Page 1 Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E Manufacturer: KAESER KOMPRESSOREN 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 http://www.kaeser.com...
Page 2 /KKW/SSC 2.02 en BA-SIGMA CONTROL DRY /KKW/SSC 2.02 20120814 111240...
Page 3 Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E Manufacturer: KAESER KOMPRESSOREN 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 http://www.kaeser.com...
Page 5: Table Of Contents
Checking the temperature sensor and overheating shutdown function ......Interpreting operation messages ..................Interpreting diagnostic messages ..................Interpreting fault messages ....................Interpreting warning messages ..................Interpreting system messages ..................Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 6 Contents Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 7: Important Settings
Setting and other work on the machine may only be carried out by the following persons: ■ persons trained on the machine/controller and persons instructed by and under the su‐ pervision of a specialist, ■ trained technicians, ■ authorised Service personnel. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 8: Setting The Contrast And The Brightness
3. Press «UP» or «DOWN» to adjust the contrast. 4. Press «Left» or «Right» to adjust the brightness. Result The settings for contrast and brightness have been adjusted. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 9: Setting The Display Language
4. Move to the required language with «UP »or «DOWN». 5. Confirm the setting with «Enter». 6. Press «Escape» repeatedly to return to the main menu. Result The display texts are now in the selected language. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 10: Entering A Password
3. Press «Enter» to confirm the logon. Result The operating mode is displayed. You are logged on. Further information See chapter 7.2.4 for a manual logon to the controller. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 11: Adjusting The System Setpoint Pressure
10. If necessary, adjust the value for switching point pB in the same way. 11. Press «Escape» repeatedly to return to the main menu. Further information See chapter 7.4 for the adjustment of the machine's pressure parameters. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 12: Set Clock Program
7. Press the «Right» key once. 00 : 00 flashes in the active line. Column time, hours display, 8. Use «UP» to specify the settings for the minutes. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 13 ■ Proceed in the same manner to deactivate the «clock» key. ■ All defined switching points will be reset simultaneously if you activate the reset check box. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 14 The machine runs according to the defined switching points of the clock program. Further information See chapter 7.5 for configuration of starting and stopping the machine. See chapter 7.7.2 for configuration of load changeover based on a clock program. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 15: Activate The "Remote Control" Key
------------------------------ RC DI 1.12 ☐ Active line with check box Key remote: ☐ Key clock: ☐ 5. Press the «UP» key. The activated check box is displayed. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 16 Proceed in the same manner to deactivate the «remote control» key. Further information See chapter 7.5 for configuration of starting and stopping the machine. See chapter 7.8 for configuration of load changeover under master control. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 17 The regulating mode DYNAMIC has been switched to QUADRO. Further information See chapter 4.7 for the functions of the control modes. See chapter 7.6 for changing the parameters of the control modes. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 18: Outputting Important Operational States Of The Machine
A message is now sent via the output assigned. 4. Press «Escape» repeatedly to return to the main menu. Further information See chapter 7.10 for configuration and use of the controller's inputs and outputs. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 19: 10 Resetting Maintenance Interval Counters
The remaining life span of the new oil filter complies with the defined maintenance interval of 8000 h (depending on the machine type). Further information See chapter 8.7 for setting the maintenance intervals. See chapter 10 for the maintenance of the controller. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 20: 11 Testing The Pressure Relief Valve
Testing the pressure relief valve 11 Testing the pressure relief valve Use the SIGMA CONTROL 2 to conveniently test the functioning of the pressure relief valves of the second compression stage at the machine outlet. When the test mode is activated, the third line of the operating mode display (see chapter 4.3) indi‐...
Page 21 ➤ Close all access doors, replace and secure all removable panels. ➤ Wear eye protection. 8. Press the «ON »key. The compressor runs in IDLE. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 22 Activating pressure of the pressure relief valve and pRV :10.00 bar ¦ p : 11.00 bar highest measured value (maximum storage) ¦ Reset ☐ ------------------------------ 2. Replace the pressure relief valve. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 23 The permissible internal pressure was exceeded by 2 bar. Test p5: p5 > pRV . Fault message SIGMA CONTROL 2 is displayed and the test is aborted. ➤ Replace the pressure relief valve. 1 2 . 0 b a r 1 1 : 1 3 7 0 .
Page 24 Result The machine is ready for operation. Reset after closing the test mode During the test, SIGMA CONTROL 2 indicates the highest value measured for output pressure p5. To reset the saved value, activate the "Reset" check box. Check box Status ☒...
Page 25 ¦ Reset ☐ ------------------------------ The function test of the pressure relief valve is to be repeated. ➤ Reset the maximum storage in test mode with an explicit Reset. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 26: Checking The Temperature Sensor And Overheating Shutdown Function
Precondition Machine cooled down by approx. 5 °C 1. Log on to SIGMA CONTROL 2 with access level 2. (see section 7.2.4). 2. In operating mode, switch to the main menu with the «Enter» key. < Machine test > menu.
Page 27 ------------------------------ 9. Press the «ON »key. The compressor runs in LOAD. Temperature T2 rises. 250 °C , SIGMA CONTROL 2 shuts the machine As soon as the modified test value shows down. 7 . 2 b a r 1 1 : 1 3 7 0 .
Page 28 6. Press «Escape» repeatedly to return to the main menu. Reset after closing the test mode SIGMA CONTROL 2 will display the highest measured value if the test for switching off at overtem‐ perature is aborted. Activate the Reset check box in order to reset the stored value.
Page 29: 13 Interpreting Operation Messages
Temperature at sensor for T3 high. T3 ⇑ run 0041 O Mean value of the temperatures at the sensors for T3 and T4 high. T4T3M ⇑ always Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 30 The cut-in temperature dropped below the minimum permissible value. Machine too cold to start 0200 O The internal voltage monitoring reports undervoltage fault IOSlot1 IOSlot1 Undervoltage error Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 31 The internal voltage monitoring reports undervoltage fault IOSlot6 IOSlot6 Undervoltage error 1000 O You successfully registered two KAESER RFID Equipment Cards at the controller. 2 RFID Equipment Cards successfully registered Tab. 5 Operational Messages Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 32: 14 Interpreting Diagnostic Messages
Diagnostic messages are identified with the letter D. They provide information on the status of the controller, the connected input and output modules and support the KAESER service in trouble-shooting. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 33: 15 Interpreting Fault Messages
Shut-off valve to the air net‐ KAESER Service. work closed. 0011 A Overload shut-down of the fan Overload shut-down Main fan overcurrent motor. of the fan motor. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 34 0022 A Oil too viscous. Keep ambient con‐ p63 > x.xbar ¦ run ditions within speci‐ Overflow valve defective. fied limits. Use suitable oil type. Contact KAESER Service. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 35 Check mains con‐ Mains contactor on? close. tactor and wiring. 0035 A Overload shut-down of the Contact Cabinet fan I ⇞ control cabinet fan motor. KAESER Service. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 36 Measuring error. Contact In SFC machines: KAESER Service. Minimum speed set too low. 0052 A Overload shut-down of the wa‐ Contact Water pump overcurrent ter pump. KAESER Service. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 37 Secondary water system tem‐ perature too high. 0064 A Temperature of the coolant in Check coolant tem‐ T10 < x°C ¦ run the primary water system too perature. low. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 38 Low coolant flow rate. fied limits. Check coolant flow rate. Check the set value of the parameter. 0073 A 0074 A 0075 A 0076 A Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 39 0110 A Function parameterised previ‐ Use different I/O. IO parameterisation module 50 ously 0130 A 0132 A 0133 A 0134 A 0140 A 0141 A 0142 A Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 40 0300 A Safety-critical temperature. Switch on the ma‐ Safety T2 = x°C chine again. 0301 A Safety-critical temperature. Switch on the ma‐ Safety T4 = x°C chine again. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 41 0542 A Valve actuation set to manual. Deactivate manual WS V14 close run period operation for the valve actuation. Tab. 6 Alarm messages and measures Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 42: 16 Interpreting Warning Messages
Do not shut off coolant flow during the cooling down phase. 0017 W Cooling oil temperature Keep ambient con‐ T66 < x°C ¦ start too cold. ditions within specified limits. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 43 0029 W Oil too viscous. Keep ambient con‐ p63 > x.xbar ¦ run ditions within Overflow valve defective. specified limits. Use suitable oil type. Contact KAESER Service. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 44 24 hours. Increase the ca‐ pacity of air receiv‐ Increase the cross- section of piping between compres‐ sor and air receiv‐ Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 45 High intake air tempera‐ Keep ambient con‐ T2T1M > x°C ¦ always ture. ditions within specified limits. In SFC machines: Minimum speed set low. Contact KAESER Service. Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 46 SC2 <=> SC2 SC2_zu_SC2_communication error tween two controllers KAESER Service. SIGMA CONTROL 2 0059 W Intake temperature too Keep ambient con‐ T1 < x°C ¦ start cold. ditions within specified limits. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 47 0070 W Insufficient cooling. Check the valve T5-T10 < x°C ¦ run position. Contact KAESER Service. 0073 W 0074 W 0075 W 0076 W Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 48 Large temperature differ‐ Contact dT1..6 > x°C after 50h stop entials within the machine. KAESER Service. 0404 W Check valve leaking. Contact p3a > x.xxbar ¦ stop KAESER Service. Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 49 0458 W Maintenance interval for Contact Electrical equipment h ⇞ the electrical systems has KAESER Service. expired. Tab. 7 Warning messages and remedies Quick user guide Controller 9_9451 00 E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 50: 17 Interpreting System Messages
RAM out of memory KAESER Service. 1000 Y System error Contact RFID error: switch SIGMA CONTROL power supply OFF→ON! KAESER Service. Tab. 8 System messages and remedies Quick user guide Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E...
Page 51 Sensors ....................... Safety and Responsibility Basic instructions ......................Specified use ........................Improper use ........................Design and Function The controller ........................Operating panel SIGMA CONTROL 2 ................Display ..........................4.3.1 Operating mode ....................4.3.2 Main menu ......................4.3.3 Setting parameters .....................
Page 52 Contents 7.2.7 Setting and activating summer/winter time ............Using KAESER CONNECT: ..................... 7.3.1 Calling up KAESER CONNECT for SIGMA CONTROL 2 ......... 7.3.2 Displaying the system status ................7.3.3 Display graphs ....................7.3.4 Displaying messages ..................7.3.5 Creating additional user accounts ..............
Page 53 11.4 Displaying the version number, machine model, material number and serial number ..163 Decommissioning, Storage and Transport 12.1 De-commissioning ......................165 12.2 Packing ..........................12.3 Storage ..........................165 12.4 Transporting ........................165 12.5 Disposal ........................... Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 54 Contents Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 55 System structure ........................Fig. 2 Keys ............................Fig. 3 Indicators ............................ Fig. 4 RFID sensor field ........................Fig. 5 KAESER CONNECT for SIGMA CONTROL 2 ................Fig. 6 Header ............................Fig. 7 Login window ..........................Fig. 8 KAESER CONNECT ......................... Fig. 9 Language selection ........................
Page 56 List of Illustrations Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 57 Master control – overview ......................Tab. 51 Profibus DP pin connection ......................Tab. 52 Master-slave configuration procedure ..................Tab. 53 Check box status ........................Tab. 54 Assigned output signals ......................Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 58 Check box status ........................139 Tab. 63 Warning messages and remedies ....................144 Tab. 64 Alarm messages and measures ....................152 Tab. 65 System messages and remedies ....................161 Service manual Controller viii SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 59: Regarding This Document Using This Document
The licenses can be also found under this address: http://www.gnu.org/licenses/gpl-2.0.txt http://www.gnu.org/licenses/gpl.txt Within three years from receipt of SIGMA CONTROL 2, you may obtain the complete source code by sending a corresponding order to the following address: Technical Office Electrical Design...
Page 60: Symbols And Labels
Signal term Meaning Consequences of non-compliance NOTICE Warns of a potentially dangerous situation Damage to property is possible Tab. 10 Danger levels and their definition (damage to property) Example: Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 61: Other Alerts And Their Symbols
The cause is named in the help text ... ➤ ... as is a solution. This symbol identifies important information or measures regarding the protection of the envi‐ ronment. Further information Further subjects are introduced here. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 62: Technical Specifications Sigma Control 2 Controller
Graphical display [px] 255 x 128 Width [mm] Height [mm] Maximum number of lines/characters 8/30 Colours Black/white with gray levels Lighting LED backlit px ≙ pixel Tab. 12 Display data Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 63: Input/Output Modules
The positions of the interfaces X1–X5 are marked on the rear of the controller. Tab. 13 Interfaces Identification with RFID Equipment Card Feature Value Hardware on the SIGMA CONTROL 2 controller RFID write/read device Hardware (external) KAESER Equipment Card Recognition distance [m] Max. 0.05...
Page 64: Tab. 7 Sc2Iom-1
Power is provided by the power supply unit within the machine. Feature Value Rated power supply (stabilised) [V DC] Current consumption SIGMA CONTROL 2 with IOM 1 [A] Current consumption IOM 2 [A] IOM ≙ input/output module Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 65: Sensors
IOM dimensions 2.1.3 Sensors Pressure transducer Feature Value Output signal [mA] 0/4–20 Connection Twin cable Tab. 22 Pressure transducer Resistance thermometer Feature Value Sensing resistance (to DIN IEC 751) PT100 Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 66 Technical Specifications SIGMA CONTROL 2 Controller Feature Value Connection Twin cable Tab. 23 Resistance thermometer Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 67: 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 68: Design And Function
4 Design and Function The controller SIGMA CONTROL 2 controls, regulates, monitors, and protects the machine. All parameters needed to operate KAESER rotary screw compressors can be set and displayed using the controller. Various user-dependent password mechanisms protect the parameters.
Page 69: Changing The Control Mode
Returns to the selected submenu. Saves and leaves the edit mode. «DOWN» Scrolls down menu. Reduces a parameter value. «Right» Jumps to the right. «Left» Jumps to the left. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 70: Tab. 17 Displays
Continuous red illumination if a communication connection (Ethernet, USS, COM modules) has a fault. Warning Flashes in yellow in the following events: ■ maintenance work due, ■ Warning message Lights continuously when acknowledged. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 71: Display
Tab. 26 RFID sensor field Further information More information about the use of RFID technology is provided in the SIGMA CONTROL 2 operat‐ ing manual. Display Use the display to read information and to enter data. The display comprises 8 lines, each of 30 characters.
Page 72: Operating Mode
7 0 . 0 ° C Language ········· Deutsch ········· Submenu ▶1 Status Submenu (here: active line) ▶2 Performance data Submenu ▶3 Operating data Submenu ▶4 Maintenance Submenu ▶5 Configuration Submenu ▶6 Compressor clock Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 73: Setting Parameters
You then press «UP». The check box is activated and flashes. Press «Enter» to save the settings. Reset is again deactivated. The parameters no longer flash and are reset. The check box for Reset Check box Status ☒ activated Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 74: Activating Keys With Check Boxes
4.3.4 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 75 Design and Function Checking the machine status with KAESER CONNECT Fig. 6 KAESER CONNECT for SIGMA CONTROL 2 Choice of language User administration System status Settings Graphs Data backup Messages KAESER CONNECT functions: ■ System status ─ Mapping of the local menu ■...
Page 76: Menus - Overview
T5 -51 °C ¦ Manl 31 °C ¦ Key - off ------------------------------ Operating parameters 13:37:50 ¦ Run 0 h Operating parameters ¦ Load 0 h ¦ Maintenance 2000 h Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 77: Menu Structure
■ Machine ─ Pressure ─ Temperature ─ Extreme value memory ■ Block motor ─ T711 ─ T712 ─ T713 ■ Quantities ■ ─ Temperatures I/O modules 1–6 ■ Curves Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 78 ■ Switching point 06: ■ Switching point 07: ■ Switching point 08: ■ Switching point 09: ■ Switching point 10: 7 User ■ Name Password ■ Current access level Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 79 Status menu Navigation Function/submenu 1.1 Messages ■ Current messages ■ Message history (event memory) ─ Compressor messages ─ Diagnostic messages ─ System messages Status report Current warnings Current faults Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 80 Third I/O module ─ DI/DO display ■ Fourth I/O module ─ DI/DO display ■ Fifth I/O module ─ DI/DO display ■ Sixth I/O module ─ DI/DO display Tab. 30 Status menu Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 81: Tab. 23 Configuration Menu
Pressure and temperature unit ─ Display illumination ■ Compressor start ─ Compressor on ─ Compressor off ■ Acknowledgement ─ Remote mode ─ Remote key ■ Data backup ─ Language ─ Save data Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 82 5.3 Accessories ■ I/O periphery ─ DO functions ─ Quantities ─ External messages ■ Clock contact ─ Switching points 1–10 ─ Reset ■ Timer ─ ─ Tab. 31 Configuration menu Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 83: Tab. 24 System Information Menu
■ External message 1 ■ External message 2 ■ External message 3 ■ External message 4 ■ External message 5 ■ External message 6 Tab. 33 I/O periphery menu Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 84: Tab. 26 Communication Menu
Cycle time ■ E-mail ─ Activate/deactivate e-mail Compressor number Language ─ Sender address Sender name Telephone number contact person Recipient address ─ SMTP server User name ─ Port Interval time Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 85 Subnet mask Gateway DNS Server 1 DNS Server 2 ■ DEVICENET ─ Status ─ Start Com module Slave number Reset ─ Bus fault Start time Time-out Tab. 34 Communication menu Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 86: Operating Modes And Control Modes
SIGMA CONTROL can work in the following control modes: ■ DUAL Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 87: Frequency-Controlled Drive (Sfc)
When the idle period has elapsed, the machine switches to STANDSTILL. QUADRO: The minimum controllable speed is reached and, depending on the air demand at the time, the ma‐ chine switches either to IDLE or STANDSTILL. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 88 The inlet valve opens and the machine delivers compressed air. The converter varies the speed of the drive motor according to the air demand. The power con‐ sumption of the motor varies accordingly with demand. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 89: 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. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 90: Installation
➤ Attach the following notice to warn of remote machine operation (suggestion): Clock control: danger of unexpected starting! ➤ Make sure the power supply disconnecting device is switched off before commencing any work on the machine. Tab. 39 Machine identification Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 91: Initial Start-Up Outline
7 Initial Start-up Outline SIGMA CONTROL 2 was designed and developed for a number of applications. Potential settings are correspondingly varied. It is possible that only a few of these settings are needed for the initial start-up. This depends on the application.
Page 92: Changing The Display Language
4. Use the «DOWN» or «UP» keys to select the desired language. 5. Press «Enter» to accept the setting. 6. Press «Escape» repeatedly to return to the main menu. The display texts are now in the selected language. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 93: Access Rights With Equipment Card
The cursor jumps to the next position. 6. Complete the remaining characters of the name. 7. Press the «Right» key. 8. Press «Enter» to accept the settings. Result The user name is entered in full. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 94 ········· Display access level 2 Current access level: 2 3. Press «Escape» repeatedly to return to the main menu. Result You are logged in with a higher access level. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 95: Checking/Setting Time And Date
12. Press «Escape» repeatedly to return to the main menu. Checking/setting the date Precondition Password level 2 is activated, < Configuration ➙ General > menu is selected (see 7.2.1). Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 96: Setting Display Formats
Select your preferred format. Format Example: DD.MM.YY 30.07.10 YY-MM-DD 10–07–30 MM/DD/YY 07/30/10 Tab. 41 Date format Precondition Password level 2 is activated, < Configuration> General > is selected (see 7.2.1). menu Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 97: Tab. 34 Time Formats
3. Change the format with the «DOWN» or «UP» keys. 4. Press «Enter» to save the setting. 5. Press «Escape» repeatedly to return to the main menu. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 98: Tab. 35 Units Of Pressure
Example: °C 46 °C 319 K °F 114 °F Tab. 44 Units of temperature Precondition Password level 2 is activated, < Configuration> General > is selected (see 7.2.1). menu Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 99: Tab. 37 Display Illumination
3. Press «Enter» to switch into setting mode. on display flashes. auto. mode. 4. Use «UP» to select the 5. Press «Enter» to save the setting. Timeout in the same manner. 6. Enter the setting for Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 100: Setting And Activating Summer/Winter Time
Calling up KAESER CONNECT for SIGMA CONTROL 2 Precondition The IP address of your controller is known. 1. Use an Ethernet cable to connect the PC and the SIGMA CONTROL 2. 2. In the web browser, enter the controller's IP address. Login window opens.
Page 101 Login window Login window Password User name «Login» key 3. Enter the user name 4. Enter the password 5. Click «Login». KAESER CONNECT for SIGMA CONTROL 2 is displayed. Fig. 9 KAESER CONNECT Language selection User administration System status Settings Graphs...
Page 102: Displaying The System Status
7. Select the required language KAESER CONNECT is displayed in the selected language. 7.3.2 Displaying the system status Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed. <System status> menu. 1. Select the The system displays the status information. Fig. 11 Status display <System status>...
Page 103: Display Graphs
When starting this menu, the recorded data from the last 60 minutes are loaded. The last 20 mi‐ nutes are displayed in a graph. The system updates the graph every ten seconds whilst the current time is displayed. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 104 LOAD ■ Speed speed is implemented only for machines with frequency converter. The display of the Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed. <Graphs> menu. 1. Select the The system displays graphs. Fig. 14 Pressure/temperature graphs <Graphs> menu...
Page 105: Displaying Messages
Current messages ■ Compressor messages ■ System messages ■ Diagnostic messages Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed. <messages> . 1. Open menu <messages> is displayed. Menu Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 106: Creating Additional User Accounts
User name: 6 to 16 characters, the second character must not be a number. ■ Password: 6 to 16 characters Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed. <User administration> menu. 1. Select the <User administration> menu. The system displays the...
Page 107 "Log on to write" window Log on to write window «OK» User name «esc» key Password 3. Enter your own user name. 4. Enter your own password. 5. Click «OK». Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 108 Similar to the creation of new user accounts, you can also update existing user accounts. ■ Changing the password ■ Changing the access level ■ Changing the status As an example, we show here how to change a password. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 109: Settings
<Settings> menu Unit of pressure Unit of temperature You want to convert your units to US values: Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed. <Settings> menu. 1. Select the <Settings> menu. The system displays the 2. Click the arrow key for the unit of pressure.
Page 110: Performing A Data Backup
Using KAESER CONNECT: 7.3.7 Performing a data backup In order to use KAESER CONNECT to easily back up data from SIGMA CONTROL 2 to your own <Data backup> menu. PC, use the You can choose to either perform a full backup or partial backups.
Page 111: Adjusting The Pressure Parameters Of The Machine
➤ Click Logout. The logout message is displayed. Result You have closed KAESER CONNECT for SIGMA CONTROL 2. Adjusting the pressure parameters of the machine This subchapter contains instructions for how to display and adjust the pressure parameters of the machine.
Page 112: Display Pressure Parameters
SP: 7.5 bar ¦ SD: - 0.4 bar ········· System pressure low ☐ ↓ < 5.0 bar ¦ SD: 0.5 bar ta: 600 s ¦ DOR 1.04 ☐ Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 113: Configuring The Pressure Parameters For Compressors
SP: 8.0 bar ¦ SD: - 0.5 bar pressure pA pB SP: 7.5 bar ¦ SD: - 0.4 bar ········· System pressure low ☐ Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 114: Tab. 43 Example: Activated Output
Set the time interval for a warning message ■ Activate the output for the warning message sys.press.low value, SIGMA CONTROL 2 will display a warning If the system pressure falls to the message for the system pressure being too low.
Page 115 IDLE. ext.load signal? is displayed. The warning message Precondition Access level 2 is activated. < Configuration ➙ Compressed air system ➙ Pressure settings > (see Section 7.4.1) 1. Select Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 116 System set-point pressure pA or pB Pressure rise dpFC System pressure band width (pA SD or pB SD) < Configuration ➙ Compressed air system ➙ Pressure settings > (see Section 7.4.1) 1. Select Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 117: Activating/Deactivating The "Idle" Key
········· Load RC DI1.13 ok ☑ loc.-load RC DI1.09 ☑ ········· Active line with check box Key idle : ☑ 3. Press «UP». The deactivated check box is displayed. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 118: Configuring Machine Start And Stop
Activate the «Timer» key 7.5.1.1 Selecting the compressor clock menu Precondition Access level 2 is activated. The display shows the operating mode. 1. Press «Enter». The main menu is displayed. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 119: Tab. 45 Example Of A Machine On/Off Timer Program
13:00 Mon-Thu 17:00 15:00 Tab. 53 Example of a machine ON/OFF timer program Precondition Password level 2 is activated, the «timer» key is activated, the "timer" menu is selected. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 120 Weekdays, time and the actions Compressor ON/Compressor OFF are set for all switching points. 7.5.1.3 Activating the«compressor timer» key Key clock is displayed as an active line. 1. Press «UP» repeatedly until Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 121: Setting The Company Shut-Down
4. Press «Enter» to switch into setting mode. Date display flashes. 5. Use «UP» or «DOWN» to change the setting for Day. 6. Press the «Right» key. 7. Setting the month. 8. Press the «Right» key. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 122: Starting The Machine Remotely From A Control Centre
ON/OFF clock program. The machine can be started from the remote control centre even though the timer is activated and the actual program sequence is OFF at this point in time. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 123 The main menu is displayed. < Configuration ➙ Machine ➙ Compressor start ➙ Compressor on > menu. 2. Select the Key remote is displayed as active line. 3. Press «DOWN» repeatedly until Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 124 Key remote : ☑ Key clock : ☐ 2. Press «Enter» to switch into setting mode. Display for input flashes. 3. Select another input with the «UP» or «DOWN» keys. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 125: Activating And Setting Up The Control Modes
7 0 . 0 ° C Current menu 5.2.4 Control mode Active line with control mode to be adjusted Local mode: DYNAMIC ------------------------------ ▶1 DUAL ▶2 QUADRO ------------------------------ Idle Period min 60 s Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 126: Adjusting The Idling Time For Quadro Mode
The shorter the period, the more often the machine will switch from IDLE to STANDSTILL. SIGMA CONTROL 2 will take into account the maximum motor switching capacity. Depending on the machine type, the machine may not fall below a minimum idling or standstill time.
Page 127: Adjusting The Minimum Running And Unloaded Period In Quadro Control
5.3.3 QUADRO Min. run period Active line set-point value for minimum run-time Trgt 240 s ¦ Actl 0 s ········· Unloaded period Trgt 240 s ¦ Actl 100 s Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 128: Configuring The Machine For Local Mode
Select menu < Configuration ➙ Pressure system ➙ Load control > Precondition Password level 2 is activated. 1. In operating mode, switch to the main menu with the «Enter» key. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 129: Configuring The System Pressure Set-Point Changeover Using The Clock
Setting the day of the week for the first switching point Precondition Password level 2 is activated, < Configuration ➙ Compressed air system ➙ Load control > menu is selected (see Sec‐ tion 7.7.1). Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 130 Password level 2 is activated. < Configuration ➙ Compressed air system ➙ Load control > is selected. Menu option pA/pB Clock is displayed as active line. 1. Press «DOWN» repeatedly until Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 131: Configuring The System Pressure Setpoint Changeover Using The Timer
In order to equally utilize two compressors in master-slave operation, select 24 hours as the timer period for pA and pB. ➤ Configure the timer first and then select the operating mode or select another operating mode first. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 132 Result The starting time for pA is set. The period is to start with pB. ➤ Press the «Enter» key and set first start pB with the «UP» key. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 133: Examples Of Time Settings For Equal Overall Load
The setpoint pressure pA/pB is configured the same for both machines. ➤ Establish a cycle with the following switching points: ■ Cycle time pA: 24 h ■ Cycle time pB: 24 h ■ Start pB: 01:00:00 Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 134: Configuring The Machine For Master Control
Example for a clock program for equal duty cycling during the week Configuring the machine for master control 7.8.1 List of the various master controllers The machine controller is provided with several methods of working under other controllers. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 135: Configuring Profibus Mode (Sigma Air Manager)
SIGMA AIR MANAGER or VESIS). The system setpoint pressure pA and pB are irrelevant for the LOAD/IDLE signals. Master control of two compressors 2 The SIGMA CONTROL 2 controllers operate as 7.8.4 with SIGMA CONTROL 2 via Ether‐ master and slave. The slave receive the com‐...
Page 136 Profibus connection A Spare Tab. 59 Profibus DP pin connection Interface plug wiring Fig. 24 Profibus plug wiring Terminal 1A Terminal 2B Terminal 1B Slide switch, terminating resistor Terminal 2A Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 137 Initial Start-up Configuring the machine for master control Wiring possibilities for master control (excerpt) Fig. 25 Electrical diagram example with SIGMA AIR MANAGER Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 138 Set the remote operating mode pB. When automatic mode is changed to manual mode at the master controller, SIGMA CONTROL 2 changes into the set remote mode. In such a case it is preferable to set the operating mode to "remote mode pB".
Page 139 When connected to a SIGMA AIR MANAGER, the slave address is determined as follows: Compressor number used at SIGMA AIR MANAGER +102. Slave is displayed as active line. 1. Press the «DOWN» key repeatedly until Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 140 Timeout: 5 s ☑ 3. Change the time using the «DOWN» or «UP» keys. 4. Press «Enter» to accept the setting. Result The suppression time for a bus alarm is set. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 141: Configuring The Profibus Interface Without Sigma Air Manager Or Vesis
Configuring the Profibus interface without SIGMA AIR MANAGER or VESIS Contact KAESER Service for information on configuring the interface if Profibus is to be used. We will then e-mail you the necessary GSD file and process image. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 142 7 . 2 b a r 1 1 : 1 3 7 0 . 0 ° C Menu 8.2 Com-Module Active line ▶1 Profibus ▶2 Modbus ▶3 Modbus TCP ▶4 DeviceNet 6. Press «Enter». Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 143: Examples For Master Control Of Two Machines Using The Ethernet Interface
Activate the «remote control» key 7.8.5.7 Both Set IP addresses for Ethernet 7.8.5.8 Both Activate master or slave 7.8.5.8 Tab. 60 Master-slave configuration procedure ➤ Proceed with the configuration as described below. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 144: Examples For Master Control Using The Ethernet Interface
Examples for master control using the Ethernet interface (master/slave opera‐ tion) Two machines with SIGMA CONTROL 2 work as master/slave in the same air network. The mas‐ ter controls the machine configured as a slave and provides the signal for the system pressure set‐...
Page 145 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 146 The weekday is set for the first switching point. Setting the time for the first switching point 1. Press the «Right» key. 2. Press «Enter» to switch into setting mode. hours 00:00 flashes. The display for Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 147 Set timer periods pA and pB ■ Select starting time for pA or pB. ■ Select the timer operating mode: pA/pB Cycle(see section7.8.5.5) ➤ Proceed in the sequence shown. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 148 4. Press the «Right» key. minutes 00:00 flashes. The display for 5. Press «UP» repeatedly until the desired number of minutes is displayed. 6. Press «Enter» to accept the settings. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 149 Access level 2 is activated. < Configuration ➙ Compressed air system ➙ Load control > menu is selected. Remote mode is displayed as active line. 1. Press «UP» or «DOWN» repeatedly until Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 150: Tab. 53 Check Box Status
3. Use the «UP» key to activate the check box. 4. Press Enter to accept the setting. The «remote control» key is activated and can be used. 5. Press the «remote control» key to enable remote mode. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 151 DNS Server 2 000.000.000.000 Restart network ☐ 3. Press «Enter» to switch into setting mode. 4. Use «UP» or «DOWN» to set the IP address of at least one machine. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 152 < Communication ➙ Ethernet ➙ Connections > is selected. Precondition The menu 1. Press «Enter». < SIGMA CONTROL 2 > menu is displayed as being active. 2. Press «Enter». Status line is displayed as being active. 7 . 2 b a r 1 1 : 1 3 7 0 .
Page 153 < Communication ➙ Ethernet ➙ Connections > is selected. Precondition The menu 1. Press «Enter». < SIGMA CONTROL 2 > menu is displayed. The Status line is displayed as being active. Mode is displayed as active line. 2. Press «DOWN» repeatedly until 3.
Page 154: Configuring Master Control Using The Load Remote Contact
7.8.6.1 Making the electrical connection for remote LOAD contact (excerpt) Machine (example) Fig. 26 LOAD remote contact ➤ Establish the electrical connection with Tue 1.13 according to the diagram. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 155 3. Use the «UP» or «DOWN» keys to select the input for the LOAD remote contact. 4. Press «Enter» to accept the setting. DI 1.13 . 5. Activate the check box for ok is displayed. Result The operating mode is now configured. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 156: Configuring The Master Control With Local/Load Remote Contact
MVS 8000. ■ Contact A open: SIGMA CONTROL 2 controls with system set-point pressurepB ■ Contact A closed: SIGMA CONTROL 2 controls using a remote contact input. ■ DI 1.13: LOAD/IDLE external ■ DI 1.09: LOAD control – switchover local/remote LOAD contact...
Page 157 The local/load remote contact operating mode is set. Assign an input for the local/load remote contact for switching over pressure control loc.-load RC is displayed as active line. 1. Press «DOWN» repeatedly until Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 158 The local operating mode pB is set. 7.8.7.4 Activate the «remote control» key Precondition Password level 2 is activated. < Configuration ➙ Compressed air system ➙ Load control > menu is selected. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 159 ▶1 pA/pB Clock ········· Load RC operating mode. 3. Use «UP» to select the 4. Press «Enter» to accept the setting. Result The remote load contact operating mode is set. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 160: Configuring Setpoint Pressure Pre-Selection Via Remote Contact
7 0 . 0 ° C Menu 5.2.2 Load control ········· active line, current operating mode Remote mode : pA/pB RC Key remote : ☐ ········· ▶1 pA/pB Clock ········· Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 161 4. Press «Enter» to accept the setting. The «remote control» key can be used. 5. Press the «remote control» key to enable remote mode. Result The operating mode is now configured. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 162: Configuring E-Mail
Initial Start-up Configuring e-mail Configuring e-mail SIGMA CONTROL 2 uses e-mail to send information (messages) to an e-mail address. For this purpose, an Ethernet connection with an SMTP server is required. ➤ Proceed with the configuration in the sequence shown.
Page 163 Write the name without separators; a predefined separator is not provided 10. Enter the user name: ■ Enter the predefined SMTP user name (28 characters) 11. Enter the password: ■ Enter the predefined SMTP password (28 characters) Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 164 Precondition Password level 2 is activated. E-mail sub-menu is displayed as being active. 1. Press «Enter». 2. Press «DOWN» repeatedly until Interval is displayed as active line. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 165 8.1.3 E-mail active line; deactivate/activate e-mail function active: ☑ Compressor number: 1 Setting the language Language: Deutsch ------------------------------ Sender address: status-kaeser@mdex.de Result The e-mail functions are configured and activated. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 166: Configuring The E-Mail Function (External Smtp Server)
■ Activate the e-mail function. Prepare the information required. You need the following information to successfully complete the configuration: ■ Provide Internet access for SIGMA CONTROL 2. ■ The following ports must be open: ─ Port 80: html access ─...
Page 167 In "GMX", this is the GMX customer number or GMX e-mail address. 11. Enter the password: ■ Enter the assigned SMTP password (28 characters) ■ The password in "GMX" 12. Port 25 standard mail sending Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 168: Configuring Input And Output Signals
The controller's binary and analog inputs and outputs can be used for other requirements. This chapter deals with the various options in the following sections: ■ 7.10.1: Outputting important operational states of the compressors. ■ 7.10.2: Displaying additional binary input signals Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 169: Outputting Important Operational States Of The Machine
Select < Configuration ➙ Accessories ➙ I/O Periphery > menu Precondition Access level 2 is activated. 1. In operating mode, switch to the main menu with the «Enter» key. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 170: Displaying Additional Binary Input Signals
A list of the defined alarm and warning messages is provided in chapters 9.3 and 9.2. Information on spare inputs is given in the machine circuit dia‐ gram. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 171 External message 1 is displayed as active line. 2. Press «Enter» to switch into setting mode. character set flashes. The display of the 3. Enter the individual message text. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 172 The delay can be set between 0.01 and 600 seconds. The delay is counted down from 600 with the «DOWN» key and counted upwards from zero in 0.01 second steps with the «UP» key. 1. Press «DOWN» once. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 173 1. Press «DOWN» repeatedly until "OUTPUT" is displayed as active line. 2. Press «Enter» to switch into setting mode. Output display flashes. 3. Select the output with the «UP» or «DOWN» keys. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 174: Activating Remote Acknowledgement
Acknowledging the message without correcting the cause, however, can lead to machine damage. The following conditions must be fulfilled: ■ The remote acknowledgement and «remote» key are activated. ■ A controller input has been assigned for the acknowledgement signal. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 175: Select Menu < Configuration ➙ Machine ➙ Acknowledgement
Remote key deactivated Key remote : ☐ ------------------------------ RC ack DI 1.11 ☐ 7.11.2 Setting the remote acknowledgement function. 1. Press «Enter» to switch into setting mode. Key flashes. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 176: Activate The "Remote Control" Key
1 1 : 1 3 7 0 . 0 ° C Menu 5.1.3 Acknowledgement Remote mode : Key+RC Key remote : ☑ ------------------------------ Active line RC ack DI 1.11 ☐ Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 177: Linking To An External Pressure Transducer
The controller processes the options in the following sequence: ■ Profibus value ■ Pressure according to the assigned external transducer ■ Net pressure pNloc, the local system pressure transducer remains activated Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 178: Selecting Menu
(local transducer) pNloc 3.8 bar AII ☐ 0.0 bar 7.12.2 Allocating the input to an external transducer 1. Press «Enter» to switch into setting mode. pNloc flashes. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...

Page 179: Configuring The Water System
7 . 2 b a r 1 1 : 1 3 7 0 . 0 ° C Menu 10.3 Water system Active line ▶3 V10 ▶4 V12 ▶5 V14 Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 180 9. Press «DOWN» twice. 10. Press «Enter» to switch into setting mode. Temperature display flashes. 11. The 12. Press the «UP» key three times. A temperature value of 40 °C is set. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 181: Starting The Machine
<ON> key and let the machine run for at least 1 minute in IDLE to allow suffi‐ ➤ Press the cient oil to enter the pressure system. 4. Press the «ON »key. 5. Press the «LOAD/IDLE »key. Result The machine switches to LOAD. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 182: Operation
1. Press the «LOAD/IDLE »key. IDLE LED flashes. The machine switches to IDLE and the 2. After allowing the machine to IDLE for 20 seconds, Press the «OFF» key. Machine ON LED extinguishes. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 183: Switching Off In An Emergency And Switching On Again
Message coming or Message going . However, warning and fault messag‐ sages immediately after es can be acknowledged only following a successful elimination of the corresponding fault. Message sequence 1 Display Message coming LED flashes Message acknowledged LED illuminates Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 184 ➤ Unlatch the «EMERGENCY STOP» pushbutton (turn in direction of the arrow) ➤ before acknowledging the alarm message. Further information A list of possible alarm messages occurring during operation are shown in chapter 9.3. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 185: Displaying The Current Operating Mode
1 1 : 1 3 7 0 . 0 ° C Menu 1 Status ▶1 Messages ▶2 Statistics ▶3 Current pressure control Active line ▶4 Current operating mode ▶5 DI/DO display Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 186: 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 7.4. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 187: Displaying Analog Data
7 . 2 b a r 1 1 : 1 3 7 0 . 0 ° C Menu 2.1 Machine Active line ▶1 Pressure ▶2 Temperature ▶3 Extreme value memory Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 188: Displaying Operating Data
Engine Motor running time (can be changed) ─ Airend: Airend running time (can be changed) ─ SIGMA CONTROL 2: Controller running time Displaying operating data Precondition Access level 2 is activated. 1. In operating mode, switch to the main menu with the «Enter» key.
Page 189: Interpreting Operation Messages
As soon as such a message is displayed, the machine will regulate to sufficiently low system temperatures. Defined set-point values will be ignored. Message Meaning 0017 O Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 190 Temperature at sensor for T13 high. T13 ⇑ always Recommendations In option W5/W6, switch the block cooling to the secondary water system. Possible cause: Water systems are not balanced hydraulically. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 191: Setting The Maintenance Interval
You successfully registered two KAESER RFID Equipment Cards at the controller. 2 RFID Equipment Cards successfully registered Tab. 69 Operational Messages Setting the maintenance interval Example: Changing the oil change service interval. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 192: Testing The Pressure Relief Valve
6. Press «Escape» repeatedly to return to the main menu. Testing the pressure relief valve Use the SIGMA CONTROL 2 to conveniently test the functioning of the pressure relief valves of the second compression stage at the machine outlet. When the test mode is activated, the third line of the operating mode display (see chapter 4.3) indi‐...
Page 193 3. Close the user's shut-off valve between the machine and the air distribution network. 4. Log on to SIGMA CONTROL 2 with access level 2 (see chapter 7.2.4). 5. In operating mode, switch to the main menu with the «Enter» key.
Page 194 Activating pressure of the pressure relief valve and pRV :10.00 bar ¦ p : 10.10 bar current value (maximum storage) ¦ Reset ☐ ------------------------------ 10. Monitor the pressure rise (indicated on the display) during the test. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 195 The «LOAD» is pressed and held. The permissible internal pressure was exceeded by 2 bar. Test p5: p5 > pRV . Fault message SIGMA CONTROL 2 is displayed and the test is aborted. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 196 ▶1 Test p5 -> pRV ▶2 Test T2 ⇞ always ▶3 Test T3 ⇞ run 6. Press «Escape» repeatedly to return to the main menu. 7. Open the shut-off valve from the machine. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 197 Result The machine is ready for operation. Reset after closing the test mode During the test, SIGMA CONTROL 2 indicates the highest value measured for output pressure p5. To reset the saved value, activate the "Reset" check box. Check box Status ☒...
Page 198: Checking The Temperature Sensor And Overheating Shutdown Function
Performing the test Precondition Machine cooled down by approx. 5 °C 1. Log on to SIGMA CONTROL 2 with access level 2. (see section 7.2.4). 2. In operating mode, switch to the main menu with the «Enter» key. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 199 9.2 Test T2 ⇞ always T2 : 51.0 °C ------------------------------ Switching point and modified test value of the mes‐ SP: 250.0°C ¦ T : 248.0 °C sage Active line ¦ Reset ☐ ------------------------------ Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 200 Checking the temperature sensor and overheating shutdown function 9. Press the «ON »key. The compressor runs in LOAD. Temperature T2 rises. 250 °C , SIGMA CONTROL 2 shuts the machine As soon as the modified test value shows down. 7 . 2 b a r 1 1 : 1 3 7 0 .
Page 201 6. Press «Escape» repeatedly to return to the main menu. Reset after closing the test mode SIGMA CONTROL 2 will display the highest measured value if the test for switching off at overtem‐ perature is aborted. Activate the Reset check box in order to reset the stored value.
Page 202: Fault Recognition And Rectification
Basic instructions 9 Fault Recognition and Rectification Basic instructions The following tables are intended to assist in locating faults. SIGMA CONTROL 2 will indicate three types of faults: ■ Fault on the machine: red LED flashes - see chapter 9.3. ■...
Page 203 KAESER Service. Hot air connection operat‐ ing. 0025 W Oil cooler clogged. Clean the cooler. T66 > x°C ¦ run Low flow rate through the Contact oil cooler. KAESER Service. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 204 The drive motor is stop‐ ped. 0035 W System pressure too high. Contact p4 > x.xbar ¦ always KAESER Service. High pressure drop over the air treatment compo‐ nents. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 205 Increased cut-out pressure troller. Take into exceeded. account pressure drops across filters The external load control and dryer. has not switched to idle (off load). Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 206 Replenish heat re‐ leaking. ceiving medium. 0054 W Coolant temperature high. Clean the cooler. T4 > x°C ¦ always Set point value T10w high. Check coolant flow rate. Contact KAESER Service. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 207 Check coolant flow rate. Check the set val‐ ue of the parame‐ ter. 0066 W Initial warning: Change the air fil‐ Air filter Δp ⇡ Air filter clogged. ter element soon. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 208 Machine was started at im‐ Keep ambient con‐ Cold start permissible low tempera‐ ditions within ture. specified limits. 0097 W JSON-RPC communication error 0201 W Compressor motor FC Service mode active Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 209 Oil change h ⇞ the gearbox oil has ex‐ box oil. pired. 0455 W Maintenance interval for Maintain the motor Fan bearings h ⇞ the fan's motor bearing bearings. has expired. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 210: Interpreting Fault Messages
0009 A Permissible enclosure temper‐ Keep ambient con‐ Sigma Control T⇞ ature for SIGMA CONTROL 2 ditions within speci‐ exceeded. fied limits. Control cabinet: Check filter mats and fan. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 211 > x.xbar ¦ always KAESER Service. 0021 A Oil level too low. Check the oil level. p66 < x.xbar ¦ run Pressure reducer defective. Contact KAESER Service. Leaks in the machine. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 212 Check coolant flow T12T11M-T14 > x°C ¦ run rate and direction. Incorrect coolant flow direction. Have the auxiliary Primary water system control switch on control valve overcompensating. valve 1 checked. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 213 Intake air temperature too Keep ambient con‐ T1 > x°C ¦ run high. ditions within speci‐ fied limits. 0050 A Measuring error. Contact T2-T1 < x°C ¦ run KAESER Service. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 214 KAESER Service. too quickly. Cooler inlet temperature T10 too high. Set point value T10w set too high (only with option W5/W6). Secondary water system tem‐ perature too high. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 215 Coolant temperature high. Keep ambient con‐ ditions within speci‐ Low coolant flow rate. fied limits. Check coolant flow rate. Check the set value of the parameter. 0073 A 0074 A Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 216 Main fan 2 temperature too high. KAESER Service. 0110 A Function parameterised previ‐ Use different I/O. IO parameterisation module 50 ously 0130 A 0132 A 0133 A 0134 A 0140 A Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 217 Input AI0 at the frequency con‐ Contact Compressor motor FC AI0 error verter, fault KAESER Service. 0215 A Input AI1 at the frequency con‐ Contact Compressor motor FC AI1 error verter, fault KAESER Service. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 218 0542 A Valve actuation set to manual. Deactivate manual WS V14 close run period operation for the valve actuation. Tab. 72 Alarm messages and measures Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 219: Interpreting System Messages
Diagnostic messages are identified with the letter D. They provide information on the status of the controller, the connected input and output modules and support the KAESER service in trouble-shooting. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 220: 10 Maintenance
Maintenance 10.1 Maintenance Work 10 Maintenance 10.1 Maintenance Work The SIGMA CONTROL 2 and the I/O modules are maintenance-free. Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 221: 11 Spares, Operating Materials, Service
7 . 2 b a r 1 1 : 1 3 7 0 . 0 ° C Menu 5.1.1.1 System information Active line ▶1 SC2 - MCS ▶2 Compressor ▶3 IO modules Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 222 1 1 : 1 3 7 0 . 0 ° C Menu 5.1.1.1.1 SC2 - MCS x.xx.xx ········· Manufacturer Prodrive Material number PN 6309.1001.1801 Serial number SN 10.46.001.231 Date of production MFGDT 2011/02 Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...
Page 223: 12 Decommissioning, Storage And Transport
➤ Follow the instructions in the machine's service manual. 12.4 Transporting ➤ Follow the instructions in the machine's service manual. 12.5 Disposal ➤ Follow the instructions in the machine's service manual. Service manual Controller 9_9451 00E SIGMA CONTROL 2 SCREW DRY 1.0.x.x...
Page 224 Decommissioning, Storage and Transport 12.5 Disposal Service manual Controller SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00E...

KAESER KOMPRESSOREN SIGMA CONTROL 2 Service Manual

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