SERVICE MANUAL E

SIGMA CONTROL
Index: BUB 72.00
GL---No.: 7_7000_0 ---00 07

Publisher:

KAESER KOMPRESSOREN GmbH

96410 Coburg PO Box 2143 GERMANY Tel. + 49 ---(0)9561 ---6400 Fax + 49 ---(0)9561 ---640130
http://www.kaeser.com
 Table of Contents
Chapter --- Page

1 Technical specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.2 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.3 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.3.1 Interface pin connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.3.1.1 RS 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.3.1.2 RS 485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.3.1.3 Profibus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.4 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 3

2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5

2.1 Explanation of Symbols and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5
2.2 Safety Regulations for the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 5

3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 7
3.1 Short Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 7

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.1 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.2 The SIGMA CONTROL System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.3 EMERGENCY STOP Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.3.1 Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 10
4.3.2 Key functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.3.3 Light emitting diodes and plain text display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 12
4.3.4 LED functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 13
4.3.4.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 14
4.4 Switching the Compressor Package On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.4.1 Switching on locally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.4.2 Switching off locally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.4.3 Switching on and off in remote . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.4.4 Switching on and off with the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.5 Resetting Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 16
4.6 Acknowledgement of Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 16
4.7 Alarm and Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17
4.8 Frequently Programmed Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 27
4.8.1 Procedure for initial startup (Standard Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 27
4.8.2 Procedure for initial startup (Expert Mode) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 30
4.8.3 Correcting the package pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 39
4.8.4 Carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 41
4.8.5 The compressor package is to be operated with a base load sequencer . . . . . 4 --- 43
4.8.5.1 MAC 41 as an example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 43
4.8.5.2 MVS 8000 as an example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 47
4.8.5.3 VESIS/SAM as an example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 53
4.8.6 Two rotary screw compressors in sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 62
4.8.6.1 Base load sequencing of two compressor packages with Sigma Control
via the RS 485 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 62

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4.8.6.1.1 Settings on both SIGMA CONTROLs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 65

4.8.6.1.2 Settings on the master SIGMA CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 66
4.8.6.1.3 Settings on the slave Sigma Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 68
4.8.6.1.4 Settings on both SIGMA CONTROLs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 71
4.8.6.2 Sequencing SIGMA and pressure switch controlled compressors . . . . . . . . . . . 4 --- 72

5 SIGMA CONTROL Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 77

5.1 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 77
5.2 Password Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 79
5.3 Display and Setup Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 80
5.4 Display Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 80

6 Display Level in SIGMA Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 84

6.1 Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 84
6.1.1 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 85
6.1.2 Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 86
6.1.3 Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 88
6.1.3.1 Printer clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 89
6.2 Analog data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 90
6.3 Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 92
6.4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 94
6.4.1 Setting/resetting the maintenance interval counter . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 96

7 Display and Setup Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 98

7.1 Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 98
7.1.1 Enter password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 99
7.1.2 View password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 101
7.2 Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 102
7.2.1 Display and set up of the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 103
7.3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 108
7.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 109
7.3.2 Pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 112
7.3.2.1 Compressor configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 112
7.3.2.2 System pressure of the vacuum package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 114
7.3.2.3 Load control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 115
7.3.3 Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 117
7.3.3.1 DUAL Control settings (normal control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 118
7.3.3.2 QUADRO control settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 118
7.3.3.3 Venting period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 118
7.3.3.4 Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 119
7.3.3.5 Modulating control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 119
7.3.4 Compressor start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 119
7.3.5 Acknowledgement (reset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 122
7.3.6 I/O periphery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 122
7.3.6.1 Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 127
7.4 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 128

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7.4.1 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 129

7.4.1.1 Power switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 129
7.4.2 Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 130
7.4.3 Air main charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 130
7.4.4 Package discharge temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 131
7.5 Package Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 132
7.5.1 Compressor test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 133
7.5.2 TÜV check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 133
7.5.2.1 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 133
7.5.2.2 Temperature sensor / shutdown temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 134
7.5.3 Binary input/output check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 134
7.5.4 Lamps test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 135
7.6 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 136
7.6.1 RS 232 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 137
7.6.2 RS 485 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 138
7.6.3 L2DP bus (Profibus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 139
7.6.4 Short message (SMS) option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 140
7.6.5 Saving settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 142
7.7 Languages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 143
7.7.1 Setting the language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 143

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 Technical Specification

1 Technical specification

1.1 Power Supply

Power supply for SIGMA CONTROL
Rated voltage . . . . . . . . . . . . . . . . . . . . . . . . . 24 V DC (stabilized)
Consumption . . . . . . . . . . . . . . . . . . . . 1.3 A (standard controller)
Consumption . . . . . . . . . . . . . . . . . . 2.5 A (with expander board)

Auxiliary voltage for sensors (from the controller)

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 V DC

Note All voltages are generated within the compressor package itself

1.2 Sensors
Pressure transducer:
Output signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20 mA
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . two wire

Resistance thermometer
Sensing resistance . . . . . . . . . . . . . . . . . . PT100 to DIN IEC 751
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . two wire

1.3 Hardware

industrial computer with Intel processor

analog inputs and outputs (0 ---20 mA, 4 ---20 mA and PT100)
230/115 V relay outputs (volt ---free contacts)
electronic 24 V outputs (common negative rail, short circuit and overload proof)
24 V common negative rail digital inputs
internal undervoltage monitoring of 24 V supply
internal temperature monitoring
3 serial interfaces:
RS 232 (modem)
RS 485 (master ---slave control)
Profibus DP
buffered real---time clock
buffer battery for RAM and real---time clock
permissible operating temperature range: ---20 ˚ C ... + 60 ˚ C

1 --- 1
 Technical Specification

1.3.1 Interface pin connections

1.3.1.1 RS 232
Connections

Pin 1 spare
Pin 2 receive data RxD
Pin 3 receive data RxD
Pin 4 reserved
Pin 5 ground
Pin 6 spare
Pin 7 request to send RTS
Pin 8 clear to send CTS
Pin 9 spare

Connect shielding to both plug housings

1.3.1.2 RS 485
Connections

Pin 1 terminating resistor RA (integrated in SIGMA CONTROL)

Pin 2 reserved
Pin 3 difference signal B
Pin 4 reserved
Pin 5 reserved
Pin 6 reserved
Pin 7 terminating resistor RB (integrated in SIGMA CONTROL)
Pin 8 difference signal A
Pin 9 reserved

Connect shielding to both plug housings

1.3.1.3 Profibus
Connections

Pin 1 spare
Pin 2 spare
Pin 3 Profibus connection B
Pin 4 TTL signal RTS
Pin 5 ground
Pin 6 + 5V for interface P5
Pin 7 spare
Pin 8 Profibus connection A
Pin 9 spare

Connect shielding to both plug housings

1 --- 2
 Technical Specification

1.4 Software
real---time operating system
soft PLC
visualization software
user software

1 --- 3
 Safety

1 --- 4
 Safety

2 Safety Regulations

2.1 Explanation of Symbols and Instructions

This symbol is placed before all instructions regarding safety where danger
to life and limb can occur during work. It is very important that these instruc-
tions are observed and that extreme care is taken. For their own protection,
all other users should be informed of these safety instructions. General
safety and accident prevention regulations must be observed as well as the
safety instructions laid down in this service manual.

Attention! This symbol is placed at text to which considerable attention must be paid to
ensure that recommendations, instructions, references and the correct se-
quence of work are complied with and that damage to or destruction of the
controller or other equipment is prevented.

Note This symbol identifies important product information, handling of the prod-
uct or the corresponding section of the documentation to which
special attention must be paid.

This symbol identifies operations and actions to be carried out by the oper-
ator or service technician.

This bullet identifies listings.

2.2 Safety Regulations for the Controller

Do not pull out or push in components (plugs) on the controller when the compressor pack-

age is running. This can cause damage to the controller.

Do not run the compressor package with supplies removed from the controller as irreversible

damage could occur (e.g. feed to the digital outputs with no power supply connected).
Do not apply other voltages to the electronic outputs on the output plug pins (i.e. external

feed via wire jumpers, etc.).

A short circuit at the power supply pins of the Profibus interface can cause irreversible dam-

age to the interface.

2 --- 5
 General

2 --- 6
 General

3 General

3.1 Short Description

The electronic controller Sigma Control comprises an industrial computer with an Intel pro-
cessor, a user interface with a background illuminated plain text display, keys, some with
integrated LEDs and digital and analog inputs and outputs. Power to the controller is provided by
a stabilised 24 V DC power supply unit.
The controller is provided with a clear, easily understood user interface that allows call---up of in-
formation or entry of settings:
LEDs indicate the most important operational states.

various functions can be keyed.

the plain text display provides the user with information on current events in the selected lan-

guage
an event information memory records the last 100 events with date and time, e.g. alarm, ser-

vice and operational messages.

Sigma Control controls, regulates, protects and monitors the compressor package.
The control function provides:
automatic changeover from load to idle or standstill ensuring optimum utilisation of the drive

motor according to the user’s actual air demand.

automatic start after a power supply failure.

Sigma Control’s protective function ensures:

automatic shutdown of the compressor package if overcurrent, overpressure, overtempera-

ture, etc. occurs, that is, if a fault occurs that can cause damage to the compressor
package.
Sigma Control’s monitoring function ensures:
punctual maintenance prompts for oil filter, air filter, V---belts, motor bearings, electrical com-

ponents and other internal components. All these functions are monitored by service hour
counters and maintenance due is displayed as warning or service messages in the plain text
display.
All important data can be transferred via the Profibus using integrated interface software.
All parameters needed to operate KAESER rotary screw compressors and vacuum packages are
contained in Sigma Control. They are set up at the factory according to compressor model.
These parameters can be displayed or changed with the help of various menus or sub ---menus in
the software (see also chapter 5).
Parameter settings and changes are entered in the Display and Setup level of the software after
input of a password. The type of drive, pressure control mode (DUAL, QUADRO or VARIO), the
model and basic model status, for example, can be entered at this level.

3 --- 7
 Operation

3 --- 8
 Operation

4 Operation

4.1 Control Panel

1 SIGMA controller
2 Emergency Stop pushbutton

4.2 The SIGMA CONTROL System

The SIGMA CONTROL unit (1) is fitted in the control cabinet. It is used for both control and oper-
ation. The panel has 11 keys and 9 LEDs. The operation of the package is determined by default
values programmed in the controller.

4.3 EMERGENCY STOP Pushbutton

The EMERGENCY STOP button shuts down the compressor package immediately.
If the EMERGENCY STOP button is pressed because of an existing hazard or alarm, then this
must be eliminated before the package is reset. To accomplish this, carry out the following pro-
cedure:
Turn the EMERGENCY STOP button in the direction of the arrow to unlatch it.
Press the acknowledge (reset) key on SIGMA Control to acknowledge the alarm. (See
chapter 4.3.1 for function keys).

4 --- 9
 Operation

4.3.1 Function keys

7
11 8
10 9
6
1

5 2

4 3
1 ON key (”I”) 7 Arrow key ( ) (menu up)
2 OFF key (”0”) 8 Escape key
3 Clock key 9 Return key ( )

4 Remote key 10 Info --- event key

5 Load/unload changeover key 11 Reset key
6 Arrow key ( ) (menu down)


4 --- 10
 Operation

4.3.2 Key functions

Symbol Item Name Function

1 ON key The compressor is switched on and runs in the pres-
elected operating mode:
local control --- remote control (control centre) --- clock
control
2 OFF key (“0”) The compressor is switched off irrespective of operating
mode.

3 Clock ON/OFF key Pressing the key causes the compressor to be switched
on and off by the integrated clock.
The LED illuminates in clock mode.
4 Remote ON key Pressing the key switches between local and remote con-
trol of the compressor package.
The LED illuminates in remote mode.
5 Load/idle change- Pressing the key switches the compressor into idle mode.
over key Pressing again switches back to the preselected mode.
If the compressor is ready for operation pressing the
idle key causes the compressor drive motor to start.
The compressor then runs continuously in idle (unloaded)
mode.
6 Arrow key Menus are scrolled downwards or a selected parameter is
reduced.

7 Arrow key Menus are scrolled upwards or a selected parameter is

increased.

8 Escape key Pressing the ‘esc’ key:

---causes a return to the next higher menu level
---exits the edit mode without saving edited parameters
If the “esc” key is held down longer than 10 s, the display
jumps back to the main menu.
9 Return key (save) Only affects the message in the third line of the dis-
play (12):
---returns to the selected submenu or
---exits edit mode and saves edited parameters
10 Info --- event key Display of current message:
They can be selected in any menu.
The display jumps back to the last menu position with the
”esc” key (8).
11 Acknowledge (reset) Acknowledges alarm messages and resets the alarm
key memory (if permitted).

4 --- 11
 Operation

4.3.3 Light emitting diodes and plain text display

13
14 12
15

16 19

17
18

20 21
12 Four ---line display 17 Load LED
13 Alarm LED 18 Idle LED
14 Communication alarm LED 19 Compressor ON LED
15 Warning --- maintenance LED 20 Remote ON LED
16 Power ON LED (to controller) 21 Timer ON LED

4 --- 12
 Operation

4.3.4 LED functions

Symbol Item. Description Function



  ˚  12 Display see 4.3.3 Alphanumeric display with 4 lines and green back-
 
 
  
       "! ground illumination

#$   "%"!

13 Alarm LED The red LED flashes if the compressor package is shut
down because of an alarm.
If the alarm is acknowledged with the reset key (11),
the LED lights continuously. It extinguishes when the
fault is removed and the alarm is reset again.
14 Communication The red LED illuminates if communication via the Profi-
alarm LED bus interface is interrupted.
If the communication fault occurs in remote mode, the
compressor package is automatically switched to local
control.
When the reset key (11) is pressed, the LED extinguis-
hes if the alarm is no longer present.
15 Service/warning LED The yellow LED flashes if there is a service message or
when maintenance is due.
If the message is acknowledged with the reset
key (11), the LED illuminates continuously until mainte-
nance is completed and (if necessary) the service inter-
val counter is reset.
16 Power ON LED The green LED lights when power is available.
(The main switch and the control transformer cutout
are switched on)
17 Idle LED The green LED illuminates continuously when the
compressor is running but no compressed air is produ-
ced.
The LED flashes if idle mode is selected with the idle
key (5).
18 Load LED The green LED illuminates when the compressor is
running under load and compressed air is being pro-
duced.
19 Package on LED The compressor package is switched on.
LEDs (17) and (18) must also be taken into considera-
tion to determine the operational status of the
package:
If LED (19) is on --- and both LEDs (17) and (18) are
off, the package is stopped and in standby. It can
start at any moment.
20 Remote control The green LED illuminates when the package is in re-
mode mote control mode.

21 Clock mode ON LED The green LED illuminates when the package is swit-
ched either on or off by the clock.

4 --- 13
 Operation

4.3.4.1 Display
The display (12) used for entry and readout of data is provided with four lines of 16 characters
each.
Example:

 
 ˚ 

 
1
2


3
4

 

  !! ¦ "$# %&˚&  1

('*)   *
,+ 2
-(% .   */012+  3
4

1 Header 3 Active line

2 Compressor status/menu text 4 Menu text

Line 1 --- header

Current system pressure and airend discharge temperature are displayed in the header.

3
These values are always shown

3 in the main menu

in setup levels in which parameter changes can be made even though the compressor is

3 running.
If an ”i” is displayed previous messages can be called up with the info key.
Note If an ”S” or an ”F” is displayed behind the temperature then switch the power
off and on again. The letters indicate an internal controller error. If this is un-
successful, contact Kaeser service department for further instructions.

Line 2
Depending on settings, either the current status of the compressor package or menu text is
shown in line 2.
Line 3 --- active line
Note Actions can only be executed if they are shown in in line 3.

This applies equally to moving to submenus or changing values.

The respective menu text is shown here.
Example:

 

% - & -(4
5 ˚ 
1   + 6 7 8
9(:;<:>=?A@CB 5
4

5 Entry line with ”Enter ( )” D

4 --- 14
 Operation

If it is possible to move to a submenu or if a parameter can be entered the ”Enter ( )” symbol (5)
appears in column 16.
Line 4
The signs , ” ” or ” ” (4) appear in line 4, column 16 after the menu text and indicate the

 

direction in which the lines can be scrolled:

--- lower stop, upwards scroll only


--- upper stop, downwards scroll only



--- scrolling in both directions



4.4 Switching the Compressor Package On and Off

Attention! Do not switch the compressor package on and off with the main switch.
Always switch on with the ON key (1) and off with the OFF key (2). Always
take the permissible motor starting frequency into account when switching
the compressor package on and off.

4.4.1 Switching on locally



Switch on the main switch.

The controller runs a selftest. When the selftest is completed the green “power ON LED (16) il-
luminates permanently.


Press the ON key (1) --- the green “compressor ON” LED (19) illuminates.
LEDs 17 and 18 must be taken into consideration to determine the operational status of the com-
pressor package:

If LED (19) is on --- and both LEDs (17) and (18) are off, the package is
stopped and in standby.

The compressor can start at any moment.

4.4.2 Switching off locally



Press the OFF key (2) --- the “Package ON” LED (19) extinguishes.


Switch off and lock out the main switch.

4.4.3 Switching on and off in remote

Remote control of the compressor package is selected with the “Remote ON” key (4) on the con-
troller.
Choice of control via volt ---free remote contacts ”RC” on a binary input can be made in the “con-
figuration compressor start compressor ON” menu.
 

4.4.4 Switching on and off with the clock

If required, the compressor package can be controlled by the clock. The procedure is the same
as for switching on and off locally except that the “Clock mode ON/OFF-key” (3) must be pressed
additionally.
Afterwards, the periods during which the compressor is to run can be entered in the “clock ---
compressor ON/OFF” menu.
See chapter 7.2 for setting up the clock.

Before carrying out any work, make sure that the package cannot be
switched on by the clock or from the control center.

4 --- 15
 Operation

4.5 Resetting Alarm Messages

If an alarm occurs, the compressor package is shut down automatically and the red LED (13) on
Sigma Control flashes.
The bottom line of the display (12) shows the current alarm.
A list of possible alarms (faults) that could occur during operation of the compressor package is
given in chapter 4.7.
Remove the fault.
Reset the alarm with the reset key (11) --- LED (13) extinguishes.
The compressor package can now be started again.

Attention! If the compressor was shut down with the EMERGENCY STOP pushbutton,
ensure that the pushbutton is enabled by turning in the direction of the arrow
before resetting the alarm.

4.6 Acknowledgement of Warning Messages

When maintenance is due the yellow LED (15) on SIGMA CONTROL flashes.
Maintenance due is shown in the display (12). A list of service messages that can be displayed
during operation is given in chapter 4.7).
Carry out the maintenance.
Acknowledge service message with the reset key (11) --- LED (15) extinguishes.

Note When the maintenance is complete the remaining interval must be reset to
the default service interval.

(see chapter 6.4.1 to reset the service interval counter).

Note Password level 4 is required to reset the service interval counter.

See chapter 7.1.1 to input the password.

4 --- 16
 Operation

4.7 Alarm and Warning Messages

Message2 Type1 Fault Remedy

access doors W Access doors opened with the com- Close the doors.
pressor package stopped
access doors A Access doors opened with the com- Close the doors.
pressor üackage running
ADT W The maximum airend discharge Ensure sufficient ventilation,
temperature (ADT) will soon be re- Ensure that the permissible ambient
ached temperature is maintained,
clean the cooler, cooling air outlet
too near a wall,
check oil level,
renew the oil filter.
ADT
A The maximum airend discharge Ensure sufficient ventilation,
temperature (ADT) exceeded Ensure that the permissible ambient
temperature is maintained,
clean cooler,
cooling air outlet too near a wall,
check oil level,
renew the oil filter.
ADT dT/dt A Airend discharge temperature (ADT) Check airend and piping to airend3,
rise rate exceeded top up the oil,
check oil circulation.
AI 1 open cct A The connection between analog check the transducer, cable and
input 1 and the system pressure transducer connections, have defec-
transducer is open circuit or there is tive transducer changed3
a short to earth
AI 2 open cct A The connection between analog check the transducer, cable and
input 2 and the pressure transducer transducer connections, have defec-
for internal pressure is open circuit tive transducer changed3
or there is a short to earth
AI 3 open cct A The connection between analog check the transducer, cable and
input 3 and the resistance thermom- transducer connections, have defec-
eter for measuring airend discharge tive transducer changed3
temperature is open circuit
AI 4 open cct A The connection between analog check the transducer, cable and
input 4 and the resistance thermom- transducer connections, have defec-
eter for measuring drive motor tem- tive transducer changed3
perature is open circuit
AI 5 open cct A The connection between analog check the transducer, cable and
input 5 and a sensor is open circuit transducer connections, have defec-
or there is a short to earth tive transducer changed3
AI 6 open cct A The connection between analog check the transducer, cable and
input 6 and a sensor is open circuit transducer connections, have defec-
or there is a short to earth tive transducer changed3
1 A alarm
 W warning


2 Symbols: high: / too high: / low: / too low:




3 Contact authorised KAESER service agent

4 --- 17
 Operation

Message2 Type1 Fault Remedy

AI 7 open cct A The connection between analog check the transducer, cable and
input 7 and a sensor is open circuit transducer connections, have defec-
tive transducer changed3
AI 8 open cct A The connection between analog check the transducer, cable and
input 8 and a sensor is open circuit transducer connections, have defec-
tive transducer changed3
air filter dp W Pressure drop across air filter car- Clean/replace the air filter cartridge
tridge high; the air filter is clogged
air filter dp A Pressure drop across air filter car- Clean/replace the air filter cartridge
tridge too high; the air filter is
clogged
air filter h
W The default service interval for Clean the air filter cartridge, see
checking the air filter has expired chapter 6.4.1 to reset the service in-
terval counter
Airend rotation A The motor is turning in the wrong Change phases: swap L1 and L2
direction power connections
Back pressure A Back pressure in the oil separator Check the venting line and the vent-
tank caused by poor venting ing valve,
check the MPCV
bearings h
W The default service interval for the Grease the motor bearings
greasing the motor bearings has ex- (see chapter 6.4.1 to reset the ser-
pired vice interval counter)
blowoff prot. W Warning: The response pressure of Change the oil separator cartridge,
the pressure relief valve will soon be check the minimum pressure/check
exceeded valve (MPCV), control valve and inlet
valve, renew defective valves3, Open
the shut ---off valve in the venting
line,
check the pressure transducer, have
defective transducer changed3
blowoff prot. A The response pressure of the pres- Change the oil separator cartridge,
sure relief valve on the oil separator Check the minimum pressure/check
tank is exceeded valve (MPCV), control valve and inlet
valve, have defective valve
changed3,
open the shut ---off valve in the vent-
ing line,
check the transducer, cable and
transducer connections, have defec-
tive transducer changed3
Buffer battery W The battery in the controller is dis- Contact Kaeser service 3
charged
Bus alarm W The bus link from the Profibus DP Check the bus link and plug, check
interface is interrupted interface configuration (see chapter
7.6.3),
Have the controller replaced3
1 A alarm
 W warning


2 Symbols: high: / too high: / low: / too low:




3 Contact authorised KAESER service agent

4 --- 18
 Operation

Message2 Type1 Fault Remedy

condensatedrain W Condensate drain full or defective Check condensate drainage (clean,
repair)
condensatedrain A Condensate drain full or defective Check condensate drainage (clean,
repair)
coolingwater low A Cooling water pressure too low Check cooling water throttling valve,
No inlet water pressure,
Shut ---off valve missing
elect. equip. h W The default service hours for check- Have electrical components
ing electrical equipment and wiring checked by a trained electrician,
have expired reset the service hours counter, see
chapter 6.4.1
emergency stop A The emergency stop button was Unlatch the pushbutton
pressed
error: RS 485 W Wrong configuration or transmission Check the link/interface connections
error between the two controllers. Check
maximum cable length and screen-
ing,
check all interface parameters, i.e.
both subscribers active,
1 master and 1 slave configured, bi-
trate and character frame (format)
for both subscribers identical
(see also chapter 4.8.6.1)
ext.load signal? W Uncertain external load signal: the The external load control has not
default high cut ---out pressure was switched to idle, even though the
exceeded maximum permissible system pres-
sure has been exceeded
Check settings of the external con-
troller
Take the pressure drops across
filters and dryer into account
Have the deviations between the
pressure transducers checked3.
ext. message 0 W Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
ext. message 0 A Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
ext. message 1 W Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
ext. message 1 A Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
ext. message 2 W Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
ext. message 2 A Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
1 A alarm

W warning

2 Symbols: high: / too high: / low: / too low:




3 Contact authorised KAESER service agent

4 --- 19
 Operation

Message2 Type1 Fault Remedy

ext. message 3 W Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
ext. message 3 A Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
ext. message 4 W Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
ext. message 4 A Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
ext. message 5 W Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
ext. message 5 A Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
fan M2 I A First fan motor shut down because Investigate cause, then reset the
of overload motor overload trip

fan M3 I A Second fan motor shut down be- Investigate cause, then reset the
cause of overload motor overload trip

fan M4 I A Third fan motor shut down because Investigate cause, then reset the
of overload motor overload trip

flash memory W Internal controller memory error Have the controller replaced3
HT cell A Fault in the high tension cell Havr the high tension cell checked3
mains cont. on? A The mains contactor does not pull in The answerback on input 0.6 (24V)
despite an ON command does nor appear after compressor
start,
check auxiliary contact block on
K1M,
Check 230 V supply to the contactor
(door interlock switch, EMERGENCY
STOP)
mains cont. off? A The mains contactor does not drop The answerback from mains contac-
out despite an OFF command tor K1M (0.6) is still present, even
though the compressor is at stand-
still
mains monitor A Fault in mains power supply an optional voltage monitor reported
a fault,
possible drop in voltage
mains voltage
W 1. Power supply failure: The com- Contactor K1M fluttered during drive
pressor will be restarted automati- motor run,
cally check power supply,
possible intermittent contack in a
door interlock switch
Model A Model indistinct Enter model again, inform the
KAESER service agent responsible,
replace controller if fault re---occurs
1 A alarm
 W warning


2 Symbols: high: / too high: / low: / too low:

 


3 Contact authorised KAESER service agent

4 --- 20
 Operation

Message2 Type1 Fault Remedy

modem problem W Sigma Control does not recognise Check the link between Sigma Con-
the modem trol and the modem
motor bearings A Overheating of motor shaft ball Grease the motor bearings with the
bearings greasing device,
bearing damage, have the bearings
replaced3
motor bearings h W The default service interval for re- Have maintenance carried out3,
placement of the motor shaft bear- Have the motor bearings replaced3
ings has expired

motor I A Drive motor shutdown because of Investigate cause,

overload then reset overload trip
motor T
W Drive motor very hot Ensure sufficient ventilation,
Fit cooling air discharge fan,
motor dirty, clean motor
motor T A Drive motor too hot Ensure sufficient ventilation,
(temperature sensed by PTC sensor Fit cooling air discharge fan,
and trip) motor dirty, clean motor
motorstarts /d W Die maximum permissible motor Lengthen idle period
starting frequency per day was ex- Increase capacity of air receiver,
ceeded during the last 24 hours
increase cross---section of piping
between compressor package and
air receiver,
check the pressure transducer, have
defective transducer changed3
motorstarts /h W The maximum permissible motor Lengthen idle period
starting frequency was exceeded Increase capacity of air receiver,
during the last 60 min
increase cross---section of piping
between compressor package and
air receiver,
check the pressure transducer, have
defective transducer changed3
neutral p ---switch W Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
neutral p ---switch A Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
neutral T---switch W Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
neutral T---switch A Message text freely definable with Remove the cause for display of
SIGMA Control message created by the user
1 A alarm
 W warning


2 Symbols: high: / too high: / low: / too low:




3 Contact authorised KAESER service agent

4 --- 21
 Operation

Message2 Type1 Fault Remedy

no press. buildup W The package cannot build up pres- Check the complete compressor
sure after a compressor start package for faults (leaks, ...), check
inlet valve, MPCV, compare indica-
tion of internal pressure in ’analog
data’ menu with the pressure gauge
on the oil separator tank
no press. buildup A The package cannot build up pres- Check the complete compressor
sure package for faults (leaks, ...), check
The setpoint pressure does not rise inlet valve, MPCV, compare indica-
above 3.5 bar for a preset period tion of internal pressure in ’analog
data’ menu with the pressure gauge
on the oil separator tank
oil change h W The default service interval for the oil Carry out an oil change,
change has expired (see chapter 6.4.1 to reset the ser-
vice interval counter)
oil content
W The initial warning value for maxi- Check the air treatment components
mum oil content in the compressed immediately,
air has been exceeded check the scavenge tube in the oil
separator cartridge
check the dirt trap strainer in the
scavenge line,
check the oil separator element,
check the oil sensor, line and con-
nections3
oil content
W The oil content value is exceeded Check the air treatment components
immediately, check the scavenge
tube in the oil separator cartridge,
check the dirt trap strainer in the
scavenge line,
check the oil separator element,
check the oil sensor, line and con-
nections3
oil filter dp
W The oil filter is clogged Change the oil filter
oil filter h W The default service interval for Carry out an oil filter change,
checking the oil filter has expired (see chapter 6.4.1 to reset the ser-
vice interval counter)
oil p  A No changeover to load as long as check oil circulation,
the minimum oil pressure is not re- Check pressure switch, line and
ached connections,
have the defective switch changed3
oil level  W Oil level too low top up the oil
oil T  W No changeover to load as long as check oil circulation,
the minimum oil temperature is not Check temperature switch, line and
reached connections,
have the defective switch changed3
1 A alarm
 W warning 

2 Symbols: high: / too high: / low: / too low:




3 Contact authorised KAESER service agent

4 --- 22
 Operation

Message2 Type1 Fault Remedy

PD-temperature W Warning: Package discharge tem- Have the fan motor checked3,
perature too low check the temperature sensor, regu-
lator3, check the frequency con-
verter3, clean the cooler, top up the
oil
PD-temperature

A Package discharge temperature too Have the fan motor checked3,
low check the temperature sensor, regu-
lator3,
check the frequency converter3,
clean the cooler, top up the oil
PD-temperatur  W Warning: Package discharge tem- Have the fan motor checked3,
perature too high check the temperature sensor, regu-
lator, check the frequency converter,
clean the cooler, top up the oil
PD-temperature  A Package discharge temperature too Have the fan motor checked3,
high have sensor, regulator tested3,
have frequency inverter tested3,
clean cooler,
top up the oil
Power supply

A 2. 2nd power supply failure: Contactor K1M fluttered during drive
The drive motor is shut down motor run,
check power supply,
possible intermittent contack in a
door-interlock switch
pRV 
A The response pressure of the pres- Change the oil separator cartridge,
sure relief valve on the oil separator Check the minimum pressure/check
tank is exceeded valve (MPCV), control valve and inlet
valve, have defective valve
changed3,
open the shut ---off valve in the vent-
ing line,
check the transducer, cable and
transducer connections, have defec-
tive transducer changed3
O 0.6/O 0.7 A The connection between output 0.6 Check consumer load, line and con-
or 0.7 and a consumer load is short nections (e.g. solenoid valve), re-
circuited. place defective consumer load
O 1.6/O 1.7 A The connection between output 1.6 Check consumer load, line and con-
or 1.7 and a consumer load is short nections (e.g. solenoid valve), re-
circuited. place defective consumer load
RAM W Internal RAM defective Check the controller
Have the controller replaced3
RD compr. p  A Pressure switch on the refrigerant Ensure sufficient ventilation, install a
compressor activated (packages discharge fan, clean the refrigerant
with refrigeration dryer only) condenser
1 A alarm
 W warning

2 Symbols: high: / too high: / low: / too low:




3 Contact authorised KAESER service agent

4 --- 23
 Operation

Message2 Type1 Fault Remedy

RD compr. T A The temperature in the refrigeration Ensure sufficient ventilation, install a
dryer is too high (only packages discharge fan, clean the refrigerant
with refrigeration dryer) condenser
RD compr. T
A The temperature in the refrigeration Contact Kaeser service 3
dryer is too low (only packages with
refrigeration dryer)
separator dp  W The oil separator is clogged Change the oil separator element

separator dp  A The oil separator is clogged Change the oil separator element

separator h  W The default service interval for Change the oil separator element
checking the oil separator has ex- (see chapter 6.4.1 to reset the ser-
pired vice interval counter)
separator T  A Air temperature at oil separator dis- Have the trip device at the oil separ-
charge exceeded ator air discharge checked3,
check the sensor and line to the trip
device, replace defective trip device
set output! The ”set output” test function is acti- End the ”set output” mode.
vated
sh.cct AI1 A Short circuit at analog input 1 Check line and connections, check
the transducer measuring system
pressure
sh.cct AI2 A Short circuit at analog input 2 Check line and connections, check
the transducer measuring internal
pressure
sh.cct AI3 A The connection between analog check sensor, line and connection,
input 3 and the resistance thermom- have the defective PT 100 sensor for
eter for measuring airend discharge ADT changed3
temperature is either short circuit or
shorted to earth
sh.cct AI4 A The line between analog input 4 and check sensor, line and connection,
a sensor is short circuited or is have the defective transducer
shorted to earth changed3
sh.cct AI5 A Short circuit at analog input 5 Check line and connections
sh.cct AI6 A Short circuit at analog input 6 check sensor, line and connection,
sh.cct AI7 A The line between analog input 7 and check sensor, line and connection,
a sensor is short circuited or is have the defective transducer
shorted to earth changed3
sh.cct AI8 A The connection between analog check sensor, line and connection,
input 8 and the resistance thermom- have the defective transducer
eter for measuring drive motor tem- changed3
perature is either short circuit or
shorted to earth
1 A alarm
 W warning 

2 Symbols: high: / too high: / low: / too low:







3 Contact authorised KAESER service agent

4 --- 24
 Operation

Message2 Type1 Fault Remedy

Sigma Control T A The temperature in Sigma Control’s Ensure sufficient ventilation, ensure
housing has exceeded 70˚ C that the permissible ambient tem-
perature is maintained

softstart A Fault in the soft start system Have the soft start system checked3
start T
W The airend discharge air tempera- The ambient temperature must be
ture (ADT) is too low too allow the higher than 3 ˚ C, have axiliary heat-
package to be started (resistance ing fitted3
thermometer temperature measure-
ment)
start T  A The airend discharge air tempera- The ambient temperature must be
ture (ADT) is too low too allow the higher than 3 ˚ C, have axiliary heat-
package to be started (resistance ing fitted3
thermometer temperature measure-
ment)
start T

W The airend discharge air tempera- The ambient temperature must be
ture (ADT) is too low too allow the higher than ---9˚ C, have axiliary
package to be started (resistance heating fitted3
thermometer temperature measure-
ment)
system press.
W The system pressure has fallen Air consumption too high, check air
below the ”syspress. low” value be- consumers,
cause of leaks, pipe fracture, etc. check pressure transducer, line and
connection,
check the ”syspress. low” warning
setting in the configuration/pressure
settings menu,
have the defective transducer
changed3
system press.
W The system pressure has risen Check vacuum package for leaks,
(vacuum packages above the ”syspress. high” value check the ”syspress. high” warning
only) because of leaks, pipe fracture, etc. setting in the configuration/pressure
settings menu,
check whether the package switches
to load (inlet valve)
V---belts broken A The V---belts have parted during ma- Fit new set of V---belts
chine operation
V---belt tension W The V---belt tension is too low Tension the V---belts

V---belt tens. h W The default service interval in Tension the V---belts, change the
SIGMA CONTROL for checking V--- belts if necessary,
belt tension has expired (see chapter 6.4.1 to reset the ser-
vice interval counter)
1 A alarm W warning
2 Symbols: high:  / too high: / low:  / too low: 
3 Contact authorised KAESER service agent

4 --- 25
 Operation

Message2 Type1 Fault Remedy

VFD A The variable frequency drive system see service manual for the drive sys-
(VFD) for the drive motor is defective tem
VFD-mains W Failure of power supply to com- Check power supply (electrician)
pressor variable frequency drive
system
1 A alarm W warning 

2 Symbols: high: / too high: / low: / too low:

3 Contact authorised KAESER service agent

4 --- 26
 Operation

4.8 Frequently Programmed Functions

In this chapter, information on frequently programmed functions is given with the help of flow dia-
grams and examples.
Initial Startup
Initial startup in clock mode
Correcting the package pressure
Carrying out maintenance
Base load changeover with MAC 41
Base load changeover with MVS 8000
Base load changeover with VESIS / SAM
Base load changeover between two compressor packages with Sigma Control
Base load changeover with a compressor package controlled by a pressure switch

4.8.1 Procedure for initial startup (Standard Mode)

When power is applied to the compressor the controller starts to boot. Both the display and the
green ‘Power ON’ LED illuminate.
The current system pressure and the airend discharge temperature are then displayed in the first
line. The compressor package can now be started with the ON key.

Start

Main menu: Select

language selec- language
tion

Activate
Main menu: password level 4
password see chapter 7.1.1

Check date and time,

Menu:
Summer/winter ---time changeover
configuration
Check formats
general
Check units

End
Start the compressor
package

4 --- 27
 Operation


Setting the language

Press and hold the arrow up key ( ) until the language setting appears in the third line of the
display.

 
  ˚ 
     
2
              
1 Current system pressure and airend discharge temperature
2 Display of selected language

 Press the return key ( ).

 Select the required language with the arrow keys ( !#" ).
 Confirm with the return key ( ) .

$
Return to the main menu with the “esc” key.
Enter password
 %
Press the arrow key ( ) until password appears in the third line of the display.
 Press the return key ( ) and the following is displayed:

& '( )* +
 ,- ˚ .
/ *0 021435+7698
: : : : :<; - =
> > > > ><?@ A

B C
By pressing the return key ( ) a flashing cursor appears below the first “X” of the password
(XXXXX).
B Change the first character with the arrow keys ( DFE ). Keep pressing the arrow keys until the
first ”X” is replaced by the character required.
B C
Press the return key ( ), the cursor now jumps to the next character in the password.
B Select the next character with the arrow keys ( DFE ).
G HI JK L
 M @ ˚N
O KP P2Q4R5L7S9T
UV > > ><?@ =
> > > > ><?@ A

B C
Press the return key ( ), the cursor now jumps to the next character in the password.

4 --- 28
 Operation

Using this method, enter the remaining characters of the password for level 4 (12EXP). When the
last character of the password is entered with the return key ( ), the activated password level is
displayed.

 
 
 

 "! #
 "! $

%
&
Exit the password menu by pressing the escape (esc) key.
Checking settings
(main menu ' configuration ' general)
% Press and hold the arrow keys ( (*) ) until “general” appears in the third line of the display.
% Press the return key ( ). +
The following display appears:

, -./ 01
 23 ˚ 4
5"6789;: < = =
,=
2 >@?BA ,-,33 -C3 D

1 Current system pressure and airend discharge temperature

2 Display of selected model
% )
&
Press the arrow key ( ), and the following details will be displayed sequentially:

&
Version details:

&
Model:

&
PN: (part number)
SN: (serial number)
% )
+
Press the arrow key ( ), the following parameters will be displayed sequentially and can be

&
set by pressing the return key ( ) (see chapter 7.3.1):

&
weekday

&
date

&
time

&
summer/winter time

&
date format

&
time format

&
unit of pressure
unit of temperature

4 --- 29
 Operation

4.8.2 Procedure for initial startup (Expert Mode)

Note Use this chapter only after reading the complete service manual in
detail

When power is applied to the compressor the controller starts to boot. Both the display and the
green ‘Power ON’ LED illuminate.
The current system pressure and the airend discharge temperature are then displayed in the first
line. The compressor package can now be started with the ON key.
If personnel are to be given instruction, parameters changed or the settings checked, then the
following procedure is recommended:

4 --- 30
 Operation

Start

Main Select
menu: language

see chapter 7.1.1

Menu: to activate
password password level 4

Menu:
Check date and time,
general
determine format
configuration

Menu:
Configuration Adapt system
pressure pressure p1
settings
Compressor
Setpoint
pressure

Menu:
Configurati Set control mode
on Control
mode

4 --- 31
 Operation

Comp on/off
from clock no

yes

Menu:
Program clock
Clock activate clock
Switch points key
01---10

Press clock key

Menu: Set the

Configuration
I/O periphery volt ---free
contacts

End

4 --- 32
 Operation


Setting the language

Press and hold the arrow up key ( ) until the language setting appears in the third line of the
display.

 
  ˚ 
     
2
              
1 Current system pressure and airend discharge temperature
2 Display of selected language

 Press the return key ( ).

 Select the required language with the arrow keys ( !#" ).
 Confirm with the return key ( ) .

$
Return to the main menu with the “esc” key.
Enter password

$
See chapter 7.1.1 for entry of the password.
Checking settings
(main menu % configuration % general)
 Press and hold the arrow keys ( !'& ) until “general” appears in the third line of the display.
 Press the return key ( ).
The following display appears:

( )* +, -
 ./ ˚ 0
132 465798: ; ;
(;
2 <=?> ()(/ / )@/ A

1 Current system pressure and airend discharge temperature

2 Display of selected model
B C
D
Press the arrow key ( ), and the following details will be displayed sequentially:

D
Version details:

D
Model:

D
PN: (part number)
SN: (serial number)

4 --- 33
 Operation


Press the arrow key ( ), the following parameters will be displayed sequentially and can be


set by pressing the return key ( ) (see chapter 7.3.1):


weekday


date


time


summer/winter time


date format


time format


unit of pressure


unit of temperature
Adjusting system pressure
(main menu  configuration  compressor)

In the main menu, press and hold the arrow key ( ) until “configuration” appears in the third
line of the display.
Press the return key ( ). 
The following display appears:


   ˚ 
    

     !!"#%$
&'!  '  ( ') *

+ ,
Press the return key ( ) when the pressure settings appear in the third line of the display;

+
“compressor” now appears in the third line.
,
+
Press the return key ( ) to display system pressure in the third line of the display.
,
Press the return key ( ) again and the following display appears.

- .
/1023 45 ˚ 6

789;:=<>#?9 : 3 877@ 3 8
:BA CD1E -.
/023 F
C#GHEJI 51.
/023 *
+ ,
+
Press the return key ( ) and a flashing cursor appears below value p1.
K
L
Increase the setpoint pressure p1 with the arrow up key ( ) and decrease it with the arrow

+
down key( ).
,
+
Enter the changed setpoint pressure with the return key ( ).
L
Press the arrow down key once ( ), so that the switching differential SD appears in the third
line of the display.

4 --- 34
 Operation

Press the return key and a flashing cursor appears below the switching differential SD.


Increase the switching differential SD with the arrow down key ( ) and decrease it with the
arrow up key (  ).
Enter the new value with the return key (  ).
(see also chapter 7.3.2).

Control mode
(main menu  configuration  control mode)
Keep pressing the arrow keys (  ) in the control mode menu option until “local mode” ap-
pears in the second line of the display and then press the return key (  ).

 
    ˚
! "#     $
%'&()*'&+ ,&-. /

SIGMA CONTROL is provided with various pressure control modes (see also chapter 7.3.3).
0 Press and hold the arrow keys ( 12 ) in local mode until the required control mode appears in
the third line of the display.
0 Press the return key ( 3 ) to confirm the selection.
4
Clock
(Main menu 5 clock)
0 In the main menu, press and hold the arrow key ( 1 ) until ”clock” appears in the third line of
the display.
0 Press the return key ( 3 ).
The following display appears:

67 8:9; * <=
˚>
?A@B?'C CD'EGFHE
IDAJD'KGFHLNM
OPOQOQOPOQOPOQOQOPOQOPOQOQOPOQOPOQOQR

S
Activate the clock key
T Press the arrow key ( U ), until ”clock key: n” appears in the third line of the display.
V Press the return key( W ), a flashing cursor appears below the ”n”.
V Change the entry from ”n” to ”y” with the arrow key ( U ).
V Confirm the change with the return key W .
X
Delete all switch points
V Press the arrow key ( U ), until ”reset: n” appears in the third line of the display.
V Press the return key( W ), a flashing cursor appears below the ”n”.
V Change the entry from ”n” to ”y” with the arrow key ( U ).
V Confirm the change with the return key W , all the preset switch points will be deleted.

4 --- 35
 Operation


Programming the clock

Press the ( ) arrow key twice.

  ).
Press the return key ( ), a flashing cursor appears below ”n.a.”.




The weekdays for the first switch point can now be set with the arrow keys (
Confirm the weekday setting with the return key( ). 
Note Blocks are available for repetitive switch points on several weekdays, e.g.
Mo--- Fr.

  
  ˚ 

    
 


Press the ( ) arrow key once.

  
  ˚ 

   
 
 !#"$&%  

  ).


Press the return key to set the time with the arrow keys (
Confirm the time setting with the return key( ). 

4 --- 36
 Operation

Press the ( ) arrow key once.

 
  ˚ 

 

 
  "!#%$ &

' (
Press the return key ( ) and the arrow key ( ) once to set the compressor to ON.

 
  ˚ 

 

 
  "!#%$) &

'
Press the return key ( ) to confirm. At this point in time the compressor switches to full load.
To shut down the compressor a further switch point has to be programmed. Ten switching points
are available.


By pressing the return key ( ) the other switching points are displayed.
Enter one after the other the appropriate weekday, the time and whether or not the com-
pressor is to be switched on or off.


  ˚ 
* 

+,- 
 "!#%$ &

.
When all switching points have been set, exit the menu with the escape esc” key.
Binary output functions
'
Press the return key ( ) when ”bin.O function” appears in the third line of the display.
The following display appears:
/
 
 01"2
334 $) ˚ 
5 6
789 :
888 ;
< =
Press the return key ( ) when ”O0.3” appears in the third line of the display.

4 --- 37
 Operation


Select a suitable output with the arrow keys ( ).
Confirm the selected output with the enter key (  ).

Note Eleven output functions are available. Only one function can be allocated to
an output.


Other output functions can be accessed with the arrow down key ( ).

Controller ON Group alarm Motor runnung

Compressor ON Group warning Remote mode
Unloaded mode (idle): On load Clock active
Clock contact (clock) Emergency stop

Setting up the clock for a clock contact
Press the return key (  ) when ”clock” appears in the third line of the display.
The following display appears:
Press the return key (  ), a flashing cursor appears below the ”n”.


Press the up arrow ( ), the ”n” changes to a ”y”.
Press the return key (  ) to delete all the previously set switching points.

Press the ( ) arrow key twice.
The following display appears:


  
   ˚ 
 

 Press the return key (  ), a flashing cursor appears below the ”n.a.”.
 Select the appropriate weekday with the arrow keys (  ).
 Confirm the selected weekday with the enter key (  ).
 Press the down arrow key ( ) once and set the time.
 Press the down arrow key ( ) once and enter the ON or OFF setting for the contact at
this point in time.
 Press the (  ) arrow key once.
The following display appears:

!"
#$%& '(
(* +,-/.&
˚)
(0'12*3# 4
57689;:579 <==?>

@ Further switching points are accessed with the down arrow key ( A ).
Further information on setting up the clock is to be found in chapter 7.2.

4 --- 38
 Operation

4.8.3 Correcting the package pressure

Start Note:

The pressure parameters can only be set within

predetermined limits:
Activate Package pressure SP (p1) Pcut---in min + SD
password level 4
Main menu: SP (switching point): when system pressure
password
see chapter 7.1.1 reaches this switching point (p1), the compres-
sor package switches to idle.
SD (differential pressure): if pressure falls be-
low the SP (p1) --- SD, the compressor package
switches to load.

Menu:
configuration Change set-
pressure set- point pres-
tings sure p1
compressor
system pres-
sure
setpoint pres-
sure p1 Is
setpoint
no
pressure p2
required?

yes
Menu:
configuration
Change
pressure set- setpoint pressure p2
tings
compressor
system pres-
sure
setpoint pres-
sure p2

End

Enter password

See chapter 7.1.1 for entry of the password.

Adjusting system pressure

(main menu  configuration  compressor)



In the main menu, press and hold the arrow key ( ) until “configuration” appears in the third
line of the display.


Press the return key ( ). 

4 --- 39
 Operation

The following display appears:



  ˚ 


 
  


!

 !  " !
# $

% &
Press the return key ( ) when the pressure settings appear in the third line of the display;

%
“compressor” now appears in the third line.
&
%
Press the return key ( ) to display system pressure in the third line of the display.
&
Press the return key ( ) again and the following display appears.


'
  ˚ 
 ()!
  
 
+* ,
-'. 


,/0.21 '

$
% &
%
Press the return key ( ) and a flashing cursor appears below value p1.
3
4
Increase the setpoint pressure p1 with the arrow up key ( ) and decrease it with the arrow

%
down key( ).
&
%
Enter the changed setpoint pressure with the return key ( ).
4
Press the arrow down key once ( ), so that the switching differential SD appears in the third

%
line of the display.

%
Press the return key and a flashing cursor appears below the switching differential SD.
4
3
Increase the switching differential SD with the arrow down key ( ) and decrease it with the

%
arrow up key ( ).
&
Enter the new value with the return key ( ).

5
(see also chapter 7.3.2).

%
Change setpoint pressure p2

4
When the switching differential SD for setpoint pressure p1 has been set, press the arrow
key ( ) once. The following display appears:


'
  ˚ 
,/0. 1 '


7 6 ,
-'. 
6 
8
9:0; <(='>?@A
BDC
E F
Press the return key ( ) and a flashing cursor appears below value p2.

4 --- 40
 Operation


Increase the setpoint pressure p2 with the arrow up key ( ) and decrease it with the arrow
down key ( ).

Enter the changed setpoint pressure with the return key ( ).

Press the arrow down key once ( ), so that the switching difference SD appears in the third
line of the display.

Press the return key ( ) and a flashing cursor appears below the switching differential SD.


Increase the switching differential SD with the arrow down key ( ) and decrease it with the
arrow up key ( ).
Enter the new value with the return key ( ). 
(see also chapter 7.3.2).

4.8.4 Carrying out maintenance

Attention! When the maintenance is complete the remaining interval (3) must be reset
to the default service interval (4).

Note Password level 4 access is required to carry out changes to the service inter-
val counters.
 Enter password


See chapter 7.1.1 for entry of the password.
Resetting the service hours
The remaining hours in the corresponding service hours counter can be individually reset after
completion of maintenance.
The following service intervals are provided:
Oil filter, oil separator, oil change, air filter, V---belts change, V---belts tensioning, bearings change,
bearings maintenance, electrical equipment.
This means, for example, that when the V---belts have been tensioned, the corresponding service
interval must be reset. The reset for V---belt tensioning is located two lines below the phrase ”V---
belt tension”.

Press the arrow down key ( ) 10 times, until “maintenance” appears in the third line of the
display.

  

  ˚ 
     
! "    #  $%


Press the return key ( ), the following display appears.

  

  ˚ 
 & '&  
7 ( ) * +,- 8
./"0/13254 6
The service counter is a down counter. The remaining hours to the next service (2) are shown,
together with the service interval (1).

4 --- 41
 Operation

By pressing the arrow down key ( ) the other service intervals are displayed.


  ˚ 
 
 

%   &
"!# $
' (
Press the arrow key ( ) once, “reset” appears in the third line of the display.

)*+-,
./ 0 1 ˚ 2
+113 4 + 13
/5657 8 9
:;:<: =
> ?
>
Press the return key ( ), a flashing cursor appears below the “n”.
@
>
Change the reset display from “n” to “y” with the arrow key ( ).
?
Confirm with the enter key ( ). The counter resets to the default service interval. At the same
time the reset display changes from “y” to “n”.

4 --- 42
 Operation

4.8.5 The compressor package is to be operated with a base load sequencer

4.8.5.1 MAC 41 as an example

3/6/9/12
MAC 41
2/5/8/11

Compressors with ribbon cable adapter Compressors without ribbon cable adapter, SX, SM
and SK before modification to spring terminals

I 0.7external load/idle

4 --- 43
 Operation

Start

Make electrical
connections

see chapter7.1.1
Main menu
to activate
Password
password level 4

Menu:
Configuration
Activate load
Pressure
control via the
settings Load
remote contact
control Remote
mode> Load
RC
Remote key: y

Press remote
key on control
panel

End

Enter password
See chapter 7.1.1 for entry of the password.
Activating load control
(main menu
configuration)


In the main menu, press and hold the arrow up key ( ) until “configuration” appears in the
third line of the display.

4 --- 44
 Operation

Press the return key ( ).

The following display appears:

 
  ˚ 

  
    

!
"#  #  $ #% &

Press the return key ( ).

'
Press the arrow down key ( ) four times, until “load control” appears in the third line of the
display.


Press the return key ( ), the following display appears.


  ˚ 

 "
#
()+(*,(*-(). (*()(*/(*,()0(*1()2(*,
(*()+ (*()(*(*( 3

4 5
Press the arrow down key ( ) seven times and the following appears in the display.

6 789 -2 : ; ˚ <

2=?>@,1= >@,.=
A BC D
EF?G@HIF JFKML P N O

Q R
Q
Press the return key ( ), a flashing cursor appears in the third line of the display.
SUT ) until “load RC” appears in the third line of the display.
Q
Press the arrow keys (
Enter the new value with the return key ( R ).

4 --- 45
 Operation

Activating the remote key


Press the arrow down key ( ) once until “remote key: n” appears in the third line of the dis-
play.


Press the return key (  ), a flashing cursor appears below the “n”.


Change the entry from “n” to “y” with the arrow keys (  ).


Confirm activation of the remote key with the return  ) key. The following display appears:

 
 

   
˚

   !"#%$ &(' )

(see also chapter 7.3.2.3).

The pressure increase pE becomes important if the rated package pressure is exceeded be-
cause of a period of external load that is too long. It then acts as the upper shutdown value.

4 --- 46
 Operation

4.8.5.2 MVS 8000 as an example

Automatic/manual mode

X4 MVS
A

X4
B
X4

A Changeover between automatic and manual modes

B Load/idle contact in the MVS
I0.7 External load/idle
I1.3 Load control changeover, local load RC

“Motor running” and “control on” messages

Wire the “motor running” and “control ON” messages from the compressor to the MVS.

Attention! It is imperative that output O0.3 “control ON” is used for the “alarm com-
pressor X” message to the MVS.

4 --- 47
 Operation

Start

Make electrical
connections

see chapter7.1.1
Main menu: to activate
password
password level 4

Menu:
Configuration
Pressure Set parameter for p2
settings
Compressor manual mode
Pressure
Setpoint p2

Menu:
Configuration
Pressure settings Setting p2 for
Load control internal control
Settings
> Local mode
Note:
> p2
The setpoint for p2 must represent a
reasonable switching combination if all
compressor packages are to be
Menu:
Configuration
controlled in manual mode, i.e. by their
Pressure settings Load changeover own default pressure settings.
Load control between local load
Remote mode
loc.---loadRC
RC
remote key: y

Menu:
Configuration Activate input for
Pressure settings
Load control remote---local
Remote mode changeover
Loc.---load RC
remote key: y

Press
remote key
on control
panel

End

4 --- 48
 Operation

Enter password
See chapter 7.1.1 for entry of the password.
Pressure parameter for manual mode



(main menu configuration)
In the main menu, press and hold the arrow up key ( ) until “configuration” appears in the


third line of the display.

Press the return key ( ).
The following display appears:

 
  ˚ 
   

     !" #
$%  %  & %' (

) *
Press the return key ( ) when “pressure settings” appears in the third line of the display;

)
“compressor” now appears in the third line.
*
)
Press the return key ( ) to display setpoint pressure in the third line of the display.
*
Press the return key ( ) again and the following display appears.

+ , -. /0 12 ˚ 3

45687:9 ;"<6 7 0 544 ,
7>= ?@A +, -. /0 B
?"CDAFE 2, -. /0 (
) G
Press the arrow down key ( ) twice, the following display appears.

+ , -. /0 12 ˚ 3

?"CDA E 2, -. /0
I7 H ?@A +, H . /0 J
K"LDM N8OP QR STVU

W X
W
Press the return key ( ) and a flashing cursor appears below value p2.
Y
Z
Increase the setpoint pressure p2 with the arrow up key ( ) and decrease it with the arrow

W
down key ( ).
X
W
Enter the new setpoint pressure with the return key ( ).
Z
Press the arrow down key once ( ), so that the switching differential SD appears in the third
line of the display.

4 --- 49
 Operation

Press the return key ( ) and a flashing cursor appears below the switching differential SD.


Increase the switching differential SD with the arrow down key ( ) and decrease it with the
arrow up key ( ).
Enter the new value with the return key ( ).



(see also chapter 7.3.2).
Setting p2 for internal control
(main menu  configuration)

In the main menu, press and hold the arrow up key ( ) until “configuration” appears in the
third line of the display.
Press the return key ( ).


The following display appears:

 
  ˚ 

 
     !""#$&%
'("  (  ) (* +
, -
,
Press the return key ( ) when “pressure settings” appears in the third line of the display.
.
Press the arrow down key ( ) four times, until “load control” appears in the third line of the

,
display.
-
Press the return key ( ), the following display appears.

/ 013245 67 ˚ 8

9:;:<=>$?@
AB;$AC? AC4ABD ACABAC<AC?AB@AC= AB5 AC?ACAB; ACABACACA +

, .
Press the arrow down key ( ) three times and the following appears in the display.

/ 013245 67 ˚ 8
;$?< 4 ; EF? D :
G HI J
KCKCK L
M N
Press the return key ( ) when “local mode” appears in the second line of the display. A flash-

M
ing cursor appears in the third line.
OQP ) until “p2” appears in the third line of the display.
M
Press the arrow keys (
Enter the new value with the return key ( N ).

4 --- 50
 Operation

Load control changeover
Having set p2 for the internal pressure control, press the arrow down key ( ) four times and

the following appears in the display.

 
  
     ˚ 
  
!#"$&%' ( )

* +
Press the return key ( ), a flashing cursor appears in the third line of the display.
* Press the arrow keys ( ,.- ) until / loc.---loadRC” appears in the third line of the display.
* +
0
Enter the new value with the return key ( ).
Activating the remote key
* -
*
Press the arrow key ( ) twice until ”remote key: n” appears in the third line of the display.
+
Press the return key( ), a flashing cursor appears below the ”n”.
* Change the entry from ”n” to ”y” with the arrow keys ( ,.- ).
* Confirm activation of the remote key with the return + key. The following display appears:

1 (2 34 5 67 ˚ 8
9 :#;<&=> ?
@ AB = C A DAFEHGJILK
? ? ? M

N
(see also chapter 7.3.2.3)
Activating changeover input
O P
Press the arrow down key ( ) until ”loc.---loadRC” appears in the second line of the display.

Q RS TU V W X ˚ Y

Z [&\] R_^ [&\ UF`a Y
a Y b R R R c Rd
U Rde
f

g h
Press the return key ( ), a flashing cursor appears below ”n.a.”.
g Press the arrow keys ( i.P ) until a suitable input has been found. The input is to be found in
the circuit diagram.

4 --- 51
 Operation

Press the return key ( ) to confirm the selected input. The following display may appear.


 
       ˚ 
      !

The following status is displayed in automatic mode:

#$% &
'( %)
+, - ./ ¦ 01 '2 3 ˚* *
(465 ))879)6:; <
01 '2 )))6=%) < "

The following status is displayed in manual mode:

# $% &
'(
 %) ˚ *
+, -./ ¦ 0 1 '28>@?A:
(465 ) )879)6:; <
01 '2 ) ))6=%) < "

4 --- 52
 Operation

4.8.5.3 VESIS/SAM as an example

Wiring of the process field bus with the help of the above circuit diagram

The terminating resistor must be connected in the plugs of the first and last subscribers of a Pro-
fibus link.

4 --- 53
 Operation

Wiring of the process field bus with the help of the above circuit diagram

4 --- 54
 Operation

Start

Make electrical
connection

Menu: Activate
password password level 4

Menu:
configuration
pressure Set parameter for
settings p2 manual mode Note:
compressor
pressure The setpoint for p2 must represent a
setpoint p2 reasonable switching combination if all
compressor packages are to be controlled
in manual mode, i.e. by their own default
pressure settings.
Menu:
configuration set p2 for
pressure internal
settings load control
control local
mode > p2

communicati Activate remote

on L2DP bus: control via the
> send + bus
receive
> slave
number
> * bus alarm
timeout: t1 s:j
> remote 1
key: y

4 --- 55
 Operation

Menu:
communication Save Attention!
data
settings
The display returns from “y” to “n” after 10
EEPROM: y seconds. No changes should be made to the
controller during this period.

Switch off
control voltage

Attention!

An error message appearing after activation

Switch off is normal. This can be finally reset in active
bus mode after all items have been pro-
control voltage
cessed.

Press
remote
key

End

Enter password

See chapter 7.1.1 for entry of the password.

4 --- 56
 Operation

Pressure parameter for manual mode



(main menu configuration)
In the main menu, press and hold the arrow up key ( ) until “configuration” appears in the


third line of the display.

Press the return key ( ).
The following display appears:

 
  ˚ 
   

     !" #
$%  %  & %' (

) *
Press the return key ( ) when “pressure settings” appears in the third line of the display;

)
“compressor” now appears in the third line.
*
)
Press the return key ( ) to display setpoint pressure in the third line of the display.
*
Press the return key ( ) again and the following display appears.

+ , -. /0 12 ˚ 3

45687:9 ;"<6 7 0 544 ,
7>= ?@A +, -. /0 B
?"CDAFE 2, -. /0 (

) G
Press the arrow down key ( ) twice, the following display appears.

+ , -. /0 12 ˚ 3

?"CDA E 2, -. /0
I7 H ?@A +, H . /0 J
K"LDM N8OP QR STVU

W X
W
Press the return key ( ) and a flashing cursor appears below value p2.
Y
Z
Increase the setpoint pressure p2 with the arrow up key ( ) and decrease it with the arrow

W
down key ( ).
X
W
Enter the new setpoint pressure with the return key ( ).
Z
Press the arrow down key once ( ), so that the switching differential SD appears in the third

W
line of the display.
X
Press the return key ( ) and a flashing cursor appears below the switching differential SD.

4 --- 57
 Operation


Increase the switching differential SD with the arrow down key ( ) and decrease it with the
arrow up key ( ).
Enter the new value with the return key ( ). 

(see also chapter 7.3.2).
Setting p2 for internal control
(main menu  configuration)

In the main menu, press and hold the arrow up key ( ) until “configuration” appears in the
third line of the display.
Press the return key ( ). 
The following display appears:

 
  ˚ 

 
     !""#$&%
'("  (  ) (* +
, -
,
Press the return key ( ) when “pressure settings” appears in the third line of the display.
.
Press the arrow down key ( ) four times, until “load control” appears in the third line of the

,
display.
-
Press the return key ( ), the following display appears.

/ 013245 67 ˚ 8

9:;:<=>$?@
ABACAC4ABD ACABACACABACAB5 ACACABACABACACA
;$? <?@= ?; +
, .
Press the arrow down key ( ) three times and the following appears in the display.

/ 013245 67 ˚ 8
;$?< ; EF? D :
4
G HI J
KCKCK L
M N
Press the return key ( ) when “local mode” appears in the second line of the display. A flash-

M
ing cursor appears in the third line.
OQP ) until “p2” appears in the third line of the display.
M
Press the arrow keys (
Enter the new value with the return key ( N ).

4 --- 58
 Operation

Activate remote control via the bus



(Main menu communication)
In the main menu, press and hold the arrow key ( ) until ”communication” appears in the


third line of the display.
Press the return key ( ). 
The following display appears:

  

  ˚ 
    !
 "    $#

% &
%
Press the arrow key ( ) twice until ”Profibus” appears in the third line of the display.
'
Press the return key ( ) when ”Profibus” appears in the third line of the display. The following
display appears:

() *+ ,- ./ ˚ 0

1 2 )3,4) 5
#

% '
%
Press the return key ( ).
6
%
Press the arrow down key ( ) until ”send+ receive” appears in the third line of the display.
'
7
Confirm with the return key ( ).

%
Set the slave number
&
%
Press the arrow key ( ) twice until ”slave no.: 2” appears in the third line of the display.
'
%
Press the return key( ), a flashing cursor appears below the number.
Set the correct slave number with the arrow keys ( 68& ).
Note If SIGMA AIR MANAGER is connected the slave number to be entered is the
compressor number used on SIGMA AIR MANAGER plus 2.
% Enter with the return key ( ). '

4 --- 59
 Operation

Bus alarm


Press the arrow key ( ) four times until ”timeout” appears under ”bus alarm” in the third line
of the display. The following display appears:

 
 
   
!  ! !"$# %'&)((  *
!
,+ !$# (-&)(( /
 .

 
 0
 !  ! !"$# %'&)(( 
!
,+ !$# (-&)(( 1*
2+ !  !$# 3 !  & .

4
Press the return key( ), a flashing cursor appears below the time.

Using the arrow keys ( 5 ) enter a time (timeout) of 20.00s. If the time is set to 0.00 then bus
monitoring is inactive.

Enter with the return key ( ). 4
Activating the remote key


Press the arrow key ( ) twice until ”remote key: n” appears in the third line of the display.
The following display appears:

 
 
&&&
+ ! + 6/+7 # 8 *
&&& 9

: ;
Press the return key( ), a flashing cursor appears below the ”n”.
: Using the arrow keys ( <>= ), change the ”n” to ”y”.
: Enter with the return key ( ). ;
(see also chapter 7.6.3)

4 --- 60
 Operation

Saving settings
All important data are stored in an EEPROM that is no ---volt safe.
Data are retained even if the buffer battery discharges completely.
If the procedure is activated it takes approximately 30 seconds for the display to change back
from “y” to “n”.

Attention! No changes should be made to the controller when saving data.

Loss of power when saving can lead to loss of data.


Press and hold the arrow keys ( ) until “data  EEPROM” appears in the third line of the
display. Press the return key (  ) .


Change the entry from “n” to “y” with the arrow keys ( ).

Confirm with the return key (  ).

When the display returns to “n” exit the submenu with the “esc” key.

4 --- 61
 Operation

4.8.6 Two rotary screw compressors in sequence

Attention! If compressor packages are sequenced the pressure losses between the
compressors and the air main must be taken into account.

In Profibus mode the following status display may appear:


   
 ˚
   ¦    
    ! " #
    $
 #&%

4.8.6.1 Base load sequencing of two compressor packages with Sigma Control
via the RS 485 interface

Sigma Control 1 Sigma Control 2

Pin Pin
1 1
2 2
3 B 3
4 4
5 5
6 6
7 7
8 A 8
9 9

4 --- 62
 Operation

Package 1 Package 2
(controlling pack- (controlled pack-
age) age)
Start
Master Slave

Activate password
Menu: Menu:
level 4
password password
see chapter
7.1.1

Menu: Menu:
configuration configuration
Set pressure
pressure settings pressure settings
parameter
compressor for system compressor
system pressure
pressures system pressure
p1 and p2
setpoint pressure setpoint pressure
p1 p1
setpoint pressure setpoint pressure
p2 p2

Menu:
pressure set-
tings Change
load control default times
settings for p1 and p2
p1/p2 clock
or
p1/p2 cycle
Menu:
configuration
Menu:
Activation of pressure set-
configuration p1/p2 Activation of tings
pressure settings changeover p2 from RS 485
from clock or load control
load control
cycle remote mode
local mode > > p1/p2 RS 485
p1/p2 clock
or
Activate remote key: y

> p1/p2 cycle

remote mode
via remote key

1 2

4 --- 63
 Operation

1 2
Note:

The bitrate settings and the data

format must be identical for both
packages (communication menu).

Menu: Menu:
communication Activation Activation communication
RS 485 master slave RS 485
> master > slave

Menu: Menu:
Save new
communication communication
interface
data settings data
EEPROM: y EEPROM: y

Attention! Attention!

An error message appearing The display returns from “y” to

after activation is normal. This Switch off “n” after 30 seconds. No
can be finally reset in active bus control voltage changes should be made to the
mode after all items have been controller during this period.
processed.

Switch on
control voltage

End

4 --- 64
 Operation

4.8.6.1.1 Settings on both SIGMA CONTROLs

Carry out the following settings on both SIGMA CONTROLs.
Enter password
See chapter 7.1.1 for entry of the password.
Adjusting system pressure




(main menu configuration compressor)
 In the main menu, press and hold the arrow key ( ) until “configuration” appears in the third
line of the display.
 Press the return key ( ). 
The following display appears:

 
  ˚ 
   

     !" $#
%&  &  ' &( )

* +
Press the return key ( ) when the pressure settings appear in the third line of the display;
“compressor” now appears in the third line.
* +
Press the return key ( ) to display system pressure in the third line of the display.
* +
Press the return key ( ) again and the following display appears.

, - .0/ 12 34 ˚ 5


678:9<; =">8 9 2 766? 2 7
9A@ BC0D ,- ./ 12 E
B"FGDIH 40- ./ 12 )
* +
Press the return key ( ) and a flashing cursor appears below value p1.
* J
K
Increase the setpoint pressure p1 with the arrow up key ( ) and decrease it with the arrow
down key( ).
* +
Enter the changed setpoint pressure with the return key ( ).
* K
Press the arrow down key once ( ), so that the switching differential SD appears in the third
line of the display.
* Press the return key and a flashing cursor appears below the switching differential SD.
* K
J
Increase the switching differential SD with the arrow down key ( ) and decrease it with the
arrow up key ( ).
* Enter the new value with the return key ( ). +
(see also chapter 7.3.2).

4 --- 65
 Operation

Change setpoint pressure p2


When the switching differential SD for setpoint pressure p1 has been set, press the arrow
key ( ) once. The following display appears:

  
  ˚ 

   

       

   
 

!


Press the return key ( ) and a flashing cursor appears below value p2.

 "
Increase the setpoint pressure p2 with the arrow up key ( ) and decrease it with the arrow

down key ( ).

 !


Enter the changed setpoint pressure with the return key ( ).
Press the arrow down key once ( ), so that the switching difference SD appears in the third

line of the display.
! 


Press the return key ( ) and a flashing cursor appears below the switching differential SD.

"
Increase the switching differential SD with the arrow down key ( ) and decrease it with the

arrow up key ( ).
!
Enter the new value with the return key ( ).
(see also chapter 7.3.2).

4.8.6.1.2 Settings on the master SIGMA CONTROL

Enter the following settings on the SIGMA CONTROL controlling both packages.
Default times for the changeover between p1 and p2
#


(Main menu configuration)
$
In the main menu, press and hold the arrow up key ( ) until “configuration” appears in the

%
third line of the display.
&
Press the return key ( ).
The following display appears:

' ()+*, - ./ ˚ 0


1325462 - ,87
9 - 28: :; - 2<:25= =>4 ?:A@
B5C D E6F5CG HIC J6K L

M N
Press the return key ( ) when the pressure settings appear in the third line of the display;

M
“compressor” now appears in the third line.
O
M
Press the arrow down key ( ) until “load control” appears in the third line of the display.
N
Press the return key ( ).

4 --- 66
 Operation

a) Clock control


Press the arrow down key ( ) until clock appears below “settings” in the third line of the dis-
play. Here the pressure change between p1 and p2 from the internal clock can be entered
(see also chapter 7.1.1 and 7.2.1).


 
    ˚ 
   !
 "

b) Internal timer control

Press the arrow down key ( ) until p1/p2 cycle appears below “settings” in the third line of
the display. Here the pressure change between p1 and p2 from the timer can be entered
(see also chapter 7.3.2.3).

 
  ˚ 

#  $%
&'()+* ,-. /
0 ,1',-.+* ,-. 2

When all settings for the load changeover have been entered; the type of load changeover re-

3
quired can be selected.
4
Press the arrow up key ( ) until local mode appears below load control in the second line of

3
the display.
5
3
Press the return key ( ) to select the load changeover.
476 ).
3
Select the required load changeover with the arrow keys (
Confirm the selected load changeover with the return key ( 5 ). The following display appears:

a) 8 9:;
<= >? ˚ @
 b) RSTVU DW XY ˚ @
ABCDA EFBGH ABCDA EFBGH
I JKLJM CABC N O I JKLJM C ZCAH O
PPP Q PP[P Q

\ Return to the main menu with the “esc” key.

4 --- 67
 Operation

Activate master



(main menu communication)
In the main menu, press and hold the arrow up key ( ) until “communication” appears in the


third line of the display.

Press the return key ( ).
The following display appears:

  
  ˚ 

    !
 "    $#

% &
%
Press the arrow down key ( ) once, until “RS485” appears in the third line of the display.
'
Press the return key ( ) when “RS485“ appears in the third line of the display. The following
display appears:

( )*+, -.0/ +1

2 354764 8
#

% '
%
Press the return key ( ).
9
%
Press the arrow up key ( ) until “master” appears in the third line of the display.
'
%
Enter the setting with the return key.
Return to the main menu with the “esc” key.

4.8.6.1.3 Settings on the slave Sigma Control

:
Enter the following settings on the slave Sigma Control.
Activation of p2 from RS 485
;
%
(main menu configuration)
<
In the main menu, press and hold the arrow up key ( ) until “configuration” appears in the

=
third line of the display.
>
Press the return key ( ).

4 --- 68
 Operation

The following display appears:



  ˚ 


 
  




  !
" #
$ %
Press the return key ( ) when the pressure settings appear in the third line of the display;

$
“compressor” now appears in the third line.
&
$
Press the arrow down key ( ) until ”load control” appears in the third line of the display.
%
$
Press the return key ( ).
%
Press the return key ( ), a flashing cursor appears below the value to be changed.


'
 
 !
 !
" ˚ 
)( 
 !
 *+-, .#

$ /10 ).
2
Select control mode “p1/p2 RS485” with the arrow keys (
3
2
Press the return key ( ).
4
Press the arrow down key ( ) once, so that “remote key: n” appears in the third line of the

2
display.
3
2
Press the return key ( ), a flashing cursor appears below the value to be changed.
4
2
Change the “n” to “y” with the arrow down key ( ).
Press the return key 563 ).

789':;
< = >
@ A)B
CDAFE GHI =
˚9 ?

< JLKNM
OJ PJQ-R SUT
VDVDV W
X Return to the main menu with the “esc” key.

4 --- 69
 Operation

Activate the slave



(main menu communication)
In the main menu, press and hold the arrow up key ( ) until “communication” appears in the


third line of the display.

Press the return key ( ).
The following display appears:

  
  ˚ 

    !
 "    $#

% &
%
Press the arrow down key ( ) once, until “RS485” appears in the third line of the display.
'
Press the return key ( ) when “RS485“ appears in the third line of the display. The following
display appears:

( )*+, -.0/ +1

2 354764 8
#

% '
%
Press the return key ( ).
9
%
Press the arrow up key ( ) until “slave” appears in the third line of the display.
'
%
Enter the setting with the return ( ) key.
Return to the main menu with the “esc” key.

4 --- 70
 Operation

4.8.6.1.4 Settings on both SIGMA CONTROLs

Carry out the following settings on both SIGMA CONTROLs.
All important data are stored in an EEPROM that is no ---volt safe.
Data are retained even if the buffer battery discharges completely.
If the procedure is activated it takes approximately 30 seconds for the display to change back
from “y” to “n”.

Attention! No changes should be made to the controller when saving data.

Loss of power when saving can lead to loss of data.


Press and hold the arrow keys ( ) until “data  EEPROM” appears in the third line of the
display. Press the return key (  ) .


Change the entry from “n” to “y” with the arrow keys ( ).
Confirm with the return key (  ).
When the display returns to “n” exit the submenu with the “esc” key.

Note Press the remote key to start the master/slave function (see 4.3.2).

4 --- 71
 Operation

4.8.6.2 Sequencing SIGMA and pressure switch controlled compressors

Example 1
A BSD 62 with Sigma Control and an existing SK 26 are to supply the demand at weekends
and during the night.
Recommendation:
The pressure switch settings of the SK 26 should lie exactly between the programmed pres-
sures of the BSD 62.

7.5 bar
p1/BSD

7.0 bar SK
p2/BSD

6.0 bar

This means that only the submenu p1/p2 of the BSD 62 is to be programmed.
If the switching point p2 is activated over the weekend and during the night then the SK 26 is
automatically selected as the base load machine.

Change to p1/p2 clock (load control, local mode)

Enter the required values (SP and SD) for p1 and p2

Activate the switching points on the clock

4 --- 72
 Operation

Example 2
Two machines of the same capacity, one with Sigma Control and the other with conventional
control, are to be sequenced as base and peak load machines.

Program the submenu p1/p2 on the Sigma Control machine according to the base load
sequence requirements.

Enter the required values (SP and SD) for p1 and p2.

Enter the changeover delays and/or periods in the load control menu.

One of the volt ---free contacts O0.3, O0.4 or O0.5 must be functionally allocated to the
p1/p2 submenu.
This contact is then used for the changeover between two pressure switches in the existing
“old compressor package” (see example circuit diagram).

21
K3 K3
22

K3

A open: Sigma Control --- package running with setpoint pressure p2

A closed: Sigma Control --- package running with setpoint pressure p1

4 --- 73
 Operation

Examples of the time settings

1. Two equivalent machines are to have equal duty cycles.
1.1 Daily changeover between p1 and p2 after 24 hours. The compressor package starts with
setpoint pressure p2 at 0.00 hours.

Start

Menu:

configuration
p1/p2 changeover
pressure settings
load control from timer
local mode
> p1/p2 cycle

Menu: Duration
configuration p1: 24h
pressure settings p2: 24h
load control
1st p2 start at:
settings
00:00
> p1/p2 cycle

End

1.2 Equal duty cycle during the day.

Start
Menu:
Load control 01 Mo ---So
p1/p2 clock 00:00
Clock p1 on

02 Mo ---So
06:00
p2 on

03 Mo ---So
12:00
p1 on

04 Mo ---So
18:00
p2 on

End

4 --- 74
 Operation

1.3 Equal duty cycle during the week

Start
Menu:
Load control
p1/p2 clock
01 Mo
Clock
00:00
p1 on

02 Mo
21:00
p2 on

03 Tu
18:00
p1 on

04 We
15:00
p2 on

05 Th
12:00
p1 on

06 Fr
09:00
p2 on

07 Sa
06:00
p1 on

08 Su
03:00
p2 on

End

4 --- 75
 Operation

1.4 A compressor package with a lower capacity that is operated as a slave is to work as a
base machine at night and at weekend.

Start

Menu:
01 Mo ---Fr
Load control
06:00
p1/p2 clock
p1 on
Clock

02 Mo ---Fr
17:00
p2 on

End

4 --- 76
 Menus --- General

5 SIGMA CONTROL Menus

When the compressor package is switched on, details of the software are initially shown in
SIGMA Control’s display. The software is then loaded and the main menu appears in the display.
Example of the initial display:


 

 











    
     


 

PN: Material number

SN: serial number
SYS: system version
S5: operating system version
HW: hardware version

5.1 Main menu

The main menu shows the current system pressure, the airend discharge temperature and the
mode of operation.
Example:

  !"
 #

˚$
%%%%%%%%%%%%%%%%
&''
2
%%%%%%%%%%%%%%%%(

1 Current system pressure and airend discharge temperature

2 Operational mode (current state)

)
If the arrow key ( ) key is pressed three times a further display level is accessed in which the
total operating hours and hours on load are additionally displayed.

5 --- 77
 Menus --- General

Example:



  ˚ 


 ¦    
2
  


 !
"#
3 $ 


 !%#
4

1 Current system pressure and airend discharge temperature

2 Operational mode (current state)
3 Total operating hours
4 Hours on load

The following information can be displayed in the second line (operational messages):

e.g. key ---ON ¦ p1 ---idle

load control status:

idle in idle mode
load in load mode
rdy motor off, but ready.
motor starts again if air is demanded
off motor off, but ready
load control from:
p1 set point pressure p1
p2 set point pressure p2
pE increased system pressure pE
(at unclear load signal)
RC Remote Contact (external load contact)
RB Remote Bus (external bus signal)
compressor status
ON compressor running
OFF compressor stopped
AL Alarm, compressor fault
compressor switched on/off by:
key “0” and “I” key on control panel
clk Internal clock
RC Remote Contact (external contact)
RB Remote Bus (external bus signal)
cRC clock or Remote Contact (external contact)

Note Return to the main menu from all other menus with the ‘esc’ key.

5 --- 78
 Menus --- General

5.2 Password Protection

When the controller is switched on, the lowest level of access (level 0) is started. An access level
(level 4) is available to the customer’s user. Changes to the settings in Sigma Control are allowed
in level 4.
See chapter 7.1.1 for entry of the password.

Attention! The password level automatically resets to level 0 within a period of

three hours.

5 --- 79
 Menus --- General

5.3 Display and Setup Level

If the main menu is scrolled upwards with the arrow up key ( ) , all menus in the Display and
Setup Level in which default values can be changed are shown. These are:
password

clock

configuration

components

package test

communication

language

5.4 Display Level

If the main menu is scrolled downwards with the arrow down key ( ), the menus in the Display


Level in which values can only be read are shown. These are:
status

analog data

operating data

maintenance

See following pages for an overall list of menus and submenus in the Display and Setup Level.
For an explanation of the abbreviated messages in the Display, see list of abbreviations in
chapter 7.8.

5 --- 80
 Menus --- General

Languages Password level 0

Display and Setup Level

communication
esc
--- RS232 (1X7)
---function
---bitrate: ....
---format: ...
package test
. --- RS485 (1X8)
esc
(master/slave) --- comp. test: y/n
---bitrate: .... --- lamps test: y/n
---format: ....
---remote key y/n
configuration
--- Profibus (1X9) esc
---> (n.a./send/ send + --- general
receive) ---version no.
---slave no.: ...
---Bus alarm
---model:
---PN number:
Clock
start: ... s ---SN number: esc
timeout: ... s ---weekday
Restart: ... ---date
---remote key y/n ---time --- compressor ON/OFF
--- SMS ---summer/winter t
---date format
-- clock key: y/n Password
---SMS status -- reset: y/n esc
---active: y/n ---time format
---buffer empty ---unit of pressure -- switch points 01 -- 10
---channel 1 ---unit of temperature --- password
---error: 0 ---password:
---modem
---location XXXXX L0
---channel 1 XXXXX L0
---channel 2
--- Data EEPROM y/n

Test menu Version menu

10.5 bar 80˚ C
system test PN: 7.7001.0 automatic --- --- --- --- --- --- --- --- --- --- ---
SN: 00000000 OFF
SYS: S5: HW: --- --- --- --- --- --- --- --- --- --- ---
UON

2.41 72.00 0.6

Main menu
5 sec.
PN: = Part number
SN: = Serial number
SYS: = System version 10.5 bar 80˚ C
S5: = Operating system version key ---OFF¦ p1---off
HW: = Hardware version run 13000h
load 12034h

Display Level
Normal text: can be read
Bold text: can be changed status
esc
messages
esc
analog data --- event info
esc
operating data --- display 1---6
statistics --- last alarm
esc --- last warning
--- system pressure --- current number
esc local --- total duty cycle
--- operating hours alarms:
--- duty cycle from
maintenance ---total hours external
--- internal pressure --- reset
warnings:
esc ---on load --- syspress. max
---compressor motor --- current
--- oil filter cut ---out pressure --- reset
--- oil separator ---airend --- syspress. min
---SIGMA CONTROL --- differential pressure
--- oil change oil separator --- reset
--- air filter ---modulating valve --- internal press. max
--- load valve ON --- ADT temperature
--- V---belts change --- ADT before start --- reset
--- V---belt tension --- kWh counter --- motor starts total
--- PD T-rise dT/dt
--- bearing change --- ADT temperature --- motor starts since
--- bearing maintenance. --- VFD speed --- reset
--- elect. equip. --- analog output --- motor starts/day
--- differential pressure --- max: ...
air filter --- motor starts/hour
Escape key --- coolwater temperature --- max: ...
esc
returns to next higher level or to the main menu --- motor temp. --- motor starts T
--- oil filter dp --- last load run
--- last idle run
Arrow key --- UP --- motor OFF
scrolls display text downwards

Arrow key --- DOWN 

Info key Enter key

scrolls display text upwards calls up current initiates move to the next submenu, enters
messages parameters and passwords

5 --- 81
 Menus --- General

Display Level
Password level 4

Test menu Version menu

UON System test PN: 7.7001.0

automatic
SN: 00000000 10.5 bar 80˚ C
SYS: S5: HW: --- --- --- --- --- --- --- --- --- --- ---
2.41 72.00 0.6 OFF
--- --- --- --- --- --- --- --- --- --- ---

5 sec. 10.5 bar 80˚ C

PN: = Part number key ---OFF¦ p1---off
run 13000h Main Menu
SN: = Serial number
SYS: = System version load 12034h

S5: = Operating system version

HW: = Hardware version

status
esc
messages
analog data esc
--- event info
esc statistics --- last alarm
--- display 1---6 esc --- last warning:
operating data --- system pressure
--- total duty cycle
--- current number
local alarms:
esc
external
print --- duty cycle from warnings:
--- operating hours --- internal pressure esc --- reset
maintenance ---total hours --- current --- syspress. max
---on load cut ---out pressure --- printer output --- reset
esc --- settings --- syspress. min
---compressor motor --- differential pressure
--- oil filter Hours ---clock --- reset
oil separator
interval; time left ---airend --- internal press. max
--- ADT temperature
--- reset Hours --- reset
--- ADT before start
--- oil separator ---SIGMA CONTROL --- motor starts total
--- PD T-rise dT/dt
interval; time left ---modulating valve --- motor starts since
--- ADT temperature
--- reset --- load valve ON --- reset
--- VFD speed
--- oil change Quantity --- motor starts/day
--- analog output
interval; time left --- kWh counter --- max: ...
--- differential pressure
--- reset Reset --- motor starts/hour
air filter
--- air filter --- max: ...
--- coolwater temperature
interval; time left --- motor starts T
--- motor temp.
--- reset --- last load run
--- oil filter dp
--- V---belts change --- last idle run
interval; time left --- motor OFF
--- reset
--- V---belt tension
interval; time left
--- reset
Enter key
--- bearing change Arrow key --- UP initiates move to the next submenu, enters
interval; time left scrolls display text downwards parameters and passwords
--- reset
Arrow key --- DOWN


Info key
--- bearing maint. calls up current messages
scrolls display text upwards
interval; time left
--- reset esc Escape key Normal text: can be read
--- elect. equip. returns to next higher level or to the main menu
interval; time left Bold text: can be changed
--- reset

5 --- 82
 Menus --- General

Display and Setup Level

Password level 4 Language
s
communication

esc
--- RS232 (1X7)
package

test -- function
-- bitrate: ....
esc
-- format: ....
--- compressor test: y / n --- RS485 (1X8)
components --- TÜV check (master/slave)
 --- TÜV check
esc relief valve: y / n
---bitrate: ....
pi= ... -- format: ....
--- motor --- TÜV check
configuration

---power switching
---start mode
ADT alarm: y / n
offset: = ... ˚ C
---remote key y/n

esc ---settings: ADT = ... ˚ C --- Profibus (1X9)

* star---delta ---> (n.a./send /
--- general ---star period --- binary inputs
---version no. send+ receive)
Clock ---model:
T : t: ...s
T
: t: ...s
--- ...
---slave no.: ...
 ---PN number: ---c/o delay t: ...s --- binary outputs ---Bus alarm
esc ---SN number: --- oil circulation --- ...
---weekday ---oil separator --- set: y / n start: ... s
---date
Password

--- compressor ON/OFF
-- clock key: y/n
---time
---summer/winter t
---diff. pressure
input
--- lamps test: y / n timeout: ... s
Restart: ...
c/0 delaytd: ...s
esc -- reset: y/n ---date format
--- booster ---remote key y / n
---time format
-- switch points 01 -- 10 ---unit of pressure ---booster on --- SMS
--- password ---unit of temperature SP: ... bar
---SD: ... bar ---SMS status
---password:
--- pressure settings output: n.a.; O... -- active: y/n
XXXXX L4 ---compressor --- AM charging ---buffer empty
XXXXX L4 ---pRV: ...bar ---valve open
---pressure increase SP: ... bar ---channel 1
pE SP: ...bar ---SD: ... bar ---error: 0
-- SD: ... bar output: n.a.; O...
-- modem
---nominal press --- PD temperature
: ... bar  ana. input n.a. ; AI..
> -- location
---setpoint pressure
p1 SP: ...bar
 SP: ...˚ C -- channel 1
SP: ...˚ C
SD: ...bar -- channel 2
p2 SP: ...bar
 SD: ...˚ C
 SP: ...˚ C
SD: ...bar SP: ...˚ C --- Data EEPROM y/n
---system pressure low td: ... s
+ SD: ...bar

 SP: ...bar
output: n.a./O...
--- cut ---in pressure min
: ...bar
---vacuum package
---system pressure high
 SP: ...bar
---SD: ...bar --- control mode
output. n.a. / O...
local mode
---setpoint pressure 
--- Dual ; Quadro ; Vario;
+ SD: ...bar
p2 SP: ...bar continuous
---settings:
+ SD: ...bar 
--- Dual
p1 SP: ...bar
---pressure fall  ---idle period t= ... s
--- Quadro
+ SD: ...bar
pA SP: ...bar ---min run period t= ... s
---load control ---unloaded period t= ... s
---venting period t= ... s --- I/O periphery

---load control
---dryer: ... ---bin.O function
local mode: p1; p2;
p1/p2 clock; ---modulating valve functions 1 ---11
p1/p2 cyclet valve closed: output: n.a.; O...
local mode: p1; p2; pN SP: ... bar Clock
p1/p2 clock; p1/p2 cycle -- SD: ... bar Switch points 01 -- 10
p1/p2 RC; p1/p2 RS485; output: n.a./O...
---show quantities
load FC; local load RC
Pressure transducer: --- compressor start --- display 1 -- 6 (p/T/II)
---compressor ON message text: 2*15
pNloc./pNext.;
selection characters
remote key: y/n
compressor ON ana. input n.a. ; AI...
---settings:
local mode Current:
* p1/p2 clock key; key+ clock 0 -- 20 mA; 4 -- 20 mA
-- reset: y/n calibration ...
-- switch points clock key: y/n
compressor ON ---external messages 0 ---5
01 -- 10 message text: 15 characters
* p1/p2 cycle remote
key; mode
key+ clock; type of message:
p1:(preset h) h, (rest) h alarm, warning, operation
p2:(preset h) h, (rest) h key+ RC; key+ clock--RC
Normal text: can be read remote key: y/n input: n.a.; I ...
1st p1 start at: Delay time: td: ...s
xy:xy remote key: y/n
Bold text: can be changed compressor ON ---switch
* p1/p2 RC
 n. a. ; I... current; p ---switch, T---switch
settings Function
* p1/p2 bin.Output
 n. a. ; I... compressor ON SP: ...bar, ˚ C
RC input: n.a./I.. SD: ...bar, ˚ C
* idle---load
 n. a. ; I... ---compressor ON message text: 15 characters
---venting: y/n type of message:
* loc. ---loadRC
 n. a. ; I... ---holidays: y/n alarm, warning, operation
(holiday period) output: n.a.; O ...
---idle key Delay time: td: ...s
active: y/n ---restart: y/n
td: ... s --- an.O parameter
-- starting temp. AO1: ... mA
SP:
... ˚ C Current:
active: y/n 0 -- 20 mA; 4 -- 20 mA
signal source: n.a.; pN; pi;
--- reset ADT; AI2 -- 8; p1(2);
dT/dt
---remote mode
calibration
key; key+ RC
-- remote key y/n --- timer
---inputs: n.a. ; I...
--- OFF: ... s
--- ON: ... s
output: n.a.; O ...

5 --- 83
 Display Level

6 Display Level in SIGMA Control

Status and measurement data, operational data and service intervals can be accessed in the
Display Level.

Note All the following points refer to password level 4.

6.1 Status Data

status

esc
messages

esc
--- event info
--- last alarm
statistics

--- last warning
esc --- current number
alarms:
--- total duty cycle
warnings:
--- duty cycle from
print

--- reset
esc --- syspress. max
--- reset
--- printer output
--- syspress. min
--- settings
--- reset
---clock
--- internal press. max
--- reset
--- motor starts from
--- reset
--- motor starts/day
--- max
--- motor starts/h
--- max
--- motorstart T
--- last load run
--- last idle run
--- motor OFF

6 --- 84
 Display Level

Display of status data


Press the arrow


key ) until “status” appears in the third line of the display and then press
the enter key ).
Three further options are displayed:

messages

statistics

print

6.1.1 Messages

Activate the “messages” menu option by pressing the return key ( ) when “messages” ap-
pears in the third line of the display.
The submenu is divided into the following options:

event information
The last 100 messages can be displayed. These include alarm messages and warning
messages.

last alarm
The time at which the last alarm occurred and the corresponding alarm number.

last warning
The time at which the last warning message occurred and the corresponding message
number.

Note This menu option shows all current alarms and warnings and is especially
useful for faultfinding.

The following display options are possible:

Example:

 
  
   ! "
2 4
 #$%#$&"
3
'( )*+)-,, .() $ 5
6

1 Type of display option

2 Type of message W Warning
A Alarm
3 Message status c Message has come
g Message has gone
a Message acknowledged (reset)
4 Time of arrival of warning or alarm
5 Date of arrival of warning or alarm
6 Actual warning or alarm

6 --- 85
 Display Level

6.1.2 Statistics

Activate the “statistics’ menu by pressing the return key ( ).

The following statistical evaluations are displayed:
total duty cycle in percent


(ratio of hours on load to total hours)

duty cycle from a defined day onwards


If the word “ reset ” is in the third line of the display, it can be selected with the return key ( )

and changed to “ y ” with the arrow key ( ). Confirm the reset with the enter key ( ).


The actual date is entered by the reset. The duty cycle of the compressor package is re-
calculated from this point in time.
Maximum system pressure


The maximum pressure evaluated since the last reset is displayed.

If the word “ reset ” is in the third line of the display, it can be selected with the return key ( )

and changed to “ y ” with the arrow up key ( ). Confirm the reset with the return key ( ).


The current value is accepted and monitoring is restarted.

Minimum system pressure


The minimum pressure evaluated since the last reset is displayed.

If the word “ reset ” is in the third line of the display, it can be selected with the return key ( )

and changed to “ y ” with the arrow up key ( ). Confirm the reset with the return key ( ).


The current value is accepted and monitoring is restarted.

Maximum internal pressure


The maximum pressure evaluated since the last reset is displayed.

If the word “ reset ” is in the third line of the display, it can be selected with the return key ( )

and changed to “ y ” with the arrow up key ( ). Confirm the reset with the return key ( ).


The current value is accepted and monitoring is restarted.

Motor starts from a defined day onwards


The number of motor starts since the last reset is displayed.

If the word “ reset ” is in the third line of the display, it can be selected with the return key ( )
and changed to “ y ” with the arrow up key ( ). Confirm the reset with the return key ( ).

The current value is accepted and monitoring is restarted.

Motor starts


The total number of motor starts is displayed and can be changed, if required. This could be
the case if another drive motor is fitted.
Motor starts at low temperatures


The total number of starts at low temperatures is displayed here.

Motor starts per day


The number of starts during the last 24 h are displayed, together with the number of per-
missible starts per day.
Motor starts per hour


The number of starts during the last 60 minutes is displayed, together with the number of
permissible starts per hour.

6 --- 86
 Display Level

Last load run

The time and date on which the last changeover from load to idle occurred or on which the
compressor was shut down under load is displayed.
Last idle run
The time and date on which the last changeover from idle to load occurred or on which the
compressor was shut down in idle is displayed.
Last motor off
The time and date on which the compressor was last shut down, or was switched to standby
when in idle is displayed.
The following display options are possible:
Example:

 
 ˚ 


  


2
3
   

1 Current system pressure and airend discharge temperature

2 Description of statistic
3 Value (minimum or maximum value)

6 --- 87
 Display Level

6.1.3 Print


Activate the print menu by pressing the return ( ) key.
All messages to be printed are displayed.


Example:


new messages


event info (history)


clock event info


parameters
parameters  file
The following display options are possible:
Example:

 
  ˚ 

 
2
  "! #
3
$

1 Current system pressure and airend discharge temperature

2 Description of status
3 Message to be printed

6 --- 88
 Display Level

6.1.3.1 Printer clock

The printer can also be controlled with the internal clock.
Press the arrow down key ( ), the following display is possible.


  ˚ 
  
  !  "
  # $&% '

(
Press the return key ( ) to set the weekdays and times.
The printer clock can be set up exactly the same as for the compressor clock (see chapter7.2).

6 --- 89
 Display Level

6.2 Analog data

analog data
esc
--- available displays 1---6
--- system pressure
--- internal pressure
--- cut ---out pressure
--- differential pressure
oil separator
--- airend discharge
temperature
--- airend discharge
temperature before start
--- airend discharge
temperature-rise
--- package discharge-
temperature
--- VFD speed
--- analog output
--- differential pressure
--- cooling water
temperature
--- motor temperature
--- oil filter dp

6 --- 90
 Display Level

Display of analog data

Press and hold the arrow key ( ) until ”analog data” appears in the third line of the display.

Press the return key ( ).
All analog data of the compressor package are displayed.


Example:


current system pressure local ( pN loc )


current system pressure external ( pN ext )*


current internal pressure ( pi )*


current cut ---out pressure ( p1(2) ) SP and SD


pressure differential across oil filter ( dp )*


airend discharge temperature ( ADT )


airend discharge temperature before start


airend discharge temperature rise rate ( dT/dt )


package discharge temperature (PDT)*


variable frequency drive speed


analog output*


pressure differential across air filter ( dp )*


cooling water temperature*


motor temperature*
pressure differential across oil filter ( dp )*
* optional or according to compressor model
The following display options are possible:
Example:

 
  ˚ 

    
2
"!#$% &' 
3
"!()*,++-+++++  /.
1 Current system pressure and airend discharge temperature
2 Description of measured value
3 Value

6 --- 91
 Display Level

6.3 Operating Data

operating data
esc
--- operating hours
--- compressor run
--- load hours
--- compressor motor
--- airend
--- SIGMA CONTROL
--- modulating valve
--- load valve ON
--- kWh counter

6 --- 92
 Display Level

Display of operating data

Press and hold the arrow key ( ) until ”operating data” appears in the third line of the dis-
play.

Press the return key ( ) to display operating hours, number of operations of the load valve



and power consumption.
Move from one display to the next with the arrow keys ( ).


).
Press the arrow key ( ) until ”operating hours” appears in the third line of the display.
Move between the different displays with the arrow keys (


All running periods are displayed, such as


compressor run


hours on load


motor running period*


airend running period*


SIGMA CONTROL operating hours*
Modulating valve operating hours*

 

* If the running period is shown in the third line of the display its value can be selected with the
return key ( ) and changed with the arrow keys ( ). Change the running period if the corre-
sponding component has been replaced.
The following display option is possible:
Example:

 
 
     "!˚ 
2
#$&%
3
' (
1 Current system pressure and airend discharge temperature
2 Description of counter
3 Counter value

6 --- 93
 Display Level

6.4 Maintenance

maintenance
esc
--- oil filter
--- reset
--- oil separator
--- reset
--- oil change
--- reset
--- air filter
--- reset
--- V---belts change
--- reset
--- V---belt tension
--- reset
--- bearing change
--- reset
--- bearing
maintenance.
--- reset
--- elect. equip.
--- reset

6 --- 94
 Display Level

Display of maintenance hours

Press and hold the arrow down key ( ) until “maintenance” appears in the third line of the
display.

Press the return key ( ).
All maintenance hours remaining until the next maintenance are displayed.


Example:


oil filter


oil separator


oil change


air filter


V---belts change


V---belt tension


bearing change


bearing maintenance
elect. equip.
The following display options are possible:
Example:

 
  ˚ 

  
2
 !#" $
4 &% ('*) +3
1 Current system pressure and airend discharge temperature
2 Description of maintenance counter
3 Remaining hours to next maintenance
(remaining time --- countdown)
4 Default maintenance interval
5 Reset of maintenance interval

6 --- 95
 Display Level

6.4.1 Setting/resetting the maintenance interval counter

Attention! When the maintenance is complete the remaining interval (3) must be reset
to the default interval (4).

Note Password level 4 access is required to carry out changes to the maintenance
interval counters.

Activate password level 4 (see chapter 7.1.1).
Resetting the maintenance interval counter


The remaining hours in the corresponding maintenance interval counter can be individually reset.
Press and hold the arrow down key ( ) until “reset” appears in the third line of the display.
Example:

 
 
     ˚ 
   

! "
!
Press the return key ( ), a flashing cursor appears below the “n”.
#
Change the reset display from “n” to “y” with the arrow up key ( ).
! $
Confirm with the return key ( ). The counter resets to the default maintenance interval.
At the same time the reset display changes from “y” to “n”.

6 --- 96
 Display Level

Setting the maintenance interval

Press and hold the arrow down key ( ) until the hours display for the required maintenance
interval appears in the third line of the display.
Example:

  
  ˚ 

    
         !
"$#&%'#)(* +-,
. /
.
Press the return key ( ), a flashing cursor appears below the maintenance interval.
0
1
The maintenance interval can be increased with the arrow up key ( ) and reduced with

.
the arrow down key ( ).
/
.
Enter the maintenance interval setting with the return key ( ).
Return to the main menu with the “esc” key.

6 --- 97
 Display and Setup Level

7 Display and Setup Level

In the Display and Setup Level the settings for the password, clock, configuration, package test
and the interfaces are displayed.
The settings can be individually adapted at this level.

Note All the following points refer to password level 4.

7.1 Password

password
esc

--- password
---password:
XXXXX L0
XXXXX L0

7 --- 98
 Display and Setup Level

7.1.1 Enter password


(Main menu password)

In the main menu, press and hold the arrow key ( ) until ”password” appears in the third line
of the display.


Press the return key ( ).
The following display appears:


  ˚ 
  
   ! "  #
2    ! "  $ 3

1 Current system pressure and airend discharge temperature

2 Designation of step to be taken
3 Activation of above step

% &
Press the return key ( ).

The cursor flashes in the first character of the password (XXXXX).

'()
*+, -. ˚ /
+0 1123,45
6 6 6 6!6 7 . 8
6 6 6 6!6 7 . $

Start here with the entry of the password.

% Scroll through the character set with the arrow keys ( 9;: ) until the desired character appears.
< =
Press the return key ( ) to confirm the selection and the cursor moves to the next character
in the password.
Repeat the procedure for the remaining characters in the password.
The activated password level is shown when the last character is entered.

The following passwords are entered in the controller on delivery:

Level Password
0 00000
4 12EXP

7 --- 99
 Display and Setup Level

7 --- 100
 Display and Setup Level

7.1.2 View password

Press the ( ) arrow key once.


  ˚ 
  
   
 
 
Press the return key ( ).
The password for the activated level is displayed.


!" #$ ˚ %
&&&&& '(
)+*-, &/.0'( 1
222 3

7 --- 101
 Display and Setup Level

7.2 Clock

clock
esc

--- compressor ON/OFF

--- clock key: y/n
--- reset: y/n
--- switch points 01--- 10

7 --- 102
 Display and Setup Level

7.2.1 Display and set up of the clock

(Main menu clock)
The compressor can be controlled with the clock from the integrated timer. The clock can be pro-
grammed in this menu option to allow the compressor to produce compressed air within
predetermined time periods and shut down when none is needed.

Ten different switching points are available.
Clock


(Main menu clock)

In the main menu, press and hold the arrow key ( ) until ”clock” appears in the third line of


the display.
Press the return key ( ). 
The following display appears:

  
  ˚ 

  
 !" #%$
&'&(&(&'&(&'&(&(&'&(&'&(&(&'&(&'&(&()
*
+
Activate the clock key
,
+
Press the arrow key ( ), until ”clock key: n” appears in the third line of the display.
-
+
Press the return key( ), a flashing cursor appears below the ”n”.
Change the entry from ”n” to ”y” with the arrow key ( ). ,
+ -
*
Confirm the change with the return key .

+
Delete all switch points
,
+
Press the arrow key ( ), until ”reset: n” appears in the third line of the display.
-
+
Press the return key( ), a flashing cursor appears below the ”n”.
,
+
Change the entry from ”n” to ”y” with the arrow key ( ).
-
*
Confirm the change with the return key , all the preset switch points will be deleted.

+
Programming the clock
.
+
Press the ( ) arrow key twice.
-
+
Press the return key ( ), a flashing cursor appears below ”n.a.”.
,/. ).
+
The weekdays for the first switch point can now be set with the arrow keys (
Confirm the weekday setting with the return key( ). -

7 --- 103
 Display and Setup Level

Note Blocks are available for repetitive switch points on several weekdays, e.g.
Mo--- Fr.



  ˚ 


 


 

 










 

 
Press the ( ) arrow key once.



  ˚ 
    

 

 
  !
#" 
 

 $% ).

Press the return key to set the time with the arrow keys (
&

Confirm the time setting with the return key( ).

Press the ( ) arrow key once.



  ˚ 
  
(')* 
  !
#" 
 

 & $
Press the return key ( ) and the arrow key ( ) once to set the compressor to ON.



  ˚ 
    
(') * 
  !
#"
+ 

 &
Press the return key ( ) to confirm. At this point in time the compressor switches to full load.
To shut down the compressor a further switch point has to be programmed. Ten switching points
are available.

7 --- 104
 Display and Setup Level

By pressing the return key ( ) the other switching points are displayed.
Enter one after the other the appropriate weekday, the time and whether or not the com-
pressor is to be switched on or off.


  ˚ 
 

    
 !#"$&% '

When all switching points have been set, exit the menu with the escape esc” key.

7 --- 105
 Display and Setup Level

Example 1:
It is intended to run a compressor from 05:30 to 12:00 and from 13:00 to 21:10 daily. It is shut
down at weekends from 14:00 Fridays to 05:30 Mondays, during company holidays from 11 July
to 26 July, and over the New Year from 12:00 on December 24 (12.00 ) until 02.01. (5.30) Jan-
uary 2.

Main menu: clock:

1st switching point 2nd switching point

01 Mo ---Th 02 Mo ---Th
05:30 12:00
compressor ON compressor OFF

3rd switching point 4th switching point

03 Mo ---Th 04 Mo ---Th
13:00 21:10
compressor ON compressor OFF

5th switching point 6th switching point

05 Fr 06 Fr
05:30 14:00
compressor ON compressor OFF

The remaining switching points are not allocated.

To ensure that the compressor is shut down during the holiday period, settings must be entered
in menu option ”configuration
compressor start compressor OFF holidays”.

7 --- 106
 Display and Setup Level

Example 2:
A compressor is required from 6:00 Monday until 22.00 Saturday because of four ---shift working
in production.

Main menu: clock:

1st switching point

01 Mo
06:00
compressor ON

2nd switching point

02 Sa
22:00
compressor OFF

Note All settings in the ‘clock’ menu are active only after the clock key has been
pressed.

Note The clock key is inactive on delivery to prevent operator error.

It can be enabled in the ’clock’ menu.

7 --- 107
 Display and Setup Level

7.3 Configuration

configuration
esc
--- general
--- pressure settings
--- control mode
--- acknowledgement
--- compressor start
--- I/O periphery
--- timer

7 --- 108
 Display and Setup Level

Display and set up of the configuration

(main menu configuration)

In the main menu, press and hold the arrow up key ( ) until “configuration” appears in the

third line of the display.
Press the return key ( ).
All settings affecting the configuration can be displayed and changed in password level 4.
The following display options are possible:
  
 general
 pressure settings
 control mode

 acknowledgement (reset)
timer
compressor start I/O periphery

Example:

  

  ˚ 
 
       !  "
#$  $  % $& 
2
'

1 Current system pressure and airend discharge temperature

2 Display of the various submenus
( )+* ).
(
Scroll between the individual entries with the arrow keys (
Scroll the desired menu option to the third line and activate with the return key ( ). ,
7.3.1 General
- -
(
(main menu configuration general)
Press and hold the arrow keys ( ).* ) until “general” appears in the third line of the display.
( Press the return key ( ).,
/
The following values are shown and can be changed, if required:

/
version no.

/
model

/
PN: (part number)

/
SN: (serial number)

(
weekday
)+*
Press and hold the arrow keys ( ) until “weekday” appears in the second line of the
display. The default weekday is displayed.

7 --- 109
 Display and Setup Level

date


Press and hold the arrow keys ( ) until “date” appears in the second line of the display.
The default date is displayed.

Press the return key (  ).


Use the arrow keys ( ) to select the current date.

Confirm with the return key (  ).
Repeat the above procedure for the month and year.

Return to the main menu with the ”esc” key.
time setting


Press and hold the arrow keys ( ) until “time” appears in the second line of the display.

Press the return key (  ).


Use the arrow keys ( ) to select the current hour.

Confirm with the return key (  ).
Repeat the above procedure for minutes and seconds.

Return to the main menu with the ”esc” key.
Summer/Winter time


Press and hold the arrow keys ( ) until ”summer/winter t” appears in the second line of
the display.

Press the return key (  ).
Start of summer time:


Press and hold the arrow keys ( ) until ”summertime” appears in the second line of the
display.

Press the return key (  ). A flashing cursor appears below the day value.


Select the required day and month for the changeover with the arrow keys ( ) and con-
firm each setting with the return key (  ).

Press the arrow key (  ) until the time appears in the third line of the display. Press the
return key (  ).


Select the hours with the arrow keys ( ) and confirm with the return key (  ).
Start of winter time:


Press and hold the arrow keys ( ) until ”wintertime” appears in the second line of the
display.

Press the return key (  ). A flashing cursor appears below the day value.


Select the day for the changeover with the arrow keys ( ) and confirm with the return
key (  ).

Press the arrow key (  ) until the time appears in the third line of the display. Press the
return key (  ).


Select the hours with the arrow keys ( ) and confirm with the return key (  ).
Activating the time changeover:


Press and hold the arrow keys ( ) until ”act.:” appears in the second line of the display.

Press the return key (  ).


Change the entry from ”n” to ”y” with the arrow keys ( ) and activate with the return
key (  ).

7 --- 110
 Display and Setup Level

data format (TT.MM.JJ)


Press and hold the arrow keys ( ) until “date format” appears in the second line of the
display.
The currently set date format is shown in the third line of the display.

Press the return key (  ).
The cursor flashes below the date format.


Use the arrow keys ( ) to select the required date format.
Example:
DD.MM.YY 30.08.98
YY---MM---DD 98 ---08 ---30
MM/DD/YY 08/30/98
D stands for day, M for month, and Y for year.

Confirm with the return key (  ).
time format (hh:mm:ss)


Press and hold the arrow keys ( ) until “time format” appears in the second line of the
display.

Press the return key (  ).
The cursor flashes below the time format.


Use the arrow keys ( ) to select the required time format.
Example:
hh:mm:ss 08:29:43
hh:mm 08:29
hh:mm:ss AM/PM 08:29:43 AM
hh:mm AM/PM 08:29 AM
h stands for hours, m for minutes, s for seconds, AM for forenoon and PM for after-
noon.

Confirm with the return key (  ).
unit of pressure (bar, hPa, MPa, psi, at, “Hg)


Press and hold the arrow keys ( ) until “unit of press.” appears in the second line of the
display.
The unit of pressure is displayed in the third line.

Press the return key (  ).
A flashing cursor appears below the unit of pressure.


Use the arrow keys ( ) to select the required unit of pressure.
Example:
bar
hPa hectopascal
MPa megapascal
psi pressure per square inch
at atmospheric gauge pressure
“Hg inches of mercury column

Confirm with the return key (  ).

7 --- 111
 Display and Setup Level

unit of temperature


Press and hold the arrow keys ( ) until “unit of temp.” appears in the second line of the
display.
The unit of temperature is displayed in the third line.

Press the return key (  ) and a flashing cursor appears below the unit of temperature.


Use the arrow keys ( ) to select the required unit of temperature.

Example:
20 ˚ C degrees Celsius
68 ˚ F degrees Fahrenheit
293 K degrees Kelvin

Confirm the selection with the return key (  ).

7.3.2 Pressure settings

(main menu  configuration  pressure settings)


Press and hold the arrow keys ( ) until “pressure settings” appears in the third line of the
display.

Press the return key (  ).
The pressure settings menu has three options:
compressor
vacuum package
load control

7.3.2.1 Compressor configuration

(main menu  configuration  pressure settings  compressor)
Pressure parameters important for the compressor are displayed and set in the following subme-
nus.

Press the return key (  ) to enter the submenus.
pRV (pressure relief valve)
The opening pressure of the pressure relief valve on the oil separator tank is shown in this
menu option.
pressure increase
(main menu  configuration  pressure settings  compressor  pressure increase)
This value is added to the nominal package pressure during external load control and serves
as the upper safety limit should the external controller malfunction.


Press and hold the arrow keys ( ) until ”press. increase” appears in the third line of the
display.

Press the return key (  ).
The currently set value for the pressure increase pE appears in the third line of the display.

Press the return key (  ).


Set the required value with the arrow keys ( ) and confirm with the return key (  ).
The same applies to the switching differential ---SD.

Return to the main menu with the “esc” key.

7 --- 112
 Display and Setup Level

Nominal pressure
The compressor is designed for this end pressure. It also represents the maximum possible
system setpoint pressure.
This value is installed at the factory and can only be changed by an authorised KAESER
agent.
Setpoint pressure
The two pressure parameters p1 and p2 at which the compressor package can be run, the
upper cut ---out point together with its switching differential (SD) in each case, are displayed
and can be changed here.
Setting up a parameter:


Scroll the required parameter into the third line of the display with the arrow keys ( ).

Press the return key (  ).


Set the required value with the arrow keys ( ) and confirm with the return key (  ).
system pressure low
The parameters for switching differential (SD) and the switching point (SP) for the low pres-
sure warning message are displayed and can be set in this menu option.
Setting a parameter:


Scroll the required parameter into the third line of the display with the arrow keys ( ).

Press the return key (  ).


Set the required value with the arrow keys ( ) and confirm with the return key (  ).
Minimum cut ---in pressure (cutin press min):
This value is installed at the factory and can only be changed by an authorised KAESER
agent.

Note Economical production of compressed air is only possible above this

pressure.

It is regarded as the system pressure lower limit minus the system pressure switching differ-
ential.

Scroll the parameter to be set into the third line of the display.

Press the return key (  ).
A cursor appears below the pressure value.


Set the required value with the arrow keys ( ) and confirm with the return key (  ).
This value is installed at the factory and can only be changed by an authorised KAESER
agent.

7 --- 113
 Display and Setup Level

7.3.2.2 System pressure of the vacuum package

(main menu configuration pressure settings vacuum package)


Press and hold the arrow keys ( ) until “vacuum package” appears in the third line of the
display.

Press the return key (  ).
This submenu is divided into the following options:
 
system pressure high setpoint pressure

pressure fall


system pressure high
The parameters for switching differential (SD) and the switching point (SP) for the high pres-
sure warning message are displayed and can be set in this menu option.
Also the output used for the warning is shown.
Setting a parameter:


Scroll the parameter to be set into the third line of the display with the arrow keys ( ).

Press the return key (  ).


Set the required value with the arrow keys ( ) and confirm with the return key (  ).

setpoint pressure
The two pressure parameters p1 and p2, i.e., the lower cut ---out point together with its
switching differential (SD) in each case, are displayed here.
Setting a parameter:


Scroll the parameter to be set into the third line of the display with the arrow keys ( ).

Press the return key (  ).


Set the required value with the arrow keys ( ) and confirm with the return key (  ).

Pressure fall
(Main menu Configuration Pressure settings Vacuum package pressure fall)
This value is subtracted from the rated package pressure during external load control and
serves as the lower safety limit should external control malfunction.


Press and hold the arrow keys ( ) until ”pressure fall” appears in the third line of the
display.

Press the return key (  ).
The currently set value for the pressure fall pA appears in the third line of the display.

Press the return key (  ).


Set the required value with the arrow keys ( ) and confirm with the return key (  ).
The same applies to the switching differential SD.

Return to the main menu with the esc” key.

7 --- 114
 Display and Setup Level

7.3.2.3 Load control

(Main menu Configuration Pressure settings Load control)


Keep pressing the arrow keys ( ) in the ”pressure settings” submenu option until ”load con-
trol” appears in the third line of the display and then press the return key (  ).

Selecting load control
The method of control for the compressor package is selected here.
With this function a changeover can be made between an external master controller (such as
SAM or MVS) and the internal pressure parameters in SIGMA Control.

Note If SIGMA Control is interfaced to a master controller via the Profibus then
no settings have to be made. The bus master (master controller) takes over
remote control automatically.

The following modes are avail- a) local mode from setpoint pressures p1 or p2
able:
b) remote mode setpoint pressure p1/p2 change or load ---
idle change from a remote signal

a) If the compressor is not controlled externally it defaults to the internal controller, SIGMA Con-
trol.
Here, it is possible to keep to p1 or p2 permanently, to switch them with the clock or to cycle
them periodically.


Scroll with the arrow keys ( ) until ”local mode” appears in the second line of the display.

Press the return key (  ). A flashing cursor appears below the operating mode.


Set the required mode with the arrow keys ( ) and confirm with the return key (  ).
b) If the compressor package is to be controlled externally it must be set to remote mode.
The setpoint pressure (p1 or p2) or if load or idle has priority in remote mode are set in this
menu option.


Scroll with the arrow keys ( ) until ”remote mode” appears in the second line of the display.

Press the return key (  ).
A flashing cursor appears below the operating mode.


Set the required mode with the arrow keys ( ).

Example:  Setpoint pressure p1  p1/p2 remote contact

 Setpoint pressure p2  p1/p2 RS485
 p1/p2 clock  load remote contact
 p1/p2 cycle  local---load remote contact

Confirm with the enter key (  ).

Note If the compressor package is to be controlled externally, activate the remote

key ( ).


Scroll with the arrow keys ( ) until ”remote key y/n” appears in the third line of the display.

Press the return key (  ).
A flashing line appears below the ”y” or ”n”.


Set the required mode with the arrow keys ( ).

Confirm with the enter key (  ).
The current load control mode selection is displayed

7 --- 115
 Display and Setup Level

Load control settings


Press and hold the arrow keys ( ) until “settings” appears.
If the compressor package is switched between p1 and p2 setpoint pressures from a remote
contact the input address is shown here.
Changeover between p1 and p2 from the internal clock:
If the compressor package is to be run using two different pressures (p1 and p2), the switching
points for both pressures can be set in this menu option.
This is required for shift working, for example.

Press the return key (  ) when ”p1/p2” stands above ”clock” in the second line of the display.
The following display appears:

  
˚ 
!"!"!!"!"!!"!"!!"!#

$ Press the return key ( % ) and then change ”n” to ”y” with the arrow keys ( &(' ).
$ Confirm with the return key ( % ); if necessary all previously set switching points are deleted.
$ Press the arrow key ( ' ) three times, the following display appears.
)*
+,-. /0
243 568796 ˚1
229:822 ;
< 3 => ?

The 01 in the upper left of the display indicates that this is the first switching point.
The appropriate weekday is set in the second and the appropriate time for the weekday in
the third line. The fourth line is used to determine whether p1 or p2 is selected from this time
on.
@ Press the down arrow key ( A ) to access the other switching points.

Note Ten switching points are available.

See chapter 7.2 for further information on setting up the clock.

B
Changeover between p1 and p2 from the internal timer.
The cycle periods can be preset if the compressor package is switched by a timer between set-
point pressures p1 and p2.
@ Press the arrow down key CED ) until “p1: ..h” appears in the third line of the display.
F Press the return key ( G ).
A flashing cursor appears below the hours.
F Set the hours with the arrow keys ( HI ).
F Confirm with the return key ( G ).
F Press the arrow down key CED ) until “p2: ..h” appears in the third line of the display.
F Press the return key ( G ).

7 --- 116
 Display and Setup Level

A flashing cursor appears below the hours.


Set the hours with the arrow keys ( ).
Confirm with the return key (  ).

Note Deactivate the timer before presetting hours.

Under timer control the start of the period must be preset.

Press the arrow down key (  ) until “  1.Start p1 at: ..h” appears in the third line of the dis-
play.
Press the return key (  ).
The cursor appears below the colon.


Select either setpoint pressure p1 or p2 with the arrow keys ( ).
Confirm with the return key (  ).


Press the arrow keys ( ) until the time below “  1.Start p1 at: ..h” appears in the third line of
the display.
Press the return key (  ).
A flashing cursor appears below the hours.


Set the hours with the arrow keys ( ).
Press the return key (  ), the cursor jumps to the minutes display.


Set the minutes with the arrow keys ( ).
Press the return key (  ) to confirm.

The input address for the remote contact can be set in various control modes.
Idle key
The idle key on the control panel can be deactivated to prevent unauthorised use.
Press the arrow keys (   ) until “idle key: y/n” appears in the third line of the display.
Press the return key (  ).
Select idle key active “y” or inactive “n” with the arrow keys (   ).
Confirm with the return key (  ).

7.3.3 Control Mode

(Main menu
Configuration
control mode)


Keep pressing the arrow keys ( ) in the control mode menu option until ”local mode” ap-
pears in the second line of the display and then press the return key (  ).
SIGMA CONTROL is provided with several control modes.


Press and hold the arrow keys ( ) in local mode until the control mode appears in the third
line of the display.
Press the return key (  ).


Select the required control mode with the arrow keys ( ).
The following control modes can be selected:
 
DUAL QUADRO
 
VARIO continuous (compressor does not shut down)

Press the return key (  ) to confirm the selection.

This activates the selected control mode!

7 --- 117
 Display and Setup Level

7.3.3.1 DUAL Control settings (normal control)

(Main menu Configuration Control mode) Dual)


Keep pressing the arrow keys ( ) in the ”control mode” menu option until ”  Dual” appears
in the third line of the display below the option ”settings” and then press the return key (  ).

Idle setting in DUALcontrol


Press the arrow keys ( ) until ”idle period” appears in the second line of the display
and then press the return key (  ).


Select the required idle period with the arrow keys ( ) and confirm with the return
key (  ).
The minimum idle period in DUAL control is 450 s.

7.3.3.2 QUADRO control settings


Press the arrow keys ( ) until  Quadro” appears in the third line of the display and then
press the enter key (  ).

Setting the unloaded period


Press and hold the arrow keys ( ) until ”unloaded period” appears in the second and
”450s 0.00s” in the third line of the display. Press the return key (  ).


Set the required period with the arrow keys ( ) and confirm with the return key (  ).

Minimum unloaded period


Scroll with the arrow key ( ) until ”unloaded period” appears in the third line of the dis-
play and then press the enter key (  ) to display the minimum unloaded period.

Minimum run period setting


Press and hold the arrow keys ( ) until ”min run period” appears in the second and
”450s 0.00s” in the third line of the display.

Press the return key (  ).


Set the required minimum run period with the arrow keys ( ) and confirm with the re-
turn key (  ).
--- minimum running period


Scroll with the arrow key ( ) until ”min run period” appears in the third line of the display
and then press the enter key (  ) to display the minimum running period.

7.3.3.3 Venting period

(Main menu Configuration Control mode venting period)


Keep pressing the arrow keys ( ) in the ”control mode” menu option until ”venting period”
appears in the second line of the display and then press the return key (  ).

A flashing cursor appears below the first period and the venting period can be set with the

arrow keys ( ).

Confirm the selected venting period with the return key (  ).
The inlet valve is closed during the venting period to allow the compressor package to vent.
When the venting period expires the drive motor is stopped.

7 --- 118
 Display and Setup Level

7.3.3.4 Dryer
(Main menu Configuration Control mode) dryer)


Keep pressing the arrow keys ( ) in the ”control mode” menu option until ”” appears in the
second line of the display and then press the return key (  ).

A flashing cursor appears below ”continuous” that can be changed over to ”timer” with the

arrow keys ( ).

Enter the new mode with the return key (  ).
The dryer ”timer” setting is an energy ---saving control option for the refrigeration dryer. With this
menu option the dryer is shut down under time control whenever no compressed air is required.
The operating temperature in the refrigeration dryer is kept constant within narrow limits under
this method of control by cycling the refrigerant circulation.

7.3.3.5 Modulating control

(Main menu Configuration Control mode Modulating valve)


Keep pressing the arrow keys ( ) in the ”control mode” menu option until ”mod. valve” ap-
pears in the third line of the display and then press the return key (  ).
Modulating control is a mechanical form of control.
The inlet valve opens more or less under the influence of a pneumatic controller.
To ensure optimal control on large compressors such as GS or HS control air for the proportional
controller is taken from an external air receiver.

Changeover point of the pressure control valve


Keep pressing the arrow keys ( ) until ”pN SP: ...bar” appears in the third line of the
display and then press the return key (  ).


Set the required change---over pressure with the arrow keys ( ) and confirm with the
return key (  ).

Note A solenoid valve changes between internal and external pressure depending
on system pressure.

Switching differential


Keep pressing the arrow keys ( ) until ” ---SD: ...bar ” appears in the third line of the
display and then press the return key (  ).


Set the required pressure switching differential with the arrow keys ( ) and confirm with
the return key (  ).

Modulating control valve address
The current output address of the modulating valve is shown in the third line of the display.

7.3.4 Compressor start

(main menu configuration compressor start)


Keep pressing the arrow keys ( ) in the “configuration” menu option until “compressor
start” appears in the third line of the display and then press the return key (  ).
The following settings can be made in this menu option:

compressor ON
The time at which the compressor packages are started can be set in this menu option. Also,
it can be differentiated between “local” and “remote”, i.e., direct control

7 --- 119
 Display and Setup Level

local mode:

The compressor package can be started locally with the ON key ( ) and additionally by the
clock.


Press and hold the arrow keys ( ) in the compressor start menu option until “com-
pressor ON” appears in the third line of the display.

Press the return key (  ).


Scroll with the arrow keys ( ) until “local mode” appears in the second line of the dis-
play.

Press the return key (  ).
A flashing cursor appears below the operating mode.

Select either “key” or “key + clock”.

In the “key” mode the compressor package is started with the ON key ( ). In the
“key + clock” mode the compressor package is additionally started by the internal clock.

Enter the selection with the return key (  ).

Press the arrow down key (  ) until “clock key” appears in the third line of the display.

Press the return key (  ).


Select clock key active “y” or inactive “n” with the arrow keys ( ).
This protects against unauthorised use.

Confirm with the return key (  ).
remote mode:

Note To start in remote mode the controller must be switched on with the ON
key ( ) and remote mode selected.

The following switching sources can be used:

--- remote contact (RC)
--- clock or remote contact (cRC)
The procedure is exactly the same as for “local mode” settings. The remote key and the
clock key can be activated or deactivated.
The remote contact input can be selected further down in the menu options.

Press the arrow down key (  ) until “* comp. ON” appears in the second line and
“RC  I....” appears in the third line of the display.

Press the return key (  ).
The cursor flashes below the input.


Select a suitable input for the remote contact with the arrow keys ( ).

Enter the selection with the return key (  ).

7 --- 120
 Display and Setup Level

Compressor OFF
Venting: y/n
The compressor shutdown venting function (unloaded start) in remote mode is activated in
this menu.


Press the return key ( ) when ”venting” appears in the third line of the display.

Select ”y” (yes) or ”n” (no) with the arrow keys (  ).


Confirm the selection with the enter key ( ).
Holidays: y/n
In this menu option the compressor package can be shut down if required during holidays
by the clock.


Press the return key ( ) when ”holidays:” appears in the third line of the display.

Select ”y” (yes) or ”n” (no) with the arrow keys (  ).


Confirm the selection with the enter key ( ).
Select the switching point with the down arrow key (  ) that can be set as follows:


Press the return key ( ) when ”holidays” appears in the second and ”00.00.” in the third
line of the display.

A flashing cursor appears below the first digit of the date; set the day with the arrow
keys (  ).


Confirm the selection with the enter key ( ). The cursor jumps to the month.

Select the month with the arrow keys (  ).


Confirm date with the return key ( ).

Press the arrow key (  ) once, until ”00:00” appears in the third line of the display.


Press the return key ( ) once to set the hours with the arrow keys (  ).


Press the return key ( ) to confirm the hours; the cursor jumps to the minutes.

Press the arrow keys (  ) to set the minutes.


Confirm with the return key ( ).
The compressor package will be shut down at the point in time entered. To ensure that the
compressor package automatically starts again a further switching point must be entered.
The switching point to be set is accessed with the down arrow key (  ).
Automatic restart after a power supply failure
When this function is activated the compressor package starts again automatically when
power returns after a power failure.

Note This function is normally activated.


Press the return key ( ) when ”restart:” appears in the third line of the display.

Select ”y” (yes) or ”n” (no) with the arrow keys (  ).


Confirm the selection with the enter key ( ).
Starting temp.
To prevent damage to the airend caused by starting at a temperature that is too low, a mini-
mum starting temperature of 2 ˚ C is set and the function activated in this menu option.

7 --- 121
 Display and Setup Level

7.3.5 Acknowledgement (reset)

(main menu configuration acknowledgement)


Keep pressing the arrow keys ( ) in the “configuration” menu option until “acknowledge-
ment” appears in the third line of the display and then press the return key (  ).
In this menu option the settings for remote acknowledgement of a message are found.

Select remote ackn. input

Scroll the
 option “remote ackn.” into the second line of the display with the arrow
keys ( ).
The following display appears:

 
  
 
˚
!#" $
&% '(

) Press the return key ( * ).

A flashing cursor appears below the input address.
) select an input with the arrow keys ( +, ).
) Confirm the selection with the return key ( * ).
-
Activating the remote key
) Scroll the option “remote key” into the third line of the display with the arrow keys ( +., )
and then press the return key ( * ).
) Select “act.: y” (yes) or “act.: n” (no) with the arrow keys ( +, ).
) Confirm the selection with the return key ( * ).

7.3.6 I/O periphery

(main menu /10 onfiguration / I/O periphery)
) Keep pressing the arrow keys ( +, ) in the “configuration” menu option until “I/O periphery”
appears in the third line of the display.
) Press the return key ( * ).
The submenus are described below:
-
Binary output functions
) Press the return key ( * ) when ”bin.O function” appears in the third line of the display.
The following display appears:
23 46578 9;:
8 8 
C D ˚<
=>?@ >AA;B
E 
C F
:
3 G H
III J

K Press the return key ( L ) when ”O0.3” appears in the third line of the display.
K Select a suitable output with the arrow keys ( MN ).
K Confirm the selected output with the enter key ( L ).

7 --- 122
 Display and Setup Level

Note Eleven output functions are available. Only one function can be allocated to
an output.

Other output functions can be accessed with the arrow down key ( ).


Controller ON Group alarm Motor runnung
Compressor ON Group warning Remote mode
Unloaded mode (idle): On load Clock active
Clock contact (clock) Emergency stop
 Setting up the clock for a clock contact

Press the return key ( ) when ”clock” appears in the third line of the display.
The following display appears:

Press the return key ( ), a flashing cursor appears below the ”n”.

Press the up arrow ( ), the ”n” changes to a ”y”.


Press the return key ( ) to delete all the previously set switching points.
Press the ( ) arrow key twice.
The following display appears:

  

  ˚ 
   
 

 
Press the return key ( ), a flashing cursor appears below the ”n.a.”.
   ).

Select the appropriate weekday with the arrow keys (


Confirm the selected weekday with the enter key ( ).


Press the down arrow key ( ) once and set the time.

Press the down arrow key ( ) once and enter the ON or OFF setting for the contact at
this point in time.
 
Press the ( ) arrow key once.
The following display appears:

!" #$ %& ' ( ˚ )

(* +,-/. &
(0'12*3# 4
57689;:579 <= =?>
@ Further switching points are accessed with the down arrow key ( ). A
Further information on setting up the clock is to be found in chapter 7.2.

7 --- 123
 Display and Setup Level

show quantities
selecting quantities


Keep pressing the arrow keys ( ) in the “I/O periphery” menu option until “show
quantities” appears in the third line of the display.

Enter the list of individual quantities with the return key (  ).
There are two displays each for pressure, temperature and other physical quantities
available.

Press the return key (  ) when the required quantity appears in the third line of the
display.
The denotation of the quantity can be individually adapted.


Set the amperage with the arrow keys ( ).

Confirm with the return key (  ).
message text

Scroll the message text into the third line of the display with the arrow down key (  ).

Press the return key (  ), a cursor appears below the first character of the message text.


Search through the character set with the arrow keys ( ) for another character. Confirm
this character with the return key (  ) and the cursor will move to the next character in
the text.
The message text can consist of up to 15 characters.

When all characters have been selected, confirm with the return key (  ).
selection of sensor input

The sensor input for this message is determined by scrolling the required input into the
third line of the display.

Press the return key (  ), a cursor appears under the corresponding input or its non ---ac-
tivation (n.a.) is displayed.


Select a suitable input with the arrow keys ( ).

Confirm with the return key (  ).
calibration


Scroll in the quantity to be processed with the arrow keys ( ) until “calibration” appears
in the second line of the display.

Press the return key (  ), a cursor appears below the quantity.

A definite quantity can now be assigned to the signal input from the sensor.


The value of this quantity can be changed with the arrow keys ( ).

Confirm with the return key (  ).
external messages
In this menu option the type of message (alarm, service or operational message), the alloca-
tion of an input and the delay period for display of the message can be set.

Press the return key (  ), as soon as “ext. messages” appears in the third line of the dis-
play, the individual messages are displayed and can be processed.


Scroll the parameter to be set into the third line of the display with the arrow keys ( ).

7 --- 124
 Display and Setup Level

message text


Scroll the message text into the third line of the display with the arrow keys ( ).

Press the return key (  ), a cursor appears below the first character of the message text.


Search through the character set with the arrow keys ( ) for another character. Confirm
this character with the return key and the cursor will move to the next character in the
text.
The message text can consist of up to 15 characters.

When all characters have been selected, confirm with the return key (  ).
type of message

Press the arrow down key (  ) to determine the type of message.

Press the return key (  ), a cursor
 appears below the message type, which can be
changed with the arrow keys ( ).

Confirm with the returnr key (  ).
Selection of switched input

Press the arrow down key (  ) to change the switched input.

Press the return key (  ), a cursor appears below the input designation.


This can be changed with the arrow keys ( ).

Confirm with the return key (  ).
delay period

Press the arrow down key (  ) to change the delay period.

Press the return key (  ), a cursor appears below the delay period.


A period between 0 and 600 seconds can be set with the arrow keys ( ).

Confirm with the return key (  ).

7 --- 125
 Display and Setup Level

Analog output parameters

The parameters for an analog output can be set in this menu option.


Press the return key ( ).

The the analog output current (mA) range is set in this menu option.

Press the (  ) arrow key twice to select the signal source.


Select one of the signal sources listed below with the return key ( ) and the arrow keys
(  ).

n.a. pN pi
ADT AI2 AI3
AI4 AI5 AI6
AI7 AI8 p1(2)
dT/dt


Confirm the parameters with the return ( ) key.

Press the down arrow key (  ) four times; here the PT 100 for determination of the ADT is
calibrated.
The following display appears:


   

  
˚
   " !   
  " !  
˚ #
˚ $
% Press the down arrow key ( & ) five times; the pressure transducer is then calibrated here.
The following display appears:

'(
)*+, -.
˚/
021 35476
4 . : 8 9"; 1=< (>.=*+, ?
. 8:9"; .(>.=*+,
$

7 --- 126
 Display and Setup Level

7.3.6.1 Timer
(Main menu Configuration Clock)
A solenoid valve for the drainage of condensate can be activated at regular intervals.


Press the arrow keys ( ) until ”timer” appears in the third line of the display and then press
the enter key (  ). The clock output is located below.

OFF period


Press the arrow keys ( ) until ”OFF” appears in the third line of the display and then
press the enter key (  ).


Set the required time period with the arrow keys ( ) and confirm with the return key (  ).

ON period


Press the arrow keys ( ) until ”ON” appears in the third line of the display and then?
press the return key (  ).


Set the required time period with the arrow keys ( ) and confirm with the return key (  ).

Output


Press the arrow keys ( ) until ”n.a.” appears in the third line of the display and then?
press the return key (  ).


Select the appropriate output with the arrow keys ( ).

Confirm the selected output with the return (  ) key.

7 --- 127
 Display and Setup Level

7.4 Components

components
esc
---motor
---oil circulation
---booster
---AM charging
---PD temperature

7 --- 128
 Display and Setup Level

Display and set up of the components

In the main menu, press and hold the arrow up key ( ) until “components” appears in the
third line of the display.

Press the return key ( ), the following display appears:

  
  ˚ 
    
    

7.4.1 Motor
 

(main menu components motor)
Keep pressing the arrow keys (   ) in the “components” menu option until “motor” appears in

the third line of the display.
Press the return key ( ).!
The submenu “power switching” appears in the display.

7.4.1.1 Power switching

(main menu  components  motor  power switching)

"
The type of motor start and the corresponding settings are entered in this menu option.


Display power switching
Press the return key ( ). !
The selected type of motor start is displayed.

Possible displays: Star ---delta start

Direct ---online---start
High tension
Soft start
Variable frequency drive (FC) compressor
" Setup of power switching
The types of motor start are repeated under the “settings:” menu option.
   ) and confirm with the return
!
Set the required type of motor start with the arrow keys (
key ( ).
The parameters for the respective type of motor start can be set in this menu option.

7 --- 129
 Display and Setup Level

7.4.2 Booster


Press the return key ( ) when “booster” appears in the third line of the display in the “com-
ponents” menu.
The pressure switching point and the pressure switching differential for a booster can be set
in this menu option.
Because a booster only works efficiently above a certain minimum pressure it should be cut
in only after achieving this pressure.
The output controlling the booster is also displayed.
Press the arrow down key (  ) until “SP: ....bar” appears in the third line of the display.


Press the return key ( ), a cursor appears below the pressure value.
Set the required pressure switching point with the arrow keys (  ).


Confirm with the return key ( ).
Press the arrow down key (  ) until “ ---SD: ....bar” appears in the third line of the display.


Press the return key ( ), a cursor appears below the pressure value.
Set the required switching differential with the arrow keys (  ).


Confirm with the return key ( ).
Return to the main menu with the “esc” key.

7.4.3 Air main charging

Press the return key ( ) when “AM charging” appears in the third line of the display in the
“components” menu.
The pressure switching point and the pressure switching differential for air main charging of
an empty air main can be set in this menu option.
A valve is located upstream of the empty air main that first opens when the working pressure
has been reached. The output controlling the valve is displayed.
Press the arrow key (  ) until “SP: ....bar” appears in the third line of the display.


Press the return key ( ), a cursor appears below the pressure value.
Set the required pressure switching point with the arrow keys (  ).


Confirm with the return key ( ).
Press the arrow key (  ) until “ ---SD: ....bar” appears in the third line of the display.


Press the return key ( ), a cursor appears below the pressure value.
Set the required switching differential with the arrow keys (  ).


Confirm with the return key ( ).
Return to the main menu with the “esc” key.

7 --- 130
 Display and Setup Level

7.4.4 Package discharge temperature

Press the return key ( ) when “PD temperature” appears in the third line of the display in the
“components” menu.
The analog input for the transducer is set in this menu option.
Press the arrow down key (  ) until “PD temperature” appears in the second line of the
display.


Press the return key ( ), a cursor appears below the displayed input.
Select the required input with the arrow keys (  ).


Confirm with the enter key ( ).
The pressure switching points and switching differentials for the high or low package dis-
charge temperature alarm and warning messages can be set in this menu option.
Press the arrow down key (  ) until “SP: ....bar” appears in the third line of the display.


Press the return key ( ), a cursor appears below the pressure value.
Set the required pressure switching point with the arrow keys (  ).


Confirm with the return key ( ).
Press the arrow down key (  ) until “ ---SD: ....bar” appears in the third line of the display.
A message delay period can be set in this option.

7 --- 131
 Display and Setup Level

7.5 Package Test

package test
esc
---compressor test
---TÜV check
---binary inputs
---binary outputs
---lamps test

Display and set up of the package test

(main menu
package test)
 
In the main menu, press and hold the arrow up key ( ) until “package test” appears in the
third line of the display.
 Press the return key ( ). 
The following display appears:

 
  ˚ 
   !  "
 #

7 --- 132
 Display and Setup Level

7.5.1 Compressor test

(Main menu Package test Compressor test)
This function is reserved for works---internal approval tests.

7.5.2 TÜV check

(main menu
package test
TÜV check)
 
Press and hold the arrow keys ( ) until “TÜV check” appears in the third line of the display.
 Press the return key (  ).
The submenu is divided into the following options:

7.5.2.1 Pressure relief valve

 Read off the opening pressure on the pressure relief valve’s nameplate and compare it with
the relief valve pressure displayed here (pRV).
 
Press and hold the arrow keys ( ) until ”relief valve: n” appears in the third line of the dis-
play.

When the ”relief valve” test mode is activated, monitoring of internal pres-
sure (blowoff protection) and system pressure regulation are inactive!

The pressure relief valve can be checked for correct function using the following procedure:
 Press the “OFF” key (“O”).
 Close the ball valve at the output of the compressor package.
 Press the return key (  ).
 
Press the arrow key ( ) until the display changes to ”relief valve: j”.
 Confirm with the enter key(  ) .

It is imperative that the pressure rise is monitored during this test. If pres-
sure exceeds the opening pressure of the pressure relief valve by more than
10 percent, abort the test immediately and carry out a visual check of the
pressure relief valve.
 Press and hold the “ON” (“I”) key until the pressure relief valve opens. As long as the
“ON” key is pressed the compressor remains on load and does not switch to idle mode
even if the rated package pressure is exceeded. The internal pressure pi that is reached
when the pressure relief valve blows is shown in the fourth line of the display.

For reasons of safety the function must be deactivated when this check is
finished.

Release the ON key immediately after the opening pressure is reached to

reduce discharge of oil mist to the atmosphere.

Note If the pRV  alarm appears on the display then the opening pressure of the
pressure relief valve has been exceeded by 2 bar. Have the pressure relief
valve replaced by an authorised KAESER service agent.

7 --- 133
 Display and Setup Level

7.5.2.2 Temperature sensor / shutdown temperature


Press and hold the arrow keys ( ) until “ADT alarm” appears in the third line of the display.
Shut down the compressor package and wait until the airend temperature has fallen by
around 5 ˚ C. The offset value is determined by subtracting the actual airend temperature
from 110 ˚ C.
Example:
--- operational airend discharge temperature: 80 ˚ C
--- airend discharge temperature after cooling: 75 ˚ C
--- offset value: 110 ˚ C minus 80 ˚ C = 30 ˚ C


Press the arrow keys ( ) until “offset= ...˚ C” appears in the third line of the display and
then press the return key (  ).


Enter the evaluated offset value with the arrow keys ( ) and confirm with the return key
( ) .


Press and hold the arrow up key ( ) until “ADT alarm:n” appears in the third line of the
Check the temperature sensor for correct function.
Press the OFF key (“0”).
Press the return key (  ).


Press the arrow up key ( ) until the display changes to “ADT alarm: y”.
Confirm with the return key (  ) .
Press and hold the ON (“I”) key and switch the compressor package to load. The ADT
display now shows the total temperature (airend discharge temperature + offset). If the
airend discharge temperature climbs to the previous temperature, the compressor pack-
age will shut down at 110 ˚ C because of the offset. The temperature prevailing at
shutdown
 is displayed in the fourth line of the display by pressing the arrow down key
( ) (ADT).


Press and hold the arrow keys ( ) until “offset= ... ˚ C” appears in the third line of the
display and then press the return key (  ).


Reset the offset value to 40 ˚ C with the arrow keys ( ) and enter with the return key (  )
.

For safety reasons the function must be deactivated when this check is fin-
ished.

7.5.3 Binary input/output check

(main menu  package test  binary inputs)
(Main menu  Package test  Binary outputs)


Press and hold the arrow keys ( ) until “binary inputs” or “binary outputs” appear in the
third line of the display.
Press the return key (  ).
The current binary states of the digital inputs and outputs are shown.
Example:
 
 
 
 ˚ 
  
 "
!!

7 --- 134
 Display and Setup Level

 
The binary status should be interpreted as follows:

 

 


 



 
 



 

7.5.4

Lamps test
Press and hold the arrow keys ( "! ) until “lamps test” appears in the third line of the display.
The following display appears:

 
$#%'& )(
˚ *
-%.0/21 30+,45+ 16387 9 :
2
;,;< = 3

1 Current system pressure and airend discharge temperature

2 Description of check to be made

>
3 Activation of above test

> ?
@
Press the return key ( ).

A B
The setting can be changed from “n’ (no) to “y’ (yes) by pressing the arrow key ( ).
Press the return key ( ) to confirm the change.
All LEDs on SIGMA CONTROL should flash.

Note In case of malfunction contact an authorised KAESER agent.

The display automatically returns to “lamps test: n” after approximately 10 seconds.

7 --- 135
 Display and Setup Level

7.6 Communication

Communication
esc
--- RS 232(1X7)
--- RS485 (1X8)
--- Profibus (1X9)
--- SMS
--- data EEPROM

7 --- 136
 Display and Setup Level

Display of and settings for the interfaces (communication menu)
Press and hold the arrow key ( ) until ”communication” in the third line of the display.

Press the return key ( ).


The following interfaces are listed:
RS232:


provides an interface to a modem or printer.
RS485:


allows two compressors to be sequenced (master ---slave).
L2DP bus (Profibus):


interfaces to a master control system (control centre, PC, PLC VESIS, SAM).
All the parameters entered are permanently stored in the EEPROM even if the power supply
fails.
The following display options are possible:

 
  ˚ 

    
2 !     "
1 Current system pressure and airend discharge temperature
2 List of interfaces

7.6.1 RS 232 interface

The RS 232 is a serial interface that is required for several functions.
This could the interface to a printer or a modem.
# $
Press the return key ( ) when RS 232 is in the third line of the display, the RS 232 menu op-
tion opens.

Function
A function can be allocated to the RS 232 in this menu option or the allocated function is dis-

#
played.
Press the arrow keys ( %'& ) until the function (printer, modem) appears in the third line of the
#
display.
$
Press the return key ( ).

#
The cursor appears below the current function.
%(& ) until the required function for this interface is set.
#
Press and hold the arrow keys (
Confirm with the enter key ( ). $

7 --- 137
 Display and Setup Level

Bitrate


Press and hold the arrow key ( ) until the current bitrate appears in the third line of the dis-
play.
Press the return key (  ).
Press and hold the arrow keys (  ) until the required bitrate appears in the third line of the
display.
Confirm with the enter key (  ).

Format
Press and hold the arrow keys (  ) until ”format” appears in the third line of the display.
The current character frame is shown in the third line of the display.
Press the return key (  ).
Press and hold the arrow keys (  ) until the required format is set.
Confirm with the enter key (  ).
Finally. accept the settings as detailed in chapter 7.6.5.

7.6.2 RS 485 interface

The RS 485 interface is used for the master ---slave function. The settings for bitrate and format
must be the same for both master and slave.

Function
A detailed description of this function is given in chapter 4.
Press and hold the arrow keys (  ) until either “master or slave or n.a.”, as required, appears
in the third line of the display.
Press the return key (  ).
Select the required function with the arrow keys (  ) and confirm with the return key (  ).
A line for the interface check is displayed below the function line. During data transfer a count of
p to 256 is displayed behind the word ”run”.
If a zero is not displayed behind the ”F” then the interface is defective. If this is the case check
the settings and the cable connections for the interface. If a zero is displayed behind the ”F” then
the data transfer is in order.

Bitrate
Press and hold the arrow keys (  ) until the preset bitrate is displayed.

Format
Press and hold the arrow keys (  ) until ”format” appears in the third line of the display.
The current character frame is shown in the third line of the display.
Press the return key (  ).
Press and hold the arrow keys (  ) until the required format appears in the third line of the
display.
Confirm with the return key (  ).

7 --- 138
 Display and Setup Level

Remote key
If the compressor package is to be controlled by a second SIGMA CONTROL via the RS 485 in-
terface (setpoint pressure changeover p1/p2) the remote key must be set to y”.


Press and hold the arrow keys ( ) until ”remote key” appears in the third line of the display.
Press the return key (  ).


Press and hold the arrow keys ( ) until the remote key is set to yes or no, as required.
Confirm with the return key (  ).
Finally, accept the settings as detailed in chapter 7.6.5.

7.6.3 L2DP bus (Profibus)


Keep pressing the arrow keys ( ) until “Profibus” appears in the third line of the display and
then confirm with the return key (  ).
Function
This option shows whether the Profibus is active or not.
Press the return key (  ) when the first entry appears in the third line of the display.
Select the options

 “not active (n.a.)” or “send” or “send and receive (send+ receive)” with
the arrow keys ( ) and then confirm with the return key (  ).
A line for the interface check is displayed below the function line. During data transfer a count of
p to 256 is displayed behind the word ”run”.
If a zero is not displayed behind the ”F” then the interface is defective. If this is the case check
the settings and the cable connections for the interface. If a zero is displayed behind the ”F” then
the data transfer is in order.
Slave number
If the compressor package is connected to a profibus system a clear allocation of the master
must be evident. This allocation is made with the slave number.


Press the arrow keys ( ) until “slave no.: ...” appears in the third line of the display and then
press the return key (  ).


Set the appropriate slave number (3...126) with the arrow keys ( ) and confirm with the re-
turn key (  ).

Bus alarm
The hardware monitoring function is shown in this menu.
The bus monitoring is deactivated for this period by the bus controller after the mains power sup-
ply is switched on.
Start td: After switching on the main power supply a bus alarm is suppressed for this
period of time.
The software monitoring can be activated in this menu.
Timeout: The bus---master must respond to a SIGMA CONTROL signal within this period
otherwise an alarm is initiated.


Press and hold the arrow keys ( ) until ”active (act.:) y/n” appears in the second line of the
display.
Press the return key (  ).


Press and hold the arrow keys ( ) until active is set to”yes” or ”no”.
Confirm with the enter key (  ).

7 --- 139
 Display and Setup Level

Restart: Displays the compressor status after removal of the bus alarm:
---auto. The compressor remains in remote mode and links to the bus
automatically.
---man.: The compressor first links to the bus after pressing the remote key.

Remote key
If the compressor package is to be controlled by a master controller via the L2DP bus the remote
key must be set to ”y”.


Press and hold the arrow keys ( ) until ”remote key” appears in the third line of the display.
Press the return key (  ).


Press and hold the arrow keys ( ) until the remote key is set to yes or no, as required.
Confirm with the enter key (  ).

7.6.4 Short message (SMS) option


Press the arrow keys ( ) until “SMS” appears in the third line of the display and then press
the return key (  ).
Settings for sending short messages to the service technician have to be entered in the “Short
messages (SMS)” menu option if a SIGMA TELE CARE agreement has been signed.
Press the arrow down key (  ) once, until ”active (act.:)” appears in the third line of the dis-
play.
Press the return key (  ) and change the “n” to a “y” with the arrow up key (  ).
Confirm with the return (  ) key.


  
  ˚
!"$#&%(' #*)&+&,"-
.//021 3

Note The short message (SMS)” option can only be used if a KAESER modem is
fitted and it is connected to the telephone line.

4
56789 :;
8=>? @
˚<
AB!C"C$D&E(F D*G&H&I"J
=K/8@@/L2M 3

N Further necessary settings are accessed with the down arrow key ( O ).
N The respective submenus are accessed by pressing the return key ( P ).

7 --- 140
 Display and Setup Level

Modem
The telephone number of the online modem is entered and necessary initialisation is carried out
in this option.

 

  ˚ 
 
 ˚ 
   
  2.x !#" !  !   ! $    !  "
    %'&( )+*& -, 

Location
The responsible Kaeser subsidiary is shown. The customer’s name, telephone number and the
language in which the SMS is to be sent can be entered in this option.

 
 ˚  7 89: ;< => ˚ ?

+. /  . !  ! 
10 @#AB#CD+EGF <
 23 4 3x HJIIIIIIIIIII 4 4x
55 5 6 HJIIIIIIIIIII 6

789: ;< => ˚ ? 789: ;< =>

CFK @#AB#CD+EGF <
8 LNMGL K ;1OP A ;1P F ˚ ?
H IIIIII 4x H QF#AC B@1R ST
H IIIIII 6
U Channel 1
The telephone number of the responsible call centre, the number of automatic redials and the
duration of the pause between two calls is entered in this menu option.
Further, the telephone number of the customer service department responsible and the type of
protocol sent in the SMS is shown.
V WXY Z[ \]
 V WXY Z[ \] ˚ ^

_`a W ^ Z aa ^ `1b_` ˚[ ^ _`a WihNjGh ^k^mln^ h
c ]d#V d#eX f 4x c ]d#V d#\o f 4x
c e d+]]e g cqp eeV] g

V WXY Z[
 \] ˚ ^ VWXY Z[ \]
r [1s _ st1s a Z#z _ s [ ` l+{ | Z a ˚^
cvuxwy f 4x b z#} Y ` [~ X 
WWW g € ~ d‚} b| ƒ
U Channel 2
The channel 2 setup is the same as for channel 1.

7 --- 141
 Display and Setup Level

7.6.5 Saving settings

All important data are stored in an EEPROM that is no ---volt safe.
Data are retained even if the buffer battery discharges completely.
If the procedure is activated it takes approximately 30 seconds for the display to change back
from “y” to “n”.

Attention! No changes should be made to the controller when saving data.

Loss of power when saving can lead to loss of data.


Press and hold the arrow keys ( ) until “data  EEPROM” appears in the third line of the
display. Press the return key (  ) .


Change the entry from “n” to “y” with the arrow keys ( ).
Confirm with the return key (  ).
When the display returns to “n” exit the submenu with the “esc” key.

7 --- 142
 Display and Setup Level

7.7 Languages

language

7.7.1 Setting the language

Press and hold the arrow up key ( ) until the language setting appears in the third line of the
display.
Press the return key ( ).


Select the required language with the arrow up key ( ).

Confirm with the return key ( ) .


Return to the main menu with the “esc” key.

7 --- 143
 Display and Setup Level

7.8 List of Abbreviations

A alarm or alarm message mod modulating
act active or activated mot motor
ADT airend discharge temperature MOPS motor overload protection
AI analog input switch
alm alarm MPa megapascal
AM air main n no (negative answer)
an. analog n.a. not activated
AO analog output Nm Newton meter
avail available, already existing no. number
bin. binary O operational message
blowoff prot blowoff protection output
C alarm activated, OM operational message
not yet acknowledged op operation
clk clock open cct. open circuit
ch characteristic os oil separator
c/o changeover P0 parameter “0”
comp compressor pA pressure fall
cont break continuity break P parity
cont. contactor p pressure, usually airmain
corr correction pressure
cRC clock remote contact para parameter
cwT cooling water temperatur partc part cooling
D Dual Control param. parameter
d day PD package discharge
DI digital input pE system pressure increase
diff. differential PDT package discharge
dir direction temperature
DO digital output pd period
DOL direct ---online PG programming function
DoR direction of rotation pi internal pressure
DOS direct ---online---start (in oil separator)
DP decentral periphery PN L2DP
dp delta p (pressure differential) pN system pressure
dT delta T (temperature press. pressure
differential) prot protection
elect. electrical profibus process field bus
equip equipment pRV pressure relief valve
ext . external PS power switching
F fault P---switch pressure switch
fil filter RAM random access memory
Fr Friday RB remote bus
fullc full cooling RC remote contact
G fault rectified, reset alarm RD refrigeration dryer
h hours rdy ready
hdy Holidays S STOP or stop bit
hPa hectapascal s second(s)
HT high tension SD switching differential
I input SN serial number
K Kelvin Sa Saturday
KLink Kaeser link sh.cct short circuit
loc. local SP switching point
max maximum SSt soft start device
min. minute Su Sunday
min minimum t time value
Mo Monday T temperature

7 --- 144
 Display and Setup Level

TAP SMS protocol W warning, or maintenance

td time delay message
temp temperature We Wednesday
tens. tension VFD variable frequency drive
Th Thursday VS variable speed
tmr timer y yes
UCP SMS protocol star ---delta star ---delta (wye---delta)

7 --- 145