KAESER KOMPRESSOREN SIGMA CONTROL 2 User manual

User Manual
Controller
SIGMA CONTROL 2 SCREW DRY ≥ 3.3.X
No.: 9_9451 04 E
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. [phone] • Fax [phone]
www.kaeser.com

/KKW/SSC 2.11 en IBA-SIGMA CONTROL DRY
/KKW/SSC 2.11
20200703 102433

1 SIGMA CONTROL 2 Quick installation guide
1.1 Operating elements .......................................................................................................... 1
1.2 Display elements .............................................................................................................. 2
1.3 Main menu – Overview ..................................................................................................... 2
1.4 Functions – Overview ....................................................................................................... 3
2 Regarding this document
2.1 Using this document ......................................................................................................... 5
2.2 Copyright .......................................................................................................................... 5
2.2.1 Software .............................................................................................................. 5
2.3 Certification ...................................................................................................................... 6
2.4 Updating the operating manual ........................................................................................ 6
2.5 Symbols and labels .......................................................................................................... 6
2.5.1 Warnings ............................................................................................................. 6
2.5.2 Potential damage warnings ................................................................................ 7
2.5.3 Other alert notes and their symbols .................................................................... 8
3 Technical Specifications
3.1 Controller SIGMA CONTROL 2 ....................................................................................... 9
3.1.1 User interface with display, CPU and interfaces ................................................. 9
3.1.2 Input/output modules .......................................................................................... 11
3.1.3 Sensors ............................................................................................................... 13
4 Safety and Responsibility
4.1 Basic instructions ............................................................................................................. 14
4.2 Specified use .................................................................................................................... 14
4.3 Improper use .................................................................................................................... 14
5 Design and Function
5.1 Controller overview .......................................................................................................... 15
5.2 Operating panel ................................................................................................................ 16
5.2.1 Operating elements ............................................................................................ 16
5.2.2 Display elements ................................................................................................ 17
5.2.3 RFID reader ........................................................................................................ 18
5.3 Display ............................................................................................................................. 19
5.3.1 Operating mode .................................................................................................. 19
5.3.2 Main menu .......................................................................................................... 20
5.3.3 Setting parameters ............................................................................................. 21
5.3.4 Activating keys with check boxes ....................................................................... 21
5.4 Access rights .................................................................................................................... 21
5.5 KAESER CONNECT ........................................................................................................ 22
5.6 Menu overview ................................................................................................................. 23
5.6.1 Operating mode .................................................................................................. 23
5.6.2 Menu structure .................................................................................................... 24
5.7 Additional information ....................................................................................................... 34
5.8 Operating points and control modes ................................................................................ 34
5.8.1 Machine operating points .................................................................................... 34
5.8.2 Control modes .................................................................................................... 35
5.8.3 Variable speed drive with frequency converter (SFC) ........................................ 36
6 Installation and Operating Conditions
6.1 Maintaining ambient conditions ........................................................................................ 37
6.2 Installation conditions ....................................................................................................... 37
7 Installation
7.1 Reporting Transport Damage ........................................................................................... 38
7.2 Machine identification ....................................................................................................... 38
Contents
No.: 9_9451 04 E
User Manual Controller
SIGMA CONTROL 2 SCREW DRY ≥ 3.3.X i

8 Initial Start-up
8.1 Outline .............................................................................................................................. 39
8.2 Setting the controller ........................................................................................................ 39
8.2.1 Selecting menu options ...................................................................................... 40
8.2.2 Setting the language ........................................................................................... 42
8.2.3 Noting the user name ......................................................................................... 43
8.2.4 User log-in with RFID Equipment Card ............................................................... 43
8.2.5 Generating a password ....................................................................................... 44
8.2.6 Manual user log-in .............................................................................................. 45
8.2.7 Create the master RFID Equipment Card ........................................................... 46
8.2.8 Checking/setting time and date .......................................................................... 47
8.2.9 Set the time zone ................................................................................................ 49
8.2.10 Set display formats ............................................................................................. 49
8.2.11 Setting the display illumination ........................................................................... 52
8.2.12 Setting the contrast and the brightness .............................................................. 53
8.2.13 Activating the remote control .............................................................................. 53
8.2.14 IP configuration .................................................................................................. 54
8.2.15 Setting the e-mail function .................................................................................. 55
8.2.16 Setting the time server ........................................................................................ 57
8.3 KAESER CONNECT benefits .......................................................................................... 58
8.3.1 Open KAESER CONNECT ................................................................................. 59
8.3.2 System status menu ........................................................................................... 60
8.3.3 Graphs menu ...................................................................................................... 62
8.3.4 Messages menu ................................................................................................. 64
8.3.5 I/O display menu ................................................................................................. 64
8.3.6 User management menu .................................................................................... 65
8.3.7 Settings menu ..................................................................................................... 68
8.3.8 Save data menu .................................................................................................. 69
8.3.9 Data recording menu .......................................................................................... 69
8.3.10 KAESER CONNECT exit .................................................................................... 70
8.4 Pressure parameters of the machine ............................................................................... 71
8.4.1 Displaying pressure parameters ......................................................................... 72
8.4.2 Setting pressure parameters .............................................................................. 73
8.5 Machine start and machine stop ...................................................................................... 78
8.5.1 Automatic start/stop in timer mode .................................................................... 78
8.5.2 Setting the company shut-down ......................................................................... 82
8.5.3 Controlling machine from a remote location ....................................................... 83
8.6 Control modes .................................................................................................................. 85
8.6.1 Setting the control mode ..................................................................................... 85
8.6.2 Setting the DUAL control mode .......................................................................... 86
8.6.3 Setting the QUADRO control mode .................................................................... 87
8.7 Refrigeration dryer ........................................................................................................... 88
8.7.1 Setting the operating mode ................................................................................. 88
8.7.2 Setting and activating messages ........................................................................ 89
8.8 Rotation dryer ................................................................................................................... 90
8.8.1 Fault message for pressure dew point ................................................................ 90
8.8.2 Setting additional parameters in the Pressure dew point menu ......................... 92
8.8.3 Setting the parameter for an additional fan ........................................................ 93
8.9 Setting the machine for local mode .................................................................................. 94
8.9.1 Menu Load control .............................................................................................. 94
8.9.2 Setting the nominal pressure change via timing program .................................. 94
8.9.3 Setting the nominal pressure change via timer ................................................... 97
8.10 Setting the machine for master control operation ............................................................ 100
8.10.1 Overview of the different master operating modes ............................................. 100
Contents
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SIGMA CONTROL 2 SCREW DRY ≥ 3.3.X No.: 9_9451 04 E

8.10.2 SAM 4.0 mode .................................................................................................... 100
8.10.3 Setting PROFIBUS operation (SIGMA AIR MANAGER) .................................... 103
8.10.4 Interconnection of two machines in master/slave operation ............................... 111
8.10.5 Configuring interconnected operation using the LOAD remote contact (e.g.
SIGMA AIR MANAGER BASIC) .........................................................................
118
8.10.6 Setting the master control with local/LOAD remote contact ............................... 120
8.10.7 Setting the nominal pressure pre-selection via remote contact .......................... 122
8.10.8 Examples of time settings for equal overall load ............................................... 123
8.11 Setting input and output signals ....................................................................................... 125
8.11.1 Output operational states of machine on digital outputs ..................................... 125
8.11.2 Output input signals on the display ..................................................................... 127
8.11.3 Output measured values on the display ............................................................. 131
8.12 Activating remote acknowledgement ............................................................................... 136
8.12.1 Setting the remote acknowledgement function ................................................... 137
8.12.2 Activating the remote control .............................................................................. 137
8.12.3 Assigning an input .............................................................................................. 138
8.13 Linking to an external pressure transducer ...................................................................... 138
8.13.1 Network actual pressure menu ........................................................................... 139
8.13.2 Assigning an input to an external pressure transducer ...................................... 139
8.14 Water system ................................................................................................................... 140
8.15 Commissioning the machine ............................................................................................ 141
9 Operation
9.1 Switching the machine on and off .................................................................................... 143
9.1.1 Switching on ....................................................................................................... 143
9.1.2 Switching off ....................................................................................................... 144
9.2 Switching off in an emergency ......................................................................................... 144
9.3 Acknowledging alarm and warning messages ................................................................. 145
9.4 Displaying messages ....................................................................................................... 146
9.4.1 Status – Messages menu ................................................................................... 147
9.5 Displaying the current operating mode ............................................................................ 149
9.6 Setting the working pressure ............................................................................................ 150
9.7 Displaying analogue data ................................................................................................. 150
9.8 Displaying operating data ................................................................................................. 152
9.8.1 Checking the operating hours ............................................................................. 152
9.8.2 Controlling the switching cycles .......................................................................... 154
9.9 Setting the maintenance interval ...................................................................................... 155
9.10 Checking the safety valve ................................................................................................ 156
9.11 Excessive temperature shut-down test ............................................................................ 162
9.12 Setting the target value for the compressed air discharge temperature .......................... 166
9.12.1 Setting the profile ................................................................................................ 166
9.12.2 Setting the T4w setpoint ..................................................................................... 167
9.12.3 Setting the operating mode ................................................................................. 168
9.13 Setting the setpoint for the pressure dew point ................................................................ 169
9.13.1 Setting the profile ................................................................................................ 169
9.13.2 Setting the M85w setpoint .................................................................................. 170
9.13.3 Setting the operating mode ................................................................................. 171
9.14 Adjusting the pressure dew point ..................................................................................... 171
9.14.1 Setting the profile ................................................................................................ 172
9.14.2 Setting "f" parameters ......................................................................................... 172
9.14.3 Setting the operating mode ................................................................................. 173
9.15 Save data ......................................................................................................................... 174
10 Fault Recognition and Rectification
10.1 Basic instructions ............................................................................................................. 177
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10.2 Interpreting alarm messages ............................................................................................ 177
10.3 Interpreting warning messages ........................................................................................ 191
10.4 Interpreting operating messages ...................................................................................... 203
10.5 Interpreting diagnostic messages .................................................................................... 208
10.6 Interpreting system messages ......................................................................................... 208
11 Maintenance
11.1 Changing the battery ........................................................................................................ 209
12 Spares, Operating Materials, Service
12.1 Note the nameplate .......................................................................................................... 210
12.2 KAESER AIR SERVICE ................................................................................................... 210
12.3 Service Addresses ........................................................................................................... 210
12.4 Displaying the version number, machine model, material number and serial number ..... 210
13 Decommissioning, Storage and Transport
13.1 De-commissioning ............................................................................................................ 212
13.2 Packing ............................................................................................................................ 212
13.3 Storage ............................................................................................................................. 212
13.4 Transporting ..................................................................................................................... 212
13.5 Battery removal and disposal ........................................................................................... 212
Contents
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SIGMA CONTROL 2 SCREW DRY ≥ 3.3.X No.: 9_9451 04 E

Fig. 1 Operating elements .................................................................................................................... 1
Fig. 2 Display elements ........................................................................................................................ 2
Fig. 3 MCS interfaces ........................................................................................................................... 10
Fig. 4 MCS system design with IOM .................................................................................................... 15
Fig. 5 Operating elements .................................................................................................................... 16
Fig. 6 Display elements ........................................................................................................................ 17
Fig. 7 RFID reader ................................................................................................................................ 18
Fig. 8 KAESER CONNECT for SIGMA CONTROL 2 ........................................................................... 22
Fig. 9 Back of the RFID Equipment Card ............................................................................................. 43
Fig. 10 User log-in with RFID Equipment Card ...................................................................................... 43
Fig. 11 User log-in with RFID Equipment Card ...................................................................................... 44
Fig. 12 Manual user log-on ..................................................................................................................... 46
Fig. 13 Log-in mask ................................................................................................................................ 59
Fig. 14 KAESER CONNECT for SIGMA CONTROL 2 ........................................................................... 60
Fig. 15 Select language: window ............................................................................................................ 60
Fig. 16 System status menu ................................................................................................................... 61
Fig. 17 Main menu .................................................................................................................................. 61
Fig. 18 Graphs (illustration similar) ......................................................................................................... 62
Fig. 19 Control keys ............................................................................................................................... 63
Fig. 20 Messages (illustration similar) .................................................................................................... 64
Fig. 21 I/O display (illustration similar) ................................................................................................... 65
Fig. 22 User management menu ............................................................................................................ 66
Fig. 23 Log on for write access: window ................................................................................................ 66
Fig. 24 User management menu ............................................................................................................ 67
Fig. 25 Settings menu ............................................................................................................................ 68
Fig. 26 Backup menu ............................................................................................................................. 69
Fig. 27 Data recording menu .................................................................................................................. 70
Fig. 28 Pressure rise in frequency-controlled machines ........................................................................ 76
Fig. 29 Wiring of the Profibus connection ............................................................................................... 104
Fig. 30 Electrical diagram example with SIGMA AIR MANAGER .......................................................... 105
Fig. 31 Communication interface ............................................................................................................ 106
Fig. 32 Insert the communication module. ............................................................................................. 107
Fig. 33 Front plate communication module Profibus .............................................................................. 108
Fig. 34 Direct connection of two SIGMA CONTROL 2 ........................................................................... 113
Fig. 35 LOAD remote contact ................................................................................................................. 118
Fig. 36 Switching the compressed air station on and off ........................................................................ 143
Fig. 37 Switching off in an emergency ................................................................................................... 144
Fig. 38 Acknowledging messages .......................................................................................................... 145
List of Illustrations
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List of Illustrations
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User Manual Controller
SIGMA CONTROL 2 SCREW DRY ≥ 3.3.X No.: 9_9451 04 E

Tab. 1 Operating elements .................................................................................................................... 1
Tab. 2 Display elements ........................................................................................................................ 2
Tab. 3 Main menu – Overview ............................................................................................................... 2
Tab. 4 Functions – Overview ................................................................................................................. 3
Tab. 5 Danger levels and their definition (personal injury) .................................................................... 7
Tab. 6 Danger levels and their definition (damage to property) ............................................................ 7
Tab. 7 Formatting options ...................................................................................................................... 8
Tab. 8 User interface ............................................................................................................................. 9
Tab. 9 Display data ................................................................................................................................ 9
Tab. 10 MCS interfaces ........................................................................................................................... 10
Tab. 11 RFID ........................................................................................................................................... 10
Tab. 12 SC2IOM-1 .................................................................................................................................. 11
Tab. 13 SC2IOM-2 .................................................................................................................................. 11
Tab. 14 SC2IOM-3 .................................................................................................................................. 12
Tab. 15 Power supply specifications ....................................................................................................... 12
Tab. 16 Cable lengths ............................................................................................................................. 12
Tab. 17 Degree of protection, IOM .......................................................................................................... 12
Tab. 18 IOM dimensions ......................................................................................................................... 13
Tab. 19 Pressure transducer ................................................................................................................... 13
Tab. 20 Resistance thermometer ............................................................................................................ 13
Tab. 21 Operating elements .................................................................................................................... 16
Tab. 22 Display elements ........................................................................................................................ 17
Tab. 23 RFID reader ................................................................................................................................ 18
Tab. 24 Data in the header depending on the machine type ................................................................... 19
Tab. 25 Reset check box status .............................................................................................................. 21
Tab. 26 Check box status ........................................................................................................................ 21
Tab. 27 KAESER CONNECT functions ................................................................................................... 22
Tab. 28 Menu structure of main menu ..................................................................................................... 24
Tab. 29 Status menu ............................................................................................................................... 28
Tab. 30 Configuration menu .................................................................................................................... 29
Tab. 31 I/O periphery menu ..................................................................................................................... 31
Tab. 32 Communication menu ................................................................................................................ 32
Tab. 33 Components menu ..................................................................................................................... 33
Tab. 34 Compressor information depending on the type ........................................................................ 34
Tab. 35 Option-dependent information .................................................................................................... 34
Tab. 36 Machine identification ................................................................................................................. 38
Tab. 37 Remote control identification ...................................................................................................... 38
Tab. 38 Machine identification ................................................................................................................. 38
Tab. 39 Supported languages ................................................................................................................. 42
Tab. 40 Date formats ............................................................................................................................... 49
Tab. 41 Possible settings for the time format .......................................................................................... 50
Tab. 42 Possible settings for the pressure unit ....................................................................................... 51
Tab. 43 Possible settings for the temperature unit .................................................................................. 51
Tab. 44 Display illumination ..................................................................................................................... 52
Tab. 45 Network parameters ................................................................................................................... 55
Tab. 46 E-mail parameters ...................................................................................................................... 56
Tab. 47 Control key functions .................................................................................................................. 63
Tab. 48 Compressor pressure parameters .............................................................................................. 71
Tab. 49 Setting limits for Setpoint pressure ............................................................................................. 73
Tab. 50 Pressure condition for LOAD ...................................................................................................... 73
Tab. 51 Pressure conditions for IDLE ...................................................................................................... 73
Tab. 52 Setting limits for Setpoint pressure ............................................................................................. 74
Tab. 53 Pressure condition for LOAD ...................................................................................................... 74
Tab. 54 Pressure conditions for IDLE ...................................................................................................... 74
List of Tables
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Tab. 55 Displaying and setting parameters ............................................................................................. 75
Tab. 56 Example: activated output .......................................................................................................... 76
Tab. 57 Settings for machine start and machine stop ............................................................................. 78
Tab. 58 User-defined clock programme machine ON/OFF ..................................................................... 79
Tab. 59 Example of a machine ON/OFF clock program .......................................................................... 80
Tab. 60 Operating modes in local operating mode (local mode) ............................................................. 94
Tab. 61 User-defined timing program for nominal pressure change ....................................................... 95
Tab. 62 Example: Switching points, nominal pressure change ............................................................... 95
Tab. 63 Master control – overview ........................................................................................................... 100
Tab. 64 Parameters for monitoring for communication malfunction ........................................................ 103
Tab. 65 Pin assignment of SUB-D 9-pole interface on the Profibus module ........................................... 104
Tab. 66 Master-slave settings ................................................................................................................. 112
Tab. 67 Example for a clock program for equal duty cycling during the day ........................................... 124
Tab. 68 Example for a timing program for equal duty cycling during the week ....................................... 124
Tab. 69 Assigned output signals ............................................................................................................. 125
Tab. 70 Logic settings ............................................................................................................................. 129
Tab. 71 Assigned analogue measured values ........................................................................................ 131
Tab. 72 Transmitting a pressure transducer value .................................................................................. 138
Tab. 73 Control valves and water pump operating modes ...................................................................... 140
Tab. 74 Check list for starting the machine ............................................................................................. 141
Tab. 75 Message sequence 1 ................................................................................................................. 145
Tab. 76 Message sequence 2 ................................................................................................................. 145
Tab. 77 Information of a message ........................................................................................................... 146
Tab. 78 Message abbreviations .............................................................................................................. 147
Tab. 79 Operating mode display ............................................................................................................. 149
Tab. 80 Abbreviation of operating modes ................................................................................................ 149
Tab. 81 Check box status ........................................................................................................................ 160
Tab. 82 Check box status ........................................................................................................................ 165
Tab. 83 Option description and setting .................................................................................................... 166
Tab. 84 Option description and setting .................................................................................................... 169
Tab. 85 Option description and setting .................................................................................................... 172
Tab. 86 Alarm messages and remedies .................................................................................................. 177
Tab. 87 Warning messages and remedies .............................................................................................. 191
Tab. 88 Operating messages .................................................................................................................. 203
Tab. 89 System messages and remedies ............................................................................................... 208
List of Tables
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