Kaeser Compressor Sigma Control Manual

SERVICE MANUAL
SIGMA CONTROL
Index: BUB 07
GL---No.: BA---7.7000.0---00 V4
Publisher:
KAESER KOMPRESSOREN GmbH

96410 Coburg : PO Box 2143 : GERMANY : Tel. + 49---(0)9561---6400 : Fax + 49---(0)9561---640130
http://www.kaeser.com
Table of Contents
Chapter --- Page
Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1
1.2
1.3
1.3.1
1.3.1.1
1.3.1.2
1.3.1.3
1.4
-----------------
1
1
1
2
2
2
2
3
Explanation of Symbols and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
Safety Regulations for the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 6
3.1
3.2
3.3
3.4
3.5
1
1
1
1
1
1
1
1
Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4

2.1
2.2
2.3
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interface pin connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RS 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RS 485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Profibus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Short Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Finding the best Type of Pressure Regulation . . . . . . . . . . . . . . . . . . . . . . . . . .
DUAL Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
QUADRO Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VARIO Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
3
3
-----------
6
7
8
9
10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.1
4.2
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.4.1
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.5
4.6
4.7
4.8
4.8.1
4.8.2
4.8.3
4.8.4
4.8.5
4.8.5.1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The SIGMA CONTROL System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMERGENCY STOP Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light emitting diodes and plain text display . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching the Compressor Package On and Off . . . . . . . . . . . . . . . . . . . . . . . .
Switching on locally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching off locally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching on and off in remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching on and off with the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acknowledgement of Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm and Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frequently Programmed Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure for initial startup (Standard Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure for initial startup (Expert Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Correcting the package pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The compressor package is to be operated with a base load sequencer . . .
MAC 41 as an example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
-----------------------------------------------
11
11
11
12
13
14
15
16
18
18
18
18
18
19
19
20
30
30
33
41
44
47
47
Table of Contents
Chapter --- Page
4.8.5.2 MVS 8000 as an example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.8.5.3 VESIS as an example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.6
Two rotary screw compressors in sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.6.1 Base load sequencing of two compressor packages with Sigma Control
via the RS 485 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.6.1.1 Settings on both SIGMA CONTROLs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.6.1.2 Settings on the master SIGMA CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.6.1.3 Settings on the slave Sigma Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.6.1.4 Settings on both SIGMA CONTROLs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8.6.2 Sequencing SIGMA and pressure switch controlled compressors . . . . . . . . .
67
70
72
75
77
78
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Password Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display and Setup Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
5
---------
83
85
86
86
Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting/resetting the maintenance interval counter . . . . . . . . . . . . . . . . . . . . . .
6
6
6
6
6
6
6
6
6
-------------------
90
91
92
93
94
96
98
100
102
Display and Setup Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ---104

7.1
7.1.1
7.2
7.2.1
7.2.1.1
7.2.1.2
7.2.1.3
7.2.1.4
7.3
7.3.1
7.3.2
7.3.2.1
7.3.2.1.1
7.3.2.2
7.3.2.2.1
7.3.2.3
7.3.3
7.3.3.1
ii
-------------
Display Level in SIGMA Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 90

6.1
6.1.1
6.1.2
6.1.3
6.1.3.1
6.2
6.3
6.4
6.4.1
4
4
4
4
4
4
Sigma Control Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 83

5.1
5.2
5.3
5.4
4 --- 52
4 --- 58
4 --- 67
Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enter password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General description of the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The daily schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The weekly schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The yearly schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clock key: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System pressure of the vacuum package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DUAL Control settings (normal control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
-------------------------------------
104
105
106
108
108
109
109
111
112
113
116
116
117
119
119
120
124
124
Table of Contents
Chapter --- Page
7.3.3.2
7.3.3.3
7.3.4
7.3.5
7.3.6
7.3.6.1
7.4
7.4.1
7.4.1.1
7.4.2
7.4.2.1
7.4.3
7.4.4
7.4.5
7.5
7.5.1
7.5.2
7.5.2.1
7.5.2.2
7.5.3
7.5.4
7.6
7.6.1
7.6.2
7.6.3
7.6.4
7.6.5
7.7
7.7.1
QUADRO control settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Modulating control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acknowledgement (reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/O periphery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air main charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Package discharge temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Package Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TV check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature sensor / shutdown temperature . . . . . . . . . . . . . . . . . . . . . . . . . . .
Binary input/output check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lamps test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RS 232 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RS 485 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
L2DP bus (Profibus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Saving settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
-----------------------------------------------------------
124
125
126
126
128
131
132
133
133
133
134
134
135
135
136
137
137
137
138
138
139
140
141
143
143
144
145
146
147
iii
Table of Contents
Chapter --- Page
iv
Technical Specification
1
Technical specification
1.1
Power Supply
Power supply for SIGMA CONTROL
Rated voltage . . . . . . . . . . . . . . . . . . . . . . . . 24 V DC (stabilized)
Consumption . . . . . . . . . . . . . . . . . . . . 1.3 A (standard controller)
Consumption . . . . . . . . . . . . . . . . . . 2.5 A (with expander board)
Auxiliary voltage for sensors (from the controller)
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 V DC
All voltages are generated within the compressor package itself
Note
1.2
Sensors
Pressure transducer:
Output signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20 mA
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . two wire
Resistance thermometer
Sensing resistance . . . . . . . . . . . . . . . . . . . PT100 to DIN IEC 751
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . two wire
1.3
Hardware
-
industrial computer with Intel processor
analog inputs and outputs (0---20 mA, 4---20 mA and PT100)
230/115 V relay outputs (volt ---free contacts)
electronic 24 V outputs (common negative rail, short circuit and overload proof)
24 V common negative rail digital inputs
internal undervoltage monitoring of 24 V supply
internal temperature monitoring
3 serial interfaces:
-
RS 232 (modem)
RS 485 (master---slave control)
Profibus DP
buffered real---time clock
buffer battery for RAM and real---time clock
permissible operating temperature range: ---20 C ... + 60 C
1 --- 1
1.3.1
Interface pin connections
1.3.1.1
RS 232
-
Connections
Pin 1
spare
Pin 2
receive data RxD
Pin 3
receive data RxD
Pin 4
reserved
Pin 5
ground
Pin 6
spare
Pin 7
request to send RTS
Pin 8
clear to send CTS
Pin 9
spare
Connect shielding to both plug housings

1.3.1.2
RS 485
-
Connections
Pin 1
terminating resistor RA
Pin 2
reserved
Pin 3
difference signal B
Pin 4
reserved
Pin 5
reserved
Pin 6
reserved
Pin 7
terminating resistor RB
Pin 8
difference signal A
Pin 9
reserved

1.3.1.3
Profibus
-
Connections
Pin 1
spare
Pin 2
spare
Pin 3
Profibus connection B
Pin 4
TTL signal RTS
Pin 5
ground
Pin 6
+ 5V for interface P5
Pin 7
spare
Pin 8
Profibus connection A
Pin 9
spare
1 --- 2
(integrated in SIGMA CONTROL)
(integrated in SIGMA CONTROL)
1.4
Software
-
real---time operating system
soft PLC
visualization software
user software
1 --- 3
Safety
2
Safety Regulations
2.1
Explanation of Symbols and Instructions

This symbol is placed before all instructions regarding safety where danger
to life and limb can occur during work. It is very important that these instructions are observed and that extreme care is taken. For their own protection,
all other users should be informed of these safety instructions. General
safety and accident prevention regulations must be observed as well as the
safety instructions laid down in this service manual.
Attention!
Note

-
This symbol is placed at text to which considerable attention must be paid to

ensure that recommendations, instructions, references and the correct sequence of work are complied with and that damage to or destruction of the
controller or other equipment is prevented.
This symbol identifies important product information, handling of the product or the corresponding section of the documentation to which
special attention must be paid.
This symbol identifies operations and actions to be carried out by the operator or service technician.
This bullet identifies listings.
Explanation of warning labels:

Beware of hot surface. Do not touch surface; danger of burning.
Beware of high voltage. Do not touch electrical components; danger of electric shock.
Beware! Machine starts automatically. Machine can start automatically or by
remote start command.
Beware of rotating parts. Do not touch rotating parts as this can cause
pinching/injury.
2 --- 4
Safety
2.2
General Instructions
Before work is carried out on electrical equipment carry out the following
measures in the order shown:
1. Switch off the main switch
2. Lock out the main switch
3. Check that no voltage is present on the equipment
Attention!
Any alterations or reconstruction carried out without consultation with and

the previous consent of KAESER COMPRESSORS will invalidate the warranty.
Attention!
Safety devices may not be modified or deactivated.

Signs and marks of reference may not be removed or rendered unreadable.
2.3
Safety Regulations for the Controller

-
Do not pull out or push in components (plugs) on the controller when the compressor package is running. This can cause damage to the controller.
Do not run the compressor package with supplies removed from the controller as irreversible
damage could occur (e.g. feed to the digital outputs with no power supply connected).
Do not apply other voltages to the electronic outputs on the output plug pins (i.e. external
feed via wire jumpers, etc.).
A short circuit at the power supply pins of the Profibus interface can cause irreversible damage to the interface.
2 --- 5
General
3
General
3.1
Short Description
The electronic controller Sigma Control comprises an industrial computer with an Intel processor, a user interface with a background illuminated plain text display, keys, some with integrated LEDs and digital and analog inputs and outputs. Power to the controller is provided by a
stabilised 24 V DC power supply unit.
The controller is provided with a clear, easily understood user interface that allows call---up of information or entry of settings:
-
LEDs indicate the most important operational states.
various functions can be keyed.
the plain text display provides the user with information on current events in the selected language
an event information memory records the last 100 events with date and time, e.g. alarm, service and operational messages.
Sigma Control controls, regulates, protects and monitors the compressor package.
The control function provides:
-
automatic changeover from load to idle or standstill ensuring optimum utilisation of the drive
motor according to the users actual air demand.
automatic start after a power supply failure.
Sigma Controls protective function ensures:

-
automatic shutdown of the compressor package if overcurrent, overpressure, overtemperature, etc. occurs, that is, if a fault occurs that can cause damage to the compressor package.
Sigma Controls monitoring function ensures:

-
punctual maintenance prompts for oil filter, air filter, V---belts, motor bearings, electrical components and other internal components. All these functions are monitored by service hour
counters and maintenance due is displayed as warning or service messages in the plain text
display.
All important data can be transferred via the Profibus using integrated interface software.
All parameters needed to operate KAESER rotary screw compressors and vacuum packages are
contained in Sigma Control. They are set up at the factory according to compressor model.
These parameters can be displayed or changed with the help of various menus or sub ---menus in
the software (see also chapter 5).
Parameter settings and changes are entered in the Display and Setup level of the software after
input of a password. The type of drive, pressure control mode (DUAL, QUADRO or VARIO), the
model and basic model status, for example, can be entered at this level.
3 --- 6
General
3.2
Finding the best Type of Pressure Regulation

Sigma Control is provided with various types of regulation. This means that the compressor
package can be operated at maximum efficiency depending on the users air demand.

select the type of regulation in the configuration menu.
reset the duty cycle from parameter in the statistic menu.
Run the compressor package for a longer period of time (at least four weeks, or more).
Evaluate the duty cycle from parameter.
Repeat this procedure for all types of pressure regulation.

DUAL control
QUADRO control
VARIO control
duty cycle (%)
Note
The type of pressure regulation with maximum duty cycle is the most efficient.
3 --- 7
General
DUAL Control
Pressure
3.3
p
max
p
min
Motor power
Full load
2 3
t1
5
t2
Idle
Standstill
Time
In DUAL control mode (combined idle and start ---stop) the compressor normally runs in load and
idle or standstill.
The controller regulates the compressor package between load and idle.
If the compressor package runs in idle for longer than the preset period (1) to (2), for example t1
= 6 minutes in idle, the drive motor is stopped completely (2). When the lower switching point
p min (3) is reached, the compressor package is automatically started again. Pressure rises to the
upper switching point p max (4), and the compressor package switches to idle. If the pressure falls
again to p min (5) within a shorter period (4) to (5), for example, t2 = 3 min, then the compressor
switches automatically from idle to load.
3 --- 8
General
Pressure
QUADRO Control
Motor power
3.4
p
max
pmin
Load
Idle
Standstill
1
1
time
tp rise
tp decay
Running
period
Unloaded
period
Venting
period
stop point for running or idle / standstill period
pmax
upper swtiching point
pmin
lower switching point
tp rise
pressure rise time (the time during which system pressure rises
from the lower to the upper switching point)
tp decay pressure decay time (the time during which system pressure decays
from the upper to the lower switching point)
Function description
Two fixed periods --- the running period and unloaded period --- are taken as the criterion for
selection of the operating mode of the compressor package when system pressure reaches the
upper switching point. These two periods are set according to the maximum permissible starting
frequency of the drive motor.
The running period starts every time the compressor package is switched on. It lasts as long as
the drive motor runs and stops when the compressor package switches to standstill.
The unloaded period starts every time the operating mode changes from load to idle. It runs during idle and also when the compressor package is switched to standstill after the idle period. It
stops when the compressor package switches to load.
Every cut ---out point is delayed by the venting period, so that the compressor package vents.
3 --- 9
General
The following switching cycles are possible:
-
If system pressure decays to the lower switching point, the compressor package switches to
load (1) irrespective of its previous operating mode. If the drive motor was at standstill, the
opening of the inlet valve is delayed to allow an unloaded compressor package start.
If system pressure rises to the upper switching point and the running period has already expired, the compressor package switches off after the run ---on period has expired (2).
If system pressure rises to the upper switching point before the running period has expired,
the pressure decay time of the previous switching cycle is taken as the criterion for the selection of the operating mode:
-- If the pressure decay time tp decay was longer than the idle/standstill period, the compressor
package switches to standstill after the run ---on period has expired (3).
-- If the pressure decay time tp decay was shorter than the period set for the idle / standstill
period, then idle mode is selected (4), that is, the inlet valve closes and the compressor
package is vented with the motor running. When the running period expires the compressor
package is also switched to standstill after the run ---on period has expired (5).
3.5
VARIO Control Mode

Functional description:
The idle period is automatically lengthened or shortened by the variable idle control in relation to
the number of motor starts. The number of motor starts during the preceding hour are measured.
A high switching frequency leads to longer idle periods.
A low switching frequency leads to shorter idle periods.
3 --- 10
Operation
4
Operation
4.1
Control Panel
2
1 SIGMA controller
2 Emergency Stop pushbutton
4.2
The SIGMA CONTROL System

The SIGMA CONTROL unit (1) is fitted in the control cabinet. It is used for both control and operation. The panel has 11 keys and 9 LEDs. The operation of the package is determined by default
values programmed in the controller.
4.3
EMERGENCY STOP Pushbutton

The EMERGENCY STOP button shuts down the compressor package immediately.
If the EMERGENCY STOP button is pressed because of an existing hazard or alarm, then this
must be eliminated before the package is reset. To accomplish this, carry out the following procedure:

Turn the EMERGENCY STOP button in the direction of the arrow to unlatch it.
Press the acknowledge (reset) key on SIGMA Control to acknowledge the alarm. (See
chapter 4.3.1 for function keys).
4 --- 11
Operation
4.3.1
Function keys
7
11
10
9
6
1
4
1
2
3
4
5
6
4 --- 12
ON key (I)
OFF key (0)
Clock key
Remote key
Load/unload changeover key
Arrow key () (menu down)
3
7
8
9
10
11
Arrow key () (menu up)

Escape key
Return key ()
Info --- event key
Reset key
Operation
4.3.2
Symbol
Key functions
Item
Description
Function
ON key
The compressor is switched on and runs in the

preselected operating mode:
local control --- remote control (control centre) --- clock
control
OFF key (0)
The compressor is switched off irrespective of operating

mode.
Clock ON/OFF key
Pressing the key causes the compressor to be switched

on and off by the integrated clock.
The LED illuminates in clock mode.
Remote ON key
Pressing the key switches between local and remote control of the compressor package.
The LED illuminates in remote mode.
Load/idle changeover key
Pressing the key switches the compressor into idle mode.

Pressing again switches back to the preselected mode.
Arrow key
Menus are scrolled downwards or a selected parameter is

reduced.
Arrow key
Menus are scrolled upwards or a selected parameter is

increased.
Escape key
Pressing the esc key:

--- returns to the next higher menu level
--- exits the edit mode without saving edited parameters
If the esc key is held down longer than 10 s a return to
the main menu is triggered.
Return key (save)
Only affects the message in the third line of the display (12):
--- returns to the selected submenu or
--- exits edit mode and saves edited parameters
10
Info --- event key
Display of the event information memory:

can be selected in any menu.
The display jumps back to the last menu position with the
esc key (8).
11
Acknowledge (reset)
key
Acknowledges alarm messages and resets the alarm

memory (if permitted).
4 --- 13
Operation
4.3.3
Light emitting diodes and plain text display
13
14
12
15
19
16
17
18
20
12 Four ---line display
13 Alarm LED
14 Communication alarm LED
15 Warning --- maintenance LED
16 Power ON LED (to controller)
4 --- 14
21
17
18
19
20
21
Load LED
Idle LED
Compressor ON LED
Remote ON LED
Timer ON LED
Operation
4.3.4
LED functions
Symbol
EDU &
21. /2$' S
WRWDO
ORDG
Item. Description
Function
12
Display see 4.3.3
Alphanumeric display with 4 lines and green background illumination
13
Alarm LED
The red LED flashes if the compressor package is shut

down because of an alarm.
If the alarm is acknowledged with the reset key (11),
the LED lights continuously. It extinguishes when the
fault is removed and the alarm is reset again.
14
Communication
alarm LED
The red LED illuminates if communication via the Profibus interface is interrupted.
If the communication fault occurs in remote mode, the
compressor package is automatically switched to local
control.
When the reset key (11) is pressed, the LED extinguishes if the alarm is no longer present.
15
Service/warning LED
The yellow LED flashes if there is a service message or

when maintenance is due.
If the message is acknowledged with the reset
key (11), the LED illuminates continuously until maintenance is completed and (if necessary) the service interval counter is reset. (see chapter 6.4.1 to reset the service interval counter)
16
Power ON LED
The green LED lights when power is available.

(The main switch and the control transformer cutout
are switched on)
17
Idle LED
The green LED illuminates continuously when the

compressor is running but no compressed air is produced.
The LED flashes if idle mode is selected with the idle
key (5).
18
Load LED
The green LED illuminates when the compressor is

running under load and compressed air is being produced.
19
Package on LED
The compressor package is switched on.

LEDs 17 and 18 must also be taken into consideration
to determine the operational status of the package:
If LED (19) is on -- and both LEDs (17) and (18) are
off, the package is stopped and in standby. It can
start at any moment.
20
Remote control
mode
The green LED illuminates when the package is in remote control mode.
21
Clock mode ON LED
The green LED illuminates when the package is switched either on or off by the clock.
4 --- 15
Operation
4.3.4.1
Display
The display (12) used for entry and readout of data and is provided with four lines of 16 characters each.
Example:
EDU
& 5

RII
E
EDU
& 5
NH\2)) S RII
WRWDO K
ORDG
K E
1
2
1
2
3
4
1
2
3
4
Header
Compressor status/menu text
3
4
Active line
Menu text
Line 1 -- header
Current system pressure and airend discharge temperature are displayed in the header.
These values are always shown
-
in the main menu
in setup levels in which parameter changes can be made even though the compressor is
running.
The letters R, S and F identify internal operational modes of the controller and are shown for
servicing purposes.
R means that the controller is in RUN mode and is working perfectly.
S means that the controller has been set to Stop by a programming unit (PG).
F means that there is a program fault.
Note
If an S or an F appears in the display, switch the power off and then back
on again to return to the R status. If this is unsuccessful, contact KAESER
service department for further instructions.
Line 2
Depending on settings, either the current status of the compressor package or menu text is
shown in line 2.
Line 3 -- active line
Note
Actions can only be executed if they are shown in in line 3.
This applies both a jump to to submenus or the changing of values.
4 --- 16
Operation
The respective menu text is shown here.
Example:
EDU
& 5
RLO ILOWHU
K

E
5
5
4
Entry line with Return ()
If it is possible to move to a submenu or if a parameter can be entered the Return () sign (5)
appears in column 16.
Line 4
The arrows C, 8 or E (4) appear in line 4, column 16 after the menu text and indicate the
direction in which the lines can be scrolled:
-
C --- lower stop, upwards scroll only
8 --- upper stop, downwards scroll only
E --- scroll in both directions
4 --- 17
Operation
4.4
Switching the Compressor Package On and Off

Attention!
4.4.1
Do not switch the compressor package on and off with the main switch.
Always switch on with the ON key (1) and off with the OFF key (2). Always
take the permissible motor starting frequency into account when switching
the compressor package on and off.
Switching on locally

Switch on the main switch.
The controller runs a selftest. When the selftest is completed the green power ON LED (16) illuminates permanently.

Press the ON key (1) --- the green compressor ON LED (19) illuminates.
LEDs 17 and 18 must be taken into consideration to determine the operational status of the compressor package:
If LED (19) is on -- and both LEDs (17) and (18) are off, the package is
stopped and in standby.
The compressor can start at any moment.
4.4.2
Switching off locally

4.4.3
Press the OFF key (2) --- the Package ON LED (19) extinguishes.
Switch off and lock out the main switch.
Switching on and off in remote

Remote control of the compressor package is selected with the Remote ON key (4) on the controller.
Choice of control via volt ---free remote contacts RC on a binary input can be made in the configuration@compressor start@ compressor ON menu.
4.4.4
Switching on and off with the clock

If required, the compressor package can be controlled by the clock. The procedure is the same
as for switching on and off locally except that the Clock mode ON/OFF-key (3) must be pressed
additionally.
Afterwards, the periods during which the compressor is to run can be entered in the clock --compressor ON/OFF menu.
See chapter 7.2 for setting up the clock.
Before carrying out any work, make sure that the package cannot be
switched on by the clock or from the control center.
4 --- 18
Operation
4.5
Resetting Alarm Messages

If an alarm occurs, the compressor package is shut down automatically and the red LED (13) on
Sigma Control flashes.
The bottom line of the display (12) shows the current alarm.
A list of possible alarms (faults) that could occur during operation of the compressor package is
given in chapter 4.7.

Remove the fault.
Reset the alarm with the reset key (11) --- LED (13) extinguishes.
The compressor package can now be started again.

Attention!
4.6
If the compressor was shut down with the EMERGENCY STOP pushbutton,
ensure that the pushbutton is enabled by turning in the direction of the arrow
before resetting the alarm.
Acknowledgement of Warning Messages

When maintenance is due the yellow LED (15) on SIGMA CONTROL flashes.
Maintenance due is shown in the display (12). A list of service messages that can be displayed
during operation is given in chapter 4.7).

Carry out the maintenance.
Acknowledge service message with the reset key (11) --- LED (15) extinguishes.
Note
(see chapter 6.4.1 to reset the service interval counter).

Note
When the maintenance is complete the remaining interval must be reset to

the default service interval.
Password level 4 is required to reset the service interval counter.
See chapter 7.1.1 to input the password.
4 --- 19
Operation
4.7
Alarm and Warning Messages
Message2
Type1 Fault
Remedy
access doors
Access doors opened with the

compressor package stopped
Close the doors.
access doors
Close the doors.
ADT C
Access doors opened with the

compressor package running
The maximum airend discharge
temperature (ADT) will soon be reached
ADT
ADT dT/dt
AI 1 open cct
The connection between analog input 1 and the system pressure

transducer is open circuit or there is
a short to earth
check pressure transducer, line and

connection,
have the defective transducer changed3
AI 2 open cct
The connection between analog input 2 and the pressure transducer

for internal pressure is open circuit
or there is a short to earth

connection,
AI 3 open cct
The connection between analog input 3 and the resistance thermometer for measuring airend discharge
temperature is open circuit
check sensor, line and connection,

have the defective sensor changed3
AI 4 open cct
The connection between analog input 4 and the resistance thermometer for measuring drive motor temperature is open circuit

AI 5 open cct
The connection between analog input 5 and a sensor is open circuit or

there is a short to earth

AI 6 open cct
The connection between analog input 6 and a sensor is open circuit or

there is a short to earth

1
2
3
The maximum airend discharge

temperature (ADT) exceeded
Ensure sufficient ventilation,

keep the ambient temperature below 40 C,
clean cooler,
cooling air outlet too near a wall,
check oil level,
renew the oil filter.
Airend discharge temperature (ADT) Check airend and piping to airend3,
rise rate exceeded
top up the oil,
check oil circulation.
A alarm
W warning
Symbols:
high:C / too high: / low:8 / too low:
Contact authorised KAESER service agent
4 --- 20

keep the ambient temperature below 40 C,
clean the cooler, cooling air outlet
too near a wall,
check oil level,
renew the oil filter.
Operation
Message2
Type1
Fault
Remedy
AI 7 open cct
AI 8 open cct
airend rotation
air filter dp C
The connection between analog input 7 and a sensor is open circuit

The connection between analog input 8 and a sensor is open circuit
The motor is turning in the wrong
direction
The pressure drop across the air filter is too high
The air filter is clogged

Change phases: swap L1 and L2
power connections
Clean/replace the air filter element
air filter h
The default service interval for

checking the air filter has expired
Clean the air filter element

see chapter 6.4.1 to reset the service interval counter
back pressure
There is still back pressure in the oil Check the venting line and the venseparator tank because of poor venting valve,
ting (V---belt drive compressors
check the MPCV
only)
back pressure?
There is still back pressure in the oil Check the venting line and the venseparator tank because of poor venting valve,
ting (direct drive compressors only) check the MPCV
bearings h
The default service interval for the

Grease the motor bearings
greasing the motor bearings has ex- (see chapter 6.4.1 to reset the serpired
vice interval counter)
blowoff prot.
Warning:
The response pressure of the pressure relief valve will soon be exceeded
Change the oil separator element,

check the minimum pressure/check
valve (MPCV), control valve, inlet
valve,
have defective valve changed3,
open the shut ---off valve in the venting line,
check the pressure transducer,
blowoff prot.
The response pressure of the pressure relief valve on the oil separator
tank is exceeded
Change the oil separator element,

check the minimum pressure/check
valve (MPCV), control valve, inlet
valve,
have defective valve changed3,
open the shut ---off valve in the venting line,
connection,
buffer battery
Contact Kaeser service 3
condensatedrain
The battery in the controller is discharged

Warning:
Condensate drain faulty
1
2
3
Check condensate drainage (clean,

repair)
A alarm
W warning
Symbols:
4 --- 21
Operation
Message2
Type1
Fault
Remedy
condensatedrain
Condensate drain faulty
coolingwater low
Cooling water pressure too low
Check condensate drainage (clean,

repair)
Check cooling water throttling valve,
No inlet water pressure,
Shut ---off valve missing
elect. equip. h C
The default service hours for checking electrical equipment and wiring
have expired
Have electrical equipment checked

by a trained electrician,
see chapter 6.4.1 to reset the service interval counter 6.4.1
emergency stop
Unlatch the pushbutton
ext.load signal?
The emergency stop button was

pressed
External load signal indistinct:
The default cut ---out pressure high
has been exceeded
The external load control has not

switched to idle, even though the
maximum permissible system pressure has been exceeded
Check settings of the external controller
Take the pressure drops across filters and dryer into account
Have the deviations between the
pressure transducers checked 3.
ext. message 0
ext. message 0
ext. message 1
ext. message 1
ext. message 2
ext. message 2
ext. message 3
ext. message 3
ext. message 4
ext. message 4
ext. message 5
ext. message 5
1
2
3
Message text freely definable with

SIGMA Control
SIGMA Control
SIGMA Control
SIGMA Control
SIGMA Control
SIGMA Control
SIGMA Control
SIGMA Control
SIGMA Control
SIGMA Control
SIGMA Control
SIGMA Control
A alarm
W warning
Symbols:
4 --- 22
Remove fault
Remove fault
Remove fault
Remove fault
Remove fault
Remove fault
Remove fault
Remove fault
Remove fault
Remove fault
Remove fault
Remove fault
Operation
Message2
Type1
Fault
Remedy
ext. message 6
Remove fault
ext. message 6
ext. message 7
ext. message 7
fan M2 I

SIGMA Control
SIGMA Control
SIGMA Control
SIGMA Control
First fan motor shut down because
of overload
fan M3 I
Second fan motor shut down because of overload
Investigate cause, then reset the

motor overload trip
fan M4 I
Third fan motor shut down because

of overload

motor overload trip
flash memory
Internal controller memory error
Have the controller replaced 3
HT cell
L2DP-controller
A
A
Fault in the high tension cell

The bus link from the Profibus DP
interface is interrupted
Have the high tension cell checked 3

Check the bus link and plug, check
interface configuration (see chapter
7.6.3),
L2DP-timeout
L2DP bus fault
Check the bus link and plug, check

interface configuration (see chapter
7.6.3),
mains cont. on?
The mains contactor does not pull in The answerback on input 0.6 (24V)
despite an ON command
does nor appear after compressor
start,
check auxiliary contact block on
K1M,
Check 230 V supply to the contactor
(door interlock switch, EMERGENCY
STOP)
mains cont. off?
The mains contactor does not drop

out despite an OFF command
The answerback from mains contactor K1M (0.6) is still present, even
though the compressor is at standstill
mains monitor
Fault in mains power supply
an optional voltage monitor reported

a fault,
possible drop in voltage
1
2
3
Remove fault
Remove fault
Remove fault
motor overload trip
A alarm
W warning
Symbols:
4 --- 23
Operation
Message2
Type1
Fault
mains voltage
1st power supply failure:

Contactor K1M fluttered during drive
The compressor will be restarted au- motor run,
tomatically
check power supply,
possible intermittent contact in a
door interlock switch
mains voltage
2nd power supply failure:

The drive motor is shut down
Contactor K1M fluttered during drive

motor run,
check power supply,
possible intermittent contact in a
door interlock switch
model
Model indistinct
Enter model again (level 5 required),

If message appears repeatedly
change the controller
modem problem
motor bearings
Sigma Control does not recognise

the modem
Overheating of motor shaft ball bearings
Check the link between Sigma Control and the modem

Grease the motor bearings with the
greasing device,
bearing damage, have the bearings
replaced3
motor bearings h
The default service interval for repla- Have maintenance carried out3,
cement of the motor shaft bearings Have the motor bearings replaced3
has expired
motor I
Drive motor shutdown because of

overload
Investigate cause,
then reset overload trip
motor T C
Drive motor very hot
Ensure sufficient ventilation

Fit cooling air discharge fan,
motor dirty, clean motor
motor T
motorstarts /h
Drive motor too hot

(temperature sensed by PTC sensor Fit cooling air discharge fan,
and trip)
motor dirty, clean motor
The maximum permissible motor
Lengthen idle period
starting frequency was exceeded
Increase capacity of air receiver,
during the last 60 min
increase cross---section of piping
between compressor package and
air receiver,
have defective sensor changed3
1
2
3
A alarm
W warning
Symbols:
4 --- 24
Remedy
Operation
Message2
Type1
Fault
Remedy
motorstarts /d
The maximum permissible motor

starting frequency per day was exceeded during the last 24 hours
Lengthen idle period

Increase capacity of air receiver,
increase cross---section of piping
between compressor package and
air receiver,
have defective sensor changed3
no press. buildup
The package cannot build up pressure after a compressor start
Check the complete compressor

package for faults (leaks, ...),
check inlet valve, MPCV, compare
indication of internal pressure in analog data menu with the pressure
gauge on the oil separator tank
no press. buildup
The package cannot build up pressure

Package pressure does not rise
above 3.5 bar within a preset period
Check the complete compressor

package for faults (leaks, ...),
check inlet valve, MPCV, compare
indication of internal pressure in analog data menu with the pressure
gauge on the oil separator tank
O 0.6/O 0.7
The connection between output 0.6

or 0.7 and a consumer load is short
circuited.
Check consumer load, line and connections (e.g. solenoid valve), replace defective consumer load
O 1.6/O 1.7
The connection between output 1.6

or 1.7 and a consumer load is short
circuited.
Check consumer load, line and connections (e.g. solenoid valve), replace defective consumer load
oil change h
The default service interval for the oil Carry out an oil change,
change has expired
(see chapter 6.4.1 to reset the service interval counter)
oil content C
Warning:
The oil content for pure air will soon
be reached
Check the scavenge tube in the oil

separator element,
check the dirt trap strainer in the
scavenge line,
check the oil separator element,
check the oil sensor, line and connections3
oil content C
The oil content for pure air will soon

be exceeded
oil filter dp C
The oil filter is clogged
Check the scavenge tube in the oil

separator element,
check the dirt trap strainer in the
scavenge line,
check the oil separator element,
check the oil sensor, line and connections3
Change the oil filter
oil filter h

checking the oil filter has expired
1
2
3
Carry out an oil filter change,

A alarm
W warning
Symbols:
4 --- 25
Operation
Message2
Type1
Fault
Remedy
oil level min
Oil level too low
Top up the oil
oil level max
Oil level too high
Drain some oil
oil p
No changeover to load as long as

the minimum oil pressure is not reached
Check oil circulation,

check pressure switch, line and
connections,
have the defective switch changed 3
oil T
No changeover to load as long as

the minimum oil temperature is not
reached
check oil circulation,

Check temperature switch, line and
connections,
have the defective switch changed3
PD temperature 8
Warning:
package discharge temperature too
low
Two ---speed cooling fan running at

high speed only --- switch to lower
speed
PD temperature
Package discharge temperature too

low

high speed only --- switch to lower
speed,
check fan motor,
check sensor, regulator,
check inverter, clean cooler, top up
the oil
PD temperature 8
Warning:
package discharge temperature too
high

low speed only --- switch to higher
speed,
check fan motor,
clean cooler,
top up the oil
PD temperature
Package discharge temperature too

high

low speed only --- switch to higher
speed,
check fan motor,
have sensor, regulator tested 3,
have frequency inverter tested 3,
clean cooler,
top up the oil
RAM
Internal RAM defective
RD compr. p
Pressure switch on the refrigerant

compressor activated (packages
with refrigeration dryer only)
Check the controller,

have the controller replaced3
fit cooling air discharge fan,
clean the refrigerant condenser
1
2
3
A alarm
W warning
Symbols:
4 --- 26
Operation
Message2
Type1
Fault
RS485err:chksum
Wrong configuration or transmission Check the link/interface connections

error
between the two controllers,
check maximum cable length and
screening,
check all interface parameters, i.e.
both subscribers active,
1 master and 1 slave configured, bitrate and character frame (format)
for both subscribers identical
(see also chapter 4.8.6.1).
RS485err:dial up

error
screening,
RS485err:initdrv

error
screening,
check all interface parameters, i.e.,
RS485err:protoc.

error
between the two controllers. Check
maximum cable length and screening,
1
2
3
Remedy
A alarm
W warning
Symbols:
4 --- 27
Operation
Message2
Type1
Fault
RS485err:transm.

error
Check maximum cable length and
screening,
check all interface parameters, i.e.,
separator dp C
The oil separator is clogged
Change the oil separator element
separator h

checking the oil separator has expired
Change the oil separator element

separator T
Air temperature at oil separator discharge exceeded
Have the trip device at the oil separator air discharge checked 3,
check the sensor and line to the trip
device, replace defective trip device
set output!
Remedy
sh.cct AI1
The set output test function is acti- End the set output mode.
vated
Short circuit at analog input 1
Check line and connections, check
the transducer that is measuring
system pressure
sh.cct AI2
Check line and connections, check

the transducer that is measuring internal pressure
sh.cct AI3

have the defective PT 100 sensor for
ADT changed3
sh.cct AI4
The connection between analog input 3 and the resistance thermometer for measuring airend discharge
temperature is either short circuit or
shorted to earth
The line between analog input 4 and
a sensor is short circuit or is shorted
to earth
sh.cct AI5
Check line and connections
sh.cct AI6
sh.cct AI7
The line between analog input 7 and check sensor, line and connection,
a sensor is short circuit or is shorted have the defective sensor changed3
to earth
sh.cct AI8
The connection between analog input 8 and the resistance thermometer for measuring drive motor temperature is either short circuit or
shorted to earth
1
2
3
A alarm
W warning
Symbols:
4 --- 28


Operation
Message2
Type1
Fault
Remedy
Sigma Control T
The temperature in Sigma Controls

housing has exceeded 70 C

keep ambient temperature below
40 C.
softstart
Fault in the soft start system
Have the soft start system checked 3
start T
The airend discharge air temperature (ADT) is too low too allow the
package to be started (resistance
thermometer temperature measurement)
The ambient temperature must be

higher than + 3C ,
have an auxiliary heating system fitted3
system press.
The system pressure has fallen below the syspress. low value because of leaks, pipe fracture, etc.
system press.
(vacuum packages
only)
The system pressure has fallen below the syspress. high value because of leaks, pipe fracture, etc.
Air consumption too high, check air

consumers,
connection,
check the syspress. low setting in
the Configuration/Pressure settings
menu,
Check vacuum package for leaks,
check the syspress. high setting in
the Configuration/Pressure settings
menu,
check whether the package
switches to full load (inlet valve)
V---belts broken
Fit new set of V---belts
V---belt tens. h
The V---belts parted during machine

operation
checking V---belt tension has expired
V---belt tension
The V---belt tension is too low
Tension the V---belts
VFD
VFD mains
The variable frequency drive system

for the drive motor is defective
Failure of power supply to compressor variable frequency drive system
see service manual for the drive system

Check power supply (electrician)
1
2
3
Tension the V---belts, change the

belts if necessary,
A alarm
W warning
Symbols:
4 --- 29
Operation
4.8
Frequently Programmed Functions

In this chapter, information on frequently programmed functions is given with the help of flow diagrams and examples.
-
Initial startup in clock mode
Correcting the package pressure

Carrying out maintenance
Base load changeover with MAC 41
Base load changeover with MVS 8000
Base load changeover with VESIS
Base load changeover between two compressor packages with Sigma Control
4.8.1
Initial Startup
Base load changeover with a compressor package controlled by a pressure switch
Procedure for initial startup (Standard Mode)

When the power supply to the controller is switched on the computer starts to boot. Both the display and the green Power ON LED illuminate.
The current system pressure and the airend discharge temperature are then displayed in the first
line. The compressor package can now be started with the ON key.
Start
Main menu:
language selection
Main menu:
password
Menu:
configuration
general
Select
language
Activate
password level 4
see chapter 7.1.1
Check date and time,

Summer/winter---time changeover
Check formats
Check units
End
Start the compressor
package
4 --- 30
Operation
-
Setting the language
Press and hold the arrow up key (D) until the language setting appears in the third line of the
display.
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1 Current system pressure and airend discharge temperature

2 Display of selected language

Press the return key ().
Select the required language with the arrow keys (D).
Confirm with the return key () .
Return to the main menu with the esc key.
Enter password
Press the arrow up key () until password appears in the third line of the display.
Press the return key () and the following is displayed:
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By pressing the return key () a flashing cursor appears below the first X of the password
(XXXXX).
Change the first character with the arrow keys (). Keep pressing the arrow keys until the
first X is replaced by the character required.
Press the return key (), the cursor now jumps to the next character in the password.
Select the next character with the arrow keys ().
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4 --- 31
Operation
Using this method, enter the remaining characters of the password for level 4 (12EXP). When the
last character of the password is entered with the return key (), the activated password level is
displayed.
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Exit the password menu by pressing the escape (esc) key.
Checking settings
(main menu configuration general)

Press and hold the arrow keys (D9) until general appears in the third line of the display.
The following display appears:
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2 Display of selected model

Press the arrow down key (9), and the following details will be displayed sequentially:
-
Model:
PN: (part number)
Version details:
SN: (serial number)
Press the arrow down key (9), the following parameters will be displayed sequentially and
can be set by pressing the return key () (see chapter 7.3.1):
-
date
time
summer/winter time
date format
time format
unit of pressure
4 --- 32
weekday
unit of temperature
Operation
4.8.2
Procedure for initial startup (Expert Mode)
Note
Use this chapter only after reading the complete service manual in
detail
When the power supply to the controller is switched on the computer starts to boot. Both the display and the green Power ON LED illuminate.
The current system pressure and the airend discharge temperature are then displayed in the first
line. The compressor package can now be started with the ON key.
If personnel are to be given instruction, parameters changed or the settings checked, then the
following procedure is recommended:
4 --- 33
Operation
Start
Main menu
Menu:
configuration
password
Menu:
configuration
general
Select
language
Activate
password level 4
see chapter
7.1.1
Check date and time,

determine formats
Menu:
configuration
pressure setpoint
compressor
Match
system pressure
p1
system pressure
ssetpoint pressure
Menu:
configuration
Set
control mode
control mode
4 --- 34
Operation

Comp. on/off
no
via clock
yes
Menu:
Program clock
clock
Activate clock
key
comp. on/off
Press
clock key
Menu:
configuration
Match volt --free
I/O periphery
contacts
End
4 --- 35
Operation
-
display.
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2 Display of selected language

Select the required language with the arrow keys (D).
Enter password
EDU
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(XXXXX).
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4 --- 36
Operation
displayed.
EDU
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Checking settings

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2 Display of selected model

Press the arrow down key (9), and the following details will be displayed sequentially:
-
Model:
PN: (part number)
Version details:
SN: (serial number)
Press the arrow down key (9), the following parameters will be displayed sequentially and
can be set by pressing the return key () (see chapter 7.3.1):
-
weekday
date
time
summer/winter time
date format
time format
unit of pressure
unit of temperature
4 --- 37
Operation
-
Adjusting system pressure
(main menu configuration compressor)

In the main menu, press and hold the arrow up key (D) until configuration appears in the
third line of the display.
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Press the return key () when the pressure settings appear in the third line of the display;
compressor now appears in the third line.
Press the return key () to display system pressure in the third line of the display.
Press the return key () again and the following display appears.
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Press the return key () and a flashing cursor appears below value p1.
Increase the setpoint pressure p1 with the arrow up key () and decrease it with the arrow
down key().
Enter the changed setpoint pressure with the return key ().
Press the arrow down key once (), so that the switching differential ---SD appears in the
Press the return key and a flashing cursor appears below the switching differential ---SD.
Increase the switching differential ---SD with the arrow up key () and decrease it with the
arrow down key ().
Enter the new value with the return key ().
(see also chapter 7.3.2.1.1).
4 --- 38
Operation
-
Control mode
(main menu configuration control mode)

Keep pressing the arrow keys (D9) in the control mode menu option until local mode appears in the second line of the display and then press the return key ().
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Sigma Control is provided with various pressure control modes (see also chapter 7.3.3).

Press and hold the arrow keys (D9) in local mode until the required control mode appears in
the third line of the display.
Press the return key () to confirm the selection.
Programming the clock
(main menu clock)

In the main menu, press and hold the arrow up key (D) until clock appears in the third line
of the display.
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Press the arrow down key once (), so that ON/OFF day appears in the third line of the display.
4 --- 39
Operation

Press the return key () to set the first switching point. Four switching points are available.
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Press the return key () and a flashing cursor appears below corresponding time.
The time can be increased or decreased with the arrow keys ().
Enter the selected time with the return ) key.
A daily schedule with four switching points is available. In this schedule the compressor package
can be started with the ON time and stopped with the OFF time. The daily schedule can be interrupted by the weekly schedule, a fact that could be useful at weekends, for example. The weekly
schedule can also be interrupted by the yearly schedule (see also chapter 7.2.1).
When all switching points have been set, the menu is exited with the escape esc key.

Press the arrow up key () once, so that clock key: n appears in the third line of the display.
Press the return key (), a flashing cursor appears below the n.
Change the entry from n to y with the arrow up key ().
4 --- 40
Activate the clock key
Confirm the change with the return key ) .
Operation
4.8.3
Correcting the package pressure
Note:
Start
Main menu:
password
The pressure parameters can only be set within

predetermined limits:
Package pressure SP (p1) Pcut---in min + SD
SP (switching point): when system pressure
reaches this switching point (p1), the compressor package switches to idle.
SD (differential pressure): if pressure falls below the SP (p1) -- SD, the compressor package
switches to load.
Activate
password level 4
see chapter 7.1.1
Menu:
configuration
pressure settings
Change setpoint pressure p1
compressor
system pressure
setpoint pressure p1
Is
pressure p2
no
required?
yes
Menu:
configuration
pressure settings
Change
compressor
system pressure
End
4 --- 41
Operation
-
Enter password
EDU
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(XXXXX).
EDU
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displayed.
EDU
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4 --- 42
Operation
-

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down key().
arrow down key ().
4 --- 43
Operation
-
When the switching differential ---SD for setpoint pressure p1 has been set, press the arrow
down key () once. The following display appears:
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down key ().
Press the arrow down key once (), so that the switching difference ---SD appears in the
Press the return key () and a flashing cursor appears below the switching differential ---SD.
arrow down key ().

4.8.4
Carrying out maintenance

Attention!
Note
When the maintenance is complete the remaining interval (3) must be reset
to the default service interval (4).
Password level 4 access is required to carry out changes to the service interval counters.
Enter password
EDU
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4 --- 44
(XXXXX).
Operation

EDU
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displayed.
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Resetting the service hours
The remaining hours in the corresponding service hours counter can be individually reset after
completion of maintenance.
The following service intervals are provided:
Oil filter, oil separator, oil change, air filter, V---belts change, V---belts tensioning, bearings change,
bearings maintenance, electrical equipment.
This means, for example, that when the V---belts have been tensioned, the corresponding service
interval must be reset. The reset for V---belt tensioning is located two lines below the phrase V--belt tension.

Press the arrow down key () 10 times, until maintenance appears in the third line of the
display.
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Press the return key (), the following display appears.
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The service counter is a down counter. The remaining hours to the next service (2) are shown,
together with the service interval (1).
4 --- 45
Operation

By pressing the arrow down key () the other service intervals are displayed.
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Press the arrow down key () once, reset appears in the third line of the display.
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Change the reset display from n to y with the arrow up key ().
4 --- 46
Confirm with the enter key (). The counter resets to the default service interval. At the same
time the reset display changes from y to n.
Operation
4.8.5
The compressor package is to be operated with a base load sequencer
4.8.5.1
MAC 41 as an example
3/6/9/12
MAC 41
2/5/8/11
Compressors with ribbon cable adapter
Compressors without ribbon cable adapter, SX, SM

and SK before modification to spring terminals
I 0.7external load/idle
4 --- 47
Operation
Start
Make
electrical
connections
Main menu:
password
Activate
password level 4
see chapter
7.1.1
Menu:
configuration
pressure settings
load control
Activate
load control
from remote key
remote mode
> load RC
remote key: y
Press
remote key on
operating panel
End
4 --- 48
Operation
-
Enter password
EDU
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;;;;; / C

(XXXXX).
EDU
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;;;;; / C

displayed.
EDU
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;;;;; / C

4 --- 49
Operation
-
Activating load control
(main menu configuration)

EDU
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Press the arrow down key () four times, until load control appears in the third line of the
display.
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Press the arrow down key () seven times and the following appears in the display.
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Press the arrow keys () until load RC appears in the third line of the display.
4 --- 50
Press the return key (), a flashing cursor appears in the third line of the display.
Operation
-
Activating the remote key
Press the arrow down key () once until remote key: n appears in the third line of the display.
Change the entry from n to y with the arrow keys ().
Confirm activation of the remote key with the return ) key. The following display appears:
EDU
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The pressure increase dpI becomes important if the rated package pressure is exceeded because of a period of external load that is too long. It then acts as the upper shutdown value.
4 --- 51
Operation
4.8.5.2
MVS 8000 as an example

Automatic/manual mode
MVS
X4
A
B
A
B
I0.7
I1.3
X4
X4
Changeover between automatic and manual modes

Load/idle contact in the MVS
External load/idle
Load control changeover, local G load RC
Motor running and control on messages

Wire the motor running and control ON messages from the compressor to the MVS.
Attention!
4 --- 52
It is imperative that output O0.3 control ON is used for the alarm compressor X message to the MVS.
Operation
Start
Make
electrical connections
Main menu:
password
Activate
password level 4
see chapter 7.1.1
Menu:
configuration
pressure settings
compressor
Set parameter for p2

manual mode
system pressure
setpoint pressure
p2
Note:
Menu:
configuration
pressure settings
load control
Set p2 for internal

control
The setpoint for p2 must result in a

reasonable switching combination if all
compressor packages are to be controlled in manual mode, i.e. by their
own default pressure settings.
Settings
> local mode
> p2
Menu:
configuration
load control
remote mode
Load changeover between localG load RC
loc.---loadRC
remote key: y
Press
remote key
on
operating
panel
End
4 --- 53
Operation
-
Enter password
EDU
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;;;;; /
;;;;; / C

(XXXXX).
EDU
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;;; /
;;;;; / C

displayed.
EDU
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;;;;; / C

Pressure parameter for manual mode

4 --- 54
Operation
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Press the return key () when pressure settings appears in the third line of the display;
Press the return key () to display setpoint pressure in the third line of the display.
EDU
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Press the arrow down key () twice, the following display appears.
EDU
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down key ().
Enter the new setpoint pressure with the return key ().
arrow down key ().

-
Setting p2 for internal control
4 --- 55
Operation

EDU
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Press the return key () when pressure settings appears in the third line of the display.
display.
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Press the arrow down key () three times and the following appears in the display.
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Press the arrow keys () until p2 appears in the third line of the display.
4 --- 56
Press the return key () when local mode appears in the second line of the display. A flashing cursor appears in the third line.
Operation
-
Load control changeover
Having set p2 for the internal pressure control, press the arrow down key () four times and
the following appears in the display.
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Press the return key (), a flashing cursor appears in the third line of the display.
Press the arrow keys () until loc. ---loadRC appears in the third line of the display.
Press the arrow down key () once until remote key: n appears in the third line of the display.
Confirm activation of the remote key with the return ) key. The following display appears:
EDU
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The following status is displayed in automatic mode:
EDU & 5

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The following status is displayed in manual mode:
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4 --- 57
Operation
4.8.5.3
VESIS as an example
Wiring of the process field bus with the help of the above circuit diagram
Vesis
Pin
comp.4
Pin
comp.5
Pin
comp.1
Pin
comp.2
Pin
comp.3
Pin
8
9
8
9
8
9
8
9
8
9
8
9
The terminating resistor must be connected in the plugs of the first and last subscribers of a
Profibus link.
4 --- 58
Operation
Start
Make
electrical
connections
Menu:
configuration
password
Activate
password level 4
see chapter 7.1.1
Menu:
configuration
pressure settings
compressor
system pressure
Set
parameter for p2
for manual mode
setpoint pressure
p2
Menu:
configuration
pressure settings
load control
Note:
The setpoint for p2 must result in a reasonable switching combination if all compressor packages are to be controlled in
manual mode, i.e. by their own default
pressure settings.
Set p2
for internal
control
local mode
> p2
L2DP bus
communication:
> send + receive
> slave number
> Software
monitoring: y
Activate
remote control
from bus
> remote key: y
4 --- 59
Operation
Menu:
communication
data
EEPROM: y
Save
settings
Attention!
An error message appearing after activation
is normal. This can be finally reset in active
bus mode after all items have been processed.
Switch off
control voltage
Attention!
Switch off
control voltage
Press
remote
key
End
4 --- 60
The display returns from y to n after 10

seconds. No changes should be made to the
controller during this period.
Operation
-
Enter password
EDU
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(XXXXX).
EDU
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displayed.
EDU
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4 --- 61
Operation
-
Pressure parameter for manual mode

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Press the return key () when pressure settings appears in the third line of the display;
Press the return key () to display setpoint pressure in the third line of the display.
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S 63 EDU
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Press the return key () twice, the following display appears.
EDU
& 5
6' EDU
S 63 EDU
6' EDU E

down key ().
Enter the new setpoint pressure with the return key ().
4 --- 62
Operation

arrow down key ().

-
Setting p2 for internal control

EDU
& 5
JHQHUDO
SUHVVXUH VHWWLQJV
FRQWURO PRGH
E

Press the return key () when pressure settings appears in the third line of the display.
display.
EDU
VHOHFWLRQ
& 5

ORDG FRQWURO
E

Press the arrow down key () three times and the following appears in the display.
EDU
& 5
ORFDO PRGH
S

Press the return key () when local mode appears in the second line of the display. A flashing cursor appears in the third line.
Press the arrow keys () until p2 appears in the third line of the display.
4 --- 63
Operation
-
Activating remote conrol from the bus
(Main menu communication)

In the main menu, press and hold the arrow up key (D) until communication appears in the
EDU
56
56
& 5
[
[ 8
Press the arrow down key () twice until L2DP bus appears in the third line of the display.
Press the return key () when L2DP bus appears in the third line of the display. The following display appears:
EDU

& 5
QD

Press the arrow up key () until send+ receive appears in the third line of the display.
Confirm with the return key ().
Setting the slave number
Press the arrow down key () twice until slave no.: 2 appears in the third line of the display.
Press the return key (), a flashing cursor appears below the number.
Set the correct slave number with the arrow keys ().
4 --- 64
Enter the selection with the return key ().
Operation
-
Activating software monitoring
Press the arrow down key () seven times until act.: n appears below software mon. in
the third line of the display. The following display appears:
EDU
& 5
VRIWZDUH PRQ
WLPHRXW V
DFWQ
8
EDU
& 5
WLPHRXW V
DFWQ

8

Press the arrow down key () twice until remote key: n appears in the third line of the display. The following display appears:
EDU
& 5

UHPRWH NH\ Q

(see also chapter 7.6.3).
4 --- 65
Operation
-
Saving settings
All important data are stored in an EEPROM that is no ---volt safe.

Data are retained even if the buffer battery discharges completely.
If the procedure is activated it takes approximately 30 seconds for the display to change back
from y to n.
Attention!
No changes should be made to the controller when saving data.

Loss of power when saving can lead to loss of data.

Change the entry from n to y with the arrow keys (D9).
4 --- 66
Press and hold the arrow keys (D9) until data @EEPROM appears in the third line of the
display. Press the return key () .
When the display returns to n exit the submenu with the esc key.
Operation
4.8.6
Two rotary screw compressors in sequence

If compressor packages are sequenced the pressure losses between the
compressors and the air main must be taken into account.
Attention!
4.8.6.1
Base load sequencing of two compressor packages with Sigma Control

via the RS 485 interface
Sigma Control 1
Sigma Control 2
Pin
Pin
1
2
2
3
6
7
7
8
9
8
9
4 --- 67
Operation
Package 1
(controlling package)
Master
Package 2
(controlled package)
Slave
Start
Activate password
level 4
see chapter
7.1.1
Menu:
configuration
password
Menu:
configuration
password
Menu:
Menu:
configuration
configuration
Set pressure
parameter
for system
pressures
p1 and p2
pressure settings
compressor
system pressure
pressure settings
compressor
system pressure
setpoint pressure
p1
setpoint pressure
p1
setpoint pressure
p2
setpoint pressure
p2
Menu:
pressure settings
load control
settings
Change
default times
for p1 and p2
p1/p2 clock
or
p1/p2 cycle
Menu:
Menu:
configuration
pressure settings
load control
configuration
Activation of
p1/p2
changeover
from clock or
cycle
local mode >

p1/p2 clock
or
> p1/p2 cycle
pressure settings
load control
remote mode
> p1/p2 RS 485
Activate
remote mode
via remote key
4 --- 68
Activation of
p2 from RS
485
remote key: y
Operation
2
Note:
The bitrate settings and the data
format must be identical for both
packages (communication menu).
Menu:
Menu:
communication
Activation
master
RS 485
communication
Activation
slave
RS 485
> master
> slave
Menu:
communication
data
EEPROM: y
Menu:
Save new
interface
settings
data
EEPROM: y
Attention!
Attention!
An error message appearing
after activation is normal. This
can be finally reset in active bus
mode after all items have been
processed.
communication
Switch off
control voltage
The display returns from y to

n after 30 seconds. No
changes should be made to the
controller during this period.
Switch on
control voltage
End
4 --- 69
Operation
4.8.6.1.1 Settings on both SIGMA CONTROLs
Carry out the following settings on both SIGMA CONTROLs.
-
Enter password
Press the arrow key () until password appears in the third line of the display.
EDU
& 5
SDVVZRUG
;;;;; /
;;;;; / C

(XXXXX).
EDU
& 5
SDVVZRUG
;;; /
;;;;; / C

displayed.
EDU
& 5
SDVVZRUG
;;;;; /
;;;;; / C

4 --- 70
Operation
-

In the main menu, press and hold the arrow key (D) until configuration appears in the third
line of the display.
EDU
& 5
JHQHUDO
SUHVVXUH VHWWLQJV
FRQWURO PRGH
E

EDU
& 5
VHWSRLQW SUHVVXUH
S 63 EDU
6' EDU
down key().
arrow down key ().
4 --- 71
Operation
-
When the switching differential ---SD for setpoint pressure p1 has been set, press the arrow
down key () once. The following display appears:
EDU
& 5
6' EDU
S 63 EDU
6' EDU E

down key ().
Press the arrow down key once (), so that the switching difference ---SD appears in the
arrow down key ().

4.8.6.1.2 Settings on the master SIGMA CONTROL
Enter the following settings on the SIGMA CONTROL controlling both packages.
-
Default times for the changeover between p1 and p2
(Main menu configuration)

EDU
JHQHUDO
& 5
SUHVVXUH VHWWLQJV
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E

4 --- 72
Press the arrow down key () until load control appears in the third line of the display.
Operation

Press the return key ( ).
a) Clock control

Press the arrow down key () until clock appears below settings in the third line of the display. Here the pressure change between p1 and p2 from the internal clock can be entered
(see also chapter 7.1.1 and 7.2.1).
EDU
& 5
SS FORFN
FORFN

E
b) Internal timer control

Press the arrow down key () until p1/p2 cycle appears below settings in the third line of
the display. Here the pressure change between p1 and p2 from the timer can be entered
EDU
& 5
SS F\FOH
S
K
S
K E
When all settings for the load changeover have been entered; the type of load changeover required can be selected.

Press the arrow up key () until local mode appears below load control in the second line of
the display.
Press the return key () to select the load changeover.
Select the required load changeover with the arrow keys .
Confirm the selected load changeover with the return key (). The following display appears:
a)
EDU
& 5
ORFDO PRGH
SS FORFN

b)
EDU
& 5
ORFDO PRGH
SS F\FOH

4 --- 73
Operation
-
Activate master
(main menu communication)

EDU
56
56
& 5
[
[ 8
Press the arrow down key () once, until RS485 appears in the third line of the display.
Press the return key () when RS485 appears in the third line of the display. The following
display appears:
56

;
QD

Press the arrow up key () until master appears in the third line of the display.
Enter the setting with the return key.
4 --- 74
Operation
4.8.6.1.3 Settings on the slave Sigma Control
Enter the following settings on the slave Sigma Control.
-
Activation of p2 from RS 485

EDU
& 5
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SUHVVXUH VHWWLQJV
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Press the arrow down key () until load control appears in the third line of the display.
Press the return key (), a flashing cursor appears below the value to be changed.
EDU & 5

UHPRWH PRGH
S
UHPRWH NH\ Q E

Select control mode p1/p2 RS485 with the arrow keys (D9).
Press the arrow down key () once, so that remote key: n appears in the third line of the
display.
Press the return key (), a flashing cursor appears below the value to be changed.
Change the n to y with the arrow down key ().
4 --- 75
Operation

Press the return key ).
EDU & 5

SS 56
UHPRWH NH\ M

Activate the slave
(main menu communication)

EDU
56
56
& 5
[
[ 8
Press the arrow down key () once, until RS485 appears in the third line of the display.
Press the return key () when RS485 appears in the third line of the display. The following
display appears:
56

;
QD

Press the arrow up key () until slave appears in the third line of the display.
Enter the setting with the return () key.
4 --- 76
Operation
4.8.6.1.4 Settings on both SIGMA CONTROLs
Carry out the following settings on both SIGMA CONTROLs.
from y to n.
Attention!

4 --- 77
Operation
4.8.6.2
Sequencing SIGMA and pressure switch controlled compressors

-
Example 1
A BS 51 with Sigma Control and an existing SK 26 are to supply the demand at weekends
and during the night.
Recommendation:
The pressure switch settings of the SK 26 should lie exactly between the programmed pressures of the BS 51.
7.5 bar
7.0 bar
p1/BS
p2/BS
SK
6.0 bar
This means that only the submenu p1/p2 of the BS 51 is to be programmed.

If the switching point p2 is activated over the weekend and during the night then the SK 26 is
automatically selected as the base load machine.

Enter the required values (SP and SD) for p1 and p2

-
Change to p1/p2 clock (load control, local mode)
Activate the switching points on the clock
Example 2
Two machines of the same capacity, one with Sigma Control and the other with conventional
control, are to be sequenced as base and peak load machines.

Program the submenu p1/p2 on the Sigma Control machine according to the base load
sequence requirements.
Enter the required values (SP and SD) for p1 and p2.
Enter the changeover delays and/or periods in the load control menu.
One of the volt ---free contacts O0.3, O0.4 or O0.5 must be functionally allocated to the
p1/p2 submenu.
This contact is then used for the changeover between two pressure switches in the existing
old compressor package (see example circuit diagram).
4 --- 78
Operation
21
K3
22
K3
K3
A open:
Sigma Control --- package running with setpoint pressure p2
A closed:
Sigma Control --- package running with setpoint pressure p1
4 --- 79
Operation
-
Examples of the time settings
1.
Two equivalent machines are to have equal duty cycles.
1.1
Daily changeover between p1 and p2 after 24 hours. The compressor package starts with
setpoint pressure p2 at 0.00 hours.
Start
Menu:
configuration
pressure settings
load control
p1/p2 changeover
from timer
local mode
> p1/p2 cycle
Menu:
configuration
pressure settings
load control
settings
> p1/p2 cycle
Duration
p1:
24h
p2:
24h
1st p2 start at:
00:00
End
1.2
Equal duty cycle during the day.
Menu:
Start
load control
p1/p2 clock
p1/p2 day
1 p1/p2 day
p2:
00:00
p1:
06:00
2 p1/p2 day
p2:
12:00
p1:
18:00
End
4 --- 80
Operation
1.3
Equal duty cycle during the week
Start
Menu:
load control
p1/p2 clock
p1/p2 week
1>
1>
1<
1<
2>
2>
2<
2<
3>
3>
3<
3<
4>
4>
4<
4<
Monday
00:00
Monday
21:00
Tuesday
18:00
Wednesday
15:00
Thursday
12:00
Friday
09:00
Saturday
09:00
Sunday
03:00
End
4 --- 81
Operation
1.4
A compressor package with a lower capacity that is operated as a slave is to work as a

base machine at night and at weekend.
Start
Menu:
load control
p1/p2 clock
p1/p2 day
1 p1/p2 day
p2:
00:00
p1:
06:00
2 p1/p2 day
p2:
17:00
p1:
23:59
Menu:
load control
p1/p2 clock
p1/p2 week
1>
1>
1<
1<
Friday
17:00
Sunday
23:59
End
4 --- 82
Menus --- General

5
Sigma Control Menus

When the compressor package is switched on, details of the software are initially shown in
SIGMA Controls display. The software is then loaded and the main menu appears in the display.
Example of the initial display:
31
61
6<6
6

+:

PN:
SN:
serial number
SYS:
system version
S5:
operating system version
HW:
5.1
part number
hardware version
Main Menu
The main menu shows the current system pressure, the airend discharge temperature and the
mode of operation.
Example:
1
2
EDU
& 5

RII
E
Current system pressure and airend discharge temperature
Operational mode (current state)
If the arrow down key () key is pressed three times a further display level is accessed in which
the total operating hours and hours on load are additionally displayed.
5 --- 83
Menus --- General

Example:
2
3
4
EDU
& 5
NH\2)) SLGOH
WRWDO K
ORDG
K
Operational mode (current state)
Total operating hours
Hours on load
The following information can be displayed in the second line (operational messages):
e.g. key---ON p1---idle
load control status:
idle
in idle mode
load in load mode

rdy
motor off, but ready.

motor starts again if air is demanded
off
motor off, but ready
load control from:

p1
set point pressure p1
p2
set point pressure p2
pE
increased system pressure pE

(at unclear load signal)
RC
Remote Contact (external load contact)
RB
Remote Bus (external bus signal)
compressor status
ON
compressor running
OFF compressor stopped

AL
Alarm, compressor fault
compressor switched on/off by:

key
0 and I key on control panel
clk
Internal clock
RC
Remote Contact (external contact)
RB
Remote Bus (external bus signal)
cRC clock or Remote Contact (external contact)

Note
5 --- 84
Return to the main menu from all other menus with the esc key.
Menus --- General

5.2
Password Protection
When the controller is switched on, the lowest level of access (level 0) is started. An access level
(level 4) is available to the customers user. Changes to the settings in Sigma Control are allowed
in level 4.
See chapter 7.1.1 for entry of the password.
Attention!
The password level automatically resets to level 0 within a period of

three hours.
5 --- 85
Menus --- General

5.3
Display and Setup Level

If the main menu is scrolled upwards with the arrow up key () , all menus in the Display and
Setup Level in which default values can be changed are shown. These are:
-
clock
configuration
components
package test
communication
5.4
password
language
Display Level
If the main menu is scrolled downwards with the arrow down key (), the menus in the Display
Level in which values can only be read are shown. These are:
-
status
analog data
operating data
maintenance
See following pages for an overall list of menus and submenus in the Display and Setup Level.
For an explanation of the abbreviated messages in the Display, see list of abbreviations in
chapter 7.8.
5 --- 86
Menus --- General
Password Level 0
language
communication
esc
--- RS232 (1X7)

---function
---bitrate: ....
---format: ...
. --- RS485 (1X8)

(master/slave)
---bitrate: ....
---format: ....
---remote key y/n
--- L2DP bus
esc
--- general
---version no.
---model:
---P number:
---S number:
---weekday
---date
---time
---date format
---time format
---unit of pressure
---unit of temperature
(1X9)
---> (n.a./send/
send
receive)
---slave no.: ...
---hardware monitoring
start: ... s
---software monitoring
timeout: ... s
---active: y/n
---remote key y/n
configuration
clock
esc
--- compressor ON/OFF
password
---ON/OFF day
---ON/OFF week
---ON/OFF year
-- clock key y/n
esc
--- password
---password:
XXXXX L0
XXXXX L0
--- SMS
---SMS status
---active: y/n
---buffer empty
---channel 1
---error: 0
---modem
---location
---channel 1
---channel 2
--- Data EEPROM y/n
Test menu
Version menu
System test
PN:
SN: 00000000
SYS: S5: HW:
2.14 0.60 0.5
Power in
10.5 bar 80C R

--- --- --- --- --- --- --- --- --- --- --off
--- --- --- --- --- --- --- --- --- --- --- F
automatic
Main Menu
5 sec.
PN:
= Part number
SN:
= Serial number
SYS: = System version
S5:
= Operating system version
HW: = Hardware version
10.5 bar 80C R

key ---OFF p1---off
total 13000h
load
12034hF
Display Level
Normal text:
can be read
Bold text:
status
can be changed
analog data
operating data
maintenance
esc
---------------
oil filter
oil separator
oil change
air filter
V---belts change
V---belt tension
bearing change
--- bearing maint.
--- elect. equip.
esc
esc
--- operating hours
---total hours
---load hours
---compressor motor
---airend
---Sigma Control
---modulating valve
--- load valve ON
Escape key
returns to next higher level or to the main menu
-------------------------------
esc
display 1---6
system pressure
internal pressure
cut ---out pressure
differential pressure
oil separator
ADT temperature
ADT before start
ADT-rise dT/dt
PD temperature
VFD frequency
analog output
air filter
coolwater temperature
motor temp.
oil filter dp
statistics
Info key
calls up current
messages
esc
esc
--- duty cycle from

--- reset
--- total duty cycle
--- syspress. max
--- reset
--- syspress. min
--- reset
--- internal press. max
--- reset
--- motor starts from
--- reset
--- motor starts total
--- motor starts/day
--- max: ...
--- motor starts/hour
--- max: ...
--- last load run
--- last idle run
--- motor OFF
Arrow key --- UP

scrolls display text downwards
Arrow key --- DOWN
scrolls display text upwards
messages
esc
---------
event info
last alarm:
last warning
current number
alarms:
Warnings:
--- current messages
Return key
initiates move to the next submenu, enters
parameters and passwords
5 --- 87
Menus --- General

Display Level
Password Level 4
Test menu
Version menu
System test
PN:
SN: 00000000
SYS: S5: HW:
2.14 0.60 0.5
Power in
automatic
10.5 bar 80C R

--- --- --- --- --- --- --- --- --- --- --off
--- --- --- --- --- --- --- --- --- --- --- F
10.5 bar 80C R
key ---OFF p1---off
total 13000h
load
12034hF
5 sec.
PN:
= Part number
SN:
= Serial number
SYS: = System version
S5:
= Operating system version
HW: = Hardware version
status
Main Menu
esc
messages
analog data
operating data
maintenance
esc
--- oil filter

interval; time left
--- reset
--- oil separator

interval; time left
--- reset
--- oil change

interval; time left
--- reset
esc
--- operating hours

---total hours
---load hours
---compressor motor
hours
---airend
hours
---Sigma Control
---modulating valve
--- load valve ON
number
--- air filter
-------------------------------
statistics
esc
display 1---6
system pressure
internal pressure
cut ---out pressure
oil separator
ADT temperature
ADT before start
ADT rise dT/dt
PD temperature
VFD speed
analog output
air filter
coolwater temperature
motor temp.
oil filter dp
print
esc
--- printer output

--- settings
--- timer
--- print day
--- print week
--- print year
interval; time left

--- reset
--- V---belts change
Arrow key --- UP

scrolls display text downwards
interval; time left

--- reset
--- V---belt tension
Arrow key --- DOWN

scrolls display text upwards
interval; time left

--- reset
--- bearing change

interval; time left
--- reset
--- bearing maint.
interval; time left
--- reset
--- elect. equip.

interval; time left
--- reset
5 --- 88
esc
Info key
calls up current messages
Escape key
returns to next higher level or to the main menu
esc
--- duty cycle from

--- reset
--- syspress. max
--- reset
--- syspress. min
--- reset
--- reset
--- reset
--- motor starts total
--- max: ...
--- motor starts/hour
--- max: ...
--- last load run
--- last idle run
--- motor OFF
esc
event info
last alarm:
last warning:
current number
alarms:
warnings:
---------
Return key
initiates move to the next submenu, enters
parameters and passwords
Normal text:
Bold text:
can be read
can be changed
Menus --- General

language
Password Level 4
communication
esc
--- RS232 (1X7)
package test
components
configuration
esc
--- general
clock
password
esc
esc
-- ON/OFF day
-- ON/OFF week
--- password
---password:
XXXXX L4
XXXXX L4
-- ON/OFF year
-- clock key y/n
--- control mode

local mode
--- Dual ; Quadro ; Vario;
continuous
---settings:
--- Dual
--- D---idle period t= ... s
--- Quadro
--- Q---idle period t= ... s
--- Q---unloaded period t= ...
s
---modulating valve
valve closed:
pN SP: ... bar
-- SD: ... bar
output: n.a./O...
--- reset
---remote reset
inputs: n.a. ; I..
---remote key: active y/n
--- compressor start

---compressor ON
selection
compressor ON
local mode
key+ clock; key
clock key: y/n
compressor ON
remote mode
key+ clock;key;
key+ RC;key+ clock -- RC
remote key: y/n
remote key: y/n
compressor ON
current; key + clock/key
settings
compressor ON
RC input: n.a./I.
compressor OFF
---venting: y/n
---restart: y/n
td: ... s
-- starting temperature

--- I/O periphery

---show quantities
--- display 1 -- 6 (p/T/II)
message text: 2* 15
characters
ana. input n.a. ; AI...
calibration ...
---external messages 0 ---7
message text: 15 characters
type of message:
alarm, warning, operation
input: n.a.; I ...
td: ... s
--- an.O parameter
AO1: ... mA
calibration ...
---version no.
---model
---P number:
---S number:
---weekday
---date
---time
---summer/winter t
---date format
---time format
---unit of pressure
---unit of temperature
--- pressure settings

---compressor
---blowoff protection
C SP: ...bar
---SD: ...bar
---rated pressure
SP: ... bar
---pressure increase
pE SP: ...bar
-- SD: ...bar
SP: ... bar
---setpoint pressure
p1 SP: ...bar
-- SD: ...bar
p2 SP: ...bar
-- SD: ...bar
---system pressure low
+ SD: ...bar
SP: ...bar
output: n.a./O...
--- cut ---in pressure min
SP: ... bar
---vacuum package
---cut ---in pressure max
SP: ...
---system pressure high
SP: ...bar
---SD: ...bar
output: n.a.; O...
---setpoint pressure
+ SD: ...bar
p2 SP: ...bar
+ SD: ...bar
p1 SP: ...bar
---rated pressure
SP: ... bar
---pressure fall
+ SD: ...bar
pA SP: ...bar
---load control
---load control
local mode: p1; p2;
p1/p2 clock; p1/p2
cycle
remote mode: p1; p2;
p1/p2 clock; p1/p2 cycle
p1/p2 RC; p1/p2 RS485;
load FC; local load RC
remote key: y/n
---settings:
* p1/p2 clock
-- p1/p2 day
-- p1/p2 week
-- p1/p2 year
* p1/p2 cycle
p1: ... h
p2: ... h
1st p1 start at:
xy:xy
* p1/p2 RC
n. a. ; I...
* idle---load
n. a. ; I...
* loc. ---loadRC
n. a. ; I...
venting period t: ... s
---idle key
active: y/n
esc
--- motor
---power switching
---selection
---settings:
* star---delta
---star period
T : t: ...s
T : t: ...s
---c/o delay t: ...s
C
8
--- oil circulation

---oil separator
---diff. pressure
input
c/0 delaytd: ...s
-- function
-- bitrate: ....
esc
--- compressor test: y / n
-- format: ....
--- RS485 (1X8)
TV check
(master/slave)
--- TV check
relief valve: y / n
pi= ...
--- TV check
ADT alarm: y / n
offset: = ... C
ADT = ... C
---bitrate: ....
-- format: ....
---remote key y/n
--- L2DP bus
(1X9)
---> (n.a./send /
--- binary inputs
send+ receive)
--- ...
---slave no.: ...
--- binary outputs
---hardware monitoring
--- ...
--- set: y / n
start: ... s
---software monitoring
--- lamps test: y / n
timeout: ... s
-- active:y / n
--- booster
---booster on
SP: ... bar
---SD: ... bar
output: n.a.; O...
---remote key y / n
--- SMS
---SMS status
--- AM charging
-- active: y/n
---valve open
SP: ... bar
---SD: ... bar
output: n.a.; O...
---buffer: empty
---channel 1
---error: 0
--- PD temperature
-- modem
> ana. input n.a. ; AI..

C SP: ...C
C SP: ...C
SD: ...C
8 SP: ...C
8 SP: ...C
td: ... s
-- location
-- channel 1
-- channel 2
--- Data EEPROM y/n
Normal text:
Bold text:
can be read
can be changed
--- timer
---OFF: ... s
--- ON: ... s
output: n.a.; O ...
5 --- 89
Display Level
6
Display Level in SIGMA Control

Status and measurement data, operational data and service intervals can be accessed in the Display Level.
Note
6.1
All the following points refer to password level 4.
Status Data
status
statistics
print
--- printer output

--- settings
--- clock
--- print day
--- print week
--- print year
6 --- 90
esc
esc
esc
--- duty cycle from
--- reset
--- syspress. max
--- reset
--- syspress. min
--- reset
--- reset
--- reset
--- max
--- motor starts/h
--- max
--- last load run
--- last idle run
--- motor OFF
messages
esc
event info
last alarm
last warning
current number
alarms:
warnings:
---------
Display Level
Display of status data
Press the arrow key ) until status appears in the third line of the display and then press
the enter key ).
Three further options are displayed:
- messages
- statistics
- print
6.1.1
Messages
Activate the messages menu option by pressing the return key () when messages appears in the third line of the display.
The submenu is divided into the following options:
- event information
The last 100 messages can be displayed. These include alarm messages and warning
messages.
- last alarm
The time at which the last alarm occurred and the corresponding alarm number.
- last warning
The time at which the last warning message occurred and the corresponding message
number.
- number of current alarm and warning messages.
- call---up of all current messages
Note
This menu option shows all current alarms and warnings and is especially
useful for faultfinding.
It can also be called up directly with the i key.
The following display options are possible:

Example:
2
3
ODVW ZDUQLQJ
: F

EORZRII SURW
Type of message
5
6
Type of display option
Alarm
Message has come
Message has gone
Message status
Warning
A
3
Message acknowledged (reset)
Time of arrival of warning or alarm
Date of arrival of warning or alarm
Actual warning or alarm
6 --- 91
Display Level
6.1.2
Statistics

Activate the statistics menu by pressing the return key ().
The following statistical evaluations are displayed:

-
total duty cycle in percent

(ratio of hours on load to total hours)
duty cycle from a defined day onwards

If the word reset is in the third line of the display, it can be selected with the return key ()
and changed to y with the arrow key (). Confirm the reset with the enter key ().
The actual date is entered by the reset. The duty cycle of the compressor package is recalculated from this point in time.
Maximum system pressure

The maximum pressure evaluated since the last reset is displayed.
and changed to y with the arrow up key (). Confirm the reset with the return key ().
The current value is accepted and monitoring is restarted.
Minimum system pressure

The minimum pressure evaluated since the last reset is displayed.
Maximum internal pressure

The maximum pressure evaluated since the last reset is displayed.
Motor starts from a defined day onwards

The number of motor starts since the last reset is displayed.
Motor starts
The total number of motor starts is displayed and can be changed, if required. This could be
the case if another drive motor is fitted.
Motor starts per day

The number of starts during the last 24 h are displayed, together with the number of permissible starts per day.
Motor starts per hour

The number of starts during the last 60 minutes is displayed, together with the number of
permissible starts per hour.
Last load run

The time and date on which the last changeover from load to idle occurred or on which the
compressor was shut down under load is displayed.
6 --- 92
Display Level
-
Last idle run

The time and date on which the last changeover from idle to load occurred or on which the
compressor was shut down in idle is displayed.
Last motor off

The time and date on which the compressor was last shut down, or was switched to standby
when in idle is displayed.

Example:
EDU
& 5

V\VSUHVV PD[
EDU E
2
3

2 Description of statistic
3 Value (percentage, minimum or maximum value)
6.1.3
Print

Activate the print menu by pressing the return () key.
All messages to be printed are displayed.

Example:
-
new messages
event info (history)
clock event info
parameters
parameters file

Example:
2
3
EDU
& 5
SULQWHU RXWSXW
!QHZ PHVVDJH

2 Description of status
3 Message to be printed
6 --- 93
Display Level
6.1.3.1
Printer clock
The printer can also be controlled with the internal clock.

Press the return key () twice, the following display appears.
EDU
FORFN

& 5
Press the return key () to set the clock for the printer in the following submenu.
The clock for the printer can be set up exactly the same as for the clock for compressor (see
chapter 7.2).
6 --- 94
Display Level
6 --- 95
Display Level
6.2
Analog data
analog data
-------------------------------
6 --- 96
esc
available displays 1---6
system pressure
internal pressure
cut ---out pressure
oil separator
airend discharge
temperature
airend discharge
temperature before start
airend discharge
temperature-rise
package dischargetemperature
VFD speed
analog output
cooling water
temperature
motor temperature
oil filter dp
Display Level
Display of analog data

Press and hold the arrow key () until analog data appears in the third line of the display.
All analog data of the compressor package are displayed.

Example:
-
current system pressure ( pN )
current internal pressure ( pi )*
current cut ---out pressure ( p1(2) ) SP and SD
pressure differential across oil filter ( dp )*
airend discharge temperature ( ADT )
airend discharge temperature before start
airend discharge temperature rise rate ( dT/s )
package discharge temperature (PDT)*
variable frequency drive speed
analog output*
pressure differential across air filter ( dp )*
cooling water temperature*
motor temperature*
pressure differential across oil filter ( dp )*
* optional or according to compressor model

Example:
2
3
EDU
& 5
V\VWHP SUHVVXUH
S1
EDU

E

2 Description of measured value
3 Value
6 --- 97
Display Level
6.3
Operating data
operating data
esc
--- operating hours
--- total hours
--- load hours
--- compressor motor
--- airend
--- Sigma Control
--- modulating valve
--- load valve ON
6 --- 98
Display Level
Display of operating data

Press and hold the arrow down key () until operating data appears in the third line of the
display.
Press the return key () to display operating hours, total hours, number of motor starts and
the number of operations of the load valve.
Move from one display to the next with the arrow keys ().
Press the return key () until operating hours appears in the third line of the display.
Move between the different displays with the arrow keys ().
All running periods are displayed, such as

-
total hours
load hours
motor running hours*
airend running hours*
Sigma Control operating hours*
modulating valve operating hours*
* If the hours shown in the third line of the display their value can be selected with the return key
() and changed with the arrow keys (). Change the hours if the corresponding component
has been replaced.
Example:
2
3
EDU
& 5
WRWDO KRXUV
K

E

2 Description of counter
3 Counter value
6 --- 99
Display Level
6.4
Maintenance
maintenance
--- oil filter

--- reset
--- oil separator
--- reset
--- oil change
--- reset
--- air filter
--- reset
--- V---belts change
--- reset
--- V---belt tension
--- reset
--- bearing change
--- reset
--- bearing
maintenance.
--- reset
--- elect. equip.
--- reset
6 --- 100
esc
Display Level
Display of maintenance hours

Press and hold the arrow down key () until maintenance appears in the third line of the
display.
All maintenance hours remaining until the next maintenance are displayed.
Example:
-
oil filter
oil separator
oil change
air filter
V---belts change
V---belt tension
bearing change
bearing maintenance
elect. equip.

Example:
2
4
EDU
& 5
RLO ILOWHU
K

UHVHW Q E
3


2 Description of maintenance counter
3 Remaining hours to next maintenance
(remaining time --- countdown)
4 Default maintenance interval
5 Reset of maintenance interval
6 --- 101
Display Level
6.4.1
Setting/resetting the maintenance interval counter

Attention!
When the maintenance is complete the remaining interval (3) must be reset
to the default interval (4).
Password level 4 access is required to carry out changes to the maintenance
interval counters.
Note

Activate password level 4 (see chapter 7.1.1.)
Resetting the maintenance interval counter
The remaining hours in the corresponding maintenance interval counter can be individually reset.

Press and hold the arrow down key () until reset appears in the third line of the display.
Example:
EDU
& 5
K
K
UHVHW Q

Change the reset display from n to y with the arrow up key ().
Confirm with the return key (). The counter resets to the default maintenance interval.
At the same time the reset display changes from y to n.
Setting the maintenance interval
Press and hold the arrow down key () until the hours display for the required maintenance
interval appears in the third line of the display.
Example:
EDU
& 5
RLO ILOWHU
K
K
5HVHW Q E

The maintenance interval can be increased with the arrow up key () and reduced with
the arrow down key ().
Enter the maintenance interval setting with the return key ().
6 --- 102
Press the return key (), a flashing cursor appears below the maintenance interval.
Display Level
6 --- 103

7

In the Display and Setup Level the settings for the password, clock, configuration, package test
and the interfaces are displayed.
The settings can be individually adapted at this level.
Note
7.1
All the following points refer to password level 4.
Password
--- password
---password:
XXXXX L0
XXXXX L0
7 --- 104
password
esc

7.1.1
Enter password
(main menu password)

In the main menu, press and hold the arrow down key (D) until password appears in the
EDU
& 5
SDVVZRUG
;;;;; /
;;;;; / E

2 Description of step to be taken
3 Activation of above step

The cursor flashes in the first character of the password (XXXXX).

Scroll through the character set with the arrow keys (D9) until the desired character appears.
Press the return key () to confirm the selection and the cursor moves to the next character
in the password.
Repeat the procedure for the remaining characters in the password.

The activated password level is shown when the last character is entered.
The following passwords are entered in the controller on delivery:
Level
Password
00000
12EXP
7 --- 105

7.2
Clock
clock
esc

--- ON/OFF day
--- ON/OFF week
--- ON/OFF year
--- clock key active: y/n
7 --- 106

Display and set up of the clock
(main menu clock)

In the main menu, press and hold the arrow up key (D) until clock appears in the third line
of the display.
The clock can be programmed in this submenu:

-
compressor ON/OFF

Example:
EDU
2
& 5
FRPS212))


2 Display of clock channel

Press the return key () to open the clock settings submenu.
Example compressor ON/OFF (clock channel for the compressor package):
2
3
4
1
2
3
4
EDU
& 5
212)) GD\
212)) ZHHN
212)) \HDU
E
Daily schedule
Weekly schedule
Yearly schedule
Scroll the menu options up and down with the arrow keys ().
Scroll the schedule to be changed to the third line and activate with the return key ().
7 --- 107

Example: daily compressor schedule (ON/OFF day)
2
3
4
1
2
3
4

7.2.1
EDU
& 5
212)) GD\
21
2))

E
First ON/OFF schedule (period)
Cut ---in time (ON switching point) of the compressor package in hours and minutes
Cut ---out time (OFF switching point) of the compressor package in hours and minutes
The cut ---in and cut ---out times of the compressor package can be changed by pressing the
return key ().
General description of the clock

The compressor package can be controlled from the clock by pressing the clock key. This allows
the fluctuating air demand to be time controlled.
Four time periods within a day, four time periods within a week and four time periods within a
year can be programmed.
A yearly schedule (month --- day of the month --- hour --- minute), a weekly schedule (weekday
--- hour --- minute) and a daily schedule (hour --- minute) is available to the user for entry of
switching points. The switching points in the yearly and weekly schedules are entered as periods
(with start and end) and the switching points in the daily schedule are entered as points in time.
The yearly schedule has the highest and the daily schedule the lowest priority. The last option in
each menu is the delete function, with which all entries in a corresponding schedule can be deleted.
7.2.1.1
The daily schedule

The compressor runtimes are entered in the daily schedule.
Four switching points are available.
The compressor package can be switched on and off automatically four times per day.
The programmed operational state of a switching point remains active until it is overridden by the
operational state of a subsequent switching point or if the weekly/yearly schedule activates.
Note
The daily schedule has the lowest and the yearly schedule the highest
priority.
Switching points in the weekly schedule have priority over switching points
in the daily schedule.
Daily switching point restrictions, such as are necessary for the weekend, are entered in the
weekly schedule.
The following conditions must be fulfilled:
-
7 --- 108
The periods entered must contain all relevant information.

(start time, end time)

7.2.1.2
The weekly schedule

All periods that are repeated during a weekly cycle are entered in the weekly schedule. If the
overriding yearly schedule is not active, a current period in the weekly schedule can be activated.
The following conditions must be fulfilled:
-
7.2.1.3
The periods entered must contain all information required (start weekday, start time, end
weekday, end time, required operational state).
The yearly schedule

An interruption of the cyclic daily schedule may be required if, for example, a public holiday occurs on a working day, or if a different schedule is required during holiday periods.
These periods can be started and ended at any convenient date and time. If no further period is
scheduled to follow the end of a period, the program returns to the weekly schedule.
As it is not possible to enter the year in the periods they are not unique, but repeat annually if not
deleted.
The following conditions must be fulfilled to enable a correctly scheduled sequence of programmed periods:
-
The periods entered must contain all relevant information.

(start date, start time, end date, end time, required operational state).
Attention!
When the clock key is pressed (3, see chapter 4.3.1) only the channel
command (compressor channel) from the clock is used to control the compressor package.
The clock function itself is not influenced, that is, the clock runs continuously in the background.
7 --- 109

Example 1:
It is intended to run a compressor from 05:30 to 12:00 and from 13:00 to 21:10 daily. It is shut
down at weekends from 14:00 Fridays to 05:30 Mondays, during company holidays from 11 July
to 26 July, and over the New Year from 12:00 on December 24 to 05:30 on January 2.
Menu: clock -- compressor ON/OFF -- ON/OFF day:
-
1 ON/OFF day
2 ON/OFF day
ON:
05:30
ON:
13:00
OFF:
12:00
OFF:
21:10
Enter 0 for day 3 and 4 switching points.

Menu: clock -- compressor ON/OFF -- ON/OFF week:
-
1 ON/OFF week
1 Friday
1 14:00
1 Sunday
1 23:59
1: comp. OFF
Enter 0 for week 2 to week 4 switching points.

Menu: clock -- compressor ON/OFF -- ON/OFF year:
-
1 ON/OFF year
2 ON/OFF year
1 11.07.
2 24.12.
1 00:00
2 12:00
26.07.
31.12.
23:59
23:59
1: comp. OFF
-
3 ON/OFF year
3 01.01.
3 00:00
3
02.01.
05:30
3: comp. OFF
7 --- 110
2: comp. OFF
Enter 0 for year switching point 4.

Example 2:
A compressor is required from 6:00 Monday until 22.00 Saturday because of four---shift working
in production.
Menu: clock -- compressor ON/OFF -- ON/OFF week:
1 ON/OFF week
1 Monday
1 06:00
1
Saturday
22:00
1: comp. ON
Note
Note
All settings in the ON/OFF compressor menu are active only after the clock
key has been pressed.
Note
7.2.1.4
> period start

< period end
The clock key is inactive on delivery to prevent operator error.

It can be enabled in the clock -- compressor ON/OFF menu.
Clock key:
Menu: clock -- compressor ON/OFF -- clock key
The clock key (
switched off.

) on Sigma Control can be deactivated to prevent clock functions being
Press the arrow keys (D9) until the following display appears:
EDU
& 5
FORFN NH\ Q
212)) GD\
C


Change the entry from act.: y to act.: n with the arrow keys (D9).
7 --- 111

7.3
Configuration
---------------
7 --- 112
general
pressure settings
control mode
acknowledgement
compressor start
I/O periphery
timer
configuration
esc

Display and set up of the configuration

All settings affecting the configuration can be displayed and changed in password level 4.
-
general
pressure settings
control mode
acknowledgement (reset) -
compressor start
I/O periphery
timer
Example:
EDU
& 5
JHQHUDO
SUHVVXUH VHWWLQJV
FRQWURO PRGH
E
Display of the various submenus

7.3.1
Scroll between the individual entries with the arrow keys (D9).
Scroll the desired menu option to the third line and activate with the return key ().
General

The following values are shown and can be changed, if required:

-
version no.
model
PN:
(part number)
SN:
(serial number)
weekday

Press and hold the arrow keys (D9) until weekday appears in the second line of the
display. The default weekday is displayed.
Use the arrow keys (D9) to select the current day of the week.
7 --- 113

-
date

Press and hold the arrow keys (D9) until date appears in the second line of the display.
The default date is displayed.

Use the arrow keys (D9) to select the current date.
Repeat the above procedure for the month and year.

-
time setting

Press and hold the arrow keys (D9) until time appears in the second line of the display.
Use the arrow keys (D9) to select the current hour.
Repeat the above procedure for minutes and seconds.

-
summer/winter time

start of summer time:
Press and hold the arrow keys (D9) until summertime appears in the second line of the
display.
Press the return key (). A flashing cursor appears below the day value.
Select the date and month with the arrow keys (D9) and confirm each setting with the
return key ().
Press the arrow down key () until the time appears in the third line of the display. Press
the return key ().
Select the hours and minutes with the arrow keys (D9) and confirm each setting with the
return key ().
start of winter time:
Press and hold the arrow keys (D9) until wintertime appears in the second line of the
display.
Press the return key (). A flashing cursor appears below the day value.
Select the date and month with the arrow keys (D9) and confirm each setting with the
return key ().
Press the arrow down key () until the time appears in the third line of the display. Press
the return key ().
7 --- 114
Press and hold the arrow keys (D9) until summer/winter t appears in the second line of
the display.
Select the hours and minutes with the arrow keys (D9) and confirm each setting with the
return key ().

Press and hold the arrow keys (D9) until time changeover appears in the second line of
the display.

-
activating the time changeover:
Change the entry from n to y with the arrow keys (D9) and activate with the return
key ().
data format (TT.MM.JJ)

Press and hold the arrow keys (D9) until date format appears in the second line of the
display.
The currently set date format is shown in the third line of the display.

The cursor flashes below the date format.

Use the arrow keys (D9) to select the required date format.
Example:
DD.MM.YY
30.08.98
YY---MM---DD
98---08---30
MM/DD/YY
08/30/98
D stands for day, M for month, and Y for year.

-
time format (hh:mm:ss)

Press and hold the arrow keys (D9) until time format appears in the second line of the
display.
The cursor flashes below the time format.

Use the arrow keys (D9) to select the required time format.
Example:
hh:mm:ss
08:29:43
hh:mm
08:29
hh:mm:ss AM/PM
08:29:43 AM
hh:mm AM/PM
08:29 AM
h stands for hours, m for minutes, s for seconds, AM for forenoon and PM for afternoon.

-
unit of pressure (bar, hPa, MPa, psi, at, Hg)

Press and hold the arrow keys (D9) until unit of press. appears in the second line of the
display.
The unit of pressure is displayed in the third line.

A flashing cursor appears below the unit of pressure.

Use the arrow keys (D9) to select the required unit of pressure.
7 --- 115

Example:
bar
hPa
MPa
pressure per square inch
at
atmospheric gauge pressure
Hg
megapascal
psi
hectopascal
inches of mercury column
unit of temperature

Press and hold the arrow keys (D9) until unit of temp. appears in the second line of the
display.
The unit of temperature is displayed in the third line.

Press the return key () and a flashing cursor appears below the unit of temperature.
Use the arrow keys (D9) to select the required unit of temperature.
Example:
20 C
68 F
7.3.2
degrees Fahrenheit
293 K

degrees Celsius
degrees Kelvin
Confirm the selection with the return key ().
Pressure settings
(main menu configuration pressure settings)

Press and hold the arrow keys (D9) until pressure settings appears in the third line of the
display.
The pressure settings menu has three options:

-
vacuum package
7.3.2.1
compressor
load control
Compressor configuration
(main menu configuration pressure settings compressor)
Pressure parameters important for the compressor are displayed and set in the following submenus.

7 --- 116
Press the return key () to enter the submenus.

7.3.2.1.1 System pressure
(main menu configuration pressure settings compressor system pressure)

Press and hold the arrow keys (D9) until system pressure appears in the third line of the
display.

Enter the submenu with the return key ().
This submenu is divided into the following options:

-
blowoff prot.
Two switching points (SP) are displayed:
stands for overpressure alarm

stands for overpressure warning
These values are installed at the factory and can only be changed by an authorised KAESER
agent.
-
nominal pressure
The compressor is designed for this end pressure. It also represents the maximum possible
system setpoint pressure.
This value is installed at the factory and can only be changed by an authorised KAESER
agent.
setpoint pressure
The two pressure parameters p1 and p2 at which the compressor package can be run, i.e.
the upper cut ---out point together with its switching differential (SD) in each case are displayed and can be changed here.
Setting up a parameter:


-
Scroll the required parameter into the third line of the display with the arrow keys (D9).
Set the required value with the arrow keys (D9) and confirm with the return key ().
system pressure low

The parameters for switching differential (SD) and the switching point (SP) for the low pressure warning message are displayed and can be set in this menu option.
Setting a parameter:


-
Scroll the required parameter into the third line of the display with the arrow keys (D9).
minimum cut ---in pressure (cutin press min):

The minimum cut ---in pressure is a design characteristic of the airend.
Note
Economical production of compressed air is only possible above this pressure.
It is regarded as the system pressure lower limit minus the system pressure switching differential.

Scroll the parameter to be set into the third line of the display.
7 --- 117

A cursor appears below the pressure value.

agent.
-
pressure increase
(main menu configuration pressure settings compressor pressure increase)

This value is added to the nominal package pressure during external load control and serves
as the upper safety limit should the external controller malfunction.

Press and hold the arrow keys (D9) until press. increase appears in the third line of the
display.
The currently set value for the pressure increase pE appears in the third line of the display.

The same applies to the switching differential ---SD.

7 --- 118

7.3.2.2
Vacuum package
(main menu configuration pressure settings vacuum package)

Keep pressing the arrow keys (D9) in the pressure settings submenu option until vacuum
package appears in the third line of the display and then press the return key ().
Pressure parameters important for the vacuum package are displayed and set in the following
submenus.

Press the return key () to enter the submenus.
7.3.2.2.1 System pressure of the vacuum package


Press and hold the arrow keys (D9) until vacuum package appears in the third line of the
display.
This submenu is divided into the following options:

-
system pressure high
cut ---in pressure max

setpoint pressure
pressure fall
nominal pressure
maximum cut ---in pressure (cutin press max)

Scroll the parameter to be set into the third line of the display with the arrow keys (D9).
A flashing cursor appears below the pressure value.

-
system pressure high

The parameters for switching differential (SD) and the switching point (SP) for the high pressure warning message are displayed and can be set in this menu option.
Also the output used for the warning is shown.


-
setpoint pressure
The two pressure parameters p1 and p2, i.e., the lower cut ---out point together with its
switching differential (SD) in each case, are displayed here.


-
nominal pressure
The vacuum package is designed for this end pressure. It also represents the minimum
possible system setpoint pressure.
agent.
7 --- 119

-
pressure fall pE

When external load control is activated this value is subtracted from the minimum rated
package pressure. It serves as the lower safety limit should the external controller malfunction.

Keep pressing the arrow keys (D9) until pressure fall appears in the third line of the display and then confirm with the return key ().
The pressure fall pE setting is shown here.
Press the return key () to set the pressure fall parameter.
The cursor appears below the pressure fall value.

Set the switching differential using precisely the same procedure.

7.3.2.3
Load control
(main menu configuration pressure settings load control)

Keep pressing the arrow keys (D9) in the pressure settings submenu option until load control appears in the third line of the display and then press the return key ().
Selecting load control
The method of control for the compressor package is selected here.

With this function a changeover can be made between an external master controller (such as
SAM or MVS) and the internal pressure parameters in Sigma Control.
Note
If Sigma Control is interfaced to a master controller via the Profibus then no

settings have to be made. The bus master (master controller) takes over remote control automatically.
The following modes are available:
a) local mode from setpoint pressures p1 or p2

b) remote mode p1/p2 from a remote contact (RC)
a)
If the compressor is not controlled externally it defaults to the internal controller, Sigma Control.
Here, it is possible to keep to p1 or p2 permanently, to switch them with the clock or to cycle
them periodically.
Scroll with the arrow keys (D9) until local mode appears in the second line of the display.
Press the return key (). A flashing cursor appears below the operating mode.
Set the required mode with the arrow keys (D9) and confirm with the return key ().
b)
If the compressor package is to be controlled externally it must be set to remote mode.

In this option, priority can be given to either setpoint pressure p1 or p2, and the medium
(clock, timer, ...) controlling the changeover between p1 and p2 can be selected.
Scroll with the arrow keys (D9) until remote mode appears in the second line of the display.

A flashing cursor appears below the operating mode.
Set the required mode with the arrow keys (D9).
7 --- 120
: setpoint pressure p1
: p1/p2 remote contact
: setpoint pressure p2
Example:
: p1/p2 RS485

: p1/p2 clock
: p1/p2 cycle

: load remote contact

: local---load remote contact

Note
If the compressor package is to be controlled externally, activate the remote

key (K).
Scroll with the arrow keys (D9) until remote key y/n appears in the third line of the display.

A flashing line appears below they or n.
Set the required mode with the arrow keys (D9).
The current load control mode selection is displayed

-
Load control settings
Press and hold the arrow keys (D9) until settings appears.
If the compressor package is switched between p1 and p2 setpoint pressures from a remote
contact the input address is shown here.
Changeover between p1 and p2 from the internal clock:
If the compressor package is to be run using two different pressures (p1 and p2), the switching
points for both pressures can be set in this menu option.
This is required for shift working, for example.

Press the return key () when p1/p2 appears in the third line of the display.
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SS
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The procedure for setting up the day, week and year schedules is exactly the same as for the
clock.
Press the return key () when the parameter to be set appears in the third line of the display.
A flashing cursor appears below the time.
Press the return key () when p1/p2 day appears in the third line of the display.
Note
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S
C
7 --- 121

Press the return key () when the parameter to be set appears in the third line of the display.
Set the hour with the arrow keys (D9).
Press the return key (), the cursor jumps to the minutes display.
Set the minutes with the arrow keys (D9).

From this switching point onwards the compressor package runs at the pressure displayed
before this point in time.
Press the return key () to enter the new switching points.
Changeover between p1 and p2 from the internal timer.
The cycle periods can be preset if the compressor package is switched by a timer between setpoint pressures p1 and p2.

Press the arrow down key ) until p1: ..h appears in the third line of the display.

A flashing cursor appears below the hours.
Set the hours with the arrow keys (D9).
Press the arrow down key ) until p2: ..h appears in the third line of the display.

Under timer control the start of the period must be preset.

Press the arrow down key () until 1.Start p1 at: ..h appears in the third line of the display.

The cursor appears below the colon.
Select either setpoint pressure p1 or p2 with the arrow keys (D9).
Press the arrow keys (D9) until the time below 1.Start p1 at: ..h appears in the third line of
the display.

Press the return key (), the cursor jumps to the minutes display.
Press the return key () to confirm.
The input address for the remote contact can be set in various control modes.
Idle key
The idle key on the control panel can be deactivated to prevent unauthorised use.
7 --- 122

Press the arrow keys () until idle key: y/n appears in the third line of the display.
Select idle key active y or inactive n with the arrow keys ().
7 --- 123

7.3.3
Control mode
(main menu configuration control mode)

Keep pressing the arrow keys (D9) in the control mode menu option until local mode
appears in the second line of the display and then press the return key ().
Sigma Control is provided with several control modes.

Press and hold the arrow keys (D9) in local mode until the control mode appears in the third
line of the display.
Select the required control mode with the arrow keys (D9).
The following control modes can be selected:
DUAL
VARIO
QUADRO
Continuous
Press the return key () to confirm the selection.
This activates the selected control mode!

7.3.3.1
DUAL Control settings (normal control)

(main menu configuration control mode) dual)

Keep pressing the arrow keys (D9) in the control mode menu option until * Dual appears
in the third line of the display below the option settings and then press the return key ().
Idle setting in DUAL control

Keep pressing the arrow keys (D9) until t = ...s appears in the third line of the display
and then press the return key ().
Set the required idle period with the arrow keys (D9), taking the minimum period allowed
into account, and confirm with the return key ().
The minimum idle period in DUAL control is 450 s.

7.3.3.2
QUADRO control settings

Press the arrow keys (D9) until * Quadro appears in the third line of the display and then
press the return key ().
Setting the unloaded period

Set the required unloaded period with the arrow keys (D9), taking the minimum period
allowed into account, and confirm with the return key ().
Minimum unloaded period
7 --- 124
Press and hold the arrow keys (D9) until unloaded period appears in the second and
t= ... s in the third line of the display. Press the return key ().
Scroll with the arrow up key (D) until unloaded period appears in the third line of the
display and then press the return key () to display the minimum unloaded period.

-
Running period setting

Press and hold the arrow keys (D9) until running period appears in the second and t=
... s in the third line of the display. Press the return key ().
Set the required running period with the arrow keys (D9), taking the minimum period allowed into account, and confirm with the return key ().
--- minimum running period

7.3.3.3
Scroll with the arrow up key (D) until running period appears in the third line of the display and then press the return key () to display the minimum running period.
Modulating control
(main menu configuration control mode modulating valve)

Keep pressing the arrow keys (D9) in the control mode menu option until mod. valve appears in the third line of the display and then press the return key ().
Modulating control is a mechanical form of control.

The inlet valve opens more or less under the influence of a pneumatic controller.
The valve can be regulated either by system pressure or the pressure in the oil separator tank.
-
Cut ---out point of the modulating control valve
Keep pressing the arrow keys (D9) until pN SP: ...bar appears in the third line of the
display and then press the return key ().
Set the required cut ---out pressure with the arrow keys (D9) and confirm with the return
key ().
Note
One of these two alternitves is selected by a solenoid valve according to

system pressure.
Switching differential
Keep pressing the arrow keys (D9) until ---SD: ...bar appears in the third line of the
Set the required switching differential with the arrow keys (D9) and confirm with the
return key ().
Modulating control valve address
The current output address of the modulating valve is shown in the third line of the display.
7 --- 125

7.3.4
Acknowledgement (reset)
(main menu configuration acknowledgement)

Keep pressing the arrow keys (D9) in the configuration menu option until acknowledgement appears in the third line of the display and then press the return key ().
In this menu option the settings for remote acknowledgement of a message are found.
-
Select remote ackn. input

Scroll the option remote ackn. into the second line of the display with the arrow
keys (D9).
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A flashing cursor appears below the input address.

-
select an input with the arrow keys (D9).


Select act.: y (yes) or act.: n (no) with the arrow keys (D9).

7.3.5
Scroll the option remote key into the third line of the display with the arrow keys (D9)
and then press the return key ().
Compressor start
(main menu configuration compressor start)

Keep pressing the arrow keys (D9) in the configuration menu option until compressor
start appears in the third line of the display and then press the return key ().
The following settings can be made in this menu option:
7 --- 126

-
compressor ON
-
delay time td: ... s
If several compressors start together there is danger of overloading the power supply.
To prevent this, each compressor package can be allocated a start delay time. This allows
the compressor packages to start at staggered intervals.

Keep pressing the arrow keys (D9) until td: ....s appears in the third line of the display
below compressor ONand then press the return key ().
Set the required delay time with the arrow keys (D9) and confirm with the return key ().
Press the return key () when compressor ON appears in the third line of the display.
The time at which the compressor packages are started can be set in this menu option. Also,
it can be differentiated between local and remote, i.e., direct control
-
local mode:
The compressor package can be started locally with the ON key (

clock.
) and additionally by the
Press and hold the arrow keys (D9) in the compressor start menu option until compressor ON appears in the third line of the display.
Scroll with the arrow keys (D9) until local mode appears in the second line of the display.
A flashing cursor appears below the operating mode.

Select either key or key + clock.
In the key mode the compressor package is started with the ON key ( ). In the
key + clock mode the compressor package is additionally started by the internal clock.

Press the arrow down key () until clock key appears in the third line of the display.
Select clock key active y or inactive n with the arrow keys (D9).
This protects against unauthorised use.

remote mode:
Note
To start in remote mode the controller must be switched on with the ON

key ( ) and remote mode selected.
The following switching sources can be used:

--- remote contact (RC)
--- clock or remote contact (cRC)
The procedure is exactly the same as for local mode settings. The remote key and the
clock key can be activated or deactivated.
The remote contact input can be selected further down in the menu options.

Press the arrow down key () until * comp. ON appears in the second line and
RC I.... appears in the third line of the display.
7 --- 127

The cursor flashes below the input.

-
Select a suitable input for the remote contact with the arrow keys (D9).
compressor OFF
Venting: y/n
The compressor shutdown venting function (unloaded start) is activated in this menu.

Select y (yes) or n (no) with the arrow keys (D9).

-
Press the return key () when venting appears in the third line of the display.
automatic restart after a power supply failure

When this function is activated the compressor package starts again automatically when
power returns after a power failure.
This function is normally activated.
Note

Select y (yes) or n (no) with the arrow keys (D9).

-
Press the return key () when restart appears in the third line of the display.
starting temp.
To prevent damage to the compressor package caused by starting at a temperature that is
too low, a minimum starting temperature of 2 C is set and the function activated in this
menu option.
7.3.6
I/O periphery
(main menu onfiguration I/O periphery)

Keep pressing the arrow keys (D9) in the configuration menu option until I/O periphery
appears in the third line of the display.

The submenus are described below:
clock contact

Press the return key () when clock contact appears in the third line of the display.
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The procedure for setting up the day, week and year schedules is exactly the same as for the
clock (see chapter 7.2.1).
Note
7 --- 128

Press the return key () when contact day appears in the third line of the display.
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Press the return key () when the parameter to be set appears in the third line of the
display.

Press the return key (), the cursor moves to the minutes display.

-
Press the return key () to enter the new switching points.
show quantities
-
selecting quantities
Keep pressing the arrow keys (D9) in the I/O periphery menu option until show quantities appears in the third line of the display.
Enter the list of individual quantities with the return key ().
There are two displays each for pressure, temperature and other physical quantities available.

Press the return key () when the required quantity appears in the third line of the display.
The denotation of the quantity can be individually adapted.

Set the amperage with the arrow keys (D9).
message text
Scroll the message text into the third line of the display with the arrow down key ().
Press the return key (), a cursor appears below the first character of the message text.
Search through the character set with the arrow keys (D9) for another character. Confirm
this character with the return key () and the cursor will move to the next character in
the text.
The message text can consist of up to 15 characters.

When all characters have been selected, confirm with the return key ().
selection of sensor input
The sensor input for this message is determined by scrolling the required input into the
Press the return key (), a cursor appears under the corresponding input or its non ---activation (n.a.) is displayed.
Select a suitable input with the arrow keys (D9).
7 --- 129

Scroll in the quantity to be processed with the arrow keys (D9) until calibration appears
in the second line of the display.
Press the return key (), a cursor appears below the quantity.
A definite quantity can now be assigned to the signal input from the sensor.
The value of this quantity can be changed with the arrow keys (D9).

-
calibration
external messages
In this menu option the type of message (alarm, service or operational message), the allocation of an input and the delay period for display of the message can be set.

Press the return key (), as soon as ext. messages appears in the third line of the display, the individual messages are displayed and can be processed.
message text
Scroll the message text into the third line of the display with the arrow keys (D9).
Press the return key (), a cursor appears below the first character of the message text.
Search through the character set with the arrow keys (D9) for another character. Confirm
this character with the return key and the cursor will move to the next character in the
text.
The message text can consist of up to 15 characters.

-
type of message
Press the arrow down key () to determine the type of message.
Press the return key (), a cursor appears below the message type, which can be
changed with the arrow keys (D9).
Confirm with the returnr key ().
Selection of switched input
Press the arrow down key () to change the switched input.
Press the return key (), a cursor appears below the input designation.
This can be changed with the arrow keys (D9).
delay period
Press the arrow down key () to change the delay period.
Press the return key (), a cursor appears below the delay period.
A period between 0 and 600 seconds can be set with the arrow keys (D9).
7 --- 130
When all characters have been selected, confirm with the return key ().

7.3.6.1
timer
(main menu configuration timer)
A solenoid valve for the drainage of condensate can be activated at regular intervals.

Press the arrow keys (D9) until timer appears in the third line of the display and then press
the return key (). The timer output is located below.
OFF period

Press the arrow keys (D9) until OFF appears in the third line of the display and then
Set the required time period with the arrow keys (D9) and confirm with the return key ().
ON period

Press the arrow keys (D9) until ON appears in the third line of the display and then
Set the required time period with the arrow keys (D9) and confirm with the return key ().
7 --- 131

7.4
Components
components
esc
---motor
---oil circulation
---booster
---AM charging
---PD temperature
7 --- 132

Display and set up of the components

In the main menu, press and hold the arrow up key (D) until components appears in the
Press the return key (), the following display appears:

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7.4.1
Motor
(main menu components motor)

Keep pressing the arrow keys (D9) in the components menu option until motor appears in
the third line of the display.

The submenu power switching appears in the display.
7.4.1.1
Power switching
(main menu components motor power switching)
The type of motor start and the corresponding settings are entered in this menu option.
-
Display of power switching

The selected type of motor start is displayed.

The following modes
are available:
star---delta start
direct ---online---start
high tension
soft start
VFD compressor
Setup of power switching

The types of motor start are repeated under the settings: menu option.

Set the required type of motor start with the arrow keys (D9) and confirm with the return
key ().
The parameters for the respective type of motor start can be set in this menu option.
7.4.2
Oil circulation

Press the return key () when oil circulation appears in the third line of the display in the
components menu option.
A submenu with the following menu option opens:
oil separator
7 --- 133

7.4.2.1
Oil separator

Press the return key () when oil separator appears in the third line of the display in the
oil circulation menu.
The inputs for the temperature and differential pressure transducers on the oil separator together with the delay period for an excessive differential pressure alarm are displayed.

Press the return key () when diff. pressure appears in the third line of the display.
Press the return key () when
switch appears in the third line of the display.
The input allocation for the oil separator pressure transducer is set in this menu option.

Press the arrow down key () until td: ....s appears in the third line of the display.
Press the return key (), a cursor appears below the delay period.
Set the required delay period with the arrow keys (D9).
Press the return key () when temperature appears in the third line of the display.
The input allocation for the oil separator temperature transducer is set in this menu option.

7.4.3
Booster

Press the return key () when booster appears in the third line of the display in the components menu.
The pressure switching point and the pressure switching differential for a booster can be set
in this menu option.
Because a booster only works efficiently above a certain minimum pressure it should be cut
in only after achieving this pressure.
The output controlling the booster is also displayed.

Press the return key (), a cursor appears below the pressure value.
Set the required pressure switching point with the arrow keys (D9).
Press the arrow down key () until ---SD: ....bar appears in the third line of the display.
Set the required switching differential with the arrow keys (D9).
7 --- 134
Press the arrow down key () until SP: ....bar appears in the third line of the display.

7.4.4
Air main charging

Press the return key () when AM charging appears in the third line of the display in the
components menu.
The pressure switching point and the pressure switching differential for air main charging of
an empty air main can be set in this menu option.
A valve is located upstream of the empty air main that first opens when the working pressure
has been reached. The output controlling the valve is displayed.

Press the arrow key () until ---SD: ....bar appears in the third line of the display.
Set the required switching differential with the arrow keys ().

7.4.5
Press the arrow key () until SP: ....bar appears in the third line of the display.
Package discharge temperature

Press the return key ( ) when PD temperature appears in the third line of the display in the
components menu.
The analog input for the transducer is set in this menu option.

Press the arrow down key () until PD temperature appears in the second line of the
display.
Press the return key (), a cursor appears below the displayed input.
Select the required input with the arrow keys (D9).
Confirm with the enter key ().
The pressure switching points and switching differentials for the high or low package discharge temperature alarm and warning messages can be set in this menu option.

Press the arrow down key () until SP: ....bar appears in the third line of the display.
Press the arrow down key () until ---SD: ....bar appears in the third line of the display.
A message delay period can be set in this option.
7 --- 135

7.5
Package Test
esc
package test
---compressor test
---TV check
---binary inputs
---binary outputs
---lamps test
Display and set up of the package test

(main menu package test)

In the main menu, press and hold the arrow up key (D) until package test appears in the
EDU
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7 --- 136

7.5.1
Compressor test
(main menu package test compressor test)

Press and hold the arrow up key (D) until the following display appears.
EDU
& 5

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This option shows whether compressor test is activated or not.
7.5.2
TV check
(main menu package test TV check)

Press and hold the arrow keys (D9) until TV check appears in the third line of the display.
The submenu is divided into the following options:

7.5.2.1
Pressure relief valve

Press and hold the arrow keys (D9) until relief valve: n appears in the third line of the display.
The pressure relief valve can be checked for correct function using the following procedure:

Press the OFF key (0).
Close the ball valve at the output of the package.
Press the arrow up key (D) until the display changes to relief valve: j.
Press and hold the ON (I) key until the pressure relief valve opens. As long as the
ON key is pressed the compressor remains on load and does not switch to idle mode
even if the nominal package pressure is exceeded. The internal pressure pi that is built
up when the pressure relief valve blows is shown in the fourth line of the display.
For safety reasons the function must be deactivated when this check is finished.
Release the ON key immediately after the pressure relief valve opens because of escaping oil mist.
7 --- 137

7.5.2.2
Temperature sensor / shutdown temperature

Press and hold the arrow keys (D9) until ADT alarm appears in the third line of the display.
Shut down the compressor package and wait until the airend temperature has fallen by
around 5 C. The offset value is determined by subtracting the actual airend temperature
from 110 C.
Example:
--- operational airend discharge temperature: 80 C
--- airend discharge temperature after cooling: 75 C
--- offset value: 110 C minus 80 C = 30 C

Press the arrow keys (D9) until offset= ...C appears in the third line of the display and
then press the return key ().
Enter the evaluated offset value with the arrow keys (D9) and confirm with the return key
() .
Press and hold the arrow up key (D) until ADT alarm:n appears in the third line of the
Check the temperature sensor for correct function.

Press the OFF key (0).
Press the arrow up key (D) until the display changes to ADT alarm: y.
Press and hold the ON (I) key and switch the compressor package to load. The ADT
display now shows the total temperature (airend discharge temperature + offset). If the
airend discharge temperature climbs to the previous temperature, the compressor package will shut down at 110 C because of the offset. The temperature prevailing at shutdown is displayed in the fourth line of the display by pressing the arrow down key (9)
(ADT).
Press and hold the arrow keys (D9) until offset= ... C appears in the third line of the
Reset the offset value to 40 C with the arrow keys (D9) and enter with the return key ()
.
For safety reasons the function must be deactivated when this check is finished.
7.5.3
Binary input/output check

(main menu package test binary inputs)
(Main menu Package test Binary outputs)

Press and hold the arrow keys (D9) until binary inputs or binary outputs appear in the
The current binary states of the digital inputs and outputs are shown.
Example:
7 --- 138
EDU
& 5

E

The binary status should be interpreted as follows:

(

(

(

(
7.5.4

Lamps test

Press and hold the arrow keys (D9) until lamps test appears in the third line of the display.
EDU
& 5

/DPSV WHVW Q

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2 Description of check to be made
3 Activation of above test

The setting can be changed from n (no) to y (yes) by pressing the arrow key (D).
Press the return key () to confirm the change.
All LEDs on SIGMA CONTROL should flash.

Note
In case of malfunction contact an authorised KAESER agent.
The display automatically returns to lamps test: n after approximately 10 seconds.
7 --- 139

7.6
Communication
--- RS 232 (1X7)

--- RS485 (1X8)
--- L2DP bus (1X9)
--- SMS
--- data EEPROM
7 --- 140
Communication
esc

Display of and settings for the interfaces (communication menu)

Press and hold the arrow up key (D) until communication appears in the third line of the
display.
The following interfaces are listed:

-
RS232:
Provides an interface to programming equipment (e.g. AS 511), a modem, a printer, etc.
RS485:
Allows two compressors to be sequenced (master---slave).
L2DP bus (Profibus):

Provides an interface to a master control system (control centre, PC, PLC).
All the parameters entered are permanently stored in the EEPROM even if the power supply fails.
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56
56
& 5
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2 List of interfaces
7.6.1
RS 232 interface
The RS 232 is a serial interface that is required for several functions.
Some examples are programming of the controller, an interface for the printer or modem.

Press the return key () when RS 232 is in the third line of the display, the RS 232 menu option opens.
Function
A function can be allocated to the RS 232 in this menu option or the allocated function is displayed.

Press the arrow keys (D9) until the function [printer, modem, programming unit (AS511)] appears in the third line of the display.

The cursor appears below the current function.
Press and hold the arrow keys (D9) until the required function for this interface is set.
7 --- 141

Bitrate

Press and hold the arrow down key () until the bitrate appears in the third line of the display.
Press and hold the arrow keys (D9) until the required bitrate appears in the third line of the
display.
Format

Press and hold the arrow keys (D9) until format appears in the third line of the display.
The current character frame is shown in the third line of the display.

Press and hold the arrow keys (D9) until the required format is set.
7 --- 142
Finally. accept the settings as detailed in chapter 7.6.5.

7.6.2
RS 485 interface
The RS 485 interface is used for the master---slave function. The settings for bitrate and format
must be the same for both master and slave.
Function
A detailed description of this function is given in chapter 4.

Press and hold the arrow keys (D9) until either master or slave or n.a., as required, appears
in the third line of the display.
Select the required function with the arrow keys (D9) and confirm with the return key ().
Bitrate

Press and hold the arrow keys (D9) until the preset bitrate is displayed.
Format

Press and hold the arrow keys (D9) until format appears in the third line of the display.
The current character frame is shown in the third line of the display.

Press and hold the arrow keys (D9) until the required format appears in the third line of the
display.
Remote key
If the compressor package is to be controlled by a master controller via the RS 485 interface the
remote key must be set to y.

Press and hold the arrow keys (D9) until the remote key is set to yes or no, as required.

7.6.3
Press and hold the arrow keys (D9) until remote key appears in the third line of the display.
Finally, accept the settings as detailed in chapter 7.6.5.
L2DP bus (Profibus)

Keep pressing the arrow keys (D9) until L2DP bus appears in the third line of the display
and then confirm with the return key ().
An example of a VESIS application is to be found in chapter 4.

Function
This option shows whether the Profibus is active or not.

Press the return key () when the first entry appears in the third line of the display.
7 --- 143

Select the options not active (n.a.) or send or send and receive (send+ receive) with
the arrow keys (D9) and then confirm with the return key ().
Slave number
If the compressor package is connected to a profibus system a clear allocation of the master
must be evident. This allocation is made with the slave number.

Press the arrow keys (D9) until slave no.: ... appears in the third line of the display and then
Set the appropriate slave number (2...126) with the arrow keys (D9) and confirm with the return key ().
Hardware monitoring
The hardware monitoring function is shown in this menu.
The bus monitoring is deactivated for this period by the bus controller after the mains power supply is switched on.
Software monitoring
The software monitoring can be activated in this menu.
Timeout:
The bus---master must respond to a Sigma Control signal within this period otherwise an alarm is initiated.
Press and hold the arrow keys (D9) until active (act.:) y/n appears in the second line of the
display.
Press and hold the arrow keys (D9) until active is set toyes orno.
Remote key
If the compressor package is to be controlled by a master controller via the L2DP bus the remote
key must be set to y.

Press and hold the arrow keys (D9) until the remote key is set to yes or no, as
required.

7.6.4
Press and hold the arrow keys (D9) until remote key appears in the third line of the display.
SMS

Press the arrow keys (D9) until SMS appears in the third line of the display and then press
the return key ().
Settings defining transmission of an SMS to the customer service department are made in this
menu.

Press the arrow down key () once, until active (act.:) appears in the third line of the display.
Press the return key () and change the n to a y with the arrow up key ().
Confirm with the return () key.
Further menu options can be accessed with the arrow down key ():
modem
The telephone number of the online modem is entered and the necessary initialisation is carried
out in this option.
7 --- 144

-
location
The responsible Kaeser subsidiary is shown. The customers name, telephone number and the
language in which the SMS is to be sent can be entered in this option.
-
channel 1
The telephone number of the responsible call centre, the number of automatic redials and the
duration of the pause between two calls is entered in this menu option.
Further, the telephone number of the customer service department responsible and the type of
protocol sent in the SMS is shown.
-
channel 2
The channel 2 setup is the same as for channel 1.

7.6.5
Saving settings
from y to n.
Attention!

7 --- 145

7.7
Languages
language
7 --- 146

7.7.1

display.
Select the required language with the arrow up key (D).
7 --- 147

7.8
List of Abbreviations
A
act
ADT
AI
alm
AM
an.
AO
avail
bin.
blowoff prot
C
clk
ch
c/o
comp
cont break
cont.
corr
cRC
D
DI
diff.
dir
DO
DOL
DoR
DOS
DP
dp
dT
tial)
elect.
equip
ext .
F
VFD
fil
Fr
G
h
hPA
HT
I
K
loc.
max
min.
min
Mo
MOPS
n
n.a.
7 --- 148
alarm or alarm message

active or activated
airend discharge temperature
analog input
alarm
air main
analog
analog output
available, already existing
binary
blowoff protection
alarm activated,
not yet acknowledged
clock
characteristic
changeover
compressor
continuity break
contactor
correction
clock remote contact
Dual Control
digital input
differential
direction
digital output
direct ---online
direction of rotation
direct ---online---start
decentral periphery
delta p (pressure differential)
delta T (temperature differenelectrical
equipment
external
FAULT
variable frequency drive
filter
Friday
fault rectified, reset alarm
hours
hectapascal
high tension
input
Kelvin
local
maximum
minute
minimum
Monday
motor overload protection
switch
no (negative answer)
not activated
no.
O
OM
op
open cct.
os
P
p
para
param.
PD
pE
PDT
pd
PG
pi
PN
pN
press.
prot
profibus
PS
RAM
RB
RC
RD
S
s
SD
SN
Sa
sh.cct
SP
SSt
Su
t
T
TAP
temp
tens.
Th
tmr
UCP
W
We
VS
y
star---delta
number
operational message
output
operational message
operation
open circuit
oil separator
parity
pressure, usually airmain
pressure
parameter
parameter
package discharge
system pressure increase
package discharge
temperature
period
programming function
internal pressure
(in oil separator)
L2DP
system pressure
pressure
protection
process field bus
power switching
random access memory
remote bus
remote contact
refrigeration dryer
STOP or stop bit
second(s)
switching differential
serial number
Saturday
short circuit
switching point
soft start device
Sunday
time value
temperature
SMS protocol
temperature
tension
Thursday
timer
SMS protocol
warning, or maintenance
message
Wednesday
variable speed
yes
star---delta (wye---delta)

Kaeser Compressor Sigma Control Manual

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Kaeser Compressor Sigma Control Manual

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SERVICE MANUAL

KAESER KOMPRESSOREN GmbH

Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

Explanation of Symbols and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4

Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 4

4.8.5.2 MVS 8000 as an example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display and Setup Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ---104

Display Level in SIGMA Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 90

Sigma Control Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 83

QUADRO control settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

industrial computer with Intel processor

analog inputs and outputs (0---20 mA, 4---20 mA and PT100)

230/115 V relay outputs (volt ---free contacts)

24 V common negative rail digital inputs

internal undervoltage monitoring of 24 V supply

internal temperature monitoring

RS 485 (master---slave control)

buffered real---time clock

buffer battery for RAM and real---time clock

permissible operating temperature range: ---20 C ... + 60 C

Interface pin connections

receive data RxD

receive data RxD

request to send RTS

clear to send CTS

Connect shielding to both plug housings

Connect shielding to both plug housings

TTL signal RTS

Connect shielding to both plug housings

(integrated in SIGMA CONTROL)

(integrated in SIGMA CONTROL)

real---time operating system

Explanation of Symbols and Instructions

This symbol is placed at text to which considerable attention must be paid to

Explanation of warning labels:

Any alterations or reconstruction carried out without consultation with and

Safety devices may not be modified or deactivated.

Safety Regulations for the Controller

LEDs indicate the most important operational states.

various functions can be keyed.

automatic start after a power supply failure.

Sigma Controls protective function ensures:

Sigma Controls monitoring function ensures:

Finding the best Type of Pressure Regulation

select the type of regulation in the configuration menu.

reset the duty cycle from parameter in the statistic menu.

Evaluate the duty cycle from parameter.

Repeat this procedure for all types of pressure regulation.

duty cycle (%)

upper swtiching point

lower switching point

VARIO Control Mode

The SIGMA CONTROL System

EMERGENCY STOP Pushbutton

Arrow key () (menu up)

The compressor is switched on and runs in the

OFF key (0)

The compressor is switched off irrespective of operating

Clock ON/OFF key

Pressing the key causes the compressor to be switched