Name: KAESER KOMPRESSOREN SIGMA CONTROL 2
Brand: KAESER KOMPRESSOREN
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User Manual

Controller

SIGMA CONTROL 2 SCREW FLUID ≥5.0.X

No.: 9_9450 12 E

Manufacturer:

KAESER KOMPRESSOREN SE

96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130

www.kaeser.com

Table of Contents3
SIGMA CONTROL 2 Quick Reference Guide11
Operating Elements11
Fig. 1 Operating Elements11
Tab. 1 Operating Elements11
Indicator Elements12
Fig. 2 Indicator Elements12
Tab. 2 Indicator Elements12
Main Menu Overview13
Functions Overview13
Tab. 3 Main Menu Overview13
Tab. 4 Functions Overview14
Regarding this Document Using this Document16
Copyright16
Software16
Certification17
Updating the Operating Manual17
Symbols and Labels17
Warnings17
Potential Damage Warnings18
Tab. 5 Danger Levels and Their Definition (Personal Injury)18
Tab. 6 Danger Levels and Their Definition (Damage to Property)18
Other Alert Notes and Their Symbols19
Tab. 7 Formatting Options19
Technical Specifications 3.1 Controller SIGMA CONTROL 220
Versions and Options20
User Interface with Display, CPU and Interfaces20
Tab. 8 Versions and Options20
Tab. 9 User Interface20
Fig. 3 MCS Interfaces21
Tab. 10 Display Data21
Tab. 11 MCS Interfaces21
Fig. 4 MCSIO Interfaces22
Tab. 12 MCSIO Interfaces22
In- and Outputs with MCSIO23
Input/Output Modules23
Tab. 13 RFID23
Tab. 14 Number of Internal Inputs and Outputs23
Tab. 15 Cable Lengths23
Tab. 16 SC2IOM-124
Tab. 17 SC2IOM-224
Tab. 18 SC2IOM-324
Sensors25
Tab. 19 Power Supply Specifications25
Tab. 20 Cable Lengths25
Tab. 21 Degree of Protection, IOM25
Tab. 22 IOM Dimensions25
KAESER I.box26
Versions and Options26
Tab. 23 Pressure Transducer26
Tab. 24 Resistance Thermometer26
Tab. 25 Modem I.box − Versions and Options26
Indicator Elements and Interfaces27
Technical Specifications27
Fig. 5 KAESER I.box − Indicator Elements and Interfaces27
Tab. 26 Technical Data KAESER I.box28
Safety and Responsibility Basic Instructions29
Specified Use29
Improper Use29
Design and Function30
Controller Overview30
Fig. 6 MCS System Design with IOM31
Fig. 7 MCSIO System Design31
Operating Panel32
Operating Elements32
Fig. 8 Operating Elements32
Display Elements33
Fig. 9 Display Elements33
Tab. 27 Operating Elements33
RFID Reader34
Display34
Fig. 10 RFID Reader34
Tab. 28 Display Elements34
Tab. 29 RFID Reader34
Operating Mode35
Tab. 30 Data in the Header Depending on the Machine Type35
Main Menu36
Setting Parameters36
Activating Keys with Check Boxes37
Access Control37
Tab. 31 Reset Check Box Status37
Tab. 32 Check Box Status37
Kaeser Connect38
Fig. 11 KAESER CONNECT for SIGMA CONTROL38
KAESER I.box39
Tab. 33 KAESER CONNECT Functions39
Menu Overview40
Operating Mode40
Fig. 12 Overview of KAESER I.box40
Menu Structure41
Tab. 34 Menu Structure of Main Menu44
Tab. 35 Status Menu46
Tab. 36 Configuration Menu50
Tab. 37 Pressure Control Menu51
Tab. 38 I/O Periphery Menu54
Tab. 39 Communication Menu56
Tab. 40 Connections Menu56
Tab. 41 Components Menu57
Tab. 42 Power Switching Menu59
Operating Points and Control Modes60
Machine Operating Points60
Control Modes60
Variable Speed Drive with Frequency Converter (SFC)62
MODULATING Control63
Installation and Operating Conditions64
Maintaining Ambient Conditions64
Installation Conditions64
Installation65
Reporting Transport Damage65
Machine Identification65
Assembly of the KAESER I.box65
Tab. 43 Machine Identification65
Tab. 44 Remote Control Identification65
Tab. 45 Machine Identification65
Initial Start-Up Outline66
Setting the Controller66
Selecting Menu Options67
Setting the Language68
Noting the User Name69
User Log-In with RFID Equipment Card70
Fig. 13 Back of the RFID Equipment Card70
Fig. 14 User Log-In with RFID Equipment Card70
Generating a Password71
Fig. 15 User Log-In with RFID Equipment Card71
Manual User Log-In72
Create the Master RFID Equipment Card73
Fig. 16 Manual User Log-On73
Checking/Setting Time and Date74
Set the Time Zone76
Set Display Formats76
Tab. 47 Date Formats76
Tab. 48 Possible Settings for the Time Format77
Tab. 49 Possible Settings for the Pressure Unit78
Setting the Display Illumination79
Tab. 50 Possible Settings for the Temperature Unit79
Tab. 51 Display Illumination79
Setting the Contrast and the Brightness80
Activating the Remote Control80
IP Configuration81
Tab. 52 Network Parameters82
Setting the E-Mail Function83
Tab. 53 E-Mail Parameters84
Setting the Time Server85
KAESER CONNECT Benefits86
Open KAESER CONNECT86
Fig. 17 Log-In Mask87
Fig. 18 KAESER CONNECT for SIGMA CONTROL87
System Status Menu88
Fig. 19 Select Language: Window88
Fig. 20 System Status Menu88
Graphs Menu89
Fig. 21 Main Menu89
Fig. 22 Graphs (Illustration Similar)90
Fig. 23 Control Keys90
Tab. 54 Control Key Functions90
Messages Menu91
I/O Display Menu92
Fig. 24 Messages (Illustration Similar)92
User Management Menu93
Fig. 25 I/O Display (Illustration Similar)93
Fig. 26 User Management Menu94
Fig. 27 Log on for Write Access: Window94
Fig. 28 User Management Menu95
Settings Menu96
Fig. 29 Settings Menu96
Save Data Menu97
Data Recording Menu97
Fig. 30 Backup Menu97
KAESER CONNECT Exit98
Fig. 31 Data Recording Menu98
Commissioning the KAESER I.box99
Pressure Parameters of the Machine99
Displaying Pressure Parameters100
Tab. 55 Compressor Pressure Parameters100
Setting Pressure Parameters101
Tab. 56 Setting Limits for the Network Nominal Pressure (* Cut-In Pressure Min)101
Tab. 57 Pressure Condition for LOAD101
Tab. 58 Pressure Conditions for IDLE101
Tab. 59 Displaying and Setting Parameters102
Activating/Deactivating the "LOAD/IDLE" Key103
Machine Start and Machine Stop104
Automatic Start/Stop in Timer Mode104
Tab. 61 Settings for Machine Start and Machine Stop104
Tab. 62 User-Defined Clock Programme Machine ON/OFF105
Tab. 63 Example of a Machine ON/OFF Clock Program106
Setting the Company Shut-Down108
Controlling Machine from a Remote Location110
Activating the Remote Control111
Venting" Function112
Auto Start" Function112
Tab. 64 Auto Start Delay Time114
Control Modes115
Setting the Control Mode115
Setting the DUAL Control Mode116
Setting the QUADRO Control Mode117
Electronic Thermal Management118
Tab. 65 Machine Type and ETM Design118
Activating the Heat Recovery for Machine Type 2119
Activating the Heat Recovery for Machine Type 3120
Deactivating Heat Recovery121
Refrigeration Dryer122
Setting the Operating Mode122
Output Messages123
Refrigeration Dryer Alarm - Compressed Air Quality Has Priority124
Refrigeration Dryer Alarm - Compressed Air Supply Has Priority126
Setting the Machine for Local Mode126
Menu Load Control126
Tab. 66 Operating Modes in Local Operating Mode (Local Mode)126
Setting the Nominal Pressure Change Via Timing Program127
Tab. 67 User-Defined Timing Program for Nominal Pressure Change127
Setting the Nominal Pressure Change Via Timer130
Setting the Machine for Master Control Operation132
Overview of the Different Master Operating Modes132
SAM 4.0 Mode132
Tab. 69 Master Control (Interconnected Operation) - Overview132
Setting PROFIBUS Operation (SIGMA AIR MANAGER)135
Tab. 70 Parameters for Monitoring for Communication Malfunction135
Fig. 32 Wiring of the PROFIBUS Connection136
Tab. 71 Pin Assignment of SUB-D 9-Pole Interface on the PROFIBUS Module136
Fig. 33 Electrical Diagram Example with SIGMA AIR MANAGER137
Fig. 34 Communication Interface138
Fig. 35 Insert the Communication Module139
Fig. 36 Front Plate Communication Module PROFIBUS140
Interconnection of Two Machines in Master/Slave Operation143
Tab. 72 Master-Slave Settings144
Fig. 37 Direct Connection of Two SIGMA CONTROL 2145
Configuring Interconnected Operation Using the LOAD Remote Contact (E.g. SIGMA AIR MANAGER BASIC)150
Fig. 38 LOAD Remote Contact151
Setting the Master Control with Local/Load Remote Contact152
Fig. 39 Wiring Diagram for Local/Load Remote Contact153
Setting the Nominal Pressure Pre-Selection Via Remote Contact156
Master Control for Machines Regulated by Pressure Switch157
Fig. 40 Machine with Pressure Switch Regulation158
Fig. 41 Function Diagram161
Tab. 73 Function Diagram161
Examples of Time Settings for Equal Overall Load162
Setting Input and Output Signals163
Output Operational States of Machine on Digital Outputs163
Tab. 75 Example for a Timing Program for Equal Duty Cycling During the Week163
Tab. 76 Assigned Output Signals164
Output Input Signals on the Display165
Tab. 77 Logic Settings168
Output Measured Values on the Display169
Tab. 78 Assigned Analogue Measured Values170
Switching And/Or Triggering Messages with Thresholds175
Timer179
Activating Remote Acknowledgement180
Setting the Remote Acknowledgement Function181
Activating the Remote Control181
Assigning an Input182
Linking to an External Pressure Transducer183
Pressure Control Menu183
Assigning an Input to an External Pressure Transducer183
Tab. 80 Transmitting a Pressure Transducer Value183
Commissioning the Machine184
Tab. 81 Check List for Starting the Machine184
Operation186
Switching the Machine on and off186
Switching on186
Fig. 42 Switching the Compressed Air Station on and off186
Switching off187
Switching off in an Emergency187
Fig. 43 Switching off in an Emergency187
Acknowledging Alarm and Warning Messages188
Fig. 44 Acknowledging Messages188
Displaying Messages189
Status - Messages Menu190
Tab. 84 Information of a Message190
Tab. 85 Message Abbreviations190
Displaying the Current Operating Mode192
Tab. 86 Operating Mode Display192
Tab. 87 Abbreviation of Operating Modes192
Setting the Working Pressure193
Displaying Analogue Data193
Displaying Operating Data194
Checking the Operating Hours194
Checking the Switching Cycles195
Displaying the Frequency Converter Settings196
Setting the Maintenance Interval197
Resetting the Maintenance Interval Counter198
Check the Safety Valve200
Tab. 88 Check Box Status200
Excessive Temperature Shut-Down Test203
Save Data204
Format SD Card206
10 Fault Recognition and Rectification207
Basic Information207
Interpreting Alarm Messages207
Interpreting Warning Messages216
Tab. 89 Alarm Messages, Possible Causes and Remedies216
Tab. 90 Warning Messages and Remedies236
Interpreting Operating Messages237
Interpreting Diagnostic Messages240
Interpreting System Messages240
KAESER I.box − Operating States and Troubleshooting241
Tab. 93 KAESER I.box − Operating States and Troubleshooting241
11 Maintenance242
Replacing the Battery242
12 Spares, Operating Materials, Service243
Note the Nameplate243
Kaeser Air Service243
Service Addresses243
Displaying the Version Number, Machine Model, Material Number and Serial Number243
13 Decommissioning, Storage and Transport245
Commissioning245
Packing245
Storage245
Transporting245
Battery Removal and Disposal245

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General

Brand	KAESER KOMPRESSOREN
Model	SIGMA CONTROL 2
Category	Controller
Language	English

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