00 flashes 5 Press UP repeatedly until the desired number of minutes is displayed 6 Press Enter to accept the settings 7 If the cycle is to start with pB press Enter and use the DOWN or UP key to set the val ue for 1 Start pB 8 Set the required starting time pB in the same manner The timer is now configured 9 Select operating mode pA pB Cycle see section 7 8 5 5 10 Press Escape repeatedly to return to the main menu The system automatically resets the times for the duration to zero 0 o gt Do not use the main switch to turn the machine on or off 7 8 5 5 Master Selecting local mode Precondition Password level 2 is activated The lt Configuration gt Pressure control gt Load control gt menu is selected Time program or timer are set 1 Press UP repeatedly until Loca mode is displayed as the active line 2 Press Enter to switch into setting mode Operating mode flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu Local mode pA pB Cycle Active line Remote mode pA Key remote
151. it is already assigned gt Select a different input Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 65 KAESER COMPRESSORS 66 7 5 4 Precondition o Result Result 7 initial Start up 7 5 Configuring machine start and stop Activating deactivating the idle phase Venting period function After receiving the OFF signal from the remote control center an additional idling phase Venting period can be activated before the machine is stopped completely The duration of the idling phase can be timed and or regulated by internal pressure Password level 2 is activated The display shows the operating mode 1 Press Enter The main menu is displayed 2 Select the lt Configuration gt Compressor start gt Compressor off gt menu The check box for Venting period is displayed in the active line 88 5 psi 08 15 176 F 5 4 2 Compressor off Menu Actual setting Venting period deactivated Holidays Start 01 01 12 00 00 End 01 01 12 3 Press Enter to switch into setting mode The check box for the Venting period function will flash 4 Press the UP key 88 5 psi 08 15 176 F 5 4 2 Compressor off Menu Actual setting Venting period activated Holidays Start 01 01 12 00 00 End 01 01 12 5 Press Enter to save the setting The check box for the Venting period function is activated The function can be deactivated in the same manner
152. itch into setting mode The display for the delay time Setpoint flashes 3 Change the time using the DOWN or UP keys 88 5 psi 08 15 176 F 5 4 Compressor start Menu 1 Compressor on gt 2 Compressor off Autostart v Target 12 s Actual 0s Active line 4 Press Enter to accept the setting 5 Press Escape repeatedly to return to the main menu Result Delay time for restart after a main power failure has been adjusted from 10 s to 12 s 7 6 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 7 provides a comprehensive description of all control modes Service manual Controller 68 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 initial Start up erol IRRIS 7 6 Activating and setting up the control modes 7 6 1 Selecting a control mode The following control modes are possible m DUAL QUADRO VARIO DYNAMIC CONTINUOUS Q The standard setting of the control mode depends on the machine type I Precondition Password level 2 is activated The display shows the operating mode 1 Press Enter The main menu is displayed 2 Select the lt Configuration gt Control mode gt menu Local mode is displayed as the active line 88 5 psi 08 15 176 F 5 3 Control mode Menu Local mode DUAL Active line gt 1 Venting per
153. ith the UP key Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 initial Start up erol IREL ES 7 8 Configuring the machine for master control 7 7 3 3 Selecting local mode Precondition Password level 2 is activated The lt Configuration gt Pressure control gt Load control gt menu is selected The clock program or timer is set up 1 Press UP repeatedly until Loca mode is displayed as active line 2 Press Enter to switch into setting mode Operating mode flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu Local mode pA pB Cycle Active line Remote mode pA Key remote 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 The clock is fully configured 7 8 Configuring the machine for master control 7 8 1 List of the various master controllers The machine controller is provided with several methods of working under other controllers Master controller type Description Section Master control via Profibus The controller and therefore the compressor 7 8 2 1 only possible with an additional module receives the instruction LOAD IDLE or local operation via the Profibus master e g
154. ivated The lt Configuration gt Pressure control gt Load control gt menu is selected Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS Result Result 7 8 7 3 O I Precondition 9_9450 02USE 7 initial Start up 7 8 Configuring the machine for master control Setting local LOAD remote contact operating mode 1 Press UP repeatedly until Remote mode is displayed as the active line 2 Press Enter to switch into setting mode The Remote operation display flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu Remote mode loc load RC Active line current operating mode Key remote current pA 3 Use UP to select the oc oad RC operating mode Press Enter to accept the setting The local load remote contact operating mode is set Assigning an input for the local LOAD remote contact for switching over pressure control 1 Press DOWN repeatedly until oc oad RC is displayed as the active line 2 Press Enter to switch into setting mode DI flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu pA pB DO DOR 1 04 No input assigned Load RC DI 1 13 ok loc load RC DI 1 09 ok m Active line Key idle 3 Use UP to select a new input for local load remote contact 4 Press Enter to accept the setting The input for local load remote contact operating mode is assigned
155. ive line 88 5 psi 08 15 176 F 4 Maintenance Oil separator 3000 h 0150 h Reset Oil change Maintenance interval description 3000 h 0150 h Reset O Active line preset interval 4 Press Enter to switch into setting mode Maintenance interval display flashes 5 Use the UP key to set the new value for the maintenance interval Simply keep the UP key pressed to quickly change the maintenance interval in increments of 10 100 or 1000 _ o 6 Press Escape repeatedly to return to the main menu 8 8 Safety relief valve checking Overview m Preparing the test Performing the test m Correct conclusion of the test Resetting When the check mode is activated monitoring of internal pressure blow off protection if provided and regulation of network pressure are deactivated o The measured value of the internal pressure pi is used to describe the test below Service manual Controller 140 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE ANEJA a 8 Operation ezel linh Eg 8 8 Safety relief valve checking Check box Status A Activated Deactivated Tab 71 Check box status A WARNING Danger of injury from pressurized components gt 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 Clo
156. justed Adjusting the value for System pressure low If the system pressure falls to the sys press owvalue 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 appears Active 80 psi messages disappears Inactive Example Activated output Access level 2 is activated 1 Select lt Configuration gt Pressure control gt Pressure settings gt see Section 7 4 1 2 Press the DOWN key repeatedly until the following is displayed as the active line 88 5 psi 08 15 176 F 5 2 2 Pressure settings Menu System pressure low 4 lt 73 psi SD 7 3 psi Current value system pressure low current switch ing differential ta 600 s DOR 1 04 Cut in pressure min 73 psi 3 Press Enter to switch into setting mode The 73 psiparameter flashes Use UP or DOWN to adjust the setting Press Enter to accept the setting Adjust the switching differential if necessary in the same way P FOV ON Press Escape repeatedly to return to the main menu 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 function
157. k box 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 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE Precondition 8 Operation 8 9 Checking the temperature sensor and overheating shutdown function For this purpose SIGMA CONTROL 2 automatically determines an offset value to be displayed During the test mode this is added to the actual airend discharge temperature to cause the ma chine 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 Perform the test Correct conclusion of the test Resetting Performing the test Machine cooled down by approximately 40 F 1 2 3 Log on to SIGMA CONTROL 2 with password level 2 see section 7 2 4 In operating mode switch to the main menu with the Enter key Select the lt Machine test gt T V inspection gt menu Safety valve is displayed in the active li
158. l key will flash 88 5 psi 08 15 176 F 5 2 3 Load control Menu Remote mode loc load RC ane current pB 3 Use the UP key to activate the check box 4 Press Enter to accept the setting The Remote control key is activated and can be used 5 Press the Remote control key to enable remote mode Result The master control is fully configured 7 8 7 5 Setting the LOAD remote contact operating mode and assigning the input Precondition Password level 2 is activated The lt Configuration gt Pressure control gt Load control gt menu is selected Service manual Controller 102 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE Precondition Result Result 7 8 8 7 initial Start up 7 8 Configuring the machine for master control Setting the LOAD remote contact operating mode Password level 2 is activated The lt Configuration gt Pressure control gt Load control gt menu is selected 1 Press DOWN repeatedly until Remote mode is displayed as the active line 2 Press Enter to switch into setting mode The Remote control mode display flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu Remote mode Load RC Active line Key remote 3 Use UP to select the Load RC operating mode 4 Press Enter to accept the setting The remote load contact operating mode is set Assigning an input for the LOAD remote contact f
159. l output relay DOR 250 VAC 8A Digital output transistor DOT 24 VDC 0 5 A Analog output current AOI 0 20 mA SC2IOM 3 Power supply specifications Input output module 1 Internal into available in the control parallel on cabinet both sides External into the compres sor interior Input output module 2 Internal into available in the control parallel on cabinet both sides 6 1 3 4 2 External into the compres sor interior 2 2 Input output module 3 Internal into available in the control parallel on cabinet both sides 6 1 3 8 a Power is provided by the power supply unit within the machine Feature Rated power supply stabilized V DC Current consumption SIGMA CONTROL 2 with IOM 1 A Current consumption IOM 2 A IOM input output module Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Value 24 2 4 2 5 External into the compres sor interior 2 3 8 9_9450 02USE COMPRESSORS 9_9450 02USE Tab 17 2 1 2 2 Tab 18 2 1 2 3 Tab 19 2 1 2 4 Tab 20 Tab 21 2 Technical Data 2 1 SIGMA CONTROL 2 Controller Feature Current consumption IOM 3 A IOM input output module Power supply specifications Maximum cable lengths Input Output Analog input current All Analog input resistor AIR Analog output current AOI Digital input Dl Digital output relay DOR Digital output resistor
160. m plete them with your defined message text possible causes and remedies Message 0001 A Direction of rotation 0002 A Motor temperature 0003 A pRV 0004 A EMERGENCY STOP 0005 A Oil separator Temperature 0007 A Mains monitor 0009 A SIGMA CONTROL 2 T 0010 A Blow off protection Service manual Controller Possible cause The compressor drive motor is turning in the wrong direction Compressor drive motor overheat ed The activating pressure of the safe ty relief valve on the oil separator tank has been exceeded EMERGENCY STOP push button actuated Maximum air temperature at the oil separator tank outlet is exceeded Fault in main power supply Permissible enclosure temperature for SIGMA CONTROL 2 exceeded The activating pressure of the safe ty relief valve on the oil separator tank has been exceeded SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Remedy Change over phase lines L1 and L2 Clean the motor Keep ambient conditions within specified limits Change the safety relief valve Unlatch the push button Check the line to the trip relay Have the main power supply checked Keep ambient conditions within specified limits Control cabinet Check filter mats and fan Change the oil separator cartridge Open the shut off valve in the venting line 145 KAESER COMPRESSORS 146 9 Fault Recognition and Rectification 9 2 Message 0011 A
161. main contactor and wiring Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative Check the cooling oil lev el Clean the cooler Check the fan motor Check main contactor and wiring Check power supply volt age Check the door interlock switch Check venting line Check the cooling oil lev el 9_9450 02 USE COMPRESSORS 9_9450 02 USE 15 Interpreting fault messages Message 0044 A No pressure buildup 0045 A Compressor T 4 0048 A High voltage cell 0051 A Aggregate A 0052 A Aggregate B 0056 A RD condensate drain 0057 A Model 0058 A Condensate drain 0059 A Back pressure run 0061 A Oil separator rise dT dt 0062 A Refrigeration dryer p 0063 A Refrigeration dryer p 0081 A Quick user guide Controller Possible cause The machine produces no com pressed air The working pressure does not rise above 50 psi within a default peri od Thermostatic valve defective Fault in the high voltage cell Aggregate A failed Aggregate B failed Refrigerated dryer The condensate drain is defective Compressor model uncertain The condensate drain is defective Drive belts or coupling broken The rate of rise of the airend dis charge temperature is too fast Refrigerated dryer Pressure too high in the refrigerant circuit Safety pressure switch tripped Refrigerated
162. menu Submenu shown here as the active line gt 3 Operating data Submenu gt 4 Maintenance Submenu gt 5 Configuration Submenu gt 6 Compressor clock Submenu Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE ESER 4 Design and Function KA COMPRESSORS Further information 9_9450 02USE 4 3 3 O I 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 6 2 Active line The active line is always shown as white text on a dark background Do not confuse this with the header which is also shown with white lettering on a black background Press Enter to open a menu in the active line This opens the selected menu Here you can change parameters For the setting of parameters see cha
163. n Change the oil separator cartridge Investigate cause of shut down Reset the overload relay Keep ambient conditions within specified limits Clean the cooler Check the cooling oil lev el Investigate cause of shut down Reset the overload relay Contact an authorized KAESER service repre sentative Change the oil separator cartridge Re grease the motor bearings Check cooling water sup ply Check main contactor and wiring Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative Check the cooling oil lev el Clean the cooler Check the fan motor 9_9450 02USE KAESER COMPRESSORS 9_9450 02USE 9 Fault Recognition and Rectification 9 2 Message 0040 A Mains contactor off 0041 A Mains voltage 0042 A Back pressure stop 0043 A Airend discharge temperature ADT rise dT dt 0044 A No pressure buildup 0045 A Compressor T 4 0048 A High voltage cell 0051 A Aggregate A 0052 A Aggregate B 0056 A RD condensate drain 0057 A Model 0058 A Condensate drain 0059 A Back pressure run 0060 A Softstart Service manual Controller Interpreting fault messages Possible cause Main contactor does not open Second power failure Back pressure in the oil separator tank caused by defective venting The rate of rise of the airend dis charge temperature ADT is too fast The machine
164. n Password level 2 is activated The electrical connection is made 1 Select menu lt Configuration gt I O periphery gt Quantities gt see chapter 7 10 Pressure Temperature are displayed Press DOWN repeatedly until Display 5 I is displayed as the active line 88 5 psi 08 15 176 F 5 7 2 Quantities Menu gt 1 Display 1 p Pressure indicator 1 gt 2 Display 2 p Pressure indicator 2 gt 3 Display 3 T Temperature gauge 1 gt 4 Display 4 T Temperature gauge 2 Active line Energy indicator 1 gt 6 Display 6 I Energy indicator 2 7 10 2 2 Edit the sensor designation and unit of measure 1 OD OVE TO Press Enter to switch into setting mode The display shows the line for the sensor designation as active line The display of the character set flashes Use the UP and DOWN keys to select characters from the character set in order to assign a name to the sensor signal There are 20 characters to choose from 88 5 psi 08 15 176 F 5 7 2 5 Display 5 I Menu Flow rate 01 The line for sensor designation All 1 02 00 Unit of measure 20mA 10000 4mA 0 AOI2 00 0 0 0 mA 20mA 16000mmmmm 4mA mmmmm Press Enter to accept the setting Press DOWN once Press the Right key once Press Enter to switch into setting mode The Unit display of the sensor flashes Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 119 Initial Start up
165. ne Press DOWN repeatedly until Arend discharge temperature ADT is displayed as the ac tive line Press Enter to switch into setting mode The check box in the active line flashes 88 5 psi 08 15 kmda Fallen airend discharge temperature 163 F 9 1 TUV inspection Menu Offset 0 F ADT 0 0 F Reset Use the UP key to activate the check box Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 143 Repl a Operation exol Vid iili 8 9 Checking the temperature sensor and overheating shutdown function 7 Press Enter to accept the setting The Offset display changes to 95 F The A rend discharge temperature ADT display changes to 226 F The test mode is now activated 88 5 psi 08 15 163 F 9 1 TUV inspection Menu NCCC mE E ETG Active line aa Offset 95 F ADT 226 F Offset airend discharge temperature 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 the airend discharge temperature attains a value of 226 F The machine does not shut down a gt 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 Ente
166. nfiguration gt Compressor start gt Compressor on gt menu 3 Press UP repeatedly until Remote mode is displayed as active line Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 63 KAESER 7 initial Start up ote i iEERL h ES 7 5 Configuring machine start and stop 4 Press Enter to switch into setting mode Key flashes 88 5 psi 08 15 TAS Fle 5 4 1 Compressor on Menu Local mode Key Remote mode Key Active line RC DI 1 12 ok Q 5 Press DOWN repeatedly until Key RC is displayed 6 Press Enter to accept the setting 88 5 psi 08 15 176 F 5 4 1 Compressor on Menu Local mode Key Remote mode Key RC Active line RC DI 1 12 ok Result The machine start is set to remote operation with Key RC 7 5 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 1 Press Enter The main menu is displayed 2 Select the lt Configuration gt Compressor start gt Compressor on gt 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 the remote control key will flash 88 5 psi 08 15 176 F 5 4 1 Compressor on Menu Local mode Key Remote mode Key RC RC DI 1 12 ok Key remote O Active line with check box Key clock
167. ng dp FC Limit of the lowest delivery quantity When the value switching point system setpoint pressre dp FC is exceeded the compressor switches from LOAD to IDLE Nominal Display pressure The compressor is designed for this pressure maximum setpoint pressure Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 53 KAESER COMPRESSORS 54 Tab 48 7 4 1 Precondition 7 initial Start up 7 4 Adjusting the pressure parameters of the machine Parameter Setpoint pressure System pressure low Cut in pressure min Explanation Setpoint pressure can be regulated to two values pA and pB Setting m Switching point pA or control pressure pA in machines with frequency converter SFC m Switching point pB or control pressure pB in machines with frequency converter SFC A warning message is displayed when the limit value for the system pressure is reached Setting SD Switching differential for system pressure low SP Switching point for system pressure low Option Configuring output signal Warning message displayed or an additional output signal is sent e g to a re mote control center Display For design reasons pressure can only be built up above this value Compressor pressure parameters gt Parameters correspond to the following specifications Displaying pressure parameters Access level 2 is activated The lt Configuration gt Pressure control
168. ng 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 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 Application Recommended control mode Compressed air station with one machine or several machines with com VARIO parable delivery 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
169. nger 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 gt 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 f you ignore the warning notice the WARNING signal word indicates that a lethal or severe injury may occur gt The measures required to protect yourself from danger are shown here 2 Always read and comply with warning instructions 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 Signal term Meaning Consequences of non compliance NOTICE Warns of a potentially dangerous situation Damage to property is possible Danger levels and their definition damage to property Example Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 1 Regarding this Document erol VIENEI ES 1 4 Symbols and labels NOTICE The type and source of the imminent danger is shown here Potential effects when ignoring the warning are indicated here
170. nterfaces User interface Feature Material Width in Height in Depth in Number of membrane keys Number of LEDs Degree of protection control cabinet exterior Degree of protection control cabinet interior Voltage V Current A Voltage source User interface Display Feature Graphical display px Width in Height in Maximum number of lines characters Colors Lighting px pixel Display data Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Value Plastics 7 5 5 1 1 8 13 9 IP 54 IP 20 24 0 3 Input output module Value 255 x 128 3 2 1 6 8 30 Black white with gray levels LED backlit 9_9450 02USE KAESER COMPRESSORS 9_9450 02USE Tab 12 Tab 13 2 Technical Data 2 1 SIGMA CONTROL 2 Controller Interfaces Interface Connection Marking Ethernet 10 100 Base T RJ 45 socket X1 IO bus 9 pole SUB D pins X2 RS485 FC USS interface 9 pole SUB D socket X3 COM modules Module optional for X4 slot for communications module Profibus Modbus Profinet Devicenet SD card SD card slot SD SDHC card X5 The positions of the interfaces X1 X5 are marked on the rear of the controller 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 RFID Input output modules There are t
171. nto 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 deactivated and the test is completed 4 Press Escape repeatedly to return to the main menu Resetting SIGMA CONTROL 2 will display the highest measured value if the test for switching off at overtem perature is aborted Activate the check box for Reset in order to reset the stored value gt Activate the check box for Reset Further information See chapter 8 9 for testing the temperature sensor Quick user guide Controller 9_9450 02 USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 19 COMPRESSORS 20 13 13 Interpreting operation messages 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 0001 O Load control pA 0002 O Load control pB 0003 O Load control RC 0004 O Load control RB 0005 O ready 0006 O Idle 0007 O On load 0008 O off 0009 O Compressor on 0010 O Controller on 0011 O Cold start release 0025 O Setpoint pressure pA 0026 O Set
172. ocal operating mode Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 105 KA COMPRESSORS 106 ESER 7 initial Start up Fig 25 Precondition 7 8 Configuring the machine for master control Assign the floating relay contact Set local operating mode Establish the electrical connections Contact A open SIGMA CONTROL 2 controls with system set point pressure pB Contact A closed SIGMA CONTROL 2 controls with system set point pressure pA m B1 1 Pressure switch for system set point pressure pB m B 1 2 Pressure switch for system set point pressure pA 1 X1 17 738 lt o a ha i a a X11W A32w XTW ae X1W aw X1W 18 X1W 32w X1W 18 K3 A kT zaa NOL 4 min 07 S0629 Machine with pressure switch regulation potential free contact SIGMA CONTROL 2 gt Make the electrical connection according to the diagram Set setpoint pressures pA and pB Access level 2 is activated The electrical connections are made 1 Select menu lt Configuration gt Pressure control gt Pressure settings gt see section 7 4 1 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE Precondition Precondition 7 initial Start up 7 8 Configuring the machine for master control 2 Press Enter to switch into setting mode Setpoint pressure pA flashes 88 5 psi 08 15 176 F 5 2 2 Pressure settings
173. odule DI DO indicator Sixth I O module DI DO indicator 1 6 pN ADT curve Diagram Rated pressure airend discharge temperature Tab 29 Status menu Service manual Controller 22 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE TO Nata 4 Design and Function oe 0st 10 2t 4 6 Menus overview 4 6 2 2 Configuration menu Navigation 5 1 General 5 2 Pressure control 5 3 Control mode 5 4 Compressor start Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Function submenu Machine model Date and time Date format Time format Pressure unit Temperature unit Display illumination System data m SIGMA CONTROL 2 MCS Software KAESER Part number Serial number Controller manufacturer Part number Serial number Date of manufacture Compressor Equipment number Part number Serial number m O modules First IOM m Pressure sensors m Pressure settings m Load control m Actual system pressure For details of the lt Pressure control gt menu see table 31 Menu Pressure Control Local mode m Venting period DUAL QUADRO Mod valve Refrigerated dryer m Compressor ON Compressor OFF Auto start Start temperature 23 KAESER COMPRESSORS 24 Tab 30 Tab 31 4 Design and Function 4 6 Menus overview Navigation 5 5 Acknowledgement 5 6 ADT 5 7 I O periphery 5 8 Timer Configuration menu Press
174. oil separator cartridge has risen Oil separator cartridge clogged 0005 W Too frequent manual on and off Do not exceed the maximum num Start inhibit switching ber of motor switchings per hour when manual on off switching 0007 W Drive motor bearing defective Contact an authorized KAESER Motor bearings service representative 0008 W Maximum airend discharge tem Clean the cooler Airend discharge perature will soon be reached Check the cooling oil level temperature ADT Replace the oil filter Ensure adequate ventilation Keep surrounding temperature with in recommended limits 0011 W The pressure differential of the Change the oil filter Oil filter Ap t oil filter has risen Oil filter clogged 0013 W Air filter clogged Change the air filter element Air filter Ap Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE 9 Fault Recognition and Rectification 9 5 Interpreting warning messages Message Possible cause 0015 W The bus link from the Profibus Bus alarm DP interface is interrupted 0017 W Refrigerated dryer Refrigeration dryer T 4 Compressed air temperature too high 0018 W Refrigerated dryer Refrigeration dryer p 4 Refrigerant lost pressure in the refrigerant circuit too low Inlet pressure switched tripped 0025 W Oil separator cartridge Oil separator h Maintenance interval has elapsed 0026 W Cooling oil Oil change h
175. on partner IP address 010 000 003 001 6 Press Enter to accept the setting 7 Press DOWN repeatedly until P address is displayed as active line Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 95 KAESER 7 initial Start up ezel i iNi EE 7 8 Configuring the machine for master control 8 Press Enter to switch into setting mode 88 5 psi 08 15 176 F 8 1 2 1 SIGMA CONTROL 2 Mode Slave Port 2001 Communication partner IP address 169 254 100 102 IP address of communication partner slave 9 Use UP or DOWN to set the IP address of machine 2 10 Press Enter to accept the setting 11 Switch off the control voltage and then switch back on Result The system automatically saves the settings independently of the voltage Specifying the controller of Machine 2 as slave Precondition The menu lt Communication gt Ethernet gt Connections gt is selected 1 Press Enter The lt SIGMA CONTROL 2 gt menu is displayed The Status line is displayed as being active 2 Press DOWN repeatedly until Mode is displayed as the active line 3 Press Enter to switch into setting mode n a flashes 88 5 psi 08 15 176 F 8 1 2 1 SIGMA CONTROL 2 Menu Status Run 0 Error 0 Active line Mode n a Port 2001 Communication partner 4 Press UP to set the lt S ave gt mode 88 5 psi 08 15 176 F 8 1 2 1 SIGMA CONTROL 2 Menu Mode Slave Active line
176. onfigure the timer 2 Select operating mode Overview Set timer periods pA and pB Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 initial Start up erol INEL ES 7 8 Configuring the machine for master control Select starting time for pA or pB m Select the timer operating mode pA pB Cycle see section7 8 5 5 gt Proceed in the sequence shown Setting timer periods pA and pB Precondition Access level 2 is activated The lt Configuration gt Pressure control gt Load control gt menu is selected 1 Press the UP repeatedly until the timer period is displayed as the active line 2 Press Enter to switch into setting mode The timer period pA flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu pA 10h 10h Active line timer period pA expired timer period example pB 18h 18h Press UP to set the timer duration pA Press Enter to accept the setting Press the Right key Press Enter to switch into setting mode SOV OB O The timer period pB flashes 7 Press UP to set the timer duration pB 8 Press Enter to accept the setting Result The timer period for pA and pB is set Setting the starting time for pA or pB 1 Press DOWN repeatedly until 7 Sfart pA is displayed as active line 2 Press Enter to switch into setting mode The display for hours 00 00 flashes 3 Press UP repeatedly until the desired number of hours is d
177. or set point pressure adjustment Configuring Profibus mode SIGMA AIR MANAGER or VESIS Overview Configuration takes place with the following steps m Selecting a Profibus interface Assigning the slave address f necessary setting suppression time for bus fault m Activating the communications module Assigning an output contact for the bus alarm message take a spare contact from the electri cal diagram Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 81 KAESER 7 initial Start up erel i iNES 7 8 Configuring the machine for master control Precondition Communications module from Profibus DP VO retrofit kit is installed The electrical connection to the bus master has been made Password level 2 is activated The display shows the operating mode Selecting a Profibus interface Press Enter Press DOWN repeatedly until lt Communication gt is displayed as the active line Press Enter Press the DOWN key Menu lt Com Module gt is displayed as the active line 88 5 psi 08 15 176 F 8 Communication Menu gt 1 Ethernet gt 2 Com Module Active line Key remote m Py SNS 5 Press Enter Profibus line is displayed as being active 88 5 psi 08 15 176 F 8 2 Com Module Menu gt 1 Profibus Active line gt 2 Modbus gt 3 Modbus TCP gt 4 DeviceNet 6 Press Enter Assigning the slave address O You only need to set the slave address for th
178. or switching overpressure control 1 Press DOWN repeatedly until Load RC is displayed as the active line 2 Press Enter to switch into setting mode D flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu pA pB RC DI 1 05 pA pB DO DOR 1 04 Load RC DI 1 13 ok m Active line loc load RC DI 1 09 3 Use UP to select a new input for load remote contact Press Enter to accept the setting The input for load remote contact is assigned Configuring setpoint pressure pre selection via remote contact The signal to changeover from setpoint pressure pA to setpoint pressure pB comes from an input contact If there is a signal at the input then system pressure is regulated on setpoint pressure pB Overview m Setting up remote contact mode pA pB Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 103 KAESER COMPRESSORS 104 7 8 8 1 Precondition Result 7 8 8 2 Result 7 initial Start up 7 8 Configuring the machine for master control m Assigning the remote contact input m Activating the remote control key gt Configure the setpoint pressure pre selection as described Setting up remote contact mode pA pB Password level 2 is activated The electrical connections are made Menu lt Configuration gt Pressure control gt Load control gt is selected 1 Press UP repeatedly until Remote mode is displayed as the active line 2 Press
179. play 1 lt System status gt menu 2 Display SIGMA CONTROL 2 with status information 2 Check the status information The entire local menu can be displayed at your PC 1 Simply click in the display of the operating mode The lt main menu gt is displayed Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 initial Start up TLS 7 3 Using KAESER CONNECT 6 8 bar 11 47 AM 66 C 2 Performance data 3 Operating data 4 Maintenance 5 Configuration 6 Compressor clock 07 C1404 Fig 9 Main menu 2 You now may click the lt Status gt menu The system displays the corresponding lt submenus gt 6 8 bar 11 47 AM 66 C 1 Status Messages Statistics DN Current pressure control 8 Current operating mode DI DO display pN ADT curve L a T EIT 9 pN n curve M gt gt gt gt gt gt gt 07 C1388 Fig 10 Status menu with submenus Messages 6 pN ADT curve Statistics pN n curve Current pressure regulation Scroll down key Current operating mode Scroll up key DI DO display 3 Navigate through the submenus by additional clicks in the display 4 Click Scroll up 9 to start the upward scroll Data not visible prior to the scroll action are now displayed Click Scroll down 8 to start the downward scroll 6 To move back between the menus click esc as often as required 7 3 2 Display graphs When start
180. point pB and switching differ ential System pressure low lt 73 psi SD 7 3 psi 3 Press Enter to switch into setting mode The display for system set point pressure pA flashes 4 Use UP or DOWN to adjust the value Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 109 KAESER COMPRESSORS Tab 62 Precondition 110 7 initial Start up 7 8 Configuring the machine for master control Press Enter to accept the setting Adjust the switching differential in the same way If necessary adjust the values for system set point pressure pB in the same manner OO Oe O Press Escape repeatedly to return to the main menu Configuring the clock program The clock program for the example is set up using the following switching points A maximum of 10 switching points are available No Weekday Time System set point pressure 01 Mon Fri 06 30 pA On 02 Mon Fri 17 00 pB On Example switching points Overview m Set the day of the week for the first switching point m Set the time for the first switching point m Set the system pressure for the first switching point Specify any further switching points Password level 2 is activated The lt Configuration gt Pressure settings gt Load control gt menu is selected gt Configure the switching program as described below Enter the weekday for the first two switching points 1 Press the DOWN key repeatedly until lt A oB Clock
181. point pressure pB 0027 O Power OFF gt ON 0028 O Meaning The machine is regulated by system set point pressure pA The machine is regulated by system set point pressure pB The machine is regulated via the remote contactor The machine is remotely regulated via the bus connection The machine is switched on and in STANDSTILL operating mode The machine is switched on and in IDLE operating mode The machine is switched on and in LOAD operating mode The machine is switched off The power supply is connected The machine is switched on The power supply is connected The controller is powered The machine can be switched on although the machine tempera ture is below the permissible starting temperature The machine can be switched on only as long as the message is displayed The value for pA is output The value for pB is output Request Switch the power supply off and on Control mode DYNAMIC DYNAMIC motor temperature t The temperature of the compressor motor is too high Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02 USE R 13 Interpreting operation messages COMPRESSORS 9_9450 02 USE Message Meaning 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 0094 O T Switch ADT 0095 O p Switch pN Tab 4 Operational Messages Quick user guide Controller SIGMA CONTROL 2
182. pter 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 Resetin the active line of the display First press Enter to switch into setting mode The check box Resetwill 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 Resetis deactivated again Check box Reset Status x activated Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 15 KAESER COMPRESSORS 16 Tab 26 4 3 4 Tab 27 4 4 o 4 4 1 4 5 4 Design and Function 4 4 Access rights Check box Reset Status deactivated Reset check box status Activating keys with check boxes Certain keys of the SIGMA CONTROL 2 are locked by default Activate the corresponding check boxes
183. r Software version Subsequently the software is loaded and the current operating mode is displayed for example 88 5 psi 176 F 08 15 Run 2500 h Load 2490 h Maintenance in 500 h Service manual Controller 18 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Current operating mode Operating parameters Operating parameters 9_9450 02USE TO Nata 4 Design and Function oe 0st EA 4 6 Menus overview The following parameters are displayed m Operating mode of the machine m nformation to the LOAD IDLE keys Remote control or Clock Value for system 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 6 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 Main menu Navigation Function submenu 1 Status m Messages Status report Current warnings Current faults Statistics Current pressure control Actual operating mode DI DO indicator Diagram Rated pressure airend discharge tempera ture For details of the lt stafus gt menu see table 29 Menu Status 2 Performance data Display of the following measured data m System pressure pNloc ADT airend discharge temperature Increased
184. r to accept the setting The offset is reset to 32 F The test mode is deactivated and the test is completed 4 Press Escape repeatedly to return to the main menu Resetting SIGMA CONTROL 2 will display the highest measured value if the test for switching off at overtem perature is aborted Activate the check box for reset in order to reset the stored value gt Activate the check box Service manual Controller 144 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE 9 1 9 2 9 Fault Recognition and Rectification 9 1 Basic instructions Fault Recognition and Rectification 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 Inall other cases Have the fault rectified by an authorized KAESER service representative Interpreting fault messages Alarm 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 Co
185. r USS alarm 0210 A Compressor motor FC Motor overload alarm 0211 A Compressor motor FC Motor overload alarm Fault messages and remedies Possible cause Main contactor does not close Main contactor does not open Overload shut down of the com pressor drive motor Overload shut down of the first fan motor Frequency converter fault Frequency converter fault Frequency converter fault Communications error Frequency converter fault Frequency converter fault Interpreting system messages System messages are identified with the letter Y The message numbers are not numbered consecutively Message 0001 Y Hardware watchdog reset 0002 Y Internal software error 0003 Y Filesystem Read Write failure 0004 Y CPU load too high Service manual Controller Possible cause Remedy System error representative System error representative System error representative System error representative SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Remedy Check main contactor and wiring Check main contactor and wiring Investigate cause of shut down Change the oil separator cartridge Investigate cause of shut down Reset the overload relay Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative Contact an authorized KAESER service repre sentative Check connection and line path Contact an authorized KAESER servic
186. r master control Assigning the input for LOAD remote contact The input for the LOAD remote contact is preassigned Setting is only necessary if you want to use a different input Press DOWN repeatedly until Load RC is displayed as the active line Press Enter to switch into setting mode The digital input display flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu pA pB DO DOR 1 04 Load RC DI 1 13 ok w Active line standard DI 1 13 loc load RC DI 1 09 Key idle Use the UP or DOWN keys to select the input for the LOAD remote contact Press Enter to accept the setting Activate the check box for D 7 73 ok is displayed The input is now configured Adjusting the pressure increase pE gt Adjust the pressure increase pE as described in section 7 4 2 3 Detailed information on this pressure parameter is found in section 7 4 2 Activating the Remote control key Password level 2 is activated The lt Configuration gt Pressure control gt Load control gt menu is selected 1 2 Press UP repeatedly until Key remote is displayed as the active line Press Enter to switch into setting mode The check box for the Remote control key will flash 88 5 psi 08 15 176 F 5 2 3 Load control Menu Local mode Remote mode Load RC oon Use the UP key to activate the check box Service manual Controller SIGMA CONTROL 2 SCREW FLUID
187. r master control Making the electrical connection for remote LOAD contact excerpt Machine example X14 py X15 p5 X14 p5 X15 P6 X16 is X16 Io X016 Y8 X016 Y9 2X016 Y 2X016 y 2X16 8 2X16 2X35 1 ANE bs lanie 2X1 a7 2X01 5 2X01 16 2X01 15 116 17 15 16 17 pe ee S S E DI 0 7 DI 1 0 DI 1 1 LOAD remote contact gt Establish the electrical connection with Tue 1 13 according to the diagram 07 S0626 Setting the remote LOAD contact operating mode and assigning the input for LOAD remote contact Password level 2 is activated The lt Configuration gt Pressure control gt Load control gt menu is selected Setting the remote LOAD contact operating mode Press UP or DOWN repeatedly until Remote mode is displayed as the active line 2 Press Enter to switch into setting mode Display for remote mode flashes 88 5 psi 08 15 176 F 5 2 3 Load control Menu Local mode Remote mode Load RC Active line current operating mode Key remote 3 Use UP to select the LOAD remote contact operating mode 4 Press Enter to accept the setting The remote LOAD contact operating mode is set Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER COMPRESSORS _ o Result 7 8 6 3 Further information 7 8 6 4 Precondition 9_9450 02USE 7 Initial Start up 7 8 Configuring the machine fo
188. rganized display of assigned output signals gt Enter the selected output in table 65 Display analog input values Up to 6 values for example pressure or temperature from various sensors transducers can be dis played in the lt ana log data gt menu Of these 2 each are assigned to pressure and temperature transducers 2 further inputs can be assigned to freely selectable sensor types A list of standard analog data that can be displayed is found in chapter 8 5 Overview The configuration is entered in menu lt Configuration gt I O periphery gt show quantities gt m Select menu lt Configuration gt I O periphery gt show quantities gt m Select display display 1 6 Edit the sensor designation and unit of measure Allocate analog input m Selecting the type of signal 4 20 mA 0 20 mA Assign a value range to the measurement signal calibration Example The following example explains the configuration The signal value from a flow measuring device is to be displayed in the measured lt data menu gt m Sensor designation Flow rate 01 m The sensor is connected to analog input All 1 03 m The sensor has a measuring range of 0 29 cfm m The sensor is operated with 4 20 mA Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 7 10 Configuring input and output signals 9_9450 02USE Initial Start up 7 10 2 1 Select the menu show quantities Preconditio
189. s Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS Result Fig 28 Result Precondition Result 8 2 9_9450 02USE 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 The Contro 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 08 S0051 Switching off in an emergency 9 EMERGENCY STOP control device Switching off gt Press the EMERGENCY STOP control device The EMERGENCY STOP button remains latched after actuation The compressor s pressure system is vented and the machine is prevented from automatically re starting Switching on 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 The machine can now be started again Acknowledging alarm and warning messages The functions for acknowledging alarm and warning messages are not yet implemented gt Ignore any corresponding references to chapter 8 2 in this manual Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x
190. s 53 Setting limits for system setpoint pressure Cut in pressure Min cceeeeeeeeeeeeeeeeeeeeees 55 Pressure condition for LOAD 0 ccccccccceeeecceeeeeceeeeeeeeeeeeeaeeeeeeaeeseceaeeeeseesaeeeeeeceeeeessneeeeeeeaees 55 Pressure condition for IDLE ccec cccceeeenceeeeeceeeeeeneeeeeeeaeeeeecaeeeeeseaeeeeeseneeeeesaeeeeeseaeeeeesneeeess 55 Example Activated Outputs e Ga aA a a ade aa E a Weer EE A a aA a ea 56 Settings for machine start ANd StOp cccccceeeeeceeeeeeceeeeeeeceeeeeeeeeeeeeaeeeeeeaeeeeescaeeeeseseeeeeeneeees 59 Example of a machine ON OFF timer program ccc ccceeeecceeeeeeeeeeeeeeeeceeeeeeeeeseeeeeseneeeeeees 60 Local operating mode local mode c ceccceeeeeceeeeeeeeeeeeeeeeeeeeaeeeeeecaeeeeeseaeeeseceeeeeeeseeeeeeeeaees 72 Example of system pressure changeover switching points ccecccceceeeeeeeeeeeeeeeeeeeeeeetees 73 Master Control OVOIrViCW ioiei ner i a paa a aes a SEa ETS 77 Profibus DP pin CONNECTION cceeeecceeeeeeceeeeeeeeeeeeeeeeeeseaeeeeeecaeeeesecaeeeeeseaeeeseceeeeeeesneeeeeseaees 78 Master slave configuration procedure cccceeeceeeeeeneeeeeeeeeeeeeeeeeeeeecaeeeeeseaeeesecneeeeeteneeeeesnnees 86 Checkbox Status aes cet cet eet at eee tin areata tat neat at Bete 93 FUNCHON Glagram eieiei eag a a ibaa inl Meet ee eee 108 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Vil COMPR
191. s incorrectly the machine switches to IDLE The warning message ext load signal is displayed Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE Precondition 7 4 2 4 Precondition Fig 20 7 initial Start up 7 4 Adjusting the pressure parameters of the machine Access level 2 is activated 1 Select lt Configuration gt Pressure control gt Pressure settings gt see Section 7 4 1 2 Press the DOWN key repeatedly until the following is displayed as the active line 88 5 psi 08 15 176 F 5 2 2 Pressure settings Menu pRV 232 psi Pressure rise pE SP 122 psi SD 7 3 psi Active line with current switching point pressure rise current switching differential ApFC 2 9 psi 3 Press Enter to switch into setting mode The 722 psi parameter flashes Use UP or DOWN to adjust the setting Press Enter to accept the setting Adjust the switching differential if necessary in the same way AO One Press Escape repeatedly to return to the main menu Adjusting pressure rise Machine with variable frequency drive SFC The pressure rise value dpfC is the limit from which the machine switches to IDLE This value can be between 2 9 psi and 5 8 psi The factory setting is 2 9 psi The pressure rise is added to the setpoint pressure In this way the setpoint pressure can be changed without having to adjust the parameter again
192. s the message is displayed The value for pA is output The value for pB is output Request Switch the power supply off and on Control mode DYNAMIC DYNAMIC motor temperature t The temperature of the compressor motor is too high Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9_9450 02USE KAESER COMPRESSORS 9_9450 02USE Tab 70 8 7 Precondition 8 Operation 8 7 Setting the maintenance interval Message Meaning 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 0094 O T Switch ADT 0095 O p Switch pN Operational Messages Setting the maintenance interval Example Changing the oil change service interval Password level 2 is activated The display shows the operating mode Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 139 Repo a Operation exel iainih Eg 8 8 Safety relief valve checking Select menu Maintenance 1 Press Enter The main menu is displayed 2 Select lt Maintenance gt The maintenance interval Oil filter is displayed as the active line 88 5 psi 08 15 176 F 4 Maintenance Oil filter Active line description of maintenance interval 3000 h 0150 h Reset Preset interval 3000 h Oil separator 3000 h 0150 h Reset 3 Press DOWN repeatedly until the maintenance interval for Oil change is displayed as the ac t
193. sage history event memory m User administration Creating and activating new user accounts Deactivating existing user accounts Changing passwords m Settings Unit display format Date display format Time display format Data backup Writing data to your own PC For the Login and other procedures please see chapter 7 3 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 17 Design and Function INN 4 COMPRESSORS 4 6 Menus overview Header Please note the designations in the menu s header The designations cover user friendly func tions such as Activate write mode You switch from read mode to write mode to create a new user account for example m Closing KAESER CONNECT Logout function in the header m Contact KAESER Service Display of KAESER Service addresses KAESER KOMPRESSOREN 1 Fig 7 Header 1 Machine designation 2 Write mode 4 6 Menus overview 4 6 1 Operating mode SIGMA CONTROL 2 1 SK25 read gt write Logout Contact Service 07 C1384 3 Logout Contact KAESER Service After the machine is switched on details of the software are displayed for example Compressor Machine model Compressor PN Compressor SN Compressor EN SIGMA CONTROL 2 MCS PN SN Software Part number and serial number of the machine Equipment number of the machine MCS Main Control System Part number and serial number of the controlle
194. se the user s shut off valve between the machine and the air distribution network 4 Log onto 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 6 Select the lt Machine test gt T V inspection gt menu Pressure relief valve is displayed as the active line 88 5 psi 08 15 176 F 9 1 TUV inspection Menu Active line with check box pRV 232 psi pi 0 psi Relief valve activating pressure example Reset 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 setpoint pressures is deactivated 88 5 psi 08 15 176 F 9 1 TUV inspection Menu Active line with check box pRV 232 psi pi 36 psi Relief valve activating pressure Reset Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 141 KAESER COMPRESSORS 142 o Result 8 9 8 Operation 8 9 Checking the temperature sensor and overheating shutdown function 4 FAINNE Excessive noise is caused when the safety relief valve blows off gt Close all access doors replace and secure all removable panels gt Wear hearing protection 5 Risk of burns due to released cooling oil and compressed air when blowing off the safety r
195. secon ee eee ee ee Se ee 1 3 Updating the operating manual ceccccceeeececeeeeceeeeeeeeeeeceaeeeeeceaeeeeeceeeeessneeeeeeseeeetees 14 Symbols and labels ricine n a E aa a T gE h WAMINGS PEE A AE AE E EE E A E E EE E E E E E E EE 9_9450 02USE 1 4 2 Potential damage warnings 1 4 3 Other alerts and their symbols Technical Data 2 1 SIGMA CONTROL 2 Controller ccccccccceeeeceeeeeeeeeeeeeeeeeeeseaeeeeseeeeesessaeeeeesneeeeeeneeees 2 1 1 User interface with display CPU and interfaces cceeeeeeeeeeeeteeteeteeees 2 1 2 Imput output MOdUIES r r a E a a a a E Aa PE E E E E E E E as eats Peet de E A A E ahd eee 2p Safety and Responsibility 3 1 Basie iNStrUCUO S orreec osne eaea aee ea e aeo aeea 3 2 Specified Use miere pe ee ee ee ee a ee e ea Ana 3 3 Mp O I USE 26 308 28 chet sey nel ae nace ease ie ate hd Rad eae aed ea ete deena Design and Function 434 Whe Controllers sscitet A E eh a Se Se kad ed a Lat ad 2d Se St kad Sad Sa Ske 4 2 Operating panel SIGMA CONTROL 2 ccccccccceeeecceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeeenneees 423 DISPIAY ATE A EA bapeT tech otteee bells ot oe boca So a i sleies EA ele a beathegs he AST lt Operating M Ode 2 y ses ete eee A eee etre le eee eee eats a S Mair tMenili ccec255 ccts23 E E top teot teotagt uentact E teeta t 4 3 3 Setting parameters cccccceecscceeeeecceeeseceeeeeeeneeeeeeaeeeeeseaeeeseeaneee
196. splay shows the operating mode Press Enter The main menu is displayed Press the UP or DOWN keys until the current language is shown as active line 88 5 psi 08 15 176 F Main menu Active line with current language gt 1 XXXXXXXXXX Submenu gt 2 XXXXXXXXXX Submenu gt 3 XXXXXXXXXX Submenu gt A XXXXXXXXXX Submenu 5 XXXXXXXXXX Submenu Use the Enter key to switch to setting mode The currently set language flashes Move to the required language with UP or DOWN Confirm the setting with Enter Press Escape repeatedly to return to the main menu The display texts are now in the selected language Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x T Vaya y 4 Entering a password COMPRESSORS Fig 1 Result Further information Entering a password Use a supplied Equipment Card to log on at the controller 04 S1102 RFID reader 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 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 2 x 9 9450 02 USE TO Naya 5 Adjusting the system setpoint pressure COMPRESSORS 5 Precondition Further information 9_94
197. t Load control gt menu is selected 1 Press DOWN once Key remote line is displayed as being active 2 Press Enter to switch into setting mode The check box will flash 88 5 psi 08 15 176 F 5 2 3 Load control Menu Remote mode pA pB Cycle ae current pA pB Cycle 3 Use the UP key to activate the check box 4 Press Enter to accept the setting The remote control key is activated and can be used 5 Press the remote control key to enable remote mode Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 93 KAESER COMPRESSORS 94 e 7 8 5 8 Precondition 7 initial Start up 7 8 Configuring the machine for master control You want to deactivate the remote control key gt Deactivate the check box for the remote control key Master and slave Configuring Ethernet interface Overview m Select menu lt Communication gt m Specify machine 1 as master m Specify machine 2 as slave m Saving the settings Access level 2 is activated The menu lt Communication gt Ethernet gt is selected Select the IP configuration menu Different IP addresses must be entered in the lt Ethernet gt IP configuration gt menu for each ma chine For a direct connection of the two machines example m Master 169 254 100 101 m Slave 169 254 100 102 1 Press Enter The lt P configuration gt menu is displayed as being active 88 5 psi 08 1
198. t4 BSD switches to LOAD Air demand not covered t5 SK also switches to LOAD System pressure pNloc starts to rise Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x t8 Air demand rises System pressure pNloc drops t9 SK switches to LOAD t10 Setpoint pressure pB reached SK switches to IDLE t11 BSD switches to LOAD Air demand not covered t12 SK switches to LOAD System pressure pNloc starts to rise 9_9450 02USE KAES COMPRESSORS 9_9450 02USE Tab 61 Fig 26 Precondition 7 initial Start up 7 8 Configuring the machine for master control Time period t1 t7 high compressed air demand Time period t8 t14 low compressed air demand t6 t13 SK switches to IDLE SK switches to IDLE t7 t14 BSD switches to IDLE BSD switches to IDLE Function diagram 07 S0630 Function diagram SD Switching differential p Pressure Time Set setpoint pressures pA and pB Access level 2 is activated 1 Select lt Configuration gt Pressure control gt Pressure settings gt see Section 7 4 1 The lt Pressure settings gt menu is displayed 2 Press DOWN repeatedly until Setpoint pressure pA SP is displayed as active line 88 5 psi 08 15 176 F 5 2 2 Pressure settings Menu Setpoint pressure pA SP 125 psi SD 7 3 psi Active line with system set point pressure pA and switching differential pB SP 119 psi SD 7 3 psi System pressure set
199. tch on the machine 3 Escape Returns to the next higher menu option level Exits the edit mode without saving 4 Enter Jumps to the selected menu option Exits the edit mode and saves 5 DOWN Scrolls down the menu options Reduces a parameter value Right Jumps to the right Left Jumps to the left Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 11 COMPRESSORS Tab 23 Fig 4 12 4 Design and Function 4 2 Operating panel SIGMA CONTROL 2 Item Name Function 8 UP Scrolls up the menu options Increases a parameter value 9 Events and information Operating mode Displays the event memory 10 Acknowledgement Acknowledges alarms and warning messages If permissible Resets the fault counter RESET 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 14 Te aD 04 S0119 Indicators Item Name Function 14 Indicator field or dis Graphic display with 8 lines and 30 characters play 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 m maintenance work due Warning message Lights continuously when acknowledg
200. tches to LOAD Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 131 KAESER COMPRESSORS 8 1 Fig 27 8 1 1 Precondition O I Result 8 1 2 132 8 Operation 8 1 Switching on and off Operation 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 i 19 Awe AQ BRD N rae ee e A 3 11 08 S0117 Switching on and off Machine ONLED green LOAD IDLE toggle key ON key LOAD LED OFF key IDLE LED Control voltage LED green 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 Contro voltage LED is lit continuously 2 Press the ON key The green Machine ONLED 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 The compressor motor starts as soon as system pressure is lower than the set point pressure cut off pressure Switching off 1 Press the LOAD IDLE key The machine switches to IDLE and the DLE LED flashes 2 After allowing the machine to IDLE for 20 seconds Press the OFF key The Machine ONLED extinguishe
201. ted 7 5 5 Tab 53 Settings for machine start and stop 7 5 1 Automatic start stop in programmed clock mode Overview m f not activated enter password for level 2 m Select the lt Compressor clock gt menu Set adjust the time program Activate the Clock key 7 5 1 1 Selecting the compressor clock menu Precondition Password level 2 is activated The display shows the operating mode 1 Press Enter The main menu is displayed Service manual Controller 9 9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 59 MAESER Ri Initial Start up COMPRESSORS 7 5 Configuring machine start and stop 2 Select lt Compressor clock gt The display for setting the Compressor clock timing program appears 88 5 psi 08 15 176 F 6 Compressor clock Key clock Reset Menu Compressor clock is activated All current switching points are reset 01 n a 00 00 off Active line 02 n a 00 00 off 03 n a 00 00 off 7 5 1 2 Setting the clock program example O 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 Mon Thu Mon Fri Mon Sat Mon Sun Sat Thu You can also program an OFF time shutdown periods see section 7 5 2 Example m Machine ON Weekdays 6 30 17 00 Fridays 6 30 15 00 m Machine OFF Sat Sun and during midday break from 12 00
202. the power supply the bus alarm can be suppressed temporarily m Settings for SIGMA AIR MANAGER without SIGMA AIR CONTROL PLUS Start 30 seconds Settings for SIGMA AIR MANAGER with SIGMA AIR CONTROL PLUS Start 40 seconds 2 Press Enter to switch into setting mode Start flashes 88 5 psi 08 15 176 F 8 2 1 Profibus Menu Com Module Start Slave No 3 Bus alarm Start td 30 s Active line suppression time for bus alarm Timeout 5 s Z Delay time active bus timeout setting 3 Change the time using the DOWN or UP keys 4 Press Enter to accept the setting Result The suppression time for a bus alarm is set Service manual Controller 9 9450 0O2USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 83 KAESER 7 initial Start up erel i iNES 7 8 Configuring the machine for master control Activating the communications module 1 Press UP repeatedly until Com Module Startis displayed as the active line 88 5 psi 08 15 176 F 8 2 1 Profibus Menu Status Run 0 Error 4 Com Module Start Active line Slave No 103 Bus alarm 2 Press Enter to switch into setting mode The check box will flash 3 Press UP or DOWN key The communications module for Profibus is activated 4 Press Enter to accept the setting If no electrical connection to the bus has been made up to this point the message bus alarm appears 5 Acknowledge the message and check the electrical conn
203. the settings The display stops flashing and the time hours minutes is set 88 5 psi 08 15 176 F 6 Compressor clock Menu 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 on offcolumn flashes 13 Press Enter to switch into setting mode 14 Use UP to specify the settings for the action Compressor ON 15 Press Enter to accept the setting The Compressor ON function is set for the first switching point 16 Specify further switching points in the same manner Weekdays time and the Compressor ON Compressor OFF functions are set for all switching points Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 61 KAESER 7 initial Start up ote iiig 7 5 Configuring machine start and stop 7 5 1 3 Activating the Compressor timer key 1 Press 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 5 psi 08 15 176 F 6 Compressor clock Menu 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 Use the UP key to activate the check box 4 Press Enter to accept the setting
204. ting clock program Entering the weekday for the first switching point Enter the time of the first switching point m Set the first pressure switching point Set up any further switching points m Select operating mode pA pB Clock see chapter 7 8 5 5 Password level 2 is activated The lt Configuration gt Pressure control gt Load control gt pA pB Clock gt menu is selected gt Edit the list items in their sequence Deleting the existing clock program To delete an existing clock program proceed as follows 1 Press UP repeatedly until Reset is displayed as the active line 2 Press Enter to switch into setting mode The Reset check box flashes 3 Press the UP key once 4 Press Enter to accept the setting The clock program is now reset Entering the weekday for the first switching point 1 Press DOWN repeatedly until the 07 switching point is displayed as the active line 2 Press Enter to switch into setting mode The display for weekday flashes 88 5 psi 08 15 176 F 5 2 3 1 pA pB Clock Menu Reset Delete clock program 01 Mon Fri 00 00 pA Active line set weekdays example 02 n a 00 00 pA 03 n a 00 00 pA 04 n a 00 00 pA 3 Press UP repeatedly until the desired weekday is displayed Press Enter to accept the setting Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 89 KAESER COMPRESSORS 90 Result Result 7 8 5 4 7 initial
205. tion gt Acknowledgement gt cceeeeeeeeeeeees 126 7 11 2 Setting the remote acknowledgement function c ecceeeeeeeeeeeeeeeeeeeeteeees 126 7 11 3 Activating the remote Control Key cccssssecceceeeseesseeeeeeeeessesetseeeeeeessesstaeeees 127 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER Contents COMPRESSORS TANA ASSIGNING ANIA PUbe eeoa paea aae a a ene need 127 7 12 Linking to an external pressure transducer cceceeeeceeeeeceeeeeeeeeeeeeeeeeeeeseeeeeetsneeeeessaees 128 7 12 1 Selecting menu lt Configuration gt Pressure control gt cccceeeeeeeeeeeeeeees 128 7 12 2 Allocating the input to an external transducer ccceecceeeeeeeeeeeeeteeeeeeeeeeees 129 7 13 Commissioning the machine ccccccceeeeceeeeeeeeeeeeeeeeeeeseeeeesecaeeeeeseeeeeseceaeeeeeeneeeeessaees 130 8 Operation 8 1 lt Switchingson and Ot ccc ceeteke teste r Era ae r Ee aae ra eaaa aar a aaan ar eea va 132 SI Switching On T a a a a r aa E 132 e PEE aae RO p OE A E ot ecole E E E E chee aptet oh 132 8 1 3 Switching off in an emergency and switching on again cceesceeeeeeees 133 8 2 Acknowledging alarm and warning messages 2 cceeeeceeeeeeeeeeeeeeeeeeeseeeeeeesnneeeeeeaees 133 8 3 Displaying the current operating mode eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeteeeeeeenaaaeeeeeeeeeeeaaea 134 8 4 Adj
206. tor running DOR 1 07 ok m 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 See chapter 7 10 for configuration and use of the controller s inputs and outputs Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 13 COMPRESSORS 10 Precondition Result Further information 14 10 Resetting maintenance interval counters Resetting maintenance interval counters For example Resetting the maintenance interval counter for oil filter 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 lt Maintenance gt menu The maintenance counter for O fi teris displayed in the active line 3 Press DOWN once Resetis displayed as an active line 4 Press Enter to switch into setting mode The check box for reset flashes 88 5 psi 08 15 176 F 4 Maintenance Menu Oil filter 6000 h 0005 h Maintenance interval remaining time Reset O Active line Oil separator 6000 h 3000 h Reset 5 Use the UP key to activate the che
207. tting mode The current idling time setting 240 s flashes 88 5 psi 08 15 176 F 5 3 2 DUAL Menu Idle period Target 300 s Actual 0s Active line with changed Idle period example 300 seconds 4 Set the required IDLE period with the UP key 5 Press Enter to accept the setting 6 Press Escape repeatedly to return to the main menu Adjusting the unloaded and minimum running period in QUADRO control mode When the minimum running period has elapsed the machine switches from IDLE to STANDSTILL Depending on the setting for the unloaded period the machine switches first from LOAD to IDLE or directly to STANDSTILL Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE KAESER 7 initial Start up erol IRRIS 7 6 Activating and setting up the control modes Precondition Password level 2 is activated The QUADRO control mode is selected The display shows the operating mode 1 Press Enter The main menu is displayed Select the lt Configuration gt Control mode gt QUADRO gt menu 3 Press DOWN repeatedly until 7argetis displayed as the active line 88 5 psi 08 15 176 F 5 3 3 QUADRO Menu Min run period Target 240 s Actual 0 s Active line setpoint value for minimum run time Unloaded period Target 240 s Actual 100 s 4 Press Enter to switch into setting mode The set point value 240 s flashes 88 5 psi 08 15 176 F 5 3 3 QUADRO Menu Min run period
208. ure control menu Navigation 5 2 1 Pressure sensors 5 2 2 Pressure settings 5 2 3 Load control 5 2 4 Network actual pressure Pressure control menu Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Function submenu Remote operation Remote control key Remote contact Ack AIR 1 00 Conduit correction Rate of rise of the airend discharge temper ature DO functions Quantities External messages Switch For details of the lt O periphery gt menu see ta ble 32 I O periphery menu On Off DOR 1 03 Function submenu m System pressure pNloc m Internal pressure pi m pRV Pressure relief valve opening pressure m Pressure increases Nominal pressure m System setpoint pressure m System pressure low Minimum cut in pressure m Setting local mode m Set remote operation Activate deactivate Remote control key Timer operating mode pA pB Remote contact operating mode pA pB Assign load remote contact m Assign local load remote contact Activate deactivate the IDLE key pNloc actual system pressure All 9_9450 02USE TO Nata 4 Design and Function oe 0st 10 2t 4 6 Menus overview 1 O periphery menu Navigation 5 7 1 DO functions 5 7 2 Quantities 5 7 3 External messages 5 7 4 Switch Tab 32 1 O periphery menu Service manual Controller 9_9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Function submenu Controller ON
209. usting working pressure cccceccceeeeeceeeeeeeeeeeeeeeeeeescaeeeeeenaeeeseseeeeeeseeeseeeneeeeesenees 135 8 5 Displaying analog data ccccccccccccceeeeceeeeeeceeeeeeaeeeeeeaeeeeeecaeeeseecaeeeeseneeeesesneeeesseeeeetees 135 8 6 Displaying operating data a a a arr raare Pr rrr e aaen a sa ar e aeai riar eir ei dra Eonar eia ani 136 8 6 1 Interpreting operation messages ccceeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeteeeeaaeeeeeeeeeeeaee 138 8 7 Setting the maintenance interval ccccceccceeeeeceeeeeeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeceeeeeenneeeetees 139 8 8 Safety relief valve CHECKING cccceccceeeeeceeeeeeeeeeeeeeaeeceeeaeeeeeecaeeeseceeeeeeeeneeeeeesneeeeeenaees 140 8 9 Checking the temperature sensor and overheating shutdown function e 142 9 Fault Recognition and Rectification 9 1 Basic instructions 2 2 2 c00sh cu ssetenceteene etnies eee eect E a a 145 9 2 Interpreting fault MESSAGES ceccccceeeeeceeeeeeceeeeeeeeeeeeeeeeeeeeseeeeeeecaeeeeeceeeeeeeeeeeeseneeeetees 145 9 3 Interpreting system messages ccccecceeceeeeceeeeeeeeeeeeeeeeeeeeeaeeeeseeaeecseseeeeeseceeeeseneeeetees 149 9 4 Interpreting diagnostic messages ccceeeeeeceeeeeceeeeeeeeeeeseeeeeeeseeeeeeseaeeeeeeseeeetsneeees 150 9 5 Interpreting warning MESSAGES ccceeeccceeeeeeeeeeeeeeeeeeeeeecesecaeeeeeceeeeesecnaeeeeesneeeeessaees 150 10 Maintenance 10 1 Maintenance
210. ve Contact an authorized KAESER service representative Clean the cooler Check the cooling oil level 151 KAESER 9 Fault Recognition and Rectification erel i iNES 9 5 Interpreting warning messages Message Possible cause Remedy 0036 W The permissible number of mo Extend the idle period Motor starts h tor starts was exceeded in the Increase the capacity of air receiv last 60 minutes er Increase the cross section of piping between compressor and air receiv er 0037 W The permissible number of mo Extend the idle period Motor starts d tor starts was exceeded in the Increase the capacity of air receiv last 24 hours er Increase the cross section of piping between compressor and air receiv er 0038 W The activating pressure of the Change the oil separator cartridge Blow off protection safety relief valve will soon be Open the shut off valve in the vent reached ing line 0041 W 1 Power failure Check power supply Mains voltage The machine is automatically Check the door interlock switch restarted 0043 W Ambiguous external load signal Check settings of the external con External load signal Increased cut out pressure ex troller Take into account pressure ceeded drops across filters and dryer The external load control has not switched to idle off load 0044 W Cooling oil temperature too low Check temperature switch line and Oil temperature 4 connection Check the oil circulation Incre
211. view Navigation Function submenu 8 2 Com Module PROFIBUS Status Start Com module Slave number Bus fault Start time Timeout MODBUS Status Start Com module Slave number Bus fault Start time Timeout Baud rate Stop bits Parity Timeout Modus MODBUS TCP Status Start Com module Bus fault Start time Timeout IP address Subnet mask Gateway DNS Server 1 DNS Server 2 DEVICENET Tab 33 Communication menu Service manual Controller 9_9450 02USE SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Status Start Com module Slave number Reset Bus fault Start time Timeout 27 KAESER 4 Design and Function eoll 4 6 Menus overview 4 6 2 4 Connections menu Navigation Function submenu 8 1 2 Connections m SIGMA CONTROL 2 Status Mode Master Slave Port IP address of communication partner Tab 34 Connections menu 4 6 2 5 Components menu Navigation Function submenu 10 1 Compressor motor Power switching Star delta start Direct start High voltage cell SFC USS Micromaster SFC USS Sinamics For details of the lt Connections gt menu see ta ble 36 Menu Connections Tab 35 Components menu Service manual Controller 28 SIGMA CONTROL 2 SCREW FLUID 1 0 2 x 9 9450 02USE TO Nata 4 Design and Function erol IERES 4 7 Operating modes and control modes 4 6 2 6 Power switching menu Navigation Function submenu 10 1 1 Power switching m Star
212. x 9 9450 02USE KAESER COMPRESSORS 9_9450 02USE 7 10 2 4 7 10 2 5 Result 7 initial Start up 7 10 Configuring input and output signals 8 Press Enter to accept the setting OK is displayed The signal value is displayed in the active line Determining the type of analog signal 0 4 20 mA 1 Press DOWN once 2 Press Right once to set the type of current signal As 4 20 mA is preset no further setting is needed Assign a value range to the measurement signal calibration The factory setting is a range from 0 16 000 that represents a signal current between 4 20 mA This quantity range has to be adapted to represent the measurement range of the sensor of 0 29 cfm 1 Press DOWN once until 20 mA is displayed in the active line 2 Press Enter to switch into setting mode Quantity range flashes 5 7 2 5 Display 5 I Menu Flow rate 01 The line for sensor designation All 1 03 ok Z 123 m3 h Measured value prior to calibration 20mA 50 4mA 0 Signal top range signal bottom range AOI2 00 0 0 0 mA 20mA 16000mmmmm 4mA mmmmm 3 Press and hold the DOWN key and to set the top of the range to 29 The quantity reduces initially in steps of units then tens hundreds and finally in thousands Using this method reduce the value to 100 and then set to 29 with the DOWN key Press the Enter key to accept the value 88 5 psi 08 15 176 F 5 7
213. yer T 0022 A Oil separator Ap 0023 A Motor bearings 0024 A Water cooling water shortage 0034 A Mains contactor on 0035 A Cabinet fan 0038 A PD temperature 0039 A PD temperature 0040 A Mains contactor off 0041 A Mains voltage 0042 A Back pressure stop 0043 A Airend discharge temperature ADT rise dT dt Quick user guide Controller Possible cause Maximum permissible airend dis charge temperature ADT exceed ed Overload shut down of the third fan motor Refrigeration dryer Compressed air temperature too low Oil separator cartridge clogged Drive motor bearings overheated Cooling water pressure is too low Main contactor does not close Overload shut down of the control cabinet fan motor Package discharge PD tempera ture too low Package discharge PD tempera ture too high Main contactor does not open Second power failure Back pressure in the oil separator tank caused by defective venting The rate of rise of the airend dis charge temperature ADT is too fast SIGMA CONTROL 2 SCREW FLUID 1 0 2 x Remedy Keep ambient conditions within specified limits Clean the cooler Check the cooling oil lev el Investigate cause of shut down Reset the overload relay Contact an authorized KAESER service repre sentative Change the oil separator cartridge Re grease the motor bearings Check cooling water sup ply Check

Service manual - Kaeser Kompressoren

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