Kaeser Sigma Control 2 Screw Fluid 4.1.X 9 - 9450 - 08e

User Manual
Controller
SIGMA CONTROL 2 SCREW FLUID ≥4.1.X

No.: 9_9450 08 E
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
/KKW/SSC 2.08 en IBA-SIGMA CONTROL FLUID
/KKW/SSC 2.08
20180814 091827
Contents
1 SIGMA CONTROL 2 Quick installation guide

1.1 Operating elements .......................................................................................................... 1
1.2 Display elements .............................................................................................................. 2
1.3 Main menu – Overview ..................................................................................................... 2
1.4 Functions – Overview ....................................................................................................... 3
2 Regarding this document
2.1 Using this document ......................................................................................................... 5
2.2 Copyright .......................................................................................................................... 5
2.2.1 Software .............................................................................................................. 5
2.3 Certification ...................................................................................................................... 6
2.4 Updating the operating manual ........................................................................................ 6
2.5 Symbols and labels .......................................................................................................... 6
2.5.1 Warnings ............................................................................................................. 6
2.5.2 Potential damage warnings ................................................................................ 7
2.5.3 Other alerts and their symbols ............................................................................ 8
3 Technical Specifications
3.1 Controller SIGMA CONTROL 2 ....................................................................................... 9
3.1.1 Versions and Options ......................................................................................... 9
3.1.2 User interface with display, CPU and interfaces ................................................. 9
3.1.3 In- and outputs with MCSIO ................................................................................ 12
3.1.4 Input/output modules .......................................................................................... 12
3.1.5 Sensors ............................................................................................................... 14
4 Safety and Responsibility
4.1 Basic instructions ............................................................................................................. 16
4.2 Specified use .................................................................................................................... 16
4.3 Improper use .................................................................................................................... 16
5 Design and Function
5.1 Controller overview .......................................................................................................... 17
5.2 Operating panel ................................................................................................................ 19
5.2.1 Operating elements ............................................................................................ 19
5.2.2 Display elements ................................................................................................ 20
5.2.3 RFID reader ........................................................................................................ 21
5.3 Display ............................................................................................................................ 21
5.3.1 Operating mode .................................................................................................. 22
5.3.2 Main menu .......................................................................................................... 23
5.3.3 Setting parameters ............................................................................................. 23
5.3.4 Activating keys with check boxes ....................................................................... 24
5.4 Access rights .................................................................................................................... 24
5.5 KAESER CONNECT ........................................................................................................ 25
5.6 Menus – overview ............................................................................................................ 26
5.6.1 Operating mode .................................................................................................. 26
5.6.2 Menu structure .................................................................................................... 27
5.7 Operating modes and control modes ............................................................................... 43
5.7.1 Machine operating modes .................................................................................. 43
5.7.2 Control modes .................................................................................................... 44
5.7.3 Variable speed drive with frequency converter (SFC) ........................................ 45
5.7.4 MODULATING control ........................................................................................ 46
6 Installation and Operating Conditions
6.1 Maintaining ambient conditions ........................................................................................ 47
6.2 Installation conditions ....................................................................................................... 47
User Manual Controller

No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X i
Contents
7 Installation
7.1 Reporting Transport Damage ........................................................................................... 48
7.2 Machine identification ....................................................................................................... 48
8 Initial Start-up
8.1 Outline .............................................................................................................................. 49
8.2 Setting the controller ........................................................................................................ 49
8.2.1 Selecting menu options ...................................................................................... 50
8.2.2 Setting the language ........................................................................................... 51
8.2.3 Noting the user name ......................................................................................... 52
8.2.4 User log-in with RFID Equipment Card ............................................................... 53
8.2.5 Generating a password ....................................................................................... 54
8.2.6 Manual user log-in .............................................................................................. 55
8.2.7 Create the master RFID Equipment Card ........................................................... 56
8.2.8 Checking/setting time and date .......................................................................... 57
8.2.9 Set the time zone ................................................................................................ 59
8.2.10 Set display formats ............................................................................................. 59
8.2.11 Setting the display illumination ........................................................................... 62
8.2.12 Setting the contrast and the brightness .............................................................. 63
8.2.13 Activating the remote control ............................................................................. 63
8.2.14 IP configuration .................................................................................................. 64
8.2.15 Setting the e-mail function ................................................................................. 65
8.2.16 Setting the time server ....................................................................................... 67
8.3 KAESER CONNECT benefits .......................................................................................... 68
8.3.1 Open KAESER CONNECT ................................................................................. 69
8.3.2 System status menu ........................................................................................... 70
8.3.3 Graphs menu ...................................................................................................... 72
8.3.4 Messages menu ................................................................................................. 74
8.3.5 I/O display menu ................................................................................................. 74
8.3.6 User management menu .................................................................................... 75
8.3.7 Settings menu ..................................................................................................... 78
8.3.8 Save data menu .................................................................................................. 79
8.3.9 KAESER CONNECT exit .................................................................................... 79
8.4 Pressure parameters of the machine .............................................................................. 80
8.4.1 Displaying pressure parameters ......................................................................... 81
8.4.2 Setting pressure parameters .............................................................................. 81
8.4.3 Activating/deactivating the «LOAD/IDLE» key .................................................... 84
8.5 Machine start and machine stop ...................................................................................... 85
8.5.1 Automatic start/stop in timer mode .................................................................... 85
8.5.2 Setting the company shut-down ........................................................................ 89
8.5.3 Controlling machine from a remote location ...................................................... 90
8.5.4 Activating the remote control ............................................................................. 92
8.5.5 "Venting" function .............................................................................................. 93
8.5.6 "Autostart" function ............................................................................................ 93
8.6 Control modes ................................................................................................................. 96
8.6.1 Setting the control mode ..................................................................................... 96
8.6.2 Setting the DUAL control mode .......................................................................... 97
8.6.3 Setting the QUADRO control mode .................................................................... 98
8.7 Electronic Thermal Management .................................................................................... 99
8.7.1 Activating the heat recovery for machine type 2 ................................................. 99
8.7.2 Activating the heat recovery for machine type 3 ................................................. 101
8.7.3 Deactivating heat recovery ................................................................................. 102
8.8 Refrigeration dryer .......................................................................................................... 103
8.8.1 Setting the operating mode ................................................................................. 103
8.8.2 Output messages ................................................................................................ 104

ii SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E
Contents
8.8.3 Fault in the refrigeration dryer – compressed air quality has priority .................. 105
8.8.4 Fault in the refrigeration dryer – compressed air supply has priority .................. 106
8.9 Setting the machine for local mode .................................................................................. 107
8.9.1 Menu Load control ............................................................................................. 107
8.9.2 Setting the nominal pressure change via timing program .................................. 107
8.9.3 Setting the nominal pressure change via timer ................................................... 110
8.10 Setting the machine for master control operation ............................................................ 112
8.10.1 Overview of the different master operating modes ............................................. 112
8.10.2 SAM 4.0 mode ................................................................................................... 113
8.10.3 Setting PROFIBUS operation (SIGMA AIR MANAGER) .................................... 116
8.10.4 Master control of two machines in master/slave operation ................................ 124
8.10.5 Configuring master control using the LOAD remote contact (e.g., 130
SIGMA AIR MANAGER BASIC) ........................................................................
8.10.6 Setting the master control with local/LOAD remote contact .............................. 132
8.10.7 Setting the nominal pressure pre-selection via remote contact ......................... 136
8.10.8 Master control for machines regulated by pressure switch ................................ 137
8.10.9 Examples of time settings for equal overall load ............................................... 142
8.11 Setting input and output signals ....................................................................................... 143
8.11.1 Output operational states of machine on digital outputs ..................................... 143
8.11.2 Output input signals on the display ..................................................................... 145
8.11.3 Output measured values on the display ............................................................. 149
8.11.4 Switching and/or triggering messages with thresholds ....................................... 155
8.12 Timer ................................................................................................................................ 159
8.13 Activating remote acknowledgement .............................................................................. 160
8.13.1 Setting the remote acknowledgement function ................................................... 161
8.13.2 Activating the remote control .............................................................................. 161
8.13.3 Assigning an input .............................................................................................. 162
8.14 Linking to an external pressure transducer ..................................................................... 163
8.14.1 Pressure control menu ........................................................................................ 163
8.14.2 Assigning an input to an external pressure transducer ...................................... 163
8.15 Commissioning the machine ........................................................................................... 164
9 Operation
9.1 Switching the compressed air station on and off .............................................................. 166
9.1.1 Switching on ....................................................................................................... 166
9.1.2 Switching off ....................................................................................................... 167
9.2 Switching off in an emergency ......................................................................................... 167
9.3 Acknowledging alarm and warning messages ................................................................. 168
9.4 Displaying messages ...................................................................................................... 169
9.4.1 Status – Messages menu ................................................................................... 170
9.5 Displaying the current operating mode ........................................................................... 172
9.6 Setting the working pressure ............................................................................................ 173
9.7 Displaying analogue data ................................................................................................ 173
9.8 Displaying operating data ................................................................................................ 174
9.8.1 Checking the operating hours ............................................................................. 174
9.8.2 Checking the switching cycles ............................................................................ 175
9.9 Displaying the frequency converter settings ................................................................... 176
9.10 Setting the maintenance interval ..................................................................................... 177
9.11 Check the safety valve .................................................................................................... 178
9.12 Excessive temperature shut-down test ........................................................................... 180
9.13 Save data ........................................................................................................................ 182
10 Fault Recognition and Rectification
10.1 Basic instructions ............................................................................................................. 184
10.2 Interpreting fault messages .............................................................................................. 184

No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X iii
Contents
10.3 Interpreting warning messages ........................................................................................ 192

10.4 Interpreting operation messages ...................................................................................... 212
10.5 Interpreting diagnostic messages .................................................................................... 216
10.6 Interpreting system messages ......................................................................................... 216
11 Maintenance
11.1 Changing the buffer battery .............................................................................................. 218
12 Spares, Operating Materials, Service
12.1 Note the nameplate .......................................................................................................... 219
12.2 KAESER AIR SERVICE ................................................................................................... 219
12.3 Service Addresses ........................................................................................................... 219
12.4 Displaying the version number, machine model, material number and serial number .... 219
13 Decommissioning, Storage and Transport
13.1 De-commissioning ............................................................................................................ 221
13.2 Packing ............................................................................................................................ 221
13.3 Storage ............................................................................................................................. 221
13.4 Transporting ..................................................................................................................... 221
13.5 Disposal ........................................................................................................................... 221
13.5.1 Dispose of the battery in accordance with local environmental regulations. ...... 221

iv SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E
List of Illustrations
Fig. 1 Operating elements .................................................................................................................... 1

Fig. 2 Display elements ........................................................................................................................ 2
Fig. 3 MCS interfaces ........................................................................................................................... 10
Fig. 4 MCSIO interfaces ....................................................................................................................... 11
Fig. 5 MCS system design with IOM .................................................................................................... 18
Fig. 6 MCSIO system design ................................................................................................................ 18
Fig. 7 Operating elements .................................................................................................................... 19
Fig. 8 Display elements ........................................................................................................................ 20
Fig. 9 RFID reader ................................................................................................................................ 21
Fig. 10 KAESER CONNECT for SIGMA CONTROL 2 ........................................................................... 25
Fig. 11 Back of the RFID Equipment Card ............................................................................................. 53
Fig. 12 User log-in with RFID Equipment Card ...................................................................................... 53
Fig. 13 User log-in with RFID Equipment Card ...................................................................................... 54
Fig. 14 Manual user log-on ..................................................................................................................... 56
Fig. 15 Log-in mask ................................................................................................................................ 69
Fig. 16 KAESER CONNECT for SIGMA CONTROL 2 ........................................................................... 70
Fig. 17 Select language: window ............................................................................................................ 70
Fig. 18 System status menu ................................................................................................................... 71
Fig. 19 Main menu .................................................................................................................................. 71
Fig. 20 Graphs (illustration similar) ......................................................................................................... 72
Fig. 21 Control keys ............................................................................................................................... 73
Fig. 22 Messages (illustration similar) .................................................................................................... 74
Fig. 23 I/O display (illustration similar) ................................................................................................... 75
Fig. 24 User management menu ............................................................................................................ 76
Fig. 25 Log on for write access: window ................................................................................................ 76
Fig. 26 User management menu ............................................................................................................ 77
Fig. 27 Settings menu ............................................................................................................................ 78
Fig. 28 Backup menu ............................................................................................................................. 79
Fig. 29 Wiring of the PROFIBUS connection ......................................................................................... 117
Fig. 30 Electrical diagram example with SIGMA AIR MANAGER .......................................................... 118
Fig. 31 Communication interface ............................................................................................................ 119
Fig. 32 Insert the communication module. ............................................................................................. 120
Fig. 33 Front plate communication module PROFIBUS ......................................................................... 120
Fig. 34 Direct connection of two SIGMA CONTROL 2 ........................................................................... 125
Fig. 35 LOAD remote contact ................................................................................................................. 131
Fig. 36 Wiring diagram for local/LOAD remote contact: ......................................................................... 133
Fig. 37 Machine with pressure switch regulation .................................................................................... 138
Fig. 38 Function diagram ........................................................................................................................ 141
Fig. 39 Switching the compressed air station on and off ........................................................................ 166
Fig. 40 Switching off in an emergency ................................................................................................... 167
Fig. 41 Acknowledging messages .......................................................................................................... 168
Fig. 42 Battery labelling .......................................................................................................................... 222

No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X v
List of Illustrations

vi SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E
List of Tables
Tab. 1 Operating elements .................................................................................................................... 1

Tab. 2 Display elements ........................................................................................................................ 2
Tab. 3 Main menu – Overview ............................................................................................................... 2
Tab. 4 Functions – Overview ................................................................................................................. 3
Tab. 5 Danger levels and their definition (personal injury) .................................................................... 7
Tab. 6 Danger levels and their definition (damage to property) ............................................................ 7
Tab. 7 Formatting options ...................................................................................................................... 8
Tab. 8 Versions and Options ................................................................................................................. 9
Tab. 9 User interface ............................................................................................................................. 9
Tab. 10 Display data ................................................................................................................................ 10
Tab. 11 MCS interfaces ........................................................................................................................... 10
Tab. 12 MCSIO interfaces ....................................................................................................................... 11
Tab. 13 RFID ........................................................................................................................................... 11
Tab. 14 Number of internal inputs and outputs ....................................................................................... 12
Tab. 15 Cable lengths ............................................................................................................................. 12
Tab. 16 SC2IOM-1 .................................................................................................................................. 13
Tab. 17 SC2IOM-2 .................................................................................................................................. 13
Tab. 18 SC2IOM-3 .................................................................................................................................. 13
Tab. 19 Power supply specifications ....................................................................................................... 14
Tab. 20 Cable lengths ............................................................................................................................. 14
Tab. 21 Degree of protection, IOM .......................................................................................................... 14
Tab. 22 IOM dimensions ......................................................................................................................... 14
Tab. 23 Pressure transducer ................................................................................................................... 14
Tab. 24 Resistance thermometer ............................................................................................................ 15
Tab. 25 Operating elements .................................................................................................................... 19
Tab. 26 Display elements ........................................................................................................................ 20
Tab. 27 RFID reader ................................................................................................................................ 21
Tab. 28 Data in the header depending on the machine type ................................................................... 22
Tab. 29 Reset check box status .............................................................................................................. 24
Tab. 30 Check box status ........................................................................................................................ 24
Tab. 31 KAESER CONNECT functions ................................................................................................... 25
Tab. 32 Menu structure of main menu ..................................................................................................... 27
Tab. 33 Status menu ............................................................................................................................... 30
Tab. 34 Configuration menu .................................................................................................................... 32
Tab. 35 Pressure control menu ............................................................................................................... 34
Tab. 36 I/O periphery menu ..................................................................................................................... 36
Tab. 37 Communication menu ................................................................................................................ 39
Tab. 38 Connections menu ..................................................................................................................... 40
Tab. 39 Components menu ..................................................................................................................... 41
Tab. 40 Power switching menu ............................................................................................................... 42
Tab. 41 Machine identification ................................................................................................................. 48
Tab. 42 Remote control identification ...................................................................................................... 48
Tab. 43 Machine identification ................................................................................................................. 48
Tab. 44 Supported languages ................................................................................................................. 51
Tab. 45 Date formats ............................................................................................................................... 59
Tab. 46 Possible settings for the time format .......................................................................................... 60
Tab. 47 Possible settings for the pressure unit ....................................................................................... 61
Tab. 48 Possible settings for the temperature unit .................................................................................. 61
Tab. 49 Display illumination ..................................................................................................................... 62
Tab. 50 Network parameters ................................................................................................................... 65
Tab. 51 E-mail parameters ...................................................................................................................... 66
Tab. 52 Control key functions .................................................................................................................. 73
Tab. 53 Compressor pressure parameters .............................................................................................. 80
Tab. 54 Setting limits for the network nominal pressure (* Cut-in pressure min) .................................... 81

No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X vii
List of Tables
Tab. 55 Pressure condition for LOAD ...................................................................................................... 82

Tab. 56 Pressure conditions for IDLE ...................................................................................................... 82
Tab. 57 Example: activated output .......................................................................................................... 82
Tab. 58 Displaying and setting parameters ............................................................................................. 83
Tab. 59 Settings for machine start and machine stop ............................................................................. 85
Tab. 60 User-defined clock programme machine ON/OFF ..................................................................... 86
Tab. 61 Example of a machine ON/OFF clock program .......................................................................... 87
Tab. 62 Autostart delay period ................................................................................................................ 94
Tab. 63 Machine type and ETM design ................................................................................................... 99
Tab. 64 Operating modes in local operating mode (local mode) ............................................................. 107
Tab. 65 User-defined timing program for nominal pressure change ....................................................... 108
Tab. 66 Example: Switching points, nominal pressure change ............................................................... 108
Tab. 67 Master control (interconnected operation) – overview ................................................................ 112
Tab. 68 Parameters for monitoring for communication malfunction ........................................................ 116
Tab. 69 Pin assignment of SUB-D 9-pole interface on the PROFIBUS module ...................................... 117
Tab. 70 Master-slave settings ................................................................................................................. 124
Tab. 71 Function diagram ........................................................................................................................ 140
Tab. 72 Example for a clock program for equal duty cycling during the day ........................................... 142
Tab. 73 Example for a timing program for equal duty cycling during the week ....................................... 143
Tab. 74 Assigned output signals ............................................................................................................. 143
Tab. 75 Logic settings ............................................................................................................................. 148
Tab. 76 Assigned analogue measured values ........................................................................................ 150
Tab. 77 Available measured values ........................................................................................................ 155
Tab. 78 Transmitting a pressure transducer value .................................................................................. 163
Tab. 79 Check list for starting the machine ............................................................................................. 164
Tab. 80 Message sequence 1 ................................................................................................................. 168
Tab. 81 Message sequence 2 ................................................................................................................. 168
Tab. 82 Information of a message ........................................................................................................... 169
Tab. 83 Message abbreviations .............................................................................................................. 170
Tab. 84 Operating mode display ............................................................................................................. 172
Tab. 85 Abbreviation of operating modes ................................................................................................ 172
Tab. 86 Check box status ........................................................................................................................ 178
Tab. 87 Fault messages, possible causes and remedies ........................................................................ 184
Tab. 88 Warning messages and remedies .............................................................................................. 193
Tab. 89 Operational messages ............................................................................................................... 212
Tab. 90 System messages and remedies ............................................................................................... 217

viii SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E
1.1 Operating elements

1.1 Operating elements
Fig. 1 Operating elements
Item Description Function

1 «Up» Scrolls up the menu options. Increases a parameter value.
2 «Left» Jumps to the left.
Moves the cursor position to the left.
3 «Right» Jumps to the right.
Moves the cursor position to the right.
4 «Down» Scrolls down the menu options.
Reduces a parameter value.
5 «Escape» Returns to the next higher menu option level.
Exits the edit mode without saving.
6 «Enter» Jumps to the selected submenu option.
Exits the edit mode and saves.
7 «ON» Switch on the machine.
8 «OFF» Switch off the machine.
10 RFID RFID reader for user log-in with RFID Equipment Card.
11 «Time control» Switches the time control on and off.
12 «Remote control» Switches the remote control on and off.
13 «LOAD/IDLE» Toggles between the LOAD and IDLE modes.
19 «Information» Displays the event memory.
21 «Acknowledgement» Confirms/acknowledges alarms and warning messages.
If permissible: Resets the fault counter (RESET).
Tab. 1 Operating elements

No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X 1
1.2 Display elements
1.2 Display elements
Fig. 2 Display elements

7 ON Display illuminates green when the machine switched on.
9 Display Graphic display with 8 lines and 30 characters per line.
11 Time control Continuous green light when the machine is controlled by the timer.
12 Remote control Continuous green light when the machine is in remote control.
14 IDLE Continuous green light when the machine is running in IDLE. Flashes
when the «LOAD/IDLE» toggle key is pressed.
15 LOAD Continuous green light when the machine is running in LOAD.
16 Voltage applied to Continuous green light when voltage is applied to the controller.
controller
17 Warning Flashes in yellow in the following events:
■ Maintenance necessary.
■ Warning message
18 Communications error Continuous red light to indicate a faulty communication connection
without machine shut-down.
20 Fault Flashes red to indicate a machine fault.
Continuous red light after acknowledgement.
Tab. 2 Display elements
1.3 Main menu – Overview

Press «Up» / «Down» / «Enter» to open the Main menu.
Menu No. Menu designation Function
1 Status Displays messages, statistics and status information

2 SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E
1.4 Functions – Overview
Menu No. Menu designation Function

2 Performance data Displays measured data of the machine and its components (e.g.,
motors)
3 Operating data Displays operating hours, switching cycles and energy data
4 Maintenance Displays maintenance data of the machine and its components
5 Configuration Setting of machine parameters, compressed air system and acces‐
sories
6 Compressor clock Setting the time control
7 User Manual user log-in and password administration
8 Communication Setting the Ethernet interface, COM modules and control centre
connection
9 Machine test Pressure relief valve and temperature sensor test and shut-down at
excessive temperature
10 Components Display of settings on machine components, e.g. the power switch‐
ing unit
Tab. 3 Main menu – Overview
See Chapter 5.6.2 for the complete menu structure.

Function Menu Action steps Chapter
No.
Setting the con‐ Main Press and hold «Information» – «Up» / «Down» 8.2.12
trast menu
Setting the Main Press and hold «Information» – «Left» / «Right» 8.2.12
brightness menu
Setting the lan‐ Main «Enter» – «Up» – «Enter» – «Up» / «Down» 8.2.2
guage menu
Setting date, 5.1 <Configuration – General> 8.2.8
time and time
zone
Identification – 8.2.4
with
RFID Equipment
Card
Setting pressure 5.2.2 <Configuration – Pressure control – Pressure settings – 8.4

parameters pA/pB>
Setting the 6 <Compressor clock – Setting timing program> 8.5.1
«time control»
Activating the 6 <Compressor clock – Key clock – ☑> 8.5.1.3
«time control»
key

Function Menu Action steps Chapter

No.
Activating – Activate the «Time control» key – Press «Time control» 8.5.1.4
«time control»
Activate 5.2.3 <Configuration – Compressor start – Compressor on – Key 8.2.13
the «remote 5.4.1 remote – ☑>
control» key
5.5
Activating the – Activate the «Remote control» key – Press «Remote control» 8.2.13
«remote control»
Setting the Con‐ 5.3 Select <Configuration – Control mode – Local mode – Control 8.6.1
trol Mode mode>
Setting the com‐ 5.4.2 <Configuration – Compressor start – Compressor off – 8.5.2
pany shut-down Holidays – Start/End/☑>
Displaying oper‐ 3 <Operating data – Operating hours / Switching cycles> 9.8
ating data
Setting the 4 <Maintenance – Select/set component> 9.10
maintenance in‐
terval
Check the pres‐ 9.1 For the test process, see Chapter 9.11
sure relief valve
Overtempera‐ 9.1 For the test process, see Chapter 9.12
ture shut-down
test
Fault messages 1.1.1 A fault message causes the machine to shut down. The Fault 10.2
LED flashes red. Fault messages are identified with the let‐
ter A. Example:
<0002 S k 31/12/2017 13:14:15 Motor temperature ⇞>
Warning mes‐ 1.1.1 If maintenance work is to be carried out or if the warning is dis‐ 10.3
sages played before an alarm, the yellow warning LED flashes. Warn‐
ing messages are identified with the letter W.
Operational 1.1.1 Operational messages provide information about the current 10.4
messages operational state of the machine. Operational messages are
identified with the letter O.
Diagnostic mes‐ 1.1.1 A diagnostic message causes the machine to shut down. They 10.5
sages provide information on the status of the controller, the connec‐
ted input and output modules and support the
KAESER SERVICE in trouble-shooting. Diagnostic messages
are identified with the letter D.
System messag‐ 1.1.1 A system message causes the machine to shut down. System 10.6
es messages are identified with the letter Y.
Tab. 4 Functions – Overview
Settings can be made after log-in with the RFID Equipment Card and access level 2.

2.1 Using this document

2.1 Using this document
The operating manual contains important information to the entire life cycle of
SIGMA CONTROL 2.
The operating manual is a component of the product.
➤ Keep the manual in a safe place throughout the life of SIGMA CONTROL 2.
➤ Pass the manual on to the next owner/user of the machine.
➤ Ensure that all amendments received are inserted into the operating manual.
2.2 Copyright
This operating manual is protected by copyright. Any queries regarding the use or duplication of
this documentation should be referred to KAESER. Correct use of information will be fully suppor‐
ted.
2.2.1 Software
The software used in SIGMA CONTROL 2 contains copyright-protected software packages which
are licensed as Open Source.
A copy of these licenses is contained in SIGMA CONTROL 2.
Display the licenses by pointing your browser to the "COPYING" file in the root directory of
SIGMA CONTROL 2.
URL:
http:// <Hostname>/COPYING
The licenses can be also found under these addresses:
http://www.gnu.org/licenses
http://code.google.com/p/curve25519-donna/
Within three years from receipt of SIGMA CONTROL 2, you may obtain the complete source code
of the copyright-protected software packages by sending a corresponding order to the following ad‐
dress:
Technical Office Electrical Design
KAESER KOMPRESSOREN SE
96450 Coburg, Postfach 2143
Germany
This offer is valid for anybody having this information.

2.3 Certification
2.3 Certification
This product has the following approvals:
■ This equipment has been tested and found to comply with the limits for a Class B digital de‐
vice, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable
protection against harmful interference in a residential installation. This equipment generates,
uses and can radiate radio frequency energy and, if not installed and used in accordance with
the instructions, may cause harmful interference to radio communications. However, there is
no guarantee that interference will not occur in a particular installation. If this equipment does
cause harmful interference to radio or television reception, which can be determined by turning
the equipment off and on, the user is encouraged to try to correct the interference by one or
more of the following measures:
─ Reorient or relocate the receiving antenna.
─ Increase the separation between the equipment and receiver.
─ Connect the equipment into an outlet on a circuit different from that to which the receiver is
connected.
─ Consult the dealer or an experienced radio/TV technician for help.
■ This device complies with part 15 of the FCC rules. The operation is subject to the following
two conditions:
─ this device may not cause harmful interference, and
─ this device must accept any interference received, including interference that may cause
undesired operation.
■ This device fulfils the provisions of the Industry Canada Licence, with the exception of the RSS
rules. The operation is subject to the following two conditions:
─ this device may not cause harmful interference, and
─ this device must accept any interference received, including interference that may cause
undesired operation.
In order to ensure permanent compliance with the FCC rules, unless explicitly approved by
the authority responsible for compliance with the provisions, no changes must be carried out
(for example: when connecting to computers or peripheral equipment use shielded cables on‐
ly).
2.4 Updating the operating manual

Go to our website http://www.kaeser.com/sc2manual to find the latest version of the operating
manual.
➤ Download the desired operating manual from our server and forward it to your operators.
2.5 Symbols and labels

➤ Please note the symbols and labels used in this document.
2.5.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.

Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of non-compliance
DANGER Warns of an imminent threat of danger Will result in death or severe injury
WARNING Warns of possible danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Tab. 5 Danger levels and their definition (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
Example:
DANGER
These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1. WARNING!
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe
injury may occur.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
2.5.2 Potential damage warnings

Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
Warning notices for damages are identified by their signal term.

Signal term Meaning Consequences of non-compliance
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 6 Danger levels and their definition (damage to property)
Example:
NOTICE
Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.

2.5.3 Other alerts and their symbols

The meaning of names is emphasised by different formatting. Depending on the font, not all for‐
matting options can be realised.
Name Formatting Example
Operating state UPPER CASE LOAD
Item number ... Open valve 4
Indication italic ON LED
Key « ... » «ON» key
Menu option < ... > <Configuration>
Menu path <Menu 1 – Menu 2 – ...> <Configuration – Pressure control>
activated ... The minutes display flashes. 00:00:00
Tab. 7 Formatting options
This symbol identifies particularly important information.
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
Here conditions relevant to safety are named that will help you to avoid dangerous situations.
➤ This symbol denotes lists of actions comprising one stage of a task.

Operating instructions with several steps are numbered in the sequence of the operating steps.
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... as is a solution.
This symbol identifies important information or measures regarding the protection of the envi‐
ronment.
Further information Further subjects are introduced here.

3.1 Controller SIGMA CONTROL 2
Industrial PC
■ Internal temperature monitoring
■ Internal undervoltage monitoring
■ Battery-buffered real-time clock
─ Battery service life: more than 10 years
─ Battery replaceable
3.1.1 Versions and Options

SIGMA CONTROL 2 is offered in different designs.
Type Prepared for connection to control Connection to control technology not

centre provided 1)
Option C3 C48
Compo‐ Main Control System (MCS): Slot for an Main Control System Input Output
nents optional communication module (to con‐ (MCSIO): Digital and analogue inputs and
nect to a control centre) outputs integrated
Input-Output-Module (IOM): Modules
with digital and analogue inputs and out‐
puts.
1)
only SIGMA CONTROL 2 FLUID
Tab. 8 Versions and Options
3.1.2 User interface with display, CPU and interfaces

User interface
Feature MCS MCSIO

Material Plastics
Width [mm] 190
Height [mm] 130
Depth [mm] 45 60
Number of membrane keys 13
Number of LEDs 9
Degree of protection, control cabinet exterior IP 54
Degree of protection, control cabinet interior IP 20
Voltage [V] 24
Current [A] 0.3 2.5
Voltage source Input/output module External
Tab. 9 User interface

Display
Characteristic Value
Graphical display [px] 255 x 128
Width [mm] 82
Height [mm] 41
Maximum number of lines/characters 8/30
Colours Black/white with grey scale
Lighting LED backlit
px ≙ pixel
Tab. 10 Display data
Fig. 3 MCS interfaces
Identification Interface Connection

X1 Ethernet 10/100 Base T RJ 45 socket
X2 I/O bus 9-pole SUB-D pins
X3 RS485–FC (USS interface) 9-pole SUB-D socket
X4 Com modules, Module optional for:
slot for communications module PROFIBUS, PROFINET,
Modbus RTU, Modbus TCP,
DeviceNet, EtherNet/IP
X5 SD card, SD card slot SD/SDHC card
X6 FE Functional earth (FE)
The positions of the interfaces X1–X6 are marked on the rear of the controller.
Tab. 11 MCS interfaces

Fig. 4 MCSIO interfaces
Marking Interface Connection

X1 Ethernet 10/100 Base T RJ 45 socket
X3 RS485–FC (USS interface) 9-pole SUB-D socket
X5 SD card, SD card slot SD/SDHC card
X6 FE Functional earth (FE)
X7 24 VDC, DII Power supply 24 VDC
Digital inputs DII1.00–DII1.05
X8 DII/DOT Digital inputs DII1.06–DII1.07
Digital outputs DOT1.00–DOT1.01
X9 AII/AIR Analogue input current 0–20 mA,
AII1.00–AII1.01
Analogue input resistor AIR1.00–
AIR1.01
X10 DOR Digital output relay 250 VAC, 4 A
DOR1.00–DOR1.04
The positions of the interfaces X1–X10 are marked on the rear of the controller.
Tab. 12 MCSIO interfaces
Identification with RFID Equipment Card
Hardware on the SIGMA CONTROL 2 controller RFID write/read device
Hardware (external) RFID Equipment Card
Recognition distance [m] max. 0.05

Frequency [MHz] 13.56
Emitted maximum transmitting power at 10 m dis‐ 11
tance [dB(µA/m)]
Tab. 13 RFID
The RFID read/write device transmits at a frequency of 13.56 MHz and is permitted for use in
EU member states.
3.1.3 In- and outputs with MCSIO

Integrated in- and outputs with MCSIO type controller
Input/Output Number
Digital input (DI), 24 VDC 8
Digital output transistor (DOT), 24 VDC, 0.5 A 2
Analogue input current (AII), 0–20 mA 2
Analogue input resistor (AIR), PT100 2
Digital output relay (DOR), 250 VAC, 4 A 5
Tab. 14 Number of internal inputs and outputs
3.1.3.1 Maximum cable lengths
Input/Output Cable length [m]

Analogue input current (AII), ＜ 30
Analogue input resistor (AIR)
Analogue output current (AOI)
Digital input (DI), ＜ 100
Digital output relay (DOR)
Digital output transistor (DOT) ＜ 30
Tab. 15 Cable lengths
3.1.4 Input/output modules

IOM modules only in combination with the MCS controller type
There are three different types of input/output modules with different numbers of inputs and out‐
puts.
The number of input/output modules actually available depends on the machine type and the avail‐
able options.
Refer to the machine's wiring diagram for the input/output modules installed in your equipment.
Every input/output module is equipped with:

■ Internal temperature monitoring

■ Internal undervoltage monitoring

■ LED indication of operational status
IOM 1
Input/Output Input/output module 1
Internal, in available in External, in
the control parallel on the compres‐
cabinet both sides sor interior
Digital input (DI), 24 VDC 4 10 2
Analogue input current (AII), 0–20 mA – 1 2
Analogue input resistor (AIR), PT100 – 1 3
Digital output relay (DOR), 250 VAC, 8 A 8 – –
Digital output transistor (DOT), 24 VDC, 0.5 A – 2 1
Analogue output current (AOI), 0–20 mA – – –
Tab. 16 SC2IOM-1
IOM 2
Digital input (DI), 24 VDC 6 – 2
Analogue input resistor (AIR), PT100 – 3 –
Analogue output current (AOI), 0–20 mA – 1 –
Tab. 17 SC2IOM-2
IOM 3
Digital input (DI), 24 VDC 6 – 2
Analogue input resistor (AIR), PT100 – 3 8
Analogue output current (AOI), 0–20 mA – 1 –
Tab. 18 SC2IOM-3

3.1.4.1 Electrical connection specifications IOM
Power is provided by the machine's power supply unit.

Rated voltage (stabilised) [V DC] 24
Current consump‐ 2.4
tion SIGMA CONTROL 2 with IOM 1 [A]
Current consumption IOM 2 [A] 2.5
Current consumption IOM 3 [A] 1.6
IOM ≙ Input/Output module
Tab. 19 Power supply specifications
3.1.4.2 Maximum cable lengths
Input/Output Cable length [m]

Analogue input current (AII), ＜ 30
Analogue input resistor (AIR)
Analogue output current (AOI)
Digital input (DI), ＜ 100
Digital output relay (DOR)
Digital output transistor (DOT) ＜ 30
Tab. 20 Cable lengths
3.1.4.3 Input/output modules – degree of protection
Degree of protection within the machine IP 54
Degree of protection within the control cabinet IP 20
Tab. 21 Degree of protection, IOM
3.1.4.4 Input/output modules – dimensions
Width [mm] 125
Height [mm] 250
Depth [mm] 44
Tab. 22 IOM dimensions
3.1.5 Sensors
Pressure transducer
Output signal [mA] 0/4–20

Connection Two-core
Tab. 23 Pressure transducer
Resistance thermometer
Sensing resistance (to DIN IEC 751) PT100
Connection Two-core
Tab. 24 Resistance thermometer

4.1 Basic instructions

SIGMA CONTROL 2 is manufactured to the latest engineering standards and acknowledged safety
regulations.
The safety regulations of the machine in which SIGMA CONTROL 2 is installed apply.
4.2 Specified use

SIGMA CONTROL 2 is solely intended for the control of machines in which SIGMA CONTROL 2 is
factory-installed. Any other use is considered incorrect. The manufacturer is not liable for any dam‐
ages that may result from incorrect use. The user alone is liable for any risks incurred.
➤ Adhere to the specifications given in these operating instructions and the machine's service
manual.
➤ Operate the machine only within its performance limits and under the permitted ambient condi‐
tions.
4.3 Improper use

Improper usage can cause damage to property and/or (severe) injuries.
➤ Use SIGMA CONTROL 2 only as intended.
➤ Do not use SIGMA CONTROL 2 to control other machines or products for which
SIGMA CONTROL 2 is not intended.

5.1 Controller overview

SIGMA CONTROL 2 controls, regulates, monitors, and protects the machine.
All parameters needed to operate KAESER rotary screw compressors can be set and displayed
using the controller. Various user-dependent password mechanisms protect the parameters.
Components
SIGMA CONTROL 2 has the following components:

■ Main Control System (MCS):
─ Industrial PC
─ Software for the control, regulation, and monitoring of the machine, for the display and mod‐
ification of settings and for communication.
─ User interface with backlit display, touch keys, LEDs, and interfaces.
─ Radio Frequency Idenfication (RFID):
Identification with RFID Equipment Card
─ Slot for customer interface; optional communications module
─ SD card slot for SD/SDHC cards:
Manual loading of updates with an SC card, reading or recording process data
■ Main Control System Input Output (MCSIO) [only SIGMA CONTROL 2 FLUID]:
─ As with MCS, but with:
─ integrated digital and analogue inputs and outputs
─ Without slot for customer interface
■ Input-Output-Module (IOM):
For SIGMA CONTROL 2 (Prepared for connection to control centre): modules with digital and
analogue inputs and outputs with autonomous power supply.

Fig. 5 MCS system design with IOM

1 Machine enclosure 6 Inputs/outputs in the interior of the control
2 Control cabinet cabinet
3 SIGMA CONTROL 2 (Prepared for con‐ 7 Inputs/outputs in the interior of the com‐
nection to control centre) pressor
4 Input-Output-Module (IOM): 8 Inputs/outputs for external sensors
5 I/O bus 9 Compressor
Fig. 6 MCSIO system design

1 Machine enclosure 7 Inputs/outputs in the interior of the com‐
2 Control cabinet pressor
3 SIGMA CONTROL 2 (Connection to con‐ 8 Inputs/outputs for external sensors
trol technology not provided) 9 Compressor
6 Inputs/outputs in the interior of the control
cabinet
Function
The control and regulating function allows:

■ Automatic changeover of the machine from LOAD to IDLE or READY.
■ Optimum utilisation of the drive motor / engine in relation to the user's actual air demand
■ Automatic restart of the machine after a power failure (can be deactivated)

5.2 Operating panel
The monitoring function allows:

■ Monitoring of all maintenance-relevant components via the maintenance interval counters.
■ Display of warning and maintenance messages for due maintenance on the display
of SIGMA CONTROL 2.
The protective function allows:

■ Automatic machine shut-down on alarms that may lead to damage to the machine, e.g. over‐
current, overpressure or overtemperature.
5.2 Operating panel

5.2.1 Operating elements
Fig. 7 Operating elements

1 «Up» Scrolls up the menu options. Increases a parameter value.
2 «Left» Jumps to the left.
Moves the cursor position to the left.
3 «Right» Jumps to the right.
Moves the cursor position to the right.
4 «Down» Scrolls down the menu options.
Reduces a parameter value.
5 «Escape» Returns to the next higher menu option level.
Exits the edit mode without saving.
6 «Enter» Jumps to the selected submenu option.
Exits the edit mode and saves.
7 «ON» Switch on the machine.
8 «OFF» Switch off the machine.
10 RFID RFID reader for user log-in with RFID Equipment Card.
11 «Time control» Switches the time control on and off.

5.2 Operating panel

12 «Remote control» Switches the remote control on and off.
13 «LOAD/IDLE» Toggles between the LOAD and IDLE modes.
19 «Information» Displays the event memory.
21 «Acknowledgement» Confirms/acknowledges alarms and warning messages.
If permissible: Resets the fault counter (RESET).
Tab. 25 Operating elements
5.2.2 Display elements
Fig. 8 Display elements

7 ON Display illuminates green when the machine switched on.
9 Display Graphic display with 8 lines and 30 characters per line.
11 Time control Continuous green light when the machine is controlled by the timer.
12 Remote control Continuous green light when the machine is in remote control.
14 IDLE Continuous green light when the machine is running in IDLE. Flashes
when the «LOAD/IDLE» toggle key is pressed.
15 LOAD Continuous green light when the machine is running in LOAD.
16 Voltage applied to Continuous green light when voltage is applied to the controller.
controller
17 Warning Flashes in yellow in the following events:
■ Maintenance necessary.
■ Warning message
18 Communications error Continuous red light to indicate a faulty communication connection
without machine shut-down.

5.3 Display

20 Fault Flashes red to indicate a machine fault.
Continuous red light after acknowledgement.
Tab. 26 Display elements
5.2.3 RFID reader

RFID is the abbreviation for “Radio Frequency Identification” and makes possible to identify per‐
sons and objects.
Placing a suitable transponder in front of the RFID reader of the controller will automatically acti‐
vate the communication between transponder and SIGMA CONTROL 2.
A suitable transponder is the RFID Equipment Card. Two of them have been provided with the ma‐
chine.
Typical application:
■ Operators log on at the machine.
(Manual input of the password not required)
The RFID Equipment Cards are carefully packed in a plastic sleeve.

This plastic sleeve is attached to the rear of the controller in the control cabinet.
Fig. 9 RFID reader

24 RFID RFID reader for the communication with a RFID Equipment Card or RFID Key.
Tab. 27 RFID reader
5.3 Display
Use the display to read information and to check entered data. The display comprises 8 lines, each
of 30 characters.
During operation, the display will indicate the operating mode.
Press «Enter» or one of the arrow keys to open the main menu. Here, you can set the language to
be used for the display of texts or open the various submenus.

5.3 Display
5.3.1 Operating mode

6.1bar 08:15AM 80° C Header
------------------------------
Load Current operating mode
------------------------------
Key – on ¦ pA – on Operating parameters
------------------------------
Run 2500h Load 2490h Operating parameters
Maintenance in 500h Maintenance indicator
Header
The header is the topmost line on the display. It is always shown as white text on a black back‐
ground.
Important information and values are displayed in the header.
The displayed data varies depending on the machine type:

Type Header, left Header, centre Header, right
SIGMA CONTROL 2 Working gauge pressure Time Airend discharge tempera‐
FLUID ture
DRY ture
VAC ture
SIGMA CONTROL 2 Pressure at the com‐ Temperature at Pressure at the compressed
BOOSTER pressed air inlet p1 the compressed air outlet p4
air outlet T2
SIGMA CONTROL 2 Working gauge pressure – Time
PISTON
Tab. 28 Data in the header depending on the machine type
Lines 3 and 5: Operational state
Depending on the settings, either the current state of the machine or a menu text is shown in line 3.
The following parameters with their current values are displayed in line 5:
■ Remote control yes/no
■ Time control yes/no
■ Pressure control
Lines 7 and 8: Machine state
The following parameters with their current values are displayed in lines 7 and 8:
■ The hours during which the machine was activated
■ The hours during which the machine ran in operating mode LOAD.
■ Remaining time of the machine until the next maintenance

5.3 Display
5.3.2 Main menu

Main menu
----------------English GB---------------- Current language
▶1 Status Active line
▶2 Performance data Sub-menu
▶3 Operating data Sub-menu
▶4 Maintenance Sub-menu
▶5 Configuration Sub-menu
Representation
The main menu is the top menu level. You open the individual submenus in the main menu.
A scrollbar appears at the right side of the display if you open a menu with more than 6 lines. It
represents the currently visible portion of the menu. A short scrollbar thus indicates that the opened
menu is very long as only a small portion can be displayed.
The image above provides an example for the appearance of the main menu (without scrollbar).
Numbering
Each menu is numbered.

Not all menus may be displayed because the access to certain menus is restricted by the access
level, and some menus are displayed or hidden due to specific settings or options.
For example, you can recognise subordinate menus in the menu structure by the number preced‐
ing their designation. The menu structure is explained in chapter 5.6.2.
Active line
The active line is always shown as white text on a dark background. In deviation of this, the header
is also shown as white text on a dark background, but cannot be selected.
Press «Enter» to open a menu in the active line. This opens the selected menu.
You change parameters in Setting mode.
5.3.3 Setting parameters

In order to set a parameter in the active line of the selected menu, you must always switch to
setting mode.
Setting parameters
Press «Enter». The value of the parameter will flash indicating that it can be changed.
The «Enter» key affects only the active line.
In some lines, you can change more than one parameter.
In this case, you must first select the specific parameter with the «Left» or «Right» keys.

5.4 Access rights
Resetting current parameters
In order to reset current parameters to zero, activate the check box for Reset in the active line of
the display.
First, press «Enter» to switch into setting mode. The check box Reset will flash.
You then press «Up». The check box is activated and flashes.
Press «Enter» to save the settings.
The display no longer flashes and the parameters are reset. The check box for Reset is again de‐
activated.
Check box Reset Status

☒ activated
☐ deactivated
Tab. 29 Reset check box status
5.3.4 Activating keys with check boxes

Certain keys of the SIGMA CONTROL 2 are locked by default. Activate the corresponding check
boxes in the active line of the display to unlock these keys.
First, press «Enter» to switch into setting mode. The check box will flash.
You then press «Up». The check box is activated and flashes.
Press again «Enter» to save the settings.
The display line no longer flashes and the key is activated.
Proceed correspondingly to deactivate a key.
Check box Status

☑ activated
☐ deactivated
Tab. 30 Check box status
5.4 Access rights

Access to the controller is governed by the user name combined with a password.
Users log on using an RFID Equipment Card by default. Alternatively, you can manually enter the
user name and the password.
When the controller is switched on, the lowest level of access (level 0) is activated.
You have access to a further level: Access level 2
Access level 2 allows you to display and adjust further parameters.
The access level will automatically return to level 0 after 10 minutes without any key being pressed.
Secure storage of the RFID Equipment Cards
You will receive 2 RFID Equipment Cards with each machine.

They are stored in a plastic sleeve.
This plastic sleeve is attached at the rear of the controller in the control cabinet.
If you lose both RFID Equipment Cards, you can register a new RFID Equipment Card only after
having entered the user name and the password. A new RFID Equipment Card may be registered
by the KAESER Service subject to a fee, if the user name and the password are lost.

5.5 KAESER CONNECT
5.5 KAESER CONNECT

Using an Internet-capable device with web browser, you can open a visualisation of the controller.
This enables remote checking of, for example, the operating and energy efficiency of your ma‐
chine. For this purpose, you must generate a password once (see Chapter 8.2.5). KAESER
CONNECT does not require additional software to do so. The display language of KAESER
CONNECT can be set independently to the language used with SIGMA CONTROL 2.
Fig. 10 KAESER CONNECT for SIGMA CONTROL 2
KAESER CONNECT functions:

Operating element Meaning
read => write Switching from read-only to read/write mode
To create users and acknowledge messages
write => read Switching from read/write to read-only mode
Logout Log out user
Contact/Service Displaying the contact information for KAESER SERVICE
Select language: Setting the display language for KAESER CONNECT
System status Menu representation on local display
Graphs ■ Pressures and temperatures are displayed in different graphs
■ Graphic representation of the machine status (STOP, IDLE, LOAD) and
RPM along the time axis
Messages ■ Current messages
■ Event history
I/O display Assignment of the input/output modules

5.6 Menus – overview
Operating element Meaning

User management ■ Creating and activating new user accounts
■ Modifying or deactivating existing user accounts
■ Changing passwords
Settings ■ Unit display format
■ Date display format
■ Time display format
Backup Saving data via KAESER CONNECT from SIGMA CONTROL 2 to a PC
Tab. 31 KAESER CONNECT functions
Further information For opening KAESER CONNECT, login and other procedures, please see chapter 8.3.

5.6.1 Operating mode
When the power supply is switched on, details of the software are displayed (for example):
Compressor Machine model
PN: SN: Material number and serial number of the machine
EN: Equipment number of the machine
SIGMA CONTROL 2 – MCS MCS: Main Control System

PN: y.yyyyyy SN: x.xx.xx Material number and serial number of the controller
Software: ABC_V.V.V Software version
Subsequently, the software is loaded and the current operating mode is displayed (example):
------------------------------
------------------------------
------------------------------
The following parameters are displayed:

■ Current operational state of machine
■ On the left-hand side of "¦" you can see from where the compressor is switched on (in the illus‐
trated example via the green «ON» key) and what the current status is (in the example "on").
■ On the right-hand side of "¦", you can see the mode of the load control (in the illustrated exam‐
ple, the network nominal pressure pA is active) and the mode of the compressor (in the exam‐
ple it is switched on).
■ Number of operating hours and hours of the machine being in LOAD mode.

5.6.2 Menu structure

Press «Enter» or one of the arrow keys to open the main menu.
In the main menu, you can:

■ Retrieve displayed information
■ Enter customer-specific settings
The menus shown require access level 2.

Depending on the SIGMA CONTROL 2 software version, machine type and available op‐
tions, only the menus that are available for this particular machine will be displayed.
Main menu
Navigation Function/Sub-menu
1 Status ■ Messages
■ Statistics
■ Current pressure control
■ Current operating mode
■ DI/DO status
■ pN/ADT curve
■ pN/n curve 1)
For details of the Status menu, please see ta‐

ble 33.
1)
Power switching with frequency converter
3)
SIGMA CONTROL 2 (Prepared for connection to control centre)

2 Performance data ■ Compressor
─ System pressure pNloc
─ Internal pressure pi
─ ADT
─ Oil separator
─ Starting temperature
─ Inlet temperature
─ PD temperature
─ Air filter
■ Compressor motor
─ Motor temperature (if available)
─ Speed 1)
─ Current 1)
─ UzK 1)
─ Torque 1)
─ Reference value 1)
■ Fan
─ Speed 1)
─ Current 1)
─ UzK 1)
─ Torque 1)
■ Analogue values
■ SIGMA CONTROL 2
3 Operating data ■ Operating hours
─ Compressor
─ On load
─ Motor
─ Compressor block
─ SIGMA CONTROL 2
─ Partial load valves
■ Switching cycles
─ Load valve on
─ Mains contactor on
■ kWh counter
1)
3)

4 Maintenance Oil filter
Oil separator
Oil change
Air filter
Valve inspection
Belt/coupling inspection
Compressor motor
Bearing lube
Bearing change
Fan motor(s)
Bearing lube
Bearing change
Electrical equipment
Annual maintenance due
5 Configuration For details of the Configuration menu, please
see table 34.
6 Compressor clock Key clock
Reset
Switching point 01:
Switching point 02
Switching point 03
Switching point 04
Switching point 05
Switching point 06
Switching point 07
Switching point 08
Switching point 09
Switching point 10
7 User Name
Password
Current access level:
8 Communication ■ Ethernet/SIGMA NETWORK
■ Com-Module 3)
Key remote
For details of the Communication menu, please
see table 37.
9 Machine test ■ TÜV inspection
1)
3)

10 Components ■ Compressor motor
─ Power switching
For details of the Components menu, please

see table 39.
1)
3)
Tab. 32 Menu structure of main menu
5.6.2.1 Status menu
1.1 Messages ■ Current messages
■ Message history
─ Compressor messages
─ Diagnostic messages
─ System messages
■ Address error
─ Incorrect parameterisation in 2)
Status report
current Alarms
current Warnings
1.2 Statistics Load (hours)
since/Reset:
Load (speed) 1)
since/Reset:
Network actual pressure pNloc
Internal pressure
Motor starts
since/Reset:
Motor starts /d
Motor starts /h
Motor starts T↓
Last load run
Last idle run
Last motor off
1)
2)
only visible in the event of parameterization error
3)

1.3 Current pressure control SIGMA CONTROL 2
Cut-out pressure
SP/SD
Network actual pressure
Frequency converter 1)
Setpoint pressure 1)
Actual pressure 1)
Speed nominal value 1)
Speed actual value 1)
Speed limits 1)
1.4 Current operating mode Compressor on
Load control
Control mode
Idle period
Acknowledgement
Heat recovery (if available)
1.5 DI/DO status 1st I/O module
DI/DO display
2nd I/O module
DI/DO display
3rd I/O module
DI/DO display
1.6 pN/ADT curve Diagram:
Nominal pressure/airend discharge temperature
1.7 pN/n curve 1) Diagram:
Nominal pressure/Speed
1)
2)
only visible in the event of parameterization error
3)
Tab. 33 Status menu

5.6.2.2 Configuration menu
5.1 General ■ System information
─ SIGMA CONTROL 2 MCS 3)
─ Software
─ KAESER:PN/SN
─ Controller manufacturer:PN/SN
─ MFGDT (Manufacturing date)
─ Compressor
─ EN (Equipment number)
─ PN (Material number)
─ SN ( Serial number)
─ I/O modules
─ First IOM
─ Second IOM (if available) 3)
─ FC information 1)
─ Compressor motor
─ Oil-/air cooler fan
─ Oil cooler fan
Model:
Date/time
Time zone
■ Time server
─ active:
─ IP address
Date format
Time format
Pressure unit
Temperature unit
Display lighting
5.2 Pressure control ■ Pressure sensors
■ Pressure settings
■ Load control
■ Network actual pressure
For details of the Pressure control menu, please

see table 35.
1)
3)
4)
SIGMA CONTROL 2 FLUID

5.3 Control mode Local mode:
■ Venting period 4)
■ DUAL
■ QUADRO 4)
■ Partial load valves 4)
5.4 Compressor start ■ Compressor on
■ Compressor off
Autostart:
Start inhibit:
Starting temperature
5.5 Acknowledgement Remote mode:
RC ack
Key remote
5.6 ETM Heat recovery
Local mode:
Remote mode:
current
RC DI
Key remote
Heat recovery
ADT controller
Thermostat valve
Oil cooler
Thermostat valve
ADT controller
■ Oil cooler
■ Heat recovery
5.7 I/O periphery ■ DO functions
■ Analogue values
■ External messages
■ Switch
For details of the I/O periphery menu, please

see table 36.
1)
3)
4)

5.8 Timer on
off
DOR
current
5.9 Refrigeration dryer (if available) Control mode
Compressor ready:
Compressor Clk/RC/RB off:
Temperature ↑
DOR
DOT
Temperature ⇟
DOR
DOT
Safe compressed air supply/Safe compressed
air quality
Error operation without RD
active:
Run time max.:
Reset Alarm:
5.10 Save data Language:
Save data
1)
3)
4)
Tab. 34 Configuration menu
Pressure control menu
5.2.1 Pressure sensors System pressure pNloc
Internal pressure pi
1)
4)
5)
SIGMA CONTROL 2 VAC

5.2.2 Pressure settings System pressure high 5)
pRV (Safety valve actuating pressure)
Pressure rise 4)
pE SP/SD
ΔpFC 1)
Nominal pressure
Setpoint pressure
pA SP/SD
pB SP/SD
System pressure low
Cut-in pressure min
Pressure fall 5)
5.2.3 Load control Local mode
Remote mode
■ pA/pB Clock
(Menu see Remote mode)
pA/pB Cycle
pA/pB RC
pA/pB DO
Load RC
loc.-load RC
Key remote
Key idle
5.2.4 Network actual pressure pNloc (localer network pressure)/FC USS 1)/AII
AII
For sensor error:
Type of message:
Warning
Alarm
1)
4)
5)
SIGMA CONTROL 2 VAC
Tab. 35 Pressure control menu

I/O periphery menu
5.7.1 DO functions Controller on
DOR
DOT
Compressor on
DOR
DOT
Motor running
DOR
DOT
Idle
DOR
DOT
On load
DOR
DOT
Group alarm
DOR
DOT
Group warning
DOR
DOT
Remote mode
DOR
DOT
Clock active
DOR
DOT
■ Clock contact
DOR
DOT
EMERGENCY STOP
DOR
DOT
1)

5.7.2 Analogue values ■ AnMod (Analogue modules)
─ AnMod_p_1
─ AnMod_p_2
─ AnMod_p_3
─ AnMod_p_4
─ AnMod_T_1
─ AnMod_T_2
─ AnMod_T_3
─ AnMod_T_4
─ AnMod_I_1
─ AnMod_I_2
■ AI (Analogue inputs)
─ AI_p_1
─ AI_p_2
─ AI_T_1
─ AI_T_2
─ AI_I_1
─ AI_I_1
■ AO (Analogue outputs)
─ AO_p_1
─ AO_p_2
─ AO_T_1
─ AO_T_2
─ AO_I_1
─ AO_I_2
─ AO_n_1 1)
■ PD (Process data)
─ PD_p_1
─ PD_p_2
─ PD_T_1
─ PD_T_2
─ PD_I_1
─ PD_I_2
5.7.3 External messages ■ External message 1
■ External message 2
1)

5.7.4 Switch ■ System pressure pNloc
■ Internal pressure pi
■ ADT
■ Inlet temperature
■ PD temperature
■ n Compressor motor
1)
Tab. 36 I/O periphery menu

5.6.2.3 Communication menu
8.1 Ethernet/SIGMA NETWORK ■ IP configuration
─ IP address
─ Subnet mask
─ Gateway
─ DNS Server 1
─ DNS Server 2
─ Restart network
■ Connections
─ SIGMA CONTROL 2
─ SAM 4.0
Restart
Timeout
Cycle time
For details of the Connections menu, please see
table 38.
■ E-mail
─ active:
Compressor number:
Language:
Repeat cut-off time:
Use SSL:
─ Sender address:
Sender name:
Contact telephone:
Receiver address:
─ SMTP Server:
User name:
Password:
─ Port/Timeout
Resend after:
MAC: MAC address
3)

8.2 Com-Module 3) The content of the menu depends on the type of
the communication module identified.
The following KAESER communications mod‐

ules may be used:
■ PROFIBUS
■ Modbus
■ Modbus TCP
■ DeviceNet
■ PROFINET
■ EtherNet/IP
3)
Tab. 37 Communication menu
5.6.2.4 Connections menu
8.1.2 Connections ■ SIGMA CONTROL 2
─ Status
─ Mode
─ Port
─ Communication partner
─ IP address
─ Communication error
Start td
Timeout
■ SAM 4.0
─ Status
─ SAM 4.0 active:
Send/receive
Send
─ IP address
─ Port
─ Communication error
Start td
Timeout
Restart
Timeout
Cycle time
Tab. 38 Connections menu

5.6.2.5 Components menu
10.1 Compressor motor USS status: Run/Error
■ Power switching
─ Star-delta start
─ DOL start
─ High-voltage cell 3)
─ SFC USS 1)
─ Softstart 3)
─ Customer-provided 3)
For details of the Power switching menu, please

see table 40.
1)
3)
Tab. 39 Components menu

5.6.2.6 Power switching menu
10.1.1 Power switching ■ Star-delta start
─ Temp. warm start
─ Star time T↑
─ Star time T↓
─ Υ/Δ switching time
─ Overload relay
─ Mains contactor
─ Star contactor
─ Delta contactor
■ DOL start
─ Run-up period:
─ Overload relay
─ Mains contactor
─ Delta contactor
■ High-voltage cell 1)
─ Run-up period:
─ ready
─ Mains contactor
■ SFC USS 1)
USS status: Run/Error
─ Run-up period:
─ Service operation
─ Heavy load monitoring
─ Mains contactor
─ STO channel A
─ STO channel B
■ Softstart 1)
─ ready
─ Motor running
─ Start-up ended
─ Start
─ Reset
─ Mains contactor
■ Customer-provided 1)
─ Temp. warm start
─ Run-up period T↑
─ Run-up period T↓
─ ready
─ Mains contactor/Alarm td
─ Redundancy contactor/Alarm td
1)
3)

5.7 Operating modes and control modes
10.1.1 Power switching If there is a power switching unit with a frequen‐

cy converter, the further content of the menu is
determined by the type of frequency converter
and the settings available for it.
Tab. 40 Power switching menu

5.7.1 Machine operating modes
STOP
The machine is connected to the power supply.

The voltage applied to controller LED lights green.
The machine is switched off. The ON LED is extinguished.
READY
The machine has been activated with «ON»:

■ The On LED lights green.
■ The compressor drive engine is stopped.
■ The inlet valve is closed.
■ The minimum pressure/check valve isolates the oil separator tank from the air system
■ The venting valve is open
The compressor motor / engine starts as soon as network pressure is lower than the network nomi‐
nal pressure (cut-off pressure).
In addition, timing and/or remote control may affect the start of the motor.
LOAD
The compressor motor / engine runs under load.

■ The inlet valve is open.
■ The airend delivers compressed air to the air network.
IDLE
The compressor motor / engine runs unloaded with low power consumption.
■ The inlet valve is closed.
■ The minimum pressure/check valve isolates the oil separator tank from the air system
■ The venting valve is open
A small volume of air circulates through the bypass bore in the inlet valve, through the airend and
back to the inlet valve via the venting line.

5.7.2 Control modes

Using the selected control mode, the controller switches the machine between its various opera‐
tional states in order to compensate for air being drawn by consumers, and to maintain the system
pressure between the set minimum and maximum values. The control mode also rules the degree
of energy efficiency of the machine.
The machine-dependant venting phase between the LOAD and READY operating modes ensures
load changes at minimum material stresses.
The controller SIGMA CONTROL 2 can operate in the following modes:

■ DUAL
■ QUADRO
■ VARIO
■ CONTINUOUS
■ DYNAMIC
Option C1 ■ MODULATING control
DUAL
In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to
maintain the machine working pressure between the preset minimum and maximum values. When
maximum pressure is reached, the machine switches to IDLE. When the preset idling time has
elapsed, the machine switches to READY.
The idling time is factory preset according to the maximum starting frequency of the compressor
motor / engine. The shorter the idling time setting, the sooner (and more frequently) the drive mo‐
tor / engine is stopped.
QUADRO
In contrast to the the DUAL regulating mode, the machine will switch from LOAD to READY in
QUADRO mode after periods with low compressed air consumption.
After periods with a high compressed air consumption, the machine will switch from LOAD to
READY after passing through IDLE.
In this control mode, the controller requires two specified times: The minimum run-time and the
unloaded period.
The shorter these times are set, the sooner (and more frequently) the motor / engine is stopped.
VARIO
The VARIO mode is based on the DUAL control mode. The difference to DUAL is that the idling
time is automatically lengthened or shortened to compensate for higher or lower machine starting
frequencies.
CONTINUOUS
In the CONTINUOUS control mode, the machine is switched back and forth between LOAD and
IDLE, in order to maintain the machine's working pressure between the preset minimum and maxi‐
mum values. When maximum pressure is reached, the machine switches to IDLE. However, the
machine does not switch to READY.

DYNAMIC
In contrast to the the DUAL regulating mode, the machine will switch from LOAD to READY in
DYNAMIC mode at low drive motor / engine temperature.
And from LOAD via IDLE to READY at a high drive motor / engine temperature.
The lower the drive motor / engine temperature, the sooner (and, therefore, more often and longer)
it is stopped.
Option C1 MODULATING control
The MODULATING control is an additional mechanical regulation. It continuously changes the flow
rate within the machine's control range.
A control valve, the proportional controller, changes the degree of opening of the inlet valve when
the machine transports compressed air into the air network (LOAD)
The load and power consumption of the drive motor / engine rises and falls with the air demand.
5.7.3 Variable speed drive with frequency converter (SFC)

If the machine runs in the LOAD mode, the ACTUAL value is compared with the TARGET value of
the network pressure. Depending on the pressure differential, the system controls the speed of the
drive motor and, thus, the airend.
The speed of the airend determines the rate of compressed air delivery and the working pressure.
If the compressed air demand rises, the motor / engine speed increases and consequently the vol‐
ume of air delivered.
If air consumption drops, SIGMA CONTROL 2 reduces the motor speed and, therefore, the volume
of air delivered.
The network pressure remains constant – within the control range of the converter – regardless of
fluctuating air demand.
If the network pressure exceeds the TARGET value:
Outside the frequency converter's range of control the machine reverts to the selected control
mode.
DUAL:
The minimum controllable speed is reached and the machine switches to IDLE mode. The drive
engine runs unloaded with low power consumption.
When the preset idling time has elapsed, the machine switches to READY.
VARIO/QUADRO/CONTINUOUS:
The minimum controllable speed is reached and, depending on the air demand at the time, the ma‐
chine switches either to READY or to IDLE. The machine remains in IDLE at least for the duration
of the venting time, before it switches to READY.
DYNAMIC:
The minimum controllable speed is reached and, depending on the air temperature of the drive mo‐
tor / engine, the machine switches either to READY or to IDLE. The machine remains in IDLE at
least for the duration of the venting time, before it switches to READY.
If the network pressure falls below the TARGET value:
The frequency converter runs the motor / engine up to a speed at which air delivery matches the
air demand.

The inlet valve opens and the machine delivers compressed air.
The speed of the drive motor / engine is regulated according to the air demand.
5.7.4 MODULATING control

With the help of a mechanical control valve (the proportional controller), the opening and closing of
the inlet valve is continuously varied in relation to the actual air demand. The airend delivers com‐
pressed air to the distribution network.
The load and power consumption of the drive motor rises and falls with the air demand.
To ensure optimal control on large compressors, the control air for the proportional controller is tak‐
en from an external air receiver.

6.1 Maintaining ambient conditions

6.1 Maintaining ambient conditions
➤ Follow the instructions in the machine's service manual.
6.2 Installation conditions

The installation and operating conditions depend the machine into which the controller is installed.
NOTICE
UV radiation!
Direct sunlight (UV radiation) can destroy the display screen.
➤ Do not allow the display screen to be subjected to direct sunlight.
➤ See the machine's operating manual for required conditions.

7 Installation
7.1 Reporting Transport Damage
7 Installation
7.1 Reporting Transport Damage
1. Check the machine for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage without delay.
7.2 Machine identification

If the machine is run in sequenced operation its identification as detailed in the installation diagram
is to be taken into account.
Identifying the machine for operation in remote mode.
➤ Attach the following notice to warn of remote machine operation (suggestion):
Remote control: Risk of injury caused by unexpected starting!

➤ Make sure the power supply disconnecting device is switched off before commencing any
work on the machine.
Tab. 41 Machine identification
➤ Label the starting device in the remote control centre as follows (suggestions):
Remote control: Risk of injury caused by unexpected starting!

➤ Before starting, make sure that no one is working on the machine and that it can be safely
started.
Tab. 42 Remote control identification
Identifying the machine for time control (clock mode operation)
➤ Attach the following notice to indicate the ON/OFF timer program machine operation (sugges‐
tion):
Time control: Risk of injury caused by unexpected starting!

➤ Make sure the power supply disconnecting device is switched off before commencing any
work on the machine.
Tab. 43 Machine identification

8 Initial Start-up
8.1 Outline
8 Initial Start-up
8.1 Outline
SIGMA CONTROL 2 was designed and developed for a number of applications. The settings that
can be made are correspondingly varied.
It is possible that only a few of these settings are needed for the initial start-up. This depends on
the application involved.
8.2: Setting the controller (display format, units, languages, etc.)
8.3: Using KAESER CONNECT
8.4: Pressure parameters of the machine
8.5: Machine start and stop
8.6: Control modes
8.7: Electronic Thermal Management
8.8: Refrigeration dryer
8.9: Setting the machine for local mode
8.10: Setting the machine for master control operation
8.11: Input and output signals
8.13: Activating remote acknowledgement
8.14: Linking to an external pressure transducer
8.15: Commissioning the machine
8.2 Setting the controller

The following chapters describe in detail the basic settings for the SIGMA CONTROL 2. The
quick installation guide at the beginning of this operating manual provides an overview of the
essential displays and operating elements, the main menu and important functions.

8 Initial Start-up
➤ Carry out settings as required:

■ 8.2.1: Selecting menu options (introduction)
■ 8.2.2: Setting the language
■ 8.2.3: Noting the user name
■ 8.2.4: User log-in with RFID Equipment Card
■ 8.2.5: Generating a password
■ 8.2.6: Manual user log-in
■ 8.2.7: Create the master RFID Equipment Card
■ 8.2.8: Checking/Setting time and date
■ 8.2.9: Setting the time zone (daylight saving time/winter time)
■ 8.2.10: Set display formats (date, time, units of pressure and temperature)
■ 8.2.11: Setting the display illumination
■ 8.2.12: Setting the contrast and the brightness
■ 8.2.13: Activating the remote control
■ 8.2.14: IP configuration
■ 8.2.15: Setting the e-mail function
■ 8.2.16: Setting the time server
■ 8.3.6: Creating a user account
8.2.1 Selecting menu options

All menu options can be selected with the «Down», «Up» and «Enter» keys.
Example: Open the < Configuration – General > menu.
1. Switch on the machine and wait for SIGMA CONTROL 2 to start.

The operating mode is displayed.
------------------------------
------------------------------
------------------------------

8 Initial Start-up
2. Press «Enter».
The Main menu is displayed.
Main menu
▶1 Status Sub-menu
▶5 Configuration Active line
3. Use «Up» or «Down» to select the Configuration line.

4. Press «Enter».
The Configuration menu is displayed
5. Use «Up» or «Down» to select the General line.
6. Press «Enter».
The General menu is displayed
5.1 General Menu
▶1 System information Sub-menu
·········
Model: XXXXXX set machine type
·········
Date/time
04/13/16 08:15:37AM current date and time
7. Use «Up» or «Down» to select a menu item in the General sub-menu such as System
information.
8. Press «Escape» repeatedly to leave this menu.
8.2.2 Setting the language

You can set the user interface to one of these languages:
Arabic Estonian Italian Norwegian Spanish
Bulgarian Finnish Japanese Polish Spanish
(South America)
Chinese French Korean Portuguese Czech
Danish French Croatian Romanian Turkish
(Canada)
German Greek Latvian Russian Hungarian
English Hebrew Lithuanian Swedish ...
English (USA) Indonesian Dutch Slovenian ...
Tab. 44 Supported languages

8 Initial Start-up
Depending on the selected language, the system automatically sets the units and the time
and date formats. You can manually change these settings (see chapter 8.2.10).
Precondition The operating mode is displayed.
1. Press «Enter».
Main menu
▶1 Status Active line
2. Press «Up» key.

The currently set language is displayed.
Main menu
----------------English GB---------------- Active line with current set language
▶1 Status Sub-menu
3. Press «Enter».
The currently set language flashes.
4. Use «Up» or «Down» to select the desired language.
5. Press «Enter».
Result The user interface is displayed in the set language.
8.2.3 Noting the user name

The number of your RFID Equipment Card is identical with the user name displayed on
SIGMA CONTROL 2 after you have successfully logged on using your RFID Equip‐
ment Card.

8 Initial Start-up
Fig. 11 Back of the RFID Equipment Card

1 Back of the RFID Equipment Card
2 Number of your RFID Equipment Card
1. Note the user name (= number of the RFID Equipment Card).

2. Keep the note at a secure location.
If your RFID Equipment Card gets damaged or can no longer be found?
➤ If you know your user name and password, you can manually log on to
SIGMA CONTROL 2 (see chapter 8.2.5).
8.2.4 User log-in with RFID Equipment Card

The RFID Equipment Card enables an easy and quick log-in at SIGMA CONTROL 2. It authorises
you to access advanced functions of the controller.
Advanced access rights allow you to:
■ Read additional data
■ Change other settings
Fig. 12 User log-in with RFID Equipment Card

8 Initial Start-up
1. Hold the RFID Equipment Card in front of the RFID reader.

Your user name and access level will be displayed.
Log-in successful Menu
Button to change password Prompt, whether the password is to be changed
------------------------------
Name: E00019895
Level: 2
2. Press «Enter».
The access right is confirmed.
The RFID Equipment Card is damaged or lost?
➤ Manually enter the user name and password, see chapter 8.2.6.
8.2.5 Generating a password

In the event that your RFID Equipment Card is damaged or lost, you must manually log on to
SIGMA CONTROL 2. A password is also required to use KAESER CONNECT to log on at
SIGMA CONTROL 2 (see chapter 8.3).
Prerequisite for this is that you know your

■ Name
■ Password
You have noted your user name and stored it at a suitable location (see chapter 8.2.3). In the next
step, generate a password on SIGMA CONTROL 2. Note this generated password as well, and
store it a suitable location. If your RFID Equipment Card is damaged or lost, the card won't be nec‐
essary to manually log on to SIGMA CONTROL 2 when you have these two pieces of information.
Precondition Any menu is displayed
Fig. 13 User log-in with RFID Equipment Card

8 Initial Start-up
1. Hold the RFID Equipment Card in front of the RFID reader.

Users are always logged on with access level 2.
------------------------------
Name: E00019895
Level: 2
2. Press the «Right» key within five seconds.

The new Password is displayed.
Password changed Menu
------------------------------
Please take note of your new
password:
xFNDQRCnDn New password
3. Note the new password.

4. Store the password at a suitable location, if it should become necessary to manually log-on
without RFID Equipment Card.
5. Press «Enter».
The setting is applied.
8.2.6 Manual user log-in

In the event that your RFID Equipment Card is damaged or lost, you can manually log on to
SIGMA CONTROL 2.
Precondition The user name (see chapter 8.2.3) and password (see chapter 8.2.5) are known.
1. Open the 7 User menu.

2. Use «Up» or «Down» to select the Name line.
3. Press «Enter».
The setting mode is active.
A column with alphanumeric characters is displayed.
The selected character flashes.

8 Initial Start-up
Fig. 14 Manual user log-on
4. Select the required character with the «Up» or «Down» keys.

5. Press the «Right» arrow.
The cursor jumps to the next position of the user name.
6. Enter the remaining characters of the user name in the same manner.
7. Press «Enter».
The user name is entered.
8. Use «Up» or «Down» to select the Password line.
9. Press «Enter».
Enter the remaining letters and digits of the password in the same manner.
The password is case sensitive!
10. Press «Enter».
The password is entered.
11. Use «Up» or «Down» to select the [Login] line.
Current access level: 2 is displayed.
Result You are now logged on to SIGMA CONTROL 2 with access level 2, having manually input your
user name and the password.
8.2.7 Create the master RFID Equipment Card

If you are running several KAESER machines with the SIGMA CONTROL 2 control it may make
sense to create a master RFID Equipment Card with which you can log onto all machines.
Precondition The RFID Equipment Card delivered with the machine and at least one additional teachable RFID
Equipment Card are available.

8 Initial Start-up
1. Hold the RFID Equipment Card delivered with the machine in front of the RFID reader.
Users are always logged on with access level 2.
------------------------------
Name: E00019895
Level: 2
2. Within 10 minutes, hold the master RFID Equipment Card to be taught in front of the RFID
reader.
The master RFID Equipment Card is not registered at the machine.
Registration successful The master RFID Equipment Card has been regis‐
tered
------------------------------
Name: E00017326
Level: 2
3. Repeat the above steps at the next machine if the master RFID Equipment Card is to be regis‐
tered at other machines.
Result You have registered a master RFID Equipment Cards at the machine.
8.2.8 Checking/setting time and date

Precondition Access level 2 is activated.
Check and set time
➤ When operating the machine with a timer program, check the time settings at least once
a year.
➤ You can automatically synchronise date and time using a time server. Manual setting of
the time is no longer required in this case. See chapter 8.2.16.
1. Open the 5.1 <Configuration – General> menu.
2. Use «Up» or «Down» to select the Date/time line.

8 Initial Start-up
3. Press the «DOWN» key.

5.1 General Menu
·········
·········
Date/time
4. Press the «Right» key.

5. Press «Enter».
The display for hours 00:00:00 flashes.
6. Use «Up» or «Down» to set the hours.
The display for minutes 00:00:00 flashes.
8. Use «Up» or «Down» to set the minutes.
The display for seconds 00:00:00 flashes.
10. Use «Up» or «Down» to set the seconds.
Check/set the date

5.1 General Menu
·········
·········
Date/time
4. Press «Enter».
The display for days 00.00.00 flashes.
5. Use «Up» or «Down» to set the day.
The display for months 00.00.00 flashes.

8 Initial Start-up
7. Use «Up» or «Down» to set the month.

The display for years 00.00.00 flashes.
9. Use «Up» or «Down» to set the years.
8.2.9 Set the time zone

Set the time zone for the SIGMA CONTROL 2 to ensure the timely automatic conversion from win‐
ter time (standard time) to daylight savings time, for example.

3. Press «Down» twice.
5.1 General Menu
·········
Date/time
04/13/16 08:15:37AM
Europe/London Time zone
·········
4. Press «Enter».
The time zone display flashes.
5. Use «Up» or «Down» to set the time zone.
6. Press «Enter».
8.2.10 Set display formats

Depending on the selected language, the system automatically sets the units and the time and
date formats. You can manually change these settings.
Setting the date format
Set the display for the date format:

Format Example
DD.MM.YY 30.07.16
YY-MM-DD 16–07–30
MM/DD/YY 07/30/16
Tab. 45 Date formats

8 Initial Start-up

2. Use «Up» or «Down» to select the Date format line.
5.1 General Menu
Europe/London
·········
▶2 Time server
·········
Date format MM/DD/YY Date format
Time format hh:mm:ssAM/PM
3. Press «Enter».
The MM/DD/YY display flashes.
4. Use «Up» or «Down» to set the date format.
5. Press «Enter».
Setting the time format
Set the display for the time format:

Format Example
hh:mm:ss 13:33:45
hh:mm 13:33
hh:mm:ssAM/PM 01:33:45PM
hh:mmAM/PM 01:33PM
Tab. 46 Possible settings for the time format

2. Use «Up» or «Down» to select the Time format line.
5.1 General Menu
Europe/London
·········
▶2 Time server
·········
Date format MM/DD/YY
Time format hh:mm:ssAM/PM time format
3. Press «Enter».
The hh:mm:ssAM/PM indication flashes.

8 Initial Start-up
4. Use «Up» or «Down» to set the time format.

5. Press «Enter».
Setting the pressure display units
Set the pressure unit for display:

Format Example
bar 5.5bar
hPa 5523hPa
MPa 0.55MPa
psi 80psi
at 5.6at
Tab. 47 Possible settings for the pressure unit

2. Use «Up» or «Down» to select the Pressure unit line.
5.1 General Menu
·········
Pressure unit bar Unit of pressure
Temperature unit °C Unit of temperature
·········
Display lighting
3. Press «Enter».
The display for the set unit flashes.
4. Use «Up» or «Down» to set the unit.
5. Press «Enter».
Setting the temperature display units
Set the temperature unit for display:

Format Example
°C 46°C
K 319K
°F 114°F
Tab. 48 Possible settings for the temperature unit

8 Initial Start-up

2. Use «Up» or «Down» to select the Temperature unit line.
5.1 General Menu
·········
·········
Display lighting
3. Press «Enter».
The display for the set unit flashes.
4. Use «Up» or «Down» to set the unit.
5. Press «Enter».
8.2.11 Setting the display illumination

Set the display lighting mode:
Mode 1 2 3
Indication automatic on off
Function The illumination extin‐ Permanent setting Permanent setting
guishes after the time- Illumination "on" Illumination "off"
out has elapsed.
Tab. 49 Display illumination

2. Use «Up» or «Down» to select the Display lighting line.
The Mode line is displayed.
5.1 General Menu
·········
·········
Display lighting
Mode: auto.¦ Timeout: 1min Active line

8 Initial Start-up
4. Press «Enter».
The display for the set mode flashes.
5. Use the «Up» or «Down» keys to set the auto. mode.
6. Press «Enter».
8. Set the value for the Timeout in the same manner: 1 min, for example.
9. Press «Enter».
Result The display illumination is set for automatic operation with deactivation after one minute without
user intervention.
8.2.12 Setting the contrast and the brightness

Contrast and brightness are factory set to normal light conditions. You can manually set contrast
and brightness for different lighting conditions.
Precondition The operating mode is displayed.
1. Press and hold the «Information» key.

2. Use «Up» or «Down» to set the contrast.
3. Use «Left» or «Right» to set the brightness.
Result Contrast and brightness are set.
8.2.13 Activating the remote control

The «remote control» key on the operating panel of the SIGMA CONTROL 2 can be activated or
deactivated. Various menus offer check boxes for this setting.

1. Open the menu, e.g. 8 Communication menu.

2. Use «Up» or «Down» to select the Key remote line.
3. Press «Enter».
The check box Key remote will flash.
8 Communication Menu
▶1 Ethernet/SIGMA NETWORK
▶2 Com-Module
Key remote :☐ Active line with deactivated check box

8 Initial Start-up

The check box Key remote is activated.
8 Communication Menu
▶1 Ethernet/SIGMA NETWORK
▶2 Com-Module
Key remote :☑ Active line with deactivated check box
5. Press «Enter».
The «Remote control» key is activated.
Proceed in the same manner to deactivate the «remote control» key.
7. Press «Remote control» key on the operating panel of SIGMA CONTROL 2.
Result SIGMA CONTROL 2 remote control is activated.
8.2.14 IP configuration
For the SIGMA CONTROL 2 to be connected to the network, you must set the IP configuration (for
KAESER CONNECT for example).
If you use SIGMA CONTROL 2 as the master control of two machines, you set other network
parameters in the IP configuration menu (see chapter 8.10.4).
The network parameters for the IP configuration must be specified manually. You cannot use
DHCP for an automatic IP configuration.

The network parameters are known. Request the required information from your IT department.
1. Connect SIGMA CONTROL 2 to the network using an Ethernet cable.

2. Open the 8.1.1 <Communication – Ethernet/SIGMA NETWORK – IP configuration> menu.
3. Use «Up» or «Down» to select the IP address line.
8.1.1 IP configuration Menu
IP address 169.254.100.101 active line, factory setting
Subnet mask 255.255.000.000
Gateway 169,254,100.97
DNS Server 1 169,254,100.97
DNS Server 2 169,254,100.97
Restart network ☐
4. Press «Enter».
The first group of numbers of the IP address flashes 169.254.100.101.

8 Initial Start-up
5. Use «Up» or «Down» to set the first group of numbers of the IP address.
The SECOND group of numbers of the IP address flashes 192.168.100.101.
7. Use «Up» or «Down» to set the second, third and fourth group of numbers of the IP address.
The IP address is correctly set.
8. Press «Enter».
9. Press «Down».
The Subnet mask line is displayed.
10. Set the remaining network parameters as described above:
Parameters Setting value Meaning

IP address IP address of the interface X1 Ethernet
Subnet mask Subnet mask of the network
Gateway Gateway address of the network
DNS Server 1 DNS server 1 address
DNS Server 2 DNS server 2 address
Restart network – Activate the changed network parameters
Tab. 50 Network parameters
11. Use «Up» or «Down» to select the Restart network line.

IP address 192.168.001.010 Example address
Subnet mask 255.255.255.000 Example address
Gateway 192.168.001.001 Example address
DNS Server 1 008.008.008.008 Example address
DNS Server 2 008.008.004.004 Example address
Restart network ☐ Active line

The check box Restart network will flash.
13. Press the «Up» key.
The check box is activated.
Result The network is restarted.

The set network parameters are active.
8.2.15 Setting the e-mail function

SIGMA CONTROL 2 is able to send messages per e-mail.
For this purpose, a network connection with an SMTP server is required.

8 Initial Start-up
Setting e-mail parameters

IP configuration is set; see chapter 8.2.14.
An SMTP server is active in the network.
The e-mail parameters are known. Request the required information from the IT department.
1. Open the 8.1.3 <Communication – Ethernet/SIGMA NETWORK – E-mail> menu.

2. Use «Up» or «Down» to select the active: line.
8.1.3 E-mail Menu
active: ☐ Activating/deactivating the e-mail function
Compressor number: 1
Language: English GB Setting the language
Repeat cut-off time: 5min
Use SSL: ☑ Encryption option
------------------------------
3. Press «Enter».
The check box active: will flash.
4. Press «Up».
The check box is deactivated.
5. Press «Enter».
The e-mail function is deactivated.
6. Set the e-mail parameters as described above:
Parameter Setting Meaning

value
Compressor This field displays the machine number that appears as the sender of
number: e-mails. The recipient is thus able to identify the different machines
sending mails.
Language: Use this field to define the language for the message texts. This setting
is independent from the language setting in SIGMA CONTROL 2 (see
chapter 8.2.2).
Repeat cut-off In this field, enter the time in minutes (repeat block time) that the sys‐
time: tem must wait in order not to send multiple recurring messages in short
time intervals.
Use SSL: E-mail sending is encrypted if the check box is ticked.
Sender address: Enter the e-mail address of the sender in this field.
Sender name: Enter the name of the sender in this field.
Contact In this field, enter a telephone number under which the air station oper‐
telephone: ator can be reached. This telephone number is sent with each e-mail.
Receiver The e-mail address of the recipient
address:
SMTP Server: IP address of the SMTP server receiving and forwarding the e-mails
User name: Log-in user name for logging on to the SMTP server

8 Initial Start-up
Parameter Setting Meaning

value
Password Log-in password for logging on to the SMTP server
Port Port address of the SMTP server
Timeout In this field, enter the seconds for SIGMA CONTROL 2 to wait for a re‐
ply by the SMTP server before e-mail sending is cancelled.
Resend after: In this field, enter the time in seconds for the system to wait after a
failed e-mail sending operation before it again attempts to send the
mail.
Retry attempts: Setting option for the number of attempts to resend after failed e-mail
sending.
Tab. 51 E-mail parameters
7. Activating the e-mail function: Activate the active: check box as described above.
Result The e-mail parameters are set and the e-mail function is activated.
8.2.16 Setting the time server

If SIGMA CONTROL 2 is connected to the network, you can set the access to an SNTP server
available in the Internet or a local Intranet. SIGMA CONTROL 2 then automatically imports the
date and time settings and ensures continuous synchronisation of the internal clock with the exter‐
nal time server.

IP configuration is set; see chapter 8.2.14.
The time server's IP address is known. Request the required information from your IT department.
1. Open the 5.1.2 <Configuration – General – Time server> menu.

5.1.2 Time server Menu
active: ☐ Activating/deactivating the time server function
IP address 192.053.103.103 Example address, time server
3. Press «Enter».
The first group of numbers of the IP address flashes 192.053.103.103.
4. Use «Up» or «Down» to set the first group of numbers of the IP address.
The second group of numbers of the IP address flashes 192.053.103.103.
6. Use «Up» or «Down» to set the second, third and fourth group of numbers of the IP address.
The IP address is correctly set.

8 Initial Start-up
8.3 KAESER CONNECT benefits
7. Press «Enter».
9. Press «Enter».
The check box active: will flash.
6.1bar 08:15AM 80° C
5.1.2 Time server Menu
active: ☑ The time server function is activated.
IP address 192.053.103.103 Example address, time server

Result Access to the selected time server is active.

The internal clock of SIGMA CONTROL 2 is permanently synchronised.

Using an Internet-capable device with web browser, you can use KAESER CONNECT to remotely
display these SIGMA CONTROL 2 menus:
■ System status
■ Graphs
■ Messages
■ I/O display
■ User management
■ Settings
■ Backup
■ Data recording
Thus, KAESER CONNECT provides an excellent option for an easy and quick check of the econo‐
my and energy efficiency of your machines.

8 Initial Start-up
The following functions are not implemented with KAESER CONNECT:
■ Remotely starting the machine

■ Remotely setting parameters
For KAESER CONNECT to be able to use the Internet-capable device, it must be registered
in the same network as SIGMA CONTROL 2.
To be able to use KAESER CONNECT, the browser installed on the Internet-capable device
must be able to display HTML5 content. For security reasons, we strongly recommend to use
only up-to-date browser versions.
8.3.1 Open KAESER CONNECT

Precondition The user name (see chapter 8.2.3) and password (see chapter 8.2.5) are known.
The controller's IP address is known, see chapters 8.2.14 and 8.10.4.
1. Use an Ethernet cable to connect SIGMA CONTROL 2 to the Internet-capable device or net‐
work.
2. In the web browser, enter the IP address of the controller.
The log-in mask is displayed.
Fig. 15 Log-in mask
3. Enter your user name in the User name: field.

4. Enter your password in the Password: field.
5. Click Login.
KAESER CONNECT for SIGMA CONTROL 2 is displayed.

8 Initial Start-up
Fig. 16 KAESER CONNECT for SIGMA CONTROL 2
6. Click the arrow key 1 to open Select language:.

The Select language: window is displayed.
Fig. 17 Select language: window

1 «Arrow key» Select language: 3 Setting the language
2 Select language: window 4 Selected language
7. Click to set the selected language 3 .
Result KAESER CONNECT is displayed in the set language.
8.3.2 System status menu

Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed.

8 Initial Start-up
Fig. 18 System status menu
1. Click the System status menu element.

The System status menu is displayed
Fig. 19 Main menu

8 Initial Start-up
2. Click in the SIGMA CONTROL 2 display.

3. Click the numbered lines.
The system displays the corresponding sub-menus.
4. Press ESC repeatedly to leave this menu.
8.3.3 Graphs menu

When starting the Graphs menu, the recorded machine data from the last 20 minutes are displayed
as diagram. The system updates the graph every ten seconds whilst the current time is displayed.
If an SD card is provided in the X5 SD card slot, you can retrieve and display the automatically-
recorded machine data for any time in the past.
Moving the mouse pointer across the graph calls up a ruler. The time selected with the ruler and
the associated values are displayed in the legend above the graph. When the ruler is hidden, the
time and associated values are displayed at the right edge of the graph.
The graph content depends on the machine type.
The Speed display is implemented only for machines with frequency converter.
1. Click the Graphs menu element.
Fig. 20 Graphs (illustration similar)
2. Check the displayed data.

8 Initial Start-up
8.3.3.1 Zoom function
Use the Zoom function to enlarge significant curve developments:

Highlight a specific area within the graph by drawing a rectangle with the mouse pointer pressed.
The selected area will be enlarged as soon as the mouse pointer is released.
Fig. 21 Control keys

1 «Start» Display the oldest data in the cache memory or load the data from the previ‐
ous 20 minutes from the SD card
2 «Scroll left» Shift the display area by 1/3 to the left
3 «Zoom-out» Time range is enlarged
4 «Scroll right» Shift the display area by 1/3 to the right
5 «End» Display the current data
6 «Refresh» Load and display the entered machine data from start time to end time
Tab. 52 Control key functions
1. Click the «Start» 1 arrow key.

The oldest data in the cache memory or the data of the last 20 minutes are loaded form the SD
card and displayed
2. Click the «Scroll right» 4 arrow key.
The display area is shifted to the right by 1/3.
3. With the mouse button pressed, draw a rectangle around the selected area.
4. Release the mouse button.
The selected area is enlarged (zoom-in function).
5. Click the «Zoom-out» 3 arrow key.
The time range is enlarged (zoom-out function).
8.3.3.2 Display past machine data
You can display the automatically-recorded machine data for any time in the past.
Precondition An SD card with sufficient free memory is inserted in the X5 SD card slot
The SD card was inserted for the entire operating time of the machine.
The SIGMA CONTROL 2 data recorder function is activated.
1. Enter the date and time for the start time in the required time period in Start:.
2. Enter the date and time for the end time in the required time period in End:.
3. Click 6 .
The machine data for the specified time interval are loaded and displayed.

8 Initial Start-up
8.3.4 Messages menu

The following messages types can be displayed:
■ Current messages
■ Compressor messages
■ System messages
■ Diagnostic messages
Fig. 22 Messages (illustration similar)
1. Click the Messages menu element.

The Messages menu is displayed
2. Click the required message type.
3. Check messages.
8.3.5 I/O display menu

The measured values of the analogue inputs and the states of the digital inputs and outputs are
displayed in the I/O display menu. Depending on the machine options, you may select from further
IOM module tabs.

8 Initial Start-up
Fig. 23 I/O display (illustration similar)
➤ Click the I/O display menu element.

The current measured data and states of the input/output modules are displayed.
8.3.6 User management menu

Use the User management menu to create additional user accounts for other employees.
In order to be able to create user accounts, you must activate the write mode. The system will
prompt you to enter and confirm your user name and your password. Subsequently, the write
mode is activated (see Chapter 8.2.5).
The write mode is granted only to one person at a time.
If a second user attempts to log on in write mode, he will be refused by the system.
The system will return an error message.
String length for personally created user names and passwords:

■ User name: 6 to 16 characters, the second character must not be a number
■ Password: 6 to 16 characters
Precondition The generated password is available.

KAESER CONNECT for SIGMA CONTROL 2 is displayed.

8 Initial Start-up
Fig. 24 User management menu
1. Click the User management menu element.

2. Click read => write to activate the read/write mode.
The Log on for write access: window is displayed.
Fig. 25 Log on for write access: window
3. Enter your user name in the User name: field.

4. Enter your password in the Password: field.
5. Click OK.
The User management menu is displayed

8 Initial Start-up
Fig. 26 User management menu
6. Enter a new user name in the User name: field.

7. Enter a new password in the Password: field.
8. Re-enter the same new password in the Repeat password: field.
9. Set Level 2 in the Access level: field.
10. Set the State: option in the Enabled field.
11. Click Add.
The new user name has been added to the user list.
Result A new user account has been created and activated.
Editing a user account
You can edit existing user accounts:

■ Changing the password
■ Changing the access level
■ Changing the status
Example: Change the password for an existing user account.
Precondition The User management menu is displayed

Write mode is activated.
1. Click the required user account in the list.

2. Enter a new password in the Password: field.
3. Re-enter the same new password in the Repeat password: field.
4. Click Update user.

8 Initial Start-up
Result The password for the existing user account is changed.
8.3.7 Settings menu

These settings are only required for access to KAESER CONNECT via web browser.
The following settings are possible.

■ Units
■ Date format
■ Time format
Fig. 27 Settings menu
For example, you want to convert your units to US values:
1. Click the Settings menu element.

2. Click the arrow key for the unit of pressure.
A selection list of units of pressure is displayed.
3. Set the appropriate pressure unit (psi).
4. Click the arrow key for the unit of temperature.
A selection list of units of temperature is displayed.
5. Set the appropriate temperature unit (°F).
6. Set additional units and date and time formats.

8 Initial Start-up
8.3.8 Save data menu

The Backup menu allows you to download data from SIGMA CONTROL 2 to the Internet-capable
device.
The following backup types are available:

■ Backup all
■ Log files
■ Settings
■ User information
1. Click the Backup menu element.
Fig. 28 Backup menu
2. Set the required backup type in the Select source: option.

3. Click Backup.
Result The data are downloaded to the Internet-capable device.
8.3.9 KAESER CONNECT exit

In order to close KAESER CONNECTfor SIGMA CONTROL 2, click Logout in the header.
➤ Click Logout.
Result The system displays a message confirming the successful logout.

8 Initial Start-up
8.4 Pressure parameters of the machine

This chapter contains instructions for how to display and adjust the pressure parameters of the ma‐
chine.
The chapter is divided into the following sections:

■ 8.4.1: Displaying pressure parameters
■ 8.4.2: Setting pressure parameters
"Display" means that the parameter will only be shown.

"Setting:" means that the parameter can also be changed.
Parameters Explanation
pRV Display:
Actuating pressure of the safety valve on the oil separator tank
pE Pressure increase
Setting:
■ pE SP: Switching point for pressure increase; upper safety limit for machine
maximum pressure; in an external LOAD control, this value is used to switch
the machine from LOAD to IDLE in the event of a fault.
■ pE SD: Switching differential of pressure increase
ΔpFC Limiting value for machines with frequency-controlled drive (SFC).
Setting:
■ dp FC: Limit of lowest flow rate. When the value [switching point system set-
point pressure +dp FC] is exceeded, the compressor switches from LOAD to
IDLE.
Nominal Display:
pressure Nominal press.:The compressor is designed for this pressure (maximum network
nominal pressure)
Setpoint Network nominal pressure can be regulated to 2 values: pA and pB.
pressure
Setting:
■ Switching point pA or control pressure pA in machines with frequency convert‐
er (SFC)
■ Switching point pB or control pressure pB in machines with frequency convert‐
er (SFC)
System A warning message is displayed when the limit value for the network pressure is
pressure low reached.
Setting:
■ SD: Switching differential for network pressure low
↓: Switching point for network pressure low
■ Option: Configure the output signal
Warning message displayed or an additional output signal is sent, e.g., to a
control centre

8 Initial Start-up
Parameters Explanation
Cut-in Display:
pressure min For design reasons, pressure can only be built up above this value.
Tab. 53 Compressor pressure parameters
➤ Set the parameters according to the following specifications
8.4.1 Displaying pressure parameters

Open the menu for pressure parameters.
1. Open the 5.2.2 <Configuration – Pressure control – Pressure settings> menu.

2. Press «Enter».
The Pressure settings menu is displayed
5.2.2 Pressure settings Menu
Setpoint pressure
pA SP: 8.0bar ¦ SD: −0.5bar Active line
pB SP: 7.5bar ¦ SD: −0.4bar
·········
System pressure low ☐
↓ < 5.0bar ¦ SD: 0.50bar
Display further parameters
1. Use «Up» or «Down» to select the Cut-in pressure min line.

↓ < 5.0bar ¦ SD: 0.50bar
ta: 600s
DOR1.03 ☐¦Logic: +
------------------------------
Cut-in pressure min : 5.0bar Active line
2. Select further parameters with the «Up» and «Down» keys.
8.4.2 Setting pressure parameters

8.4.2.1 Setting the network nominal pressure: pA and pB
The pressure parameters can only be set within certain limits:

Nominal machine pressure ≥ SP: pA /pB ≥ Min. cut-in pressure* + switching differential
Tab. 54 Setting limits for the network nominal pressure (* Cut-in pressure min)

8 Initial Start-up
The machine switches to LOAD under the following condition:

Network pressure ≤ SP: pA /pB - switching differential
Tab. 55 Pressure condition for LOAD
The machine switches to IDLE under the following conditions:

Network pressure = Network nominal pressure
Tab. 56 Pressure conditions for IDLE

2. Use «Up» or «Down» to select the pASP line.
Setpoint pressure
·········
↓ < 5.0bar ¦ SD: 0.50bar
3. Press «Enter».
4. Use «Up» or «Down» to set the pA SP value.
5. Press «Enter».
6. Set the SD switching differential in the same manner.
7. If necessary, adjust the value for the pB SP and the SD switching differential in the same way.
Result The parameters for the network nominal pressure pA and pB are set.
8.4.2.2 Setting "System pressure low" parameters
When the network pressure drops to the value System pressure low, SIGMA CONTROL 2 displays
a warning message for insufficient network pressure.
The switching differential influences the pressure at which the message can be acknowledged or
the optionally activated output will again switch:
Message Output
5.0 bar Message coming Active
5.5 bar Message going Inactive
Tab. 57 Example: activated output

8 Initial Start-up
2. Use «Up» or «Down» to select the ↓< line.

↓ < 5.0bar ¦ SD: 0.50bar current network pressure low point
ta: 600s
DOR1.03 ☐¦Logic: +
------------------------------
Cut-in pressure min : 5.0bar
3. Press «Enter».
4. Use «Up» or «Down» to set the value for System pressure low.
5. Press «Enter».
6. If necessary, adjust the value for the SD switching differential in the same way.
8.4.2.3 Setting the SD switching differential of the pressure increase
The pressure increase pE SP serves as a safety limit when the machine is externally controlled.
When the network nominal pressure reaches the value pE SP (for example, when the external con‐
trol functions incorrectly) the machine switches to IDLE. The warning message External load
signal? is triggered.
The parameter for pE SP pressure increase is pre-set and cannot be changed. You can, however,
adjust the SD switching differential.
Displaying and adjusting the pressure increase parameters:

Pressure increase Display parameters Setting parameters
Switching point pE SP x –
Switching differential SD x x
x ≙ fitted, − ≙ not fitted
Tab. 58 Displaying and setting parameters

8 Initial Start-up
2. Use «Up» or «Down» to select the pE SP line.

pRV: 16.0bar
------------------------------
Pressure rise
pE SP: 8.4bar ¦ SD: −0.6bar Active line
ΔpFC: 0.20bar
·········
3. Press «Enter».
4. Use «UP» or «DOWN» to set the required value for SD.
5. Press «Enter».
8.4.3 Activating/deactivating the «LOAD/IDLE» key

In order to prevent unauthorised users from switching the machine to IDLE, you can deactivate the
«LOAD/IDLE» key on the SIGMA CONTROL 2 operating panel.
1. Open the 5.2.3 <Configuration – Pressure control – Load control> menu.

2. Use «Up» or «Down» to select the Key idle line.
3. Press «Enter».
The check box Key idle will flash.
5.2.3 Load control Menu
Logic : +
loc.-load RC DI1.07 ☑
Logic : +
·········
Key remote: ☐
Key idle: ☑ Active line with deactivated check box


8 Initial Start-up
8.5 Machine start and machine stop
5. Press «Enter».
The «IDLE» key is de-activated.
Logic : +
loc.-load RC DI1.07 ☑
Logic : +
·········
Key remote: ☐
Key idle: ☐ Active line with deactivated check box
Result Thus, it is ensured that unauthorised users can press the «IDLE» key without the machine switch‐
ing to IDLE.

➤ In addition to manually starting the machine locally, you have the following alternatives:
Function State on delivery, setting See

Automatic start/stop in timer mode No clock (time) program set 8.5.1
Holidays Not set 8.5.2
Controlling machine from a remote location Deactivated 8.5.3
"Venting" function Activated 8.5.5
"Autostart" function Activated 8.5.6
Tab. 59 Settings for machine start and machine stop
8.5.1 Automatic start/stop in timer mode

Overview
■ Open the Compressor clock menu
■ Set clock program
■ Activate the «Timer» key
■ Activating time control
8.5.1.1 Compressor clock

8 Initial Start-up
1. Open the 6 Compressor clock menu.

The Compressor clock menu is displayed
6 Compressor clock Menu
Key clock : ☐ The time control key is activated
Reset : ☐ All current switching points are reset
·········
01 n.a. 00:00AM off Active line
02 n.a. 00:00AM off
03 n.a. 00:00AM off
User-defined clock program

No.: Day Time Function
01
02
03
04
05
06
07
08
09
10
Tab. 60 User-defined clock programme machine ON/OFF
8.5.1.2 Setting the clock program (example)
When setting a clock programme for the first time, note first the switching times on the "User-
defined clock programme" table for example.
In addition to individual weekdays, the controller has the following cycles:

■ Mon-Thu
■ Mon-Fri
■ Mon-Sat
■ Mon-Sun
■ Sat-Thu
You can also program an OFF time (plant vacation shut-down) (see Section 8.5.2).
Example
■ Machine ON: On weekdays 06:30AM – 05:00PM, Fridays 06:30AM – 03:00PM
■ Machine OFF: Sat – Sun and during midday break 12:00PM – 01:00PM

8 Initial Start-up
The following switching points result:

No.: Day Time Function
01 Mon-Fri 06:30AM on
02 Mon-Fri 12:00PM off
03 Mon-Fri 01:00PM on
04 Mon-Thu 05:00PM off
05 Fri 03:00PM off
Tab. 61 Example of a machine ON/OFF clock program
1. Open the 6Compressor clock menu.

2. Use «Up» or «Down» to select the 01 line.
·········
01 n.a. 00:00AM off Active line with switching point 01
02 n.a. 00:00AM off Switching point 02
3. Press «Enter».
The n.a. indication flashes.
4. Use «Up» or «Down» to set the weekdays.
5. Press the «Enter» key.
7. Press «Enter».
The display for hours, 00:00 flashes.
10. The display for minutes, 00:00 flashes.

8 Initial Start-up

·········
01 Mon-Fri 06:30AM on Switching point 01 is set
02 Mon-Fri 12:00PM off Switching point 02 is set
03 Mon-Fri 01:00PM on Switching point 03 is set
04 Mon-Thu 05:00PM off Switching point 04 is set
05 Fri 03:00PM off Switching point 05 is set

The on/off indicator flashes.
15. Use «Up» or «Down» to set the Compressor On action.
The Compressor ON action is set for the first switching point.
17. Set the other switching points in the same manner.
Result Weekdays, time and the Compressor ON/Compressor OFF actions are set for all switching points
of the user-defined clock program.
8.5.1.3 Activate the «Timer» key
1. Use «Up» or «Down» to select the Key clock line.

2. Press «Enter».
The check box Key clock will flash.
Key clock :☑ Active line with deactivated check box
Reset :☐
01 Mon-Fri 06:30AM on Switching point 01:
02 Mon-Fri 12:00PM off Switching point 02
03 Mon-Fri 01:00PM on Switching point 03

4. Press «Enter».
Result The «Time control» key is activated.

8 Initial Start-up
8.5.1.4 Activating time control
Precondition The «Time control» key is activated; see chapter 8.5.1.3.
➤ Press the «Time control» key on the SIGMA CONTROL 2 operating panel to activate the time
control.
Result The Time control LED on the operating panel of the SIGMA CONTROL 2 signalises with green
continuous light that the machine is operated with activated time control.
The time control of SIGMA CONTROL 2 switches the machine according to the defined switching
points of the time program.
8.5.2 Setting the company shut-down

In addition to the weekly repeating settings of the time control, you can also set a longer lasting
shut-down time. For company shut-down, see the time as follows:
1. Open the 5.4.2 <Configuration – Compressor start – Compressor off> menu.

2. Use «Up» or «Down» to select the Start line.
5.4.2 Compressor off Menu
·········
Holidays : ☐
Start : 01/01/16 Active line
00:00AM
End : 01/01/16
03:00AM
3. Press «Enter».
The display for days 00.00.00 flashes.
4. Use «Up» or «Down» to set the day.
The display for months 00.00.00 flashes.
6. Use «Up» or «Down» to set the month.
The display for years 00.00.00 flashes.
8. Use «Up» or «Down» to set the years.
9. Press «Enter».
10. Press «Down».
The display for hours 00:00:00 flashes.
The display for minutes 00.00.00 flashes.

8 Initial Start-up

The date and time for the start of the company shut-down are set.
16. Se the date and time for the end of the company shut-down in the same manner.
·········
Holidays : ☐
Start : 12/23/16 Date for start
05:00PM Time for start
End : 01/04/17 Date for end
06:30AM Time for end
17. Use «Up» or «Down» to select the Holidays line.

·········
Holidays : ☐ Active line

The check box Holidays will flash.
19. Press «UP».
·········
Holidays : ☑ Active line with deactivated check box
Result In this example, a company shut-down (standstill time) for the time between 12/23/16 / 05:00PM
until 01/04/17 / 06:30AM has been set for the machine.
8.5.3 Controlling machine from a remote location

If the machine is to be started and stopped from a remote control centre, provide the following set‐
tings:

8 Initial Start-up
Overview
■ Make the electrical connection (a spare input for the remote contact is to be found in the elec‐
trical wiring diagram for the machine, DI 1.07 being preferred).
■ Switch machine start to remote mode
■ Activating the «remote control» key
■ If necessary, activate the «Time control» key and configure the clock program (see chap‐
ter 8.5.1.2).
■ If required, assign a different input for the remote contact RC.
■ Press the «Remote control» key.
8.5.3.1 Switch machine start to remote mode
Two methods are available to start the machine remotely from a control centre:
■ Variant A: Start the machine with the input signal from the remote control centre.
■ Variant B: Starting the machine from the remote control centre in addition to a configured
ON/OFF clock program.
The machine can be started from the remote control centre even though the time control is ac‐
tivated and the ON/OFF program has selected OFF at this point in time.
Precondition The electrical connection has been made.

Access level 2 is activated.
1. Open the 5.4.1 <Configuration – Compressor start – Compressor on> menu.

2. Use «Up» or «Down» to select the Remote mode line.
4. Press «Enter».
The currently active operating mode flashes.
5.4.1 Compressor on Menu
Local mode:
Key
Remote mode:
Key Active line
------------------------------
RC DI1.07 ok ☑
5. Use «Up» or «Down» to set the Key + remote contact input.

8 Initial Start-up
6. Press «Enter».
Local mode:
Key
Remote mode:
Key + remote contact Active line
------------------------------
RC DI1.07 ok ☑
Result The machine start is set to Remote mode Key + remote contact.
8.5.3.2 Assigning another input
Inputs already assigned cannot be further assigned.
1. Use «Up» or «Down» to select the RC line.

------------------------------
RC DI1.07 ok ☑ Remote contact DI 1.07 (default)
Logic : +
·········
Key remote :☑
Key clock :☐
2. Press «Enter».
The display for the currently set input flashes.
3. Select another input with the «Up» or «Down» keys.
4. Press «Enter».
The input has now been assigned.
5. Press the «Remote control» key to enable the machine to be started from the remote control
centre.
If your entry is rejected it means that the input is already assigned.
➤ Select a different input.

➤ Activate remote control see chapter 8.2.13.

8 Initial Start-up
8.5.5 "Venting" function

Prior to the machine's transition from the operating modes LOAD to READY you can also activate
an IDLE phase ("venting" function). The duration of the IDLING phase can be timed and/or regula‐
ted by internal pressure. The machine-dependent venting phase between the LOAD and READY
operating modes ensures load changes at minimum material stresses and is therefore activated at
the factory (default setting). If this function is not required, you can deactivate it.
1. Open the 5.4.2 <Configuration – Compressor start – Compressor off> menu.

2. Use «Up» or «Down» to select the Start line.
Venting period : ☑ Factory setting: "Venting" function activated
·········
Holidays : ☐
Start : 01/01/16
00:00AM
End : 01/01/16
3. Press «Enter».
The check box Venting period will flash.
4. Press «UP».
Venting period : ☐ Active line with deactivated check box
·········
Holidays : ☐
Start : 01/01/16
00:00AM
End : 01/01/16
5. Press «Enter».
Apart from the discontinuation of the pressure or load requirement, venting of the machine is also
executed when the «OFF» key is pressed.
Press the «OFF» key twice to immediately shut the machine off.
➤ Press the «OFF» key twice.
Result The machine is switched off without venting (IDLE phase).
8.5.6 "Autostart" function

The Autostart: function is activated (default setting).
To avoid overloading the mains power supply through several machines starting simultaneously a
delay period determining the autostart of each machine can be entered.

8 Initial Start-up
1. Open the 5.4 <Configuration – Compressor start> menu.

2. Press «Enter».
The Compressor start menu is displayed
5.4 Compressor start Menu
▶1 Compressor on Active line
▶2 Compressor off
·········
Autostart: ☑ Autostart activated
Target 10s ¦ Actual 0s Set/expiring delay time
·········
Setting the autostart delay period
If you operate several machines, it is better to start them in sequence.

Use the "Delay time for autostart" table to plan the time-delayed machine start. In the "Start
period" column, enter for each individual machine the real time required for the first possible
LOAD. Cumulatively add these values in the "Delay time" column. Enter the value of the de‐
lay time of each machine in the corresponding controller.
The first machine may start immediately and does not require a delay time.
Machine number Start time [sec] Delay time [sec]

1 –– ––
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Tab. 62 Autostart delay period

8 Initial Start-up
1. Open the 5.4 Compressor start menu.

2. Use «Up» or «Down» to select the Target line.
▶2 Compressor off
·········
·········
3. Press «Enter».
The Target display flashes.
4. Use «Up» or «Down» to set the time delay in seconds.
▶2 Compressor off
·········
Target 12s ¦ Actual 0s
·········
5. Press «Enter».
Result The delay time for an autostart after a power failure has been adjusted from 10 s to 12 s.
Deactivate/activate the Autostart function
1. Use «Up» or «Down» to select the Autostart: line.

▶2 Compressor off
·········
Autostart: ☐ Autostart deactivated
·········
2. Press «Enter».
The check box Autostart: will flash.
The check box Autostart: is deactivated.

8 Initial Start-up
8.6 Control modes
4. Press «Enter».
The Autostart: function can be activated in the same manner.

Result Autostart after a power failure is deactivated.
8.6 Control modes

The controller is provided with various control modes that can bring about different capacity utilisa‐
tion depending on machine application. Chapter 5.7 provides a comprehensive description of all
control modes.
8.6.1 Setting the control mode

These control modes are possible:
■ DUAL
■ QUADRO
■ VARIO
■ DYNAMIC
■ Continuous
■ The standard setting of the control mode depends on the machine type.
■ The machine-dependant venting phase between the LOAD and READY operating modes
ensures load changes at minimum material stresses.
1. Open the 5.3 <Configuration – Control mode > menu.

2. Use «Up» or «Down» to select the Local mode line.
5.3 Control mode Menu
Local mode: Active line
DUAL
------------------------------
▶1 Venting period Venting period menu
·········
▶2 DUAL
3. Press «Down».
The currently set control mode is displayed.

8 Initial Start-up
8.6 Control modes
4. Press «Enter».
The currently active control mode flashes.
5.3 Control mode Menu
Local mode: Active line
DUAL
------------------------------
▶1 Venting period Venting period menu
·········
▶2 DUAL
5. Use «Up» or «Down» to set the control mode.

6. Press «Enter».
8.6.2 Setting the DUAL control mode

The machine is READY when the specified idle time has elapsed.
The shorter the period, the more often the machine will switch from IDLE to READY.
SIGMA CONTROL 2 will take into account the maximum motor / engine switching capacity.
Depending on the machine type, the machine's motor / engine may not fall below a minimum idling
or standstill time.

The DUAL control mode is set.
1. Open the 5.3.2 <Configuration – Control mode – DUAL> menu.

5.3.2 DUAL Menu
Idle period
Target 240s ¦ Actual 0s active line

8 Initial Start-up
8.6 Control modes
2. Use «Up» or «Down» to select the Target line.

5.3.2 DUAL Menu
Idle period
Target 300s ¦ Actual 0s increased idle time (e.g. 300 s)
3. Press «Enter».
The seconds display flashes.
5. Press «Enter».
8.6.3 Setting the QUADRO control mode

When the minimum running period has elapsed, the machine switches from IDLE to READY. The
expired duration of the unloaded period controls whether the machine switches from IDLE to
READY only after expiry of the set unloaded period or after expiry of the venting period.

The QUADRO control mode is set.
1. Open the 5.3.3 <Configuration – Control mode – QUADRO> menu.

5.3.3 QUADRO Menu
Min. run period
Target 240s ¦ Actual 0s Set value for minimum run-time
·········
Unloaded period
Target 240s ¦ Actual 0s Set value for unloaded period
2. Use the «Up» or «Down» keys to select the Min. run period line.
4. Press «Enter».
The seconds display flashes.

8 Initial Start-up
8.7 Electronic Thermal Management

5.3.3 QUADRO Menu
Min. run period
Target 260s ¦ Actual 0s changed set-point for minimum run-time
·········
Unloaded period
Target 260s ¦ Actual 100s changed set-point for unloaded period
6. Press «Enter».
7. If necessary, adjust the target value for the Unloaded period switching differential in the same
way.
Further information See chapter 5.7 for an overview of the control modes.

The design of the electronic thermal management (ETM) is determined by your machine's options.
Type Electronic thermal management (ETM)
Machine type 1 Without heat recovery
Machine type 2 Heat recovery without electrically controlled valve
Machine type 3 Heat recovery with adjustable airend discharge temperature for the
regulator of the electrically controlled heat recovery valve
Tab. 63 Machine type and ETM design
Note:
■ The machine runs with increased airend discharge temperature when heat recover is set to ac‐
tive.
■ An increased airend discharge temperature causes poorer efficiency of the compressed air
generation.
1. Check whether your machine is fitted with an electronic thermal management.

2. Check whether the nominal value of the discharge temperature for the regulator of the electri‐
cally controlled heat recovery valve can be adjusted.
3. Activate the heat recovery only if you can use the machine's exhaust heat.
4. Deactivate the heat recovery if you cannot use the machine's exhaust heat.
8.7.1 Activating the heat recovery for machine type 2

The heat recovery can be set for local operation, as well as for remote operation. In remote opera‐
tion, the heat recovery can be controlled by means of a load remote contact.
Example: Heat recovery for machines in "remote operation".

8 Initial Start-up
1. Open the 5.6 <Configuration – ETM> menu.

2. Use «Up» or «Down» to select the Remote mode: line.
5.6 ETM Menu
Heat recovery
Local mode:
inactive
Remote mode:
inactive Active line
current inactive Status of heat recovery

4. Press «Enter».
5. Use «Up» or «Down» key to set the active option.
6. Press «Enter».
5.6 ETM Menu
Heat recovery
Local mode:
inactive
Remote mode:
active Active line
current active Status of heat recovery
7. If a load remote contact controls the remote control, set the remote contact option.
5.6 ETM Menu
Remote mode:
remote contact
------------------------------
RC DI1.07 ok ☑ Active line
Key remote :☑
8. Subsequently, set the requested digital input DI in line RC and activate the corresponding
check box.
9. Activate the «Remote control» key (see chapter 8.2.13).
Result The heat recovery system in "remote operation" has been activated.
The «Remote control» key is activated.
No other settings are required.

8 Initial Start-up
The current status for the heat recovery is displayed in the current line.
8.7.2 Activating the heat recovery for machine type 3

Example: Heat recovery with adjustable setpoint for the airend discharge temperature for the
regulator of the electrically controlled heat recovery valve for machines in "local operation".

2. Use «Up» or «Down» to select the Local mode: line.
5.6 ETM Menu
Heat recovery
Local mode:
inactive Active line
Remote mode:
inactive
current inactive Status of heat recovery

4. Press «Enter».
5. Use «Up» or «Down» key to set the active option.
6. Press «Enter».
5.6 ETM Menu
Heat recovery
Local mode:
active Active line
Remote mode:
inactive
Result The heat recovery system has been activated.
Further information The setpoint value for the airend discharge temperature for the regulator of the electrically control‐
led heat recovery valve can be set manually; see chapter 8.7.2.1.

8 Initial Start-up
8.7.2.1 Setting the setpoint value for the airend discharge temperature
The airend discharge temperature and the water outlet temperature are related. To increase
the value for the water outlet temperature, you must increase the setpoint value for the airend
discharge temperature.
Maximum setting = 92 °C.
The specific value of the discharge temperature depends on the respective application for the
heat recovery at the customer's.

2. Use «Up» or «Down» to select the ADT controller line.
5.6 ETM Menu
·········
Oil cooler
ADT controller Active line
·········
▶1 Oil cooler Indication
▶2 ADT controller Indication
3. Press «Enter».
4. Use «Up» or «Down» to set the setpoint for the ADT controller.
5.6 ETM Menu
·········
Oil cooler
ADT controller Active line
·········
▶1 Oil cooler Indication
▶2 ADT controller Indication
5. Press «Enter».
Result The setpoint value of the airend discharge temperature for the regulator of the electrically control‐
led heat recovery valve is set.
8.7.3 Deactivating heat recovery

If the heat recovery is set to inactive, you have improved efficiency in compressed air genera‐
tion.
➤ Set the heat recovery to "inactive" if you cannot use the machine's exhaust heat.

8 Initial Start-up
8.8 Refrigeration dryer

Overview:
■ Setting the operating mode
■ Output messages
■ Procedures following a fault of the refrigeration dryer:
─ The quality of the compressed air has priority:
Immediately contact KAESER SERVICE
■ Procedures following a fault of the refrigeration dryer:
─ Compressed air supply has priority:
Activate fault mode without refrigeration dryer
➤ It is mandatory to follow the procedures indicated according to the priorities established for the
compressed air quality or compressed air supply!
8.8.1 Setting the operating mode

The CONTINUOUS or TIMER modes can be activated for the refrigeration dryer.
If the TIMER setting is used, the refrigeration dryer is shut-down under timing control whenever
compressed air is not required.
The operating temperature in the refrigeration dryer is kept constant within narrow limits under this
method of control by cycling the refrigerant circulation.
1. Open the 5.9 <Configuration – Refrigeration dryer> menu.

2. Use «Up» or «Down» to select the Compressor ready: line.
5.9 Refrigeration dryer Menu
Control mode
Compressor ready:
Continuous Active line
off
·········
4. Press «Enter».

8 Initial Start-up
5. Use «Up» or «Down» to set the Timer operating mode.

Control mode
Compressor ready:
Timer Active line
off
·········
6. Press «Enter».
Result The CONTINUOUS operating mode has been switched to the TIMER operating mode.
8.8.2 Output messages

If required, you can activate messages regarding the operating temperature of the refrigeration dry‐
er as a binary signal.
You can assign to DOR or DOT.
If you have correctly parameterised, ok will be displayed.

2. Use «Up» or «Down» to select the Temperature line.
Temperature ↑ Active line, temperature high
DOR1.07 ☐¦Logic : +
DOT1.01 ☐¦Logic : +
Temperature⇟

4. Press «Enter».

8 Initial Start-up
5. Select a free input DOR with the «Up» or «Down» key.

Temperature ↑ Temperature high
DOR1.05 ☐¦Logic : + Active line, example: DOR selected
Temperature⇟ Temperature low
6. Press «Enter».
8. Press «Enter».
9. Press «UP».
Temperature ↑ Temperature high
DOR1.05 ok ☑¦Logic : + Active line
Temperature⇟ Temperature low

ok is displayed in the active line.
11. Set the Temperature ⇟ message if necessary in the same way.
Upon activation of the check box, err is displayed.
➤ The parameterisation is incorrect.
➤ Deactivate the check box.
➤ Assign another and/or free output.
8.8.3 Fault in the refrigeration dryer – compressed air quality has priority
After a fault occurs in the refrigeration dryer, the SIGMA CONTROL 2 shut the machine down.
No compressed air is delivered.
Because compressed air quality (dried compressed air) is crucial, you must call
KAESER SERVICE immediately.
Precondition The operator decides: Compressed air quality has a higher priority than the compressed air supply
1. Keep machine shut down because the required compressed air quality is no longer delivered.
2. Immediately contact KAESER SERVICE.
The KAESER Service Technician eliminates the fault and executes a reset.
The machine is ready for the delivery of high-quality, dried compressed air.

8 Initial Start-up
8.8.4 Fault in the refrigeration dryer – compressed air supply has priority
NOTICE
Higher residual humidity in the compressed air
Corrosion due to higher residual humidity in the compressed air.
➤ Assess a "Fault mode without refrigeration dryer" in respect to the further use of the
compressed air.
After a fault occurs in the refrigeration dryer, the SIGMA CONTROL 2 shut the machine down.
In order to ensure compressed air supply for a defined period of time, the operator can activate the
Error operation without RD function. The quality of the compressed air (dried compressed air) is
compromised in this case. The 0069 Error operation without RD
→ Call service! warning message is displayed. The 0069 warning message remains active for the
entire time of operation in fault mode.
Precondition The operator decides: Compressed air supply has a higher priority than the compressed air quality

2. Use «Up» or «Down» to select the Error operation without RD line.
·········
Safe compressed air quality
·········
active: ☐ Active line
Run time max.: 8h Running time (fixed)
4. Press «Enter».
·········
Safe compressed air quality
·········
active: ☑ Active line
Run time max.: 8h Running time (fixed)
6. Press «Enter».
Result "Fault mode without refrigeration dryer" function is activated.

The compressor provides compressed air for connected consumers.

8 Initial Start-up
8.9 Setting the machine for local mode
The compressed air delivered in this mode contains a higher residual humidity because the func‐
tion of the refrigeration dryer is defective.

In local mode the machine is regulated with the nominal pressure pA or pB . The controller offers
the following modes of operation:
Operating mode Description See

chapter
pA The machine is controlled by the nominal pressure pA 8.9.3.3
pB The machine is controlled by the nominal pressure pB
pA/pB Clock The changeover between the nominal pressures pA and pB is regu‐ 8.9.2
lated by a timer program
pA/pB Cycle The changeover between the nominal pressures pA and pB is regu‐ 8.9.3
lated by a programmed time pulse
Tab. 64 Operating modes in local operating mode (local mode)
➤ Set the nominal pressure as described in chapter 8.4.

Overview
■ Open the Configuration menu
■ Set the timing program (see chapter 8.9.2)
or set the timer (see chapter 8.9.3)
■ Setting local operating mode
8.9.1 Menu Load control

1. Open the 5.2.3 <Configuration – Pressure control – Load control > menu.
The Load control menu is displayed.
8.9.2 Setting the nominal pressure change via timing program

Note the setting sequence:
➤ First, set the timing program.
➤ Then select the operating mode.
Overview
■ Deleting an existing timing program
■ Entering the weekday for the first switching point
■ Enter the time of the first switching point.
■ Set the nominal pressure for the first switching point pA or pB
■ Set up any further switching points.
■ Select the operating mode pA/pB Clock : see chapter 8.9.3.3.

8 Initial Start-up
User-defined timer program

No.: Day Time Nominal pressure
01
02
03
04
05
06
07
08
09
10
Tab. 65 User-defined timing program for nominal pressure change
When setting a clock programme for the first time, note first the switching times on the "User-
defined clock program" table for example.
In addition to individual weekdays, the controller has the following cycles:

■ Mon-Thu
■ Mon-Fri
■ Mon-Sat
■ Mon-Sun
■ Sat-Thu
Example
■ Base load period: Weekdays from 06:30AM–05:00PM, Fridays 06:30AM–03:00PM
■ Low load period: Midday from 12:00PM–01:00PM and remaining time
The timing program is established with the following switching points (maximum 10 switching
points available):
No.: Weekday Time Nominal pressure

01 Mon-Fri 06:30AM pA on
02 Mon-Fri 12:00PM pB on
03 Mon-Fri 01:00PM pA on
04 Mon-Thu 05:00PM pB on
05 Fri 03:00PM pB on
Tab. 66 Example: Switching points, nominal pressure change
Deleting an existing timing program
Delete an existing timing program as follows:

8 Initial Start-up
2. Use the «Up» or «Down» keys to select the pA/pB Clock line.
The Timing program menu is displayed.
4. Use the «Up» or «Down» keys to select the Reset line.
5.2.3.1 pA/pB Clock Menu
Reset :☐ Active line
·········
01 Mon-Fri 06:30AM pA
02 Mon-Fri 12:00PM pB
03 Mon-Fri 01:00PM pA
04 Mon-Thu 05:00PM pB

The check box Reset: will flash.
6. Press the «UP» key.
The timing program is now deleted.
Setting the switching point
1. Open the 5.2.3.1 <Configuration – Pressure control – Load control – pA/pB Clock > menu.
The Timing program menu is displayed.
Reset :☐
·········
01 n.a. 00:00AM pA
02 n.a. 00:00AM pA
03 n.a. 00:00AM pA
04 n.a. 00:00AM pA

The display for the set operating mode flashes.
Reset :☐
·········
01 Mon-Fri 06:30AM pA Setting for weekdays, time, pA
02 Mon-Fri 12:00PM pB Setting for weekdays, time, pB
03 Mon-Fri 01:00PM pA
04 Mon-Thu 05:00PM pB

8 Initial Start-up
3. Use «Up» or «Down» to set the weekdays.

The display for hours, 00: 00 flashes.
9. The mnutes display 00: 00 flashes.
10. Use «Up» or «Down» keys to set the minutes.
12. Press the «Right » key.
The pA/pB indicator flashes.
14. Adjust the setting with the «Up», «Down» pA or pB keys.
16. Set the other switching points in the same manner.
The timing program is now set.
17. Select the operating mode pA/pB Clock : see chapter 8.9.3.3.
8.9.3 Setting the nominal pressure change via timer

Overview
■ Delete the old timer configuration, if necessary
■ Set timer period pA and pB
■ Set starting point for pA or pB
■ Select the operating mode pA/pB Cycle : see chapter 8.9.3.3
8.9.3.1 Set timer period pA and pB
Observe and keep to the configuration sequence. The pA/pB Cycle operating mode must not
be activated when configuring the timer period.
➤ First set the timer and then the operating mode, or set another operating mode before‐
hand.
2. Use the «Up» or «Down» keys to select the pA/pB Cycle line.
The pA line is displayed.
The display for the cycle duration in hours, 00 flashes.

8 Initial Start-up

▶1 pA/pB Clock
·········
pA/pB Cycle
pA : 10h – 10h pB : 18 h – 18h Active line, manually set setpoint value – automati‐
cally elapsing value (example)
1.Start pA ¦ 00:00
·········

8. Set the cycle duration for pB in the same way.
The cycle duration for the nominal pressure pA and pB is set.
8.9.3.2 Set starting time for pA or pB
1. Use the «Up» or «Down» keys to select the 1.Start pA line.

The display for hours, 00: 00 flashes.
▶1 pA/pB Clock
·········
pA/pB Cycle
pA : 10h – 10h pB : 18 h – 18h Active line, starting time
1.Start pA ¦ 06:30AM
·········

The minutes display, 00 : 00 flashes.
6. Use «Up» or «Down» keys to set the minutes.
Result The starting time for pA is set.
The cycle is set to start with pB .

➤ Press the «Enter» key and adjust with «Up» 1.Start pB key.
8.9.3.3 Setting local mode

The timing program or timer is set up.

8 Initial Start-up
8.10 Setting the machine for master control operation
2. Use the «Up» or «Down» keys to select the Local mode line.
The display for the set operating mode flashes.
Local mode : pA/pB Cycle Active line
Remote mode : pB
------------------------------
▶1 pA/pB Clock
·········
pA/pB Cycle
4. Press the «Up» or «Down» keys to set the desired operating mode (pA , pB , pA/pB Clock ,
pA/pB Cycle ).
Result The timer setting is completed.

8.10.1 Overview of the different master operating modes
The controller offers several possibilities to work together with other controllers:
Method Description Section

Master control with SAM 4.0 The operating mode settings on the SIGMA 8.10.2
CONTROL 2 must be changed via a
SIGMA NETWORK to enable control by a
SIGMA AIR MANAGER 4.0.
Interconnected operation via Using the PROFIBUS Master (e. g. 8.10.3
PROFIBUS SIGMA AIR MANAGER), the controller (and
(only available with SIGMA therefore the machine) receives, for example, the
CONTROL 2 - prepared for connec‐ LOAD, IDLE or local mode command. The sys‐
tion to a control centre with optional tem setpoint pressures pA and pB are irrelevant
communications module) for the LOAD/IDLE signals.
Master control of two compressors The two SIGMA CONTROL 2 controllers operate 8.10.4
with SIGMA CONTROL 2 via Ether‐ as master and slave. The slave receive the com‐
net interface mand to switch between the two system setpoint
pressures pA and pB from the master.

8 Initial Start-up
Method Description Section

Master control via LOAD remote con‐ LOAD remote contact 8.10.5
tact. An input signal from a superordinate controller
Master control via a LOAD remote switches the machine to LOAD or IDLE. The set‐
contact is another method of control‐ point pressure settings pA and pB have no rele‐
ling the machine externally. vance.
Local/LOAD remote contact: 8.10.6
Using two inputs, a master controller (e.g.
MVS 8000) switches the machine between
LOAD/IDLE and local operation.
Setpoint pressure pre-selection pA/pB remote contact: 8.10.7
An input contact provides the signal to switch
from the system setpoint pressure pA to pB.
Master control of machines regulated On machines with the same flow rate, 8.10.8.1
by pressure switch SIGMA CONTROL 2 controls the pressure switch
via a floating relay output.
On machines supplying an unequal flow rate, the 8.10.8.2
pressure ranges are matched to each other.
Tab. 67 Master control (interconnected operation) – overview
Further information Examples of timing programs for equal machine loading are given in section 8.10.9.
8.10.2 SAM 4.0 mode

You must modify the settings in SIGMA CONTROL 2 for the operation via SIGMA NETWORK us‐
ing, for example, the KAESER SIGMA AIR MANAGER 4.0 (SAM 4.0).
Precondition SIGMA CONTROL 2 is connected to SAM 4.0 via SIGMA NETWORK and ready for operation (see
the SAM 4.0 operating manual in the chapter “Installation”)
Network pressure pB is set as the pressure for the “SAM 4.0 manual mode".
The remote control is activated (see chapter 8.2.13)
Setting the IP configuration
1. Open the 8.1.1 <Communication – Ethernet/SIGMA NETWORK – IP configuration> menu.

8 Initial Start-up

IP address 169.254.100.103 active line, factory setting
Subnet mask 255.255.000.000
Gateway 169,254,100.97
DNS Server 1 169,254,100.97
DNS Server 2 169,254,100.97
Restart network ☐
3. Set the IP address for SIGMA CONTROL 2 using the following pattern:
169.254.100.(SAM 4.0 machine number +102)
(for the setting see chapter 8.2.14).
Setting SAM 4.0 mode
The IP address for SAM 4.0 has been set on SIGMA CONTROL 2 at the factory:
169.254.100.100 and must not be changed. The same applies to Port 2000.
1. Open the 8.1.2.2 <Communication – Ethernet/SIGMA NETWORK – Connections – SAM 4.0>

menu.
2. Use «Up» or «Down» to select the SAM 4.0 active: line.
8.1.2.2 SAM 4.0 Menu
Status Counter 0
No error
------------------------------
SAM 4.0 active: ☑ Active line
Send
IP address : 169.254.100.100
3. Press «Enter».
The SAM 4.0 active: check box flashes.
4. Press «UP».
5. Press «Enter».
7. Press «Enter».

8 Initial Start-up
8. Use «Up» or «Down» to set the Send/receive value.

8.1.2.2 SAM 4.0 Menu
Status Counter 0
No error
------------------------------
SAM 4.0 active: ☑
Send/receive Active line
IP address : 169.254.100.100

10. Use «Up» or «Down» to select the Starttd line.
8.1.2.2 SAM 4.0 Menu
IP address : 169.254.100.100
Port : 2000
·········
Communication error : ☑
Start td: 15s active line
Timeout : 5s ☑

12. Use «Up» or «Down» to set the Start td value to 30 s.
8.1.2.2 SAM 4.0 Menu
IP address : 169.254.100.100
Port : 2000
·········
Start td: 30s active line
Timeout : 5s ☑

Result SIGMA CONTROL 2 communicates with SAM 4.0 via SIGMA NETWORK.
The communication is working smoothly when neither SIGMA CONTROL 2 nor SAM 4.0 report any
communication fault.

8 Initial Start-up
8.10.2.1 Reaction in the event of a communication malfunction
After switching on the power supply, monitoring for communication malfunctions is suppressed for
a period of time which can be defined by means of the Start td parameter. The setting depends on
the time passing at the bus master between return of voltage and start of communication via the
bus.
For the communication with SAM 4.0, the value of Start td must be set to 30 s.
SIGMA CONTROL 2 can monitor the bus communication at user level. For this purpose, the bus
master reads a value ("toggle bit") that changes with every bus cycle and returns it without change.
SIGMA CONTROL 2 returns a communication malfunction if the value does not change for a time
longer than set (Timeout).
Monitoring for communication malfunction can be activated if needed. For this purpose, the
Send/receive option must be set for the data exchange. Activate the Communication error
check box to enable monitoring for communication malfunctions.

8.1.2.2 SAM 4.0 Menu
IP address : 169.254.100.100
Port : 2000
·········
Communication error : ☑ active line
Start td 30s
Timeout : 5s ☑
Settings for connection to SAM 4.0.
Parameters Factory setting Set value

Check box Communication error Check box ☑ activated 1)
Start td 30 s
Timeout 5s
Check box Timeout Check box ☑ activated
1)
Prerequisite: The Send/receive option has been set
Tab. 68 Parameters for monitoring for communication malfunction
8.10.3 Setting PROFIBUS operation (SIGMA AIR MANAGER)

Only possible with SIGMA CONTROL 2 (prepared for connection to control centre)
Overview:
■ PROFIBUS DP-V0 Retrofit Kit required
■ Establishing the electrical connection
■ Set the remote operating mode pB.
■ Set the PROFIBUS interface
Precondition Retrofit kit PROFIBUS required

8 Initial Start-up
Establishing the electrical connection
Pin Assignment
1 Spare
2 Spare
3 PROFIBUS connection B
4 TTL signal RTS
5 Earth
6 +5 V for bus terminal
7 Spare
8 PROFIBUS connection A
9 Spare
Tab. 69 Pin assignment of SUB-D 9-pole interface on the PROFIBUS module
Interface plug wiring
Fig. 29 Wiring of the PROFIBUS connection

1 Terminal 1A 4 Terminal 2B
2 Terminal 1B 5 Slide switch, terminating resistor
3 Terminal 2A

8 Initial Start-up
Electrical diagram example with SIGMA AIR MANAGER (extract)
Fig. 30 Electrical diagram example with SIGMA AIR MANAGER

8 Initial Start-up
1. Connect the bus subscribers one after the other according to the pin assignment below.
2. Connect the screening to the plug housings at both ends.
3. Set the terminating resistor in the plug to ON for the first and last subscribers to the
PROFIBUS connection.
Result The terminals for the remaining bus conduit (2A/2B) are switched off.
8.10.3.1 Installing the communication module
The SIGMA CONTROL 2 communication interface is closed with a plastic cover when shipped
from the factory. Before you can insert the communication module in the X4 interface, you must
remove the plastic cover from the SIGMA CONTROL 2 . The designation of the interfaces is provi‐
ded on the rear of the SIGMA CONTROL 2.
Material Small screwdriver

Torx screwdriver, size 9
Precondition The machine is disconnected from the power supply.

The absence of voltage has been verified.
➤ Work with caution.
Remove the plastic cover.
Fig. 31 Communication interface

1 Designation of the interfaces 6 Communication interface X4 (customer in‐
2 Rear side of the SIGMA CONTROL 2 con‐ terface)
troller 7 Plastic cover
3 Ethernet interface X1 8 Fin
4 IO BUS X2 9 Communication interface X4 without plastic
5 RS485–FC (USS interface) X3 cover
1. Place the screwdriver next to the fin.

2. Insert the tip into the slot between the plastic cover and the enclosure of the
SIGMA CONTROL 2.
3. Press the screwdriver down until the fin breaks.

8 Initial Start-up
4. Break the other fins in the same manner.

5. Remove the plastic cover 7 .
Inserting and fixing the communication module

Align the communication module until both cable connectors are at the same height.
Precondition The plastic cover is removed.
Fig. 32 Insert the communication module.

1 Bay, interface X4 5 Cable connector, communication module
2 Cable connector, interface X4 6 Communication module
3 Guiding plate 7 Front plate
4 Recess, module bay
1. Align the communication module 6 .

2. Insert the communication module into the bay of interface X4 1 until it latches (see Fig. 32).
The module is correctly installed when its front plate 7 is seated solidly in the recess of the
module bay 4 .
3. Use the Torx T9 screwdriver to screw in the fixing screws.
8.10.3.2 Activating operation via PROFIBUS
Overview:
■ Set the slave number
■ Set reaction for a communication malfunction.
■ Activate the communications module
■ Activate the remote mode
Precondition The communication module is plugged and screwed into the X4 interface.
The bus is wired to the bus master.
The machine's voltage supply is activated.
The machine is parametrised as a slave in the bus master.
The bus master is operational.
Fig. 33 Front plate communication module PROFIBUS

1 Communication module PROFIBUS 3 Status LED
2 Operation LED 4 PROFIBUS-Interface

8 Initial Start-up
➤ Proceed as shown.
Activate the communications module
1. Open the 8.2 <Communication – Com-Module> menu.

The Com-Module menu is displayed
2. Use «Up» or «Down» to select the Com-Moduleactive line.
3. Press «Enter».
The Com-Module active check box flashes.
8.2 Com-Module Menu
Status Counter 1
Com-Module deactivated
------------------------------
Type None
Send/receive
Com-Module active : ☐ Active line

5. Press «Enter».
The communication module is activated.
8.2 Com-Module Menu
Status Counter 1
Com-Module deactivated
------------------------------
Type PROFIBUS
Send/receive
Com-Module active : ☑ Active line
Set the slave number
You must set the slave address for the communication with the SIGMA AIR MANAGER.
When connected to a SIGMA AIR MANAGER, the slave address is determined as follows:
Compressor number used at SIGMA AIR MANAGER +102.

8 Initial Start-up
1. Open the 8.2 <Communication – Com-Module> menu.

The Com-Module menu is displayed
8.2 Com-Module Menu
Send/receive
Com-Module active : ☑ Active line
Reset : ☐
Slave No. : 103
·········
2. Use «Up» or «Down» to select the SlaveNo. line.

8.2 Com-Module Menu
Send/receive
Com-Module active : ☑
Reset : ☐
Slave No. : 103 Active line
·········
3. Press «Enter».
The display for the slave address flashes.
4. Use «Up» or «Down» to set the slave address 104.
5. Press «Enter».
8.2 Com-Module Menu
Send/receive
Com-Module active : ☑
Reset : ☐
Slave No. : 104 Active line
·········
Communication error : ☑ Monitoring for communication malfunction is active.
Result Slave address 104 is set.
Reaction in a PROFIBUS communication malfunction
Exchange of data with a PROFIBUS connection takes place in fixed cycles. The PROFIBUScon‐
nection can be monitored with the help of the cycle time:
The bus connection is considered to be interrupted if no data is exchanged between the bus mas‐
ter and the controller (as bus subscriber) after expiry of a set time period (time-out).
Time-out monitoring is activated. You may neither adjust nor deactivate time-out for
SIGMA AIR MANAGER.

8 Initial Start-up
After switching on the power supply, the communication malfunction can be suppressed tem‐
porarily.
Monitoring for communication malfunction can be deactivated if needed. For this purpose, the
Send option must be selected for the data exchange.
■ Settings for SIGMA AIR MANAGER without SIGMA AIR CONTROL PLUS
─ Start: 30 seconds
■ Settings for SIGMA AIR MANAGER with SIGMA AIR CONTROL PLUS
─ Start: 40 seconds
1. Use «Up» or «Down» to select the Communication error line.

8.2 Com-Module Menu
Reset : ☐
Slave No. : 103
·········
Communication error : ☐ active line
Start td 30s
Timeout : 5s ☑
2. Press «Enter».
The check box Communication error will flash.
3. Press «Up».
The monitoring for communication malfunctions is active.
4. Use «Up» or «Down» to select the Starttd line.
8.2 Com-Module Menu
Reset : ☐
Slave No. : 103
·········
Communication error : ☑ Communication monitoring is activated
Start td 30s active line
Timeout : 5s ☑
5. Press «Enter».
The 00 seconds display flashes.
7. Press «Enter».
Activating the remote control

The bus master can remotely control the SIGMA CONTROL 2.

8 Initial Start-up
8.10.4 Master control of two machines in master/slave operation

Two machines with SIGMA CONTROL 2 work as master/slave in the same air network. The mas‐
ter controls the machine with the controller configured as a slave and provides the instruction for
the pA and pB target pressures.
Example: Two machines with different flow rates

Local operating mode of the master: Local mode pA/pB Clock.
■ A clock program switches between the pA and pB target pressures.
■ At peak load times, pressure is regulated to the pA target pressure.
During periods of low air demand, pressure is regulated to pB target pressure (e.g., at week‐
ends).
■ The machine with the lower flow rate is the slave.
In times with lower compressed air demand, the machine with the lower flow rate is used more
frequently.
Example: Two machines with equal flow rates

■ Local operating mode of the master: Local mode pA/pB Cycle.
(A timer switches between pA and pB target pressure).
The timer ensures even loading of both machines. The target pressures are set the same for
both machines.
■ For cycle time 1, the master regulates to pA and gives the slave the signal for pB.
For cycle time 2, the master regulates to pB and gives the slave the signal to regulate to pA.
If two machines with SIGMA CONTROL 2 are to work in master-slave mode, their controllers
must have the same software version.
➤ Follow the configuration steps as described in table 70:
Controller Procedure Chapter

Both Establishing the electrical connection 8.10.4.1
Both Set the target pressures for both, pA and pB. The pressure for the pA 8.10.4.2 and
and pB switching points is measured directly at the compressor. 8.10.4.3
Pressure losses in the network do not need to be taken into account.
Master Either set up switching times for the clock program 8.10.4.2
or set switching times for the clock 8.10.4.2
Master Set the type of LOAD control (clock program or clock) in local mode. 8.10.4.2
Slave Set remote mode pA/pB SC2 8.10.4.3
Slave Activating the remote control 8.10.4.3
Both Set IP addresses for Ethernet 8.10.4.2 and
8.10.4.3
Both Activate controller as master or slave 8.10.4.2 and
8.10.4.3
Tab. 70 Master-slave settings
8.10.4.1 Establishing the electrical connection
You need the following accessories to create the network connection with SIGMA NETWORK or
Ethernet:

8 Initial Start-up
■ SIGMA NETWORK cable (7.9679.0) or Ethernet cable with a maximum connection length of
100 m each
■ For each machine with SIGMA CONTROL 2:
─ Retrofit kit LAN RJ45 (7.5250.01870)
■ For connecting the machines to a network (LAN) or switch:
─ 2x RJ45 plug (7.7628.1)
➤ Create the electrical connection according to the local condition. For more information, see the
installation manual for the retrofit kit LAN RJ45 (7.5250.01870)
Install the Ethernet cable
Use a cross-linked Ethernet cable for the direct connection of two machines.
Fig. 34 Direct connection of two SIGMA CONTROL 2

1 Controller machine 1 (Master mode) 4 Controller machine 2 (Slave mode)
2 Ethernet interface X1 5 Ethernet interface X1
3 Ethernet cable, cross-linked
➤ Install the Ethernet cable between the two machines.

When you connect the machines to a network (LAN) or switch (when using KAESER CONNECT
for example).
➤ Install the Ethernet cable from each machine to the LAN connection or switch.
Connect the Ethernet cable with the machine
For each machine:

1. Insert the Ethernet cable into the machine and the machine's control cabinet, using an EMC
connection.
2. Lead the Ethernet cable through the cable ducts to SIGMA CONTROL 2. Use the wiring path
in the 24V range (blue wiring) of the ducts.

8 Initial Start-up
3. Attach the RJ45-plug to the cable end.

4. Plug the RJ45 plug into the Ethernet interface X1 of the SIGMA CONTROL 2 until it latches.
For connecting the machines to a network (LAN) or switch:
Connect the Ethernet cable for each machine to the LAN connection or switch.
1. Attach the RJ45-plug to the cable end.
2. Plug the RJ45plug into the network socket until it latches.
8.10.4.2 Setting the controller of machine 1 as master
Precondition The electrical connection is made.

Setting the switching points pA and pB

2. Press «Enter».
The value for pA flashes.
Setpoint pressure
·········
↓ < 5.0bar ¦ SD: 0.50bar
3. Use «Up» or «Down» to set the pA value.

4. Press «Enter».
5. Press «Down».
The pB line is displayed.
6. If necessary, adjust the value for the pB switching differential in the same manner.
Setting the times
SIGMA CONTROL 2 provides the following options for selecting times:
■ 1: Clock program
■ 2: Timer
1. Decide for clock program or timer.

2. Follow the instructions below for the settings required.

8 Initial Start-up
Alternative 1: Set clock program

➤ Setting the target pressure change with a clock program; see chapter 8.9.2.
Alternative 2: Setting the timer

1. Setting the timer for pA and pB; see chapter 8.9.3.1.

2. Setting the starting time for pA or pB; see chapter 8.9.3.2.
Alternative 3: Setting the base load change switching
In this mode the automatic base load change between the two machines is carried out in a manner
that idle times of the two compressors are prevented and the energy-efficiency of the compressed
air generation is increased.

➤ Setting local operating mode to pA/pB SC2.

Local mode: pA/pB SC2
Remote mode: pA Active line, current operating mode
------------------------------
▶1 pA/pB Clock
·········
pA/pB Cycle
Master IP configuration
If the controllers of both machines are linked directly, they must be given different IP addresses.
Example:
■ IP addressController machine 1 (Master mode): 169.254.100.101
■ IP address Controller machine 2 (Slave): 169.254.100.102

1. Set IP address for the master: For instructions, see chapter 8.2.14, IP address for the above
example.
The IP address of machine 1 (master) is set correctly.
2. Open the 8.1.2.1 <Communication – Ethernet/SIGMA NETWORK – Connections – SIGMA
CONTROL 2> menu.
3. Use «Up» or «Down» to select the Mode line.

8 Initial Start-up
4. Press «Enter».
8.1.2.1 SIGMA CONTROL 2 Menu
Status Run 0 ¦ Error 0
------------------------------
Mode : Master Active line
Port : 2.001
·········
Communication partner
5. Use «Up» or «Down» to set Machine 1 Master operating mode.

6. Press «Enter».
8. Press «Enter».
9. Set the IP address of the communication partner (slave, see above example).
The IP address of machine 2 (slave) is set correctly.
Result The controller of machine 1 is set as master.
8.10.4.3 Setting the machine 2 controller as slave

Setting the switching points pA and pB

2. Press «Enter».
The value for pA flashes.
Setpoint pressure
·········
↓ < 5.0bar ¦ SD: 0.50bar

8 Initial Start-up
4. Press «Enter».
5. Press «Down».
The pB line is displayed.
6. If necessary, adjust the value for the pB switching differential in the same manner.
Activating the remote control
Set the remote operating mode


3. Press «Enter».
Local mode: pA/pB Cycle
Remote mode: pA/pB SC2 Active line, current operating mode
------------------------------
▶1 pA/pB Clock
·········
pA/pB Cycle
4. Use «Up» or «Down» to set the pA/pB SC2 input.

5. Press «Enter».
Slave IP configuration
If the controllers of both machines are linked directly, they must be given different IP addresses.
Example:
■ IP addressController machine 1 (Master mode): 169.254.100.101
■ IP address Controller machine 2 (Slave): 169.254.100.102

1. Set IP address for the master: For instructions, see chapter 8.2.14, IP address for the above
example.
The IP address of machine 2 (slave) is set correctly.

8 Initial Start-up
2. Open the 8.1.2.1 <Communication – Ethernet/SIGMA NETWORK – Connections – SIGMA

CONTROL 2> menu.
3. Use «Up» or «Down» to select the Mode line.
4. Press «Enter».
5. Use «Up» or «Down» to set Machine 2 Slave operating mode.
6. Press «Enter».
8. Press «Enter».
9. Set the IP address of the communication partner (master, see above example).
Result The controller of machine 2 is set as slave.
8.10.5 Configuring master control using the LOAD remote contact (e.g.,
SIGMA AIR MANAGER BASIC)
Overview
■ Establish the electrical connection for LOAD remote contact
■ Set the LOAD remote contact operating mode and assign the input
■ If required, set temporary pressure increase pE.
➤ Set master control as described below.

8 Initial Start-up
8.10.5.1 Establish the electrical connection for remote LOAD contact (excerpt)
Machine (example)
Fig. 35 LOAD remote contact

1 Electrical connection DI 1.12 4 LOAD remote contact closed (LOAD)
2 LOAD remote contact open (IDLE) 5 SIGMA AIR MANAGER BASIC contacts
3 Electrical connection DI 1.12
➤ Establish the electrical connection for DI 1.12 according to the diagram.
8.10.5.2 Setting the remote LOAD contact operating mode and assigning the input for LOAD remote contact
Set the LOAD remote contact operating mode

3. Press «Enter».
The currently active operating mode Remote mode flashes.
Remote mode: Load RC Active line
------------------------------
▶1 pA/pB Clock
·········
pA/pB Cycle
4. Use «Up» or «Down» to set the Load RC input.

5. Press «Enter».
The LOAD remote contact operating mode is set.

8 Initial Start-up
Assign the input for LOAD remote contact
The input for the LOAD remote contact is pre-assigned.

Setting is only necessary if you deliberately want to use a different input.
1. Use «Up» or «Down» to select the Load RC line.

2. Press «Enter».
The DI display flashes.
pA/pB DO DOR1.03 ☐
Logic : +
·········
Load RC DI1.06 ok ☑ Active line; standard DI 1.13
Logic : +
loc.-load RC DI1.07 ☐
3. Use «Up» or «Down» to select the input for the LOAD remote contact.
4. Press «Enter».
6. Press «Enter».
The check box Load RC will flash.
7. Press «Up».
8. Press «Enter».
ok is displayed to the left of the check box.
The operating mode is set.
8.10.5.3 Setting the SD switching differential of the pressure increase
➤ Set the SD switching differential of the pressure increase as described in chapter 8.4.2.3.
Further information Detailed information on the pressure parameters is provided in chapter 8.4.2.
8.10.5.4 Activating the remote control
8.10.6 Setting the master control with local/LOAD remote contact

Overview
■ Set the local/LOAD remote contact operating mode and assign the input.

8 Initial Start-up
■ Set local operating mode, if necessary.

➤ Set master control as described below.
8.10.6.1 Establishing the electrical connection
■ Contact A open: SIGMA CONTROL 2controls with pB nominal pressure.

■ Contact A closed: SIGMA CONTROL 2 controls via external LOAD mode contact.
■ DI 1.13: LOAD/IDLE external
■ DI 1.09: LOAD control – switch to local/LOAD remote contact.
Fig. 36 Wiring diagram for local/LOAD remote contact:

A Changeover between automatic and manual modes
B LOAD/IDLE contact
➤ Make the electrical connection according to the diagram.
8.10.6.2 Set the local/LOAD remote contact operating mode and assign the input.
Set local/LOAD remote contact operating mode:


8 Initial Start-up
3. Press «Enter».
The currently active operating mode Remote mode flashes.
Remote mode : loc.-load RC Active line
------------------------------
▶1 pA/pB Clock
·········
pA/pB Cycle
4. Use «Up» or «Down» to set the loc.-load RC input.

5. Press «Enter».
The local/LOAD remote contact operating mode is set.
Assign an input for the local/LOAD remote contact for switching the pressure control
1. Use «Up» or «Down» to select the loc.-load RC line.

2. Press «Enter».
pA/pB DO DOR1.03 ☐ No input assigned
Logic : +
·········
Load RC DI1.06 ok ☑
Logic : +
loc.-load RC DI1.07 ☑ Active line
3. Use «Up» or «Down» to select a new input for local/LOAD remote contact.
4. Press «Enter».
The input for local/LOAD remote contact is assigned.
8.10.6.3 Setting local operating mode pB
The pB nominal pressure is normally set for local operation.

➤ When setting the pB nominal pressure, bear in mind that, under certain circumstances,
more than one compressor may be operating in local mode (see section 8.4 for adjusting
the nominal pressure).


8 Initial Start-up
3. Press «Enter».
The operating mode display flashes.
Local mode: pB
Remote mode : loc.-load RC Active line
------------------------------
▶1 pA/pB Clock
·········
pA/pB Cycle
4. Use «Up» or «Down» to set the pB input.

5. Press «Enter».
6. Adjust the pB nominal pressure, if necessary (see section 8.4).
The local operating mode pB is set.
8.10.6.5 Assign an input for the LOAD remote contact for switching the pressure control

2. Use «Up» or «Down» to select the Load RC line.
3. Press «Enter».
pA/pB RC DI1.05 ☐
Logic : +
Logic : +
·········
Load RC DI1.06 ok ☑ Active line
4. Use «Up» or «Down» to select the input for the LOAD remote contact.
5. Press «Enter».
The input for LOAD remote contact is assigned.

8 Initial Start-up
8.10.7 Setting the nominal pressure pre-selection via remote contact

The signal to changeover from nominal pressure pA to nominal pressure pB comes from an input
contact. If a signal is activated at the input, the nominal pressure is regulated to pB.
Overview
■ Setting up remote contact mode pA/pB
■ Assigning the remote contact input
■ Activating the remote control
➤ Set the nominal pressure pre-selection as described.
8.10.7.1 Setting up remote contact mode pA/pB


3. Press «Enter».
Local mode : pB
Remote mode : pA/pB RC Active line
------------------------------
▶1 pA/pB Clock
·········
pA/pB Cycle
4. Use «Up» or «Down» to set the pA/pB RC input.

5. Press «Enter».
Result The pA/pB RC operating mode is set.
8.10.7.2 Assigning the remote contact input
A spare input can be found in the machine circuit diagram.

1. Use «Up» or «Down» to select the pA/pB RC line.

8 Initial Start-up
2. Press «Enter».
pA/pB RC DI1.05 ☑ Active line
Logic : +
Logic : +
·········
3. Use «Up »or «Down» to set the DI input.

4. Press «Enter».
Result The input for remote contact has now been assigned.
8.10.8 Master control for machines regulated by pressure switch

➤ Set the master control as described below.
8.10.8.1 Master control via floating relay contact
Requirement:
A machine with SIGMA CONTROL 2 (e.g. series BSD) and a conventional machine without
SIGMA CONTROL 2 with the same flow rate are to run in sequence as base load or peak load
machines.
Suggestion:
■ Set the clock program or clock on SIGMA CONTROL 2.
■ Select local mode with time control pA/pB Clock or clock pA/pB Cycle.
■ Select the network nominal pressures pA and pB analogous to the required values. They must
be identical to the pressure switch settings on the machine without SIGMA CONTROL 2.
■ To make the nominal pressure changeover between the two machines possible, a floating re‐
lay contact must be assigned to the selected local operating mode. An auxiliary contactor can
be energised via this contact to activate the pressure switches for pA and pB on the compres‐
sor without SIGMA CONTROL 2. See the example wiring diagram below.
Overview
■ Set the network nominal pressure pA and pB.
■ Set operating mode in local operating mode
■ Assigning the floating relay contact
■ Set local operating mode

8 Initial Start-up
Establishing the electrical connection
■ Contact A open: SIGMA CONTROL 2 controls with network nominal pressure pB

■ Contact A closed: SIGMA CONTROL 2 controls with network nominal pressure pA
■ B 1.1: Pressure switch for network nominal pressure pB
■ B 1.2: Pressure switch for network nominal pressure pA
-K3 A1
A2
07-S0629
Fig. 37 Machine with pressure switch regulation

A potential-free contact SIGMA CONTROL 2
➤ Make the electrical connection according to the diagram.
Set the network nominal pressure pA and pB.

The electrical connection is made.
1. Open the <5.2.2 – Pressure control – Pressure settings> menu (see chapter 8.4.1).
3. Press «Enter».
The Setpoint pressure pAdisplay flashes.
Setpoint pressure
·········
↓ < 5.0bar ¦ SD: 0.50bar

8 Initial Start-up
4. Use «Up» or «Down» to set the value for pA.

5. Press «Enter».
6. If necessary, adjust the value for SD in the same manner.
7. If necessary, adjust the value for pB/SD in the same manner.
Setting local mode
➤ Set the clock program or clock as described in section 8.9.
Assigning the potential-free contact (activate)

The electrical connection made (select spare contact from the machine's electrical diagram).
1. Select the 5.2.3 <Configuration – Pressure control – Load control> menu.

2. Use «Up» or «Down» to select the pA/pB DO line.
pA/pB RC DI1.10 ☐
Logic : +
pA/pB DO DOR1.03 ☐ Active line, no output assigned
Logic : +
·········
3. Press «Enter».
4. Use «Up» or «Down» to set the required output.
5. Press «Enter».
Result This output can now be used for the changeover between the two pressure switches.
Setting local mode

8 Initial Start-up

Local mode: pA
Remote mode : pA Active line, current operating mode
------------------------------
▶1 pA/pB Clock
·········
pA/pB Cycle
3. Press «Enter».
4. Use «Up» or «Down» to set the pA/pB Clock or pA/pB Cycle operating mode.
5. Press «Enter».
8.10.8.2 Master control without an electrical connection
Requirement:
A machine with SIGMA CONTROL 2 (e. g. type BSD) and high flow rate is to work as a base load
machine. A second machine (e.g., SK) without SIGMA CONTROL 2 is to supply air in times of low
demand.
Suggestion:
■ Select the system set-point pressures pA and pB of the BSD machine for the switching point of
the SK machine's pressure switch to be in between. When pB is activated for the periods of
low demand, the SK machine automatically functions as the base load machine.
■ Set the required values for a clock program on SIGMA CONTROL 2.
■ Select local mode pA/pB Clock.
■ Activate the compressor timer
Function diagram:
Period t1–t7: high air demand Period t8–t14: low air demand
t1 t8:
Air demand rises. Air demand rises.
System pressure pNloc drops. System pressure pNloc drops.
t2 t9:
BSD switches to LOAD. SK switches to LOAD.
t3: t10:
Network nominal pressure pA reached. Network nominal pressure pB reached.
BSD switches to IDLE. SK switches to IDLE.
t4: t11:
BSD switches to LOAD. BSD switches to LOAD.
Air demand not covered. Air demand not covered.

8 Initial Start-up
Period t1–t7: high air demand Period t8–t14: low air demand
t5: t12:
SK also switches to LOAD. SK switches to LOAD.
System pressure pNloc begins to rise. System pressure pNloc begins to rise.
t6: t13:
SK switches to IDLE. SK switches to IDLE.
t7: t14:
BSD switches to IDLE. BSD switches to IDLE.
Tab. 71 Function diagram
Fig. 38 Function diagram

SD Switching differential
p Pressure
t Time
Set the network nominal pressure pA and pB.
1. Open the <5.2.2 – Pressure control – Pressure settings> menu (see chapter 8.4.1).
Setpoint pressure
·········
↓ < 5.0bar ¦ SD: 0.50bar
3. Press «Enter».
The pA display flashes.

8 Initial Start-up

5. Press «Enter».
6. If necessary, adjust the value for SD in the same manner.
7. If necessary, adjust the value for pB/SD in the same manner.
Set clock program
➤ Set the clock program as described in chapter 8.9.2.
8.10.9 Examples of time settings for equal overall load

Requirement:
Two machines with comparable flow rate are to be equally utilized. Versions A, B and C describe
the different possibilities of achieving this requirement.
A detailed description for creating a timing program or setting the timer can be found in Chap‐
ter 8.9.
Variant A: Daily switch between network nominal pressure pA and network nominal pressure pB
after 24 hours
The machines start with a network nominal pressure pB at 0:00 hours. A timer triggers the switch
between network nominal pressure pA and network nominal pressure pB (local operating mode:
pA/pB Cycle local mode).
Precondition The network nominal pressure pA/pB is configured the same for both machines.
➤ Establish a cycle with the following switching points:

■ Cycle time pA: 24 h
■ Cycle time pB: 24 h
■ Start pB: 00:00AM
Variant B: Equal duty cycle during the day
A timer triggers the switch between network nominal pressure pA and network nominal pressure
pB (local operating mode pA/pB Clock.
➤ The clock program is set up using the following switching points:
No.: Weekday Time Network nominal pressure

01 Mon-Sun 00:00AM pA On
02 Mon-Sun 06:30AM pB On
03 Mon-Sun 12:00PM pA On
04 Mon-Sun 05:00PM pB On
Tab. 72 Example for a clock program for equal duty cycling during the day

8 Initial Start-up
8.11 Setting input and output signals
Variant C: Equal duty cycle during the week
A timing program triggers the switch between network nominal pressure pA and network nominal
pressure pB (local operating mode: pA/pB SC2Clk).
➤ The timing program is set up using the following switching points:
No.: Weekday Time Network nominal pressure

01 Mon 00:00AM pA On
02 Mon 09:00PM pB On
03 Tue 05:00PM pA On
04 Wed 03:00PM pB On
05 Thu 12:00PM pA On
06 Fri 09:00AM pB On
07 Sat 06:30AM pA On
08 Sun 03:00AM pB On
Tab. 73 Example for a timing program for equal duty cycling during the week

The controller's analogue and digital inputs and outputs can be used for customised messages
and/or other functions.
The various options are explained in the following chapters:

■ 8.11.1: Output operational states of machine on digital outputs
■ 8.11.2: Output input signals on the display
■ 8.11.3: Output measured values on the display
■ 8.11.4: Switching and/or triggering messages with thresholds
The controller only allows assignment of spare inputs and outputs.

Any assignment of a pre-assigned input or output is discarded by the controller.
When delivered from the factory, the outputs DO0.3 to DO0.5 are available for assignment.
Further spare outputs can be found in the machine circuit diagram.
➤ Set the inputs and outputs as described below.
8.11.1 Output operational states of machine on digital outputs

Important operational machine states can be made available as digital signals via floating contacts.
Each output can be assigned only once.
The following messages can be output:

Message Explanation Output
Controller on Controller is powered up
Compressor on The machine is switched on
Motor running Compressor engine running

8 Initial Start-up
Message Explanation Output

IDLE The machine is running in IDLE mode
ON LOAD The machine is running in LOAD mode
Group alarm Fault has occurred
Group warning Warning message has appeared
Remote mode Informs you whether the «Remote control» key is active
Clock active Informs you whether the time control for the compressor
(«Time control» key lights up in green) is active
Clock contact Timer with which a relay/transistor output can be switched
EMERGENCY STOP Signals whether the EMERGENCY STOP command device has
been actuated
Tab. 74 Assigned output signals
8.11.1.1 DO functions menu
The requested message can be assigned to a free digital output (DOR orDOT).
1. Open the 5.7.1 <Configuration – I/O periphery – DO functions> menu.

A menu containing a list of available messages and their assigned outputs is displayed.
5.7.1 DO functions Menu
Controller on Active line
DOR1.05 ☐ ¦ Logic : +
DOT1.02 ☐ ¦ Logic : +
Compressor on
DOR1.03 ☐ ¦ Logic : +
DOT1.02 ☐ ¦ Logic : +
8.11.1.2 Assigning a message to an output
1. Select the required message with the «Up» or «Down» keys.

2. Press the «Down» key once.
Output DOR has been selected
3. Press «Down» twice.
Output DOT has been selected

8 Initial Start-up
4. Press «Enter».
The output of the selected message flashes.
5.7.1 DO functions Menu
Controller on Active line
DOR1.05 ok ☐ ¦ Logic : + Active line with assigned output
DOT1.02 ☐ ¦ Logic : +
Compressor on
DOR1.03 ☐ ¦ Logic : +
DOT1.02 ☐ ¦ Logic : +
5. Select a free output with the «Up» or «Down» key.

6. Press «Enter».
8. Press «Enter».
The check box will flash.
The check box associated to the output is activated.
If the message is correctly assigned to the output and activated, ok is displayed.
11. If necessary, set the Logic option.
Result A message about the operational state is now sent via the assigned digital output.
You are missing an organised display of assigned output signals?

➤ Enter the selected output in table 74.
8.11.2 Output input signals on the display

In addition to the defined alarm and warning messages there are six further freely selectable input
signals that can be used to display messages. A list of the alarm and warning messages is provi‐
ded in chapters 10.2 and 10.3. Please see the machine's wiring diagram for information on free
inputs.
An input signal can be classified as either a fault, a warning or an operational message. To sup‐
press any possible contact bounce or similar problems, the input signal can be delayed by an ad‐
justable period. This ensures that the signal must be apparent for a minimum period before it can
be processed as a message.
If an input signal is classified as fault, the controller goes into the alarm state and shuts down
the machine.
Overview
Use the External messages menu for specifying the settings.
■ Enter the message text
■ Assign and activate the input
■ Set the time delay
■ Setting the logic

8 Initial Start-up
■ Assign and activate the output

■ Selecting the message type
■ Activate the message.
8.11.2.1 External messages menu

1. Open the 5.7.3 <Configuration – I/O periphery – External messages> menu.

The External messages menu is displayed
6.1bar 08:15AM 80° C
5.7.3 External messages Menu
▶1 External message 1 Active line with external message No. 1
▶2 External message 2
8.11.2.2 Enter the message text
In the below example we select External message 1.

1. Use «Up» or «Down» to select the External message 1 line.
2. Press «Enter».
The External message 1 menu is displayed
5.7.3.1 External message 1 Menu
External message 1 Message text
DI1.06 ☐ No input assigned
td: 0s ¦ Logic : + Logic
DOR1.04 ☐
Warning ☑ Message type (operational, alarm, warning)
3. Press «Enter».
The cursor is located at the first character of the message text.
The cursor jumps to the next position of the message text.
6. Enter the remaining characters of the message text in the same manner.
7. Press «Enter».
The message text has been entered.

8 Initial Start-up
8. Press «Enter».
8.11.2.3 Assign and activate the input
1. Use «Up» or «Down» to select the DI line.

2. Press «Enter».
The display for the currently set input flashes.
3. Use «Up» or «Down» to select the input.
4. Press «Enter».
DI1.07 ☐ The output has been selected.
DOR1.04 ☐
Warning ☑ Example: Warning message type

6. Press «Enter».
The check box assigned to the input flashes.
DI1.07 ok ☑ Input selected
DOR1.04 ☐
8. Press «Enter».
ok is displayed.
The input is assigned and activated.
8.11.2.4 Set the time delay
The delay can be set between 0 and 600 seconds. The delay is counted down from 600 in 1
second increments with the «DOWN» key and counted upwards from 0 (zero) in 1 second
increments with the «UP» key.
1. Use «Up» or «Down» to select the td line.

8 Initial Start-up
2. Press «Enter».
The td delay time flashes.
td: 0s ¦ Logic : + set time delay td
DOR1.04 ☐

4. Press «Enter».
Result The td delay time has been set.
8.11.2.5 Setting the logic
Possible logic settings

Message at Sign
24 V +
0V -
Tab. 75 Logic settings

3. Press «Enter».
The control field Logic flashes.
4. Use «UP» or «Down» to set the desired behaviour, see table 75.
td: 0s ¦ Logic : + active line, set logic control field
DOR1.04 ☐
5. Press «Enter».
Result For messages at 24 V, the logic is set with the + symbol.
8.11.2.6 Setting the message type
1. Select the message type line with the «Up» and «Down» keys.

8 Initial Start-up
2. Press «Enter».
The display for the message type flashes.
3. Use «Up» or «Down» to set the message type.
DOR1.04 ☐
4. Press «Enter».
The message type is set.
8.11.2.7 Assign and activate the output
1. Use «Up» or «Down» to select the DOR line.

2. Press «Enter».
The DOR display flashes.
3. Select the output with the «Up» and «Down» keys.
4. Press «Enter».
DOR1.01 ☑ Output is selected and activated

6. Press «Enter».
The check box assigned to the output flashes.
8. Press «Enter».
The output is assigned and activated.
Result The signal at the DI digital input is available as External message 1 and as output signal at the
selected DOR output.
8.11.3 Output measured values on the display

For analogue measured values you can define customised messages.

8 Initial Start-up
The message can be classified as either a fault, a warning or an operational message.

If exceeding the switching point is classified as a fault, the controller goes into the fault state
when the signal continues and shuts down the machine.
The following messages can be output:

Message Explanation Measured Output
value
AnMod_p_1 Customised monitoring of the pressure value p1
AnMod_T_1 Customised monitoring of the temperature value T1
AnMod_I_1 Customised monitoring of the current value I1
AnMod_I_2 Customised monitoring of the current value I2
T-Switch inlet Customised monitoring of the intake temperature
temperature
p-Switch pi Customised monitoring of internal pressure pi in the oil sep‐
arator tank
T-Switch ADT Customised monitoring of the airend discharge temperature
ADT
p-Switch pN Customised monitoring of local network pressure pNloc at
compressor output
T-Switch PDT Customised monitoring of the compressed air discharge
temperature
Tab. 76 Assigned analogue measured values
Overview
Use the Analogue values or Switch menus for specifying the settings.
■ Enter the message text
■ Select and activate measured value
■ Set the time delay
■ Setting the logic
■ Selecting the message type
■ Assign and activate the output
Below, the settings are displayed based on an example in the Analogue values menu. Use the
Switch menu analogously for specifying the settings.
8.11.3.1 Analogue values menu


8 Initial Start-up
1. Open the 5.7.2 <Configuration – I/O periphery – Analogue values> menu.

The Analogue values menu is displayed
6.1bar 08:15AM 80° C
5.7.2 Analogue values Menu
▶1 AnMod Analogue modules
▶2 AI Analogue inputs
▶3 AO Analogue outputs
▶4 PD Process Data
8.11.3.2 Enter the message text
In the following example, a message from the analogue module is defined by pressure value p1.
1. Use «Up» or «Down» to select the AnMod line.
2. Press «Enter».
The 5.7.2.1 AnMod menu is displayed.
6.1bar 08:15AM 80° C
5.7.2.1 AnMod Menu
▶1 AnMod_p_1 AnMod_p_1 measured value
▶2 AnMod_p_2
▶3 AnMod_p_3
▶4 AnMod_p_4
▶5 AnMod_T_1
▶6 AnMod_T_2
3. Use «Up» or «Down» to select the AnMod_p_1 line.

4. Press «Enter».
The 5.7.2.1.1 AnMod_p_1 menu is displayed.
5.7.2.1.1 AnMod_p_1 Menu
AnMod_p_1 Title 0.0 bar Message text
pNloc ☐ analogue measured value
·········
SP: 8.0bar ¦ SD: −0.5bar Switching point (SP) and switching differential (SD)
td: 0s Time delay (td)
·········
5. Press «Enter».
The cursor is located at the first character of the message text.

8 Initial Start-up

The cursor jumps to the next position of the message text.
8. Enter the remaining characters of the message text in the same manner.
9. Press «Enter».
The message text has been entered.
8.11.3.3 Select and activate measured value

2. Press «Enter».
The display for the currently set measured value flashes.
3. Use «Up» or «Down» to select the measured value.
4. Press «Enter».
pNloc ☐ selected analogue measured value
·········
·········

6. Press «Enter».
pNloc ☑ selected analogue measured value, activated
·········
·········
8. Press «Enter».
The measured value is assigned and activated.

8 Initial Start-up
8.11.3.4 Setting the switching point and switching differential
1. Use «Up» or «Down» to select the SP line.

·········
·········
2. Press «Enter».
The display for the current value of the switching point flashes.
3. Use «Up» or «Down» to set the SP value.
4. Press «Enter».
5. If necessary, adjust the value for SD in the same manner
Result The threshold value for the SP switching point and the SD switching differential are set.
2. Press «Enter».
·········
·········

4. Press «Enter».

8 Initial Start-up
2. Press «Enter».
·········
Warning ☐ set message type, in the example: Warning
·········
DOR1.02 ☐ ¦ Logic: +
4. Press «Enter».
6. Press «Enter».
The check box assigned to the message type flashes.
8. Press «Enter».
Result The message type is set and activated.
By triggering the message one or two digital DOR outputs can be switched.
2. Press «Enter».
4. Press «Enter».
·········
Warning ☐ set message type, in the example: Warning
·········
DOR1.02 ☐ ¦ Logic: + active line (DOR output)

6. Press «Enter».

8 Initial Start-up
8. Press «Enter».
The control field Logic flashes.
11. Use «UP» or «Down» to set the desired behaviour, see table 75.
Result For messages at 24 V, the logic is set with the + symbol.
Result The pNloc measured value at the analogue AnMod_p_1 input is available as a message and as
output signal at the selected DOR output.
8.11.4 Switching and/or triggering messages with thresholds

Some measured values of the controller can be used for customised messages and/or other
switching functions.
The following measured values are available:

Measured value Explanation Message # Output
System pressure pNloc Threshold for pressure System pressure pNloc (lo‐ 0095 O/W/A
cal network pressure at compressor output)
Internal pressure pi Threshold for pressure Internal pressure pi (internal 0093 O/W/A
pressure pi in the oil separator tank)
ADT Threshold for temperature ADT (discharge tempera‐ 0094 O/W/A
ture)
Inlet temperature Threshold for temperature Inlet temperature (inlet 0092 O/W/A
temperature)
PD temperature Threshold for temperature PD temperature (com‐ 0096 O/W/A
pressed air discharge temperature)
n Compressor motor 1) Threshold for the compressor motor speed 0098 O/W/A
1)
Tab. 77 Available measured values
Example: Setting for the local network pressure at compressor output System pressure pNloc.

8 Initial Start-up
1. Open the 5.7.4 <Configuration – I/O periphery – Switch> menu.

A menu containing a list of available measured values is displayed.
5.7.4 Switch Menu
▶1 System pressure pNloc Active line
▶2 Internal pressure pi
▶3 ADT
▶4 Inlet temperature
▶5 PD temperature
▶6 n Compressor motor
2. Use «Up» or «Down» to select the measured value.

3. Press «Enter».
The menu for the selected measured value (in the example System pressure pNloc) is dis‐
played.
5.7.4.1 System pressure pNloc Menu
active: ☐ active line with check box
·········
SP: 2.25bar ¦ SD: 0.0bar Switching point (SP) and switching differential (SD)
td: 0s ¦Logic + Delay (td) and logic
DOR1.01 ☐ Output DOR
Operation ☐ Type of message
8.11.4.1 Setting the switching point and switching differential
1. Use «Up» or «Down» to select the SP line.

active: ☐
·········
2. Press «Enter».
The display for the current threshold of the switching point flashes.
3. Use the «Up» or «Down» keys to set the SP threshold.
4. Press «Enter».
5. If necessary, adjust the value for the SD switching differential in the same way.
Result The threshold for the SP switching point and the SD switching differential are set.

8 Initial Start-up
2. Press «Enter».
active: ☐
·········

4. Press «Enter».
Once the threshold has been reached you can switch a digital output DOR.
2. Press «Enter».
4. Press «Enter».
active: ☐
·········
DOR1.03 ok ☑ Output DOR

6. Press «Enter».

8 Initial Start-up
8. Press «Enter».
ok is displayed.
2. Press «Enter».
active: ☐
·········
Warning ☑ Type of message
4. Press «Enter».
6. Press «Enter».
The check box assigned to the message type flashes.
The message is activated.
8. Press «Enter».
Result The message type is set and activated.
8.11.4.5 Activating the threshold

2. Press «Enter».
active: ☑ active line with check box
·········
Warning ☑ Type of message


8 Initial Start-up
8.12 Timer

The threshold is selected and activated.
Result In the above example the switching point for System pressure pNloc has been set and is active. If
the pressure is reached or exceeded and remains longer than the set time delay td, the message is
triggered with the set message type and the set output DOR is switched. If the pressure falls below
the threshold SP + switching differential SD, the message and output are reset. The switching be‐
haviour is inverted by setting "-" of Logic parameter.
The settings for the other measured values are carried out in the same manner.
8.12 Timer
SIGMA CONTROL 2 is equipped with an integrated timer that can control an adjustable DOR out‐
put for customer-specific applications. Valid setting values for the cutting in and out duration are
between 24 h ≥ t ≥ 15 m.

The electrical connection has been established (for information about a spare DOR output please
see the machine's wiring diagram)
1. Open the 5.8<Configuration – Timer> menu.

5.8 Timer Menu
on : 00h:00m:00s Cut-in period
off : 00h:00m:00s Cut-out period
DOR1.02 ☐ set output
·········
current off Current status DOR
00h:00m:00s Remaining time until status change
2. Use «Up» or «Down» to select the on line.

3. Press «Enter».
The display for hours 00h:00m:00s flashes.
The display for minutes 01h:00m:00s flashes.
The display for seconds 01h:15m:00s flashes.
9. Press «Enter».
10. Use the «Up» or «Down» keys to select the off line.
11. Proceed in the same manner to set the cut-out period.
12. Use the «Up» or «Down» keys to select the DOR line.

8 Initial Start-up
8.13 Activating remote acknowledgement

14. Use «Up» or «Down» to set the required output DOR.
The check box associated to output DOR is activated.
If output DOR is correctly assigned and activated, ok is displayed.
5.8 Timer Menu
on : 01h:15m:00s Cut-in period
off : 01h:15m:00s Cut-out period
DOR1.03 ok ☑ Set output DOR
·········
current on Current status DOR
00h:55m:34s Remaining time until status change
Result The set output DOR is controlled by the timer.

The current status of output DOR is displayed in the current line. The remaining time until the next
status change is displayed in the line underneath.

When fault or warning messages are routed to a remote control centre via an output it makes
sense to have these messages acknowledged by the control centre.
Acknowledging the message without correcting the cause, however, can lead to machine
damage.
Safety-relevant "EMERGENCY STOP device" and "Maintenance door limit switch" messages
cannot be acknowledged remotely.
The following conditions must be fulfilled:

■ The remote control of the compressor is set (see chapter 8.5.3 Controlling machine from a re‐
mote location)
■ Remote control is activated (see chapter 8.2.13 Activating remote control)
■ A controller input has been assigned for the acknowledgement signal.
Overview
■ Select the <Configuration – Acknowledgement> menu.
■ Set the "Remote acknowledgement" function.
■ Activating the remote control

8 Initial Start-up
■ Assigning an input
■ Press the «Remote control» key.
CAUTION
Machine damage can result from acknowledging a fault message without remedying its
cause!
➤ Find the failure cause.
➤ Decide to acknowledge or not.
8.13.1 Setting the remote acknowledgement function

1. Open the 5.5 < Configuration – Acknowledgement > menu.

4. Press «Enter».
5. Use «Up» or «Down» to set the Key + remote contact input.
5.5 Acknowledgement Menu
Remote mode:
Key + remote contact Active line with "Key + remote contact" setting
------------------------------
RC ack DI1.07 ☐
Key remote :☑
6. Press «Enter».
Result The Remote acknowledgement function is set.


8 Initial Start-up
8.13.3 Assigning an input

1. Use «Up» or «Down» to select the RCack line.
Remote mode:
Key + remote contact
------------------------------
RC ack DI1.07 ☐ Active line
Key remote :☑
2. Press «Enter».
3. Use «Up» or «Down» to set the input.
4. Press «Enter».
The input has now been assigned.
6. Press «Enter».
8. Press «Enter».
The input is assigned and activated.
Remote mode:
Key + remote contact
------------------------------
RC ack DI1.06 ok ☑ Input for remote contact assigned and activated
Key remote :☑
9. Press the «Remote control» key to enable remote acknowledgement.
Result Should a message occur, it can now be acknowledged from a control centre.

8 Initial Start-up
8.14 Linking to an external pressure transducer
8.14 Linking to an external pressure transducer

If the air system is operated with an air receiver, the pressure in the receiver can be regulated by
an external pressure transducer.
Transmitting a pressure transducer value Assignment to an input
The external pressure transducer is connected to AII assign
SIGMA CONTROL 2.
Pressure transducer characteristics:
■ 4–20 mA
■ 0–16.0 bar
Tab. 78 Transmitting a pressure transducer value
The controller processes the options in the following sequence:

■ Pressure according to the assigned external transducer
■ The local system pressure transducer (pNloc) remains active.
Overview
Example: The external pressure transducer is connected to SIGMA CONTROL 2.
■ Open the <Configuration – Pressure control> menu.
■ Assigning an input
8.14.1 Pressure control menu

1. Open the 5.2.4 < Configuration – Pressure control – Network actual pressure> menu.
The Network actual pressure menu is displayed
5.2.4 Network actual pressure Menu
pNloc 6.1bar Active line (local pressure transducer)
AII1.01 ☐ 0.0bar
For sensor error:
Alarm
8.14.2 Assigning an input to an external pressure transducer

1. Press «Enter».
The pNloc indication flashes.

8 Initial Start-up
8.15 Commissioning the machine
2. Use «Up »or «Down» to set the AII input.

AII 6.1bar Active line (external pressure transducer)
AII1.01 ☐ 0.0bar
For sensor error:
Alarm
3. Press «Enter».
The AII input is set.
4. Press «Down».
The line for activating the input is displayed.
6. Press «Enter».
AII 6.1bar Active line
AII1.01 ok ☑ 0.0bar
For sensor error:
Alarm
7. Press «UP».
ok is displayed.
8. Press «Enter».
Result The input for the external transducer is now activated.

Checking the controller settings Chapter Confirmed?
➤ Language correctly set? 8.2.2
➤ Date and time correct? 8.2.8
➤ Display format correctly set? 8.2.10
➤ System pressure setpoint correctly set? 8.4
Tab. 79 Check list for starting the machine

8 Initial Start-up
1. Check and confirm all the items in the check list before first start-up of the machine.
When power is applied to the machine the controller boots and carries out a self test.
The display and the Controller on LED illuminate.
------------------------------
------------------------------
------------------------------
2. Continue the commissioning process as described in chapter "Commissioning" of the ma‐

chine's operating manual.

9 Operation
9.1 Switching the compressed air station on and off
9 Operation
9.1 Switching the compressed air station on and off
Always switch the machine on with the «ON» key and off with the «OFF» key.
Precondition A power supply isolating device has been installed by the user.
Fig. 39 Switching the compressed air station on and off

7 «ON» key 14 IDLE LED
8 «OFF» key 15 LOAD LED
13 «Load/Idle» toggle key 16 Voltage applied to controller LED
9.1.1 Switching on
Precondition No personnel are working on the machine.
All maintenance doors and removable panels are in place and secured.
The ambient conditions as described in Chapter "Installation and Operating Conditions" are met
1. Switch on the user's power supply isolating device.

2. Switch on the machine and wait for SIGMA CONTROL 2 to start.
The voltage applied to controller LED 16 lights green.
3. Press the «On» 7 key.
The On LED lights green.
If a power failure occurs, the machine is not prevented from re-starting automatically when
power is resumed.
The compressor motor / engine may automatically re-start as soon as power is restored (see
chapter 8.5).
Result At the first switching-on after the power has been restored, the compressor starts as soon as net‐
work pressure is lower than the network nominal pressure.

9 Operation
9.2 Switching off in an emergency
9.1.2 Switching off

1. Press the «OFF» key.
The machine switches to IDLE and the IDLE LED flashes. The SIGMA CONTROL 2 display
Stopping is displayed. The ON LED extinguishes as soon as the automatic shut-off action is
completed.
2. Switch off and lock out the power supply isolating device.
Result The Voltage applied to controller LED extinguishes. The machine is switched off and disconnected
from the mains supply.
In rare cases, you may want to shut down the machine immediately and cannot wait until the
automatic shut-down process is finished.
➤ Press «OFF» once again.
9.2 Switching off in an emergency

The EMERGENCY STOP command device is located below the controller.
Fig. 40 Switching off in an emergency

22 EMERGENCY STOP command device
Switching off
➤ Press the EMERGENCY STOP command device.

After actuating the EMERGENCY STOP command device, the machine is shut down. How‐
ever, the machine is still connected to the electrical mains supply.
Result The EMERGENCY STOP command device remains latched after actuation.
The compressor's pressure system is vented and the machine is prevented from automatically re-
starting.
Switching on
Precondition The fault has been rectified
1. Turn the EMERGENCY STOP command device in the direction of the arrow to unlatch it.
2. Acknowledge any existing alarm messages.

9 Operation
9.3 Acknowledging alarm and warning messages
Result The machine can now be started again.
9.3 Acknowledging alarm and warning messages

Messages are displayed on the "new value" principle: You can acknowledge warning or fault mes‐
sages immediately after Message coming or Message going. However, warning and fault messag‐
es can be acknowledged only following a successful elimination of the corresponding fault.
Message sequence 1 Indication
Message coming LED flashes
Message acknowledged LED illuminates
Message going LED off
Tab. 80 Message sequence 1
Message sequence 2 Indication

Message coming LED flashes
Message going LED flashes
Message acknowledged LED off
Tab. 81 Message sequence 2
Fig. 41 Acknowledging messages

17 Warning LED (yellow)
20 Alarm LED (red)
21 Key «Acknowledge»
Alarm message
An alarm message shuts the machine down automatically.

The red Alarm LED flashes.
Precondition The fault has been rectified
➤ Press «Ack» to acknowledge the fault message.

Alarm LED extinguishes. The machine is again ready for operation.

9 Operation
9.4 Displaying messages
If the machine has been stopped with the EMERGENCY STOP control device
➤ First turn the EMERGENCY STOP control device in the direction of the arrow to unlatch
it.
➤ Then acknowledge the alarm message.
Further information A list of possible alarm messages occurring during operation are shown in chapter 10.2.
Warning message
If maintenance work is to be carried out or if the warning is displayed before an alarm, the yel‐
low warning LED flashes.
Precondition The danger of an alarm is eliminated.

Maintenance has been carried out
➤ Press «Ack» to acknowledge the warning message.

The Maintenance LED extinguishes. The machine is again ready for operation.
Further information A list of possible warning messages occurring during operation are shown in chapter 10.3.

The following information can be accessed in the 1.1 <Status – Messages> menu:
■ Current messages
─ Last alarm
─ Last warning
─ Number of currently registered fault and/or warnings
■ Message history: The last 1000 events, these include fault and warning messages
─ Compressor messages
─ Diagnostic messages
─ System messages
■ Address error: Display of incorrect parameterisation in menu X
The information (message) is shown in three lines of the display.

Line Submenu/Segment/Text
1 Selected submenu:
■ Compressor messages
■ Diagnostic messages
■ System messages
2 Segment:
■ Message number
■ Message type
■ Message status
■ Message date
■ Message time

9 Operation
Line Submenu/Segment/Text
3 Text:
■ Message text
■ –
Tab. 82 Information of a message
Message type and status are shown abbreviated.

Segment Display Meaning
Message number 0059 (example) Message 0059
Type of message W Warning and maintenance message
A Alarm
Message status c Message has come
g Message gone
a Message acknowledged
Date 04/13/16 (Example) Date
Time 08:15:37AM (Example) Time
Tab. 83 Message abbreviations
9.4.1 Status – Messages menu

1. Open the 1.1 <Status – Messages > menu.
The Messages menu is displayed
The number of current faults and warnings is displayed in the two bottom lines.
1.1 Messages Menu
▶1 Current messages Active line
▶2 Message history
▶3 Address error Only displayed in the event of I/O parametrisation
error
Status report 01:00 ☐
------------------------------
current Alarms 2 Number of currently registered faults

9 Operation
Displaying the last fault/warning
1. Open the 1.1.1 <Status – Messages – Current messages> menu.

The third line displays the last fault or warning message.
6.1bar 08:15AM 80° C
1.1.1 Current messages Menu
0300 W c 04/16/16 01:32:49PM Last message
SD card write error
0015 W a 04/16/16 01:06:43PM Second to last message
Com-Module communication error
0034 O c 04/13/16 08:15:37AM
E-mail send unsuccessful!
Displaying the message history
1. Open the 1.1.2 <Status – Messages – Message history> menu.

The Message history menu is displayed
6.1bar 08:15AM 80° C
1.1.2 Message history Menu
▶1 Compressor messages Active line with sub-menu: Compressor messages
▶2 Diagnostic messages Diagnostic messages
▶3 System messages System messages
2. Press «Enter».
The 1.1.2.1 Compressor messages menu is displayed.
The third line displays the last fault or warning message.
6.1bar 08:15AM 80° C
1.1.2.1 Compressor messages Menu
0300 W c 04/16/16 01:32:49PM Last message
SD card write error Message text for message 0300
0015 W a 04/16/16 01:06:43PM
Com-Module communication error Message text for message 0015
0034 O c 04/13/16 08:15:37AM
E-mail send unsuccessful! Message text for message 0034

9 Operation
9.5 Displaying the current operating mode
9.5 Displaying the current operating mode

The operating mode is displayed in 2 segments (example):
On/off switching via Load control via
Key pA
Tab. 84 Operating mode display
1. Open the 1.4 <Status – Current operating mode > menu.

The Current operating mode menu is displayed
1.4 Current operating mode Menu
Compressor on Active line
Key
Load control
pA
·········
Control mode
Abbreviation of operating modes
Segment Display Meaning

On/off switching via Key «ON» key on the operating panel of SIGMA CONTROL 2
Key + clock Cycle Control
Key + remote Remote contact (FK): external LOAD signal
contact
Key + remote Remote bus (FB): external bus signal
bus
LOAD control via pA pA nominal pressure
pB pB nominal pressure
pA/pB Clock Nominal pressure via time control
pA/pB Cycle Nominal pressure via timer
pA/pB SC2 Nominal pressure via 2 machines working in master-slave
mode
pA/pB RC Nominal pressure via remote contact
pA/pB RB Nominal pressure via remote bus
Load RC LOAD remote contact (external LOAD signal)
Load RB Remote bus (external bus signal)
loc.-load RC Local/LOAD remote contact
Tab. 85 Abbreviation of operating modes

9 Operation
9.6 Setting the working pressure
9.6 Setting the working pressure

➤ Adjust the pressure parameter to suit the compressor and application.
Further information A detailed explanation of all pressure parameter settings is given in chapter 8.4.
9.7 Displaying analogue data

The following information regarding the components shown below can be called up in
the Performance data menu option:
■ Compressor
■ Compressor motor
■ Fan
■ Analogue values
■ SIGMA CONTROL 2
Displaying analogue data

1. Open the 2 Performance data menu.

A list of the components is displayed.
2 Performance data Menu
▶1 Compressor Active line
▶2 Compressor motor
▶3 Fan
▶4 Analogue values
▶5 SIGMA CONTROL 2
2. If necessary, repeatedly press «Up» or «Down» to select the required component.

3. Press «Enter».
The measured data of the selected component are displayed.
2.1 Compressor Menu
System pressure pNloc 6.1 bar Local System pressure pNloc
·········
ADT T 80°C Airend discharge temperature
dT/dt 0.0°C/s Rise of airend discharge temperature
·········
Oil separator Δp 0.0bar Differential pressure, oil separator cartridge

9 Operation
9.8 Displaying operating data

The following information can be called up in the Operating data menu:
■ Operating hours
─ Compressor: Total machine running time
─ On load: Machine running time in LOAD mode
─ Motor: Running time of compressor motor (adjustable)
─ Compressor block: Running time of airend (adjustable)
─ SIGMA CONTROL 2: Controller running time
■ Switching cycles
─ Load valve on
─ Mains contactor on (adjustable)
■ kWh counter
➤ Reset the run times after replacing the compressor block or the compressor motor.
➤ Reset the mains contactor switching cycle counter after replacing the mains contactor.
9.8.1 Checking the operating hours

Display the operating hours
1. Open the 3 Operating data menu.

3 Operating data Menu
▶1 Operating hours Active line
▶2 Switching cycles
▶3 kWh counter
Changing the operating hours
The running times of the compressor motor and compressor block components can be adjusted.
This may be required after a replacement, for example.

9 Operation
1. Open the 3.1 <Operating data – Operating hours> menu.

3.1 Operating hours Menu
Compressor 3050h active line
On load 3030h
Motor 3050h
Compressor block 3050h
SIGMA CONTROL 2 3050h
2. Use «Up» or «Down» to select the Compressor block line.

3. Press «Enter».
The runtime display flashes.
3.1 Operating hours Menu
Compressor 3050h
On load 3030h
Motor 3050h
Compressor block 0h active line
SIGMA CONTROL 2 3050h
4. Use «Down» or «Up» key to set the value for operating hours to zero.
5. Press «Enter».
Result The operating hours for the new airend are set to 0 h.
9.8.2 Checking the switching cycles

The system monitors the usage times of safety-relevant components to ensure the proper
condition of all safety-relevant functions. Depending on the component, the usage time may
be defined by run time or switching cycles. For the mains contactor, the usage time is defined
by the maximum permissible number of switching cycles.
The mains contactor switching cycle counter in SIGMA CONTROL 2 records the number of
switching cycles and generates a warning message when the maximum permissible number
of switching cycles is exceeded.
When this warning message is generated, the safety-relevant function is no longer ensured.
The mains contactor must be replaced!
➤ Comply with all instructions.
Displaying switching cycles
1. Open the 3.2 <Operating data – Switching cycles> menu.

9 Operation
9.9 Displaying the frequency converter settings
2. Compare the maximum permissible number of switching cycles with the value displayed by the
switching cycle counter.
3.2 Switching cycles Menu
Load valve on 3 Active line
·········
Mains contactor on
max: 1100000¦ 10227 Maximum value/switching cycle timer
Reset: ☐
Result The safety-relevant function is ensured.

The maximum permissible number of switching cycles have not exceeded.
The mains contactor can still be used.
The safety-relevant function is not ensured.

The maximum permissible number of switching cycles have exceeded.
➤ Have the mains contactor replaced.
Replacing the mains contactor
If the displayed value of the mains contactor exceeds the maximum permissible number of
switching cycles, SIGMA CONTROL 2 generates the warning message 0024 Mains contactor
operations ⇞.
The mains contactor must be replaced.
➤ Have the mains contactor replaced by authorised KAESER SERVICE.
Resetting the mains contactor switching cycle counter
➤ Have the mains contactor replaced by authorised KAESER SERVICE.
9.9 Displaying the frequency converter settings

Precondition Machine with frequency converter option
1. Open the 10.1.1 <Components – Compressor motor – Power switching> menu.

9 Operation
9.10 Setting the maintenance interval
2. Use «Up» or «Down» to select the Local operating mode: line.

In the two lines underneath Local operating mode:, the source for the speed setting and the
setting values for the minimal and maximum speed are shown.
10.1.1 Power switching
▶4 SFC USS
▶5 Softstart
▶6 Customer-provided
Local operating mode:
Speed sensor All Speed setting
nMin= 0/min ¦ nMax= 0/min
9.10 Setting the maintenance interval

Maintenance tasks are tasks to be completed to ensure the functionality of a technical instal‐
lation.
Time interval established by the manufacturer at which end a maintenance task must be
completed.
Example: Changing the oil change service interval.

NOTICE
Unauthorised extended maintenance intervals
Progressing damage to the machine up to functional incapacity.
➤ Observe the maintenance intervals of the manufacturer.
Maintenance menu
1. Open the 4 Maintenance menu.

2. Use «Up» or «Down» to select the Oil change line.
4 Maintenance
Oil change active line, Description maintenance interval
3000h¦ 0150h Reset: ☐ Preset interval 3000 h
·········
Air filter
3000h¦ 0150h Reset: ☐
·········

9 Operation
9.11 Check the safety valve

The maintenance interval for oil change is displayed as active line.
4 Maintenance
Oil change Maintenance interval description
4000h¦ 0150h Reset: ☐ Active line, factory-defined interval
·········
Air filter
3000h¦ 0150h Reset: ☐
·········
4. Press «Enter».
5. Use «Up» or «Down» to set the new value for the maintenance interval.
Keep the «Up» key pressed to change the maintenance interval in increments of 10, 100 or
1000.
6. Press «Enter».
7. Press «Escape» repeatedly to return to the main menu.

Overview
■ Preparing the inspection
■ Performing the inspection
■ Correct conclusion of the test
■ Resetting
When the check mode is activated, the threshold value for the blow-off protection is raised
and regulation of the network pressure is deactivated.
The measured value of the pi pressure value is used to describe the test below.
Check box Status

☑ activated
☐ deactivated
Tab. 86 Check box status
WARNING
Danger of injury from pressurised components!
➤ Perform the following actions in the sequence provided.
Preparing the inspection
1. Note the safety valve's actuating pressure from the machine's nameplate.
2. Press the «Off» key to shut down the machine.

9 Operation
3. Close the user's shut-off valve between the machine and the air distribution network.
4. Log on with access level 2.
5. Open the 9.1 <Machine test – TÜV inspection> menu.
9.1 TÜV inspection Menu
Safety valve :☐ Active line with check box
pRV: 16.0bar ¦ pi ⇞ 0.0bar Safety valve actuating pressure (example)
Reset : ☐
·········
ADT ⇞ :☐
Offset 0°C ¦ ADT ⇞ 0.0°C
Performing the inspection
1. Use «Up» or «Down» to select the Safety valve line.

2. Press «Enter».
The check box Safety valve will flash.
3. Press «Up».
4. Press «Enter».
The test mode is now activated.
Safety valve :☑ Active line with check box
pRV: 16.0bar ¦ pi ⇞ 2.5bar Safety valve actuating pressure, internal pressure
Reset : ☐
·········
ADT ⇞ :☐
5. WARNING!
Risk of hearing damage when safety valve blows off!
➤ Close all access doors, replace and secure all removable panels.
➤ Always wear ear protection.
6. WARNING!
Risk of burns due to released cooling oil and compressed air when blowing off the safety
valve!
➤ Close all access doors, replace and secure all removable panels.
➤ Wear eye protection.
7. Press the «ON» key. After the motor / engine start is completed, keep the «LOAD/IDLE» key
pressed. Otherwise, the machine remains in IDLE and is stopped after two minutes.
The machine switches to LOAD and the machine's pi pressure rises.
8. Use the display to monitor the pi pressure rise during the TÜV check.

9 Operation
9.12 Excessive temperature shut-down test
9. If the pi pressure increases to 11 % above the actuating pressure of the safety valve, immedi‐
ately release the «LOAD/IDLE» key.
10. Shut down the machine with the «OFF» key and immediately replace the safety valve.
If the alarm message pRV ⇞ appears, the safety valve is defective. pi pressure has exceeded
the actuating pressure of the safety valve by 2.0 bar.
➤ Have the safety valve replaced immediately.
Avoid oil mist:
➤ Release the «LOAD/IDLE» key immediately as soon as the safety valve actuates, in or‐
der to prevent unnecessary oil mist.
Correct conclusion of the test
1. Press «Enter».
The check box Safety valve will flash.
3. Press «Enter».
The test mode is de-activated and the test is completed.
5. Open the user's shut-off valve between the machine and the air distribution network.
Result The machine is ready for operation.
Resetting
If the test is cancelled when opening the safety valve, SIGMA CONTROL 2 will indicate the highest
measured value as internal pressure.
To reset the saved value, activate the Reset check box.
➤ Activate the Reset check box.

The machine should shut down if the airend discharge temperature (ADT) reaches a maximum of
110°C.
SIGMA CONTROL 2 will simulate a higher temperature for checking this function.
For this purpose, SIGMA CONTROL 2 automatically determines an offset value to be displayed.
During the test mode, this offset is added to the actual airend discharge temperature to cause the
machine to shut down prematurely.
No warning message is generated. However, the corresponding fault message "0015Airend
discharge temperature ADT ⇞" switches off the machine once the maximum discharge tempera‐
ture has been reached.
Overview
■ Allow the machine to warm up, then shut it down and allow it to cool down slightly
■ Performing the inspection
■ Correct conclusion of the test
■ Resetting

9 Operation
Performing the inspection
The offset value of 35.0°C displayed in activated test mode refers to the discharge tempera‐
ture of 73°C as shown in the example.
Precondition Allow the machine to warm up. Shut down the machine as soon as the discharge temperature
(VET) has stabilised.
Machine has cooled down by approx. 5°C (from discharge temperature of warmed up machine)
1. Open the 9.1 <Machine test – TÜV inspection> menu.

2. Use «Up» or «Down» to select the ADT line.
Safety valve :☐
Reset : ☐
·········
ADT ⇞ :☐ Active line with check box
3. Press «Enter».
The ADT ⇞ check box flashes.
The display Offset switches to 35.0°C.
The display ADT ⇞ switches to 108°C.
The test mode is now activated.
6.1bar 08:15AM 7 3° C Header
Safety valve :☐
Reset : ☐
·········
ADT ⇞ :☑ Active line with check box
Offset 35.0°C ¦ ADT ⇞ 108°C
6. Press the «ON» key.

The machine is running in LOAD.
The discharge temperature increases again.
The machine will switch off as soon as the discharge temperature attains a value of 110°C.
The machine does not shut down?
➤ Abort the test and contact authorised KAESER SERVICE as soon as possible.

9 Operation
9.13 Save data
Correct conclusion of the test
1. Press «Enter».
The check box flashes in line ADT ⇞.
3. Press «Enter».
The offset is reset to 0°C.
Result The test mode is de-activated and the test is completed.
Resetting
SIGMA CONTROL 2 will display the highest measured value if the test for switching off at exces‐
sive temperature is aborted.
Activate the Reset check box in order to reset the stored value.
➤ Activate the Reset check box.
9.13 Save data

SIGMA CONTROL 2 settings can be backed up to an SD card.
Precondition An SD card with compatible file system (FAT32) and minimum 50 MB free memory is plugged into
the SD card slot X5 of SIGMA CONTROL 2
The write protection of the SD card has been deactivated.
1. Open the 5.10 <Configuration – Save data> menu.

2. Use «Up» or «Down» to select the Language: line.
5.10 Save data Menu
Language: en_GB English Active line
·········
Save data :☐
3. Press «Enter».
The display for the set language flashes.
4. Use «Up» or «Down» to select the desired language.
5. Press «Enter».

9 Operation
9.13 Save data
6. Use «Up» or «Down» to select the Save data line.

5.10 Save data Menu
Language: en_GB English
·········
Save data :☑ Active line
7. Press «Enter».
The check box Save data will flash.
9. Press «Enter».
A security query is displayed.
Result The settings are saved on the SD card.


The following tables are intended to assist in locating faults.
SIGMA CONTROL 2 will indicate three types of faults:

■ Fault on the machine:
The red LED flashes, the machine is shut down, see chapters 10.2 and 10.5.
■ Fault on the controller:
The machine is shut down, see chapter 10.6.
■ Warning:
The yellow LED illuminates, the machine is not shut down, see chapter 10.3.
The messages valid for your machine are dependent on the controller and individual equipment.
1. Do not attempt fault rectification measures other than those given in this manual!
2. In all other cases:
Have the fault rectified by an authorised KAESER SERVICE technician.
10.2 Interpreting fault messages

If an input signal is classified as a fault, the controller will display the fault upon the signal's
arrival.
Consequences:
■ The red LED flashes:
■ The controller switches the machine off.
Fault messages are identified with the letter A.
The message numbers are not numbered consecutively.
In this table, you will see "%d" for a variable value, e.g. a number, duration or I/O address.
1)
Messages 0073-0078 and 0081-0098 are customer-specific.
Complete possible causes and remedies for your defined message text (see chapter 8.11).
Message Possible cause Remedy

0001 A The compressor drive motor is Changeover phase lines L1 and L2.
Direction of rotation turning in the wrong direction.
0002 A Compressor drive motor overhea‐ Keep ambient conditions within
Motor temperature ⇞ ted. specified limits.
Check the cooling air supply.
Clean the motor.
0003 A The actuating pressure of the Change the safety valve.
pRV ⇞ safety valve on the oil separator
tank has been exceeded.
0004 A EMERGENCY STOP command Unlatch the push button.
EMERGENCY STOP device actuated.


0005 A Maximum air temperature at the Check the line to the trip relay.
Oil separator oil separator tank outlet is excee‐ Check the oil separator cartridge for
Temperature ⇞ ded. damage.
0006 A Over voltage in the power supply Check power supply.
Surge arrester (only in version for Canada) Call KAESER SERVICE.
0007 A Overvoltage and undervoltage in Check setting of the voltage alarm
Power supply monitor the power supply and power supply.
Call KAESER SERVICE.
0008 A A diagnostic message has occur‐ For more details, see the text of the
Diagnostics group alarm red. diagnostic message.
0010 A The actuating pressure of the Check the safety valve.
Blow-off protection ⇞ safety valve on the oil separator
tank has been exceeded.
0011 A Overload shut-down of the fan Investigate cause of shut-down.
Oil-/air cooler fan motor. Reset the overload relay.
overcurrent
0012 A Door open / interlocked panel re‐ Fit and secure all panels and close
Access doors moved while the machine is run‐ access doors.
ning.
0013 A Overload shut-down of the com‐ Investigate cause of shut-down.
Compressor motor pressor drive motor.
overcurrent
0014 A Overload shut-down of the oil Investigate cause of shut-down.
Oil cooler fan overcurrent cooler fan motor. Reset the overload relay.
0015 A Maximum permissible airend dis‐ Keep ambient conditions within
Airend discharge charge temperature (ADT) excee‐ specified limits.
temperature ADT ⇞ ded. Clean the cooler.
Check the cooling oil level.
0016 A Overload shut-down of the air Investigate cause of shut-down.
Air cooler - Fan cooler fan motor. Reset the overload relay.
Overcurrent
0017 A Maximum permissible airend dis‐ Keep ambient conditions within
Safety shutdown ADT charge temperature (ADT) excee‐ specified limits.
ded. Clean the cooler.
Check the cooling oil level.
0018 A Overload shut-down of the air Investigate cause of shut-down.
Interior fan Overcurrent cooler fan motor. Reset the overload relay.
0019 A Inlet valve defective. Call KAESER SERVICE.
Internal pressure pi ⇟
0021 A Refrigeration dryer: Call KAESER SERVICE.
Refrigeration dryer T ⇟ Compressed air temperature too
low.
0022 A Oil separator cartridge clogged. Change the oil separator cartridge.
Oil separator Δp ⇞


0033 A Oil level too low. Check the cooling oil level.
Oil pressure ⇟ Defective oil pump (provided only If necessary, request that
in vacuum machines). KAESER SERVICE replaces the oil
pump.
0034 A Mains contactor of the compres‐ Check mains contactor and wiring.
Mains contactor on? sor motor does not activate.
0035 A Overload shut-down of the control Call KAESER SERVICE.
Cabinet fan I ⇞ cabinet fan motor.
0038 A Package discharge (PD) temper‐ Call KAESER SERVICE.
PD temperature ⇟ ature too low.
0039 A Package discharge (PD) temper‐ Check the cooling oil level.
PD temperature ⇞ ature too high. Clean the cooler.
Check the fan motor.
0040 A Mains contactor of the compres‐ Check mains contactor and wiring.
Mains contactor off? sor motor does not deactivate.
0041 A Second power failure. Check power supply voltage.
Mains voltage ⇟ Checking the door interlock switch.
0042 A Back pressure in the oil separator Check venting line.
Back pressure stop tank caused by defective venting.
0043 A The rate of rise of the airend dis‐ Check the cooling oil level.
Airend discharge charge temperature (ADT) is too
temperature ADT rise fast.
dT/dt⇞
0044 A The machine does not produce Check the machine for leaks.
No pressure buildup compressed air. Check coupling and V-belt.
The working pressure does not Call KAESER SERVICE.
rise above 3.5 bar within the
specified time period.
The machine does not enter
LOAD mode
Minimum pressure/check valve
defective.
0048 A Fault in the high voltage cell. Call KAESER SERVICE.
High-voltage cell
0050 A Power switching module not Check power switching module.
Customer-provided power ready or faulty.
element
0051 A Aggregate A failed. Call KAESER SERVICE.
Aggregate A
0052 A Aggregate B failed. Call KAESER SERVICE.
Aggregate B
0053 A Refrigeration dryer: Refrigeration dryer:
Condensate drain 2 Condensate drain faulty Check the condensate drain and
conduits.


0056 A Refrigeration dryer: Refrigeration dryer:
RD condensate drain Condensate drain faulty Check the condensate drain and
conduits.
0057 A Compressor model uncertain. Call KAESER SERVICE.
Model?
0058 A Condensate drain faulty. Check the condensate drain and
Condensate drain conduits.
0059 A Drive belt or coupling broken. Drive belts:
Back pressure run Replace drive belts.
Coupling:
0060 A Fault in the soft start equipment. Call KAESER SERVICE.
Softstart
0062 A Refrigeration dryer: Clean the refrigerant condenser.
Refrigeration dryer p ⇞ Pressure in refrigerant circuit Check the fan motor.
high.
Maintain operating conditions.
Pressure monitor has tripped.
0063 A Refrigeration dryer: Call KAESER SERVICE.
Refrigeration dryer p ⇟ refrigerant lost; pressure in the
refrigerant circuit too low.
The pressure monitor has tripped.
0064 A Permissible ambient tempera‐ Check and lower ambient tempera‐
Refrigeration dryer tures exceeded. tures.
compressor motor Condenser cooling insufficient. Clean the condenser.
temperature ⇞ Compressed air inlet temperature Check the fan.
is too high. Check compressed air cooling at
Low refrigerant level. the compressor.
Clean the compressor cooler.
0067 A The electrical connection is inter‐ Check the electrical connection.
SC2 <=> SC2 rupted. Check the IP configuration.
communication error IP configuration incorrect.
0073 A 1)
External message 1
0074 A 1)
External message 2
0075 A 1)
External message 3
0076 A 1)
External message 4
0077 A 1)
External message 5
0078 A 1)
External message 6
0081 A 1)
AnMod_p_1


0082 A 1)
AnMod_p_2
0083 A 1)
AnMod_p_3
0084 A 1)
AnMod_p_4
0085 A 1)
AnMod_T_1
0086 A 1)
AnMod_T_2
0087 A 1)
AnMod_T_3
0088A 1)
AnMod_T_4
0089A 1)
AnMod_I_1
0090 A 1)
AnMod_I_2
0092 A 1)
T-Switch inlet
temperature
0093 A 1)
p-Switch pi
0094 A 1)
T-Switch ADT
0095 A 1)
p-Switch pN
0096 A 1)
T-Switch PDT
0098 A 1)
n-Switch Compressor
motor
0100 A Star contactor of the compressor Check star contactor and wiring.
Star contactor on? motor does not activate.
0101 A Star contactor of the compressor Check star contactor and wiring.
Star contactor off? motor does not deactivate.
0102 A Delta contactor of the compressor Check delta contactor and wiring.
Delta contactor on? motor does not activate.
0103 A Delta contactor of the compressor Check delta contactor and wiring.
Delta contactor off? motor does not deactivate.
0104 A High-voltage cell does not acti‐ Call KAESER SERVICE.
High-voltage cell on? vate.
0105 A High-voltage cell does not deacti‐ Call KAESER SERVICE.
High-voltage cell off? vate.


0106 A Soft start device does not acti‐ Call KAESER SERVICE.
Softstarter DI%.2d vate.
closed?
0107 A Soft start device does not deacti‐ Call KAESER SERVICE.
Softstarter DI%.2d open? vate.
0108 A Run-up of the soft start device is Call KAESER SERVICE.
Softstarter DI%.2d not completed.
closed?
0109 A Run-down of the soft start device Call KAESER SERVICE.
Softstarter DI%.2d open? is not completed.
0150 A Redundancy contactor does not Check redundancy contactor and
Redundancy contactor activate. wiring.
on?
0151 A Redundancy contactor does not Check redundancy contactor and
Redundancy contactor deactivate. wiring.
off?
0200 A Frequency converter fault Call KAESER SERVICE.
Compressor motor USS
alarm
alarm
alarm
Compressor motor FC
PKW failure P%d.E%d
Compressor motor FC
PKW failure P%d.E%d
Compressor motor FC
PKW failure P%d.E%d
0206 A Fault caused by software driver. Call KAESER SERVICE.
USS bus communication
error %d
error %d
error %d
0210 A Compressor motor temperature Keep ambient conditions within
Compressor motor FC too high. specified limits.
Over temperature alarm Cooler maintenance.


0211 A Fault message of the frequency Call KAESER SERVICE.
Compressor motor FC converter with message number.
Alarm %d
0212 A Speed sensor of the frequency Call KAESER SERVICE.
Compressor motor FC converter.
AI2 error
0220 A Compressor motor overload. Call KAESER SERVICE.
Compressor motor FC
Motor overload alarm
Alarm %d
0230 A Compressor motor overload. Call KAESER SERVICE.
Compressor motor FC
Alarm %d
0232 A Speed sensor of the frequency Call KAESER SERVICE.
Compressor motor FC converter.
AI1 error
alarm
Compressor motor FC
PKW failure P%d.E%d
error %d
Alarm %d
0244 A Frequency converter incorrectly Call KAESER SERVICE.
Compressor motor FC activated.
activation failed
0245 A Minimum speed not reached with Check the set value.
Compressor motor FC a defined time (can be set). Call KAESER SERVICE.
run-up time exceeded
0246 A Below minimum speed by a spe‐ Check the set value.
Compressor motor FC cific speed (can be set) for a spe‐ Call KAESER SERVICE.
nMin undershot cific time (can be set).
0247 A Parametrisation error Call KAESER SERVICE.
Compressor motor FC:
STO function inactive


0248 A Parametrisation error Call KAESER SERVICE.
Compressor motor FC off
- STO?
Oil-/air cooler fan USS
alarm
Oil-/air cooler fan FC
PKW failure P%d.E%d
error %d
0270 A Fan motor overload. Call KAESER SERVICE.
Oil-/air cooler fan FC converter with message number.
Alarm %d
alarm
PKW failure P%d.E%d
error %d
Oil-/air cooler fan FC converter with message number.
Alarm %d
0284 A Fan frequency converter incor‐ Call KAESER SERVICE.
Oil-/air cooler fan FC rectly activated.
activation failed
0287 A Frequency converter parametris‐ Check frequency converter para‐
Oil-/air cooler fan FC: ing incorrect. metrising.
STO function inactive Call KAESER SERVICE.
Oil-/air cooler fan FC off - ing incorrect. metrising.
STO? Call KAESER SERVICE.
Oil cooler fan USS alarm
Oil cooler fan FC PKW
failure P%d.E%d

10.3 Interpreting warning messages

error %d
0320 A Fan motor overload. Call KAESER SERVICE.
Oil cooler fan FC Motor
overload alarm
Oil cooler fan FC converter with message number.
Alarm %d
Oil cooler fan USS alarm
Oil cooler fan FC PKW
failure P%d.E%d
error %d
Oil cooler fan FC converter with message number.
Alarm %d
0334 A Fan frequency converter incor‐ Call KAESER SERVICE.
Oil cooler fan FC rectly activated.
activation failed
Oil cooler fan FC: STO ing incorrect. metrising.
function inactive Call KAESER SERVICE.
Oil cooler fan FC off - ing incorrect. metrising.
STO? Call KAESER SERVICE.
0500 A An I/O address has been as‐ Have the menu with the incorrect
I/O parameterisation signed more than once. parametrisation displayed in the
incorrect in module %d! 1.1.3Address error menu and cor‐
rect the parameter in there
Tab. 87 Fault messages, possible causes and remedies

If an input signal is classified as a warning, the controller will display the warning upon the
signal's arrival.
Consequences:
■ The yellow LED flashes.
■ The controller does not switch off the machine.
Warning messages are identified with the letter W.

Messages 0073-0078 and 0081-0096, and 0098 are customer-specific.

1)
Complete possible causes and remedies for your defined message text (see chapter 8.11).

0001 W Equipment number entered incom‐ Call KAESER SERVICE.
Equipment number pletely or not at all.
incomplete
0002 W Drive motor overheating. Keep ambient conditions within
Motor temperature ↑ specified limits.
Check the cooling air supply.
Clean the motor.
0003 W Initial warning: Air filter clogged. Change the air filter element soon.
Air filter Δp ⇡
0004 W Increased differential pressure of the Change the oil separator car‐
Oil separator Δp ↑ oil separator cartridge. tridge.
Oil separator cartridge clogged.
0005 W Idle warming up is activated —
Idle warm-up
0006 W Over voltage in the power supply (only Check power supply.
Surge arrester in version for Canada) Call KAESER SERVICE.
0007 W Overvoltage and undervoltage in the Check setting of the voltage alarm
Power supply monitor power supply and power supply.
0008 W Maximum airend discharge tempera‐ Clean the cooler.
Airend discharge ture will soon be reached. Check the cooling oil level.
temperature ADT ↑
Change the oil filter.
Ensure adequate ventilation.
Keep surrounding temperature
within recommended limits.
0010 W Increased pressure differential of the Change the oil filter.
Oil filter 2 Δp ↑ oil filter.
Oil filter clogged.
0011 W Increased pressure differential of the Change the oil filter.
Oil filter 1 Δp ↑ oil filter.
Oil filter clogged.
0013 W Air filter clogged. Change the air filter.
Air filter Δp ↑
0015 W The bus link via PROFIBUS interface Check bus lines and plug.
Com-Module is interrupted.
communication error
0021 W Refrigeration dryer: Keep ambient conditions within
Refrigeration dryer T Compressed air temperature too low. specified limits.
⇟ Call KAESER SERVICE.


0024 W The maximum permissible number of Have the mains contactor re‐
Mains contactor switching cycles has been exceeded. placed by an authorised
operations ⇞ KAESER SERVICE representa‐
tive.
0025 W Oil separator cartridge: Change the oil separator car‐
Oil separator h ⇞ Maintenance interval has elapsed. tridge.
0026 W Cooling oil Change the cooling oil.
Oil change h ⇞ Maintenance interval has elapsed.
0027 W Oil filter: Change the oil filter.
Oil filter h ⇞ Maintenance interval has elapsed.
0028 W Air filter: Change the air filter.
Air filter h ⇞ Maintenance interval has elapsed.
0029 W Valves: Call KAESER SERVICE.
Valve inspection h ⇞ Maintenance interval has elapsed.
0030 W Belt tension/coupling: Carry out a visual inspection.
Belt/coupling Maintenance interval has elapsed. Tension the drive belt.
inspection h ⇞
0031 W Motor bearing of compressor motor: Call KAESER SERVICE.
Motor bearing h ⇞ Maintenance interval has elapsed.
0032 W Electric components and electrical in‐ Inspect and reset the mainte‐
Electrical equipment h stallation: nance interval counter.
⇞ Maintenance interval has elapsed.
0033 W Motor bearing of fan motors: Call KAESER SERVICE.
Fan bearing h ⇞ Maintenance interval has elapsed.
0034 W Package discharge (PD) temperature Call KAESER SERVICE.
PD temperature ↓ too low.
0035 W Compressed air discharge tempera‐ Clean the cooler.
PD temperature ↑ ture too high. Check the cooling oil level.
0036 W The permissible number of motor Extend the idle period.
Motor starts/h ⇞ starts was exceeded in the last 60 mi‐ Increase the capacity of the air re‐
nutes. ceiver.
Increase the cross-section of pip‐
ing between compressor and air
receiver.
0037 W The permissible number of motor Extend the idle period.
Motor starts/d ⇞ starts was exceeded in the last Increase the capacity of the air re‐
24 hours. ceiver.
Increase the cross-section of pip‐
ing between compressor and air
receiver.
0038 W The safety valve's actuating pressure Change the oil separator car‐
Blow-off protection ↑ will soon be reached. tridge.
Open the shut-off valve in the
venting line.


0041 W 1. Power supply failure: Check power supply.
Mains voltage ↓ The machine is automatically re-star‐
ted.
0043 W External load signal indistinct: Check settings of the external
External load signal? Increased cut-out pressure exceeded. controller. Take into account pres‐
The external load control has not sure drops across filters and dry‐
switched to IDLE. er.
0044 W Cooling oil temperature too low. Check temperature switch, line
Oil temperature ↓ and connection.
Check the oil circuit.
Increase room temperature.
0045 W Test operation for the manual actua‐ Switch the power supply off and
DO test active tion of individual outputs is active. on again.
0046 W Network pressure has fallen below the Check air demand.
System pressure ↓ set 'network pressure low' value. Check cable runs and sensor con‐
Air consumption too high. nections.
Check the 'network pressure low'
warning value.
0047 W The machine does not produce com‐ Check the machine for leaks.
No pressure buildup pressed air. Check coupling and V-belt.
The working pressure does not rise Call KAESER SERVICE.
above 3.5 bar within the specified time
period.
The machine does not enter LOAD
mode
Minimum pressure/check valve defec‐
tive.
0048 W Re-grease the motor bearings. Re-grease the motor bearings.
Bearing lube h ⇞ Maintenance interval has elapsed.
0049 W Last maintenance was 1 year ago. Carry out the necessary mainte‐
Annual maintenance nance and reset the correspond‐
ing maintenance interval counter.
0050 W Maintenance interval has elapsed. Re-grease the fan bearing.
Fan bearing lube h ⇞
0051 W Last maintenance was 1 year ago. Carry out the necessary mainte‐
Double aggregate nance and reset the correspond‐
emergency operation! ing maintenance interval counter.
0053 W Condensate drain 2 faulty / not ready. Check the condensate drain and
Condensate drain 2 Too much condensate. conduits.
Line interrupted. Check the lines.
Condensate cannot be drained. Check ECO-DRAIN.
Check inlet conditions.
0058 W The electrical connection is interrup‐ Check the electrical connections.
SC2 <=> SC2 ted. Check the IP configuration.
communication error IP configuration incorrect


0059 W The airend temperature is too low (< Keep ambient conditions within
Start temperature ↓↓ −10 °C) for the machine to be operat‐ specified limits.
ed.
0060 W The airend temperature is too low Keep ambient conditions within
Start temperature ↓ (<+2 °C). specified limits.
0061 W The airend discharge temperature Call KAESER SERVICE.
Compressor T ↓ (ADT) did not reach the minimum val‐
ue within the specified time.
0062 W Refrigeration dryer: Clean the refrigerant condenser.
Refrigeration dryer p Pressure too high in the refrigerant cir‐ Check the fan motor.
⇞ cuit.
Maintain operating conditions.
Safety pressure switch tripped.
0063 W Refrigeration dryer: Call KAESER SERVICE.
Refrigeration dryer p Refrigerant lost; pressure in the refrig‐
⇟ erant circuit too low. Inlet pressure
switched tripped.
0064 W Permissible ambient temperatures ex‐ Check and lower ambient temper‐
Refrigeration dryer ceeded. atures.
compressor motor Condenser cooling insufficient Clean the condenser.
temperature ⇞ Compressed air inlet temperature is Check the fan.
too high. Check compressed air cooling at
Low refrigerant level. the compressor.
Clean the compressor cooler.
0065 W Low room temperature. Keep ambient conditions within
Refrigeration dryer Risk that refrigeration dryer freezes. specified limits.
external shut-off Check temperature sensor.
Refrigeration dryer has automatically
been deactivated.
0067 W Network pressure is above the "net‐ Check cable runs and sensor con‐
System pressure ↑ work pressure high" value. nections.
Check the "network pressure
high" warning setting.
0068 W Condensate drain faulty / not ready. Check the condensate drain and
Condensate drain Too much condensate. conduits.
Line interrupted. Check the lines.
Condensate cannot be drained. Check ECO-DRAIN.
Check inlet conditions.
0069 W Refrigeration dryer defective. Immediately contact
Error operation Compressed air supply with non-dried KAESER SERVICE.
without RD → Call air is activated.
service!
0070 W Refrigeration dryer: Maintain operating conditions.
Refrigeration dryer T Compressed air temperature too high. Clean the refrigerant condenser.
↑
Clean the cooler.
Install an extractor fan.


0071 W Cooling oil level too low. Top up the cooling oil.
Oil level ↓
0072 W Refrigeration dryer: Check the condensate drain.
RD condensate drain Condensate drain faulty.
0073 W 1)
External message 1
0074 W 1)
External message 2
0075 W 1)
External message 3
0076 W 1)
External message 4
0077 W 1)
External message 5
0078 W 1)
External message 6
0081 W 1)
AnMod_p_1
0082 W 1)
AnMod_p_2
0083 W 1)
AnMod_p_3
0084 W 1)
AnMod_p_4
0085 W 1)
AnMod_T_1
0086 W 1)
AnMod_T_2
0087 W 1)
AnMod_T_3
0088 W 1)
AnMod_T_4
0089 W 1)
AnMod_I_1
0090 W 1)
AnMod_I_2
0092 W 1)
T-Switch inlet
temperature
0093 W 1)
p-Switch pi
0094 W 1)
T-Switch ADT
0095 W 1)
p-Switch pN


0096 W 1)
T-Switch PDT
0097 W Bus link via SIGMA NETWORK inter‐ Check bus lines and plug.
SAM 4.0 rupted
communication error
0098 W 1)
n-Switch Compressor
motor
0200 W Frequency converter in service mode. Terminate service mode.
Compressor motor FC
Service mode active
Compressor motor FC
Service mode active
Compressor motor FC
Service mode active
Compressor motor FC
Service mode active
0210 W Pressure transducer of the frequency Call KAESER SERVICE.
Compressor motor FC converter faulty
AI1 error
0230 W Pressure transducer of the frequency Call KAESER SERVICE.
Compressor motor FC converter faulty
AI0 error
0231 W Malfunction at compressor motor or its Call KAESER SERVICE.
Compressor motor FC frequency converter.
Alarm %d
0240 W Run time of the frequency converter Temporarily fully disconnect the
Compressor motor FC since last shut-down too large. machine from the power supply.
test shut-off required (Required for the safety func‐
tions.)
0243 W Malfunction at compressor motor or its Call KAESER SERVICE.
Compressor motor FC frequency converter.
Alarm %d
Service mode active
Oil cooler fan FC
Service mode active
Oil cooler fan FC
Service mode active


Service mode active
0260 W Fault in frequency converter for fan. Acknowledge message.
Oil-/air cooler fan FC Call KAESER SERVICE.
Alarm %d
Oil-/air cooler fan FC Call KAESER SERVICE.
Alarm %d
Oil cooler fan FC Call KAESER SERVICE.
Alarm %d
Oil cooler fan FC Call KAESER SERVICE.
Alarm %d
0300 W Write protection activated? Deactivate the write protection.
SD card write error Memory card defective. Use a new memory card.
0866 W Power supply for ext. sensor at ana‐ Check the voltage supply.
AII%d.0%d - error logue input faulty.
power supply
0867 W Overload on the analogue input for Call KAESER SERVICE.
AII%d.0%d - overload ext. sensor.
fault
0868 W No continuity in line for ext. sensor at Check cable runs and sensor con‐
AII%d.0%d - open analogue input. nections.
circuit
0869 W Short circuit in line for ext. sensor at Check cable runs and sensor con‐
AII%d.0%d - short- analogue input. nections.
circuit
power supply
fault
circuit
circuit
power supply
fault


circuit
circuit
power supply
fault
circuit
circuit
0897 W Short circuit in line for indicated ana‐ Check cable runs and sensor con‐
AIR%d.0%d - short- logue input. nections.
circuit
0898 W Open circuit in line for indicated ana‐ Check cable runs and sensor con‐
AIR%d.0%d - open logue input. nections.
circuit
0899 W Sensor fault at indicated analogue in‐ Check cable runs and sensor con‐
AIR%d.0%d - sensor put. nections.
fault
circuit
circuit
circuit
fault
circuit
circuit


circuit
fault
circuit
circuit
circuit
fault
circuit
circuit
circuit
fault
circuit
circuit
circuit
fault
circuit


circuit
circuit
fault
circuit
circuit
circuit
fault
circuit
circuit
circuit
fault
circuit
circuit
circuit
fault


circuit
power supply
fault
circuit
circuit
power supply
fault
circuit
circuit
power supply
fault
circuit
circuit
power supply
fault


circuit
circuit
1058 W No ground fault in line for ext. sensor Check cable runs and sensor con‐
AIR%d.0%d - at analogue input. nections.
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit
circuit


fault
circuit
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit
circuit


fault
circuit
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit
circuit


fault
circuit
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit
circuit
fault
circuit
power supply
fault
circuit


circuit
power supply
fault
circuit
circuit
power supply
1215W Overload on the analogue input for Call KAESER SERVICE.
fault
circuit
circuit
power supply
fault
circuit
circuit
accidental ground
circuit


circuit
fault
circuit
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit


circuit
fault
circuit
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit


circuit
fault
circuit
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit
circuit
fault
circuit
accidental ground
circuit

10.4 Interpreting operation messages

circuit
fault
circuit
accidental ground
circuit
circuit
fault
circuit
Tab. 88 Warning messages and remedies

The controller will automatically display operation messages informing you about the current opera‐
tional state of the machine.
Operating messages are identified with the letter O.
Messages 0073-0078 and 0081-0098 are customer-specific.

1)
Complete the meaning of the message for your defined message text (see also chapter 8.11).
Message Meaning
0001 O Total duration until the machine is ready to start after pow‐
Delayed start (%ds) active er has been restored or after a communication error to the
master controller (e.g. SAM 4.0) or after switching on the
SAM manual mode.
0009 O The machine is switched on.
Compressor on

Message Meaning
0010 O The controller is switched on with the «ON» key.
Controller on
0011 O The machine can be switched on although the machine
Cold start release temperature is below the permissible starting temperature.
The machine can be switched on only as long as the mes‐
sage is displayed.
0027 O Request:
Power OFF → ON Switch the power supply off and on.
0028 O Control mode DYNAMIC:

DYNAMIC motor temperature ↑ The temperature of the compressor motor / engine is too
high.
0030 O Mains power supply returned after mains failure.
Voltage restored
0033 O Machine report sent by e-mail
Machine report
0034 O No e-mail sending of machine information.
E-mail send unsuccessful!
0073 O 1)
External message 1
0074 O 1)
External message 2
0075 O 1)
External message 3
0076 O 1)
External message 4
0077 O 1)
External message 5
0078 O 1)
External message 6
0081 O 1)
AnMod_p_1
0082 O 1)
AnMod_p_2
0083 O 1)
AnMod_p_3
0084 O 1)
AnMod_p_4
0085 O 1)
AnMod_T_1
0086 O 1)
AnMod_T_2

Message Meaning
0087 O 1)
AnMod_T_3
0088 O 1)
AnMod_T_4
0089 O 1)
AnMod_I_1
0090 O 1)
AnMod_I_2
0092 O 1)
T-Switch inlet temperature

0093 O 1)
p-Switch pi
0094 O 1)
T-Switch ADT
0095 O 1)
p-Switch pN
0096 O 1)
T-Switch PDT
0098 O 1)
n-Switch Compressor motor

0200 O The internal voltage monitoring reports undervoltage fault
IOSlot1 Undervoltage error %d IOSlot1





0300 O Service information

Cycle-exact data recording active
Safety shutdown "IOMDiagnosis()"
Safety shutdown "Safeguard()"
0550 O Short-term overload fault without shut-down occurred at
ADT channel error "currleak" detected ADT.

Message Meaning
ADT channel error "channel open" ADT.
detected
0850 O IOM bus fault
IOSlot%d - bus error
AII%d.0%d - overload fault All.



1000 O You successfully registered 2 RFID Equipment Cards at

2 RFID Equipment Cards successfully the controller.
registered









10.5 Interpreting diagnostic messages
Message Meaning










Tab. 89 Operational messages
10.5 Interpreting diagnostic messages

A diagnostic message causes the machine to shut down.
Diagnostic messages are identified with the letter D.

They provide information on the status of the controller, the connected input and output modules
and support the KAESER SERVICE in trouble-shooting.
10.6 Interpreting system messages

A system message causes the machine to shut down. Contact KAESER SERVICE.

10.6 Interpreting system messages
System messages are identified with the letter Y.


0001 Y System error Call KAESER SERVICE.
Hardware watchdog reset
Internal software error
Filesystem Read/Write failure
CPU load too high
RAM out of memory
RFID error: switch SIGMA CONTROL power supply
OFF → ON!
Tab. 90 System messages and remedies

11 Maintenance
11.1 Changing the buffer battery
11 Maintenance
11.1 Changing the buffer battery
When SIGMA CONTROL 2 displays a warning message indicating that the integrated buffer bat‐
tery has discharged and requires replacement, please contact KAESER SERVICE.

12.1 Note the nameplate

12.1 Note the nameplate
The nameplate contains all information to identify your machine. This information is essential to us
in order to provide you with optimal service.
➤ Please give the information from the nameplate with every enquiry and order for spares.
12.2 KAESER AIR SERVICE

KAESER AIR SERVICE offers:
■ Authorised service technicians with KAESER factory training
■ Increased operational reliability ensured by preventive maintenance
■ Energy savings achieved by avoidance of pressure losses
■ optimum conditions for operation of the compressed air system,
■ The security of genuine KAESER spares.
■ Increased legal certainty as all regulations are kept to.
➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement.

Your advantage:
lower costs and higher compressed air availability.
12.3 Service Addresses

Addresses of KAESER agents are given at the end of this user manual.
12.4 Displaying the version number, machine model, material number

and serial number
1. Open the 5.1.1 <Configuration – General – System information> menu.
5.1.1 System information Menu
▶1 SIGMA CONTROL 2 MCS Active line
▶2 Compressor
▶3 I/O modules
▶4 FC information

12.4 Displaying the version number, machine model, material number and serial number
2. Press «Enter».
The system information is displayed.
5.1.1.1 SIGMA CONTROL 2 MCS Menu
Software fluid_4.1.X Software version
·········
KAESER
PN 7.7601.0 Material number
SN 123456 Serial number
·········
3. Repeatedly press «Up» or «Down» to display further information.

5.1.1.1 SIGMA CONTROL 2 MCS Menu
SN 123456
·········
Prodrive Manufacturer
PN 6309.1000.7900 Material number
SN 10.34.000.961 Serial number
MFGDT 2017/04 Manufacturing date

13.1 De-commissioning

13.1 De-commissioning
13.2 Packing
13.3 Storage
13.4 Transporting
13.5 Disposal
Precondition SIGMA CONTROL 2 is de-commissioned.
1. Disconnect SIGMA CONTROL 2 from all connections.

2. If necessary, use a tool to forcefully remove the rear enclosure panel.
3. Use a suitable tool to remove the internally installed buffer battery.
4. Properly dispose of the buffer batteries.
5. Hand the SIGMA CONTROL 2 over to an authorised disposal expert.
13.5.1 Dispose of the battery in accordance with local environmental regulations.

Batteries contain substances that are harmful to living beings and the environment. For this reason,
batteries must not be disposed of with unsorted residential waste. They must be delivered to the
national battery collection system. This procedure facilitates the handling and recycling of batteries.
The 2006/66/EC directive stipulates for the EU member states that old batteries are returned to the
point of sale or delivered to a designated disposal system (free of charge). These disposal facilities
may be local recycling yards for used electric and electronic devices and their points of sale.

13.5 Disposal
Fig. 42 Battery labelling

1 Do not dispose of batteries with residential waste.
2 Battery contains lead (if applicable)
➤ Comply with national disposal regulations and dispose of batteries in an environmentally-

friendly manner.
You actively contribute to the protection of our environment when you bring used bateries to
the appropriate recycling system.


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User Manual

SIGMA CONTROL 2 SCREW FLUID ≥4.1.X

1 SIGMA CONTROL 2 Quick installation guide

User Manual Controller

User Manual Controller

User Manual Controller

10.3 Interpreting warning messages ........................................................................................ 192

User Manual Controller

Fig. 1 Operating elements .................................................................................................................... 1

User Manual Controller

User Manual Controller

Tab. 1 Operating elements .................................................................................................................... 1

User Manual Controller

Tab. 55 Pressure condition for LOAD ...................................................................................................... 82

User Manual Controller

1 SIGMA CONTROL 2 Quick installation guide

Fig. 1 Operating elements

Item Description Function

Tab. 1 Operating elements

User Manual Controller

1.2 Display elements

Fig. 2 Display elements

Item Description Function

Tab. 2 Display elements

1.3 Main menu – Overview

User Manual Controller

Menu No. Menu designation Function

Tab. 3 Main menu – Overview

See Chapter 5.6.2 for the complete menu structure.

1.4 Functions – Overview

Setting pressure 5.2.2 <Configuration – Pressure control – Pressure settings – 8.4

User Manual Controller

Function Menu Action steps Chapter

Tab. 4 Functions – Overview

User Manual Controller

2 Regarding this document

User Manual Controller

2.4 Updating the operating manual

2.5 Symbols and labels

User Manual Controller

Tab. 5 Danger levels and their definition (personal injury)

2.5.2 Potential damage warnings

Warning notices for damages are identified by their signal term.

Tab. 6 Danger levels and their definition (damage to property)

➤ Carefully read and fully comply with warnings against damages.

User Manual Controller

2.5.3 Other alerts and their symbols

Tab. 7 Formatting options

This symbol identifies particularly important information.

➤ This symbol denotes lists of actions comprising one stage of a task.

Further information Further subjects are introduced here.

User Manual Controller

3.1.1 Versions and Options

Type Prepared for connection to control Connection to control technology not

Tab. 8 Versions and Options

3.1.2 User interface with display, CPU and interfaces

Feature MCS MCSIO

Tab. 9 User interface

User Manual Controller