Alteration information

Controller

SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010

7_7005 10 USE

Manufacturer:

KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
/KKW/SSCB 2.10 en Z1 7_7005

20150209 100529
 Contents

1 Regarding this Document

1.1 Using this document ......................................................................................................... 1
2 Design and Function
2.1 Operating panel SIGMA CONTROL BASIC .................................................................... 2
2.2 SIGMA CONTROL BASIC function .................................................................................. 3
2.2.1 Display layout ..................................................................................................... 3
2.2.2 Parameter ........................................................................................................... 4
2.2.3 Messages ........................................................................................................... 7
2.3 Operating modes and control modes ............................................................................... 7
2.3.1 Operating modes ................................................................................................ 7
2.3.2 Control modes .................................................................................................... 8
2.4 Remote LOAD / IDLE switching ....................................................................................... 9
3 Installation
3.1 Ensuring safety ................................................................................................................ 11
3.2 Connecting the remote LOAD-IDLE control ..................................................................... 12
3.3 Exchanging the controller ................................................................................................. 12
3.3.1 Exchanging the controller ................................................................................... 13
3.3.2 Bridging the remote contact of the LOAD-IDLE control ...................................... 13
3.3.3 Inserting the program module ............................................................................. 13
4 Initial Start-up
4.1 Setting the network setpoint pressure .............................................................................. 15
4.1.1 Machine without variable frequency drive ........................................................... 15
4.1.2 Machine with variable frequency drive: SINAMICS ............................................ 15
4.1.3 Machine with variable frequency drive: MICROMASTER ................................... 18
5 Operation
5.1 Switching on and off ......................................................................................................... 22
5.1.1 Switching on ....................................................................................................... 22
5.1.2 Switching off ....................................................................................................... 23
5.2 Acknowledging alarm and warning messages ................................................................. 23
5.3 Setting parameters ........................................................................................................... 24
6 Fault Recognition and Rectification
6.1 Basic instructions ............................................................................................................. 26
6.2 Alarm messages (machine shut down) ............................................................................ 26
6.3 Warning messages .......................................................................................................... 27

Alteration information Controller

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 Contents

Alteration information Controller

ii SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 List of Illustrations

Fig. 1 SIGMA CONTROL BASIC nameplate ........................................................................................ 1

Fig. 2 Keys – overview ......................................................................................................................... 2
Fig. 3 Indicators – overview .................................................................................................................. 3
Fig. 4 Connections SIGMA CONTROL BASIC ................................................................................... 12
Fig. 5 Exchanging the controller ........................................................................................................... 13
Fig. 6 Connections to SIGMA CONTROL BASIC ............................................................................... 13
Fig. 7 Program module ......................................................................................................................... 14
Fig. 8 Setting the pressure parameters ................................................................................................ 16
Fig. 9 Setting the pressure parameters ................................................................................................ 19
Fig. 10 Switching on and off ................................................................................................................... 22
Fig. 11 Acknowledging messages .......................................................................................................... 23

Alteration information Controller

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 List of Illustrations

Alteration information Controller

iv SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 List of Tables

Tab. 1 Keys ........................................................................................................................................... 2

Tab. 2 Indicators .................................................................................................................................... 3
Tab. 3 Display ........................................................................................................................................ 3
Tab. 4 Parameters (without SXC series) ............................................................................................... 4
Tab. 5 Parameters (SXC series only) .................................................................................................... 5
Tab. 6 Energy-efficient control modes ................................................................................................... 8
Tab. 7 Setpoint pressure setting on the frequency converter (selection) .............................................. 16
Tab. 8 Setting the setpoint pressure in the frequency converter ........................................................... 17
Tab. 9 Setting the IDLE switching point. ................................................................................................ 18
Tab. 10 Setting the LOAD switching point ............................................................................................... 18
Tab. 11 Network setpoint pressure setting on the frequency converter (selection) ................................. 19
Tab. 12 Network setpoint pressure conversion ....................................................................................... 20
Tab. 13 Setting the IDLE switching point. ................................................................................................ 20
Tab. 14 Setting the LOAD switching point ............................................................................................... 21
Tab. 15 Switching off with/without run-on time ....................................................................................... 23
Tab. 16 Alarm indications ........................................................................................................................ 26
Tab. 17 Warning messages ..................................................................................................................... 27

Alteration information Controller

7_7005 10 USE SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 v
 List of Tables

Alteration information Controller

vi SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 1 Regarding this Document
1.1 Using this document

1 Regarding this Document

1.1 Using this document
The range of functions of the SIGMA CONTROL BASIC controller have been extended. This
means there are changes to the service manual supplied with your compressor. This document
gives information on using the controller.

The nameplate on the controller will tell you if the alteration information applies to your machine.
■ KAESER material number: 7.8700E0 / 7.8701E0 / 7.8701E00010
■ Valid from product version: 14

Fig. 1 SIGMA CONTROL BASIC nameplate

1 Product version 3 SIEMENS material number
2 KAESER material number 4 SIEMENS serial number

1. Compare the material number and/or product version of this alteration information with the de‐
tails on the controller nameplate.
2. Please note the alteration information and the machine's service manual.
3. Insert the alteration information in the service manual.

Alteration information Controller

7_7005 10 USE SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 1
 2 Design and Function
2.1 Operating panel SIGMA CONTROL BASIC

2 Design and Function

2.1 Operating panel SIGMA CONTROL BASIC
Keys

Fig. 2 Keys – overview

Position Name Function

1 «ON» Switch on the machine.
2 «OFF» Switches the machine off.
Resets alarms (acknowledge).
Resets the maintenance interval counter.
6 «Down» Scrolls down the parameter list.
Reduces a parameter value.
7 «Up» Scrolls up the parameter list.
Increases a parameter value.
8 «Cancel» Exits the edit mode without saving.
9 «Accept» Enters edit mode.
Exits the edit mode and saves.
Acknowledge the message.
Only affects the value in the third line of the display.

Tab. 1 Keys

Alteration information Controller

2 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 2 Design and Function
2.2 SIGMA CONTROL BASIC function

Indicators

Fig. 3 Indicators – overview

Position Name Function

12 Display Alphanumeric display with 4 lines.
13 Fault Flashes red when an alarm occurs.
Lights continuously when acknowledged.
15 Warning Lights yellow for:
■ maintenance work due,
■ Warning messages
16 Controller voltage Lights green when the power supply is switched on.
19 ON Lights green when the machine switched on.

Tab. 2 Indicators

2.2 SIGMA CONTROL BASIC function

2.2.1 Display layout
x x . x ba r Line 1
y y °C Line 2
z 0000 h Line 3
12345678SpT i Line 4

Line Indication Meaning

1 xx.x Current system pressure in bar, psi or MPa.
2 yy Current airend discharge temperature (ADT) in °C or °F.
3 z Display of parameters and their settings (see table 45)
4 1, 2, ... Error code for alarm and warning messages (see table 16 and table 17).
Operating state: LOAD
Operating state: IDLE

Tab. 3 Display

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 2 Design and Function
2.2 SIGMA CONTROL BASIC function

2.2.2 Parameter
The parameters for machines of the SXC series differ from all other series.
The first table lists parameters applicable to the series SX to ASK. The second table lists the pa‐
rameters for the SXC series.

SIGMA CONTROL BASIC (without SXC series)

Parameter Meaning
0 Operating hours counter
Displays the total time the drive motor was switched on.
Only an authorized KAESER service representative is permitted to change these pa‐
rameters.
1 Load hours counter
Shows the total time the drive motor has run under LOAD.
Only an authorized KAESER service representative is permitted to change these pa‐
rameters.
2 Maintenance interval counter
Displays the number of operating hours until the next scheduled maintenance is due.
SIGMA CONTROL BASIC counts down the operating hours from a default value. The
warning message “S” is displayed when the counter reaches zero.
The maintenance interval counter must be reset to its default value after the mainte‐
nance work has been carried out. The interval starts anew.
A password is required to change this parameter.
3 Relief valve test mode
This function switches the activating pressure check mode for the safety relief valve on
and off.
The warning message “I” is displayed when the check mode is switched on.
A password is required to change this parameter.
4 Temperature display unit
The airend outlet temperature can be displayed in either °C or °F.
5 Pressure display unit
The current working pressure can be displayed in bar, psi or MPa.
6 Control modes
Factory setting: OFF

This parameter changes the control mode:

■ OFF: QUADRO
■ ON: DUAL
7 Refrigeration dryer control mode
Factory setting: OFF

This parameter changes the dryer control mode:

■ OFF: TIMER
■ ON: CONTINUOUS

Alteration information Controller

4 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 2 Design and Function
2.2 SIGMA CONTROL BASIC function

Parameter Meaning
8 Switching the refrigeration dryer on/off
Factory setting: ON (Option T3)

This parameter switches the dryer permanently on or off:

■ OFF: Dryer switched off
■ ON: Dryer switched on

A password is required to change this parameter. In machines without a refrigeration

dryer, the parameter is factory set to OFF.
C Setpoint pressure: switching differential
The switching differential determines the distance between cut-in and cut-out pressure
(system setpoint pressure: switching point) and therefore the switching frequency from
LOAD to IDLE.
Range of adjustment [psig]: -1.5 ... −73
D Setpoint pressure: switching point
The switching point corresponds to the working pressure of the air system and the cut-
out pressure of the machine.
Setting range [psig]: 80... maximum working pressure
E Maximum possible setpoint pressure setting
Only an authorized KAESER service representative is permitted to change these pa‐
rameters.
F Maximum permitted number of switching cycles reached
This parameter (value: OFF) and the “S” warning message are displayed as soon as
the maximum permitted number of switching cycles is reached.
A password is required to change this parameter.

Replace the main contactor and reset the parameter:

■ OFF: Maximum permitted number of switching cycles reached
■ ON: The counter is reset and the “S” warning message is acknowledged.
G Options
The displayed values inform KAESER service concerning the controller's internal ma‐
chine configuration.

Tab. 4 Parameters (without SXC series)

SIGMA CONTROL BASIC (SXC series only)

Parameter Meaning
0 Operating hours counter
Displays the total time the drive motor was switched on.
Only an authorized KAESER service representative is permitted to change these pa‐
rameters.

Alteration information Controller

7_7005 10 USE SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 5
 2 Design and Function
2.2 SIGMA CONTROL BASIC function

Parameter Meaning
2 Maintenance interval counter
Displays the number of operating hours until the next scheduled maintenance is due.
SIGMA CONTROL BASIC counts down the operating hours from a default value. The
warning message “S” is displayed when the counter reaches zero.
The maintenance interval counter must be reset to its default value after the mainte‐
nance work has been carried out. The interval starts anew.
A password is required to change this parameter.
3 Relief valve test mode
This function switches the activating pressure check mode for the safety relief valve on
and off.
The warning message i is displayed when the check mode is switched on.
A password is required to change this parameter.
➤ Have the relief valve function checked by an authorized KAESER service repre‐
sentative as, by nature of the design, both cannot be tested together.
4 Temperature display unit
The airend outlet temperature can be displayed in either °C or °F.
5 Pressure display unit
The current working pressure can be displayed in bar, psi or MPa.
8 Switching the refrigeration dryer on/off
Factory setting: ON (Option T3)

This parameter switches the dryer permanently on or off:

■ OFF: Dryer switched off
■ ON: Dryer switched on

A password is required to change this parameter.

A Fan: Switching differential
The difference between cut-in and cut-out temperatures is the fan switching differen‐
tial.
Only an authorized KAESER service representative is permitted to change these pa‐
rameters.
B Fan: Switching point
The switching point determines the fan cut-in temperature.
Only an authorized KAESER service representative is permitted to change these pa‐
rameters.
C Setpoint pressure: Switching differential
The switching differential determines the distance between cut-in and cut-out pressure
(system setpoint pressure: switching point) and thus the switching frequency from
LOAD to READY.
Range of adjustment [psig]: -1.5 ... −73
D Setpoint pressure: Switching point
The switching point corresponds to the working pressure of the air system and the cut-
out pressure of the machine.
Range of adjustment [psig]: 80 ... maximum working pressure

Alteration information Controller

6 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 2 Design and Function
2.3 Operating modes and control modes

Parameter Meaning
E Maximum possible setpoint pressure setting
Only an authorized KAESER service representative is permitted to change these pa‐
rameters.
F Maximum permitted number of switching cycles reached
This parameter (value: OFF) and the “S” warning message are displayed as soon as
the maximum permitted number of switching cycles is reached.
A password is required to change this parameter.

Replace the main contactor and reset the parameter:

■ OFF: Maximum permitted number of switching cycles reached
■ ON: The counter is reset and the “S” warning message is acknowledged.
G Options
The displayed values inform KAESER Service concerning the controller's internal ma‐
chine configuration.

Tab. 5 Parameters (SXC series only)

Further information Means of changing or adjusting parameters are given in chapter 5.3.

2.2.3 Messages
Alarm message

An alarm shuts the machine down automatically. The red LED 13 (Fig. 3) flashes.

Warning message

The yellow LED 15 (Fig. 3) lights to indicate a warning.

2.3 Operating modes and control modes

2.3.1 Operating modes
STOP

The machine is connected to the power supply.

The Voltage applied to controller LED lights green.
The machine is switched off. The ON LED is extinguished.

READY

The machine has been activated with «ON»:

■ The ON LED lights green.
■ The drive motor is stopped.
■ The inlet valve is closed.
■ The minimum pressure/check valve shuts off the oil separator from the distribution network.
■ The venting valve is open.

The compressor motor starts as soon as pressure is demanded.

Alteration information Controller

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 2 Design and Function
2.3 Operating modes and control modes

In addition, timing and/or remote control may affect the start of the compressor drive motor.

LOAD

The compressor motor runs under load.

■ The inlet valve is open.
■ The airend delivers compressed air to the system.

IDLE

The compressor motor runs unloaded with low power consumption.

■ The inlet valve is closed.
■ The minimum pressure/check valve shuts off the oil separator from the distribution network.
■ The venting valve is open.

A small volume of air circulates through the bleed hole in the inlet valve, through the airend and
back to the inlet valve via the venting line.

2.3.2 Control modes

Using the selected control mode, the controller switches the drive motor according to definite rules
(the control mode) between the various operating modes in order to compensate for air being
drawn off by consumers and maintain the machine's working pressure between the preset cut-in
and cutout pressures.
The machine-dependant venting phase between the LOAD and READY operating modes ensures
load changes at minimum material stresses.

The controller SIGMA CONTROL BASIC can operate in the following modes:
■ DUAL
■ QUADRO
Option C1 ■ MODULATING control
■ START/STOP control mode (only SXC)

Energy-efficient control modes for various applications:

Application Recommended
control mode
Compressed air station with one machine or several machines with com‐ QUADRO
parable delivery
Machine for peak load in a compressed air station DUAL
Machine for intermediate load in a compressed air station QUADRO
Machine for basic load in a compressed air station QUADRO

Tab. 6 Energy-efficient control modes

The SIGMA CONTROL BASIC controller is factory set to QUADRO control mode unless specifi‐
cally ordered otherwise.

Alteration information Controller

8 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 2 Design and Function
2.4 Remote LOAD / IDLE switching

DUAL

In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to
maintain the machine working pressure between the preset minimum and maximum values. When
maximum pressure is reached, the machine switches to IDLE. When the preset idling time has
elapsed, the machine switches to READY.
The idling time is factory preset according to the maximum starting frequency of the compressor
motor. The shorter the idling time setting, the sooner (and more frequently) the drive motor is stop‐
ped.

QUADRO

In contrast to the DUAL regulating mode, the machine will switch from LOAD to READY in
QUADRO mode after periods with low compressed air consumption.
After periods with a high compressed air consumption, the machine will switch from LOAD to
READY after passing through IDLE.
In this control mode, the controller requires two specified times: The running time and the idle/
standstill time.
The shorter these times are set, the sooner (and more frequently) the motor is stopped.

Option C1 MODULATING control

The MODULATING control is an additional mechanical regulation. It continuously changes the de‐
livery volume within the machine's control range.
A control valve, the proportional controller, changes the degree of opening of the inlet valve when
the machine transports compressed air into the air network (LOAD)
The load and power consumption of the drive motor rises and falls with the air demand.

Only SXC: START/STOP control mode

Using the selected control mode, the controller toggles the machine between the operating modes
LOAD and READY in order to compensate for air being drawn by consumers, and to maintain the
system pressure between the set minimum and maximum values.
The machine automatically continues to run under LOAD if the duty cycle is too low. This
event lasts a few minutes at maximum.
A sufficient duty cycle prevents harmful condensate.

2.4 Remote LOAD / IDLE switching

The controller enables the remote control of the LOAD phase by an external floating relay contact.

Connections

Delivery condition
■ The connections in the controller are provided with a jumper.
■ With the jumper in place, the controller toggles the machine between LOAD and IDLE.

➤ Re-instate this delivery condition when the machine is not to be controlled remotely.

Alteration information Controller

7_7005 10 USE SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 9
 2 Design and Function
2.4 Remote LOAD / IDLE switching

Function

■ Contact closed: LOAD

■ Contact open: IDLE

When the contact closes the machine switches to LOAD. When the contact opens the machine
switches to IDLE.
At the end of the idling period, the machine switches to READY and is in stand-by. The length of
the idling period depends on the control mode selected.
If the «ON» key is pressed while the remote contact is open, the machine remains in stand-by and
starts as soon as the remote contact closes.

Alteration information Controller

10 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 3 Installation
3.1 Ensuring safety

3 Installation
3.1 Ensuring safety
Follow the instructions below for safe installation.
Warning instructions are located before a potentially dangerous task.

Disregard of warning instructions can cause serious injuries!

Complying with safety warnings

Disregard of safety warnings can cause unforeseeable dangers!

➤ Note the instructions in the machine operating manual, chapter "Safety and responsibility".
➤ Installation work may only be carried out by authorized personnel.
➤ Make sure that no one is working on the machine.
➤ Ensure that all service doors and panels are locked.

Working on live components

Touching voltage carrying components can result in electric shocks, burns or death.
➤ Work on electrical equipment may only be carried out by authorized electricians.
➤ Switch off and lock out the power supply disconnecting device and check that no voltage is
present.
➤ Check that there is no voltage on floating relay contacts.

Working on the compressed air system

Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following safety concerns relate to any work on components that could be under
pressure.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air network to en‐
sure that no compressed air can flow back into the machine.
➤ Depressurize all pressurized components and enclosures.
➤ Check all hose couplings in the compressed air system with a hand-held pressure gauge to en‐
sure that they all read 0 psig.
➤ Do not open or dismantle any valves.

Working on the drive system

Touching voltage carrying components can result in electric shocks, burns or death.
Touching the fan wheel, the coupling or the belt drive while the machine is switched on can result
in serious injury.
➤ Switch off and lock out the power supply disconnecting device and check that no voltage is
present.
➤ Do not open the cabinet while the machine is switched on.

Alteration information Controller

7_7005 10 USE SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 11
 3 Installation
3.2 Connecting the remote LOAD-IDLE control

3.2 Connecting the remote LOAD-IDLE control

Material Screwdriver: DIN 5264 A – 0.4x2.5 mm
Flexible conductor: 0.5–1.5 mm2 (maximum length 330 ft; recommended: NYSLYÖ 2x1.0 mm2)

Fig. 4 Connections SIGMA CONTROL BASIC

1 Input I4: Pin 7
2 Supply 24 VDC: Pin 9

1. Lay the cable in a manner that it is not stressed when the control cabinet door is opened.
2. Strip 8 mm of insulation from the ends of the conductors.
3. Use a screwdriver to open the spring-loaded terminals and insert the ends of the conductors in
the square openings above the corresponding terminals.
4. Secure the cable so there is no tension on the X2 plug.
5. Seal the cable gland against ingress of dirt or moisture.

3.3 Exchanging the controller

The control cabinet is designed to prevent entry of dirt and moisture. When exchanging the control‐
ler make sure that gaskets and assembly parts are properly fitted.

Material Spare parts

(as required):
Wire jumper from flexible conductor: 0.5–1.5 mm2 (recommended: NYSLYÖ 2x1.0 mm2)
Screwdriver: DIN 5264 A – 0.4x2.5 mm
Program module for machine with frequency converter (SFC)

➤ Perform the tasks in the sequence given:

■ Replace the controller (see chapter 3.3.1).
■ Bridge the remote contact of the LOAD/IDLE running periods (see Chapter 3.3.2)
■ Insert the program module (see Chapter 3.3.3)
■ Close the control cabinet and all access doors. Replace and lock all cabinet panels and
doors.

Alteration information Controller

12 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 3 Installation
3.3 Exchanging the controller

3.3.1 Exchanging the controller

Fig. 5 Exchanging the controller

1. Disconnect all the plug connections on the rear of the controller.

2. Remove the defective controller and replace with the new one.
3. Plug in all connections on the rear.

3.3.2 Bridging the remote contact of the LOAD-IDLE control

If no conductor is connected to pins 7 and 9 of the plug for the X2 connection, these pins must be
bridged with a wire jumper. The machine will start only if the remote contact of the LOAD/IDLE con‐
trol is connected or these pins are bridged.

Material Screwdriver: DIN 5264 A – 0.4x2.5 mm

Flexible conductor: 0.5–1.5 mm2 (recommended: NYSLYÖ 2x1.0 mm2)

Fig. 6 Connections to SIGMA CONTROL BASIC

1 Input I4: Pin 7
2 Supply 24 VDC: Pin 9

1. Strip 0.3 in. of insulation from the ends of the conductors.

2. Use a screwdriver to open the spring-loaded terminals and insert the ends of the conductors in
the square openings above the corresponding terminals.

3.3.3 Inserting the program module

Machines with frequency converters (SFC) require a program module.

Alteration information Controller

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 3 Installation
3.3 Exchanging the controller

➤ Verify that the program module is suitable for the controller. Only program modules with
the material number 7.7056.xxxxx may be used in controllers with the number 7.7005.4.
Contact an authorized KAESER service representative if this is not the case.

Fig. 7 Program module

1 Program module

➤ Remove the program module from the defective controller and insert it in the rear-sided slot of
the new controller.

Result Controller exchange is complete. The closed machine can now be started.

If, upon switching on, the controller displays SYSTEM ERROR ⊸ CALL SERVICE.
The program module is incorrect. The controller has no usable program.
➤ Contact an authorized KAESER service representative.

Alteration information Controller

14 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 4 Initial Start-up
4.1 Setting the network setpoint pressure

4 Initial Start-up
4.1 Setting the network setpoint pressure
➤ Take you machine's design into account when setting the network setpoint pressure.
■ Machine without variable frequency drive: Chapter 4.1.1
■ Machine with SINAMICS variable frequency drive: Chapter 4.1.2
■ Machine with MICROMASTER variable frequency drive: Chapter 4.1.3

4.1.1 Machine without variable frequency drive

The setpoint pressure (cut-out pressure) is factory set at the maximum permissible working pres‐
sure of the compressor.
Adjustment is necessary for individual operating conditions.
Do not set the setpoint pressure of the machine higher than the maximum working pressure
of the compressed air system.
The machine may not toggle more than twice per minute between LOAD and IDLE.
To improve the switching frequency:
➤ Increase the difference between cut-in and cut-out pressure.
➤ Add a larger air receiver downstream to increase buffer capacity.

System setpoint pressure: Switching point

1. Scroll with the arrow keys until the parameter D "Network setpoint pressure: switching point" is
displayed in line 3.
2. Press and hold «enter» for at least 3 seconds until the cursor flashes.
3. Use the arrow keys to set the desired switching point and confirm with the «Enter» key.

System setpoint pressure: Switching differential

This switching differential is factory set. Adjust this parameter if the motor starting frequency is too
high.
1. Scroll with the arrow keys until the parameter C "Network setpoint pressure: switching differen‐
tial" is displayed in line 3.
2. Press and hold «enter» for at least 3 seconds until the cursor flashes.
3. Use the arrow keys to set the desired differential and confirm with «enter».

4.1.2 Machine with variable frequency drive: SINAMICS

The setpoint pressure (cut-out pressure) is factory set at the maximum permissible working pres‐
sure of the compressor.
Adjustment is necessary for individual operating conditions.
Do not set the setpoint pressure of the machine higher than the maximum working pressure
of the compressed air system.
The machine may not toggle more than twice per minute between LOAD and IDLE.
To improve the switching frequency:
➤ Increase the difference between cut-in and cut-out pressure.
➤ Add a larger air receiver downstream to increase buffer capacity.

Alteration information Controller

7_7005 10 USE SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 15
 4 Initial Start-up
4.1 Setting the network setpoint pressure

Fig. 8 Setting the pressure parameters

1 p 5 pmax
Network pressure 3.0...6.0 psi
2 D 6 C
Switching point IDLE (parameter D) Switching differential between D and pmin
3 pA (parameter C)
Network setpoint pressure (parame‐ 7 t
ter 2255) Time
4 pmin
Switching point LOAD

The network setpoint pressure is set in several steps:

1. Set the network setpoint pressure in the frequency converter.
2. Set the IDLE switching point on SIGMA CONTROL BASIC .
3. Set the LOAD switching point at the SIGMA CONTROL BASIC .

Result The frequency converter regulates the compressor motor speed in the LOAD operating point.
SIGMA CONTROL BASIC switches the machine to IDLE when the network pressure rises and to
LOAD when the network pressure drops.

4.1.2.1 Setting the setpoint pressure in the frequency converter

The setpoint pressure is set with parameter 2255 on the frequency converter control panel.
The network setpoint pressure is entered as a percentage of the maximal measuring range of
the pressure transducer.
The range of measurement is printed on the pressure transducer. The standard range of
measurement of pressure transducers is 0-232 psi.

Measuring range 0-232 psi 0–145 psi

Network setpoint pres‐ Setting value [%] Setting value [%]
sure [psi]
80 34.38 55.00
85 37.50 60.00
95 40.63 65.00
100 43.75 70.00
110 46.88 75.00
115 50.00 80.00
125 53.13 85.00
125 56.25 90.00

Alteration information Controller

16 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 4 Initial Start-up
4.1 Setting the network setpoint pressure

Measuring range 0-232 psi 0–145 psi

Network setpoint pres‐ Setting value [%] Setting value [%]
sure [psi]
130 59.38 95.00
145 62.50 100.00
150 65.63 –
160 68.75 –
165 71.88 –
175 75.00 –
180 78.13 –
190 81.25 –
195 84.38 –
200 87.50 –
210 90.63 –
215 93.75 –

Tab. 7 Setpoint pressure setting on the frequency converter (selection)

➤ Set the setpoint pressure on the frequency converter as in the table below.

Action Indication
➤ If required, unlock the keyboard:
Press both keys, «Enter» and «ESC» for more than 3 seconds.
➤ Use the «UP» and «DOWN» keys to select the < PARAMS > menu and con‐ PARAMS
firm with «Enter».
➤ Use the «UP» and «DOWN» keys to select the < ExPERT FILtEr > menu and ExPERT
confirm with «Enter». FILtEr
➤ Use the «UP» and «DOWN» keys to select the P2255 parameter. P2255
➤ Press «Enter». 75
The value of the parameter starts flashing.
(example: 75%; corresponds to 175 psi where the measurement range is 0–
232 psi)
➤ Use the «UP» and «DOWN» keys to change the parameter. 50
(example: 50%; corresponds to 116 psi where the measurement range is 0–
232 psi)
➤ Press the «Enter» key to confirm and save the setting. P2255
➤ If required, lock the keyboard:
Press both keys, «Enter» and «ESC» for more than 3 seconds.

Tab. 8 Setting the setpoint pressure in the frequency converter

4.1.2.2 Setting the IDLE switching point in the SIGMA CONTROL BASIC.

Parameter D "Network setpoint pressure: switching point" is used to define the switching point for
IDLE.

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7_7005 10 USE SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 17
 4 Initial Start-up
4.1 Setting the network setpoint pressure

Condition: D = p1 + 3.0...6.0 psi

Factory setting: D = p1 + 4.0 psi

➤ Set the IDLE switching point in the SIGMA CONTROL BASIC according to the table below.

Action Indication
➤ Scroll with the «UP»/«DOWN» keys until parameter D is displayed in line 3. D 165 psi
(example: old value 165 psi)
➤ Press and hold «enter» for at least 3 seconds until the cursor flashes. D 165 psi
➤ Select the required switching point with the «UP»/«DOWN» keys. (exam‐ D 120 psi
ple: 120 psi)
➤ Press «Enter» to confirm and save the value.

Tab. 9 Setting the IDLE switching point.

4.1.2.3 Setting the LOAD switching point in the SIGMA CONTROL BASIC

Parameter C “Network setpoint pressure: switching differential” is used to set the LOAD switching
point.
This switching differential is factory set. Adjust this parameter only if the motor starting frequency is
too high.
Condition: p1 > D – C
Factory setting: C = 6.0 psi

➤ Set the LOAD switching point in the SIGMA CONTROL BASIC according to the table below.

Action Indication
➤ Scroll with the «UP»/«DOWN» keys until parameter C is displayed in line 3. C 6.0 psi
(example: old value 6.0 psi)
➤ Press and hold «enter» for at least 3 seconds until the cursor flashes. C 6.0 psi
➤ Set the required switching differential with the «UP»/«DOWN» keys. (exam‐ C 7.0 psi
ple: 7.0 psi)
➤ Press «Enter» to confirm and save the value.

Tab. 10 Setting the LOAD switching point

4.1.3 Machine with variable frequency drive: MICROMASTER

The network setpoint pressure (cut-out pressure) is factory set at the maximum permissible work‐
ing pressure of the compressor.
Adjustment is necessary for individual operating conditions.
Do not set the setpoint pressure of the machine higher than the maximum working pressure
of the compressed air system.
The machine may not toggle more than twice per minute between LOAD and IDLE.
To improve the switching frequency:
➤ Increase the difference between cut-in and cut-out pressure.
➤ Add a larger air receiver downstream to increase buffer capacity.

Alteration information Controller

18 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 4 Initial Start-up
4.1 Setting the network setpoint pressure

Fig. 9 Setting the pressure parameters

1 p 5 pmax
Network setpoint pressure 3.0...6.0 psi
2 D 6 C
IDLE switching point Switching differential between D and pmin
3 p1 7 t
Network setpoint pressure (parame‐ Time
ter 2255)
4 pmin
Switching point LOAD

The network pressure is set in several steps:

1. Set the network setpoint pressure in the frequency converter.
2. Set the IDLE switching point at the SIGMA CONTROL BASIC .
3. Set the LOAD switching point at the SIGMA CONTROL BASIC .

Result The frequency converter regulates the compressor motor speed in the LOAD operating point.
SIGMA CONTROL BASIC switches the machine to IDLE when the system pressure rises and to
LOAD when the system pressure falls.

4.1.3.1 Setting the network setpoint pressure in the frequency converter

The network setpoint pressure is set with parameter 2255 on the frequency converter control pan‐
el.
The network setpoint pressure is entered as a percentage of the maximal measuring range of
the pressure transducer.
The range of measurement is printed on the pressure transducer. The standard range of
measurement of pressure transducers is 0-232 psi.

Measuring range 0-232 psi 0–145 psi

Network setpoint pres‐ Setting value [%] Setting value [%]
sure [psi]
80 34.38 55.00
90 37.50 60.00
95 40.63 65.00
100 43.75 70.00
110 46.88 75.00
115 50.00 80.00
125 53.13 85.00

Alteration information Controller

7_7005 10 USE SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 19
 4 Initial Start-up
4.1 Setting the network setpoint pressure

Measuring range 0-232 psi 0–145 psi

Network setpoint pres‐ Setting value [%] Setting value [%]
sure [psi]
130 56.25 90.00
140 59.38 95.00
145 62.50 100.00
150 65.63 –
160 68.75 –
165 71.88 –
175 75.00 –
180 78.13 –
190 81.25 –
195 84.38 –
200 87.50 –
210 90.63 –
215 93.75 –

Tab. 11 Network setpoint pressure setting on the frequency converter (selection)

➤ Set the network setpoint pressure on the frequency converter as in the table below.

Action Indication
➤ Press the «parameter access» key. r0000
➤ Press the «Increase value» key until P2255 is displayed. P2255
➤ Press the «parameter access» key to enter the settings level. (example: old value 69.00
69)
➤ Set the required network setpoint pressure with the «Increase value»/ 50.00
«Decrease value» keys. (example: 50%; corresponds to 116 psi where the meas‐
urement range is 0–232 psi)
➤ Press the «parameter access» key to confirm and save the value. P2255

Tab. 12 Network setpoint pressure conversion

4.1.3.2 Setting the IDLE switching point in the SIGMA CONTROL BASIC

Parameter D "Network setpoint pressure: switching point" is used to define the switching point for
IDLE.
Condition: Parameter D = p1 + 3.0...6.0 psi
Factory setting: Parameter D = p1 + 4.0 psi

➤ Set the IDLE switching point in the SIGMA CONTROL BASIC according to the table below.

Action Indication
➤ Scroll with the «UP»/«DOWN» keys until parameter D is displayed in line 3. D 165 psi
(example: old value 165 psi)
➤ Press and hold «enter» for at least 3 seconds until the cursor flashes. D 165 psi

Alteration information Controller

20 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 4 Initial Start-up
4.1 Setting the network setpoint pressure

Action Indication
➤ Select the required switching point with the «UP»/«DOWN» keys. (exam‐ D 120 psi
ple: 120 psi)
➤ Press «Enter» to confirm and save the value.

Tab. 13 Setting the IDLE switching point.

4.1.3.3 Setting the LOAD switching point in the SIGMA CONTROL BASIC

Parameter C “Network setpoint pressure: switching differential” is used to set the LOAD switching
point.
This switching differential is factory set. Adjust this parameter only if the motor starting frequency is
too high.
Condition: p1 > parameter D - parameter C
Factory setting: Parameter C = 6.0 psi

➤ Set the LOAD switching point in the SIGMA CONTROL BASIC according to the table below.

Action Indication
➤ Scroll with the «UP»/«DOWN» keys until parameter C is displayed in line 3. C 6.0 psi
(example: old value 6.0 psi)
➤ Press and hold «enter» for at least 3 seconds until the cursor flashes. C 6.0 psi
➤ Set the required switching differential with the «UP»/«DOWN» keys. (exam‐ C 7.0 psi
ple: 7.0 psi)
➤ Press «Enter» to confirm and save the value.

Tab. 14 Setting the LOAD switching point

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7_7005 10 USE SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 21
 5 Operation
5.1 Switching on and off

5 Operation
5.1 Switching on and off
Always switch the machine on with the «ON» key and off with the «OFF» key.
A power supply disconnecting device needs to be installed by the user.

Fig. 10 Switching on and off

1 ON LED (green) 3 «OFF» key
2 «ON» key 8 Controller on LED (green)

5.1.1 Switching on
Precondition No personnel are working on the machine.
All access doors and panels are closed and secure.

1. Switch on the power supply disconnecting device.

After the controller has carried out a self-test, the green Controller on LED is lit continuously.
2. Press the «ON» key.
The green ON LED lights continuously.
If a power failure occurs, the machine is not prevented from restarting automatically when
power is resumed.
It can restart automatically as soon as power is restored.

Result The compressor motor starts as soon as system pressure is lower than the set point pressure (cut-
off pressure).

Alteration information Controller

22 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 5 Operation
5.2 Acknowledging alarm and warning messages

5.1.2 Switching off

Depending on current operating condition, the machine shuts down after a protective run-on peri‐
od.
LOAD IDLE
The machine switches to IDLE. The motor stops immediately.
The Machine ON LED flashes. The ON LED extinguishes.
The drive motor comes to a stop after
about 15 seconds.
The ON LED extinguishes.

Tab. 15 Switching off with/without run-on time

1. Press the «OFF» key.

The machine is ready to operate as soon as the ON LED is extinguished. The machine can be
restarted.
2. Switch off and lock out the power supply disconnecting device.
The machine is switched off and disconnected from the power supply supply. The Controller on
LED extinguishes.

5.2 Acknowledging alarm and warning messages

Fig. 11 Acknowledging messages

10 Warning LED (yellow)
11 Alarm LED (red)
12 «Acknowledge» key

Alarm message

Messages are displayed on the "new value" principle:

■ Message received: LED flashes
■ Message acknowledged: LED lights
■ Message gone: LED extinguished

or

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7_7005 10 USE SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 23
 5 Operation
5.3 Setting parameters

■ Message received: LED flashes

■ Message gone: LED flashes
■ Message reset: LED extinguished

➤ Rectify the fault and acknowledge the message with the «acknowledge» key.
alarm LED extinguishes.
The machine is now ready to start again.

Warning message

■ Message coming: LED flashes

■ Message gone: LED extinguished

➤ Rectify fault or carry out maintenance.

The Warning LED extinguishes as soon as the cause of the warning is rectified.

5.3 Setting parameters

If a password is needed it is requested automatically.
Every action can be cancelled with the «escape» key.
If no key is pressed for ten seconds in the edit mode, the display automatically returns to the
previous mode.
Restarting the controller is not necessary. Edited parameters are immediately effective.
Network pressure and airend discharge temperature are neither updated nor displayed while
in the edit mode.

Entering the edit mode

1. Scroll with the «UP»/«DOWN» keys until the desired parameter appears in line 3.
2. Depress the «enter» key for at least 3 seconds.

Result Depending on the parameter, either the displayed value or the first character of the required pass‐
word flashes.

Changing a parameter that is not password protected

Precondition The current parameter setting flashes.

➤ Use the «UP»/«DOWN» keys to change the value of the parameter and confirm with «enter».

Changing a password protected parameter

Some parameters can only be edited after a password has been entered.
Password: BASIC
This password will be automatically reset if no key is pressed within 5 minutes.

Precondition The first character flashes.

Alteration information Controller

24 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 5 Operation
5.3 Setting parameters

1. Select the first character with the «UP»/«DOWN» key and confirm with «enter».
The next character flashes.
2. Repeat until all characters have been entered.
When the correct password is entered the parameters are displayed.
3. Use the «UP»/«DOWN» keys to change the value of the parameter and confirm with «enter».

Alteration information Controller

7_7005 10 USE SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 25
 6 Fault Recognition and Rectification
6.1 Basic instructions

6 Fault Recognition and Rectification

6.1 Basic instructions
The following tables are intended to assist in locating faults.

■ Fault: red LED flashes - see chapter 6.2.

■ Warning: yellow LED lights- see chapter 6.3.

The messages valid for your machine are dependent on the controller and individual equipment.
1. Do not attempt fault rectification measures other than those given in this manual!
2. In all other cases:
Have the fault rectified by an authorized KAESER service representative.

6.2 Alarm messages (machine shut down)

The fault code appears in the 4th line of the display field.
A sticker with symbols on the machine explains the fault code.

Fault Sign Meaning Remedy

code
1 EMERGENCY STOP push but‐ ➤ Unlatch the EMERGENCY STOP push
ton actuated. button.
Interlocked access door open or ➤ Close the access door or fit the panel.
panel (if present) removed.
2 Motor alarm ➤ Check the setting of the overload protec‐
Overload protection of drive or tion cut-out / motor overload protection
fan motor (if fitted) switch.
On machine with frequency- ➤ Change the oil separator cartridge
controlled drive: ➤ Check minimum pressure/check valve.
Alarm in the frequency convert‐ ➤ Have the frequency converter checked by
er an authorized KAESER service represen‐
tative.
3 There is build-up of back pres‐ ➤ Changeover phase lines L1 and L2.
sure: ➤ Replace drive belts.
■ Incorrect direction of motor ➤ Have the frequency converter checked by
rotation an authorized KAESER service represen‐
■ Drive belts parted tative.
■ No venting at READY
■ Back-pressure switch defec‐
tive

Brief interruption of power sup‐

ply

Alteration information Controller

26 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE
 6 Fault Recognition and Rectification
6.3 Warning messages

Fault Sign Meaning Remedy

code
4 Maximum permissible airend ➤ Clean the cooler.
discharge temperature excee‐ ➤ Maintain sufficient distance between the
ded cooling air inlet and exhaust openings
and any wall. Check the cooling oil level.
➤ Ensure that the permissible room temper‐
ature is not exceeded.
➤ Change the oil filter.
5 Fault in the refrigeration dryer ➤ Clean the refrigerant condenser.
➤ Ensure adequate ventilation.
➤ Install an extractor fan.
6 Defective analog input (pres‐ ➤ Check lines and connections.
sure or temperature sensor)

7 Maximum permissible tempera‐ ➤ Ensure adequate ventilation.

ture of the controller housing ex‐ ➤ Ensure that the permissible room temper‐
ceeded ature is not exceeded.
8 – Reserve –

Tab. 16 Alarm indications

6.3 Warning messages

The fault code appears in the 4th line of the display field.
An adhesive label at the machine explains the fault code using symbols.

Fault Symbol Meaning Remedy

code
S Maintenance counter has elapsed. ➤ Carry out maintenance.

p Back pressure present. ➤ Check direction of drive motor ro‐

tation.

T Machine below minimum permissi‐ ➤ Increase room temperature.

ble starting temperature.

i Safety relief valve check mode ➤ Check safety relief valve.

switched on. ➤ Deactivate check mode.

Tab. 17 Warning messages

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7_7005 10 USE SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 27
 6 Fault Recognition and Rectification
6.3 Warning messages

Alteration information Controller

28 SIGMA CONTROL BASIC 7.8700E0 / 7.8701E0 / 7.8701E00010 7_7005 10 USE