KAESER KOMPRESSOREN SIGMA CONTROL 2 User manual

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. [phone] • Fax [phone]
www.kaeser.com

/KKW/SSC 2.12 en IBA-SIGMA CONTROL FLUID
/KKW/SSC 2.12
20210526 085236

1 SIGMA CONTROL 2 Quick reference guide
1.1 Operating elements .......................................................................................................... 1
1.2 Indicator elements ............................................................................................................ 2
1.3 Main menu overview ........................................................................................................ 3
1.4 Functions overview .......................................................................................................... 3
2 Regarding this document
2.1 Using this document ......................................................................................................... 6
2.2 Copyright .......................................................................................................................... 6
2.2.1 Software .............................................................................................................. 6
2.3 Certification ...................................................................................................................... 7
2.4 Updating the operating manual ........................................................................................ 7
2.5 Symbols and labels .......................................................................................................... 7
2.5.1 Warnings ............................................................................................................. 7
2.5.2 Potential damage warnings ................................................................................ 8
2.5.3 Other alert notes and their symbols .................................................................... 9
3 Technical Specifications
3.1 Controller SIGMA CONTROL 2 ....................................................................................... 10
3.1.1 Versions and Options ......................................................................................... 10
3.1.2 User interface with display, CPU and interfaces ................................................. 10
3.1.3 In- and outputs with MCSIO ................................................................................ 13
3.1.4 Input/output modules .......................................................................................... 13
3.1.5 Sensors ............................................................................................................... 15
3.2 KAESER i.Box .................................................................................................................. 16
3.2.1 Versions and options .......................................................................................... 16
3.2.2 Indicator elements and interfaces ....................................................................... 17
3.2.3 Technical specifications ...................................................................................... 17
4 Safety and Responsibility
4.1 Basic instructions ............................................................................................................. 19
4.2 Specified use .................................................................................................................... 19
4.3 Improper use .................................................................................................................... 19
5 Design and Function
5.1 Controller overview .......................................................................................................... 20
5.2 Operating panel ................................................................................................................ 22
5.2.1 Operating elements ............................................................................................ 22
5.2.2 Display elements ................................................................................................ 23
5.2.3 RFID reader ........................................................................................................ 24
5.3 Display ............................................................................................................................. 24
5.3.1 Operating mode .................................................................................................. 25
5.3.2 Main menu .......................................................................................................... 26
5.3.3 Setting parameters ............................................................................................. 26
5.3.4 Activating keys with check boxes ....................................................................... 27
5.4 Access control .................................................................................................................. 27
5.5 KAESER CONNECT ........................................................................................................ 28
5.6 KAESER i.Box .................................................................................................................. 29
5.7 Menu overview ................................................................................................................. 30
5.7.1 Operating mode .................................................................................................. 30
5.7.2 Menu structure .................................................................................................... 31
5.8 Operating points and control modes ................................................................................ 50
5.8.1 Machine operating points .................................................................................... 50
5.8.2 Control modes .................................................................................................... 50
5.8.3 Variable speed drive with frequency converter (SFC) ........................................ 52
5.8.4 MODULATING control ........................................................................................ 53
Contents
No.: 9_9450 12 E
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥5.0.X i

6 Installation and Operating Conditions
6.1 Maintaining ambient conditions ........................................................................................ 54
6.2 Installation conditions ....................................................................................................... 54
7 Installation
7.1 Reporting Transport Damage ........................................................................................... 55
7.2 Machine identification ....................................................................................................... 55
7.3 Assembly of the KAESER i.Box ....................................................................................... 55
8 Initial Start-up
8.1 Outline .............................................................................................................................. 56
8.2 Setting the controller ........................................................................................................ 56
8.2.1 Selecting menu options ...................................................................................... 57
8.2.2 Setting the language ........................................................................................... 58
8.2.3 Noting the user name ......................................................................................... 59
8.2.4 User log-in with RFID Equipment Card ............................................................... 60
8.2.5 Generating a password ....................................................................................... 61
8.2.6 Manual user log-in .............................................................................................. 62
8.2.7 Create the master RFID Equipment Card ........................................................... 63
8.2.8 Checking/setting time and date .......................................................................... 64
8.2.9 Set the time zone ................................................................................................ 66
8.2.10 Set display formats ............................................................................................. 66
8.2.11 Setting the display illumination ........................................................................... 69
8.2.12 Setting the contrast and the brightness .............................................................. 70
8.2.13 Activating the remote control ............................................................................. 70
8.2.14 IP configuration .................................................................................................. 71
8.2.15 Setting the e-mail function .................................................................................. 73
8.2.16 Setting the time server ....................................................................................... 75
8.3 KAESER CONNECT benefits .......................................................................................... 76
8.3.1 Open KAESER CONNECT ................................................................................. 76
8.3.2 System status menu ........................................................................................... 78
8.3.3 Graphs menu ...................................................................................................... 79
8.3.4 Messages menu ................................................................................................. 81
8.3.5 I/O display menu ................................................................................................. 82
8.3.6 User management menu .................................................................................... 83
8.3.7 Settings menu ..................................................................................................... 86
8.3.8 Save data menu .................................................................................................. 87
8.3.9 Data recording menu .......................................................................................... 87
8.3.10 KAESER CONNECT exit .................................................................................... 88
8.4 Commissioning the KAESER i.Box .................................................................................. 89
8.5 Pressure parameters of the machine ............................................................................... 89
8.5.1 Displaying pressure parameters ......................................................................... 90
8.5.2 Setting pressure parameters .............................................................................. 91
8.5.3 Activating/deactivating the «LOAD/IDLE» key .................................................... 93
8.6 Machine start and machine stop ...................................................................................... 94
8.6.1 Automatic start/stop in timer mode .................................................................... 94
8.6.2 Setting the company shut-down ........................................................................ 98
8.6.3 Controlling machine from a remote location ...................................................... 100
8.6.4 Activating the remote control ............................................................................. 101
8.6.5 “Venting" function ............................................................................................... 102
8.6.6 "Auto start" function ............................................................................................ 102
8.7 Control modes .................................................................................................................. 105
8.7.1 Setting the control mode ..................................................................................... 105
8.7.2 Setting the DUAL control mode .......................................................................... 106
8.7.3 Setting the QUADRO control mode .................................................................... 107
Contents
ii User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥5.0.X No.: 9_9450 12 E

8.8 Electronic Thermal Management ..................................................................................... 108
8.8.1 Activating the heat recovery for machine type 2 ................................................. 109
8.8.2 Activating the heat recovery for machine type 3 ................................................. 110
8.8.3 Deactivating heat recovery ................................................................................. 111
8.9 Refrigeration dryer ........................................................................................................... 112
8.9.1 Setting the operating mode ................................................................................. 112
8.9.2 Output messages ................................................................................................ 113
8.9.3 Refrigeration dryer alarm – Compressed air quality has priority ......................... 114
8.9.4 Refrigeration dryer alarm – Compressed air supply has priority ......................... 116
8.10 Setting the machine for local mode .................................................................................. 116
8.10.1 Menu Load control .............................................................................................. 116
8.10.2 Setting the nominal pressure change via timing program .................................. 117
8.10.3 Setting the nominal pressure change via timer ................................................... 120
8.11 Setting the machine for master control operation ............................................................ 122
8.11.1 Overview of the different master operating modes ............................................. 122
8.11.2 SAM 4.0 mode ................................................................................................... 122
8.11.3 Setting PROFIBUS operation (SIGMA AIR MANAGER) .................................... 125
8.11.4 Interconnection of two machines in master/slave operation ............................... 133
8.11.5 Configuring interconnected operation using the LOAD remote contact (e.g.
SIGMA AIR MANAGER BASIC) 3) ......................................................................
140
8.11.6 Setting the master control with local/LOAD remote contact 3) ............................ 142
8.11.7 Setting the nominal pressure pre-selection via remote contact ......................... 146
8.11.8 Master control for machines regulated by pressure switch ................................. 147
8.11.9 Examples of time settings for equal overall load ............................................... 152
8.12 Setting input and output signals ....................................................................................... 153
8.12.1 Output operational states of machine on digital outputs ..................................... 153
8.12.2 Output input signals on the display ..................................................................... 155
8.12.3 Output measured values on the display ............................................................. 159
8.12.4 Switching and/or triggering messages with thresholds ....................................... 165
8.13 Timer ................................................................................................................................ 169
8.14 Activating remote acknowledgement .............................................................................. 170
8.14.1 Setting the remote acknowledgement function ................................................... 171
8.14.2 Activating the remote control .............................................................................. 171
8.14.3 Assigning an input .............................................................................................. 172
8.15 Linking to an external pressure transducer ..................................................................... 173
8.15.1 Pressure control menu ........................................................................................ 173
8.15.2 Assigning an input to an external pressure transducer ...................................... 173
8.16 Commissioning the machine ........................................................................................... 174
9 Operation
9.1 Switching the machine on and off .................................................................................... 176
9.1.1 Switching on ....................................................................................................... 176
9.1.2 Switching off ....................................................................................................... 177
9.2 Switching off in an emergency ......................................................................................... 177
9.3 Acknowledging alarm and warning messages ................................................................. 178
9.4 Displaying messages ...................................................................................................... 179
9.4.1 Status – Messages menu ................................................................................... 180
9.5 Displaying the current operating mode ............................................................................ 182
9.6 Setting the working pressure ............................................................................................ 183
9.7 Displaying analogue data ................................................................................................ 183
9.8 Displaying operating data ................................................................................................. 184
9.8.1 Checking the operating hours ............................................................................. 184
9.8.2 Checking the switching cycles ............................................................................ 185
9.9 Displaying the frequency converter settings .................................................................... 186
9.10 Setting the maintenance interval ...................................................................................... 187
Contents
No.: 9_9450 12 E
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥5.0.X iii

9.11 Resetting the maintenance interval counter ..................................................................... 188
9.12 Check the safety valve ..................................................................................................... 190
9.13 Excessive temperature shut-down test ............................................................................ 193
9.14 Save data ......................................................................................................................... 194
9.14.1 Format SD card .................................................................................................. 196
10 Fault Recognition and Rectification
10.1 Basic information .............................................................................................................. 197
10.2 Interpreting alarm messages ............................................................................................ 197
10.3 Interpreting warning messages ........................................................................................ 206
10.4 Interpreting operating messages ...................................................................................... 227
10.5 Interpreting diagnostic messages .................................................................................... 230
10.6 Interpreting system messages ......................................................................................... 230
10.7 KAESER i.Box − Operating states and troubleshooting ................................................... 231
11 Maintenance
11.1 Replacing the battery ....................................................................................................... 232
12 Spares, Operating Materials, Service
12.1 Note the nameplate .......................................................................................................... 233
12.2 KAESER AIR SERVICE ................................................................................................... 233
12.3 Service Addresses ........................................................................................................... 233
12.4 Displaying the version number, machine model, material number and serial number ..... 233
13 Decommissioning, Storage and Transport
13.1 De-commissioning ............................................................................................................ 235
13.2 Packing ............................................................................................................................ 235
13.3 Storage ............................................................................................................................. 235
13.4 Transporting ..................................................................................................................... 235
13.5 Battery removal and disposal ........................................................................................... 235
Contents
iv User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥5.0.X No.: 9_9450 12 E

Fig. 1 Operating elements .................................................................................................................... 1
Fig. 2 Indicator elements ...................................................................................................................... 2
Fig. 3 MCS interfaces ........................................................................................................................... 11
Fig. 4 MCSIO interfaces ....................................................................................................................... 12
Fig. 5 KAESER i.Box − indicator elements and interfaces ................................................................... 17
Fig. 6 MCS system design with IOM .................................................................................................... 21
Fig. 7 MCSIO system design ................................................................................................................ 21
Fig. 8 Operating elements .................................................................................................................... 22
Fig. 9 Display elements ........................................................................................................................ 23
Fig. 10 RFID reader ................................................................................................................................ 24
Fig. 11 KAESER CONNECT for SIGMA CONTROL 2 ........................................................................... 28
Fig. 12 Overview of KAESER i.Box ........................................................................................................ 30
Fig. 13 Back of the RFID Equipment Card ............................................................................................. 60
Fig. 14 User log-in with RFID Equipment Card ...................................................................................... 60
Fig. 15 User log-in with RFID Equipment Card ...................................................................................... 61
Fig. 16 Manual user log-on ..................................................................................................................... 63
Fig. 17 Log-in mask ................................................................................................................................ 77
Fig. 18 KAESER CONNECT for SIGMA CONTROL 2 ........................................................................... 77
Fig. 19 Select language: window ............................................................................................................ 78
Fig. 20 System status menu ................................................................................................................... 78
Fig. 21 Main menu .................................................................................................................................. 79
Fig. 22 Graphs (illustration similar) ......................................................................................................... 80
Fig. 23 Control keys ............................................................................................................................... 80
Fig. 24 Messages (illustration similar) .................................................................................................... 82
Fig. 25 I/O display (illustration similar) ................................................................................................... 83
Fig. 26 User management menu ............................................................................................................ 84
Fig. 27 Log on for write access: window ................................................................................................ 84
Fig. 28 User management menu ............................................................................................................ 85
Fig. 29 Settings menu ............................................................................................................................ 86
Fig. 30 Backup menu ............................................................................................................................. 87
Fig. 31 Data recording menu .................................................................................................................. 88
Fig. 32 Wiring of the PROFIBUS connection ......................................................................................... 126
Fig. 33 Electrical diagram example with SIGMA AIR MANAGER .......................................................... 127
Fig. 34 Communication interface ............................................................................................................ 128
Fig. 35 Insert the communication module. ............................................................................................. 129
Fig. 36 Front plate communication module PROFIBUS ......................................................................... 130
Fig. 37 Direct connection of two SIGMA CONTROL 2 ........................................................................... 135
Fig. 38 LOAD remote contact ................................................................................................................. 141
Fig. 39 Wiring diagram for local/LOAD remote contact: ......................................................................... 143
Fig. 40 Machine with pressure switch regulation .................................................................................... 148
Fig. 41 Function diagram ........................................................................................................................ 151
Fig. 42 Switching the compressed air station on and off ........................................................................ 176
Fig. 43 Switching off in an emergency ................................................................................................... 177
Fig. 44 Acknowledging messages .......................................................................................................... 178
List of Illustrations
No.: 9_9450 12 E
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥5.0.X v

List of Illustrations
vi User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥5.0.X No.: 9_9450 12 E

Tab. 1 Operating elements .................................................................................................................... 1
Tab. 2 Indicator elements ...................................................................................................................... 2
Tab. 3 Main menu overview .................................................................................................................. 3
Tab. 4 Functions overview ..................................................................................................................... 3
Tab. 5 Danger levels and their definition (personal injury) .................................................................... 8
Tab. 6 Danger levels and their definition (damage to property) ............................................................ 8
Tab. 7 Formatting options ...................................................................................................................... 9
Tab. 8 Versions and Options ................................................................................................................. 10
Tab. 9 User interface ............................................................................................................................. 10
Tab. 10 Display data ................................................................................................................................ 11
Tab. 11 MCS interfaces ........................................................................................................................... 11
Tab. 12 MCSIO interfaces ....................................................................................................................... 12
Tab. 13 RFID ........................................................................................................................................... 12
Tab. 14 Number of internal inputs and outputs ....................................................................................... 13
Tab. 15 Cable lengths ............................................................................................................................. 13
Tab. 16 SC2IOM-1 .................................................................................................................................. 14
Tab. 17 SC2IOM-2 .................................................................................................................................. 14
Tab. 18 SC2IOM-3 .................................................................................................................................. 14
Tab. 19 Power supply specifications ....................................................................................................... 15
Tab. 20 Cable lengths ............................................................................................................................. 15
Tab. 21 Degree of protection, IOM .......................................................................................................... 15
Tab. 22 IOM dimensions ......................................................................................................................... 15
Tab. 23 Pressure transducer ................................................................................................................... 15
Tab. 24 Resistance thermometer ............................................................................................................ 16
Tab. 25 Modem i.Box − versions and options ......................................................................................... 16
Tab. 26 Technical data KAESER i.Box ................................................................................................... 17
Tab. 27 Operating elements .................................................................................................................... 22
Tab. 28 Display elements ........................................................................................................................ 23
Tab. 29 RFID reader ................................................................................................................................ 24
Tab. 30 Data in the header depending on the machine type ................................................................... 25
Tab. 31 Reset check box status .............................................................................................................. 27
Tab. 32 Check box status ........................................................................................................................ 27
Tab. 33 KAESER CONNECT functions ................................................................................................... 28
Tab. 34 Menu structure of main menu ..................................................................................................... 31
Tab. 35 Status menu ............................................................................................................................... 35
Tab. 36 Configuration menu .................................................................................................................... 37
Tab. 37 Pressure control menu ............................................................................................................... 40
Tab. 38 I/O periphery menu ..................................................................................................................... 42
Tab. 39 Communication menu ................................................................................................................ 45
Tab. 40 Connections menu ..................................................................................................................... 46
Tab. 41 Components menu ..................................................................................................................... 47
Tab. 42 Power switching menu ............................................................................................................... 48
Tab. 43 Machine identification ................................................................................................................. 55
Tab. 44 Remote control identification ...................................................................................................... 55
Tab. 45 Machine identification ................................................................................................................. 55
Tab. 46 Supported languages ................................................................................................................. 58
Tab. 47 Date formats ............................................................................................................................... 66
Tab. 48 Possible settings for the time format .......................................................................................... 67
Tab. 49 Possible settings for the pressure unit ....................................................................................... 68
Tab. 50 Possible settings for the temperature unit .................................................................................. 69
Tab. 51 Display illumination ..................................................................................................................... 69
Tab. 52 Network parameters ................................................................................................................... 72
Tab. 53 E-mail parameters ...................................................................................................................... 74
Tab. 54 Control key functions .................................................................................................................. 80
List of Tables
No.: 9_9450 12 E
User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥5.0.X vii

Tab. 55 Compressor pressure parameters .............................................................................................. 89
Tab. 56 Setting limits for the network nominal pressure (* Cut-in pressure min) .................................... 91
Tab. 57 Pressure condition for LOAD ...................................................................................................... 91
Tab. 58 Pressure conditions for IDLE 12) ................................................................................................. 91
Tab. 59 Displaying and setting parameters ............................................................................................. 92
Tab. 60 Example: activated output .......................................................................................................... 93
Tab. 61 Settings for machine start and machine stop ............................................................................. 94
Tab. 62 User-defined clock programme machine ON/OFF ..................................................................... 95
Tab. 63 Example of a machine ON/OFF clock program .......................................................................... 96
Tab. 64 Auto start delay time ................................................................................................................... 103
Tab. 65 Machine type and ETM design ................................................................................................... 108
Tab. 66 Operating modes in local operating mode (local mode) ............................................................. 116
Tab. 67 User-defined timing program for nominal pressure change ....................................................... 117
Tab. 68 Example: Switching points, nominal pressure change ............................................................... 118
Tab. 69 Master control (interconnected operation) – overview ................................................................ 122
Tab. 70 Parameters for monitoring for communication malfunction ........................................................ 125
Tab. 71 Pin assignment of SUB-D 9-pole interface on the PROFIBUS module ...................................... 126
Tab. 72 Master-slave settings ................................................................................................................. 134
Tab. 73 Function diagram ........................................................................................................................ 150
Tab. 74 Example for a clock program for equal duty cycling during the day ........................................... 152
Tab. 75 Example for a timing program for equal duty cycling during the week ....................................... 153
Tab. 76 Assigned output signals ............................................................................................................. 153
Tab. 77 Logic settings ............................................................................................................................. 158
Tab. 78 Assigned analogue measured values ........................................................................................ 160
Tab. 79 Available measured values ........................................................................................................ 165
Tab. 80 Transmitting a pressure transducer value .................................................................................. 173
Tab. 81 Check list for starting the machine ............................................................................................. 174
Tab. 82 Message sequence 1 ................................................................................................................. 178
Tab. 83 Message sequence 2 ................................................................................................................. 178
Tab. 84 Information of a message ........................................................................................................... 179
Tab. 85 Message abbreviations .............................................................................................................. 180
Tab. 86 Operating mode display ............................................................................................................. 182
Tab. 87 Abbreviation of operating modes ................................................................................................ 182
Tab. 88 Check box status ........................................................................................................................ 190
Tab. 89 Alarm messages, possible causes and remedies ...................................................................... 197
Tab. 90 Warning messages and remedies .............................................................................................. 207
Tab. 91 Operational messages ............................................................................................................... 227
Tab. 92 System messages and remedies ............................................................................................... 230
Tab. 93 KAESER i.Box − Operating states and troubleshooting ............................................................. 231
List of Tables
viii User Manual Controller
SIGMA CONTROL 2 SCREW FLUID ≥5.0.X No.: 9_9450 12 E