HPC Sigma Control 2 User manual

Service Manual
Controller
SIGMA CONTROL 2 SCREW FLUID ≥1.1.3
9_9450 03 HCE
This manual is intendend as a guide to the installation, operation
and maintenance of your HPC Screw Compressor.
It is important from a safety point of view that the work of
installing and maintaining the compressor is undertaken by
trained personnel and should be entrusted to an
HPC Authorised Distributor
Victoria Gardens, Burgess Hill, West Sussex RH15 9RQ
Telephone: [phone] ● Fax: [phone]
[email protected] ● www.hpccompressors.co.uk
Manufacturer:
KAESER KOMPRESSOREN
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com

/KKW/SSC 2.03 en 02 BA-SIGMA CONTROL FLUID
/KKW/SSC 2.03 02
20130508 151238

Quick User Guide
Controller
SIGMA CONTROL 2 SCREW FLUID ≥1.1.3
9_9450 03 HCE
Manufacturer:
KAESER KOMPRESSOREN
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com

1. Important settings ............................................................................................................. 1
2. Setting the contrast and the brightness ............................................................................ 2
3. Setting the display language ............................................................................................ 3
4. Logging on with Equipment Card ..................................................................................... 4
5. Adjusting the system setpoint pressure ........................................................................... 6
6. Activating the «clock» key. ............................................................................................... 7
7. Activate the «remote control» key .................................................................................... 10
8. Changing the control mode .............................................................................................. 13
9. Outputting important operational states of the machine ................................................... 14
10. Resetting maintenance interval counters ......................................................................... 15
11. Pressure relief valve checking ......................................................................................... 17
12. Checking the temperature sensor and overheating shutdown function ........................... 20
13. Interpreting operation messages ...................................................................................... 22
14. Interpreting diagnostic messages .................................................................................... 25
15. Interpreting fault messages .............................................................................................. 26
16. Interpreting warning messages ........................................................................................ 31
17. Interpreting system messages ......................................................................................... 36
Contents
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Quick User Guide Controller
SIGMA CONTROL 2 SCREW FLUID ≥1.1.3 i

Contents
ii Quick User Guide Controller
SIGMA CONTROL 2 SCREW FLUID ≥1.1.3 9_9450 03 HCE

1 Important settings
In this chapter, important or often used settings are explained in brief. Detailed information on func‐
tion, configuration, fault removal and important instructions concerning safe operation are found in
subsequent chapters.
Setting and other work on the machine may only be carried out by the following persons:
■ persons trained on the machine/controller and persons instructed by and under the su‐
pervision of a specialist,
■ trained technicians,
■ authorised Service personnel.
1 Important settings
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2 Setting the contrast and the brightness
The display settings for contrast and brightness are set to the highest possible values by default.
Change the settings if adverse lighting conditions make it difficult to read the displayed information.
Optimising the contrast settings:
■ Press and hold the «Information» key.
■ At the same time, press the «Left» or «Right» key.
Optimising the brightness settings:
■ Press and hold the «Information» key.
■ At the same time, press the «UP» or «DOWN» key.
Precondition The display shows the operating mode.
1. Press «Enter».
The main menu is displayed.
2. Press and hold the «Information» key.
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Main menu
········· Deutsch ········· Active line with current language
▶1 xxxxxxxxxx Submenu
▶2 xxxxxxxxxx Submenu
▶3 xxxxxxxxxx Submenu
▶4 xxxxxxxxxx Submenu
▶5 xxxxxxxxxx Submenu
3. Press «UP» or «DOWN» to adjust the contrast.
4. Press «Left» or «Right» to adjust the brightness.
Result The settings for contrast and brightness have been adjusted.
2 Setting the contrast and the brightness
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3 Setting the display language
Precondition The display shows the operating mode.
1. Press «Enter».
The main menu is displayed.
2. Press the «UP» or «DOWN» keys until the current language is shown as active line.
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Main menu
········· Deutsch ········· Active line with current language
▶1 xxxxxxxxxx Submenu
▶2 xxxxxxxxxx Submenu
▶3 xxxxxxxxxx Submenu
▶4 xxxxxxxxxx Submenu
▶5 xxxxxxxxxx Submenu
3. Use the «Enter» key to switch to setting mode.
The currently set language flashes.
4. Move to the required language with «UP »or «DOWN».
5. Confirm the setting with «Enter».
6. Press «Escape» repeatedly to return to the main menu.
Result The display texts are now in the selected language.
3 Setting the display language
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4 Logging on with Equipment Card
Proceed as follows:
■ Take the plastic sleeve from the control cabinet.
■ Remove one Equipment Card.
■ Note the number on the reverse side of the Equipment Card.
■ Safely store the number.
■ Log on with Equipment Card
➤ Proceed in the prescribed sequence of actions.
Remove the Equipment Card from the control cabinet.
The supplied Equipment Cards are stored in a plastic sleeve.
This plastic sleeve is attached to the rear of the controller in the control cabinet.
The number shown on the rear of the Equipment Card is also the user name.
The user name is required for a manual log on without Equipment Card.
Fig. 1 KAESER Equipment Card
1KAESER Equipment Card
2Number of the KAESER Equipment Card
1. Open the control cabinet.
2. Remove the plastic sleeve from the rear of the controller.
3. Remove one Equipment Card from the plastic sleeve.
4. Note the number shown on the backside of the Equipment Card.
5. Store this information at a suitable location.
Log on with Equipment Card
Use a supplied KAESER Equipment Card to log on at the controller.
Two of them have been provided with the machine.
4 Logging on with Equipment Card
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Fig. 2 RFID reader
1. Hold the Equipment Card for a short time in front of the RFID reader.
The data are read.
Your user name and access level are displayed.
2. Press «Enter» to confirm the log-on.
The operating mode is displayed.
Result You are logged on.
Further information See chapter 7.2.6 for a manual log-on to the controller.
4 Logging on with Equipment Card
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5 Adjusting the system setpoint pressure
Precondition Access level 2 is activated.
The display shows the operating mode.
1. Press «Enter».
The main menu is displayed.
2. Select the < Configuration ➙ Pressure control ➙ Pressure settings > menu.
The pA switching value is displayed in the active line.
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5.2.2 Pressure settings Current menu
Setpoint pressure Parameter to be adjusted
pA SP : 8.0 bar ¦ SD : -0.5 bar Active line, setting for switching point pA
pB SP : 7.7 bar ¦ SD : - 0.5 bar Setting for switching point pB
·········
System pressure low ☐
↓< 5.0 bar ¦ SD : 0.5 bar
3. Press «Enter» to switch into setting mode.
The current value flashes.
4. Use «UP» or «DOWN» to adjust the setting for the switching point pA .
5. Press «Enter» to accept the setting.
6. Press the «Right» key once.
7. Press «Enter» to switch into the setting mode for the switching differential.
The current value flashes.
8. Use «UP» or «DOWN» to adjust the setting for the switching differential.
9. Press «Enter» to accept the setting.
10. If necessary, adjust the value for switching point pB in the same way.
11. Press «Escape» repeatedly to return to the main menu.
Further information See chapter 7.4 for the adjustment of the machine's pressure parameters.
5 Adjusting the system setpoint pressure
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6 Activating the «clock» key.
Activating/deactivating the check box
Check box Check box for reset Status
☑ ☒ activated
☐ ☐ deactivated
Tab. 1 Check box status
Precondition Password level 2 is activated.
The display shows the operating mode.
Select the clock compressor menu
1. Press «Enter».
The main menu is displayed.
2. Select < Compressor clock > .
The display for setting the Compressor clock timing program appears.
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6 Compressor clock Menu
Key clock: ☐
Reset: ☐
·········
01 n.a. 00:00 off Enter switching point 01 (active line)
02 n.a. 00:00 off Enter switching point 02
03 n.a. 00:00 off Enter switching point 03
Entering switching points
1. Press «Enter» to switch into setting mode.
The n.a. column flashes in the active line.
2. Use «UP» to specify the settings for the weekdays.
3. Press «Enter» to accept the setting.
4. Press the «Right» key once.
5. Press «Enter» to switch into setting mode.
Column time, hours display, 00 : 00 flashes in the active line.
6. Use «UP» to specify the settings for the hours.
7. Press the «Right» key once.
Column time, hours display, 00 : 00 flashes in the active line.
8. Use «UP» to specify the settings for the minutes.
6 Activating the «clock» key.
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9. Press «Enter» to accept the settings.
The display stops flashing and the time (hours/minutes) is set.
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6 Compressor clock Current menu
Key clock: ☐
Reset: ☐
·········
01 Mon-Fri 06:30 on example for weekdays
02 Mon-Fri 12:00 off example for time
03 Mon-Fri 13:00 on For example, compressor ON action
10. Press the «Right» key once.
11. Press «Enter» to switch into setting mode.
Column action on/off flashes.
12. Use «UP» to specify the settings for the compressor ON action.
13. Press «Enter» to accept the setting.
The compressor ON action is setz for the first switching point.
14. Specify further switching points in the same manner.
Result Weekdays, time and the compressor ON / compressor OFF actions are set for all switching points.
Activating the «clock» key.
1. Use «UP» key to change to line Key clock .
2. Press «Enter» to switch into setting mode.
The check box flashes in the active line.
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6 Compressor clock Menu
Key clock: ☑ Active line with check box
Reset: ☐ Resetting all current switching points
·········
01 Mon-Fri 06:30 on
02 Mon-Fri 12:00 off
03 Mon-Fri 13:00 on
3. Use the «UP» key to activate the check box.
4. Press «Enter» to accept the setting.
The «clock» key is activated.
5. Press «Escape» repeatedly to return to the main menu.
6. Press the «clock» key.
■ Proceed in the same manner to deactivate the «clock» key.
■ All defined switching points will be reset simultaneously if you activate the reset check
box.
6 Activating the «clock» key.
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Result The machine runs according to the defined switching points of the clock program.
Further information See chapter 7.5 for configuration of starting and stopping the machine.
See chapter 7.8.2 for configuration of load changeover based on a clock program.
6 Activating the «clock» key.
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7 Activate the «remote control» key
Further settings have to be made to allow the machine to be remotely controlled.
➤ Refer to the section "Additional information" in this chapter.
Activating/deactivating the check box
Check box Status
☑ activated
☐ deactivated
Tab. 2 Check box status
The following menus are used to activate the «remote control» key:
■ Menu <Compressor ON>
■ Menu <Load control>
The function will be available as soon as the «remote control» key in one of the menus has been
activated.
Precondition Access level 2 is activated.
The display shows the operating mode.
Activating the «remote control»key in the compressor ON menu
1. Press «Enter».
The main menu is displayed.
2. Select < Configuration ➙ Compressor start ➙ Compressor on > .
3. Press «DOWN» repeatedly until Key remote is displayed as active line.
4. Press «Enter» to switch into setting mode.
The check box for «remote control» key flashes.
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5.4.1 Compressor on Menu
Local mode: Key
Remote mode: Key
------------------------------
RC DI 1.12 ☐
Key remote: ☐ Active line with check box
Key clock: ☐
5. Press the «UP» key.
The activated check box is displayed.
7 Activate the «remote control» key
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6. Press «Enter» to save the setting.
The «remote control» key is activated and can be used.
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5.4.1 Compressor on Menu
Local mode: Key
Remote mode: Key
------------------------------
RC DI 1.12 ☐
Key remote: ☑ Active line with check box
Key clock: ☐
7. Press «Escape» repeatedly to return to the main menu.
8. Press the «remote control» key to enable remote mode.
Proceed in the same manner to deactivate the «remote control» key.
Activating the «remote control» key in the load control menu
Precondition Access level 2 is activated.
The display shows the operating mode.
1. Press «Enter».
The main menu is displayed.
2. Select < Configuration ➙ Pressure control ➙ Load control > .
3. Press «UP» repeatedly until Key remote is displayed as active line.
4. Press «Enter» to switch into setting mode.
The check box for «remote control» key flashes.
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5.2.3 Load control Menu
Local mode pA
·········
Remote mode: pA
Key remote: ☐ Active line with check box
·········
▶1 pA/pB Clock
5. Press the «UP» key.
The activated check box is displayed.
7 Activate the «remote control» key
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6. Press «Enter» to accept the setting.
The «remote control» key is activated and can be used.
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5.2.3 Load control Menu
Local mode pA
·········
Remote mode: pA
Key remote: ☑ Active line with check box
·········
▶1 pA/pB Clock
7. Press «Escape» repeatedly to return to the main menu.
8. Press the «remote control» key to enable remote mode.
Proceed in the same manner to deactivate the «remote control» key.
Further information See chapter 7.5 for configuration of starting and stopping the machine.
See chapter 7.9 for configuration of load changeover under master control.
7 Activate the «remote control» key
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8 Changing the control mode
The standard setting of the control mode depends on the machine type.
As an example, the change from DUAL to QUADRO control mode is described below.
Precondition Access level 2 is activated.
The display shows the operating mode.
1. Press «Enter».
The main menu is displayed.
2. Select the < Configuration ➙ Control mode > menu.
Local mode is displayed as active line.
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5.3 Control mode Current menu
Local mode: DUAL Active line with control mode to be adjusted
------------------------------
▶1 Venting period
·········
▶3 DUAL
▶4 QUADRO
3. Press «Enter» to switch into setting mode.
The display for DUAL control mode flashes.
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5.3 Control mode Current menu
Local mode: QUADRO Active line with changed control mode
------------------------------
▶1 Venting period
·········
▶3 DUAL
▶4 QUADRO
4. Use «UP» to select QUADRO.
5. Press «Enter» to accept the setting.
6. Press «Escape» repeatedly to return to the main menu.
Result The regulating mode DUAL has been switched to QUADRO.
Further information See chapter 4.7 for the functions of the control modes.
See chapter 7.6 for the parameters of the control modes.
8 Changing the control mode
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9 Outputting important operational states of the ma‐
chine
Important operational machine states can be assigned via floating relay contacts as a binary signal
on the outputs DOR 1.05 – DOR 1.07. Further outputs are optionally available. You can assign ev‐
ery output only once.
Precondition Access level 2 is activated.
The display shows the operating mode.
Configuration ➙ I/O Periphery ➙ DO Functions menu
1. Press «Enter».
The main menu is displayed.
2. Select the < Configuration ➙ I/O periphery ➙ DO functions > menu.
A list of available messages and their assigned outputs is displayed.
Controller on line is displayed as being active.
3. Select the required message with the «UP» or «DOWN» keys.
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5.7.1 DO functions Menu
Controller on Active line
DOR 1.05 ☐ ¦ Logic : +
DOT 1.02 ☐ ¦ Logic : +
Compressor on
DOR 1.03 ☐ ¦ Logic : +
DOT 1.02 ☐ ¦ Logic : +
Assigning a message to an output
1. Press «Enter» to switch into setting mode.
The display flashes.
2. Select a free output with the «UP» or «DOWN» key.
3. Press «Enter» to accept the setting.
A message is now sent via the assigned output.
4. Press «Escape» repeatedly to return to the main menu.
Further information See chapter 7.11 for the configuration and use of the controller's inputs and outputs.
9 Outputting important operational states of the machine
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