KAESER SIGMA CONTROL BUB 82 Series Service Manual
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KAESER SIGMA CONTROL BUB 82 Series Service Manual

KAESER SIGMA CONTROL BUB 82 Series Service Manual

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Service manual
Controller
SIGMA CONTROL
BUB 82.XX
7_7000_0 11USE

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Summary of Contents for KAESER SIGMA CONTROL BUB 82 Series

  • Page 1 Service manual Controller SIGMA CONTROL BUB 82.XX 7_7000_0 11USE...
  • Page 2 /KKW/SSC 1.01 en 01 BA-SIGMA CONTROL...
  • Page 3 Quick user guide Controller SIGMA CONTROL BUB 82.XX 7_7000_0 11 USE...

  • Page 5: Table Of Contents

    Contents Important settings ......................Changing the display language ..................Entering and displaying passwords .................. Adjusting the system setpoint pressure ................Activating the «clock» key ....................Activating the «remote control» key ................. Changing the control mode ....................Outputting important operational states of the machine ........... Resetting maintenance interval counters .................
  • Page 6 Contents Quick user guide Controller SIGMA CONTROL BUB 82.XX 7_7000_0 11 USE...

  • Page 7: Important Settings

    Important settings 1 Important settings In this chapter, important or often used settings are explained in brief. Detailed information on function, configuration, fault removal and important instructions concerning safe operation are found in sub‐ sequent chapters. Setting and other work on the machine may only be carried out by the following persons: ■...

  • Page 8: Changing The Display Language

    Changing the display language 2 Changing the display language 1. In the main menu, press the «UP» key until the current language appears. p s i g 1 7 6 ° F Current language → D e u t s c h ↲...

  • Page 9: Entering And Displaying Passwords

    Entering and displaying passwords 3 Entering and displaying passwords The following passwords have been entered in the controller at the factory: Level 0 Level 4 password 00000 12EXP Tab. 1 Passwords password appears in the third line of the 1. In the main menu, keep pressing the «UP» key until display.

  • Page 10: Adjusting The System Setpoint Pressure

    Adjusting the system setpoint pressure 4 Adjusting the system setpoint pressure The information relates to settings for a compressor. Vacuum pumps or other devices should be treated accordingly. Precondition Password level 4 is activated. Select menu configuration > press. settings. configuration appears in the third line of 1.

  • Page 11: Activating The "Clock" Key

    Activating the «clock» key 5 Activating the «clock» key Precondition Password level 4 is activated. Select the clock menu 1. From the main menu, keep pressing the «UP» key until clock appears in the third line of the display. 2. Press «Enter». p s i g 1 7 6 °...

  • Page 12: Activating The "Remote Control" Key

    Activating the «remote control» key 6 Activating the «remote control» key Further settings have to be made to allow the machine to be remotely controlled. ➤ Refer to further information in this chapter. The «remote control» key can be activated in two menus: <...

  • Page 13: Changing The Control Mode

    Changing the control mode 7 Changing the control mode Select menu configuration > control mode Precondition Password level 4 is activated. configuration appears in the third line 1. From the main menu, keep pressing the «UP» key until of the display. 2.

  • Page 14: Outputting Important Operational States Of The Machine

    Outputting important operational states of the machine 8 Outputting important operational states of the ma‐ chine Important operational machine states can be assigned via floating relay contacts as a binary signal on the outputs DO0.3 – DO0.5. Further outputs are optionally available. Each output can be assigned only once.

  • Page 15: Resetting Maintenance Interval Counters

    Resetting maintenance interval counters 9 Resetting maintenance interval counters Precondition Maintenance carried out, warning message acknowledged, password level 4 activated. Select menu maintenance > maintenance interval counter maintenance appears in the third 1. From the main menu, keep pressing the «DOWN» key until line of the display.

  • Page 16: 10 Displaying Messages

    Displaying messages 10 Displaying messages Selecting menu status > messages status appears in the third line of 1. From the main menu, keep pressing the «DOWN» key until the display. 2. Press «Enter». messages appears in the display. 3. Press «Enter». event info appears in the display.

  • Page 17: 11 Pressure Relief Valve Checking

    Pressure relief valve checking 11 Pressure relief valve checking Overview ■ Preparation for the test ■ Carrying out the check ■ Correct conclusion of the test When the check mode is activated, monitoring of internal pressure (blowoff protection - if pro‐ vided) and regulation of network pressure are deactivated.
  • Page 18 If the alarm message internal pressure was exceeded by 29 psi. ➤ Have the pressure relief valve replaced by an authorized KAESER Service Technician. Avoid oil mist: ➤ Release the «ON» key as soon as the pressure relief valve opens to minimize oil mist blow off.

  • Page 19: Checking The Temperature Sensor And Overheating Shutdown Function

    Checking the temperature sensor and overheating shutdown function 12 Checking the temperature sensor and overheating shutdown function The machine should shut down if the airend discharge temperature (ADT) reaches 230 °F. A higher temperature is simulated to check this function. For this, it is necessary to determine and enter an offset value.
  • Page 20 As soon as a value ADT of 230 °F is reached, the machine shuts down and an alarm is activated. The machine does not shut down? ➤ Abort the test and contact KAESER Service as soon as possible. Correct conclusion of the test 1.
  • Page 21 Contents Regarding this Document Using this document ......................Further documents ......................Copyright .......................... Symbols and markings ..................... 1.4.1 Warning notices ....................1.4.2 Display illustration ....................1.4.3 Other notices and symbols ................. Technical Data Technical specifications ....................2.1.1 Power supply ...................... 2.1.2 Sensors .......................
  • Page 22 Contents 7.2.3 Entering and displaying passwords ..............7.2.4 Checking/setting time and date ................7.2.5 Setting display formats ..................7.2.6 Setting and activating summer/winter time ............7.2.7 Activating/deactivating the «IDLE» key .............. Matching the pressure parameters of the machine and possible components ....7.3.1 Display pressure parameters ................
  • Page 23 Contents 7.10.6 Allocating a value range to the measurement (scaling) ........7.11 Configuring the compressed air outlet temperature (PD temperature) ......7.11.1 Compensating for line resistance ............... 7.11.2 Entering the correction value ................7.11.3 Switching levels for the package discharge temperature ........7.12 Activating remote acknowledgement ................
  • Page 24 10.2.2 Testing the LEDs on the controller ..............128 Spares, Operating Materials, Service 11.1 Note the nameplate ......................129 11.2 KAESER AIR SERVICE ....................129 11.3 Service addresses ......................129 11.4 Displaying the version number, machine model, material number and serial number ..129 Decommissioning, Storage and Transport 12.1 De-commissioning ......................
  • Page 25 List of Illustrations Fig. 1 Keys ............................Fig. 2 Indicators ............................ Fig. 3 Pressure rise in frequency-controlled machines ................ Fig. 4 Profibus plug wiring ........................Fig. 5 Electrical diagram example with SIGMA AIR MANAGER ............Fig. 6 Electrical connections between the two controllers ..............Fig.
  • Page 26 List of Illustrations Service manual Controller SIGMA CONTROL BUB 82.XX 7_7000_0 11USE...
  • Page 27 List of Tables Tab. 1 The levels of danger and their meaning ..................Tab. 2 Power supply ..........................Tab. 3 Pressure transducer ........................Tab. 4 Pressure transducer ........................Tab. 5 Keys ............................Tab. 6 Indicators ............................ Tab. 7 Internal operating mode ......................Tab.
  • Page 28 List of Tables Service manual Controller viii SIGMA CONTROL BUB 82.XX 7_7000_0 11USE...

  • Page 29: Regarding This Document Using This Document

    Copyright This service manual is protected by copyright. Any queries regarding the use or duplication of this documentation should be referred to KAESER. We would be pleased to help you in using the infor‐ mation to meet your unique requirements.

  • Page 30: Display Illustration

    Regarding this Document Symbols and markings ➤ Always read and comply with warning instructions. Signal word Meaning Consequences of non-observance DANGER Warns of an imminent threat of danger Death or serious injury may result WARNING Warns of possible danger Death or serious injury are possible CAUTION Warns of a possibly dangerous situa‐...

  • Page 31: Technical Data Technical Specifications

    Technical Data Technical specifications 2 Technical Data Technical specifications 2.1.1 Power supply Power is provided by the power supply unit within the machine. Feature Value Stabilized power supply [V DC] Current draw [A] (standard device) Current draw [A] (with expansion card) Tab.
  • Page 32 Technical Data Technical specifications Interfaces ■ RS 232 ■ RS 485 ■ Profibus DP Further information Further details concerning inputs and outputs are to be found in the electrical diagrams of the ma‐ chine. Service manual Controller SIGMA CONTROL BUB 82.XX 7_7000_0 11USE...

  • Page 33: Safety And Responsibility Basic Instructions

    ➤ Immediately rectify (have rectified) any faults that could be detrimental to safety. Specified use The controller is designed exclusively for use in connection with KAESER screw compressors and vacuum pumps in an industrial environment. It may only be used in conjunction with a machine de‐...

  • Page 34: Safely Dealing With Sources Of Danger

    Safety and Responsibility Safely dealing with sources of danger ➤ Ensure that personnel entrusted with operation, installation and maintenance are qualified and authorized to carry out their tasks. This applies particularly for: ■ installation and commissioning, ■ maintenance and service work, ■...

  • Page 35: Design And Function

    The controller The controller controls, regulates, monitors and protects the machine. All parameters needed to operate KAESER rotary screw compressors and rotary vacuum pumps can be entered and displayed using the controller. The parameters are protected by passwords at various access levels.

  • Page 36: Sigma Control Keys And Indicators

    Design and Function SIGMA CONTROL keys and indicators SIGMA CONTROL keys and indicators Fig. 1 Keys Item Name Function «ON» Switches the machine on. The programmed operating mode is active. «OFF» Switches the machine off. «Clock» Switches clock control on and off. «Remote control»...

  • Page 37: Display

    Design and Function Display Fig. 2 Indicators Item Name Function Indicator field or display Alphanumeric display with 4 lines. Alarm Flashes red when an alarm occurs. Lights continuously when acknowledged. Communication Lights red if communication via the Profibus interface is interrupted. Warning Flashes yellow for: ■...

  • Page 38: Password Protection

    Design and Function Password protection Line 1: header Current system pressure and airend discharge temperature are displayed in the header. These values are shown in the following menus or setup level: ■ Main menu ■ In set-up levels in which parameter changes can be made even though the machine is running The letters s and F can be displayed in the header.

  • Page 39: The Menu Structure

    Design and Function The menu structure A further access level (level 4) is available to the customer. Further parameters can be displayed and set in level 4, for example, the system pressure setpoint or reset of the maintenance interval counters. The password protected level automatically resets to level 0 three hours after the last data input.

  • Page 40: Menu Configuration

    Design and Function Settings level Menu Menu options Menu option: clock ■ Activating the «clock» key – ■ Clock program of compressor cut-in and cut-out (switching points) ■ Resetting clock program configuration ■ general ■ press. settings ■ control mode ■...
  • Page 41 Design and Function Settings level Navigation (menu / > menu option) Function general Display: ■ Version no. ■ Compressor model ■ PN: (material number) ■ SN: (serial number) Setting ■ Date ■ Time ■ Summertime/wintertime ■ Date format ■ Time format ■...
  • Page 42 Design and Function Settings level Navigation (menu / > menu option) Function control mode Setting > settings ■ Venting period control mode Setting > dryer ■ CONTINUOUS > > timer ■ TIMER control mode Setting > mod. valve ■ Switch points Display: ■...

  • Page 43: Menu Components

    Design and Function Settings level 4.6.2 Menu components < components > menu. Parameters for individual machine components are displayed and set in the The menu comprises the following options (depending on drive motor type): Navigation (menu / > menu option) Function motor Display of motor starting configuration...

  • Page 44: Menu Communication

    RS232 Setting ■ Modem connection RS232 Setting > SMS ■ The sending of short messages (e. g. to KAESER Service in connection with a SIGMA TELE CARE contract). RS485 Setting ■ Master-slave operation ■ Activate the remote key ProfiBus Display ■...
  • Page 45 Design and Function The display level Navigation (menu / > menu option) Function status Display > messages ■ Event memory ■ Last alarm ■ Last warning ■ Number of current alarm and warning mes‐ sages. status Display > statistics ■ Overall duty cycle in percent and for the SFC with USS protocol (frequency-controlled machines).

  • Page 46: Operating Modes And Control Modes

    The load and power consumption of the drive motor rises and falls with the air demand. The regulating valve is factory set. The setting should not be changed without consultation with KAESER Service. 4.8.2 Control modes Using the selected control mode, the controller switches the drive motor according to definite rules...

  • Page 47: Variable Speed With Frequency Converter (Sfc)

    Design and Function Operating modes and control modes DUAL In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to maintain pressure between the preset cut-in and cut-out values. When cut-out pressure is reached, idle period has elapsed, the machine switches to the machine switches to IDLE.

  • Page 48: Modulating Control

    Design and Function MODULATING control If network pressure exceeds the target value: Once outside the frequency convert's control range the machine reverts to the selected control mode. DUAL: The minimum controllable speed is reached and the machine switches to IDLE. The drive motor runs without load and draws little current.

  • Page 49: Installation And Operating Conditions

    Installation and Operating Conditions Maintaining ambient conditions 5 Installation and Operating Conditions Maintaining ambient conditions ➤ Follow the instructions in the machine's service manual. Installation conditions The installation and operating conditions influence the machine into which the controller is installed. CAUTION UV radiation! Direct sunlight (UV radiation) can destroy the display screen.

  • Page 50: Installation

    Installation Reporting transport damage 6 Installation Reporting transport damage 1. Check the controller for visible and hidden transport damage. 2. Inform the carrier and the manufacturer in writing of any damage without delay. Machine identification If the machine is run in sequenced operation its identification as detailed in the installation diagram is to be taken into account.

  • Page 51: Initial Start-Up Outline

    Initial Start-up Outline 7 Initial Start-up Outline SIGMA CONTROL was designed and developed for a number of practical applications. Potential settings are correspondingly varied. It is possible that only a few of these settings are needed for the initial start-up. This depends on the application.

  • Page 52: Changing The Display Language

    Initial Start-up Configuring the controller The SIGMA CONTROL menu structure is arranged in 2 levels: ■ Settings level («UP» key) ■ Display level («DOWN» key) For example: Selecting menu option < configuration < general<. 1. Move from the main menu to the settings level with the «UP» key. configuration appears in the third line of the display.

  • Page 53: Checking/Setting Time And Date

    Initial Start-up Configuring the controller 2. Press «Enter». p s i g 1 7 6 ° p a s s w o r d X X X X X ↲ Current level X X X X X 3. Press «Enter». An inverse cursor appears.

  • Page 54: Setting Display Formats

    Initial Start-up Configuring the controller 2. Press «Enter». An inverse cursor appears in the third line. 3. Change the time with the «DOWN» or «UP» key. 4. Save the hours with the «Enter» key. 5. Repeat for the minutes and seconds. 6.
  • Page 55 Initial Start-up Configuring the controller Setting the time format The time can be shown in the following formats: 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. 23 Time formats Precondition Password level 4 is activated. Menu option <...

  • Page 56: Setting And Activating Summer/Winter Time

    Initial Start-up Configuring the controller 3. Change the unit with the «DOWN» or «UP» key. 4. Save the selected unit with «Enter». 5. Press the «Escape» key as often as necessary to return to the main menu. Setting the unit of temperature Temperature can be displayed in the following units: Format Example...

  • Page 57: Activating/Deactivating The "Idle" Key

    Initial Start-up Configuring the controller 2. Press «Enter». The changeover times for the start of summer time are shown one after the other. p s i g 1 7 6 ° s u m m e r t i m e Month of changeover →...

  • Page 58: Matching The Pressure Parameters Of The Machine And Possible Components

    Initial Start-up Matching the pressure parameters of the machine and possible components 8. Use the «DOWN»or «UP» key to set the required value and confirm by pressing «Enter». 9. Press the «Escape» key as often as necessary to return to the main menu. Matching the pressure parameters of the machine and possible com‐...
  • Page 59 Initial Start-up Matching the pressure parameters of the machine and possible components Parameter Explanation setpoint press. Setpoint pressure can be regulated to two values: p1 and p2 Setting ■ p1 SP: switching point p1, p1 SD: Switching differential p1 ■ p2 SP: switching point p2, p2 SD: Switching differential p2 sys.press.

  • Page 60: Display Pressure Parameters

    Initial Start-up Matching the pressure parameters of the machine and possible components Components Parameter Explanation (displayed text, setting) booster ➤ Take the minimum inlet pressure of the booster into account Setting ■ PN SP: switching point for signalling booster free to start, PN SD: switching differential for signalling booster free to start.

  • Page 61: Configuring The Pressure Parameters For Compressors

    Initial Start-up Matching the pressure parameters of the machine and possible components 2. Press «Enter». p s i g 1 7 6 ° . . . Current switching differential p1 S D : - 7 . 3 p s i g ↲...
  • Page 62 Initial Start-up Matching the pressure parameters of the machine and possible components 3. Press «Enter» to adjust the switching differential 4. Adjust the value with the «UP» or «DOWN» key. 5. Press «Enter» to accept the value. 6. Adjust the system pressure SP: in the same way. 7.

  • Page 63: Configuring The Pressure Parameters For Vacuum Pumps

    Initial Start-up Matching the pressure parameters of the machine and possible components Fig. 3 Pressure rise in frequency-controlled machines System pressure Switching point LOAD: Switching point IDLE: (setpoint pressure + dpFC) − switching dif‐ setpoint pressure + dpFC ferential System setpoint pressure p1 or p2 Pressure rise dpFC System pressure band width <...

  • Page 64: Adjusting Pressure Parameters For Components

    Initial Start-up Matching the pressure parameters of the machine and possible components 7.3.3.2 Vacuum pump: adjusting sys.press. high A message warning of high system pressure is displayed when the value sys.press. high is reached. The configuration of the output for the warning message is described in section 7.10.1. Precondition Password level 4 is activated.

  • Page 65: Adjusting Pressure Parameters For Booster And Air Main Charging System

    Initial Start-up Matching the pressure parameters of the machine and possible components 2. Keep pressing the «DOWN» key until the following is displayed: 2 . 6 ” H g 1 7 6 ° F p r e s s u r e f a l l actual switching differential for pressure fall S D :...

  • Page 66: Configuring Machine Start And Stop

    The switching point and switch‐ ing differential for the output signal to the valve are set as follows: Contact KAESER Service for advice. <components > AM charging> (see section 7.3.4).
  • Page 67 Initial Start-up Configuring machine start and stop 7.4.1.1 Select the clock menu Precondition Password level 4 is activated. clock appears in the third line of the 1. From the main menu, keep pressing the «UP» key until display. 2. Press «Enter». p s i g 1 7 6 °...

  • Page 68: Setting Up The Holiday Period

    Initial Start-up Configuring machine start and stop Precondition Password level 4 is activated, «clock» key is activated, clock menu is selected. 1. Keep pressing the «DOWN» key until the following is displayed: p s i g 1 7 6 ° –...

  • Page 69: Starting The Machine Remotely From A Control Center (Remote On/Off)

    Initial Start-up Configuring machine start and stop configuration appears in the third line 1. From the main menu, keep pressing the «UP» key until of the display. 2. Press «Enter». compressorstart appears in the third line of the display. 3. Keep pressing the «DOWN» key until 4.
  • Page 70 Initial Start-up Configuring machine start and stop Overview ■ Make the electrical connection (a spare input for the remote contact is to be found in the electrical wiring diagram for the machine, DI1.0 being preferred). ■ Switch machine start to remote mode. ■...

  • Page 71: Activating/Deactivating The Idle Phase (Unloading Function)

    Initial Start-up Configuring machine start and stop 2. Press «Enter». An inverse cursor appears. 3. Press the «UP» key. remote key: y . The display changes to 4. Confirm the setting with «Enter». The «remote control» key can be deactivated in the same way. The remote control function is activated and can be used.

  • Page 72: Activating/Deactivating And Setting Up Automatic Restart After A Power Failure

    Initial Start-up Configuring machine start and stop 5. Confirm the setting with «Enter». The venting function can be deactivated in the same way. The venting function is activated. 7.4.5 Activating/deactivating and setting up automatic restart after a power failure 'Auto start' is activated as standard. To avoid overloading the main power supply through several machines starting simultaneously a delay period determining the restart of each machine can be entered.

  • Page 73: Setting Up The Star-Delta Starting Configuration

    Initial Start-up Activating and setting up the control modes Setting up the automatic restart delay period If several machines are in operation, set them up for a staggered start. Orientate the automatic restart delay period to the IDLE to LOAD periods set on the other ma‐ chines.

  • Page 74: Adjusting The Idle Period For Dual Control Mode

    Initial Start-up Activating and setting up the control modes ■ QUADRO ■ VARIO ■ DYNAMIC ■ CONTINUOUS Precondition Password level 4 is activated. configuration appears in the third line 1. From the main menu, keep pressing the «UP» key until of the display.

  • Page 75: Setting The Control Pressure Valve For Modulating Mode

    Initial Start-up Activating and setting up the control modes Precondition Password level 4 is activated, < configuration > control mode > is selected (see section 7.5.1). menu 1. Keep pressing the «DOWN» key until < settings > appears. p s i g 1 7 6 °...

  • Page 76: Configuring The Machine For Local Mode

    Initial Start-up Configuring the machine for local mode Configuring the machine for local mode In local mode the machine is regulated with the system setpoint pressure p1 or p2. The controller is provided with the following modes of operation: Operating mode Description See section The machine is regulated by system setpoint pressure p1.
  • Page 77 Initial Start-up Configuring the machine for local mode When setting up a clock program, note the switching times on a sheet of paper first. As well as individual weekdays, the following cycles are also available: Mon – Thu, Mon – Fri, Mon –...

  • Page 78: Configuring The System Pressure Setpoint Changeover Using The Timer

    Initial Start-up Configuring the machine for local mode 3. Keep pressing the «DOWN» key until the following is displayed: p s i g 1 7 6 ° – – – – – – – – – – The first switching point is not active. n .
  • Page 79 Initial Start-up Configuring the machine for local mode settings appears. 1. Keep pressing the «DOWN» key until p s i g 1 7 6 ° . . . Start of the settings. s e t t i n g s 2.

  • Page 80: Configuring The Machine For Master Control

    Initial Start-up Configuring the machine for master control Configuring the machine for master control 7.7.1 List of the various master controllers ➤ The machine controller is provided with several methods of working under other controllers. Method Description Section Master control via Profibus The controller (and therefore the compressor) re‐...

  • Page 81: Fig. 4 Profibus Plug Wiring

    Initial Start-up Configuring the machine for master control Making the electrical connections Connections Spare Spare Profibus connection B TTL signal RTS Earth +5 V for interface P5 Spare Profibus connection A Spare Tab. 38 Profibus DP pin connection Interface plug wiring 07-C0623 Fig.

  • Page 82: Fig. 5 Electrical Diagram Example With Sigma Air Manager

    Initial Start-up Configuring the machine for master control Wiring possibilities for master control (excerpt) Fig. 5 Electrical diagram example with SIGMA AIR MANAGER 1. Connect the bus subscribers one after the other according to the pin assignment below. Service manual Controller SIGMA CONTROL BUB 82.XX 7_7000_0 11USE...
  • Page 83 Initial Start-up Configuring the machine for master control 2. Connect the screening to the plug housings at both ends. 3. Switch in the terminating resistor in the plugs of the first and last subscribers to the Profibus. Set the remote operating mode p2. When automatic mode is changed to manual mode at the bus controller, SIGMA CONTROL changes into the set remote mode.
  • Page 84 Initial Start-up Configuring the machine for master control 4. Press «Enter». P r o f i B u s Profibus is inactive → n . a . ↲ R u n 5. Press «Enter» again. 6. Keep pressing the «UP» key until Send+Receive appears.

  • Page 85: Configuring The Profibus Interface Without Sigma Air Manager / Vesis

    4. Press the «remote control» key to enable remote mode. 5. Restart the controller 7.7.3 Configuring the Profibus interface without SIGMA AIR MANAGER / VESIS Contact KAESER Service for information on configuring the interface if Profibus is to be used.. Overview ■ Selecting a Profibus interface ■...
  • Page 86 Precondition Password level 4 is activated, electrical connection with the Bus-Master is made. the files required from KAESER are available. Selecting a Profibus interface communication appears in the third line 1. From the main menu, keep pressing the «UP» key until of the display.

  • Page 87: Master Control Via The Rs 485 Interface

    Initial Start-up Configuring the machine for master control 7.7.4 Master control via the RS 485 interface. Configuration procedure Controller Procedure Section Both Making the electrical connections 7.7.4.2 Both Set up the appropriate system pressure setpoints p1 and p2 taking air losses in 7.7.4.3 the air main into account.

  • Page 88: Fig. 6 Electrical Connections Between The Two Controllers

    Initial Start-up Configuring the machine for master control 7.7.4.2 Making the electrical connections Fig. 6 Electrical connections between the two controllers 1. Make the electrical connections as shown in the table below. 2. Connect the screening to the plug housings at both ends. 3.
  • Page 89 Initial Start-up Configuring the machine for master control 5. If necessary, adjust the value for p2 in the same way. 6. Press the «Escape» key as often as necessary to return to the main menu. Further information Further information on setting up the pressure parameters is found in section 7.3. 7.7.4.4 Master: configuring the setpoint changeover using a clock program Keep to the order of the configuration!
  • Page 90 Initial Start-up Configuring the machine for master control 5. Keep pressing the «DOWN» key until the following is displayed: p s i g 1 7 6 ° F . . . first switching point for the weekday n . a . ↲...
  • Page 91 Initial Start-up Configuring the machine for master control 2. Confirm the setting with the «Enter» key. 3. Use the «DOWN» or «UP» keys to set the timer period p1 and confirm with «Enter». 4. Press the «DOWN» key. 5. Press «Enter» and set timer period p2 with the «DOWN» or «UP» key. 6.
  • Page 92 Initial Start-up Configuring the machine for master control remote mode appears in the second line of the 1. Keep pressing the «UP» or «DOWN» key until display. 2. Press «Enter». An inverse cursor appears. p s i g 1 7 6 °...

  • Page 93: Configuring Master Control Using The Load Remote Contact (E.g. Mic 4000)

    Initial Start-up Configuring the machine for master control 4. Press «Enter». R S 4 8 5 Interface is not active → n . a . ↲ R u n Setting the controller as master or slave → n.a. appears in the third line of the display. 1.

  • Page 94: Fig. 7 Remote Load Contact With Transfer Module

    Initial Start-up Configuring the machine for master control 7.7.5.1 Making the electrical connection for remote LOAD contact (excerpt) Machine with transfer module (example) Fig. 7 Remote LOAD contact with transfer module. ➤ Make the electrical connection with DI0.7 according to the diagram. Machine without transfer module (example) Applicable to series SX, SM and SK prior to spring terminals.
  • Page 95 Initial Start-up Configuring the machine for master control 7.7.5.2 Setting the remote LOAD contact operating mode and assigning the remote contact input Precondition Password level 4 is activated, menu < configuration > press. settings > load control > is selected. Setting the remote LOAD contact operating mode remote mode appears in the second line of the 1.

  • Page 96: Configuring Master Control Using The Local/Remote Contact (E.g. Mic 8000)

    Initial Start-up Configuring the machine for master control y with the «UP» or «DOWN» key and confirm with «Enter». 3. Select the value The «remote control» key is activated and can be used. 4. Press the «remote control» key to enable remote mode. 7.7.6 Configuring master control using the local/remote contact (e.g.
  • Page 97 Initial Start-up Configuring the machine for master control 7.7.6.2 Activate the «remote control» key Precondition Password level 4 is activated, menu < configuration > press. settings > load control > is selected. remote key: n appears in the third line of the 1.

  • Page 98: Configuring Setpoint Pressure Pre-Selection Via Remote Contact

    Initial Start-up Configuring the machine for master control Precondition Password level 4 is activated, < configuration > press. settings > load control > is selected. menu 1. Keep pressing the «UP» or «DOWN» key until local mode appears in the second line of the display.

  • Page 99: Configuring Master Control Of Compressors Regulated By Pressure Switch

    Initial Start-up Configuring the machine for master control 1. Keep pressing the «DOWN» key until the following is displayed: p s i g 1 7 6 ° p 1 / p 2 No input assigned → n . a . ↲...

  • Page 100: Fig. 10 Machine With Pressure Switch Regulation

    Initial Start-up Configuring the machine for master control ■ Configuring/adjusting local operating mode ■ Assigning the floating relay contact ■ Setting local mode Making the electrical connections ■ Contact A open: SIGMA CONTROL regulates to setpoint pressure p2. ■ Contact A closed: SIGMA CONTROL regulates to setpoint pressure p1. ■...
  • Page 101 Initial Start-up Configuring the machine for master control Assigning the floating relay contact Precondition Password level 4 is activated, electrical connection made (select spare contact from the machine's electrical diagram). < configuration > press. settings > load control > . 1.

  • Page 102: Fig. 11 Function Diagram

    Initial Start-up Configuring the machine for master control Function diagram: Period t1–t7: high air demand Period t8–t14: low air demand Demand rises. Air demand rises. System pressure falls. System pressure falls. BSD switches to LOAD. SK switches to LOAD. t10: Setpoint pressure p1 reached.
  • Page 103 Initial Start-up Configuring the machine for master control 3. Adjust the value with the «UP» or «DOWN» key. 4. Press «Enter» to accept the value. 5. Adjust the switching differential p1 in the same way. 6. If necessary, adjust the value for p2 in the same way. 7.

  • Page 104: Example Of Time Settings For Even Loading

    Initial Start-up Configuring the machine for master control Enter the time of the first switching point. 1. Press the «DOWN» key. 2. Press «Enter». p s i g 1 7 6 ° Weekday setting. M o n - F r i Precise start time.

  • Page 105: Configuring The Output For Pc And Modem

    Initial Start-up Configuring the output for PC and MODEM ➤ Establish a cycle with the following switching points: ■ Cycling period p1: 24 h ■ Cycling period p2: 24 h ■ Start p2: 24:00 Method B: Equal duty cycle during the day Changeover p1/p2 is by time program (local operating mode p1/p2 clock).

  • Page 106: Pin Connections Rs232

    If, for example, a SIGMA TELE-CARE agreement has been signed, the controller can send informa‐ tion to KAESER Service in SMS form to make remote diagnosis possible. A modem must be fitted that can be connected to the phone network.

  • Page 107: Activating The Sms Function

    Initial Start-up SMS configuration Overview Configure the SMS option as follows: ■ Activating the SMS function ■ Suppressing repeat messages (filter) ■ Entering the modem's phone number (modem) ■ Entering company data (site location) ■ Selecting the Call Centers (channel 1(2)) ■...

  • Page 108: Entering The Modem's Phone Number (Modem)

    (For customers with SIGMA TELE CARE contract) ( already set) customer : Name of the company ■ tel. customer : Telephone number at which KAESER Service can call back. ■ SMS language : Language of the SMS (select for each KAESER subsidiary). ■...

  • Page 109: Configuring Selection Of The Call Center (Channel)

    7.9.5 Configuring selection of the Call Center (channel) Overview < channel 1 > : The preset data entered by KAESER are displayed in menu option ■ Telephone number of the responsible Call Centre ■ Phone number of the SMS messages ■...

  • Page 110: Outputting Important Operational States Of The Machine

    Initial Start-up 7.10 Configuring input and output signals The controller only allows assignment of spare inputs and outputs. If an occupied input or output n.a. is already assigned this will be rejected by the controller (the display returns to when «Enter» is pressed). When delivered from the factory, the outputs DO0.3 toDO0.5 are available for assignment.

  • Page 111: Display Analog Input Values

    Initial Start-up 7.10 Configuring input and output signals 5. Press «Enter» again. A list of available messages and their assigned outputs is displayed. p s i g 1 7 6 ° Message controller ON c o n t r o l l e r No output assigned →...
  • Page 112 Initial Start-up 7.10 Configuring input and output signals 2. Press «Enter». p s i g 1 7 6 ° Pressure display 1 d i s p l a y 1 ( p ) ↲ Pressure display 2 d i s p l a y 1 ( p ) 7.10.2.2 Select display (display 1–6)

  • Page 113: Displaying Additional Binary Input Signals

    Initial Start-up 7.10 Configuring input and output signals 3. Confirm the entry with «Enter». 4. Enter the unit of measure in the line below in the same way. < analog data > menu (see chap‐ The signal value from the sensor can now be displayed in the ter 8.5).
  • Page 114 Initial Start-up 7.10 Configuring input and output signals 7.10.3.3 Selecting the message type (operational, alarm, warning) 1. Press «Enter» again. 2. Use the «UP» key to select the message type and confirm with the «Enter» key. 7.10.3.4 Assigning an input. 1.

  • Page 115: Using Machine Pressure And Temperature Values As Switches

    Initial Start-up 7.10 Configuring input and output signals 7.10.4 Using machine pressure and temperature values as switches The pressure transducers and temperature sensors connected to the controller (both in the machine and on the user's premises) can be also be used as switches. ■...
  • Page 116 Initial Start-up 7.10 Configuring input and output signals 7.10.4.2 Selecting the type of sensor 1. Press «Enter» to select the pressure switch the «DOWN» key once to select the temperature switch. 2. Confirm with «Enter». 7.10.4.3 Selecting the sensor 1. Display p s i g 1 7 6 °...

  • Page 117: Configuring Analog Outputs

    Initial Start-up 7.10 Configuring input and output signals 1. Press the «DOWN» key once, then «Enter». An inverse cursor appears. p s i g 1 7 6 ° Selected message type o p e r a t i o n Current time delay t d : 0 .

  • Page 118: Allocating A Value Range To The Measurement (Scaling)

    Initial Start-up 7.10 Configuring input and output signals ■ Selecting the type of signal (4–20 mA / 0–20 mA) ■ Assign the quantity range (calibration, if required) ➤ Configure analog output as follows. 7.10.5.1 Select menu ext. messages. Precondition Password level 4 is activated, menu <...

  • Page 119: Configuring The Compressed Air Outlet Temperature (Pd Temperature)

    Initial Start-up 7.11 Configuring the compressed air outlet temperature (PD temperature) Pressure value scaling A range of 0 – 232 psig is factory set for signal strength from 0–20 mA or 4–20 mA. If the sensor covers another pressure range then it must be scaled. 1.

  • Page 120: Entering The Correction Value

    Initial Start-up 7.11 Configuring the compressed air outlet temperature (PD temperature) 7.11.2 Entering the correction value corr. 31 °F appears in the third line of the display. 1. Keep on pressing the «DOWN» key until 2. Press «Enter». A cursor appears inverse over the temperature value. 3.

  • Page 121: Activating Remote Acknowledgement

    Initial Start-up 7.12 Activating remote acknowledgement 7.11.3.2 Setting the switching point and switching differential 1. Keep pressing the «DOWN» key until the following is displayed: p s i g 1 7 6 ° Maximum temperature ⇞ > 1 2 2 °...

  • Page 122: Select Menu Acknowledgement

    Initial Start-up 7.12 Activating remote acknowledgement ■ Assigning an input. ■ Press the «remote » key. CAUTION Machine damage can result from acknowledging a fault message without remedying its cause! ➤ Find the fault and then decide to acknowledge or not. 7.12.1 Select menu <configuration >...

  • Page 123: Linking To An External Pressure Transducer

    Initial Start-up 7.13 Linking to an external pressure transducer Result Should a warning message occur, it can now be acknowledged from a control centre. 7.13 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.

  • Page 124: Setting The Timer For Condensate Drainage

    Initial Start-up 7.14 Setting the timer for condensate drainage 2. Select the input with the «UP» key or the «DOWN» key. For measured values via the frequency FC USS . controller select 3. Confirm with «Enter». Result The input for the external transducer is now activated. 7.14 Setting the timer for condensate drainage A solenoid valve can be activated at regular intervals for the drainage of condensate.

  • Page 125: Activating The Energy-Saving Mode For The Refrigeration Dryer

    Initial Start-up 7.15 Activating the energy-saving mode for the refrigeration dryer 7.15 Activating the energy-saving mode for the refrigeration dryer CONTINUOUS or TIMER modes can be activated for control of the refrigeration dryer. Using the menu option TIMER the dryer can be shut down under time control whenever no compressed air is required.
  • Page 126 Initial Start-up 7.16 Commissioning the machine 1. Check and confirm all the items in the checklist before starting the machine. When power is applied to the machine the controller boots and carries out a self test. The display controller power light up. and LED The current system pressure and the airend discharge temperature are displayed in the first line of the display.

  • Page 127: Operation

    Operation Switching the machine on and off 8 Operation Switching the machine on and off Fig. 12 Switching on and off Machine ON (green) «OFF» key Controller ON (green) «ON» key The power supply disconnecting device cuts power abruptly from the machine. It is not suitable for normal on and off switching.

  • Page 128: Switching The Machine Off Locally

    Operation Switching the machine on and off 2. Press the «ON» key. Machine ON LED lights continuously. The compressor motor starts as soon as system The green pressure is lower than the setpoint pressure (cut-out pressure). Automatic restart The automatic restart is activated at the factory. If the current system pressure is lower than the setpoint, the machine starts automatically after a power failure.

  • Page 129: Switching On And Off From A Remote Control Center

    Operation Switching the machine on and off Fig. 13 Switching off in an emergency EMERGENCY STOP pushbutton Shutdown ➤ Press the EMERGENCY STOP pushbutton. The pushbutton remains latched in. The compressor's pressure system is vented and the machine is prevented from automatically re-starting.

  • Page 130: Switching On And Off With The Clock

    Operation Switching the machine on and off Fig. 14 Switching on and off from a remote control center «Remote control» key Remote control LED ➤ Press the «remote control» key. remote control LED lights. The machine can be remotely controlled. Result Further information Further information on activating remote control can be found in chapter 7.4.3..

  • Page 131: Acknowledging Alarm And Warning Messages

    Operation Acknowledging alarm and warning messages Fig. 15 Switching on and off with the clock «Clock» key Clock LED ➤ Press the «clock» key. clock LED lights. The machine is switched on and off by the clock. Result Further information Further information on activating the clock can be found in chapter 7.4.1..

  • Page 132: Fig. 16 Acknowledging Messages

    Operation Acknowledging alarm and warning messages Fig. 16 Acknowledging messages Warning LED (yellow) Alarm LED (red) «Acknowledge» key Alarm message alarm flashes. An alarm shuts the machine down automatically. The red LED The last line in the display shows the actual fault causing the alarm. Precondition The fault has been rectified ➤...

  • Page 133: Displaying The Current Operating Mode

    Operation Displaying the current operating mode Displaying the current operating mode The operating mode is displayed in 4 segments (example): On/off switching via Machine state LOAD control via State of the LOAD control empty Tab. 48 Operating mode display ➤ Press the «DOWN» key once to display the current operating mode. p s i g 1 7 6 i d l e...

  • Page 134: Adjusting Working Pressure

    Operation Adjusting working pressure Adjusting 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 7.3. Displaying messages The following information can be called up in the <...

  • Page 135: Status Data Displaying, Resetting And Printing

    Operation Status data displaying, resetting and printing Displaying event information 1. Press «Enter». The last registered message is displayed. The messages are displayed chronologically in the order in which they occur. 2. Scroll through past events with the «DOWN» key and back to the current message with the «UP»...

  • Page 136: Displaying And Resetting Machine Duty Cycle

    Operation Status data displaying, resetting and printing ■ Maximum and minimum network pressure and internal pressure. ■ Motor starts as from a specified day. 8.6.1 Displaying and resetting machine duty cycle 1. In the main menu, keep on pressing the «DOWN» key until status appears in the third line of the display.

  • Page 137: Further Status Data Displaying And Resetting

    Operation Status data displaying, resetting and printing 8.6.2 Further status data displaying and resetting < status > statistics > to display the following status data: 1. Press the «DOWN» key in menu option ■ Duty cycle from a specified day ■...

  • Page 138: Overview Of Important Settings

    Operation Displaying analog data Precondition Password level 4 is activated, the interface is configured and a PC is connected to the serial interface. communication appears in the third line of 1. In the main menu, keep pressing the «UP» key until the display.

  • Page 139: Displaying Operating Data

    Operation Displaying operating data ■ Cooling water temperature (WC temperature)* ■ Motor temperature (motor temp.)* ■ Pressure drop across oil filter (oil filter dp)* < configuration > press. settings > press.act.value The data for actual pressure can be displayed in >...

  • Page 140: Micromaster: Display Parameter/Messages On The Frequency Converter

    Operation MICROMASTER: Display parameter/messages on the frequency converter Changing the operating hours The motor and airend running times can be changed, e.g. in the case of an exchanged motor. Precondition Password level 4 is activated. operating data appears in the third line 1.

  • Page 141: Resetting Maintenance Interval Counters

    Operation 8.10 Resetting maintenance interval counters 8.10 Resetting maintenance interval counters Maintenance interval counters indicate the operating hours between maintenance tasks. The re‐ maining hours in the respective maintenance interval counter can be individually reset. The controller registers the maintenance intervals for the following components: ■...

  • Page 142: Setting The Maintenance Interval

    Operation 8.11 Setting the maintenance interval 8.11 Setting the maintenance interval Overview Proceed as follows to set a maintenance interval: ■ If not activated, enter password for level 4. < maintenance > . ■ Select menu ■ Changing the maintenance interval Precondition Password level 4 is activated.

  • Page 143: Checking The Pressure Relief Valve

    Operation 8.13 Checking the pressure relief valve ➤ To acknowledge the message, proceed as described in chapter 8.10. The controller stores the current date and starts the next annual interval. 8.13 Checking the pressure relief valve Overview ■ Preparation for the test ■...

  • Page 144: Checking The Temperature Sensor And Overheating Shutdown Function

    If the alarm message internal pressure was exceeded by 29 psi. ➤ Have the pressure relief valve replaced by an authorized KAESER Service Technician. Avoid oil mist: ➤ Release the «ON» key as soon as the pressure relief valve opens to minimize oil mist blow off.
  • Page 145 Operation 8.14 Checking the temperature sensor and overheating shutdown function Ascertaining offset 1. Read off the airend discharge temperature under load (normal working temperature) (first line of the display, e.g.: 176 °F) 2. Calculate offset: Offset = 230 °F − indicated airend discharge temperature (e.g.: Offset = 54 °F at 176 °Fairend discharge temperature) 3.

  • Page 146: Determining The Optimal Control Mode

    8.15 Determining the optimal control mode The machine does not shut down? ➤ Abort the test and contact KAESER Service as soon as possible. Correct conclusion of the test 1. Press «Enter». 2. Reset the offset to 104 °F and confirm with «Enter».

  • Page 147: Fault Recognition And Rectification

    The messages valid for your machine are dependent on the controller and individual equipment. 1. Do not attempt fault rectification measures other than those given in this manual. 2. In all other cases, have the fault rectified by an authorized KAESER Service Technician. Alarm messages (machine stop) Message...
  • Page 148 2 ext. message 3 ext. message 4 ext. message 5 Frequency converter faulty. Call KAESER Service. back press. run Drive belts or coupling broken. Drive belts: Replace drive belts. Coupling: Call KAESER Service.
  • Page 149 M2 I⇞ Overload shut-down of the first fan mo‐ Investigate cause of shut-down. tor. Reset overload protection cut-out. Call KAESER Service. fan M3 I⇞ Overload shut-down of the second fan Investigate cause of shut-down. motor. Reset overload protection cut-out.

  • Page 150: Warning Messages (Yellow Led Lights)

    Control cabinet: Check filter mats and fan. softstart Fault in the soft start equipment. Call KAESER Service. start T⇟ Airend discharge temperature (ADT) Keep ambient conditions within speci‐ too low. fied limits. Ambient temperature <+37°F...
  • Page 151 Check maximum cable length and screen‐ ing. 1 master and 1 slave configured. error: SMS SMS can not be sent. Call KAESER Service. ext. message 0 Customer specific: Carry out maintenance on connected com‐ ext. message 1 Connected component initiates a ponent.
  • Page 152 The maintenance interval for check‐ Have the motor bearings checked by an au‐ ing the compressor drive motor thorized KAESER Service Technician. bearings has expired. ext.load signal? Uncertain external load signal: Check settings of the external controller.
  • Page 153 Re-tension drive belts. blt.coup.insp.h⇞ The belts/coupling change interval Drive belts: has expired. Check drive belts. Coupling: Call KAESER Service. start T↓ The airend temperature is too low (< Keep ambient conditions within specified +37 °F). limits. start T↓↓ The airend temperature is too low Keep ambient conditions within specified (<14 °F) for the machine to be op‐...
  • Page 154 Fault Recognition and Rectification Warning messages (yellow LED lights) Message Possible cause Remedy TRAP Interrupts System message Call KAESER Service. valve insp. h⇞ The motor bearings checking inter‐ Call KAESER Service. val has expired. ADT ↑ Maximum airend discharge temper‐...

  • Page 155: 10 Maintenance

    Maintenance 10.1 Safety 10 Maintenance 10.1 Safety Follow the instructions below to ensure safe machine maintenance. Warning instructions are located before a potentially dangerous task. Basic safety instructions 1. Follow the instructions in chapter 3 'Safety and Responsibility'. 2. Maintenance work may only be carried out by authorized personnel. 3.

  • Page 156: Testing The Leds On The Controller

    The lamps test is now activated. All LEDs start to flash. The test ends automatically after 10 seconds. 6. Press the «Escape» key as often as necessary to return to the main menu. Not all LEDs flash? ➤ Call KAESER Service. Service manual Controller SIGMA CONTROL BUB 82.XX...

  • Page 157: 11 Spares, Operating Materials, Service

    Your advantage: lower costs and higher compressed air availability. 11.3 Service addresses Addresses of KAESER agents are given at the end of this manual. 11.4 Displaying the version number, machine model, material number and serial number configuration appears in the third line 1.
  • Page 158 Spares, Operating Materials, Service 11.4 Displaying the version number, machine model, material number and serial number version 5. For further information on hard and software, press the «UP» key and then select number with «Enter». p s i g 1 7 6 °...

  • Page 159: 12 Decommissioning, Storage And Transport

    Decommissioning, Storage and Transport 12.1 De-commissioning 12 Decommissioning, Storage and Transport 12.1 De-commissioning ➤ Follow the instructions in the machine's service manual. 12.2 Packing ➤ Follow the instructions in the machine's service manual. 12.3 Storage ➤ Follow the instructions in the machine's service manual. 12.4 Transporting ➤...
  • Page 160 Decommissioning, Storage and Transport 12.5 Disposal Service manual Controller SIGMA CONTROL BUB 82.XX 7_7000_0 11USE...

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