KAESER KOMPRESSOREN SIGMA CONTROL 2 User manual

Service manual
Controller
SIGMA CONTROL 2 SCREW DRY 1.0.x.x
9_9451 00E
Manufacturer:
KAESER KOMPRESSOREN
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
http://www.kaeser.com

/KKW/SSC 2.02 en BA-SIGMA CONTROL DRY
/KKW/SSC 2.02
20120814 111240

Quick user guide
Controller
SIGMA CONTROL 2 SCREW DRY 1.0.x.x
9_9451 00 E
Manufacturer:
KAESER KOMPRESSOREN
96410 Coburg • PO Box 2143 • GERMANY • Tel. [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. Entering a password ........................................................................................................ 4
5. Adjusting the system setpoint pressure ........................................................................... 5
6. Set clock program ............................................................................................................ 6
7. Activate the «remote control» key .................................................................................... 9
8. Changing the control mode .............................................................................................. 11
9. Outputting important operational states of the machine ................................................... 12
10. Resetting maintenance interval counters ......................................................................... 13
11. Testing the pressure relief valve ...................................................................................... 14
12. Checking the temperature sensor and overheating shutdown function ........................... 20
13. Interpreting operation messages ...................................................................................... 23
14. Interpreting diagnostic messages .................................................................................... 26
15. Interpreting fault messages .............................................................................................. 27
16. Interpreting warning messages ........................................................................................ 36
17. Interpreting system messages ......................................................................................... 44
Contents
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Quick user guide Controller
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Contents
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Quick user guide Controller
SIGMA CONTROL 2 SCREW DRY 1.0.x.x 9_9451 00 E

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 Entering a password
Use a supplied Equipment Card to log on at the controller.
You received two cards with the machine.
The Equipment Cards are stored in the control cabinet.
Fig. 1 RFID reader
1. Remove the Equipment Card from the control cabinet.
2. Hold the Equipment Card for a short time in front of the RFID reader.
The system reads the data and displays your access level.
3. Press «Enter» to confirm the logon.
Result The operating mode is displayed. You are logged on.
Further information See chapter 7.2.4 for a manual logon to the controller.
4 Entering a password
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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 ➙ Compressed air system ➙ Pressure settings > menu.
Switching point pA is displayed in the active line.
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5.2.1 Pressure settings Current menu
Setpoint pressure Parameter to be adjusted
pA SP: 8.0 bar ¦ SD: -0.5 bar active line, settings for switching point pA
pB SP: 7.7 bar ¦ SD: - 0.5 bar Settings 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 Set clock program
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.
Selecting the compressor clock 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 Set clock program
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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 action Compressor ON.
13. Press «Enter» to accept the setting.
The action Compressor ON is set for the first switching point.
14. Specify further switching points in the same manner.
Result Weekdays, time and the actions Compressor ON/Compressor OFF are set for all switching points.
Activate the «Timer» 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 Set clock program
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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 7.7.2 for configuration of load changeover based on a clock program.
6 Set clock program
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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 menu < 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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5.1.2.1 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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5.1.2.1 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.
Further information See chapter 7.5 for configuration of starting and stopping the machine.
See chapter 7.8 for configuration of load changeover under master control.
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.
Precondition Access level 2 is activated.
The display shows the operating mode.
1. Press «Enter».
The main menu is displayed.
2. Select menu < Configuration ➙ Compressed air system ➙ Control mode > .
Local mode is displayed as an active line.
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5.2.4 Control mode Current menu
Local mode: DYNAMIC active line with control mode to be adjusted
------------------------------
▶1 DUAL
▶2 QUADRO
------------------------------
Idle Period min 60 s
3. Press «Enter» to switch into setting mode.
The control mode display DYNAMIC flashes.
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5.2.4 Control mode Current menu
Local mode: QUADRO active line with adjusted control mode
------------------------------
▶1 DUAL
▶2 QUADRO
------------------------------
Idle Period min 60 s
4. Use «UP» key to select the control mode QUADRO.
5. Press «Enter» to accept the setting.
6. Press «Escape» repeatedly to return to the main menu.
Result The regulating mode DYNAMIC has been switched to QUADRO.
Further information See chapter 4.7 for the functions of the control modes.
See chapter 7.6 for changing the parameters of the control modes.
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.
Select menu Configuration ➙ Accessories ➙ I/O Periphery
1. Press «Enter».
The main menu is displayed.
2. Select menu < Configuration ➙ Accessories ➙ I/O periphery ➙ DO functions > .
Controller on line is displayed as being active.
3. Select the required message with the «UP» or «DOWN» key.
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5.3.1.1 DO functions Menu
Controller on Active line
DOR 1.05 ☑ ¦ Logic +
Compressor on
DOR 1.04 ☐ ¦ Logic +
Motor running
DOR 1.07 ok ☑ ¦ 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 output assigned.
4. Press «Escape» repeatedly to return to the main menu.
Further information See chapter 7.10 for configuration and use of the controller's inputs and outputs.
9 Outputting important operational states of the machine
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10 Resetting maintenance interval counters
Example: Resetting the maintenance interval counter for oil filter.
Precondition Maintenance has been performed.
Warning message has been acknowledged.
Access level 2 is activated.
The display shows the operating mode.
Maintenance menu
1. Press «Enter».
The main menu is displayed.
2. Select menu < Maintenance >
The maintenance counter for Oil filter is displayed in the active line.
3. Press «DOWN» once.
Reset is displayed as an active line.
4. Press «Enter» to switch into setting mode.
The check box for reset flashes.
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4 Maintenance Menu
Oil filter 8000 h ¦ 0005 h Maintenance interval, remaining time
Reset ☐ Active line
·········
Oil change 16000 h ¦ 3000 h
Reset ☐
·········
5. Use the «UP» key to activate the check box for reset.
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4 Maintenance Menu
Oil filter 8000 h ¦ 8000 h Maintenace interval, remaining new time
Reset ☑ Active line
·········
Oil change 16000 h ¦ 3000 h
Reset ☐
·········
6. Press «Enter» to accept the setting.
The check box for reset is deactivated automatically.
Result The remaining life span of the new oil filter complies with the defined maintenance interval of
8000 h (depending on the machine type).
Further information See chapter 8.7 for setting the maintenance intervals.
See chapter 10 for the maintenance of the controller.
10 Resetting maintenance interval counters
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11 Testing the pressure relief valve
Use the SIGMA CONTROL 2 to conveniently test the functioning of the pressure relief valves of the
second compression stage at the machine outlet.
When the test mode is activated, the third line of the operating mode display (see chapter 4.3) indi‐
cates the following: Test p5 -> pRV .
When the test is properly terminated, the operating mode display must no longer show Test p5 ->
pRV .
For testing the functioning of the pressure relief valve of the first compression stage, you must re‐
move the valve and test it on a suitable test rig. The pressure relief valve of the second compres‐
sion stage may also be tested on a test rig.
Overview
■ Preparing the test
■ Test successful – pressure relief valve opens at preset pressure.
■ Manually abort the test – set pressure is exceeded by more than 10 %.
■ Automatic test abortion – set pressure is exceeded by 2 bar.
■ Correct conclusion of the test
■ Resetting
Blow off protection and air system pressure monitoring are switched off during the test.
WARNING
Danger of injury from pressurised components!
➤ Perform the following actions in the sequence provided.
Preparing the test
1. Note the activating pressure of the pressure relief valve (second compression stage) from the
machine's nameplate.
2. Press the «OFF» key to shut down the machine.
3. Close the user's shut-off valve between the machine and the air distribution network.
4. Log on to SIGMA CONTROL 2 with access level 2 (see chapter 7.2.4).
5. In operating mode, switch to the main menu with the «Enter» key.
6. Select the < Machine test > menu.
The Automatic mode is displayed as being active.
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9 Machine test Menu
Machine operating mode
Automatic Active line
------------------------------
▶1 Test p5 → pRV Submenu, pressure relief valve test
▶2 Test T2 ⇞ always
▶3 Test T3 ⇞ run
11 Testing the pressure relief valve
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