Page 1 User manual Controller SIGMA CONTROL 2 SCREW FLUID ≥ 6.4.1 9_9450 22 E Manufacturer: KAESER KOMPRESSOREN SE 96410 Coburg • PO BOX 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 www.kaeser.com...
Page 2 SBA-CM-SC2 FLUID-9_9450-CE-PDF 3 GUID-C76C4C6A-1953-4AE7-AD40-C7CF0E585914 04/12/2023 en-GB 04122023 135239...
Page 3: Table Of Contents
Contents Contents 1 Quick reference guide Operating elements ......................Display elements ....................... Main menu overview ......................Functions overview ......................2 About this document Warning notices ........................ Material damage warnings ....................Symbols and pictograms ....................Copyright ........................... Software ..........................Approvals .......................... Updating the manual ......................
Page 4 Contents 5.7.1 Machine operating points ..................5.7.2 Control modes ...................... 5.7.3 Variable speed control with frequency converter (SFC) ........6 Commissioning Topic overview ........................Controller settings ......................6.2.1 Selecting a menu item ..................6.2.2 Language ......................6.2.3 User log-in ......................6.2.4 Date and time .......................
Page 5 Contents 6.10.8 Master control for machines regulated via pressure switch ......... 153 6.11 Inputs and outputs ......................159 6.11.1 Operating states ....................159 6.11.2 Analogue values ....................161 6.11.3 Digital inputs ......................166 6.11.4 Threshold values ....................171 6.12 Timer ..........................176 6.13 Remote acknowledgement ....................
Page 6 Contents 11 Documents and drawings 11.1 Notes ..........................252 11.2 Software versions ......................253 11.3 Time settings ........................253 11.4 Network parameters ......................254 11.5 E-mail parameters ......................254 11.6 User-defined time program ON/OFF ................. 255 11.7 Setpoint pressure change in the user time program ............255 11.8 Delay times ........................
Page 7 List of Illustrations Fig. 1 Operating elements........................Fig. 2 Display elements......................... Fig. 3 MCS interfaces..........................Fig. 4 MCSIO interfaces........................Fig. 5 MCS system configuration with IOM.................... Fig. 6 MCSIO system configuration....................... Fig. 7 Operating elements........................Fig. 8 RFID Reader..........................Fig. 9 Display elements......................... Fig.
Page 8 List of Tables Tab. 1 Operating elements........................Tab. 2 Display elements......................... Tab. 3 Main menu overview........................Tab. 4 Functions overview........................Tab. 5 Signal words and their consequences..................Tab. 6 Symbols and pictograms......................Tab. 7 Versions and options........................Tab. 8 Electrical and mechanical specifications..................Tab.
Page 9 List of Tables Tab. 57 Machine type and ETM version....................110 Tab. 58 Operating modes in Local mode....................119 Tab. 59 Example: Setpoint pressure changeover switching points............120 Tab. 60 Master control overview....................... 125 Tab. 61 Parameters for communications fault monitoring................ 128 Tab.
Page 10: Quick Reference Guide
Quick reference guide Operating elements 1 Quick reference guide 1.1 Operating elements Fig. 1 Operating elements Item Operating element Function «Up» Scrolls the menu up. Increases a parameter value. «Left» Moves to the left. Moves the cursor position to the left. «Right»...
Page 11: Display Elements
Quick reference guide Display elements 1.2 Display elements Fig. 2 Display elements Item Display ele- Colour Function ment Illuminates when the machine is switched on. Green Display — User interface and graphic display. Time control Illuminates when the machine is being controlled via the timer. Green Remote control Illuminates when the machine is being controlled remotely.
Page 12: Main Menu Overview
Quick reference guide Main menu overview Item Display ele- Colour Function ment Fault Flashes to indicate a fault with the machine. Remains illuminated after the message has been acknowl- edged. Tab. 2 Display elements 1.3 Main menu overview Pressing the «Enter» key or one of the arrow keys opens up the main menu. Menu no.
Page 13 Quick reference guide Functions overview Function Menu Action steps Chapter User log-in — 6.2.3.2 User log-in via RFID Equip- RFID Equip- ment Card ment Card Set pressure 5.2.2 <Configuration – Pressure control – Pressure settings 6.4 Pressure parameters – pA / pB> parameters Set time <Compressor clock> – Enter data for the time pro- 6.5.1 Time control gram...
Page 14 Quick reference guide Functions overview Function Menu Action steps Chapter Warning 1.1.1 If maintenance work needs to be carried out or if 8.3 Warning messages the warning message is displayed before a fault, the messages Warning control indicator flashes yellow .
Page 15: About This Document
About this document Warning notices 2 About this document Read the operating manual carefully and ensure you are familiar with the contents before using this product. This document constitutes an integral part of the product and describes the product at the time of initial delivery following completion.
Page 16: Symbols And Pictograms
About this document Symbols and pictograms NOTICE Description of the hazard, cause and consequences ▶ Instructions on how to avoid the damage 2.3 Symbols and pictograms Symbols and pictograms in this document draw your attention to information that requires special attention.
Page 17: Software
Within three years of receiving your SIGMA CONTROL 2, you may obtain the complete source code for the copyright-protected KAESER software packages by order to the following address: K&E Elektrokonstruktion KAESER KOMPRESSOREN SE 96450 Coburg, P.O. Box 2143 Germany 2.6 Approvals This product is subject to the following approvals: ▪...
Page 18: Updating The Manual
About this document Updating the manual 2.7 Updating the manual You can find the current version of this manual on our Internet page https://www.kaeser.de/man- uals. It is recommended to download the manual after each software update, in order to familiarise yourself with any new or modified functionality.
Page 19: Technical Data
Technical data SIGMA CONTROL 2 controller 3 Technical data 3.1 SIGMA CONTROL  2 controller Industrial PC with the following equipment: ▪ Internal temperature monitoring ▪ Internal undervoltage monitoring ▪ Real-time clock with battery buffer (battery life: > 10 years) Versions and options SIGMA CONTROL 2 is offered in different technical versions. Type Prepared for connection to control Connection to control technology not...
Page 20: Interfaces
Technical data SIGMA CONTROL 2 controller Characteristic Value Height [mm] Number of lines Number of characters per line Colours Black and white with grey scale Lighting LED backlit px ≙ pixels Tab. 9 Display 3.1.2 Interfaces Fig. 3 MCS interfaces Identification Interface Connection Ethernet 10 / 100 Base T RJ45 socket I/O bus...
Page 21: Fig. 4 Mcsio Interfaces
Technical data SIGMA CONTROL 2 controller Identification Interface Connection The positions of interfaces X1 – X6 are indicated on the rear of the controller Tab. 10 MCS interfaces Fig. 4 MCSIO interfaces Identification Interface Connection Ethernet 10 / 100 Base T RJ45 socket RS485-FC 9-pole SUB-D socket (USS inter- face) SD card Slot for SD / SDHC card...
Page 22: Mcsio Inputs And Outputs
Technical data Input/Output Modules RFID Characteristic Value SIGMA CONTROL 2 controller hardware RFID Reader Hardware (external) RFID Equipment Card Maximum distance for short-range detection [mm] Frequency [MHz] 13.56 Maximum emitted transmit power at 10 m distance [dB(µA / m)] Tab. 12 RFID The RFID Reader transmits at a frequency of 13.56 MHz and is permitted for use in EU member states.
Page 23: Electrical Connection Data Iom
Technical data Input/Output Modules ▪ Internal undervoltage monitoring ▪ Control indicator for operating state IOM  1 Input / Output Control cab- Control cab- Interior inet inet or inte- rior Digital input (DI), 24 V DC Analogue input current (AII), 0 – 20 mA — Analogue input resistor (AIR), Pt100 —...
Page 24: Maximum Cable Lengths
Technical data Sensors Characteristic Value Current consumption with IOM 1 [A] Current consumption IOM 2 [A] Current consumption IOM 3 [A] IOM ≙ Input/Output module Tab. 18 Electrical connection data 3.2.2 Maximum cable lengths Input / Output Cable length [m] Analogue input current (AII) < 30 Analogue input resistor (AIR) Analogue output current (AOI) Digital input (DI) < 100...
Page 25: Resistance Thermometer
Technical data Sensors Characteristic Value Number of electrical conductors Tab. 22 Pressure transducer 3.3.2 Resistance thermometer Characteristic Value Measuring resistor (as per DIN IEC 751) Pt100 Number of electrical conductors Tab. 23 Resistance thermometer User manual Controller 9_9450 22 E SIGMA CONTROL 2 SCREW FLUID ≥ 6.4.1...
Page 26: Safety And Responsibility
Safety and responsibility Intended use 4 Safety and responsibility This product is manufactured to the latest engineering standards and in accordance with acknowl- edged safety regulations. Nevertheless, dangers can arise through its use: ▪ Danger to life and limb for the operator or third parties. ▪...
Page 27: Design And Function
Design and function Controller overview 5 Design and function 5.1 Controller overview SIGMA CONTROL 2 controls, regulates, monitors, and protects the machine. All parameters needed to operate KAESER compressed air generators can be displayed and set via the controller. Some parameters are protected by user-dependent access levels. 5.1.1 Components SIGMA CONTROL 2 consists of the following components:...
Page 28: Functions
Design and function Controller overview Fig. 5 MCS system configuration with IOM Machine housing Inputs/outputs, control cabinet interior Control cabinet Inputs/outputs, compressor interior SIGMA CONTROL 2 (prepared for con- Inputs/outputs for external sensors nection to control technology) Compressor Input/Output module (IOM) I/O bus Fig.
Page 29: Control Panel
Design and function Control panel ▪ Display of warning or maintenance messages relating to pending maintenance tasks on the SIGMA CONTROL 2 Protective function ▪ Automatic shutdown of the machine in the event of a fault that could result in machine damage, e.g.
Page 30: Rfid Reader
Design and function Control panel Item Operating element Function «Acknowledge» Acknowledges messages. Tab. 24 Operating elements 5.2.2 RFID Reader RFID is the abbreviation for “Radio Frequency IDentification” and enables identification of persons and objects. Placing a suitable transponder before the RFID Reader will automatically activate communication between the transponder and SIGMA CONTROL 2.
Page 31: Display Elements
Design and function Control panel 5.2.3 Display elements Fig. 9 Display elements Item Display ele- Colour Function ment Illuminates when the machine is switched on. Green Display — User interface and graphic display. Time control Illuminates when the machine is being controlled via the timer. Green Remote control Illuminates when the machine is being controlled remotely.
Page 32: Display
Design and function Display Item Display ele- Colour Function ment Fault Flashes to indicate a fault with the machine. Remains illuminated after the message has been acknowl- edged. Tab. 26 Display elements 5.3 Display The display allows the user to read off information and check entered data. The display is fully graphical.
Page 33: Tab. 27 Machine-Dependent Data In The Header
Design and function Display 5.3.1.1 Header The header is the uppermost line on the screen and is always displayed inversely. Important information and values are displayed in the header. The data displayed by the SIGMA CONTROL 2 controller varies according to machine type Header, left Header, centre Header, right...
Page 34: Parameters
Design and function Display 5.3.2.2 Numbering Each menu is numbered hierarchically. You can identify the menu structure from the numbering. Not all menus are displayed. The menu display depends on the authorisation level and on certain settings and options. Further information regarding the menu structure can be found in chapter 5.6 Menu structure.
Page 35: User Log-In Via Rfid Equipment Card
Design and function User log-in via RFID Equipment Card The display ceases flashing and the key is activated. Follow the same steps to deactivate a key. Tick box Status ☑ Activated ☐ Deactivated Tab. 29 Tick box status 5.4 User log-in via RFID Equipment Card Upon switching the controller on, the lowest access level is activated.
Page 36: Kaeser Connect
Design and function KAESER CONNECT 5.5 KAESER CONNECT The user interface for SIGMA CONTROL 2 can be displayed on an Internet-enabled device with a web browser. To do so, SIGMA CONTROL 2 must be connected directly (network cable) or indirectly (network) to the Internet-enabled device via the X1 interface.
Page 37 Design and function KAESER CONNECT Operating element Meaning Graphs ▪ Display pressures and temperatures in a variety of graphs ▪ Graphic representation of machine status (STOP, IDLE , LOAD) and speed over the time axis Messages ▪ Current messages ▪ Message history I/O display Assignment of input/output modules User management...
Page 38: Menu Structure
Design and function Menu structure 5.6 Menu structure In the main menu, you can access displayed information and enter customer-specific settings. The menus depicted require access level 2. Depending on the SIGMA CONTROL 2 software version, the machine type and the options fitted, only the menus available for the specific machine will be displayed.
Page 39 Electr.interior Power Torque Air cooler - Fan Speed Current consum. Torque ▪ Analogue values ▪ SIGMA CONTROL 2 3 Operating data ▪ Operating hours ▪ Compressor ▪ Load run ▪ Motor ▪ Compressor airend ▪ SIGMA CONTROL 2 ▪ Partial load valves ▪...
Page 40 Design and function Menu structure Navigation Function / Submenu 4 Maintenance ▪ External counter ▪ External counter 1 ▪ External counter 2 ▪ External counter 3 Oil filter Oil separator Oil change Control valve(s) open: Air filter Prefilter changed: Cleaning completed: Valve inspection Belt/coupling inspection Compressor motor...
Page 41: Tab. 31 Main Menu Structure
Design and function Menu structure Navigation Function / Submenu 6 Compressor clock Key clock Reset Switching point 01 Switching point 02 Switching point 03 Switching point 04 Switching point 05 Switching point 06 Switching point 07 Switching point 08 Switching point 09 Switching point 10 7 User Name Password...
Page 42: Status Menu
Motor starts per day Motor starts per hour Motor starts T↓ Last load run Last idle run Last motor off 1.3 Current pressure control SIGMA CONTROL 2 Cut-out pressure Network actual pressure Frequency converter Setpoint pressure Actual pressure Speed nominal value...
Page 43: Tab. 32 Status Menu
Design and function Menu structure Navigation Function / Submenu 1.4 Current operating mode Compressor on Load control Control mode Idle period Idle warm-up Acknowledgement Frequency converter Heat recovery HR valve (if available) 1.5 DI/DO status First Input/Output module DI/DO display Second Input/Output module DI/DO display Third Input/Output module DI/DO display...
Page 44: Configuration Menu
Design and function Menu structure 5.6.2 Configuration menu Navigation Function / Submenu 5.1 General ▪ System information ▪ SIGMA CONTROL 2 MCS Software KAESER: PN / SN Controller manufacturer: PN / SN / MFGDT (Date of manufac- ture) ▪ Compressor EN (Equipment number) PN (Material number) SN (Serial number) ▪...
Page 45 Design and function Menu structure Navigation Function / Submenu 5.3 Control mode Local mode: ▪ Venting period ▪ DUAL ▪ QUADRO ▪ Partial load valves 5.4 Compressor start ▪ Compressor on ▪ Compressor off Autostart: Start inhibit: Start temperature 5.5 Acknowledgement Remote mode: RC Ack Key remote 5.6 ETM...
Page 46: Tab. 33 Configuration Menu
Design and function Menu structure Navigation Function / Submenu 5.9 Refrigeration dryer (if available) Control mode Compressor ready: CONTINUOUS / INTERMITTING Compressor Clk/RC/RB off: CONTINUOUS / INTERMITTING Temperature↑ Temperature ⇟ For RD fault:  Compressor on / Compressor off Error operation without RD active: Run time max.: Actual Reset Alarm: 5.10 PD temperature controller Nominal value Actual value...
Page 47: Tab. 34 Pressure Control Menu
Design and function Menu structure Pressure control menu Navigation Function / Submenu 5.2.1 Pressure sensors System pressure pNloc Internal pressure pi 5.2.2 Pressure settings pRV (Safety valve actuating pressure) Pressure rise pESP / SD ΔpFC Nominal pressure Setpoint pressure pA SP / SD pB SP / SD System pressure low Cut-in pressure min 5.2.3 Load control Local mode...
Page 48 Design and function Menu structure I/O peripherals menu Navigation Function / Submenu 5.7.1 DO functions Controller on DOR / DOT Compressor on DOR / DOT Compressor motor running DOR / DOT Fan motor running DOR / DOT Idle DOR / DOT Load run DOR / DOT Group alarm DOR / DOT Group warning continuous DOR / DOT Group warning interrupted DOR / DOT Remote mode...
Page 49: Tab. 35 I/O Peripherals Menu
Design and function Menu structure Navigation Function / Submenu 5.7.2 Analogue values ▪ AnMod (Analogue modules) ▪ AnMod_p_1 ▪ AnMod_p_2 ▪ AnMod_p_3 ▪ AnMod_p_4 ▪ AnMod_T_1 ▪ AnMod_T_2 ▪ AnMod_T_3 ▪ AnMod_T_4 ▪ AnMod_I_1 ▪ AnMod_I_2 ▪ AI (Analogue inputs) ▪ AI_p_1 ▪...
Page 50: Communication Menu
▪ IP address ▪ Subnet mask ▪ Gateway ▪ DNS Server 1 ▪ DNS Server 2 ▪ Restart network ▪ Connections ▪ SIGMA CONTROL 2 ▪ SAM 4.0 Restart Timeout Cycle time Connections Further information regarding the menu can be found in Tab.
Page 51: Connections Menu
Design and function Menu structure 5.6.4 Connections menu Navigation Function / Submenu 8.1.2 Connections ▪ SIGMA CONTROL 2 ▪ Status ▪ Mode ▪ Port ▪ Communication partner ▪ IP address ▪ Communication error Start td Timeout ▪ SAM 4.0 ▪ Status ▪ SAM 4.0active:...
Page 52: Power Switching Menu
Design and function Menu structure 5.6.6 Power switching menu Navigation Function / Submenu 10.1.1 Power switching USS status:Run / Error ▪ Star-delta start ▪ Temp. warm start ▪ Star time T↑ ▪ Star time T↓ ▪ Υ/Δ switching time ▪ Overload relay ▪ Mains contactor ▪...
Page 53: Tab. 39 Power Switching Menu
Design and function Menu structure Navigation Function / Submenu 10.1.1 Power switching Operating mode: Pressure control / Speed control Manual / FC USS Nominal value: / Actual value Local mode: Pressure control / Speed set point man- ual / Speed sensor All Remote mode: Pressure control / Speed set point man- ual / Speed sensor All Key remote ▪...
Page 54: Operating Points And Control Modes
Design and function Operating points and control modes 5.7 Operating points and control modes 5.7.1 Machine operating points STOP The machine is connected to the power supply: Voltage applied to controller control indicator is illuminated in green ▪ The ▪ The machine is switched off. ON control indicator is off.
Page 55 Design and function Operating points and control modes ▪ MODULATING CONTROL (Partial load control) 5.7.2.1 DUAL In the DUAL control mode, the machine first switches back and forth between LOAD and IDLE in order to maintain the working pressure between the specified minimum and maximum pressure values.
Page 56: Variable Speed Control With Frequency Converter (Sfc)
Design and function Operating points and control modes 5.7.2.6 MODULATING CONTROL (Partial load control) MODULATING CONTROL continuously changes the flow rate within the machine’s control range. A control valve, the proportional controller, adjusts the degree of opening for the inlet valve whilst the machine is delivering compressed air into the network (LOAD).
Page 57: Commissioning
Commissioning Topic overview 6 Commissioning 6.1 Topic overview SIGMA CONTROL 2 is designed for a multitude of potential applications. The settings options are correspondingly varied. It is possible that only a few of these settings are necessary for the initial commissioning. The steps required depend on your application.
Page 58: Selecting A Menu Item
Commissioning Controller settings 6.2.1 Selecting a menu item Use the «Up» and «Down» keys to select a menu. Use the «Enter» key to open the selected menu. Example: Select the line General . Proceed as follows: 1. Switch on the machine and wait for SIGMA CONTROL 2 to start up. The operating display is on view.
Page 59: Language
Model: XXXXXX Set machine type ········· Date/time 7. To exit the menu, press the «Escape» key multiple times. 6.2.2 Language The following user guidance languages can be set in SIGMA CONTROL 2: Arabic Estonian Italian Norwegian Spanish Bulgarian Finnish Japanese...
Page 60: User Log-In
Commissioning Controller settings 6.1bar 08:15 80°C Header Main menu ---------------- English GB ---------------- Current set language ▶1 Status Submenu ▶2 Performance data Submenu ▶3 Operating data Submenu ▶4 Maintenance Submenu ▶5 Configuration Submenu 3. Press the «Enter» key. The current set language flashes. 4. Set the desired language. 5.
Page 61: Fig. 12 User Log-In Via Rfid Equipment Card
Commissioning Controller settings Advanced access rights allow you to: ▪ Read off additional data ▪ Modify additional settings Fig. 12 User log-in via RFID Equipment Card Proceed as follows: 1. Hold the RFID Equipment Card in front of the RFID Reader. Your username and access level will be displayed. 6.1bar 08:15 80°C...
Page 62: Fig. 13 Log-In Via Rfid Equipment Card
Commissioning Controller settings Fig. 13 Log-in via RFID Equipment Card Proceed as follows: 1. Hold the RFID Equipment Card in front of the RFID Reader. Users are logged in with access level 2. 6.1bar 08:15 80°C Header Log-in successful Menu Button to change password Prompt for whether the password should be changed ------------------------------ Name:...
Page 63: Fig. 14 Logging In Manually
Commissioning Controller settings ▪ The username is known, see chapter 6.2.3.1 Noting the username. ▪ The password is known, see chapter 6.2.3.3 Generating a password. ▪ The operating display is on view. Proceed as follows: 1. Open the menu 7 <User>. Name .
Page 64: Date And Time
Commissioning Controller settings ▪ The operating display is on view. Proceed as follows: 1. Hold the RFID Equipment Card supplied with the machine in front of the RFID Reader. Users are logged in with access level 2. 6.1bar 08:15 80°C Header Log-in successful Menu Button to change password Prompt for whether the password should be changed...
Page 65 Commissioning Controller settings 1. Open the menu 5.1 <Configuration – General>. Date/time . 2. Select the line 3. Press the «Down» key. 6.1bar 08:15 80°C Header 5.1 General Menu Model: XXXXXX Set machine type ········· Date/time Current date and time 13/04/2023 08:15:37 Europe/London 4.
Page 66 Commissioning Controller settings 6.1bar 08:15 80°C Header 5.1 General Menu Model: XXXXXX Set machine type ········· Date/time 13/04/2023 08:15:37 Current date and time Europe/London 4. Press the «Enter» key. 00. 00.00 . The day indicator flashes: 5. Set the day. 6. Press the «Right» key. 00.
Page 67 Commissioning Controller settings 6. Press the «Enter» key. The setting is applied accordingly. 7. To exit the menu, press the «Escape» key multiple times. 6.2.4.4 Time server If the SIGMA CONTROL 2 is connected to a network, access to an Internet or intranet-based SNTP time server can be established.
Page 68: Display Formats
Commissioning Controller settings 6.1bar 08:15 80°C Header 5.1.2 Time server Menu active: ☑ The time server function is activated. IP address 192.053.103.103 Example address, time server 11. Press the «Enter» key. 12. To exit the menu, press the «Escape» key multiple times. Access to the selected time server is active.
Page 69: Tab. 42 Settings Options For The Time Format
Commissioning Controller settings 4. Set the date format. 5. Press the «Enter» key. The setting is applied accordingly. 6. To exit the menu, press the «Escape» key multiple times. 6.2.5.2 Time format Set the format for the time indicator: Format Example hh:mm:ss 13:33:45 hh:mm 13:33...
Page 70: Tab. 43 Settings Options For The Pressure Units
Commissioning Controller settings Format Example 0.55 MPa 80 psi 5.6 at 550 kPa Tab. 43 Settings options for the pressure units ▪ Access level 2 is activated. Proceed as follows: 1. Open menu 5.1 <Configuration – General>. Pressure unit . 2. Select the line 6.1bar 08:15 80°C Header 5.1 General...
Page 71: Display
Commissioning Controller settings 6.1bar 08:15 80°C Header 5.1 General Menu Time format hh:mm:ss Time format ········· Pressure unit Pressure units Temperature unit °C Temperature units ········· Display lighting 3. Press the «Enter» key. The indicator for the selected units flashes. 4. Set the units. 5.
Page 72: Contrast And Brightness
Commissioning Controller settings 6.1bar 08:15 80°C Header 5.1 General Menu ········· Pressure unit Pressure units Temperature unit °C Temperature units ········· Display lighting Mode auto.¦ Timeout : 1min Active line 4. Press the «Enter» key. The indicator for the specified mode flashes. auto. . 5.
Page 73: Ip Configuration
Commissioning Controller settings 6.1bar 08:15 80°C Header 8 Communication Menu ▶1 Ethernet/SIGMA NETWORK ▶2 Com-Module Key remote : ☐ Active line with deactivated tick box 4. Press the «Up» key. Key remote tick box is activated. 6.1bar 08:15 80°C Header Menu 8 Communication ▶1 Ethernet/SIGMA NETWORK ▶2 Com-Module Key remote : ☑...
Page 74: Tab. 46 Network Parameters
Commissioning Controller settings IP address . 3. Select the line 6.1bar 08:15 80°C Header 8.1.1 IP configuration Menu IP address 169.254.100.101 Active line, factory setting Subnet mask 255.255.000.000 Gateway 169.254.100.097 DNS Server 1 169.254.100.097 DNS Server 2 169.254.100.097 Restart network ☐ 4.
Page 75: E-Mail
Commissioning Controller settings 6.1bar 08:15 80°C Header 8.1.1 IP configuration Menu IP address 169.168.001.010 Example address Subnet mask 255.255.255.000 Example address Gateway 169.168.001.001 Example address DNS Server 1 008.008.008.008 Example address DNS Server 2 008.008.008.004 Example address Restart network ☐ Active line 12.
Page 76: Tab. 47 E-Mail Parameters
Controller settings 6. Set the E-mail parameters in the same way, as described above: If SIGMA CONTROL 2 is connected to SAM 4.0 via the SIGMA NETWORK and E-mails are to be forwarded via SAM 4.0, the following settings are required: SMTP Server: 169.254.100.100 (IP address for X6 interface on SAM 4.0, see ▪...
Page 77: Kaeser Connect
Commissioning KAESER CONNECT 6.3 KAESER CONNECT The following SIGMA CONTROL 2 menus can be displayed remotely on the web browser of an Internet-enabled device via KAESER CONNECT: ▪ 6.3.2 System status menu ▪ 6.3.3 Graphs menu ▪ 6.3.4 Messages menu ▪ 6.3.5 I/O display menu ▪...
Page 78: System Status Menu
Commissioning KAESER CONNECT Fig. 16 KAESER CONNECT for SIGMA CONTROL 2 5. Click on [Login] . KAESER CONNECT for SIGMA CONTROL 2 is displayed. Fig. 17 Select language: window Select language: arrow key Set language Select language: window Selected language 6. Click on Arrow key for Select language:.
Page 79: Fig. 18 System Status Menu
Commissioning KAESER CONNECT Fig. 18 System status menu System status menu element with the mouse. 1. Click on the System status menu is displayed. Fig. 19 Main menu 2. Click in the displayed SIGMA CONTROL 2 screen. The main menu is displayed. User manual Controller 9_9450 22 E SIGMA CONTROL 2 SCREW FLUID ≥...
Page 80: Graphs Menu
Commissioning KAESER CONNECT 3. Click on the numbered lines. The corresponding submenus are displayed. 4. Click esc multiple times to exit the menu. 6.3.3 Graphs menu Graphs menu, recorded machine data from the last 20 minutes are displayed in a On opening the diagram.
Page 81: Fig. 21 Control Keys
Commissioning KAESER CONNECT Highlight a specific area within the diagram by drawing a frame around it with the mouse cursor pressed down. The selected area will be enlarged when the mouse cursor is released. Fig. 21 Control keys Position Designation Function Start Display the oldest data in the cache memory or load the data for the previous 20 minutes from the SD card...
Page 82: Messages Menu
Commissioning KAESER CONNECT 6.3.4 Messages menu The following message types can be displayed: ▪ Current messages ▪ Compressor messages ▪ System messages ▪ Diagnostic messages ▪ KAESER CONNECT for SIGMA CONTROL 2 is displayed. Proceed as follows: Messages menu element. 1. Click on the Messages menu is displayed.
Page 83: User Management Menu
Commissioning KAESER CONNECT Fig. 23 I/O display menu (example) Proceed as follows: I/O display menu element. Click on the The current measured data and status of the input/output modules are displayed. 6.3.6 User management menu User management menu, you have the option of creating new user accounts for additional In the users.
Page 84: Fig. 24 User Management Menu
Commissioning KAESER CONNECT Fig. 24 User management menu read => write . 2. Activate write mode by clicking on Log on for write access: window is displayed. Log on for write access: window Fig. 25 User name: field. 3. Enter your username in the Password: field.
Page 85: Fig. 26 User Management Menu
Commissioning KAESER CONNECT Fig. 26 User management menu User name: field. 6. Enter a new username in the Password: field. 7. Enter a new password in the Repeat password: field. 8. Re-enter the new password in the Access level: field. 9.
Page 86: Settings Menu
Commissioning KAESER CONNECT The password for the existing user account has been changed. 6.3.7 Settings menu These settings only apply to KAESER CONNECT access via a web browser. You have the option of entering the following settings: ▪ Units ▪ Date format ▪...
Page 87: Save Data Menu
Commissioning KAESER CONNECT 6.3.8 Save data menu Backup menu, you have the option of downloading data from the SIGMA CONTROL 2 onto In the an Internet-capable device. The following backup types are available: ▪ Backup all ▪ Log files ▪ Settings ▪...
Page 88: Exiting Kaeser Connect
Commissioning KAESER CONNECT ▪ KAESER CONNECT for SIGMA CONTROL 2 is displayed. ▪ An SD card with sufficient free memory space has been inserted into the X5 SD card slot on the SIGMA CONTROL 2 whilst the machine was running. Proceed as follows: Data recording menu element.
Page 89: Pressure Parameters
Commissioning Pressure parameters 6.4 Pressure parameters This chapter contains information on how to display and adjust the pressure parameters on the machine. The chapter is divided into the following sections: ▪ 6.4.1 Displaying pressure parameters ▪ 6.4.2 Set pressure parameters “Indicator”: The current setting value for the parameter is displayed.
Page 90: Displaying Pressure Parameters
Commissioning Pressure parameters Parameter Description Cut-in pres- Indicator: sure min For design reasons, pressure generation is only possible from this value up- wards. Tab. 49 Compressor pressure parameters Proceed as follows: ▶ Set the parameters as per the following information. 6.4.1 Displaying pressure parameters ▪...
Page 91: Set Pressure Parameters
Commissioning Pressure parameters 6.4.2 Set pressure parameters 6.4.2.1 Setting the network setpoint pressure: pA and pB The pressure parameters can be set within certain limits: Rated machine pressure ≥ SP: pA / pB ≥ Minimum cut-in pressure (Cut-in pressure min) - switching differential Tab. 50 Setting limits for the network setpoint pressure The machine switches to LOAD under the following condition: Network pressure ≤...
Page 92: Tab. 53 Displaying Or Setting Parameters
Commissioning Pressure parameters 6.4.2.2 Setting the switching differential SD for the pressure increase pE SP serves primarily as a safety limit value when the machine is control- The pressure increase pE SP (e.g. in the event that the led externally. If the setpoint pressure reaches the value set for external control does not work correctly), the machine switches to IDLE.
Page 93: Tab. 54 Example: Activated Output
Commissioning Pressure parameters SD influences the pressure value at which the message can be acknowl- The switching differential edged or the optionally activated output switches again: Message Output 5.0 bar Incoming message Active 5.5 bar Outgoing message Inactive Tab. 54 Example: Activated output ▪...
Page 94: Key "Load/Idle
Commissioning Pressure parameters 6.1bar 08:15 80°C Header 5.2.2 Pressure settings Menu System pressure low ☐ ↓ 5.0bar ¦ SD : 0.5bar 600s DOR1.03 ☐¦Logic: Active line ------------------------------ Cut-in pressure min: 5.0bar 12. Press the «Enter» key. Setting mode is active. DOR output. 13. Set a free 14.
Page 95 Commissioning Pressure parameters 6.1bar 08:15 80°C Header 5.2.3 Load control Menu Logic: loc.-load RC DI1.07 ☑ Logic: ········· Key remote: ☐ Key idle: ☑ Active line with activated tick box 4. Press the «Up» key. The tick box is deactivated. 5. Press the «Enter» key. IDLE key is deactivated.
Page 96: Machine Start And Machine Stop
Commissioning Machine start and machine stop 6.5 Machine start and machine stop In addition to manually starting the machine locally, the following alternatives are available to you: Function Default setting Chapter Automatic start or switch-off via time control Time program not set 6.5.1 Time control Shutdown periods Not set...
Page 97: Tab. 56 Time Program Example: Machine On/Off
Commissioning Machine start and machine stop ▪ Mon-Thu ▪ Mon-Fri ▪ Mon-Sat ▪ Mon-Sun ▪ Sat-Thu ▪ Sun-Thu Alternatively, a shutdown period can also programmed, see chapter 6.5.2 Shutdown periods. Example ▪ Machine ON: Weekdays 06:30 – 17:00, Fridays 06:30 – 15:00 ▪ Machine OFF: Sa – Su and at lunchtimes 12:00 – 13:00 This results in the following switching points: No.: Time...
Page 98 Commissioning Machine start and machine stop 00: 00 flashes. 10. The minute indicator 11. Set the minutes. 12. Press the «Enter» key. The setting is applied accordingly. 6.1bar 08:15 80°C Header Menu 6 Compressor clock ········· Switching point 01 is set Mon-Fri 06:30 Mon-Fri 12:00...
Page 99: Shutdown Periods
Commissioning Machine start and machine stop 5. To exit the menu, press the «Escape» key multiple times. The «Time control» key is activated. 6.5.1.4 Activating time control ▪ The «Time control» key is activated, see chapter 6.5.1.3 «Time control» key. Proceed as follows: ▶...
Page 100 Commissioning Machine start and machine stop 10. Press the «Down» key. 11. Press the «Enter» key. 00: 00 flashes. The hour indicator 12. Set the hours. 13. Press the «Right» key. 00: 00 flashes. The minute indicator 14. Set the minutes. 15. Press the «Enter» key. The date and time for the start of the shutdown period are set.
Page 101: Remote Control
Commissioning Machine start and machine stop In the example above, a shutdown period (standstill time) has been set for this machine from 23/12/2023 / 17:00 until 04/01/2024 / 06:30. 6.5.3 Remote control If the machine is to be controlled remotely, enter the following settings: Overview ▪...
Page 102 Commissioning Machine start and machine stop 6.1bar 08:15 80°C Header 5.4.1 Compressor on Menu Local mode : Remote mode : Key + remote contact Active line ------------------------------ DI1.07 ☑ Key + remote contact . 5. Set the operating mode to 6. Press the «Enter» key. The setting is applied accordingly.
Page 103: Venting Period
Commissioning Machine start and machine stop Remote control of SIGMA CONTROL 2 is activated. 6.5.4 Venting period Prior to the machine switching between the LOAD and READY operating points, another IDLE phase can be activated (“Venting period” function). The duration of the IDLE phase can be time-de- pendent and/or regulated via the internal pressure.
Page 104: Autostart
Commissioning Machine start and machine stop The machine is shut down without venting (IDLE phase). 6.5.5 Autostart: In order to avoid overloading the mains power supply due to multiple machines starting simultane- ously, a time delay for the automatic start can be set. Autostart: is activated as the default setting.
Page 105 Commissioning Machine start and machine stop 6.1bar 08:15 80°C Header 5.4 Compressor start Menu ▶1 Compressor on ▶2 Compressor off ········· Autostart: ☑ Auto start activated Target 10s ¦ Actual Set or elapsing delay time ········· 3. Press the «Enter» key. Target indicator flashes. 4. Set the time delay in seconds. 6.1bar 08:15 80°C...
Page 106 Commissioning Machine start and machine stop 4. Press the «Enter» key. Autostart: function in the same way as you activated the Autostart: tick box. Activate the The setting is applied accordingly. 5. To exit the menu, press the «Escape» key multiple times. Auto start following a power failure is set.
Page 107: Control Modes
Commissioning Control modes 6.6 Control modes The controller offers a variety of control modes that can provide different levels of utilisation and energy efficiency dependent upon the machine application. The default control mode setting depends on the machine type. Depending on the application, deviating control modes can increase energy efficiency.
Page 108: Setting Dual Control Mode
Commissioning Control modes 6.6.2 Setting DUAL control mode ▪ The operating display is on view. ▪ Access level 2 is activated. Proceed as follows: 1. Open menu 5.3.2 <Configuration – Control mode – DUAL>. 6.1bar 08:15 80°C Header 5.3.2 DUAL Menu Idle period Target 240s ¦ Actual Active line...
Page 109 Commissioning Control modes 6.1bar 08:15 80°C Header 5.3.3 QUADRO Menu Min. run period Target 240s ¦ Actual Setpoint value for minimum running period ········· Unloaded period Target 240s ¦ Actual Setpoint value for unloaded period Min. run period . 2. Select the line 3. Press the «Down» key. 4.
Page 110: Electronic Thermo Management - Etm
Commissioning Electronic Thermo Management – ETM 6.7 Electronic Thermo Management – ETM Electronic Thermo Management is only available on certain machine types. The Electronic Thermo Management (ETM) version is determined by your machine’s equipment: Type Electronic Thermo Management (ETM) Machine type 1 Heat recovery not available Machine type 2 Heat recovery without electrically controlled valve Machine type 3 Heat recovery with adjustable airend discharge temperature for the regulator on the electrically controlled thermostatic valve...
Page 111: Heat Recovery For Machine Type 3
Commissioning Electronic Thermo Management – ETM 6.1bar 08:15 80°C Header 5.6 ETM Menu Heat recovery Local mode: inactive Remote mode: inactive Active line current inactive Heat recovery status 3. Press the «Down» key. 4. Press the «Enter» key. The indicator flashes for the operating mode currently selected. active option.
Page 112 Commissioning Electronic Thermo Management – ETM ▪ Access level 2 is activated. Proceed as follows: 1. Open menu 5.6 <Configuration – ETM>. Local mode: . 2. Select the line 3. Press the «Down» key. 6.1bar 08:15 80°C Header 5.6 ETM Menu Heat recovery Local mode: inactive Active line Remote mode: inactive current...
Page 113 Commissioning Electronic Thermo Management – ETM ▪ Access level 2 is activated. Proceed as follows: 1. Open the menu 5.6 <Configuration – ETM>. ADT controller – SP . 2. Select the line 6.1bar 08:15 80°C Header 5.6ETM Menu ········· Heat recovery ADT controller 80°C Active line Oil cooler...
Page 114: Refrigeration Dryer
Commissioning Refrigeration dryer 6.8 Refrigeration dryer Overview ▪ 6.8.1 Operating modes ▪ 6.8.2 Displaying messages ▪ 6.8.3 Refrigeration dryer fault – Dried compressed air has priority ▪ 6.8.4 Refrigeration dryer fault – Compressed air supply has priority Proceed as follows: ▶...
Page 115: Displaying Messages
Commissioning Refrigeration dryer 6.1bar 08:15 80°C Header 5.9 Refrigeration dryer Menu Control mode Compressor ready: CONTINUOUS Active line Compressor Clk/RC/RB off: ········· 6. Press the «Enter» key. The setting is applied accordingly. 7. To exit the menu, press the «Escape» key multiple times. The operating mode has been switched from INTERMITTING to ...
Page 116: Refrigeration Dryer Fault - Dried Compressed Air Has Priority
Commissioning Refrigeration dryer 6.1bar 08:15 80°C Header 5.9 Refrigeration dryer Menu Temperature ↑ Temperature high DOR 1.05 ☐ ¦ Logic : Active line, example: DOR selected DOT 1.01 ☐ ¦ Logic : Temperature ⇟ Temperature low DOR 1.03 ☐ ¦ Logic : DOT 2.01 ☐ ¦ Logic : 6. Press the «Enter» key. The setting is applied accordingly. 7. Press the «Right» key. 8.
Page 117: Refrigeration Dryer Fault - Compressed Air Supply Has Priority
Commissioning Refrigeration dryer 6.8.4 Refrigeration dryer fault – Compressed air supply has priority NOTICE Higher residual moisture in the compressed air Danger of corrosion due to humid compressed air. ▶ Weigh up the merits and demerits of using the “Fault mode operation without refrigeration dryer”...
Page 118 Commissioning Refrigeration dryer Since the refrigeration dryer is out of commission until the fault is resolved, the compressed air supplied contains a higher level of residual moisture. Arrange for the refrigeration dryer fault to be resolved as soon as possible. User manual Controller 9_9450 22 E SIGMA CONTROL 2 SCREW FLUID ≥...
Page 119: Local Mode Of Load/Idle Control
Commissioning Local mode of load/idle control 6.9 Local mode of load/idle control pA or pB . The controller offers In Local mode, the machine is controlled via the setpoint pressure the following operating modes: Operating Description Chapter mode The machine is controlled via the setpoint pres- 6.9.4 Setting local operating sure mode...
Page 120: Tab. 59 Example: Setpoint Pressure Changeover Switching Points
Commissioning Local mode of load/idle control If you create a new time program, note the switching times down in the table provided in chapter 11.7 Setpoint pressure change in the user time program. In addition to individual weekdays, the controller makes the following cycles available: ▪...
Page 121: Setting Switching Points
Commissioning Local mode of load/idle control 6. Press the «Up» key. The tick box is activated. 7. Press the «Enter» key. The time program has been deleted. 6.9.2.2 Setting switching points ▪ Access level 2 is activated. Proceed as follows: 1. Open the menu 5.2.3.1 <Configuration – Pressure control – Load control – pA/pB Clock>. Time program menu is displayed.
Page 122: Setpoint Pressure Changeover Via Timer
Commissioning Local mode of load/idle control 11. Press the «Enter» key. The setting is applied accordingly. 12. Press the «Right» key. 13. Press the «Enter» key. pA / pB flashes. The indicator pA or pB . 14. Set 15. Press the «Enter» key. The setting is applied accordingly. 16.
Page 123 Commissioning Local mode of load/idle control 6.1bar 08:15 80°C Header 5.2.3 Load control Menu ▶1 pA/pB Clock ········· pA/pB Cycle pA : 10h – 10h pB: 18h – 18h Active line, manually specified setpoint – automatically elaps- ing value (example) 1.Start pA ¦ 00:00 ········· 7. Press the «Right» key. pB in the same way.
Page 124: Setting Local Operating Mode
Commissioning Local mode of load/idle control 6.9.4 Setting local operating mode ▪ Access level 2 is activated. ▪ The time program or timer has been set. Proceed as follows: 1. Open the menu 5.2.3 <Configuration – Pressure control – Load control> . Local mode .
Page 125: Master Control
Commissioning 6.10 Master control 6.10 Master control 6.10.1 Overview of different master control operating modes The controller offers a variety of options for operation in conjunction with other controllers: Type Description Chapter Master control via SIGMA For operation under the control of 6.10.2 Master AIR MANAGER 4.0 a SIGMA AIR MANAGER 4.0 via the...
Page 126: Master Control Via Sigma Air Manager 4.0
Commissioning 6.10 Master control 6.10.2 Master control via SIGMA AIR  M ANAGER  4 .0 For operation via the SIGMA NETWORK, e.g. when controlling via a SIGMA AIR MANAGER 4.0 (SAM 4.0), settings must be entered in SIGMA CONTROL 2. Overview ▪ 6.10.2.1 Setting the IP configuration ▪...
Page 127 Commissioning 6.10 Master control 6.1bar 08:15 80°C Header 8.1.2.2 SAM 4.0 Menu Status Counter 0 No error ------------------------------ SAM 4.0 active: ☑ Active line Send IP address 169.254.100.100 3. Press the «Enter» key. SAM 4.0 active: tick box flashes. The 4. Press the «Up» key. The tick box is activated.
Page 128: Tab. 61 Parameters For Communications Fault Monitoring
Commissioning 6.10 Master control 6.1bar 08:15 80°C Header 8.1.2.2 SAM 4.0 Menu IP address 169.254.100.100 Port 2000 ········· Communication error : ☑ Start td : Active line Timeout : ☑ 13. Press the «Enter» key. The setting is applied accordingly. SIGMA CONTROL 2 communicates with SAM 4.0 via the SIGMA NETWORK. If no communications errors are reported by SIGMA CONTROL 2 and/or SAM 4.0, communica- tion is working perfectly.
Page 129: Master Control Via Profibus
Commissioning 6.10 Master control ▶ Make a note of the settings in the table provided in chapter 11.9 Communications fault monitoring parameters. 6.10.2.4 Activating remote control Proceed as follows: ▶ For activating remote control, see chapter 6.2.7 «Remote control» key. Remote control of SIGMA CONTROL 2 is activated. 6.10.3 Master control via PROFIBUS Only with SIGMA CONTROL 2...
Page 130: Fig. 30 Profibus Electrical Connection
Commissioning 6.10 Master control Fig. 30 PROFIBUS electrical connection Terminal 1A Terminal 2B Terminal 1B Slide switch, terminating resistor Terminal 2A User manual Controller 9_9450 22 E SIGMA CONTROL 2 SCREW FLUID ≥ 6.4.1...
Page 131: Fig. 31 Example Wiring Diagram With Sigma Air Manager
Commissioning 6.10 Master control Example wiring diagram for SIGMA AIR MANAGER (excerpt) Fig. 31 Example wiring diagram with SIGMA AIR MANAGER Proceed as follows: 1. Establish the electrical connection for the bus subscribers as per the specified assignment. User manual Controller 9_9450 22 E SIGMA CONTROL 2 SCREW FLUID ≥...
Page 132: Fig. 32 Communications Interface
Commissioning 6.10 Master control 2. Place the screening at both cable ends on the connector housing. 3. Set the terminating resistor in the PROFIBUS connector to ON for the first and last network subscribers. The terminals (2A/2B) for the continuing bus cable are switched off. 6.10.3.2 Installing a communications module When delivered from the factory, the SIGMA CONTROL 2 communications interface is closed with...
Page 133: Fig. 33 Inserting The Communications Module
Commissioning 6.10 Master control 1. Position the slotted screwdriver beside bar 2. Insert the tip into the slot between the plastic cover and the SIGMA CONTROL 2 housing. 3. Press the slotted screwdriver downwards until the bar breaks. 4. Break all the other bars in the same way.
Page 134: Fig. 34 Profibus Communications Module Front Face
Commissioning 6.10 Master control ▪ The communications module is inserted and screwed into the X4 interface. ▪ Bus cabling to the bus master has been established. ▪ The machine power supply is switched on. ▪ The machine is parametrised as a Slave in the bus master. ▪...
Page 135 Commissioning 6.10 Master control 6.1bar 08:15 80°C Header 8.2 Com-Module Menu Status Counter 1 Com-Module deactivated ------------------------------ Type PROFIBUS Send/receive Com-Module active ☑ Active line 6. To exit the menu, press the «Escape» key multiple times. Setting the Slave address To communicate with SIGMA AIR MANAGER, it is necessary to set the Slave address. When connecting to SIGMA AIR MANAGER, the Slave address is determined as follows: Machine number used in SIGMA AIR MANAGER +102.
Page 136 Commissioning 6.10 Master control 6.1bar 08:15 80°C Header 8.2 Com-Module Menu Send/receive Com-Module active ☑ Reset ☐ SlaveNo. : Active line ········· Communication error ☑ 5. Press the «Enter» key. The setting is applied accordingly. 104 is set. The Slave address 6.10.3.4 Procedure in the event of a communications fault With a connection via PROFIBUS, the data exchange takes place in fixed cycles.
Page 137: Tab. 63 Parameters For Communications Fault Monitoring
Commissioning 6.10 Master control 6.1bar 08:15 80°C Header 8.2 Com-Module Menu Reset ☐ Slave No. : ········· Communication error ☑ Communications monitoring is activated Start td Active line Timeout : ☑ Parameter Factory setting Communication error tick box ☑ tick box activated Start td 30 s Timeout 5 s Timeout tick box...
Page 138: Master/Slave Operation
Commissioning 6.10 Master control 6.10.4 Master/Slave operation Two machines with SIGMA CONTROL 2 work as Master/Slave in the same compressed air net- work. The Master controls the machine with the controller configured as the Slave. For both machines to work in redundancy operation, the electrical connections and settings on both controllers must be carried out and configured identically.
Page 139: Tab. 64 Master/Slave Settings Overview
Commissioning 6.10 Master control Controller Procedure Chapter Both Establish the electrical connection 6.10.4.1 Establishing the electrical con- nection Both Set the respective setpoint pressures Setting the switching points pA and pB pB . The pressure for the switching pA and pB is measured directly at points the compressor.
Page 140: Fig. 35 Direct Connection Of Two Sigma Control 2 Controllers
Commissioning 6.10 Master control Fig. 35 Direct connection of two SIGMA CONTROL 2 controllers Controller, machine 1 (Master) Controller, machine 2 (Slave) Ethernet interface X1 Ethernet interface X1 Ethernet cable, crossed Proceed as follows: 1. Run a crossed Ethernet cable between the two machines. When connecting the machines to a network (LAN) or switch (e.g.
Page 141 Commissioning 6.10 Master control 6.10.4.2 Setting the controller of machine 1 as master ▪ The electrical connection is established. ▪ Access level 2 is activated. Setting the switching points pA and pB Proceed as follows: 1. Open the menu 5.2.2 <Configuration – Pressure control – Pressure settings>. pA SP .
Page 142 IP address see example above. The IP address for machine 1 (Master) is set correctly. 2. Open the menu 8.1.2.1 <Communication – Ethernet/SIGMA NETWORK – Connections – SIGMA CONTROL 2>. Mode . 3. Select the line 4. Press the «Enter» key.
Page 143 Commissioning 6.10 Master control 6.1bar 08:15 80°C Header 8.1.2.1 SIGMA CONTROL 2 Menu ------------------------------ Mode Master Active line Port 2001 ········· Communication partner IP address 169.254.100.102 Master . 5. Set machine 1 to 6. Press the «Enter» key. The setting is applied accordingly.
Page 144 Commissioning 6.10 Master control 4. Press the «Enter» key. The setting is applied accordingly. 5. Press the «Down» key. pB is displayed. The line pB in the same way. 6. If required, set the value for Activating remote control Proceed as follows: ▶...
Page 145 IP address, see example above. The IP address for machine 2 (Slave) is set correctly. 2. Open the menu 8.1.2.1 <Communication – Ethernet/SIGMA NETWORK – Connections – SIGMA CONTROL 2>. Mode . 3. Select the line 4. Press the «Enter» key.
Page 146: Remote Load Contact
Commissioning 6.10 Master control 6.10.5 Remote LOAD contact Overview ▪ 6.10.5.1 Electrical connection for remote LOAD contact ▪ 6.10.5.2 Setting the remote LOAD contact operating mode and assigning an input ▪ 6.10.5.3 Setting the switching differential SD for the pressure increase ▪...
Page 147 Commissioning 6.10 Master control 6.1bar 08:15 80°C Header 5.2.3 Load control Menu Local mode : pA/pB Cycle Remote mode : Load RC Active line, current operating mode ------------------------------ ▶1 pA/pB Clock ········· pA/pB Cycle Load RC . 4. Set the operating mode to 5. Press the «Enter» key. The remote LOAD contact operating mode is set.
Page 148: Remote Local / Load Contact
Commissioning 6.10 Master control ▶ Set the switching differential SD for the pressure increase as described in chapter 6.4.2.2 Setting the switching differential SD for the pressure increase. Further information regarding pressure parameters can be found in chapter 6.4.2 Set pressure parameters. 6.10.5.4 Activating remote control Proceed as follows:...
Page 149 Commissioning 6.10 Master control ▶ Establish the electrical connection as per the wiring diagram. 6.10.6.2 Set the local/LOAD remote contact operating mode and assign the input. ▪ Access level 2 is activated. Setting remote local / LOAD contact operating mode Proceed as follows: 1.
Page 150 Commissioning 6.10 Master control 6.10.6.3 Setting local operating mode pB pB , bear in mind that at times multiple machines ▶ When setting the setpoint pressure may be set to local operation. Adjust the setpoint pressure as required, see chapter Pressure parameters.
Page 151: Setpoint Pressure Pre-Selection Via Remote Contact
Commissioning 6.10 Master control 6.1bar 08:15 80°C Header 5.2.3 Load control Menu pA/pB RC DI 1.05 ☐ Logic : pA/pB DO DOR 1.04 ☐ Logic : ········· Load RC DI 1.06 ok ☑ Active line 4. Assign the input for the remote LOAD contact. 5. Press the «Enter» key. The input for the remote LOAD contact is assigned.
Page 152 Commissioning 6.10 Master control 6.1bar 08:15 80°C Header 5.2.3 Load control Menu Local mode : Remote mode : pA/pB RC Active line, current operating mode ------------------------------ ▶1 pA/pB Clock ········· pA/pB Cycle pA/pB RC . 4. Set the operating mode 5. Press the «Enter» key. pA/pB RC is set.
Page 153: Master Control For Machines Regulated Via Pressure Switch
Commissioning 6.10 Master control 6.10.8 Master control for machines regulated via pressure switch Proceed as follows: ▶ Set master control as described below. 6.10.8.1 Master control via floating contact Requirement: A machine with SIGMA CONTROL 2 (e.g. type BSD) and a machine without SIGMA CONTROL 2 with identical flow rates should operate alternately as the base load or peak load machine.
Page 154: Fig. 38 Machine With Pressure Switch Control
Commissioning 6.10 Master control Fig. 38 Machine with pressure switch control SIGMA CONTROL 2 floating contact Proceed as follows: ▶ Establish the electrical connection in accordance with the wiring diagram. Setting the network setpoint pressure pA and pB ▪ The electrical connection has been established. ▪...
Page 155 Commissioning 6.10 Master control pB-SD in the same way. 7. If required, set the value for 8. To exit the menu, press the «Escape» key multiple times. Setting local operating mode Proceed as follows: ▶ Set the time program or timer as described in chapter 6.9 Local mode of load/idle control.
Page 156 Commissioning 6.10 Master control 6.1bar 08:15 80°C Header 5.2.3 Load control Menu Local mode : Active line, current operating mode Remote mode : ------------------------------ ▶1 pA/pB Clock ········· pA/pB Cycle 3. Press the «Enter» key. Setting mode is active. pA/pB Clock or pA/pB Cycle . 4. Set the operating mode 5.
Page 157: Fig. 39 Functional Diagram
Commissioning 6.10 Master control Period t1  –   t 7: high compressed air demand Period t8 – t14: low air compressed demand t13: SK switches to IDLE. SK switches to IDLE. t14: BSD switches to IDLE. BSD switches to IDLE. Tab.
Page 158 Commissioning 6.10 Master control 6.1bar 08:15 80°C Header 5.2.2 Pressure settings Menu Setpoint pressure pA SP : 8.5bar ¦ SD : -0.5bar Active line pB SP : 8.2bar ¦ SD : -0.5bar ········· System pressure low ☐ ↓ 5.0bar ¦ SD : -0.5bar pA . 4. Set the value for 5. Press the «Enter» key. The setting is applied accordingly.
Page 159: Inputs And Outputs
Commissioning 6.11 Inputs and outputs 6.11 Inputs and outputs The controller’s analogue and digital inputs and outputs, as well as operating states and measured values, can be used for customer-specific messages and/or switching functions. Overview ▪ 6.11.1 Operating states ▪ 6.11.2 Analogue values ▪...
Page 160 Commissioning 6.11 Inputs and outputs 6.11.1.1 DO functions menu The desired information can be assigned to a free digital output (DOR or DOT). ▪ Access level 2 is activated. Proceed as follows: 1. Open the menu 5.7.1 <Configuration – I/O peripherals – DO functions>. A menu containing a list of the selectable information and assigned outputs is displayed.
Page 161: Analogue Values
Commissioning 6.11 Inputs and outputs 8. Press the «Enter» key. The tick box flashes. 9. Press the «Up» key. The tick box assigned to the output is activated. 10. Press the «Enter» key. ok will be displayed. If the message is correctly assigned to the output and activated, Logic option.
Page 162 Commissioning 6.11 Inputs and outputs ▪ 6.11.2.4 Setting the switching point and switching differential ▪ 6.11.2.5 Setting the time delay ▪ 6.11.2.6 Setting the message type ▪ 6.11.2.7 Assigning and activating an output Below, the settings are depicted based on an example in menu 5.7.2.1 <AnMod>. Settings in other menus are made in the same way.
Page 163 Commissioning 6.11 Inputs and outputs 4. Press the «Enter» key. AnMod_p_1 is displayed. Menu 5.7.2.1.1 6.1bar 08:15 80°C Header Menu 5.7.2.1.1 AnMod_p_1 Title AnMod_p_1 0.0bar Message text pNloc ☐ Analogue measured value ········· SP : 8.0bar ¦ SD : -0.5bar Switching point (SP) and switching differential (SD) td : Time delay (td) ·········...
Page 164 Commissioning 6.11 Inputs and outputs 7. Press the «Up» key. The tick box is activated. 6.1bar 08:15 80°C Header Menu 5.7.2.1.1 AnMod_p_1 Title AnMod_p_1 0.0bar Message text pNloc ☑ Selected analogue measured value, activated ········· SP : 8.0bar ¦ SD : -0.5bar Switching point (SP) and switching differential (SD) td : Time delay (td) ·········...
Page 165 Commissioning 6.11 Inputs and outputs 2. Press the «Enter» key. td flashes. The indicator for the time delay 6.1bar 08:15 80°C Header Menu 5.7.2.1.1 AnMod_p_1 Title AnMod_p_1 0.0bar Message text pNloc ☑ Selected analogue measured value, activated ········· SP : 8.0bar ¦ SD : -0.5bar Switching point (SP) and switching differential (SD) td : Time delay (td) ·········...
Page 166: Digital Inputs
Commissioning 6.11 Inputs and outputs The message type is set and activated. 6.11.2.7 Assigning and activating an output When a message is triggered, one or two DOR or DOT digital outputs can be switched. DOR . 1. Select the line 2.
Page 167 Commissioning 6.11 Inputs and outputs delay ensures that the signal must be present for a minimum period of time before a message is triggered. Should an input signal be classified as a fault, the controller will display a fault upon receiving the signal and switch the machine off.
Page 168 Commissioning 6.11 Inputs and outputs 6.1bar 08:15 80°C Header 5.7.3.1 External message 1 Menu External message 1 Message text DI 1.06 ☐ No input assigned td : 0s ¦ Logic : Logic DOR 1.04 ☐ Warning ☑ Message type (operating, fault, warning) 3. Press the «Enter» key. The cursor is positioned at the first character in the message text. A column containing a selection of characters is displayed.
Page 169 Commissioning 6.11 Inputs and outputs 7. Press the «Up» key. The tick box is activated. 6.1bar 08:15 80°C Header Menu 5.7.3.1 External message 1 External message 1 Message text DI 1.07 ok ☑ Input selected td : 0s ¦ Logic : Logic DOR 1.04 ☐ Warning ☐ Example: Message type Warning 8.
Page 170: Tab. 68 Logic Settings
Commissioning 6.11 Inputs and outputs Message at Symbol 0 V Tab. 68 Logic settings Proceed as follows: td . 1. Select the line 2. Press the «Right» key. 3. Press the «Enter» key. Logic control field flashes. 4. For setting the desired characteristics, see chapter Tab.
Page 171: Threshold Values
Commissioning 6.11 Inputs and outputs 6.11.3.7 Assigning and activating an output Proceed as follows: DOR . 1. Select the line 2. Press the «Enter» key. DOR output flashes. The indicator for the 3. Select the output. 4. Press the «Enter» key. The setting is applied accordingly. 6.1bar 08:15 80°C...
Page 172: Tab. 69 Available Measured Values
Commissioning 6.11 Inputs and outputs Measured value Description Message PD temperature PD temperature Threshold value for temperature 0096 O/W/A (compressed air discharge temperature) Threshold value for compressor motor speed 0098 O/W/A n Compressor motor Power switching with frequency converter Tab. 69 Available measured values Example: Setting for local network pressure at compressor outlet.
Page 173 Commissioning 6.11 Inputs and outputs 6.1bar 08:15 80°C Header 5.7.4.1 System pressure pNloc Menu active: ☐ ········· SP : 0.5bar ¦ SD : -0.6bar Switching point (SP) and switching differential (SD) td : 0s ¦ Logic Time delay (td) and logic DOR 1.01 ☐ DOR output Operation ☐ Message type 2.
Page 174 Commissioning 6.11 Inputs and outputs Proceed as follows: DOR . 1. Select the line 2. Press the «Enter» key. DOR output flashes. The indicator for the 3. Select the output. 4. Press the «Enter» key. The setting is applied accordingly. 6.1bar 08:15 80°C Header 5.7.4.1 System pressure pNloc...
Page 175 Commissioning 6.11 Inputs and outputs 6. Press the «Enter» key. The tick box assigned to the message type flashes. 7. Press the «Up» key. The message is activated. 8. Press the «Enter» key. 9. Make a note of the settings in the table provided in chapter 11.12 Threshold value settings.
Page 176: Timer
Commissioning 6.12 Timer 6.12 Timer SIGMA CONTROL 2 is equipped with an integrated timer that can control an adjustable output for customer-specific applications. Valid setting values for the cut-in and cut-out period are in the range 10 h ≥ t ≥ 1 s. ▪ The electrical connection has been established. ▪...
Page 177 Commissioning 6.12 Timer 18. Press the «Up» key. DOR output is activated. The tick box assigned to the 6.1bar 08:15 80°C Header Menu 5.8 Timer 01h:15m:00s Cut-in period 01h:15m:00s Cut-out period DOR 1.02 ☑ Set DOR output ········· current current DOR status 00h:55m:34s Remaining time until status change 19.
Page 178: Remote Acknowledgement
Commissioning 6.13 Remote acknowledgement 6.13 Remote acknowledgement If fault or warning messages are routed to a control centre via an output, it may make sense for these messages to be acknowledged remotely by the control centre, e.g. in cases where the machine is controlled remotely via remote contact. However, acknowledging the message without resolving the cause may result in damage to the machine.
Page 179: Assigning An Input
Commissioning 6.13 Remote acknowledgement 6.1bar 08:15 80°C Header 5.5 Acknowledgement Menu Remote mode : Key + remote contact Active line with “Key + remote contact” setting ------------------------------ RC Ack DI1.07 ☐ Key remote : ☑ 6. Press the «Enter» key. The setting is applied accordingly. The remote acknowledgement function is set.
Page 180: Activating Remote Control
Commissioning 6.13 Remote acknowledgement 6.1bar 08:15 80°C Header 5.5 Acknowledgement Menu Remote mode : Key + remote contact ------------------------------ RC Ack DI 1.06 ok ☑ Input for remote contact assigned and activated Key remote : ☑ 9. Press the «Remote control» key to enable remote acknowledgement. Messages can be acknowledged from the control centre. 6.13.3 Activating remote control Proceed as follows:...
Page 181: External Pressure Transducer
Commissioning 6.14 External pressure transducer 6.14 External pressure transducer If the compressed air station is operated with an air receiver, SIGMA CONTROL 2 can control the pressure in the air receiver via the measured value from the external pressure transducer. For better control, it is advisable to measure the pressure near to the consumers, downstream from the compressed air treatment components (filters, dryer, etc.) if applicable.
Page 182: Assigning An Input
Commissioning 6.14 External pressure transducer 6.1bar 08:15 80°C Header 5.2.4 Network actual pressure Menu 6.1bar Active line (external pressure transducer) AII 1.00 ☐ 0.0bar AII , is set. 3. The desired source for the actual pressure, e.g 4. Press the «Enter» key. The setting is applied accordingly. 5.
Page 183 Commissioning 6.14 External pressure transducer 6.1bar 08:15 80°C Header 5.2.4 Network actual pressure Menu pNloc 6.1bar Active line AII1.01 ok ☑ 0.0bar For sensor error: Alarm 7. Press the «Up» key. The tick box is activated. ok indicator is displayed. The 8. Press the «Enter» key. The setting is applied accordingly.
Page 184: Commissioning The Machine
Commissioning 6.15 Commissioning the machine 6.15 Commissioning the machine ▪ Commissioning is carried out as described in the “Commissioning” chapter of the machine operating manual. Proceed as follows: 1. Check and confirm that all of the items on the checklist in chapter 11.15 Commissioning checklist have been fulfilled before commissioning the machine.
Page 185: Operation
Operation Messages 7 Operation 7.1 Messages 7.1.1 Acknowledging messages Messages are displayed according to the “new value” principle. Warning and fault messages can Message incoming or Message gone . The prerequisite for be acknowledged immediately following acknowledging warning and fault messages, however, is always that the error responsible for the message has been resolved successfully.
Page 186: Display Messages
Operation Messages Fault control indicator is extinguished. The machine is ready to start again. The machine has been stopped via the EMERGENCY STOP command device. • Unlock the EMERGENCY STOP command device by turning in the direction of the arrow. • Acknowledge the fault message.
Page 187: Tab. 74 Message Abbreviations
Operation Messages Message type and status are abbreviated: Segment Indicator Meaning 0059 (example) Message number Message 0059 Message type Warning or maintenance message Alarm Operating message Diagnostic message System message Message status Message arrived Message gone Message acknowledged 16/04/2023 (example) Date Date 08:15:37 (example)
Page 188 Operation Messages 6.1bar 08:15 80°C Header 1.1.1 Current messages Menu 0300 W c 16/04/2023 13:32:49 Last message SD card write error 0057A c 16/04/2023 13:06:43 Penultimate message Model? 2. To exit the menu, press the «Escape» key multiple times. Displaying the message history Proceed as follows: 1. Open the menu 1.1.2 <Status – Messages – Message history>. Message history menu is displayed.
Page 189: Current Operating Mode
Operation Current operating mode 7.2 Current operating mode The operating mode is displayed for two functions: Function Operating mode (example) Switching on and off via LOAD control via Tab. 75 Operating mode indicator 6.1bar 08:15 80°C Header 1.4 Current operating mode Menu Compressor on Active line Load control...
Page 190: Measured Data
▪ T_1 ▪ T_2 ▪ I_1 ▪ I_2 ▪ n_1 ▪ SIGMA CONTROL 2 ▪ MCS internal temperature ▪ IOMNo. 1 / 2 / 3 internal temperature Only visible if the sensor is fitted ▪ The operating display is on view. ▪ Access level 2 is activated.
Page 191 Header 2 Performance data Menu ▶1 Compressor Active line ▶2 Compressor motor ▶3 Fan motor(s) ▶4 Analogue values ▶5 SIGMA CONTROL 2 2. If required, press the «Up» or «Down» key multiple times to select the desired component. 6.1bar 08:15 80°C Header 2.1 Compressor Menu Local System pressure pNloc System pressure pNloc 6.1bar...
Page 192: Operating Data
Operation Operating data 7.4 Operating data Operating data menu: The following information is available in the ▪ Operating hours ▪ Compressor: Total machine run time ▪ Load run: Machine run time in LOAD operating point ▪ Motor: Compressor motor run time (adjustable) ▪...
Page 193: Switching Cycles
Operation Operating data 6.1bar 08:15 80°C Header 3.1 Operating hours Menu Compressor 3050h Active line Load run 3030h Motor 3050h Compressor airend 3050h SIGMA CONTROL 2 3633h Compressor airend . 2. Select the line 3. Press the «Enter» key. The run time indicator flashes. 6.1bar 08:15 80°C...
Page 194 Operation Operating data Proceed as follows: 1. Open menu 3.2 <Operating data – Switching cycles>. NOTICE The maximum permissible number of switching cycles has been exceeded. Safety-rele- vant function is no longer assured! ▶ Arrange for the affected component to be replaced as soon as possible by an authorised service partner.
Page 195: Source For Speed Setting
Operation Source for speed setting 7.5 Source for speed setting The source for the speed setting can be checked. No customer-end setting options are available. ▪ Machine with frequency converter. ▪ The operating display is on view. ▪ Access level 2 is activated. Proceed as follows: 1.
Page 196: Interval Counter For Maintenance Task
Operation Interval counter for maintenance task 7.6 Interval counter for maintenance task Maintenance tasks comprise work that must be completed in order to ensure the functionality of a technical system. A maintenance interval is a period of time specified by the manufacturer, at the end of which a maintenance task falls due.
Page 197: Resetting The Interval Counter
Operation Interval counter for maintenance task 6.1bar 08:15 80°C Header 4 Maintenance Menu Oil change Interval counter for maintenance task Control valve(s) open: ☐ 4000h¦ 2998h Reset:: ☐ Active line, new interval ········· Air filter 3000h¦ 2998h Reset: ☐ 5. Set the new value for the maintenance interval. First, set the increment size.
Page 198: External Interval Counter
Operation Interval counter for maintenance task 6.1bar 08:15 80°C Header 4 Maintenance Menu Oil change Control valve(s) open: ☐ 4000h¦ 3998h Reset:: ☒ Active line, activated tick box ········· Air filter 3000h¦ 2998h Reset: ☐ 7. Press the «Enter» key. The indicator ceases flashing and the interval counter is reset. Reset: tick box is deactivated again.
Page 199 Operation Interval counter for maintenance task 6.1bar 08:15 80°C Header 4 Maintenance Menu ▶1 External counter Active line ········· Oil filter 3000h¦ 3000h Reset ☐ ········· Oil separator 3. Press the «Enter» key. The menu 4.1 <Maintenance – External counter> is displayed. 6.1bar 08:15 80°C Header Menu...
Page 200 Operation Interval counter for maintenance task 6.1bar 08:15 80°C Header 4.1 External counter Menu External counter 1 Motor running Active line 3000h¦ 2319h Reset ☐ ········· External counter 2 inactive 4. Set the desired mode. Possible settings: ▪ inactive ▪ Motor running ▪...
Page 201: Testing The Safety Valve
Operation Testing the safety valve 7.7 Testing the safety valve Overview ▪ 7.7.1 Preparing the test ▪ 7.7.2 Performing the test ▪ 7.7.3 Concluding the test ▪ 7.7.4 Resetting When the test mode is activated, the threshold value for a blow-off protection fault is increased and network pressure control is switched off.
Page 202: Performing The Test
Operation Testing the safety valve 7.7.2 Performing the test WARNING Danger of hearing damage when safety valve blows off ▶ Wear ear protection CAUTION Danger of burns from released compressor oil and compressed air ▶ Wear protective clothing ▶ Wear eye protection ▶...
Page 203: Concluding The Test
Operation Testing the safety valve pi exceed the actuating pressure for the safety valve by 5. Should the measured pressure value pRV ⇞ is displayed. 2.0bar, the fault message The safety valve is defective. Decommission the machine. Arrange for the safety valve to be replaced immediately by an authorised service partner. 7.7.2.2 Rotary screw compressors without internal pressure transducer (pN) Proceed as follows:...
Page 204: Testing The Temperature Shutdown Function
Operation Testing the temperature shutdown function 7.8 Testing the temperature shutdown function As soon as the airend discharge temperature (ADT) reaches the limit value of 110 °C, the safety shutdown function switches the machine off. To test this function, SIGMA CONTROL 2 simulates a higher temperature. For this purpose, SIGMA CONTROL 2 automatically determines an offset value to be displayed.
Page 205: Concluding The Test
Operation Testing the temperature shutdown function 6.1bar 08:15 73 °C Header 9.1 Inspections Menu Safety valve : ☐ pRV: 16.0bar ¦ pi ⇞ 0.0bar Reset : ☐ ········· ADT ⇞ : ☑ Active line with activated tick box Offset 35°C ¦ ADT ⇞ 108°C Specified offset 6.
Page 206: Save Data
Operation Save data 7.9 Save data A data backup of the SIGMA CONTROL 2 settings can be saved to an SD card. ▪ An SD card with compatible file system (FAT32) and minimum 50 MB of free memory is inserted into the X5 SD card slot on the SIGMA CONTROL 2. ▪...
Page 207: Removing The Sd Card
Operation Save data 7.9.1 Removing the SD card Eject SD card , the SD card is securely logged out of the electronic controller and Using the function can be removed without the risk of data loss. Proceed as follows: Eject SD card . 1.
Page 208 Operation Save data 6.1bar 08:15 80°C Header 5.11 Save data Menu Save data : ☐ ········· Eject SD card : ☐ Status recognised ········· Format SD card ☑ Active line 5. Press the «Enter» key. A confirmation prompt is displayed. 6. Press the «Enter» key. The SD card is formatted.
Page 209: Fault Recognition And Rectification
Fault recognition and rectification Basic information 8 Fault recognition and rectification 8.1 Basic information The following tables are intended to assist in locating the causes of errors. SIGMA CONTROL 2 distinguishes between three different types of error: ▪ Machine fault: Fault control indicator flashes or illuminates in red, the machine is switched off, see chapter 8.2 Fault messages...
Page 210: Fault Messages
Fault recognition and rectification Fault messages 8.2 Fault messages If an input signal or event is classified as a fault, the controller will display a fault message. Fault control indicator flashes or illuminates in red ▪ The ▪ The controller switches the machine off. Fault messages are indicated by the letter A.
Page 211 Fault recognition and rectification Fault messages Message Possible cause Remedy These messages are customer-specific. Add in the possible cause and remedy for the message text you have defined, see chapter 6.11 Inputs and outputs. These messages are customer-specific. Add in the possible causes and measures for the message text you have defined, see chapter 6.11 Inputs and outputs.
Page 212 Fault recognition and rectification Fault messages Message Possible cause Remedy 0039 A Compressed air discharge tem- Check cooling oil level. perature too high. PD temperature ⇞ Clean cooler. Check fan motor. 0040 A Compressor motor mains con- Check mains contactor and tactor not switching off. wiring.
Page 213 Fault recognition and rectification Fault messages Message Possible cause Remedy Condensate drain 1 faulty or Check condensate drain and 0058 A not ready. condensate lines. Condensate drain 1 Too much accumulated con- Check intake conditions. densate. Line broken/disconnected. Check lines. Condensate cannot be drained. Check condensate drain. Drive belt or coupling broken.
Page 214 Fault recognition and rectification Fault messages Message Possible cause Remedy 0076 A External message 4 0077 A External message 5 0078 A External message 6 0081 A AnMod_p_1 0082 A AnMod_p_2 0083 A AnMod_T_1 0084 A AnMod_T_2 0085 A AnMod_I_1 0086 A AnMod_I_2 0087 A AnMod_p_3 0088A AnMod_p_4 0089A AnMod_T_3 0090 A AnMod_T_4 0092 A...
Page 215 Fault recognition and rectification Fault messages Message Possible cause Remedy Compressor motor star contac- Check star contactor and wir- 0100 A tor not switching on. ing. Star contactor on? Compressor motor star contac- Check star contactor and wir- 0101 A tor not switching off. ing.
Page 216 Fault recognition and rectification Fault messages Message Possible cause Remedy 0204 A Frequency converter error. Contact an authorised service partner. Compressor motor FC PKW er- ror P%d.E%d 0205 A Frequency converter error. Contact an authorised service partner. Compressor motor FC PKW er- ror P%d.E%d 0206 A Fault triggered by software...
Page 217 Fault recognition and rectification Fault messages Message Possible cause Remedy 0241 A Frequency converter error. Contact an authorised service partner. Compressor motor FC PKW er- ror P%d.E%d 0242 A Error on bus to frequency con- Contact an authorised service verter. partner. Compressor motor USS error Frequency converter fault mes- Contact an authorised service 0243 A...
Page 218 Fault recognition and rectification Fault messages Message Possible cause Remedy 0281 A Frequency converter error. Contact an authorised service partner. Oil-/air cooler fan FC PKW er- ror P%d.E%d 0282 A Fault triggered by software Contact an authorised service driver. partner. Oil-/air cooler fan USS error Frequency converter fault mes- Contact an authorised service 0283 A...
Page 219 Fault recognition and rectification Fault messages Message Possible cause Remedy 0334 A Fan frequency converter Contact an authorised service switched on incorrectly. partner. Oil cooler fan FC activation failed 0337 A Frequency converter parametr- Check frequency converter isation incorrect. parametrisation. Oil cooler fan FC: STO function inactive Contact an authorised service partner.
Page 220 Fault recognition and rectification Fault messages Message Possible cause Remedy 0412 A Frequency converter switched Contact an authorised service on incorrectly. partner. Compressor motor FC activa- tion failed 0413 A Minimum speed not reached Contact an authorised service within a defined time (configu- partner.
Page 221 Fault recognition and rectification Fault messages Message Possible cause Remedy 0458 A Frequency converter error. Contact an authorised service partner. Oil-/air cooler fan FC: Calibra- tion rotor pos. sensor! 0459 A Frequency converter error. Contact an authorised service partner. Oil-/air cooler fan FC: ICV ⇟ Frequency converter error.
Page 222: Tab. 78 Fault Messages, Possible Causes And Remedies
Fault recognition and rectification Fault messages Message Possible cause Remedy An I/O address has been as- Display incorrect parametrisa- 0500 A signed more than once. tion in menu 1.1.3 <Address I/O parameterisation incorrect error> and correct parameter in module %d! there. These messages are customer-specific. Add in the possible cause and remedy for the message text you have defined, see chapter 6.11 Inputs and...
Page 223: Warning Messages
Fault recognition and rectification Warning messages 8.3 Warning messages If an input signal or event is classified as a warning, the controller will display a warning message. Warning control indicator flashes or illuminates in ▪ The yellow. ▪ The controller does not switch the machine off. Warning messages are indicated with the letter W.
Page 224 Fault recognition and rectification Warning messages Message Possible cause Remedy Increased differential pressure Change oil filter. 0011 W in oil filter. Oil filter 1 Δp ↑ Oil filter clogged. Air filter clogged. Change air filter. 0013 W Air filter Δp ↑ - Change air filter! Bus link via PROFIBUS inter- Check bus lines and bus con-...
Page 225 Fault recognition and rectification Warning messages Message Possible cause Remedy Permissible number of motor 0036 W Extend idling period. starts exceeded in last 60 mi- Motor starts/h ⇞ Increase air receiver capacity. nutes. Increase piping cross-section between machine and air re- ceiver. Maximum permissible number Extend idle period.
Page 226 Fault recognition and rectification Warning messages Message Possible cause Remedy Fan motor: Re-lubricate anti-friction bear- 0050 W Interval counter expired. ings. Fan motor bearing lube h ⇞ For double-unit machines: Once maintenance or repair 0051 W Maintenance or repair work on work has been completed, de- Double aggregate emergency one of the units activate individual operation by...
Page 227 Fault recognition and rectification Warning messages Message Possible cause Remedy Permissible ambient tempera- 0064 W Keep ambient conditions within tures exceeded. specified limits. Refrigeration dryer compressor motor temperature ⇞ Clean condenser. Check fan. Condenser cooling insufficient. Check compressed air cooling on compressor. Compressed air inlet tempera- Clean compressor cooler.
Page 228 Fault recognition and rectification Warning messages Message Possible cause Remedy 0077 W External message 5 0078 W External message 6 0081 W AnMod_p_1 0082 W AnMod_p_2 0083 W AnMod_T_1 0084 W AnMod_T_2 0085 W AnMod_I_1 0086 W AnMod_I_2 0087 W AnMod_p_3 0088 W AnMod_p_4 0089 W AnMod_T_3 0090 W AnMod_T_4 0092 W T-Switch inlet temperature 0093 W p-Switch pi 0094 W...
Page 229 Fault recognition and rectification Warning messages Message Possible cause Remedy Centrifugal separator and Clean centrifugal separator and 0103 W housing dirty. housing. Air filter Δp ↑ - Clean centri- fuge and housing! Air filter clogged. Change air filter. 0114 W Air filter Δp ↑ - Change air filter cartridge! Frequency converter in service Exit service mode.
Page 230 Fault recognition and rectification Warning messages Message Possible cause Remedy 0253 W Frequency converter in service Exit service mode. mode. Oil cooler fan FC Service mode active 0254 W Frequency converter in service Exit service mode. mode. Oil cooler fan FC Service mode active 0255 W Frequency converter in service...
Page 231 Fault recognition and rectification Warning messages Message Possible cause Remedy 0453 W Power electronics temperature Keep ambient conditions within too high. specified limits. Oil-/air cooler fan FC: Power amplifier T ↑ Contact an authorised service partner. 0454 W Motor temperature too high. Keep ambient conditions within specified limits.
Page 232 Fault recognition and rectification Warning messages Message Possible cause Remedy 0475 W Control cabinet temperature Keep ambient conditions within too high. specified limits. Oil-/air cooler fan FC: Electron- ic interior T ↑ Check cooling air supply. Clean motor. Contact an authorised service partner.
Page 233 Fault recognition and rectification Warning messages Message Possible cause Remedy 0881 W Short circuit in line for ext. sen- Check line path and sensor sor at analogue input. connection. AII%d.0%d - short-circuit 0884 W Power supply for ext. sensor at Check voltage supply. analogue input faulty.
Page 234 Fault recognition and rectification Warning messages Message Possible cause Remedy 0917 W Sensor error at indicated ana- Check line path and sensor logue input. connection. AIR%d.0%d - sensor fault 0918 W Wire break in line for indicated Check line path and sensor analogue input.
Page 235 Fault recognition and rectification Warning messages Message Possible cause Remedy 0947 W Sensor error at indicated ana- Check line path and sensor logue input. connection. AIR%d.0%d - sensor fault 0948 W Wire break in line for indicated Check line path and sensor analogue input.
Page 236 Fault recognition and rectification Warning messages Message Possible cause Remedy 1049 W Short circuit in line for ext. sen- Check line path and sensor sor at analogue input. connection. AII%d.0%d - short-circuit 1052 W Power supply for ext. sensor at Check voltage supply. analogue input faulty.
Page 237 Fault recognition and rectification Warning messages Message Possible cause Remedy 1073 W Sensor error at indicated ana- Check line path and sensor logue input. connection. AIR%d.0%d - sensor fault 1074 W Wire break in line for indicated Check line path and sensor analogue input.
Page 238 Fault recognition and rectification Warning messages Message Possible cause Remedy 1095 W Short circuit in line for ext. sen- Check line path and sensor sor at analogue input. connection. AIR%d.0%d - short-circuit 1096 W Wire break in line for indicated Check line path and sensor analogue input.
Page 239 Fault recognition and rectification Warning messages Message Possible cause Remedy 1118 W No earth fault in line for ext. Check line path and sensor sensor at analogue input. connection. AIR%d.0%d - accidental ground 1119 W Short circuit in line for ext. sen- Check line path and sensor sor at analogue input.
Page 240 Fault recognition and rectification Warning messages Message Possible cause Remedy 1221 W Overload on the analogue input Contact an authorised service for ext. sensor. partner. AII%d.0%d - overload fault 1222 W Wire break in line for ext. sen- Check line path and sensor sor at analogue input.
Page 241 Fault recognition and rectification Warning messages Message Possible cause Remedy 1244 W No earth fault in line for ext. Check line path and sensor sensor at analogue input. connection. AIR%d.0%d - accidental ground 1245 W Short circuit in line for ext. sen- Check line path and sensor sor at analogue input.
Page 242 Fault recognition and rectification Warning messages Message Possible cause Remedy 1265 W Sensor error at indicated ana- Check line path and sensor logue input. connection. AIR%d.0%d - sensor fault 1266 W Wire break in line for indicated Check line path and sensor analogue input.
Page 243: Tab. 79 Warning Messages And Remedies
Fault recognition and rectification Warning messages Message Possible cause Remedy 1287 W Short circuit in line for indicated Check line path and sensor analogue input. connection. AIR%d.0%d - short-circuit 1288 W Wire break in line for indicated Check line path and sensor analogue input.
Page 244: Operating Messages
Fault recognition and rectification Operating messages 8.4 Operating messages The controller will automatically display operating messages as required, inform you regarding the current operating state of the machine and provide general instructions and information. Operating messages are indicated by the letter O. Messages are not numbered consecutively.
Page 245 Fault recognition and rectification Operating messages Message Meaning Machine undergoing maintenance work by an 0040 O authorised service partner. Technician on site 0073 O External message 1 0074 O External message 2 0075 O External message 3 0076 O External message 4 0077 O External message 5 0078 O External message 6 0081 O...
Page 246 Fault recognition and rectification Operating messages Message Meaning 0090 O AnMod_T_4 0092 O T-Switch inlet temperature 0093 O p-Switch pi 0094 O T-Switch ADT 0095 O p-Switch pN 0096 O T-Switch PDT 0098 O n-Switch Compressor motor Internal voltage monitoring reports undervolt- 0200 O age error IOSlot 1. IOSlot1 Undervoltage error %d Internal voltage monitoring reports undervolt- 0201 O age error IOSlot 2.
Page 247 Fault recognition and rectification Operating messages Message Meaning Short-term overload fault without shutdown 0551 O occurred at ADT. ADT channel error \"channel open\" detected Temporary IOM bus fault without shutdown 0850 O occurred. IOSlot%d - bus error 0867 O Temporary overload fault without shutdown occurred at AII.
Page 248: Tab. 80 Operating Messages
Fault recognition and rectification Operating messages Message Meaning 1221 O Temporary overload fault without shutdown occurred at AII. AII%d.0%d - overload fault These messages are customer-specific. Add in the possible cause and remedy for the message text you have defined, see chapter 6.11 Inputs and outputs.
Page 249: Diagnostic Messages
Fault recognition and rectification Diagnostic messages 8.5 Diagnostic messages A diagnostic message switches the machine off. Diagnostic messages provide information regarding the status of the controller and the connected input/output modules. They also assist authorised service partners with troubleshooting. Diagnostic messages are identified with the letter D. 8.6 System messages A system message switches the machine off.
Page 250: Maintenance
Header Menu 5.1.1 System information ▶1 SIGMA CONTROL 2 MCS Active line ▶2 Compressor ▶3 I/O modules ▶4 FC information SIGMA CONTROL 2 MCS line. 2. Select e.g. the 3. Press the «Enter» key. An overview of the system information is displayed. 6.1bar 08:15 80°C Header 5.1.1.1 SIGMA CONTROL 2 MCS...
Page 251: Decommissioning, Dismantling And Disposal
10 Decommissioning, dismantling and disposal 10.1 Decommissioning 10 Decommissioning, dismantling and disposal 10.1 Decommissioning Proceed as follows: ▶ Follow the instructions in the machine operating manual. 10.2 Battery removal and disposal ▪ The SIGMA CONTROL 2 has been decommissioned. Proceed as follows: 1.
Page 252: Documents And Drawings
11 Documents and drawings 11.1 Notes 11 Documents and drawings 11.1 Notes Notes Tab. 82 Service Technician settings User manual Controller 9_9450 22 E SIGMA CONTROL 2 SCREW FLUID ≥ 6.4.1...
Page 253: Software Versions
11 Documents and drawings 11.2 Software versions 11.2 Software versions Software version Date and time Name Remark Person who performed the software update. Tab. 83 Software versions 11.3 Time settings Date Time Time zone Update time Time server IP address Name automatically? Factory setting: Europe/Berlin...
Page 254: Network Parameters
11 Documents and drawings 11.4 Network parameters 11.4 Network parameters Parameter Setting value Name IP address Subnet mask Gateway DNS Server 1 DNS Server 2 Person who entered the setting. Tab. 85 Network parameters 11.5 E-mail parameters Parameter Setting value Name Compressor number: Language:...
Page 255: User-Defined Time Program On/Off
11 Documents and drawings 11.6 User-defined time program ON/OFF 11.6 User-defined time program ON/OFF No.: Time Function Tab. 87 User-defined time program Machine ON/OFF 11.7 Setpoint pressure change in the user time program No.: Time Nominal pressure ...
Page 256: Communications Fault Monitoring Parameters
11 Documents and drawings 11.9 Communications fault monitoring parameters Machine number Start time [sec] Delay time [sec] Tab. 89 Delay times 11.9 Communications fault monitoring parameters Parameter Set value Communication error tick box Start td Timeout Timeout tick box Tab. 90 Communications fault monitoring parameters 11.10 Output signals for operating states Message...
Page 257: Analogue Value Settings
11 Documents and drawings 11.11 Analogue value settings Message Output Activated Clock contact EMERGENCY STOP Tab. 91 Assigned output signals 11.11 Analogue value settings Message Value Output Message type AnMod_p_1 AnMod_p_2 AnMod_p_3 AnMod_p_4 AnMod_T_1 AnMod_T_2 AnMod_T_3 AnMod_T_4 AnMod_I_1 AnMod_I_2 T-Switch inlet temperature p-Switch pi T-Switch ADT p-Switch pN...
Page 258: External Messages
11 Documents and drawings 11.13 External messages 11.13 External messages External Message text Message type Input Output Activated message Tab. 94 External messages 11.14 Machine parameter settings Parameter Setting value Setpoint pressure pA Setpoint pressure pB System pressure low Control mode Heat recovery Master control mode Tab.
Page 259: Index
Index Electrical and mechanical specifications Electronic Thermo Management – ETM Access control Environment Approval Evaluating analogue inputs Autostart: Evaluating digital inputs Activating / deactivating Evaluating threshold values Time delay Fault cause Backlight Fault message Battery Formatting the SD card Frequency converter (SFC) Function Cable length Control mode...
Page 260 Index Master control Switching cycles Operating mode Switching differential Pressure switch Symbol PROFIBUS operation System information Remote contact System messages Remote LOAD contact System pressure low Remote local / LOAD contact SAM 4.0 operation Material damage Measured data Temperature shutdown Message Testing the safety valve Acknowledging Thermometer...

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