Page 1 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...
Page 2 /KKW/SSC 2.08 en IBA-SIGMA CONTROL FLUID /KKW/SSC 2.08 20180814 091827...
Page 3: Table Of Contents
Contents SIGMA CONTROL 2 Quick installation guide Operating elements ......................Display elements ......................Main menu – Overview ..................... Functions – Overview ....................... Regarding this document Using this document ......................Copyright .......................... 2.2.1 Software ......................Certification ........................Updating the operating manual ..................
Page 4 Activating the heat recovery for machine type 3 ..........101 8.7.3 Deactivating heat recovery ................. 102 Refrigeration dryer ......................8.8.1 Setting the operating mode ................. 103 8.8.2 Output messages ....................104 User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 5 9.12 Excessive temperature shut-down test ................180 9.13 Save data ........................182 Fault Recognition and Rectification 10.1 Basic instructions ......................184 10.2 Interpreting fault messages ....................184 User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 6 13.1 De-commissioning ......................221 13.2 Packing ..........................13.3 Storage ..........................221 13.4 Transporting ........................221 13.5 Disposal ........................... 13.5.1 Dispose of the battery in accordance with local environmental regulations..User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 7 Insert the communication module....................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.
Page 8 List of Illustrations User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 9 E-mail parameters ........................Tab. 52 Control key functions ........................Tab. 53 Compressor pressure parameters ....................Tab. 54 Setting limits for the network nominal pressure (* Cut-in pressure min) ........User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 10 Fault messages, possible causes and remedies ................ 184 Tab. 88 Warning messages and remedies ....................193 Tab. 89 Operational messages ....................... Tab. 90 System messages and remedies ....................217 User Manual Controller viii SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 11: Sigma Control 2 Quick Installation Guide
SIGMA CONTROL 2 Quick installation guide Operating elements 1 SIGMA CONTROL 2 Quick installation guide Operating elements Fig. 1 Operating elements Item Description Function «Up» Scrolls up the menu options. Increases a parameter value. «Left» Jumps to the left. Moves the cursor position to the left.
Page 12: Display Elements
SIGMA CONTROL 2 Quick installation guide Display elements Display elements Fig. 2 Display elements Item Description Function Display illuminates green when the machine switched on. Display Graphic display with 8 lines and 30 characters per line. Time control Continuous green light when the machine is controlled by the timer.
Page 13: Functions - Overview
SIGMA CONTROL 2 Quick installation guide Functions – Overview Menu No. Menu designation Function Performance data Displays measured data of the machine and its components (e.g., motors) Operating data Displays operating hours, switching cycles and energy data Maintenance Displays maintenance data of the machine and its components Configuration Setting of machine parameters, compressed air system and acces‐...
Page 14: Tab. 4 Functions - Overview
SIGMA CONTROL 2 Quick installation guide Functions – Overview Function Menu Action steps Chapter Activating – Activate the «Time control» key – Press «Time control» 8.5.1.4 «time control» <Configuration – Compressor start – Compressor on – Key Activate 5.2.3 8.2.13 remote –...
Page 15: Regarding This Document Using This Document
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:...
Page 16: Certification
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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 17: Potential Damage Warnings
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. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 18: Other Alerts And Their Symbols
➤ ... as is a solution. This symbol identifies important information or measures regarding the protection of the envi‐ ronment. Further information Further subjects are introduced here. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 19: Technical Specifications Controller Sigma Control
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 Option Compo‐...
Page 20: Fig. 3 Mcs Interfaces
SD card, SD card slot SD/SDHC card Functional earth (FE) The positions of the interfaces X1–X6 are marked on the rear of the controller. Tab. 11 MCS interfaces User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 21: Fig. 4 Mcsio Interfaces
The positions of the interfaces X1–X10 are marked on the rear of the controller. Tab. 12 MCSIO interfaces Identification with RFID Equipment Card Characteristic Value Hardware on the SIGMA CONTROL 2 controller RFID write/read device Hardware (external) RFID Equipment Card Recognition distance [m] max. 0.05...
Page 22: In- And Outputs With Mcsio
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 User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 23: Tab. 16 Sc2Iom-1
Digital output relay (DOR), 250 VAC, 8 A – – Digital output transistor (DOT), 24 VDC, 0.5 A – Analogue output current (AOI), 0–20 mA – – Tab. 18 SC2IOM-3 User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 24: Sensors
Power is provided by the machine's power supply unit. Characteristic Value Rated voltage (stabilised) [V DC] Current consump‐ tion SIGMA CONTROL 2 with IOM 1 [A] Current consumption IOM 2 [A] Current consumption IOM 3 [A] IOM ≙ Input/Output module Tab. 19 Power supply specifications 3.1.4.2...
Page 25: Tab. 23 Pressure Transducer
Controller SIGMA CONTROL 2 Characteristic Value Connection Two-core Tab. 23 Pressure transducer Resistance thermometer Characteristic Value Sensing resistance (to DIN IEC 751) PT100 Connection Two-core Tab. 24 Resistance thermometer User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 26: Safety And Responsibility Basic Instructions
The safety regulations of the machine in which SIGMA CONTROL 2 is installed apply. Specified use SIGMA CONTROL 2 is solely intended for the control of machines in which SIGMA CONTROL 2 is factory-installed. Any other use is considered incorrect. The manufacturer is not liable for any dam‐...
Page 27: Design And Function
─ 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. User Manual Controller No.: 9_9450 08 E...
Page 28: Fig. 5 Mcs System Design With Iom
MCS system design with IOM Machine enclosure Inputs/outputs in the interior of the control Control cabinet cabinet SIGMA CONTROL 2 (Prepared for con‐ Inputs/outputs in the interior of the com‐ nection to control centre) pressor Input-Output-Module (IOM): Inputs/outputs for external sensors...
Page 29: Operating Panel
Switch on the machine. «OFF» Switch off the machine. RFID RFID reader for user log-in with RFID Equipment Card. «Time control» Switches the time control on and off. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 30: Display Elements
Flashes in yellow in the following events: ■ Maintenance necessary. ■ Warning message Communications error Continuous red light to indicate a faulty communication connection without machine shut-down. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 31: Rfid Reader
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‐...
Page 32: Operating Mode
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 User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 33: Main Menu
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. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 34: Activating Keys With Check Boxes
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.
Page 35: Kaeser Connect
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...
Page 36: Menus - Overview
■ 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.
Page 37: Menu Structure
■ 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...
Page 38 Switching cycles ─ Load valve on ─ Mains contactor on ■ kWh counter Power switching with frequency converter SIGMA CONTROL 2 (Prepared for connection to control centre) User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 39 For details of the see table 37. 9 Machine test ■ TÜV inspection Power switching with frequency converter SIGMA CONTROL 2 (Prepared for connection to control centre) User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 40: Tab. 32 Menu Structure Of Main Menu
Compressor motor ─ Power switching Components menu, please For details of the see table 39. Power switching with frequency converter SIGMA CONTROL 2 (Prepared for connection to control centre) Tab. 32 Menu structure of main menu Status menu 5.6.2.1 Navigation Function/Sub-menu 1.1 Messages...
Page 41: Tab. 33 Status Menu
Nominal pressure/airend discharge temperature Diagram: 1.7 pN/n curve Nominal pressure/Speed Power switching with frequency converter only visible in the event of parameterization error SIGMA CONTROL 2 (Prepared for connection to control centre) Status menu Tab. 33 User Manual Controller No.: 9_9450 08 E...
Page 42 Network actual pressure Pressure control menu, please For details of the see table 35. Power switching with frequency converter SIGMA CONTROL 2 (Prepared for connection to control centre) SIGMA CONTROL 2 FLUID User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 43 Switch I/O periphery menu, please For details of the see table 36. Power switching with frequency converter SIGMA CONTROL 2 (Prepared for connection to control centre) SIGMA CONTROL 2 FLUID User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 44: Tab. 34 Configuration Menu
Run time max.: Reset Alarm: 5.10 Save data Language: Save data Power switching with frequency converter SIGMA CONTROL 2 (Prepared for connection to control centre) SIGMA CONTROL 2 FLUID Configuration menu Tab. 34 Pressure control menu Navigation Function/Sub-menu 5.2.1 Pressure sensors...
Page 45: Tab. 35 Pressure Control Menu
/AII For sensor error: Type of message: Warning Alarm Power switching with frequency converter SIGMA CONTROL 2 FLUID SIGMA CONTROL 2 VAC Pressure control menu Tab. 35 User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 46 Controller on Compressor on Motor running Idle On load Group alarm Group warning Remote mode Clock active ■ Clock contact EMERGENCY STOP Power switching with frequency converter User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 47 External message 1 ■ External message 2 ■ External message 3 ■ External message 4 ■ External message 5 ■ External message 6 Power switching with frequency converter User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 48: Tab. 36 I/O Periphery Menu
System pressure pNloc ■ Internal pressure pi ■ ■ Inlet temperature ■ PD temperature ■ n Compressor motor Power switching with frequency converter I/O periphery menu Tab. 36 User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 49 Sender name: Contact telephone: Receiver address: ─ SMTP Server: User name: Password: ─ Port/Timeout Resend after: MAC: MAC address SIGMA CONTROL 2 (Prepared for connection to control centre) User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 50: Tab. 37 Communication Menu
■ PROFIBUS ■ Modbus ■ Modbus TCP ■ DeviceNet ■ PROFINET ■ EtherNet/IP SIGMA CONTROL 2 (Prepared for connection to control centre) Communication menu Tab. 37 Connections menu 5.6.2.4 Navigation Function/Sub-menu 8.1.2 Connections ■ SIGMA CONTROL 2 ─ Status ─...
Page 51: Tab. 39 Components Menu
─ Customer-provided Power switching menu, please For details of the see table 40. Power switching with frequency converter SIGMA CONTROL 2 (Prepared for connection to control centre) Components menu Tab. 39 User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 52 Run-up period T↓ ─ ready ─ Mains contactor/Alarm td ─ Redundancy contactor/Alarm td Power switching with frequency converter SIGMA CONTROL 2 (Prepared for connection to control centre) User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 53: Operating Modes And Control Modes
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. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 54: Control Modes
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 ■...
Page 55: Variable Speed Drive With Frequency Converter (Sfc)
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.
Page 56: Modulating Control
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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 57: Installation And Operating Conditions
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. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 58: Installation
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 User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 59: Initial Start-Up Outline
8 Initial Start-up 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.
Page 60: 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.
Page 61: Setting The Language
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 User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 62: Noting The User Name
8.2.3 Noting the user name user name displayed on The number of your RFID Equipment Card is identical with the SIGMA CONTROL 2 after you have successfully logged on using your RFID Equip‐ ment Card. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 63: User Log-In With Rfid Equipment Card
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: ■...
Page 64: Generating A Password
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.
Page 65: Manual User Log-In
2. Use «Up» or «Down» to select the 3. Press «Enter». The setting mode is active. A column with alphanumeric characters is displayed. The selected character flashes. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 66: Create The Master Rfid Equipment Card
11. Use «Up» or «Down» to select the 12. Press «Enter». 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.
Page 67: Checking/Setting Time And Date
See chapter 8.2.16. <Configuration – General> menu. 1. Open the 5.1 Date/time line. 2. Use «Up» or «Down» to select the User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 68 4. Press «Enter». 00.00.00 flashes. The display for days 5. Use «Up» or «Down» to set the day. 6. Press the «Right» arrow. 00.00.00 flashes. The display for months User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 69: Set The Time Zone
11. Press «Escape» repeatedly to leave this menu. 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. Precondition Access level 2 is activated.
Page 70: Tab. 46 Possible Settings For The Time Format
8 0 ° C Menu 5.1 General Europe/London ········· ▶2 Time server ········· Date format MM/DD/YY time format Time format hh:mm:ssAM/PM 3. Press «Enter». hh:mm:ssAM/PM indication flashes. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 71: Tab. 47 Possible Settings For The Pressure Unit
6. Press «Escape» repeatedly to leave this menu. Setting the temperature display units Set the temperature unit for display: Format Example °C 46°C 319K °F 114°F Tab. 48 Possible settings for the temperature unit User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 72: Setting The Display Illumination
8 0 ° C Menu 5.1 General ········· Unit of pressure Pressure unit Unit of temperature Temperature unit °C ········· Display lighting Active line Mode: auto.¦ Timeout: 1min User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 73: Setting The Contrast And The Brightness
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. Precondition Access level 2 is activated.
Page 74: Ip Configuration
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 IP configuration menu (see chapter 8.10.4).
Page 75: Setting The E-Mail Function
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. User Manual Controller No.: 9_9450 08 E...
Page 76 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‐...
Page 77: Setting The Time Server
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‐...
Page 78: Kaeser Connect Benefits
12. Press «Escape» repeatedly to leave this menu. Result Access to the selected time server is active. The internal clock of SIGMA CONTROL 2 is permanently synchronised. KAESER CONNECT benefits Using an Internet-capable device with web browser, you can use KAESER CONNECT to remotely display these SIGMA CONTROL 2 menus: ■...
Page 79: Open Kaeser Connect
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.
Page 80: System Status Menu
7. Click to set the selected language Result KAESER CONNECT is displayed in the set language. 8.3.2 System status menu Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 81: Fig. 18 System Status Menu
Initial Start-up KAESER CONNECT benefits System status menu Fig. 18 System status menu element. 1. Click the System status menu is displayed Fig. 19 Main menu User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 82: Graphs Menu
Initial Start-up KAESER CONNECT benefits 2. Click in the SIGMA CONTROL 2 display. The Main menu is displayed. 3. Click the numbered lines. The system displays the corresponding sub-menus. 4. Press ESC repeatedly to leave this menu. 8.3.3 Graphs menu...
Page 83: Fig. 21 Control Keys
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. Start: . 1. Enter the date and time for the start time in the required time period in End: .
Page 84: Messages Menu
■ Compressor messages ■ System messages ■ Diagnostic messages Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed. Messages (illustration similar) Fig. 22 Messages menu element. 1. Click the Messages menu is displayed 2. Click the required message type. 3. Check messages.
Page 85: User Management Menu
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. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 86: Fig. 24 User Management Menu
Log on for write access: window User name: field. 3. Enter your user name in the Password: field. 4. Enter your password in the 5. Click OK. User management menu is displayed User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 87: Fig. 26 User Management Menu
1. Click the required user account in the list. Password: field. 2. Enter a new password in the Repeat password: field. 3. Re-enter the same new password in the 4. Click Update user. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 88: Settings Menu
Settings menu Fig. 27 For example, you want to convert your units to US values: Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed. 1. Click the Settings menu element. 2. Click the arrow key for the unit of pressure.
Page 89: Save Data Menu
Initial Start-up KAESER CONNECT benefits 8.3.8 Save data menu 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 Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed.
Page 90: Pressure Parameters Of The Machine
↓: 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 User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 91: Displaying Pressure Parameters
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) User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 92: Tab. 55 Pressure Condition For Load
The parameters for the network nominal pressure 8.4.2.2 Setting "System pressure low" parameters System pressure low , SIGMA CONTROL 2 displays When the network pressure drops to the value a warning message for insufficient network pressure. The switching differential influences the pressure at which the message can be acknowledged or...
Page 93 ≙ fitted, − ≙ not fitted Tab. 58 Displaying and setting parameters Precondition Access level 2 is activated. 1. Open the 5.2.2 <Configuration – Pressure control – Pressure settings> menu. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 94: Activating/Deactivating The "Load/Idle" Key
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. Precondition Access level 2 is activated. 1. Open the 5.2.3 <Configuration –...
Page 95: Machine Start And Machine Stop
Compressor clock menu ■ Open the ■ Set clock program ■ Activate the «Timer» key ■ Activating time control 8.5.1.1 Compressor clock Precondition Access level 2 is activated. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 96: Tab. 60 User-Defined Clock Programme Machine On/Off
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 User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 97 8. Use «Up» or «Down» to set the hours. 9. Press the «Right» arrow. 00 flashes. 10. The display for minutes, 00: 11. Use «Up» or «Down» to set the minutes. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 98 The check box is activated. 4. Press «Enter». The setting is applied. 5. Press «Escape» repeatedly to leave this menu. Result The «Time control» key is activated. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 99: Setting The Company Shut-Down
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 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.
Page 100: Controlling Machine From A Remote Location
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: User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 101 8 0 ° C Menu 5.4.1 Compressor on Local mode: Remote mode: Active line ------------------------------ DI1.07 ☑ Key + remote contact input. 5. Use «Up» or «Down» to set the User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 102: Activating The Remote Control
If your entry is rejected it means that the input is already assigned. ➤ Select a different input. 8.5.4 Activating the remote control ➤ Activate remote control see chapter 8.2.13. Result SIGMA CONTROL 2 remote control is activated. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 103: Venting" Function
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. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 104: Tab. 62 Autostart Delay Period
The first machine may start immediately and does not require a delay time. Machine number Start time [sec] Delay time [sec] –– –– Tab. 62 Autostart delay period Precondition Access level 2 is activated. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 105 Set/expiring delay time Target 12s ¦ Actual ········· 2. Press «Enter». Autostart: will flash. The check box 3. Press «Up» key. Autostart: is deactivated. The check box User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 106: Control Modes
5.3 Control mode Active line Local mode: DUAL ------------------------------ Venting period menu ▶1 Venting period ········· ▶2 DUAL 3. Press «Down». The currently set control mode is displayed. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 107: Setting The Dual Control Mode
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.
Page 108: Setting The Quadro Control Mode
240s ¦ Actual Min. run period line. 2. Use the «Up» or «Down» keys to select the 3. Press the «DOWN» key. 4. Press «Enter». The seconds display flashes. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 109: Electronic Thermal Management
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". User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 110 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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 111: Activating The Heat Recovery For Machine Type 3
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. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 112: 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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 113: Refrigeration Dryer
8 0 ° C Menu 5.9 Refrigeration dryer Control mode Compressor ready: Active line Continuous Compressor Clk/RC/RB off: ········· 4. Press «Enter». The currently active operating mode flashes. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 114: Output Messages
Temperature ↑ DOR1.07 ☐¦Logic : DOT1.01 ☐¦Logic : Temperature⇟ DOR1.03 ☐¦Logic : DOT2.01 ☐¦Logic : 3. Press the «DOWN» key. 4. Press «Enter». The setting mode is active. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 115: Fault In The Refrigeration Dryer - Compressed Air Quality Has Priority
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.
Page 116: Fault In The Refrigeration Dryer - Compressed Air Supply Has Priority
➤ 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.
Page 117: Setting The Machine For Local Mode
Set the nominal pressure for the first switching point pA or pB ■ Set up any further switching points. pA/pB Clock : see chapter 8.9.3.3. ■ Select the operating mode User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 118 Deleting an existing timing program Delete an existing timing program as follows: Precondition Access level 2 is activated. 1. Open the 5.2.3 <Configuration – Pressure control – Load control > menu. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 119 8 0 ° C Menu 5.2.3.1 pA/pB Clock Reset : ☐ ········· Setting for weekdays, time, pA Mon-Fri 06:30AM Setting for weekdays, time, pB Mon-Fri 12:00PM Mon-Fri 01:00PM Mon-Thu 05:00PM User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 120: Setting The Nominal Pressure Change Via Timer
4. Press the «Enter» key. 00 flashes. The display for the cycle duration in hours, 5. Use «Up» or «Down» to set the hours. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 121 ➤ Press the «Enter» key and adjust with «Up» 8.9.3.3 Setting local mode Precondition Access level 2 is activated. The timing program or timer is set up. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 122: Setting The Machine For Master Control Operation
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‐...
Page 123: Sam 4.0 Mode
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...
Page 124 (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. <Communication – Ethernet/SIGMA NETWORK – Connections – SAM 4.0>...
Page 125 13. Press the «Enter» key. The setting is applied. Result SIGMA CONTROL 2 communicates with SAM 4.0 via SIGMA NETWORK. The communication is working smoothly when neither SIGMA CONTROL 2 nor SAM 4.0 report any communication fault. User Manual Controller No.: 9_9450 08 E...
Page 126: Setting Profibus Operation (Sigma Air Manager)
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.
Page 127: Fig. 29 Wiring Of The Profibus Connection
Pin assignment of SUB-D 9-pole interface on the PROFIBUS module Interface plug wiring Fig. 29 Wiring of the PROFIBUS connection Terminal 1A Terminal 2B Terminal 1B Slide switch, terminating resistor Terminal 2A User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 128: Fig. 30 Electrical Diagram Example With Sigma Air Manager
Initial Start-up 8.10 Setting the machine for master control operation Electrical diagram example with SIGMA AIR MANAGER (extract) Fig. 30 Electrical diagram example with SIGMA AIR MANAGER User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 129: Fig. 31 Communication Interface
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.
Page 130: Fig. 32 Insert The Communication Module
The machine is parametrised as a slave in the bus master. The bus master is operational. Fig. 33 Front plate communication module PROFIBUS Communication module PROFIBUS Status Operation PROFIBUS-Interface User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 131 When connected to a SIGMA AIR MANAGER, the slave address is determined as follows: Compressor number used at SIGMA AIR MANAGER +102. Precondition Access level 2 is activated. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 132 (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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 133 Activating the remote control ➤ Activate remote control see chapter 8.2.13. Result SIGMA CONTROL 2 remote control is activated. The bus master can remotely control the SIGMA CONTROL 2. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 134: Master Control Of Two Machines In Master/Slave Operation
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 pA and pB target pressures.
Page 135: Fig. 34 Direct Connection Of Two Sigma Control 2
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.
Page 136 Setting the machine for master control operation 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.
Page 137 The IP address of machine 1 (master) is set correctly. <Communication – Ethernet/SIGMA NETWORK – Connections – SIGMA 2. Open the 8.1.2.1 CONTROL 2> menu. Mode line. 3. Use «Up» or «Down» to select the User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 138 SP: 8.2bar ¦ SD: −0.5bar ········· System pressure low ☐ ↓ < 5.0bar ¦ SD: 0.50bar pA value. 3. Use «Up» or «Down» to set the User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 139 6. If necessary, adjust the value for the Activating the remote control ➤ Activate remote control see chapter 8.2.13. Result SIGMA CONTROL 2 remote control is activated. Set the remote operating mode Precondition The electrical connection is made. Access level 2 is activated.
Page 140: Configuring Master Control Using The Load Remote Contact (E.g., Sigma Air Manager Basic)
Set the LOAD remote contact operating mode and assign the input pE . ■ If required, set temporary pressure increase ■ Activating the «remote control» key ➤ Set master control as described below. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 141: Fig. 35 Load Remote Contact
▶1 pA/pB Clock ········· pA/pB Cycle Load RC input. 4. Use «Up» or «Down» to set the 5. Press «Enter». The LOAD remote contact operating mode is set. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 142: Setting The Master Control With Local/Load Remote Contact
Detailed information on the pressure parameters is provided in chapter 8.4.2. 8.10.5.4 Activating the remote control ➤ Activate remote control see chapter 8.2.13. Result SIGMA CONTROL 2 remote control is activated. 8.10.6 Setting the master control with local/LOAD remote contact Overview ■...
Page 143: Fig. 36 Wiring Diagram For Local/Load Remote Contact
■ Contact A open: SIGMA CONTROL 2controls with ■ 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.
Page 144 Access level 2 is activated. <Configuration – Pressure control – Load control> menu. 1. Open the 5.2.3 Local mode line. 2. Use «Up» or «Down» to select the User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 145 8.10.6.4 Activating the remote control ➤ Activate remote control see chapter 8.2.13. Result SIGMA CONTROL 2 remote control is activated. 8.10.6.5 Assign an input for the LOAD remote contact for switching the pressure control Precondition Access level 2 is activated.
Page 146: Setting The Nominal Pressure Pre-Selection Via Remote Contact
Assigning the remote contact input A spare input can be found in the machine circuit diagram. pA/pB RC line. 1. Use «Up» or «Down» to select the User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 147: Master Control For Machines Regulated By Pressure Switch
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: ■...
Page 148: Fig. 37 Machine With Pressure Switch Regulation
8.10 Setting the machine for master control operation 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 ■...
Page 149 This output can now be used for the changeover between the two pressure switches. Setting local mode Precondition Access level 2 is activated. 1. Open the 5.2.3 <Configuration – Pressure control – Load control> menu. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 150 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.
Page 151: Fig. 38 Function Diagram
8.5bar ¦ SD: −0.5bar pB SP: 8.2bar ¦ SD: −0.5bar ········· System pressure low ☐ ↓ < 5.0bar ¦ SD: 0.50bar 3. Press «Enter». pA display flashes. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 152: Examples Of Time Settings For Equal Overall Load
On Mon-Sun 06:30AM pB On Mon-Sun 12:00PM pA On pB On Mon-Sun 05:00PM Tab. 72 Example for a clock program for equal duty cycling during the day User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 153: Setting Input And Output Signals
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 User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 154: Tab. 74 Assigned Output Signals
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 User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 155: Output Input Signals On The Display
External messages menu for specifying the settings. Use the ■ Enter the message text ■ Assign and activate the input ■ Set the time delay ■ Setting the logic User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 156 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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 157 «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. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 158: Tab. 75 Logic Settings
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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 159: Output Measured Values On The Display
The signal at the DI digital input is available as selected DOR output. 8.11.3 Output measured values on the display For analogue measured values you can define customised messages. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 160: Tab. 76 Assigned Analogue Measured Values
Below, the settings are displayed based on an example in the Switch menu analogously for specifying the settings. 8.11.3.1 Analogue values menu Precondition The electrical connection has been made. Access level 2 is activated. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 161 The cursor is located at the first character of the message text. A column with alphanumeric characters is displayed. The selected character flashes. 6. Select the required character with the «Up» or «Down» keys. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 162 ☑ ········· Switching point (SP) and switching differential (SD) 8.0bar ¦ SD: −0.5bar Time delay (td) ········· 8. Press «Enter». The measured value is assigned and activated. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 163 4. Press «Enter». td delay time has been set. Result 8.11.3.6 Setting the message type 1. Select the message type line with the «Up» and «Down» keys. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 164 ☐ ¦ Logic: 5. Press the «Right» arrow. 6. Press «Enter». The check box assigned to the output flashes. 7. Press the «Up» key. The check box is activated. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 165: Switching And/Or Triggering Messages With Thresholds
Power switching with frequency converter Tab. 77 Available measured values System pressure pNloc . Example: Setting for the local network pressure at compressor output Precondition Access level 2 is activated. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 166 SD switching differential in the same way. 5. If necessary, adjust the value for the SP switching point and the SD switching differential are set. Result The threshold for the User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 167 ☐ 5. Press the «Right» key. 6. Press «Enter». The check box assigned to the output flashes. 7. Press the «Up» key. The check box is activated. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 168 −0.6bar Delay (td) and logic 0s ¦Logic Output DOR DOR1.03 ok ☑ Type of message Warning ☑ 3. Press the «Up» key. The check box is activated. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 169: Timer
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.
Page 170: Activating Remote Acknowledgement
A controller input has been assigned for the acknowledgement signal. Overview <Configuration – Acknowledgement> menu. ■ Select the ■ Set the "Remote acknowledgement" function. ■ Activating the remote control User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 171: Setting The Remote Acknowledgement Function
Result The Remote acknowledgement function is set. 8.13.2 Activating the remote control ➤ Activate remote control see chapter 8.2.13. Result SIGMA CONTROL 2 remote control is activated. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 172: Assigning An Input
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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 173: Linking To An External Pressure Transducer
■ 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. <Configuration – Pressure control> menu. ■ Open the ■ Assigning an input 8.14.1...
Page 174: Commissioning The Machine
8.2.2 ➤ Date and time correct? 8.2.8 ➤ Display format correctly set? 8.2.10 ➤ System pressure setpoint correctly set? Tab. 79 Check list for starting the machine User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 175 ------------------------------ Operating parameters 2500h Load 2490h Maintenance indicator Maintenance in 500h 2. Continue the commissioning process as described in chapter "Commissioning" of the ma‐ chine's operating manual. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 176: Operation
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. voltage applied to controller LED lights green.
Page 177: Switching Off
Switching off in an emergency 9.1.2 Switching off 1. Press the «OFF» key. IDLE LED flashes. The SIGMA CONTROL 2 display The machine switches to IDLE and the Stopping is displayed. The ON LED extinguishes as soon as the automatic shut-off action is completed.
Page 178: Acknowledging Alarm And Warning Messages
Alarm LED flashes. The red Precondition The fault has been rectified ➤ Press «Ack» to acknowledge the fault message. Alarm LED extinguishes. The machine is again ready for operation. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 179: Displaying Messages
Selected submenu: ■ Compressor messages ■ Diagnostic messages ■ System messages Segment: ■ Message number ■ Message type ■ Message status ■ Message date ■ Message time User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 180: Status - Messages Menu
▶2 Message history Only displayed in the event of I/O parametrisation ▶3 Address error error Status report 01:00 ☐ ------------------------------ Number of currently registered faults current Alarms User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 181 Message text for message 0015 Com-Module communication error 0034 O c 04/13/16 08:15:37AM Message text for message 0034 E-mail send unsuccessful! 3. Press «Escape» repeatedly to leave this menu. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 182: Displaying The Current Operating Mode
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...
Page 183: Setting The Working Pressure
System pressure pNloc 6.1 bar ········· Airend discharge temperature 80°C Rise of airend discharge temperature dT/dt 0.0°C/s ········· Differential pressure, oil separator cartridge Oil separator Δp 0.0bar User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 184: Displaying Operating Data
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) ■...
Page 185: Checking The 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.
Page 186: Displaying The Frequency Converter Settings
Replacing the mains contactor If the displayed value of the mains contactor exceeds the maximum permissible number of 0024 Mains contactor switching cycles, SIGMA CONTROL 2 generates the warning message operations ⇞ . The mains contactor must be replaced. ➤ Have the mains contactor replaced by authorised KAESER SERVICE.
Page 187: Setting The Maintenance Interval
8 0 ° C 4 Maintenance active line, Description maintenance interval Oil change Preset interval 3000 h 3000h¦ 0150h Reset: ☐ ········· Air filter 3000h¦ 0150h Reset: ☐ ········· User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 188: Check The Safety Valve
➤ 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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 189 Otherwise, the machine remains in IDLE and is stopped after two minutes. pi pressure rises. The machine switches to LOAD and the machine's pi pressure rise during the TÜV check. 8. Use the display to monitor the User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 190: Excessive Temperature Shut-Down Test
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.
Page 191 The machine will switch off as soon as the discharge temperature attains a value of The machine does not shut down? ➤ Abort the test and contact authorised KAESER SERVICE as soon as possible. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 192: Save Data
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. Reset check box in order to reset the stored value.
Page 193 8. Press the «Up» key. The check box is activated. 9. Press «Enter». A security query is displayed. 10. Press «Enter». Result The settings are saved on the SD card. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 194: 10 Fault Recognition And Rectification
10.1 Basic instructions The following tables are intended to assist in locating faults. SIGMA CONTROL 2 will indicate three types of faults: ■ Fault on the machine: red LED flashes, the machine is shut down, see chapters 10.2 and 10.5.
Page 195 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 ⇞ User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 196 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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 197 0074 A External message 2 0075 A External message 3 0076 A External message 4 0077 A External message 5 0078 A External message 6 0081 A AnMod_p_1 User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 198 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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 199 Call KAESER SERVICE. USS bus communication error %d 0210 A Compressor motor temperature Keep ambient conditions within Compressor motor FC too high. specified limits. Over temperature alarm Cooler maintenance. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 200 (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 User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 201 0301 A Frequency converter fault Call KAESER SERVICE. Oil cooler fan USS alarm 0303 A Frequency converter fault Call KAESER SERVICE. Oil cooler fan FC PKW failure P%d.E%d User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 202: Interpreting Warning Messages
LED flashes. ■ ■ The controller does not switch off the machine. Warning messages are identified with the letter W. The message numbers are not numbered consecutively. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 203 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. User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 204 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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 205 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 User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 206 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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 207 AnMod_T_3 0088 W AnMod_T_4 0089 W AnMod_I_1 0090 W AnMod_I_2 0092 W T-Switch inlet temperature 0093 W p-Switch pi 0094 W T-Switch ADT 0095 W p-Switch pN User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 208 Frequency converter in service mode. Terminate service mode. Oil cooler fan FC Service mode active 0254 W Frequency converter in service mode. Terminate service mode. Oil cooler fan FC Service mode active User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 209 Check the voltage supply. AII%d.0%d - error logue input faulty. power supply 0879 W Overload on the analogue input for Call KAESER SERVICE. AII%d.0%d - overload ext. sensor. fault User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 210 AIR%d.0%d - open logue input. nections. circuit 0909 W Short circuit in line for indicated ana‐ Check cable runs and sensor con‐ AIR%d.0%d - short- logue input. nections. circuit User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 211 AIR%d.0%d - sensor put. nections. fault 0930 W Open circuit in line for indicated ana‐ Check cable runs and sensor con‐ AIR%d.0%d - open logue input. nections. circuit User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 212 AIR%d.0%d - open logue input. nections. circuit 0953 W Sensor fault at indicated analogue in‐ Check cable runs and sensor con‐ AIR%d.0%d - sensor put. nections. fault User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 213 Check the voltage supply. AII%d.0%d - error logue input faulty. power supply 1053 W Overload on the analogue input for Call KAESER SERVICE. AII%d.0%d - overload ext. sensor. fault User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 214 AIR%d.0%d - short- logue input. nections. circuit 1072 W Open circuit in line for indicated ana‐ Check cable runs and sensor con‐ AIR%d.0%d - open logue input. nections. circuit User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 215 AIR%d.0%d - short- logue input. nections. circuit 1090 W Open circuit in line for indicated ana‐ Check cable runs and sensor con‐ AIR%d.0%d - open logue input. nections. circuit User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 216 AIR%d.0%d - short- logue input. nections. circuit 1108 W Open circuit in line for indicated ana‐ Check cable runs and sensor con‐ AIR%d.0%d - open logue input. nections. circuit User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 217 AII%d.0%d - overload ext. sensor. fault 1204 W No continuity in line for ext. sensor at Check cable runs and sensor con‐ AII%d.0%d - open analogue input. nections. circuit User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 218 1227 W Short circuit in line for indicated ana‐ Check cable runs and sensor con‐ AIR%d.0%d - short- logue input. nections. circuit User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 219 1245 W Short circuit in line for indicated ana‐ Check cable runs and sensor con‐ AIR%d.0%d - short- logue input. nections. circuit User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 220 1263 W Short circuit in line for indicated ana‐ Check cable runs and sensor con‐ AIR%d.0%d - short- logue input. nections. circuit User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 221 1281 W Short circuit in line for indicated ana‐ Check cable runs and sensor con‐ AIR%d.0%d - short- logue input. nections. circuit User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 222: Interpreting Operation Messages
Delayed start (%ds) active master controller (e.g. SAM 4.0) or after switching on the SAM manual mode. 0009 O The machine is switched on. Compressor on User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 223 0077 O External message 5 0078 O External message 6 0081 O AnMod_p_1 0082 O AnMod_p_2 0083 O AnMod_p_3 0084 O AnMod_p_4 0085 O AnMod_T_1 0086 O AnMod_T_2 User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 224 Service information Safety shutdown "IOMDiagnosis()" 0501 O Service information Safety shutdown "Safeguard()" 0550 O Short-term overload fault without shut-down occurred at ADT. ADT channel error "currleak" detected User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 225 AII%d.0%d - overload fault 1354 O IOM bus fault IOSlot%d - bus error 1371 O Short-term overload fault without shut-down occurred at All. AII%d.0%d - overload fault User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 226: Interpreting Diagnostic Messages
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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 227: Tab. 90 System Messages And Remedies
RAM out of memory 1000 Y System error Call KAESER SERVICE. RFID error: switch SIGMA CONTROL power supply OFF → ON! Tab. 90 System messages and remedies User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 228: 11 Maintenance
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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 229: 12 Spares, Operating Materials, Service
0 8 : 1 5 A M 8 0 ° C Menu 5.1.1 System information Active line ▶1 SIGMA CONTROL 2 MCS ▶2 Compressor ▶3 I/O modules ▶4 FC information User Manual Controller No.: 9_9450 08 E SIGMA CONTROL 2 SCREW FLUID ≥4.1.X...
Page 230 0 8 : 1 5 A M 8 0 ° C Menu 5.1.1.1 SIGMA CONTROL 2 MCS 123456 ········· Manufacturer Prodrive Material number 6309.1000.7900 Serial number 10.34.000.961 Manufacturing date MFGDT 2017/04 User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...
Page 231: 13 Decommissioning, Storage And Transport
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.
Page 232: Fig. 42 Battery Labelling
➤ 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. User Manual Controller SIGMA CONTROL 2 SCREW FLUID ≥4.1.X No.: 9_9450 08 E...

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