7_7000_0-00_09E

SERVICE MANUAL
Controller SIGMA CONTROL

Index: 7_7000_0 ---00 09 E --- BUB 80.XX
Publisher:
KAESER KOMPRESSOREN GmbH

96410 Coburg PO Box 2143 GERMANY Tel. + 49 ---(0)9561 ---6400 Fax + 49 ---(0)9561 ---640130
http://www.kaeser.com
Foldout: control panel, display and indications
Symbol Item Key Symbol Item Key
1 ON 6,7 DOWN, UP
2 OFF 8 Escape
3 Clock 9 Enter
4 Remote 10 Information
5 LOAD/ 11 Reset
IDLE
Symbol Item Description Symbol Item Description

12 Display 16 Controller power
13 Alarm 17 LOAD mode
14 Communication 18 IDLE
mode
15 Maintenance/ 19 Machine ON
Warning
QUICK USER GUIDE
SIGMA CONTROL
7_7000_0 ---00 09 E --- BUB 80.XX
Table of Contents
Page
1. Important Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. Changing Display Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
3. Entering the Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. Adjusting System Pressure Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
5. Activating the Clock Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Activating the remote key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
7. Changing the Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
8. Outputting Important Operational States of the Machine. . . . . . . . . . . 7
9. Resetting Maintenance Interval Hours Counters . . . . . . . . . . . . . . . . . . . 8
10. Displaying Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
11. Testing the Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
12. Checking the Temperature Sensor and Shutdown Temperature Function 12
i
Quick User Guide
1. Important Settings
In this chapter, important or often used settings are explained in brief. Detailed information
on function, configuration, fault removal and important instructions concerning safe oper-
ation are found in subsequent chapters.
Setting ---up procedures and other work may only be carried out on the ma-
chine
by persons trained on the machine/controller and persons instructed

by and under the supervision of a specialist
by specialists
by authorised maintenance personnel.
2. Changing Display Language
1. In the main menu press the UP key until the required language appears.
6.1bar 80°C 1
2
->english < 3 current language
- - - - - - - - - 4
2. Press the Enter key.
3. Keep on pressing the DOWN key or the UP key until the required language appears in
the display.
The language is now set.
5. Press the Escape key as often as necessary to return to the main menu.
1
Quick User Guide
3. Entering the Password
The following passwords are entered in the controller on delivery:

Password for level 0: 00000
Password for level 4: 12EXP
1. In the main menu, keep on pressing the UP key until password appears in the third
line of the display.
6.1bar 80°C 1
Password 2
XXXXX L0 < 3
XXXXX L0 4
The cursor flashes on the first character of the password XXXXX.
4. Keep on pressing the DOWN key or the UP key until the required character appears.
The flashing cursor jumps to the next character of the password.
6. Set the remaining characters of the password until it is complete.
After entering the last character the activated password level is displayed.
Further information:
See chapter 7.1 for the configuration of the controller.
2
Quick User Guide
4. Adjusting System Pressure Setpoint
Select menu option configuration > pressure settings
Condition: password level 4 is activated.
1. In the main menu, keep on pressing the UP key until configuration appears in
the third line of the display.
pressure settings appears in the display.
compressor appears in the display.
6.1bar 80°C 1
setpoint press. 2
p1 SP: 5.5bar < 3 actual p1 pressure setpoint (example)
SD: -0.5bar 4 actual p1 switching difference (example)
Setting system pressure setpoint and switching difference for p1

5. Press the Enter key to adjust pressure setpoint p1.
A flashing cursor appears in the display under p1 SP: 5.5bar
6. Adjust the value with the UP key or the DOWN key.
7. Press the Enter key to accept the value.
8. Press the DOWN key once.
6.1bar 80°C 1
p1 SP: 6.1bar 2 changed pressure setpoint
SD: -0.5bar < 3 actual p1 switching difference
p2 SP: 7.2bar 4 actual p2 pressure setpoint
9. Press the Enter key to adjust switching difference p1.
A flashing cursor appears in the display under p1 SD:-0.5bar.
10. Adjust the value with the UP key or the DOWN key.
12. If necessary, adjust the values for p2 in the same way.
See chapter 7.2 for all machine pressure parameters and their adjustment.
3
Quick User Guide
5. Activating the Clock Key
Select the clock menu option
1. In the main menu, keep on pressing the UP key until clock appears in the third line
of the display.
6.1bar 80°C 1
clock key n 2
reset: n < 3
- - - - - - - - 4
Activating the clock key

3. Press the UP key once.
6.1bar 80°C 1
2
clock key: n < 3
reset: n 4
A flashing cursor appears in the display.
The display changes to clock key y.
The clock key is activated and can be used.
The clock key can be deactivated in the same way.
See chapter 7.3 for configuration of starting and stopping the machine.
See chapter 7.5.2 for configuration of p1/p2 load changeover based on a time schedule.
4
Quick User Guide
6. Activating the remote key
Further settings have to be made to allow the machine to be remotely con-

trolled.
Refer, in this case, to the section Further information in this chapter.
Select menu option configuration > pressure settings

The remote key can be activated in two menu options: compressor start or load control.
Activating the remote key in the compressor start menu option
1. Keep on pressing the DOWN key until compressor start appears in the third line
of the display.
compressor ON appears in the third line of the display.
3. Press the Enter key again.
4. Keep on pressing the DOWN key until remote key: n appears in the third line of
the display.
The cursor flashes below the n (remote key not activated).
6. Press the UP key.
The display changes to remote key y.
7. Confirm the setting with the Enter key.
The remote key is activated and can be used.
8. Press the remote key to enable remote mode.
The remote key can be deactivated in the same way.
Activating the remote key in the load control menu option
1. Keep on pressing the DOWN key until load control appears in the third line of the
display.
3. Keep on pressing the UP or DOWN key until remote-key: y/n appears in the
third line of the display.
The cursor flashes below the y (remote key active) or n (remote key inactive).
5. Use the UP key or DOWNkey to select y and confirm with Enter.
See chapter 7.3 for configuration of starting and stopping the machine.
See chapter 7.6 for configuration of p1/p2 load changeover in sequenced mode.
5
Quick User Guide
7. Changing the Control Mode
Select menu option configuration > control mode
3. Press the DOWN key once, then the Enter key to select the control mode menu option.
Changing the control mode

6.1bar 80°C 1
local mode 2
-> Quadro < 3 actual control mode
control mode 4
5. Select the control mode with the UP key or the DOWN key.
6. Press the Enter key to accept the control mode.
See chapter 4.7 for the functions of the control modes.
See chapter 7.4 for configuring the parameters of the control modes.
See chapter 8.15 to determine the optimal control mode.
6
Quick User Guide
8. Outputting Important Operational States of the Machine.
Important operational states of the machine can be assigned via contacts to outputs
DO 0.3 --- DO 0.5 as a binary signal. Further outputs are optionally available.
Select menu options configuration > I/O periphery > DO functions
3. Press the DOWN key until I/O periphery appears.
4. Press the Enter key twice to select menu option DO functions
6.1bar 80°C 1
Controller ON 2 controller ON message
-> n.a. < 3 no output assigned
group alarm 4 group alarm message
Assigning a message to an output

5. Select the required message with the UP key or the DOWN key.
The cursor flashes below n.a. (or below the assigned output).
7. Use the DOWN key or the UP key to select a spare output and confirm by pressing
Enter.
A message is now sent via the output assigned.
See chapter 7.9 for configuration and use of the controller’s inputs and outputs.
7
Quick User Guide
9. Resetting Maintenance Interval Hours Counters
Condition: maintenance task completed,

service message reset,
password level 4 is activated.
Select menu option maintenance > maintenance interval hours counter (unit to be
maintained, e.g. oil filter, bearing change, etc.)
1. In the main menu, keep on pressing the DOWN key until maintenance appears in
3. The maintenance interval hours counter (e.g. oil filter) appears.
6.1bar 80°C 1
oil filter 2 Name of the maintenance interval hours counter
6000h | 0150h < 3 preset interval / remaining hours
reset: n 4
4. Keep on pressing the UP or DOWN key until the unit to be maintained appears in the
second line of the display.
Resetting maintenance interval hours counters

5. Press the DOWN key.
The cursor flashes below reset n.
7. Use the UP key to select y and confirm with Enter.
The interval hours remaining now change to the total hours of the maintenance inter-
val, the reset parameter changes from y to n.
See chapter 8.11 for setting the maintenance intervals.
See chapter 10 for the maintenance of the controller.
8
Quick User Guide
10. Displaying Messages
Select menu options status > messages

1. In the main menu keep on pressing the DOWN key until status appears in the third
messages appears in the display.
event info appears in the display.
Displaying event information
The last message (event) displayed appears in the display. The messages are dis-
played chronologically.
5. Scroll through historical events with the DOWN key and back to current events with the
UP key.
Displaying the last alarm
Condition: menu option status > messages is selected
1. Keep on pressing the DOWN key until last alarm: appears in the third line of the
display.
The last alarm is displayed.
Displaying the last warning
1. Keep on pressing the DOWN key until last warning: appears in the third line of
the display.
The last warning is displayed.
Displaying the number of current alarms or warnings
1. Keep on pressing the DOWN key until number of current alarms and warnings ap-
pears.
See chapter 8.2 to reset alarms
See chapter 8.3 to reset warnings
9
Quick User Guide
11. Testing the Pressure Relief Valve
Compressed air is dangerous!
WARNING
The instructions listed below must be followed.
Preparation for the test

1. Ascertain from the machine’s nameplate the opening pressure (or activating pressure)
of the pressure relief valve and write it down.
2. Press the OFF key to shut down the machine.
3. Close the shut ---off valve supplying the air main network from the machine.
4. Activate password level 4 in the controller (see chapter 3.).
5. In the main menu, press the UP key as often as necessary until package test ap-
pears in the third line of the display.
TÜV check appears in the display.
6.1bar 80°C 1
TÜV check 2
relief valve: n < 3
pRV: 16.00 bar 4 activating pressure of pressure relief valve (example)
The cursor flashes below relief valve: n.
Carrying out the test

The ”pressure relief valve” check mode is activated. Monitoring of internal pressure
and system setpoint pressure is deactivated!
10. Press the DOWN key once to display the internal pressure:
6.1bar 80°C 1
relief valve: y 2
pRV: 16.00 bar < 3 activating pressure of the pressure relief valve
pi : 2.50 bar 4 actual internal pressure
11. Press and hold the ON key.
The machine switches to load, the internal pressure pi of the machine rises.
12. Keep an eye on the rise in pi on the display as long as the test is running.
13. If pressure pi rises to 10 % above the activating pressure of the relief valve
shut down the machine with the OFF key and replace the pressure relief valve.
Avoiding oil mist:
Release the ON key as soon as the pressure relief valve opens to keep
build ---up of oil mist as low as possible.
10
Quick User Guide
If the pRV^ alarm appears in the display, the pressure relief valve is defec-
tive. The permissible internal pressure was exceeded by 2 bar.
Have the pressure relief valve replaced by an authorized KAESER Ser-

vice agent.
Due conclusion of the test

The cursor flashes below relief valve: y.
16. Use the DOWN key to select n and confirm with Enter.
The ”pressure relief valve” check mode is de---activated and the test ended.
18. Open the shut ---off valve from the machine again.
The machine is ready for operation.
See chapter 8.13 to test the pressure relief valve.
11
Quick User Guide
12. Checking the Temperature Sensor and Shutdown Temperature

Function
Ascertaining offset
1. Read off the airend-discharge temperature under load (normal working temperature)
(first line in the display, e.g.: 80 ˚ C)
2. Offset = 110 ˚ C minus the airend discharge temperature
(offset in this case = 30 ˚ C)
3. Shut down the machine with the OFF key
4. Watch the first line of the display and wait until the airend discharge temperature has
dropped by about 5 ˚ C
Setting the offset
5. Activate password level 4 in the controller (see chapter 3.).
6. In the main menu, keep pressing the UP key until package test appears in the
”TÜV inspection” appears in the display.
8. Keep pressing the DOWN key until the following is displayed:
6.1bar 80°C 1
ADT alarm: n 2 Shutdown temperature
Offset: 40 °C < 3 Offset value set (example)
ADT ^ : 0 °C 4
The cursor flashes below offset: 40°C.
10. Use the DOWN key or the UP key to set the calculated offset and confirm by pressing
Enter.
Carrying out the test
Condition: the machine has cooled down by about 5 ˚ C
11. Press the UP key once so that ADT alarm: n appears in the third line of the dis-
play.
The cursor flashes under ADT alarm: n.
The ”ADT alarm” check mode is activated.
14. Press the DOWN key once to display working temperature + offset:
6.1bar 73°C 1 Lowered working temperature (73 ˚ C).
ADT alarm: y 2 Shutdown temperature
Offset: 30 °C < 3 Offset value set (example)
ADT ^ : 103 °C 4 Working temperature + offset
15. Press the ON key to switch the machine to LOAD.
The machine runs on load and the airend discharge temperature rises to the working
temperature again.
If the ADT reaches 110 ˚ C the machine should shut down after two seconds and an
alarm displayed.
12
Quick User Guide
The machine does not shut down:
Abort the test and contact KAESER Service as soon as possible.
Due conclusion of the test

17. Reset the offset to 40 ˚ C and confirm with Enter.
18. Deactivating ADT alarm check mode: press the UP key once so that ADT alarm: y
appears in the third line of the display.
20. Use the UP key to select n and confirm with Enter.
The ”Shutdown temperature” check mode is de---activated and the test ended.
See chapter 8.14 for testing the temperature sensor.
13
Contents
Chapter --- page
1 Regarding this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1 Using the Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.2 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.3 Symbols and Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4 Graphic portrayal of the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
2 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3

2.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
2.2 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
2.3 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
2.4 Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3
3 Safety and Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 4

3.1 Specified Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 4
3.2 Unspecified Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 4
3.3 User’s Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 4
3.4 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 5
3.5 Safety Regulations for the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 5
4 Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 6

4.1 Short Description of the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 6
4.2 Keys and LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 7
4.2.1 Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 7
4.2.2 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 8
4.2.3 The Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.3 Password Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 10
4.4 Short Description of the Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 10
4.4.1 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 10
4.4.2 The two navigation levels in SIGMA CONTROL . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.5 Outline of the Display and Setup Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.5.1 Configuration menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 12
4.5.2 Components menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 14
4.5.3 Package test menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 14
4.5.4 Communication menu option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.6 Outline of the Display Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 16
4.7 Operating and Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
4.7.1 Machine operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
4.7.2 Control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 18
4.7.3 Variable speed drive with frequency converter (SFC) . . . . . . . . . . . . . . . . . . 4 --- 19
4.8 MODULATING Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 19
5 Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 20

5.1 Surroundings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 20
5.2 Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 20
i
Contents
Chapter --- page
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 21
6.1 Reporting Transport Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 21
6.2 Machine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 21
7 Initial Start---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 22

7.1 Configuring the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 23
7.1.1 Selecting menu options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 23
7.1.2 Changing display language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 23
7.1.3 Entering and displaying passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 24
7.1.4 Setting up time and date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 25
7.1.5 Setting display formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 26
7.1.6 Setting and activating Summer/Winter time . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 28
7.1.7 Activating/deactivating the IDLE mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29
7.2 Configuring the pressure settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 29
7.2.1 List of pressure parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 30
7.2.2 Displaying pressure parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 32
7.2.3 Configuring the pressure parameters for compressors . . . . . . . . . . . . . . . . 7 --- 33
7.2.4 Configuring the pressure parameters for vacuum pumps . . . . . . . . . . . . . . 7 --- 34
7.2.5 Configuring pressure parameters for boosters and air main
charging compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 36
7.3 Configuring machine start and stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 37
7.3.1 Automatic start/stop in programmed clock mode . . . . . . . . . . . . . . . . . . . . . 7 --- 37
7.3.2 Setting up the holiday period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 40
7.3.3 Starting the machine remotely from a control centre (remote ON/OFF) . . 7 --- 41
7.3.4 Activating/deactivating the IDLE phase (venting function) . . . . . . . . . . . . . . 7 --- 43
7.3.5 Activating/deactivating and setting up automatic restart after a power failure . . . . . . .
7 --- 43
7.3.6 Setting up the delays for star-delta-start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 45
7.4 Activating and setting up the control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 45
7.4.1 Selecting control modes DUAL/QUADRO/VARIO/CONTINUOUS . . . . . . . . 7 --- 45
7.4.2 Setting up the IDLE period in DUAL control . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 46
7.4.3 Setting the unloaded and minimum running period in QUADRO
control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 46
7.4.4 Setting up the control pressure valve for MODULATING control mode . . . 7 --- 47
7.5 Configuring the machine for local mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 48
7.5.2 Configuring the system pressure setpoint changeover using the clock. . . 7 --- 49
7.5.3 Configuring the system pressure setpoint changeover using the timer. . . . 7 --- 50
7.6 Configuring the machine for operation in sequence . . . . . . . . . . . . . . . . . . . . . . 7 --- 53
7.6.2 Configuring Profibus mode (SAM or VESIS) . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 53
7.6.3 Configuring the Profibus interface without SAM/VESIS . . . . . . . . . . . . . . . . 7 --- 58
7.6.4 Configuring master-slave mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 60
7.6.5 Configuring sequencing mode using the LOAD remote contact
(e.g. MAC 41) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 66
7.6.6 Configuring sequencing mode using the local/remote contact
(e.g. MVS 8000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 68
7.6.7 Configuring the sequencing mode from the remote contact . . . . . . . . . . . . 7 --- 71
7.6.8 Sequencing mode with machines controlled by the pressure switch . . . . . 7 --- 72
ii
Contents
Chapter --- page
7.7 Configuring PC or Modem Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 79

7.7.2 Configuring the RS 232 interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 79
7.8 Configuring the SMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 80
7.8.1 Activating the SMS function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 80
7.8.2 Suppress repeat messages (filter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 81
7.8.3 Entering the modem’s phone number (modem) . . . . . . . . . . . . . . . . . . . . . . 7 --- 81
7.8.4 Entering company data (site location) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 82
7.8.5 Configuring selection of the Service Centre (channel) . . . . . . . . . . . . . . . . . 7 --- 82
7.9 Configuring input and output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 83
7.9.1 Outputting important operational states of the machine. . . . . . . . . . . . . . . . 7 --- 84
7.9.2 Displaying analog input values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 85
7.9.3 Displaying additional binary input signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 87
7.9.4 Using machine pressure and temperature values as switches . . . . . . . . . . 7 --- 89
7.9.5 Configuring analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 91
7.10 Configuring the Package Discharge Air Temperature . . . . . . . . . . . . . . . . . . . . . 7 --- 93
7.10.1 Compensating line resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 93
7.10.2 Entering the correction value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 94
7.10.3 Switching levels for the package discharge temperature . . . . . . . . . . . . . . . 7 --- 94
7.11 Activating Remote Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 95
7.11.1 Selecting menu option configuration > acknowledgement . . . . . . . . . . . . . 7 --- 96
7.11.2 Setting the remote reset function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 96
7.11.3 Activating the remote key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 96
7.11.4 Assign an input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 96
7.12 Linking to an external pressure transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 97
7.12.1 Selecting menu option configuration > pressure settings > load control . 7 --- 97
7.12.2 Assign an input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 97
7.12.3 Defining the type of analog signal (4 - 20 mA/0 - 20 mA) . . . . . . . . . . . . . . . 7 --- 98
7.13 Setting up the timer for condensate drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 98
7.13.1 Selecting menu option configuration > timer . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 98
7.13.2 Setting the timer OFF and timer ON periods . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 98
7.13.3 Assigning an output to the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 98
7.14 Activating the energy ---saving mode for the refrigeration dryer . . . . . . . . . . . . 7 --- 99
7.15 Initial Start ---up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 100
8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 101

8.1 Switching the Machine On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 101
8.1.1 Switching on the machine in local mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 101
8.1.2 Switching off the machine in local mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 102
8.1.3 Remote on and off switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 102
8.1.4 Switching on and off with the clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 102
8.2 Resetting alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 103
8.3 Resetting warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 104
8.4 Displaying the Actual Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 104
8.5 Setting up Machine Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 106
8.6 Displaying Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 106
8.6.1 Selecting menu option status > messages . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 106
iii
Contents
Chapter --- page
8.7 Displaying status data, resetting and printing . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 107

8.7.1 Displaying and resetting machine duty cycle . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 108
8.7.2 Displaying and resetting further status data . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 109
8.7.3 Changing the permissible number of motor starts . . . . . . . . . . . . . . . . . . . . 8 --- 109
8.7.4 Transferring event memory data or parameter data to a PC . . . . . . . . . . . . 8 --- 110
8.8 Displaying analog data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 110
8.9 Displaying operating data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 111
8.10 Resetting maintenance interval hours counters . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 112
8.11 Setting the maintenance interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 113
8.12 Resetting annual maintenance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 114
8.13 Checking the pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 114
8.14 Checking the Temperature Sensor and
Overtemperature Shutdown Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 116
8.15 Determining the optimal control mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 118
9 Fault Finding and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 119

9.1 Alarm messages to the controller
(machine shut ---down, red LED blinking) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 119
9.2 Warning messages on the controller (yellow LED flashes) . . . . . . . . . . . . . . . . 9 --- 122
9.3 Other Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 125
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 127

10.1 Testing the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 127
10.1.1 Displaying binary inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 127
10.1.2 Testing the LEDs on the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 128
11 Spares, Operating Materials, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 129

11.1 Note the nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 129
11.2 Maintenance Contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 129
11.3 Service Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 129
11.4 Displaying the version number, machine model,
material number and serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 129
12 Decommissioning, Storage and Transport . . . . . . . . . . . . . . . . . . . . . . 12 --- 130
13 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 131
iv
Directory of Illustrations
Chapter --- page
Fig. 1 The function keys on SIGMA CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 7

Fig. 2 SIGMA CONTROL LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 8
Fig. 3 Wiring the Profibus plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 54
Fig. 4 Example of connections for sequencing with SAM . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 55
Fig. 5 Electrical connections between the two controllers . . . . . . . . . . . . . . . . . . . . . . . 7 --- 61
Fig. 6 LOAD remote contact wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 67
Fig. 7 Wiring diagram for local/remote contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 69
Fig. 8 Wiring diagram for machine with pressure switch regulation . . . . . . . . . . . . . . . 7 --- 73
Fig. 9 Function diagram of pressure switch regulation and
SIGMA CONTROL regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 75
Fig. 10 Switching On and Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 101
Fig. 11 Resetting warning and alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 103
Fig. 12 Resetting warning and alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 104
v
Table Directory
Chapter --- page
Tab. 1 SIGMA CONTROL function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 7

Tab. 2 SIGMA CONTROL LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 8
Tab. 3 Internal operating modi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
Tab. 4 Characters in the navigation line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
Tab. 5 Outline of the Display and Setup Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
Tab. 6 Configuration menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 13
Tab. 7 Components menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 14
Tab. 8 Package test menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 14
Tab. 9 Communication menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
Tab. 10 Outline of the Display Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17
Tab. 11 Date format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 26
Tab. 12 time formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 26
Tab. 13 Units of pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 27
Tab. 14 Units of temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 27
Tab. 15 Pressure parameters of the compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 30
Tab. 16 Pressure parameters for rotary screw vacuum pumps . . . . . . . . . . . . . . . . . . . . . 7 --- 31
Tab. 17 Pressure parameters for the components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 31
Tab. 18 Example of a machine ON/OFF clock program . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 38
Tab. 19 Operating modes in local mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 48
Tab. 20 Example of system pressure changeover switching points . . . . . . . . . . . . . . . . . 7 --- 49
Tab. 21 Table of controllers working in sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 53
Tab. 22 Profibus DP pin assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 54
Tab. 23 Master-slave configuration procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 60
Tab. 24 RS 485 pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 61
Tab. 25 Example switching points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 76
Tab. 26 Example clock program for equal duty cycling during the day . . . . . . . . . . . . . . 7 --- 78
Tab. 27 Example clock program for equal duty cycling during the week . . . . . . . . . . . . . 7 --- 78
Tab. 28 RS 232 pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 79
Tab. 29 Assigned output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 84
Tab. 30 Checklist of installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 100
Tab. 31 Displayed analog data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 110
Tab. 32 Alarm messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 122
Tab. 33 Warning messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 125
Tab. 34 Other faults and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 126
vi
Regarding this Document
1 Regarding this Document
1.1 Using the Document

This service manual is part of the controller.
The chapter ”Important Settings” is a guide to making settings that are important or often
needed. It can be separated from the manual by tearing along the perforated line.
A graphic representation of the control panel and the menu tree are shown on the fold ---out
pages at the beginning and end of the service manual.
Keep the service manual available as long as work is done on the controller.
Pass the manual on to the next owner/user of the machine.
Make sure that every subsequent modification to the controller is also entered in the
service manual.
1.2 Copyright
This service manual is protected by copyright. Please contact KAESER if you have any
queries regarding the use and duplication of this documentation. We will gladly help you in
the appropriate use of the information.
1.3 Symbols and Identification

The following signs and symbols have been used in this service manual:
Warnings
Example:
This is a hazard warning.
DANGER
The possible consequences of ignoring a hazard warning are shown here.
Measures for avoiding such a hazard are given here.
Hazard levels:
Warnings are divided into three hazard levels signified by the signal word below the hazard
symbol.
Signal word Meaning Consequence

DANGER Warning of an imminent Death or grievous bodily harm may result
threat of danger
WARNING Warning of a possible Death or grievous bodily harm and/or serious
threat of danger damage to the controller is possible
CAUTION Warns of a possibly haz- Light injury or material damage is possible
ardous situation
This character refers to important information. Pointers are given here con-
cerning procedures and useful additional information.
1 --- 1
Regarding this Document
This symbol identifies environmental protection measures.
Condition: Stipulations are listed that have to be satisfied before action is taken.
This bullet is part of a list of instructions comprising one stage of action.

1. Where several stages of action are concerned each individual step is numbered.
1.4 Graphic portrayal of the display

After pressing the Enter key, the result of the action is shown as follows (example):
Portrayal additional comments
6.1 bar 80 °C 1
-> 23.07.04 2 actual date
-> 16:10:31 < 3 actual time, entry line <
... 4
1 --- 2
Technical Specification
2 Technical Specification
The power supply is fed from a power supply unit in the machine.
2.1 Power Supply

Rated voltage 24 V DC (stabilised)
Current flow (standard controller): 1.3 A
Current flow with expansion card: 2.5 A
2.2 Sensors
Pressure transducer:
Output signal: 4 ---20 mA
Connection: 2 ---wire
Resistance thermometer:
Sensing resistance PT100 (to DIN IEC 751)
Connection: 2 ---wire
2.3 Hardware
Industrial computer
Internal temperature monitoring
Internal low volts monitoring of the 24 V supply
2.4 Inputs and Outputs

The number of inputs and outputs is linked to the type of controller used.
DO 0.3 - DO 0.5 are always available as spare outputs.
Further details concerning inputs and outputs are to be found in the electri-
cal diagrams of the machine.
Interfaces
RS 232
RS 485
Profibus-DP
2 --- 3
Safety and Responsibility
3 Safety and Responsibility
Serious injuries
WARNING
Disregard of the following information can result in serious injury.
Please read and pay attention to the following information.
The controller is manufactured to the latest engineering standards and acknowledged

safety regulations. Nevertheless, risk of injury and death to the user and third parties or
adverse effects to the controller and other material damages can arise from its use.
Use the controller only if it is in technically perfect condition for the purpose for which it is
intended under compliance with the safety measures and instructions detailed in the ser-
vice manual.
In particular, immediately rectify (have rectified) any faults that could be detrimental to
safety.
3.1 Specified Use

The controller is intended exclusively for the operation of KAESER compressors in fields of
industry and may only be operated within the machine. Any other use is considered incor-
rect. The manufacturer is not liable for any damages resulting from unspecified use or ap-
plication. The risk involved in such unspecified use is taken solely by the user.
Correct use also includes compliance with the instructions contained in this service man-
ual.
3.2 Unspecified Use

Do not subject the controller to direct sunlight, rain, splashing water or very dusty condi-
tions.
3.3 User’s Responsibilities

Personnel
Only specialists or personnel trained to use the controller may carry out any work on it.
This applies particularly to:

installation and initial start ---up

maintenance and service work

repairs

inspections
Allow only qualified electricians or trained personnel under the supervision of a qualified
electrician to work according to electrical engineering regulations on electrical equipment.
Ensure that all persons working on the controller have read and understood and that they
comply with the safety instructions and the passages relevant to them in the service man-
ual.
Give clear instructions on reporting faults and damage to the controller.
Observe relevant statutory legislation during installation, operation, maintenance and repair
of the controller. For example, nationally applied European directives and/or valid national
legislation, safety and accident prevention regulations.
3 --- 4
Safety and Responsibility
3.4 Hazards
Basic rule: comply with accepted regulations
Observe all accepted safety regulations and national legislation applicable to all work
carried out on the controller.
Examples of these are directives and national regulations concerning safety and accident
prevention.
Electrical hazards
Electricity!
DANGER There is danger of fatal injury caused by touching electrically live compo-
nents.
Observe all accepted safety regulations and national legislation appli-
cable to all work carried out on the controller.
Work on the electrical equipment may only be carried out by a qualified electrician or by
trained personnel under the supervision of a qualified electrician.
Comply with the accepted regulations for safety at work when carrying out work on electri-
cal equipment.
Before the machine is switched on for the first time the user is to provide measures to
guard against electric shock caused by direct or indirect contact and is to check these
measures for effectiveness:
1. Isolate all phases of the mains power supply (switch off the supply disconnecting (iso-
lating) device.
2. Ensure that the power supply cannot be switched on again (lock out).
3. Check that no voltage is present.
4. Work carefully.
Before switching on again, ensure that

no maintenance personnel are working on the machine,

all panels are in place and secured,

all access doors are closed.
3.5 Safety Regulations for the Controller

Pay attention to the following points to avoid damage to the controller:

Do not remove any controller plugs when the machine is in operation.

Operate the controller only when all supplies are connected.

Do not apply other voltages (i.e. external supplies) to the electronic outputs in the out-
put plugs.

Do not short circuit the supply pins of the Profibus interface. A short circuit can cause
irreversible damage to the profibus interface.
3 --- 5
Design and Function
4 Design and Function
4.1 Short Description of the Controller

The controller controls, regulates, monitors and protects the machine.
All parameters needed to operate KAESER rotary screw compressors and rotary vacuum
pumps can be entered and displayed using the controller. The parameters are protected
by passwords at various access levels.
Components
SIGMA CONTROL is made up of the following components:

industrial computer with Intel processor
software, with which the settings can be called up and altered
integrated interface software with which data can be transferred over a Profibus
a user interface with illuminated display, keys and light ---emitting diodes
digital and analog inputs and outputs
Function
The control and regulating function allows:
automatic changeover of the machine from LOAD to IDLE or STANDSTILL
optimum utilization of the drive motor in relation to the user’s actual air demand
automatic restart of the machine after a power failure (can be deactivated)
The monitoring function allows:
monitoring of compressor components with maintenance hours counters
warning and maintenance prompts in the controller’s display for maintenance due
punctual maintenance prompts for oil filter, air filter, V---belts (or coupling), drive motor
bearings, electrical equipment and other components
The protective function allows:
automatic machine shutdown on alarms that may lead to damage to the machine, e.g.
overcurrent, overpressure, overtemperature
4 --- 6
Design and Function
4.2 Keys and LEDs

(see foldout)
4.2.1 Keys
Fig. 1 The function keys on SIGMA CONTROL
Symbol Item Key Function
1 ON --- Switches on the machine.

--- Programmed operating mode is active.
2 OFF --- Switches off the machine.
3 Clock --- Switches clock control on and off.

--- The LED lights when the machine is under clock
control.
4 Remote --- Switches remote control on and off.
--- The LED illuminates when the machine is under
remote control.
5 LOAD/ --- Toggles the machine between LOAD and IDLE.
IDLE
6 DOWN ---
Scrolls down menu options.
---
Reduces a parameter value.
7 UP ---
Scrolls up the menu options.
---
Increases a parameter value.
8 Escape ---
Returns to the next higher menu option level.
---
Exits the edit mode without saving.
9 Enter ---
Enters the selected menu option.
---
Exits the edit mode and and saves.
10 Information ---
Displays the event memory.
---
Available in all menus.
---
Return to menu option with the escape key (8).
11 Reset ---
Acknowledges (resets) alarm, maintenance and
warning messages and resets the event mem-
ory (if possible).
Tab. 1 SIGMA CONTROL function keys
4 --- 7
Design and Function
4.2.2 LEDs
Fig. 2 SIGMA CONTROL LEDs
Symbol Item Description Function
12 Plain text display Alphanumeric 4 line display.
13 Alarm Flashes red when an alarm occurs.

Lights red continuously when acknowledged.
14 Communication Lights red if communication via the Profibus inter-
face is interrupted.
15 Maintenance and Flashes yellow if:
warning LED --- maintenance work is due
--- there is a warning message
Lights yellow continuously when acknowledged.
16 Controller power Lights green when the power supply to the controller
is switched on.
17 LOAD mode Lights green when the machine is on LOAD
18 Operating mode Lights green when the machine is in IDLE mode.

IDLE
Flashes if the manual mode LOAD/IDLE key is
pressed (5).
19 Machine ON The machine is switched on.
Tab. 2 SIGMA CONTROL LEDs
4 --- 8
Design and Function
4.2.3 The Display

The display is used for the display and entry of data. The display comprises four lines with
16 characters each.
6.1 bar 80 °C Header
Key ON| p1-idle Machine status/Menu texts
run 000032 h active line
load 000031 h menu text
Line 1: header
Actual system pressure and airend discharge temperature are displayed in the header.
These values appear:
in the main menu
in set ---up levels in which parameter changes can be made even though the machine
is running
The letters S and F can be displayed in the header. They indicate internal operational
modes and are shown for maintenance purposes.
Letter Operational mode

S Controller set to ”stop” by the administrator from the pro-
gramming unit
F Program error (fault)
Tab. 3 Internal operating modi
Line 2: Machine status/menu text

Depending on settings, either the actual status of the machine or menu text is shown in
line 2.
Line 3: Active line

The appropriate menu text/sub ---option text or the menu option is shown in line 3.
Only the actions shown in the active line can be executed. This applies
both to a jump to a menu option/sub ---option and the alteration of values.
Line 4: Menu text

The characters below appear at the end of line 4 behind the menu option text and indicate
the possible scrolling direction with the UP or DOWN keys.
Character Explanation

Appears at the end of the line
if it is possible to jump to a sub ---option
or
parameters can be entered

Only an upwards scroll is possible with the UP key

Only a downwards scroll is possible with the DOWN key

Scrolling in both directions is possible
Tab. 4 Characters in the navigation line
4 --- 9
Design and Function
4.3 Password Protection

Access to the controller is protected by password.
When the controller is switched on, the lowest level of access (Password Level 0) is acti-
vated. In Password Level 0 parameters can be displayed (Display Level) and certain para-
meters can be set (Display and Setup Level) e.g. language and time.
A further access level (Level 4) is available to the customer. Further parameters can be dis-
played and set in Level 4, for example, the system pressure setpoint or reset of the main-
tenance interval counters.
The Password-Level automatically resets to Level 0 within a period of three
hours.
The following passwords have been entered in the controller at the factory:
Password for Level 0: 00000
Password for Level 4: 12EXP
4.4 Short Description of the Menu Structure

A list of Setup and Display Levels is shown in the foldout at the end of this
manual.
4.4.1 Main menu

When the machine is switched on, details of the software are displayed.
Example:
PN : 7.7000.0 material number
SN: 00234006 serial number
Sys: S5: HW: system software hardware
4.46 80.00 019 version version version
Subsequently, the software is booted and the main menu appears in the display together
with actual system pressure, airend discharge temperature and actual machine status.
6.1bar 80 °C system pressure and airend discharge temperature
- - - - - - - -
off operational mode (actual state of the machine)
- - - - - - - -
After pressing the DOWN key three times the operational state of the machine, total operat-
ing hours and the hours on load appears.
6.1bar 80 °C
Key ON| p1-idle operational status
run 000032h total operating hours
load 000031h total hours on load
The operational state in the second line of the display shows the following settings:
compressor on/off switching
compressor status
type of load control
the load control status
4 --- 10
Design and Function
4.4.2 The two navigation levels in SIGMA CONTROL

In the main menu, scroll upwards with the UP key to enter the Display and Setup Level.
Preprogrammed machine parameters can be displayed and changed in the Display and
Setup Level.
In the main menu, scroll downwards with the DOWN key to enter the Display Level. At this
level, parameters can only be displayed or reset.
4.5 Outline of the Display and Setup Level

The Display and Setup Level comprises the following menus:
Menu options Sub options Menu option: see

Password Enter password ---
Clock --- Activation of the Clock key ---
--- Timing of compressor cut ---in and
cut ---out (switching points)
--- Reset timing
Configuration --- General 4 --- 12
--- Pressure settings
--- Control mode
--- Compressor start
--- Reset
--- I/O periphery
--- Timer
Components --- Motor 4 --- 14
--- Booster
--- Air main charging
--- PD temperature
Package test --- TÜV check 4 --- 14
--- Binary inputs
--- Binary outputs
--- Lamps test
Communication --- RS 232 4 --- 15
--- RS 485
--- Profibus
--- SMS
Languages Selecting the displayed language ---
Tab. 5 Outline of the Display and Setup Level
4 --- 11
Design and Function
4.5.1 Configuration menu

The parameters for configuration of the controller and the machine are set up in the con-
figuration menu option. The menu option has the following sub ---options:
--- General
--- Pressure settings
--- Control mode
--- Compressor start
--- Reset
--- I/O periphery
--- Timer
Navigation (option/sub--- option) Function

General Display:
--- Version No.
--- Model
--- PN: (material number)
--- SN:(serial number)
Settings:
--- Date
--- Time
--- Summer/Winter time
--- Date format
--- Time format
--- Unit of pressure
--- Unit of temperature
Pressure settings Display:
> Compressor --- Activating pressure (pRV)
> System pressure --- Nominal pressure
--- Min. cut ---in pressure
Settings:
--- Pressure setpoints p1 and p2
--- System pressure low
--- Pressure increase pE
Pressure settings Settings:
> Vacuum package --- System pressure high
> Vacuum package --- Setpoint press.
--- Pressure fall pA
Pressure settings Settings:
> Load control --- Local mode
--- Remote mode
Control mode Settings:
--- Dual
--- Quadro
--- Vario
--- Continuous
> Settings --- idle period
> Dual
4 --- 12
Design and Function

> Settings --- Min run period
> Quadro --- Unloaded period
> Settings --- Venting period
> Refrigeration dryer --- OFF period
> Timer --- ON period
--- Binary output
> Modulating valve --- Switching point setting
Compressor start Settings:
> Compressor ON --- Local mode selection
--- Remote mode selection
--- Clock key
--- Remote key
--- Remote contact
Compressor start Settings:
> Compressor OFF --- Venting
--- Holidays
Reset Settings:
--- Remote reset selection
--- Remote key
--- Remote contact
I/O periphery Settings:
--- Binary output function
--- Show quantities
--- External messages
--- Switch
--- Analog output parameter
Tab. 6 Configuration menu
4 --- 13
Design and Function
4.5.2 Components menu

Parameters for individual machine components are displayed and set in the components
menu oprion. The menu option comprises the following sub ---options (depending on drive
motor type):

Motor Display of start mode:
> Power switching unit --- Star-delta
--- Direct start
--- High tension
--- SFC contact
--- Softstart
Settings:
--- Star ---delta
Booster Settings:
--- Pressure setpoint
--- Pressure difference
Air main charging Settings:
--- Pressure setpoint
--- Pressure difference
PD temperature Settings:
(package discharge temperature) --- Analog transducer input
--- Switching points for excessive or low package
discharge temperature
Tab. 7 Components menu
4.5.3 Package test menu

In the package test menu functions are available for testing the machine. The menu option
has the following sub ---options:

TÜV check Settings:
--- Pressure relief valve test
--- Temperature sensor test
Binary inputs Display:
--- Binary inputs signal state
Binary outputs Display:
--- Binary outputs signal state
Lamps test Settings:
--- Controller LED test
Tab. 8 Package test menu
4 --- 14
Design and Function
4.5.4 Communication menu option

Interface parameters are displayed and set in the communication menu option. The menu
option has the following sub ---options:

RS 232 Settings:
--- Modem or printer connection
--- Bitrate
--- Transmission format
RS 485 Settings:
--- Master-slave-mode
--- Bitrate
--- Transmission format
--- Activating the remote key
Profibus Display:
--- Bus alarm
Settings:
--- Linking the machine to a master control sys-
tem (e.g. SAM, central control, PLC, etc.)
--- Slave number
--- Activating the remote key
SMS Settings:
--- Sending short messages
(e. g. to KAESER Service on conclusion of a
SIGMA TELE CARE-agreement)
Tab. 9 Communication menu
4 --- 15
Design and Function
4.6 Outline of the Display Level

Parameters can be displayed and reset, if required, in the Display Level. In the main menu
scroll down with the DOWN key to sequentially display all Display Level options. Options
with lower menu level options can be selected from the main menu.

Status data Display:
> Messages --- Event info (message history)
--- Last alarm
--- Last warning
--- Number of current alarm and warning mess-
ages
--- Call---up of all current messages
> Statistics --- Total duty cycle in percent and for SFC RS485
(Machine with frequency converter)
--- Duty cycle from a certain day and for
SFC RS485
--- Syspress. max
--- Syspress. min
--- Internal press. max
--- Motor starts since a defined day
--- Motor starts total
--- Motor starts per day
--- Motor starts per hour
--- Motor starts below min. temperature
--- Last load run
--- Last idle run
--- Last motor off
Settings:
--- Resets of duty cycle, motor starts and system
pressure from a certain day
> Printer --- All messages that are to be printed
Settings:
--- Printer clock
analog data Display:
--- All data that are to be monitored
Operating data Display:
--- Compressor, load run, motor, airend, SIGMA
CONTROL, modulating valve operating hours
--- Load valve ON
--- kWh counter
Settings:
--- kWh counter reset
4 --- 16
Design and Function

Maintenance Display:
--- Time left to the next due maintenance
Settings:
--- Maintenance interval counter
--- Maintenance interval
Tab. 10 Outline of the Display Level
4 --- 17
Design and Function
4.7 Operating and Control Modes

4.7.1 Machine operating modes
There are three operating modes:
LOAD: the inlet valve is open. The airend delivers compressed air to the system net-
work.
The drive motor runs under full load.
IDLE: The inlet valve is closed. The minimum pressure/check valve isolates the oil sep-
arator tank from the air system. The oil separator is vented down to idling pressure. A
residual quantity of air circulates through the bypass hole in the inlet valve, through
the airend and back to the inlet valve via the venting valve.
The drive motor is unloaded and runs at very low power.
STANDSTILL: The inlet valve is closed. The minimum pressure/check valve isolates the
oil separator tank from the air system. The oil separator tank is vented.
The drive motor is stopped.
4.7.2 Control modes

In order to maintain system pressure between set minimum and maximum values the con-
troller switches the drive motor back and forth between operating points according to spe-
cific rules determined by a selected control mode. This is independent of the volume of
compressed air consumed in each case.
One of the various control modes available will provide an optimum duty cycle that
matches the individual compressed air demand placed on the machine.
The controller can operate in the following modes:
DUAL
VARIO
QUADRO
CONTINUOUS
DUAL
In the DUAL control mode, the drive motor is switched back and forth between full load
and idle to keep system pressure between the preset minimum and maximum values.
When maximum pressure is reached the drive motor switches to IDLE. When the settable
idle period has elapsed the motor switches to STANDSTILL.
The shorter the idle period setting is made, the sooner (and more frequently) the motor is
stopped.
VARIO
VARIO mode is based on the DUAL control mode. The difference is that the idle period is
automatically increased or decreased in relation to an increase or decrease in drive motor
switching frequency.
QUADRO
In QUADRO mode the controller switches from LOAD to IDLE during periods of high air
demand and directly from LOAD to STANDSTILL during periods of low air demand.
This mode of control requires two pre---set time periods: the running period and the idle/
standstill period. The shorter these time settings, the sooner (and more frequently) the
motor stops.
CONTINUOUS
In CONTINUOUS mode, the drive motor is switched back and forth between full load and
idle to keep system pressure between preset minimum and maximum values. When maxi-
mum pressure is reached the drive motor switches to IDLE. The drive motor does not
switch to STANDSTILL.
4 --- 18
Design and Function
4.7.3 Variable speed drive with frequency converter (SFC)

In LOAD mode the frequency converter compares ACTUAL system pressure with a system
pressure SETPOINT and, depending the difference, adjusts the speed of the drive motor
(and therefore the airend) accordingly.
The speed of the airend determines the free air delivery and the working pressure.
If air consumption rises, the frequency converter increases motor speed and therefore in-
creases the volume of air delivered.
If air consumption drops, the converter reduces motor speed and therefore reduces the
volume of air delivered.
The network pressure remains constant --- within the control range of the converter --- re-
gardless of fluctuating air demand.
System pressure exceeds the SETPOINT:
Outside the frequency converter’s range of control the machine reverts to

the selected control mode.
DUAL:
The minimum controllable speed is reached and the machine switches to IDLE mode. The
drive motor runs unloaded and consumes very low power.
When the idle period has elapsed the machine switches to STANDSTILL.
VARIO / QUADRO:
The minimum controllable speed is reached and, depending on the air demand at the
time, the machine switches either to IDLE or STANDSTILL.
System pressure falls below the SETPOINT:

The frequency converter runs the motor up to a speed at which air delivery matches the air
demand.
The inlet valve opens and the machine delivers compressed air.
The converter varies the speed of the drive motor according to the air demand. The power
consumption of the drive motor rises and falls according to air demand.
4.8 MODULATING Control Mode

With the help of a mechanical control valve, the proportional controller continuously varies
the opening and closing of the inlet valve in relation to the actual air demand. The airend
delivers compressed air to the system network.
The load and power consumption of the drive motor rises and falls with the air demand.
To ensure optimal control on large compressors, the control air for the proportional con-
troller is taken from an external air receiver.
4 --- 19
Installation and Operating Conditions
5 Installation and Operating Conditions
5.1 Surroundings
See Service Manual for the machine
5.2 Installation Conditions

See Service Manual for the machine
5 --- 20
Installation
6 Installation
6.1 Reporting Transport Damage

1. Check the controller for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage without delay.
6.2 Machine Identification

If the machine is run in sequenced operation its identification as detailed in
the installation diagram is to be taken into account.
Identifying the machine for operation in remote mode.

If the machine is operated from a remote control centre:
Attach the following notice to warn of remote machine operation.
”WARNING: This machine is remotely controlled and can start automatically at
any time.”
Label the starting device in the remote control centre as follows:
”Before starting, make sure that no one is working on the machine and that it can
be safely started.”
Identifying the machine for clock control mode operation
Attach the following notice to warn of clock controlled machine operation.

”WARNING: This machine is clock --- controlled and can start at any
time.”
6 --- 21
Initial Start-up
7 Initial Start---up
Outline
SIGMA CONTROL was designed and developed for a number of practical applications.
Potential settings are correspondingly varied.
It is possible that only a few of these settings are needed for the initial start ---up. This de-
pends on the application.
The following sections explain the large number of practical applications, but only one con-
figuration is relevant for a specific use.
7.1: Configuring the controller (display format, units, languages, etc.)
7.2: Matching the pressure parameters of the machine and possible modules
7.3: Configuring machine start and stop
7.4: Setting the control mode
7.5: Configuring local operating modes
7.6: Configuring sequencing modes (Profibus, master-slave, remote contact, etc.)
7.7: Configuring output to a PC or modem (serial interface)
7.8: Configuring SMS messages (e.g. for a SIGMA TELE-CARE contract)
7.9: Configuring input and output signals
7.10: Configuring the machine’s discharge air temperature
7.11: Activating remote reset
7.12: Linking to an external pressure transducer
7.13: Setting up the timer for condensate drainage
7.14: Activating energy ---saving mode for the refrigeration dryer
7.15: Initial start ---up
7 --- 22
Initial Start-up
7.1 Configuring the Controller

All controller settings are explained in detail in the following sections. For
experienced users, the most common settings are listed in the ”Quick User
Guide”.
This chapter explains the following:

7.1.1: Selecting menu options (introduction)
7.1.2: Changing display language
7.1.3: Entering and displaying passwords
7.1.4: Setting up time and date
7.1.5: Setting up display format (date, time, units of pressure and temperature)
7.1.6: Activating summer/winter time
7.1.7: Activating/deactivating the IDLE mode
7.1.1 Selecting menu options
The keys and LED indications are shown in the fold ---out to this service
manual.
All menu options can be selected with the DOWN, UP and Enter keys.
The menu options are arranged in two levels:
For example: to select menu option Configuration > General

1. Move from the main menu to the Display and Set ---up Level with the UP key.
2. Keep on pressing the UP key until configuration appears in the third line of the
display.
3. Press the Enter key to open the configuration menu.
The options in the configuration menu can be selected with the DOWN or UP keys, for
example general or pressure settings.
4. Keep on pressing the UP key until general appears in the third line of the display.
The actual menu is the general menu option in the configuration menu. Using the
DOWN or UP keys the menu options in the general menu, for example version no.
or weekday, can now be selected.
7.1.2 Changing display language

1. Keep pressing the UP key until the selected language appears.
3. Keep on pressing the DOWN key or the UP key until the required language appears.
4. Press the Enter key to accept the language.
7 --- 23
Initial Start-up
7.1.3 Entering and displaying passwords

The following passwords have been entered in the controller at the factory:
Password for Level 0: 00000
Password for Level 4: 12EXP
1. Keep pressing the UP key until password appears.
6.1bar 80°C
Password
XXXXX L0 <
XXXXX L0 actual level

The cursor appears in inverse over the first character of the password XXXXX.
4. Keep on pressing the DOWN key or the UP key until the required character appears.
The cursor jumps to the next character of the password.
6. Set the remaining characters of the password until it is complete.
After entering the last character the activated password level is displayed.
Displaying the actual password

1. In the main menu, keep on pressing the UP key until password appears in the third
6.1bar 80°C
Password
XXXXX L 4 < display of actual level
XXXXX L 4
The actual password is displayed.
Changing the actual password
The password entered at the factory can be changed here. However, this is
not recommended.
7 --- 24
Initial Start-up
7.1.4 Setting up time and date
Condition: password level 4 is activated,

menu option configuration > general is selected
(see 7.1.1).
Checking and setting time
If the machine is being operated with a time program (in clock mode)
check the time at regular intervals for discrepancies (generally once per
year).
1. Keep on pressing the DOWN key until the actual time appears in the third line of the
display.
6.1bar 80°C
-> 23.07.2004
-> 16:10:31 < actual time
. . .
The cursor appears in inverse over the first numeral (hours)
3. Change the time with the DOWN or UP key.
4. Save the hours with the Enter key.
5. Repeat for the minutes and seconds.
Setting the date

(see 7.1.1).
1. Keep on pressing the DOWN key until the actual date appears in the third line of the
display.
6.1bar 80°C
Friday actual weekday.
-> 22.07.2004 < actual date
-> 10:25:54 actual time

The cursor appears in inverse over the first numeral 22.07.04
3. Change the date with the DOWN or UP key.
4. Save the date with the Enter key.
5. Repeat for the month and year.
7 --- 25
Initial Start-up
7.1.5 Setting display formats

Setting the date format
The date can be shown in the following formats:
Format Example:
DD:MM:YY 30.08.04
YY---MM---DD 04 ---08 ---30
MM/DD/YY 08/30/04
Tab. 11 Date format

(see 7.1.1).
1. Press the DOWN key until date format appears.

6.1bar 80°C
Date format
-> DD.MM.YY < actual date format
. . .
2. Press the Enter key to change the format.
A cursor appears in inverse over the last character -> DD.MM.YY.
3. Change the format with the DOWN or UP key.
4. Save the format with the Enter key.
Setting the time format
The time can be shown in the following formats:
Format Example:
hh:mm:ss 13:33:45
hh:mm 13:33
hh:mm:ssAM/PM 01:33:45PM
hh:mm AM/PM 01:33PM
Tab. 12 time formats

(see 7.1.1).
1. Press the DOWN key until time format appears.

6.1bar 80°C
time format
-> hh:mm:ss < actual time format
...
7 --- 26
Initial Start-up
2. Press the Enter key to change the format.

A cursor appears in inverse over the last character -> hh.mm.ss.
3. Change the display format with the DOWN or UP key.
4. Save the display format with the Enter key.
Setting the unit of pressure

Pressure can be displayed in the following units:
Format Example:
bar 5.5 bar
hPa (Hectopascal) 5523 hPa
MPa (Megapascal) 0.55 MPa
psi (pressure per square inch) 80 psi
at (atmospheric pressure) 5.6 at
”Hg (inches mercury) 162.9 ”Hg
Tab. 13 Units of pressure

(see 7.1.1).
1. Press the DOWN key until unit of pressure appears.
6.1bar 80°C
Unit of pressure
-> bar < actual unit of pressure
. . .
2. Press the Enter key to change the unit.
A cursor appears in inverse over the last character -> bar.
3. Change the unit with the DOWN or UP key.
4. Save the selected unit with the Enter key.
Setting the unit of temperature

Temperature can be displayed in the following units:
Format Example:
˚ C (degrees Celsius) 46 ˚ C
K (Kelvin) 319 K
˚ F (degrees Fahrenheit) 45.56 ˚ C
Tab. 14 Units of temperature
7 --- 27
Initial Start-up

(see 7.1.1).
1. Press the DOWN key until unit of temperature appears.
6.1bar 80°C
unit of temp.
-> °C < actual unit of temperature
. . .
2. Press the Enter key to change the unit.
A cursor appears in inverse over the last character -> °C.
3. Change the unit with the DOWN or UP key.
4. Save the selected unit with the Enter key.
7.1.6 Setting and activating Summer/Winter time

The controller can automatically changeover summer and winter time. To do this it is
necessary, in certain cases, to
set the changeover time for the start of summer and winter times
activate automatic changeover.
Setting the changeover time for summer/winter time

(see 7.1.1).
1. Keep on pressing the DOWN key until summer/winter t appears in the third line
of the display.
The changeover times for the start of summer time are shown one after the other:
6.1bar 80°C
summertime
-> March month of changeover
-> last day of changeover
3. Press the DOWN key once to display further settings:

--- month of changeover [January - December]
--- day of changeover in the month [1.,2.,3., last but one, last (day of the month)]
--- weekday changeover [Monday - Sunday]
--- changeover time [0:00 hours - 23:59 hours]
The changeover times for winter are shown in the same order.
Note the required times of changeover on a piece of paper before chang-

ing any settings.
7 --- 28
Initial Start-up
4. Scroll to the required changeover time with the DOWN or UP keys.

5. Press the Enter key to select the required changeover time.
6. Change the settings with the DOWN or UP key.
7. Save the changeover time with the Enter key.
Activating summer/winter time
8. Keep pressing the DOWN key until the act.: n is displayed:
A cursor appears in inverse over n in active: n.
The display changes from ”n” to ”y”.
6.1bar 80°C
...
act.: y <
11. Confirm automatic changeover with the Enter key.

7.1.7 Activating/deactivating the IDLE mode

The IDLE mode key on the control panel can be deactivated to prevent unauthorized use.
menu option configuration is selected (see 7.1.1).
1. Keep pressing the UP or DOWN key until pressure settings appears in the
3. Keep pressing the UP or DOWN key until load control appears in the third line of
the display.
5. Keep pressing the DOWN key until settings appears in the third line of the display.
6. Keep pressing the DOWN key until idle key: y appears in the third line of the dis-
play.
The cursor appears in inverse over the y (active).
8. Use the DOWN key or the UP key to set as required and confirm by pressing Enter.
7.2 Configuring the pressure settings

This chapter contains information on the display and configuration of all the machine pres-
sure parameters and is divided into the following sections:
7.2.1: List of pressure parameters (compressors, vacuum pumps, components)
7.2.2: Displaying pressure parameters
7.2.3: Configuring pressure parameters for compressors
7.2.4: Configuring pressure parameters for vacuum pumps
7.2.5: Configuring pressure parameters for boosters and air main charging compressors
7 --- 29
Initial Start-up
7.2.1 List of pressure parameters

Different parameters are set depending on whether the machine is operated as a rotary
screw compressor or rotary screw vacuum pump. The machine is configured with the fol-
lowing parameters:
Compressors Explanation
pRV (pressure relief Display:
valve) Relief valve: pRV: activating pressure of the pressure relief
valve on the oil separator tank
Nominal pressure Display:
Nominal press.:The compressor is designed for this pressure
(maximum system pressure setpoint)
System pressure set- The system pressure setpoint can be controlled by two differ-
point ent values p1 and p2
Settings:
--- p1 SP: switching point p1,
SD: switching differential p1
Pressure increase pE Settings:
--- pE SP: switching point pE; upper safety limit for maximum
machine pressure; in external LOAD control this para-
meter serves to switch from LOAD to IDLE mode in case
of a fault.
--- pE SD: pE switching differential
--- dp FC: the limit for machines with variable frequency
speed control (SFC); limit of lowest air delivery, when this
value is exceeded [maximum system pressure setpoint
SP+ dpFC] the compressor is switched from LOAD to
IDLE mode.
System pressure low When the ”sys.press. low” limit is reached a warning message
is displayed.
Settings:
--- SD: differential pressure for low system pressure,
SP: switching point for low system pressure
--- A warning message is optional: no message, warning
message on the display or an output signal, e.g. to the
remote control centre.
Minimum cut ---in pres- Display:
sure cut ---in press min
For design reasons, pressure can only be built up above this
value.
Tab. 15 Pressure parameters of the compressors
7 --- 30
Initial Start-up
Vacuum pumps Explanation

System pressure high Minimum system pressure
When the ”sys.press. high” limit is reached a warning mess-
age can be displayed.
Settings:
--- SD: differential pressure for high system pressure,
SP: switching point for high system pressure
--- A warning message is optional: no message, warning
message on the display or an output signal, e.g. to the
remote control centre.
System pressure set- The system pressure setpoint can be controlled by two separ-
point ate parameters
p1 and p2:
Settings:
Pressure fall pA Settings:
--- pA SP: switching point pA;
Lower safety limit for minimum machine pressure; in ex-
ternal LOAD mode the parameter pA serves to change
from IDLE to LOAD mode if there is a fault.
pA SD: Switching differential pA
Tab. 16 Pressure parameters for rotary screw vacuum pumps
Components Explanation (displayed text, settings)

Booster Reminder: take the inlet pressure of the booster into account
Settings:
--- pN SP: booster ON switching point
pN SD: booster ON switching differential
In addition:
--- output for the control signal to the booster
Air main charging When the air main is discharged a valve can be fitted down-
stream of the machine that only opens when the value pN SP
is reached.
Settings:
--- pN SP: air main charging switching point,
pN SD: air main charging switching differential
In addition:
--- output for the control signal to the air main charging valve
Note:
Contact KAESER Service for advice.
Tab. 17 Pressure parameters for the components
7 --- 31
Initial Start-up
7.2.2 Displaying pressure parameters
1. In the main menu, keep pressing the UP key until configuration appears in the
6.1bar 80°C
Pressure sensors
compressor < menu option for compressors
Vacuum package menu option for vacuum pumps
Displaying compressor parameters

6.1bar 80°C
Setpoint press.
p1 SP: 5.5bar < actual p1 pressure setpoint
SD: -0.5bar actual p1 switching difference
2. Display further parameters with the UP and DOWN keys.
Displaying vacuum pump parameters

1. Using the DOWN key, select vacuum package in the pressure settings
menu option.
6.1bar 80°C
. . .
SD: -0.5bar < actual p1 switching difference
p1 SP: 5.5bar actual p1 pressure setpoint
3. Display further parameters with the UP and DOWN keys.
7 --- 32
Initial Start-up
7.2.3 Configuring the pressure parameters for compressors
7.2.3.1 Configuring system pressure setpoints p1 and p2 for the compressor

The pressure parameters can only be set within certain limits:
Min. cut ---in pressure

Nominal machine pres- system pressure setpoint
(cut-in press min) +
sure SP
switching differential SD
If system pressure SP falls below SP --- SD the machine switches to LOAD mode. When the
system pressure setpoint SP is reached the machine switches to IDLE mode.
1. Select menu options configuration > pressure settings > compressor

(see section 7.2.2)
2. Press the Enter key to configure the system pressure setpoint for p1.
3. Set the value with the UP key or the DOWN key.
5. Configure the switching difference p1 SD in the same way.
6. If necessary, configure the value for p2 in the same way.
7.2.3.2 Configuring low system pressure

A message warning of low pressure is displayed when the value set for low system pres-
sure is reached.
The configuration of the output for the warning message is described in 7.9.1.
1. Select menu options configuration > pressure settings > compressor (see sec-
tion 7.2.2).
6.1bar 80°C
System pressure
low
SD: 0.5bar < actual switching differential
SP: 4.0bar actual low system pressure
3. Press the Enter key to configure the switching difference

6. Configure the system pressure low SP in the same way.
7 --- 33
Initial Start-up
7.2.3.3 Configuring pressure increase pE

Pressure increase pE serves as a safety limit when the machine is externally controlled.
When pressure reaches value pE (for example, when the external control functions incor-
rectly) the machine is switched into IDLE mode.
The warning message ext.load signal? is displayed.
tion 7.2.2)
6.1bar 80°C
press. increase
pE SP: 7.1bar< actual pressure increase
SD: -0.6bar actual pressure increase switching differential
3. Press the Enter key to configure the pressure increase

6. If required, set the switching differential SD and dpFC in the same way.
7.2.4 Configuring the pressure parameters for vacuum pumps
7.2.4.1 Adjusting system pressure setpoint for the vacuum pump

The pressure parameters can only be set within certain limits:
system pressure setpoint SP System pressure high
If system pressure rises above SP + SD the machine switches to LOAD mode. When the
system pressure setpoint SP is reached the machine switches to IDLE mode.
1. Select menu option configuration > pressure settings > vacuum package
(see section 7.2.2).
7 --- 34
Initial Start-up
7.2.4.2 Configuring high vacuum pump system pressure

A message warning of high pressure is displayed when the value set for high system pres-
sure is reached.
The configuration of the output for the warning message is described in section 7.9.1.
Condition: password level 4 is activated
2. Keep pressing the UP key until the following is displayed:
89hpa 80°C
System pressure
high
SP: 100hpa < actual system pressure high
SD: 100hpa actual switching differential
3. Press the Enter key to configure the switching point SP

6. Configure the switching differential SD in the same way.
7.2.4.3 Configuring pressure fall pA for the vacuum package

Pressure fall pA serves as a safety limit when the machine is externally controlled. When
the pressure reaches the value pA (for example, when the external control functions incor-
rectly) the machine is switched into IDLE mode.
The warning message ext.load signal? is displayed.
(see section 7.2.2)
89hpa 80°C
pressure fall
SD: 20hpa < actual switching differential for pressure fall
pA SP: 20hpa actual switching point for pressure fall
3. Press the Enter key to configure the switching point SP for pressure fall
7 --- 35
Initial Start-up
7.2.5 Configuring pressure parameters for boosters and air main charging compressors
Depending on the type of compressor, pressure parameters for peripheral components
can be configured. The settings for peripheral components are made in the menu option
components.
1. In the main menu, keep pressing the UP key until components appears in the third
6.1bar 80°C
motor < menu option for drive motor settings

Booster menu option for the booster settings
3. Further menu options can be selected with the DOWN key.

6.1bar 80°C
Booster menu option for the booster settings
AM charging < menu option for air main charging settings
PD temperature menu option for package discharge temperature settings
7.2.5.1 Configuring booster pressure parameters

Boosters may only be started when a defined inlet pressure has been built up. The con-
troller provides an output signal that enables a booster start. The switching point and
switching differential for the output signal are set as follows:
1. In the main menu select components > booster

6.1bar 80°C
booster ON
pN SP: 6.5bar < actual switching point for booster ON
SD: -2.0bar actual switching differential

7 --- 36
Initial Start-up
7.2.5.2 Configuring the pressure parameters for air main charging

An air main charging system is only used for rotary screw compressors. The controller pro-
vides an output signal for an air main charging valve upstream of the air main. The switch-
ing point and switching differential for the output signal to the valve are set as follows:
Contact KAESER Service for advice.
1. In the main menu select components > booster

6.1bar 80°C
valve open
pN SP: 4.5bar < actual switching point for air main charging
SD: -0.5bar actual switching differential
7.3 Configuring machine start and stop

The following settings can be made to start the machine:
Function Status on delivery/setting See

Manual start with the ON key always possible ---
Automatic start/stop in programmed no clock (time) program entered 7.3.1
clock mode
Holidays not set 7.3.2
Remote start, e.g. from a control deactivated 7.3.3
centre
IDLE phase (venting function) deactivated 7.3.4
Automatic restart after power failure activated 7.3.5
(after delay period)
Minimum airend starting temperature set to 2 ˚ C ---
Drive motor start mode (depending set 7.3.6
on type)
7.3.1 Automatic start/stop in programmed clock mode

Overview
If not activated, enter password for level 4
Select the clock menu option
Activating the clock key
Set up the clock program if this has not already been done
7 --- 37
Initial Start-up
7.3.1.1 Select the clock menu option

1. In the main menu, keep pressing the UP key until clock appears in the third line of
the display.
6.1bar 80°C
clock key: n
reset: n
<
- - - - - - -
7.3.1.2 Activating the clock key

6.1bar 80°C
clock key: n<

reset: n
An inverse cursor appears in the third line.
The display changes to clock key y.
The clock key is activated.
5. Press the clock key to enable clock mode.
7.3.1.3 Setting the clock program (example)

When a clock program is first set up, note the ON and OFF times on a
sheet of paper first.
As well as individual weekdays, the following cycles are also available: Mon
- Thu, Mon - Fri, Mon- Sat, Mon - Sun, Sat - Thu.
As well as these fixed cycles, an OFF period (holidays) can also be pro-
grammed (see section 7.3.2).
Example:
Machine ON: weekdays 06:30 - 17:00, Fridays 06:30 - 15:00;
Machine OFF: Sat - Sun and during midday break from 12:00 - 13:00
The following switching points result:
No. Day Time Action
1 Mon - Fri 06:30 ON
2 Mon - Fri 12:00 OFF
3 Mon - Fri 13:00 ON
4 Mon - Thu 17:00 OFF
5 Fri 15:00 OFF
Tab. 18 Example of a machine ON/OFF clock program
7 --- 38
Initial Start-up

the clock key is activated,
the clock menu option is selected.

6.1bar 80°C
- - - - - - -
01: n.a. < switching point 01: not active
- - - - - - -
3. Press the UP key until 01 Mon-Fri appears and confirm with the Enter key.
5. Press the Enter key to configure the ON time.
6.1bar 80°C
01 Mon-Fri
00:00 < first ON switching point hh:mm
compr. OFF
6. First set 6 hours and then 30 minutes with the DOWN or UP keys, confirming each
entry with the Enter key.
6.1bar 80°C
06:30 switching point setting
comp. OFF < actual action
- - - - - - - -
9. Press the UP key and, using the Enter key, select comp. ON.
The first ON cycle from Mon - Fri has been programmed.
10. Set up the remaining switching points in the same way.
12. Press the clock key to enable clock mode.
7 --- 39
Initial Start-up
7.3.2 Setting up the holiday period

As well as the fixed cycles of a clock program or a timer a longer standstill period can be
set for, for example, company holidays.
Overview
Selecting menu options configuration > compressorstart> compressor OFF
Activate holidays
Set up the holiday period, if this has not already been done
Selecting menu options configuration > compressorstart> compressor OFF

menu option configuration is selected.
3. Keep pressing the DOWN key until compressor start appears in the third line of
the display.
6.1bar 80°C
compressor ON <
Compressor OFF
6. Press the Enter key to select menu option compressor OFF
Activating/deactivating the holidays function

7. Keep pressing the DOWN key until holidays: n appears in the third line of the dis-
play.
The cursor appears inverse over n
The display changes to holidays y.
The holidays function is activated and can be used.
The holidays function can be deactivated in the same way.
11. Configure the holiday period if this has not already been done
7 --- 40
Initial Start-up
Setting the holiday period

The set date and time of the holiday period appears in the display.
6.1bar 80°C
holidays: y the holiday period is activated
-> 01.01. < actual date: start of holiday dd.yy
00:00 actual time: start of holiday hh:mm
A cursor appears inverse over the first digit of the date.
14. Use the DOWN key or the UP key to set the required day, then the month and confirm
each setting by pressing Enter.
15. Press the DOWN key to change to the time setting and configure the remaining switch-
ing points in the same way.
7.3.3 Starting the machine remotely from a control centre (remote ON/OFF)
If the machine is to be started and stopped from a remote control centre then the following
settings have to be made:
Overview
Make the electrical connection (a spare input for the remote contact is to be found in
the electrical wiring diagram for the machine, DI 1.0 being preferred).
Switch machine start to remote mode
Activating the remote key
If required, activate the clock key and configure the clock program (see sec-
tion 7.3.1.3)
If necessary, assign the remote contact to another input
Press the remote key
7.3.3.1 Switch the machine to remote mode

Two methods are available to start the machine remotely from a control centre:
Method A: starting the compressor with the input signal from the remote control
centre.
Method B: starting the compressor from the remote control centre in addition to the
configured ON/OFF clock program.
The machine can be started from the remote control centre even though the clock key
is activated and the program has selected compressor OFF at this point in time.
Condition: an electrical connection has been made,
password level 4 is activated,
1. Keep pressing the DOWN key until compressor start appears in the third line of
the display.
6.1bar 80°C
compressor ON <
Compressor OFF
7 --- 41
Initial Start-up

6.1bar 80°C
remote mode
-> key < actual setting (example)
remote key: n remote key not activated

6. For method A, keep pressing the DOWN key until ->key+RC appears.
or
For method B, keep pressing the DOWN key until ->key+clock-RC appears.
7. Save the setting with the Enter key.
7.3.3.2 Activating/deactivating the remote key

6.1bar 80°C
->key+RC compressor start via the remote contact activated
remote key: n< remote key (not activated)
clock key: n clock key (not activated)

The cursor appears inverse over the n (remote key not activated).
The display changes to remote key y.
The remote key function is activated and can be used.
12. If the method with the clock program is selected, the clock key must be activated in
the same way.
7.3.3.3 Assigning another input

6.1bar 80°C
* comp. ON
RC ->DI1.0 < remote contact DI 1.0 (preset)

The cursor appears inverse over 1.0.
15. Use the DOWN key to select another input and confirm with the Enter key.
The input has now been assigned.
16. Press the remote key to enable the machine to be started from the remote control
centre.
7 --- 42
Initial Start-up
7.3.4 Activating/deactivating the IDLE phase (venting function)

After receiving an OFF signal from the remote control centre an additional IDLE (venting)
phase can be activated before the machine is stopped completely. The duration of the
IDLE phase is regulated by the internal pressure.

menu option compressor OFF is selected (see 7.3.2).

2. Press the Enter key to select menu option compressor OFF
6.1bar 80°C
* comp. OFF
venting: n< actual setting: venting deactivated
. . .
The display changes to venting: y.
The venting function is activated.
The venting function can be deactivated in the same way.
7.3.5 Activating/deactivating and setting up automatic restart after a power failure

Automatic restart after a power failure function is normally activated.
To avoid overloading the mains power supply through several machines starting simulta-
neously a delay period determining the restart of each machine can be entered.
Overview
Select menu options configuration > compressorstart> compressor ON
Activate/deactivate the automatic restart function
or
Set up the restart delay period

1. In the main menu, keep pressing the DOWN key until compressorstart appears
in the third line of the display.
6.1bar 80°C
Compressor ON
Compressor OFF
7 --- 43
Initial Start-up
Deactivating/activating automatic restart

6.1bar 80°C
. . .
restart: y automatic restart activated
10.0 s | 0.0 s entered | expiring delay period

A cursor appears inverse over the y.
The display changes to n.
6. Press the Enter key to accept the setting.
Automatic restart after a power failure is now deactivated.
The function can be activated in the same way.
Setting up the automatic restart delay period

menu option configuration is selected (see above).
If several machines are in operation, set them up for a staggered start.
Orientate the automatic restart delay period to the IDLE to LOAD

periods set on the other machines.

6.1bar 80°C
restart: y automatic restart is activated
10.0s | 0.00s < entered | expiring delay period
. . .
3. Use the DOWN key or UP key to set the delay period and confirm with the Enter key.
7 --- 44
Initial Start-up
7.3.6 Setting up the delays for star-delta-start

If the machine is started in star-delta configuration, adjustments to the changeover delays
can be made in the menu option components > motor.
6.1bar 80°C
motor < menu option for drive motor settings

Booster
3. Press the Enter key to select menu option motor.
The menu option power switching appears.
The motor start configuration appears.
5. Keep pressing the DOWN key until settings appears.
6. The changeover delays for the star-delta start can be set up in this menu option.
7.4 Activating and setting up the control modes

The controller is provided with various control modes that can bring about different capac-
ity utilisation depending on machine application. A list of control modes is given in
chapter 4.7.2.
7.4.1 Selecting control modes DUAL/QUADRO/VARIO/CONTINUOUS

3. Keep pressing the DOWN key until control mode appears in the third line of the
display.
6.1bar 80°C
local mode Operating mode
-> Dual < actual control mode
Control mode
A cursor appears inverse over the actual control mode.
6. Use the UP key or the DOWN key to select the required control mode and confirm by
pressing Enter.
7 --- 45
Initial Start-up
7.4.2 Setting up the IDLE period in DUAL control

When the idling period has elapsed, the machine comes to a STANDSTILL. The shorter the
period, the more often the machine will switch from IDLE to STANDSTILL. In this respect
the maximum motor starting frequency must also be taken into account.
Take the motor starting frequency into consideration:
Keep to the upper and lower limits of the idle period.

menu option configuration > control mode is selected
(see section 7.4.1)
1. Keep pressing the DOWN key until the following display appears in the settings
option.
6.1bar 80°C
- - - - - - -
* Dual <
* Quadro
2. Press the Enter key to select menu option Dual.
The actual IDLE period appears.
A cursor appears over the IDLE period.
4. Set the required IDLE period with the UP or DOWN keys.
5. Press the Enter key again to accept the value.
7.4.3 Setting the unloaded and minimum running period in QUADRO control mode
When the minimum running period has elapsed, the machine switches from IDLE to
STANDSTILL. Depending on the setting for the unloaded period, the machine goes from
LOAD to IDLE or comes directly to a STANDSTILL.
Take the motor starting frequency into consideration:
Pay attention to the upper and lower limits for the idle period.

(see section 7.4.1)
1. Keep pressing the DOWN key until the following display appears in the settings
option.
6.1bar 80°C
* Dual
* Quadro <
. . .
7 --- 46
Initial Start-up
2. Press the Enter key to select menu option Quadro.

6.1bar 80°C
Min run period
400s ¦ 400s < actual minimum running period
Unloaded period
A cursor appears inverse over the running period.
4. Set the required minimum running period with the UP or DOWN keys.
5. Press the Enter key again to accept the value.
6. Set up the unloaded period in the same way.
7.4.4 Setting up the control pressure valve for MODULATING control mode
In MODULATING control the inlet valve is continuously opened and closed according to
the air demand with the help of a control valve (proportional controller). Depending on sys-
tem pressure, a solenoid valve switches between internal and external control pressure.
The switching point and switching differential of the control pressure valve can be set in the
controller.

(see section 7.4.1)
1. Keep pressing the DOWN key until mod. valve appears in the third line of the dis-
play.
6.1bar 80°C
mod. valve
SD: -0.5bar < switching differential
pN SP: 5.5bar switching point of the control pressure valve

A cursor appears inverse over the value for the switching point.
4. Set the required switching point with the UP or DOWN keys.
6. Set the value for the switching differential in the same way.
7 --- 47
Initial Start-up
7.5 Configuring the machine for local mode

In local mode the machine is controlled with the system pressure setpoints p1 or p2. The
controller is provided with the following modes of operation:
Operating mode Description See

p1 The machine is controlled by system pressure set- 7.5.3.3
point p1
p2 The machine is controlled by system pressure set-
point p2
p1/p2 clock The changeover between p1 and p2 is regulated 7.5.2
by a clock program
p1/p2 cycle The changeover between p1 and p2 is regulated 7.5.3
by a timer program
Tab. 19 Operating modes in local mode
Instructions for setting up system pressure setpoints are given in section 7.2.
Overview
Select menu option configuration > pressure settings > load control
Set/change the clock program (see section 7.5.2)
or
Set/change the timer (see section 7.5.3)
Select local mode
7.5.1 Select menu option configuration > pressure settings > load control
4. Press the DOWN key until load control appears.
The menu option load control is now selected.
7 --- 48
Initial Start-up
7.5.2 Configuring the system pressure setpoint changeover using the clock.
Keep to the order of the configuration!
First set up the clock program and then the operating mode.
Overview


Set the day of the week for the first switching point (delete any existing clock program)

Entering the time of the first switching point

Select the system setpoint pressure for the first switching point p1 or p2.

Set up any further switching points.

Select operating mode p1/p2 clock, see section 7.5.3.3
When a clock program is first set up, note the ON and OFF times on a
sheet of paper first.
As well as individual weekdays, the following cycles are also available: Mon
- Thu, Mon - Fri, Mon- Sat, Mon - Sun, Sat - Thu.
Example:

Peak load period: weekdays 06:30 - 17:00, Fridays 06:30 - 16:00;

Low load period: Midday from 12:00 to 13:00 and the remaining period
The clock program is set up using the following switching points:
(a maximum of 10 switching points are available):
No. Weekday Time System pressure
setpoint
01 Mon - Fri 06:30 p1 on
02 Mon - Fri 12:00 p2 on
03 Mon - Fri 13:00 p1 on
04 Mon - Thu 17:00 p2 on
05 Fri 16:00 p2 on
Tab. 20 Example of system pressure changeover switching points
Setting the day of the week for the first switching point
menu option configuration > pressure settings > load control is se-
lected (see section 7.5.1)

6.1bar 80°C
. . .
Settings start of the settings
- - - - - - - -
2. Press the DOWN key again until the following is displayed:
6.1bar 80°C
- - - - - - - -
* p1/p2 clock <
. . .
7 --- 49
Initial Start-up

6.1bar 80°C
* p1/p2 clock
reset: n <
. . .
Deleting the existing clock program:
4. If at first an existing clock program is to be deleted, press the Enter key again and then
the UP key.
The display changes to reset: y.
The display changes to reset: n. The clock program is now deleted.
6.1bar 80°C
- - - - - - -
01 n.a. < the first switching point is not active
00:00 start time for the first switching point
8. Press the UP key until 01 Mon-Fri appears and confirm with the Enter key.
Setting the time of the first switching point
6.1bar 80°C
01 Mon-Fri weekday setting
00:00 < actual start time
p1 on
11. First set the hours and then the minutes with the DOWN or UP keys, confirming each
setting with the Enter key.
Setting the system pressure setpoint for the first switching point
13. Press the Enter key and select p1 or p2 with the UP or DOWN keys (not necessary in
this example).
The clock program is now finished.
15. Select operating mode p1/p2 clock (see section 7.5.3.3)
7.5.3 Configuring the system pressure setpoint changeover using the timer.
Overview
Delete the old timer configuration, if necessary
Setting up p1 and p2 timer periods
Select the start times for p1 and p2
Select operating mode p1/p2 timer, see section 7.5.3.3
7 --- 50
Initial Start-up
7.5.3.1 Setting up p1 and p2 timer periods
Keep to the order of the configuration. Make sure operating mode p1/p2
timer is not activated when configuring the timer periods.
Configure the timer first and then select the operating mode or select
another operating mode first.

lected.

6.1bar 80°C
. . .
Settings start of the settings
- - - - - - -
6.1bar 80°C
* p1/p2 cycle
p1: 10h | 10h < timer period p1| expiring period (example)
p2: 18h | 18h timer period p2| expiring period (example)

4. Use the DOWN key or the UP key to set the timer period p1 and confirm by pressing
Enter.
6. Press Enter and set timer period p2 with the DOWN or UP key.
7.5.3.2 Selecting the start times for p1 and p2

6.1bar 80°C
p2: 7h ! 7h
-> 1. Start p1 < start with p1 (example)
09:00 start time
2. If the timer period is to start with p2, press Enter and select start p2 with the DOWN or
UP key.
The timer is now configured.
7 --- 51
Initial Start-up
7.5.3.3 Selecting local mode

lected,
the clock program and/or timer are set up.

The cursor appears inverse over the operating mode.
4. Press the UP or DOWN key to select the required operating mode
(p1, p2, p1/p2 clock or p1/p2 cycle).
5. Press the Enter key to accept the operating mode.
The actual operating mode is displayed.
7 --- 52
Initial Start-up
7.6 Configuring the machine for operation in sequence
7.6.1 List of the various sequencing modes

The controller is provided with several methods of sequencing with other controllers:
Method Description Section

Profibus The controller (and therefore the machine) receives 7.6.2
the instruction LOAD, IDLE or local mode, for example,
via the Profibus master (e.g. SAM or VESIS).
The system pressure setpoints p1 and p2 have no rel-
evance when the LOAD/IDLE mode instruction is re-
ceived.
Master-Slave Two SIGMA CONTROL controllers are working in 7.6.4
Master-Slave-mode.
The slave receives the instruction from master via the
RS 485 interface to change between system pressures
p1 or p2.
Sequencing Sequencing via a remote contact is another method of
mode via remote controlling the machine externally. There are three
contact possibilities:
--- LOAD remote contact: 7.6.5
The machine is switched to LOAD or IDLE mode
by an input signal from a master controller (e.g. a
MAC 41). The system pressure setpoints p1 and
p2 have no relevance.
--- Local / LOAD remote contact
The machine is switched to LOAD/IDLE modes or 7.6.6
local mode by a master controller (e.g. an
MVS 8000) via two inputs.
--- p1/p2 remote contact
The signal for the change from system pressure
setpoint p1 to p2 is initiated by an input contact. 7.6.7
Sequencing with If the machine is operating in sequence with a ma- 7.6.8
machines con- chine controlled by a pressure switch the following
trolled by the two methods can be used:
pressure switch --- On machines supplying an equal air delivery 7.6.8.1
SIGMA CONTROL controls the pressure switch
via a volt ---free output.
--- On machines supplying an unequal air delivery 7.6.8.2
the pressure ranges are matched to each other.
To finalise, some examples of clock programs for 7.6.8.3
equal loading of the machines are given.
Tab. 21 Table of controllers working in sequence
7.6.2 Configuring Profibus mode (SAM or VESIS)

Overview
Make the electrical connections
Set operating mode p2
Configure the Profibus interface
Activate the remote key
7 --- 53
Initial Start-up
7.6.2.1 Make the electrical connections
Profibus DP pin assignments

Connect the bus subscribers one after the other according to the pin assignment
below.
Connect the screening to the plug housings at both ends.
Pin Connections
1 spare
2 spare
3 Profibus connection B
4 RTS TTL signal
5 ground
6 + 5 V for interface P5
7 spare
8 Profibus connection A
9 spare
Tab. 22 Profibus DP pin assignments
Wiring the interface plug

Switch in the terminating resistor in the plugs of the first and last subscribers to the
Profibus.
Fig. 3 Wiring the Profibus plug
7 --- 54
Initial Start-up
Wiring possibilities for machine sequencing (excerpt)
Fig. 4 Example of connections for sequencing with SAM
7 --- 55
Initial Start-up
7.6.2.2 Setting operating mode p2
When automatic mode is changed to manual mode at the bus controller,

SIGMA CONTROL changes into the preset remote mode. In such a case it
is preferable to set the operating mode to remote mode p2.
When setting up system pressure setpoint p2 note that under certain

circumstances several machines will be set to local mode
(Anpassung des Netz-Solldrucks, siehe Abschnitt 7.2).

lected,
1. Keep pressing the UP or DOWN key until remote mode appears in the second line
of the display.
6.1bar 80°C
remote mode
->p1 < actual operating mode in remote mode
. . .
3. Set operating mode p2 with the UP key or the DOWN key.
5. If required, set system pressure setpoint p2 (see section 7.2).
7.6.2.3 Configuring the Profibus interface for SAM/VESIS

Overview

Selecting the Profibus interface

Assign the slave address

If required, set reaction should a bus alarm (bus timeout) occur

If required, assign an output contact for the bus alarm message
(see machine circuit diagram for a spare output)
the electrical connection to the bus master is made.

1. In the main menu, keep pressing the UP key until communication appears in the
3. Keep pressing the DOWN key until Profibus appears in the third line of the display.
Profibus
-> n.a. < Profibus is inactive

Run ### | F 0
7 --- 56
Initial Start-up

6. Keep pressing the UP key until Send+Receive appears in the display.
If no electrical connection to the bus has been made up to this point the message
bus alarm appears.
8. Acknowledge the message and check the electrical connections.
When sequencing with SAM the slave address is determined as follows:

Compressor number used in SAM + 2. The permissible range of ad-
dresses is between 3 to 126.

6.1 bar 80°C
. . .
Slave no.: 2< actual slave address assigned
. . .
The cursor appears inverse over the slave address.
11. Select the required slave address with the UP or DOWN keys and confirm with the
Enter key.
Setting reaction if a bus alarm (bus timeout) occurs
The controller can react in two ways when a bus alarm occurs:
Automatic: the controller remains in remote mode and tries to connect to
the bus.
Manual: the controller changes to the preset local mode. Sequencing
mode is started again by pressing the Remote key.
Exchange of data with a Profibus connection takes place in three fixed cycles. The Profibus
connection can be monitored with the help of the cycle time:
The bus connection is considered to be interrupted if no data is exchanged between the
bus master and the controller (as bus subscriber) after expiry of a set time period (time-
out). If the period for bus timeout is set to zero then the bus alarm is inactive.
6.1 bar 80°C
* bus alarm
start td: 15.0s < delay period*
timeout: 5.00s actual bus timeout setting
* after switching on the power supply the bus alarm can be suppressed for the ”start td
period.
13. Keep pressing the DOWN key until timeout appears in the third line of the display.
15. Change the setting for bus timeout with the DOWN or UP key.
If the bus alarm is to be deactivated, set timeout to 0.00s.
16. Save the settings with the Enter key.
7 --- 57
Initial Start-up
Setting the output contact for the bus alarm

The bus alarm can be sent to a remote control centre or device via a volt ---free contact.
6.1 bar 80°C
Restart: auto. reaction during a bus alarm*
-> n.a. < bus alarm output inactive
. . .
* the controller’s reaction during a bus alarm can only be changed by KAESER service
personnel.
The cursor appears inverse over n.a.
19. Choose a spare output with the UP key.
20. Press the Enter key to confirm the output.
21. Save the settings with the Enter key.
Saving data
The settings are automatically saved in an EEPROM that is no ---volt safe. The settings are
still available even if the buffer battery discharges completely.
7.6.2.4 Activating the remote key

the menu option communication > Profibus is selected.
1. Keep on pressing the UP or DOWN key until remote key appears in the third line of
the display.
The cursor appears inverse over the y (remote key active) or n (remote key inactive).
3. Use the UP key or DOWN key to select y and confirm with Enter.
7.6.3 Configuring the Profibus interface without SAM/VESIS
Further data from KAESER is needed to configure the Profibus interface

(xls- and gsd-files). If these data are not available, contact KAESER Ser-
vice.
Overview
the electrical connection to the bus master is made,
the data required from KAESER are available.
7 --- 58
Initial Start-up

3. Keep pressing the DOWN key until Profibus appears in the third line of the display.
Profibus
-> n.a. < Profibus is inactive

Run ### | F 0
6. Press the UP key until send appears in the display.
If no electrical connection to the bus has been made up to this point the message
bus alarm appears.
8. Acknowledge the message and check the electrical connections.

Profibus
. . .
Slave no.: 2< actual slave address assigned
. . .
The cursor appears inverse over the slave address.
11. Select the required slave address with the UP or DOWN keys and confirm with the
Enter key.
Further steps
Carry out further configuration as outlined in section 7.6.2.3:
7 --- 59
Initial Start-up
7.6.4 Configuring master-slave mode
7.6.4.1 Examples showing master-slave applications

In master-slave mode two SIGMA CONTROL controllers operate in sequence to supply a
common air main. The master controls the machine with the controller configured as a
slave and provides the instruction for the air system pressure setpoint.
Example: two machines with differing air deliveries

Master’s local operating mode p1/p2 clock:
Toggled between system pressure setpoints p1 and p2 by a clock program.
At peak load times (high air demand) pressure is regulated to system pressure set-
point p1. During periods of low air demand, e.g. at weekends, pressure is regulated to
system pressure setpoint p2.
The machine with the lesser air delivery is the slave. At peak load times the machine is
only cut in under conditions of high air demand. During periods of low air demand the
machine with the lesser air delivery is cut in more often.
Example: two machines with equal air deliveries

Master’s local operating mode p1/p2 cycle:
(toggled between system pressure setpoints p1 and p2 by a timer).
The timer ensures even loading of both machines. The system pressure setpoints are
set the same for both machines.
During cycle 1 master regulates on p1 and instructs slave to regulate on p2.
During cycle period 2 master regulates on p2 and instructs slave to regulate on p1.
Both controllers must have the same software version to allow two Sigma
Controls to work in master-slave mode.
7.6.4.2 Configuration procedure

The configuration procedure is described in the following sections:
Controller Procedural step Section

Both Make the electrical connections 7.6.4.3
Both Setting up the appropriate system pressure set- 7.6.4.4
points p1 and p2 taking air losses in the air main
into account.
Master Setting up switching times for the clock program 7.6.4.5
or
setting up switching times for the timer 7.6.4.6
Master Selecting the type of LOAD control (clock program 7.6.4.7
or timer) in local mode
Slave Setting p1/p2 remote mode via RS485 7.6.4.8
Slave Activating the remote key 7.6.4.9
Both Activating master or slave 7.6.4.10
Tab. 23 Master-slave configuration procedure
7 --- 60
Initial Start-up

RS 485 pin assignment
1. Make the electrical connections as shown in the table below.
2. Connect the screening to the plug housings at both ends.
3. Wire the jumpers in the plug as shown in Fig. 5.
Pin Connections Remarks

1 terminating resistor RA (integrated in the controller)
2 reserved
3 difference signal B
4 reserved
5 reserved
6 reserved
7 terminating resistor RA (integrated in the controller)
8 difference signal A
9 reserved
Tab. 24 RS 485 pin assignment
SIGMA CONTROL 1 SIGMA CONTROL 2

Pin Pin
1 1
2 2
3 B 3
4 4
5 5
6 6
7 A 7
8 8
9 9
Fig. 5 Electrical connections between the two controllers
7.6.4.4 Both: setting up system pressure setpoints p1 and p2

menu option configuration > pressure settings > compressor is se-
lected.
Further information on setting up the pressure parameters is found in section 7.2.
7 --- 61
Initial Start-up
7.6.4.5 Master: configuring the system pressure setpoint changeover using the clock.
First set up the clock program and then select the operating mode.
When a clock program is first set up, note the start times for the system
pressure setpoints on a sheet of paper first.
As well as the individual weekdays, the following cycles are also available:
Mon - Thu, Mon - Fri, Mon- Sat, Mon - Sun, Sat - Thu.
The settings for a clock program are described in more detail using the
example given in section 7.5.2.
Overview

Entering the weekday for the first switching point


Set the system pressure setpoint for the first switching point


Select operating mode p1/p2 clock (see section 7.6.4.7)
lected.

1. Keep pressing the DOWN key until *p1/p2 clock appears in the third line of the
display.
6.1bar 80°C
* p1/p2 clock
reset: n <
. . .
the UP key.
6.1bar 80°C
- - - - - - - -
01 n.a. < first switching point for the weekday
7. Press the UP key to set the weekday for the first switching point and confirm with the
Enter key.
7 --- 62
Initial Start-up

6.1bar 80°C
01 Mon-Fri weekday settings (example)
p1 on
12. Press the Enter key and select p1 or p2 with the UP or DOWN keys.
The clock program is now finished.
14. Select operating mode p1/p2 clock (see section 7.6.4.7)
7.6.4.6 Master: configuring the system pressure setpoint changeover using the timer.
First set up the timer and then select the operating mode.
Overview


Select the start times for p1 and p2

Select operating mode p1/p2 timer (see section 7.6.4.7)
lected.

6.1bar 80°C
* p1/p2 cycle
p1: 10h | 10h < timer period p1| expired timer period (example)
p2: 18h | 18h
3. Use the DOWN key or the UP key to set the timer period p1 and confirm by pressing
Enter.
7 --- 63
Initial Start-up
Selecting the start times for p1 and p2

6.1bar 80°C
p2: 7h | 7h
-> 1. Start p1 < actual setting: start with p1 (example)
09:00 actual start time setting
8. If the timer period is to start with p2, press Enter and select start p2 with the DOWN or
UP key.
13. Select operating mode p1/p2 timer (see section 7.6.4.7)
Resetting the timer period!
Do not switch the machine on and off with the main switch, otherwise
the timer period will always be reset to zero.
7.6.4.7 Master: selecting local mode

lected,
the clock program and/or timer are set up.

6.1bar 80°C
local mode
->p1 < operating mode in local mode
. . .
3. Press the UP or DOWN key to select the required local mode
(p1, p2, p1/p2 clock or p1/p2 cycle).
7 --- 64
Initial Start-up
7.6.4.8 Setting remote mode via RS 485

lected.
of the display.
6.1bar 80°C
remote mode
-> p1 < actual operating mode
remote key: n
3. Use the DOWN key or the UP key to select operating mode p1/p2 RS485 and con-
firm by pressing Enter.
7.6.4.9 Slave: activating/deactivating the remote key

lected,
1. Keep pressing the UP or DOWN key until remote-key: y/n appears in the third
7.6.4.10 Both: configuring the RS 485 interface

Overview
Selecting the communication menu option
Determine master and slave
Saving the settings
Selecting the communication menu option

3. Keep pressing the DOWN key until RS485 appears in the third line of the display.
6.1bar 80°C
RS232
RS485 <
Profibus
7 --- 65
Initial Start-up

RS485
-> n.a. < interface is not active

Run ### | F 0
Setting the controller as master or slave

5. Press the DOWN or UP key until ->n.a appears in the third line of the display.
A cursor appears inverse over ->n.a.
7. Press the UP key once or twice to select Slave or Master and confirm with the
Enter key.
The controller now starts the interface test. After Run there is a 0 ---256 counter. If a
zero appears after the F the machine is OK.
8. If no zero appears: check the cable connections or the settings on the Master and
Slave controllers.
RS485
-> n.a. <

Run 0 | F 0 interface test counter
Saving the settings

7.6.5 Configuring sequencing mode using the LOAD remote contact (e.g. MAC 41)
Overview
Setting the LOAD remote contact operating mode and assigning the input
Adjusting the pressure increase pE settings, if required
7 --- 66
Initial Start-up
7.6.5.1 Electrical connections for LOAD remote contact (excerpt)
3/6/9/12
MAC 41
2/5/8/11
Fig. 6 LOAD remote contact wiring diagram
Example: Example:
Compressors with ribbon cable adapter Compressors without a ribbon cable
adapter; SX, SM and SK before modifi-
cation to spring terminals
DI 0.7 LOAD/IDLE external DI 0.7 LOAD/IDLE external
7.6.5.2 Setting the LOAD remote contact operating mode and assigning the remote contact
input

lected.
Setting the LOAD remote contact operating mode

of the display.
6.1bar 80°C
remote mode
remote key: n
3. Use the DOWN key or the UP key to select operating mode load RC and confirm by
pressing Enter.
7 --- 67
Initial Start-up
Assigning the remote contact input

6.1bar 80°C
* idle - load
RC -> DI0.7 < Standard: DI 0.7
. . .
6. Use the DOWN key or the UP key to select an input for the remote contact and confirm
by pressing Enter.
The operating mode is now configured.
7.6.5.3 Setting the pressure increase pE

Instructions for setting up the pressure increase parameter pE are given in section 7.2.3.3.
Detailed information on this pressure parameter is found in section 7.2.1.

lected.
1. Keep pressing the UP or DOWN key until remote-key: n appears in the third line
of the display.
The cursor appears in inverse over the n (remote key not activated).
7.6.6 Configuring sequencing mode using the local/remote contact (e.g. MVS 8000)
Overview
Setting the local/remote contact operating mode and assigning the input
Configure the operating mode in local mode, if required
7 --- 68
Initial Start-up
Use output O0.3 “control on” for the “Alarm machine X” message to the
MVS 8000 to ensure open circuit protection!
Wire the ”motor running” (O0.5) and ”control on” (O0.3) messages from the com-
pressor to the MVS 8000.
Wiring diagram (excerpt)
X4 MVS
A
X4
B
X4
Fig. 7 Wiring diagram for local/remote contact
A Changeover between automatic and manual modes

B LOAD/IDLE contact in the MVS
DI 0.7 external LOAD/IDLE
DI 1.3 local and LOAD remote contact LOAD-control changeover

lected.
1. Keep pressing the UP or DOWN key until remote-key: n appears in the third line
of the display.
The cursor appears in inverse over the n (remote key not activated).
7 --- 69
Initial Start-up
7.6.6.3 Setting the local/remote contact operating mode and assigning the input
lected.
Setting the local/remote operating mode

of the display.
6.1bar 80°C
remote mode
remote key: n
3. Use the DOWN key or the UP key to select operating mode loc.-load RC and
confirm by pressing Enter.
6.1bar 80°C
* loc.-loadRC
RC -> n.a. < no input assigned
. . .
by pressing Enter.
7.6.6.4 Selecting local mode p2 parameter
Operating mode p2 is normally selected for local operation.
When setting up system pressure setpoint p2 note that under certain

circumstances several machines will be set to local mode
(Anpassung des Netz-Solldrucks, siehe Abschnitt 7.2).

lected,
1. Keep on pressing the UP or DOWN key until local mode appears in the second line
of the display.
6.1bar 80°C
local mode
->p1 < actual local operating mode
. . .
7 --- 70
Initial Start-up

3. Set operating mode p2 with the UP key or the DOWN key.
5. If required, set system pressure setpoint p2 (see section 7.2).
7.6.7 Configuring the sequencing mode from the remote contact

The signal for the change from system pressure setpoint p1 to p2 is initiated via an input
contact.
If there is a signal at the input then system pressure is regulated on setpoint p2.
Overview
Setting up remote contact RC p1/p2 operating mode
7.6.7.1 Setting up remote contact RC p1/p2 operating mode

the electrical connections are made,
lected.
of the display.
6.1bar 80°C
remote mode
remote key: n
3. Use the DOWN key or the UP key to select operating mode p1/p2 RC and confirm
by pressing Enter.
7.6.7.2 Assigning the remote contact input

A spare input can be found in the machine circuit diagram.
6.1bar 80°C
* p1/p2 RC
RC -> n.a. < no input assigned
. . .
by pressing Enter.
7 --- 71
Initial Start-up

lected.
1. Keep pressing the UP or DOWN key until remote-key: y/n appears in the third
7.6.8 Sequencing mode with machines controlled by the pressure switch
7.6.8.1 Configuring sequencing mode from a volt--- free contact

Requirement:
A machine with SIGMA CONTROL (e.g. model BSD) and a conventional machine without
SIGMA CONTROL of the same capacity are to run in sequence as base load and/or peak
load machines.
Proposal:
Set the clock program and/or timer on SIGMA CONTROL
Select local operating mode p1/p2 clock or p1/p2 timer
The system pressure setpoints p1 and p2 should correspond to the required values.
They must be identical to the pressure switch settings on the conventional machine.
To make the p1/p2 pressure setpoint changeover between the two machines possible
the local operating mode selected has to be assigned a volt ---free contact. An auxiliary
contactor can be energized via this contact to activate the pressure switches for p1
and p2 on the conventional compressor. See example wiring diagram below.
7 --- 72
Initial Start-up
Example wiring diagram (excerpt)
21
K3 K3
22
K3
Fig. 8 Wiring diagram for machine with pressure switch regulation
A: SIGMA CONTROL volt ---free contact, K3: auxiliary contactor

B1.1: pressure switch for pressure setpoint p2, B1.2: pressure switch for pressure set-
point p1
Contact A open: SIGMA CONTROL runs with pressure setpoint p2,
Contact A closed: SIGMA CONTROL runs with pressure setpoint p1
Overview
Setting pressure setpoints p1 and p2
Configure/adjust local operating mode
Assigning the volt ---free relay contact
Selecting local mode
7 --- 73
Initial Start-up

the electrical connections have been made
tion 7.2.2)
Configuring local mode
A detailed description for setting up a clock or timer program can be found in section 7.5.
Assigning the volt--- free relay contact
an electrical connection has been made,
(see machine circuit diagram for a spare relay contact)
1. Select menu option configuration > pressure settings > load control
6.1bar 80°C
* p1/p2 DO
n.a. < no output assigned
. . .
5. Use the DOWN key or the UP key to select the required output and confirm by pres-
sing Enter.
This output can now be used for the changeover between the two pressure switches.
6.1bar 80°C
local mode
. . .
4. Select operating mode p1/p2 clock or p1/p2 cycle with the UP or DOWN keys.
7 --- 74
Initial Start-up
7.6.8.2 Configuring sequencing mode without an electrical connection

Requirement:
A high capacity machine with SIGMA CONTROL (e.g. model BSD) is to work as a base
load machine. A second machine (e.g. model SK) with pressure switch regulation is in-
tended to cover the air demand during periods of low load.
Proposal:
Select the system pressure setpoints p1 and p2 for the BSD such that the pressure
switch switching points of the SK machine are in between. If p2 is activated for the
periods of low load, the SK machine automatically functions as the base load
machine.
Set up the required values for a clock program on SIGMA CONTROL
Select local operating mode p1/p2 clock
Activate the clock
Function diagram:
p
p1(BSD) 1 3 6 7
8 10 13 14
p(SK)
p1 - SD
p2(BSD)
p(SK) - SD
p2 - SD
2 4 5 9 11 12
Fig. 9 Function diagram of pressure switch regulation and SIGMA CONTROL regula-
tion
Period t1 - t7: high air demand Period t8 - t14: low air demand
t1: air demand rises, system pressure t8: air demand rises, system pressure falls
falls
t2: BSD switches to LOAD mode t9: SK switches to LOAD mode
t3: system pressure setpoint p1 at- t10: system pressure setpoint p2 attained, SK
tained, BSD switches to IDLE switches to IDLE
t4: BSD switches to LOAD mode, air t11: BSD switches to LOAD mode, air demand is
demand is not covered not covered
t5: SK switches additionally to LOAD t12: SK switches to LOAD mode, system pres-
mode, system pressure starts to rise sure starts to rise
t6: SK switches to IDLE mode t13: SK switches to IDLE mode
t7: BSD switches to IDLE mode t14: BSD switches to IDLE mode
7 --- 75
Initial Start-up
tion 7.2.2)
Configuring the clock program

The clock program for the example is set up using the following switching points:
(a maximum of 10 switching points are available):

setpoint
01 Mon - Fri 06:30 p1 on
02 Mon - Fri 17:00 p2 on
Tab. 25 Example switching points
Overview

the menu option configuration > pressure settings > load control is
selected,
p1/p2 clock local mode is selected.

1. Keep pressing the DOWN key until *p1/p2 clock appears in the third line of the
display.
6.1bar 80°C
* p1/p2 clock
reset: n <
. . .
the UP key.
7 --- 76
Initial Start-up

6.1bar 80°C
- - - - - - -
01 n.a. < the first weekday switching point is inactive

7. Press the UP key to set the weekday and confirm with the Enter key.

6.1bar 80°C
01 Mon-Fri weekday setting
p1 on
Selecting system setpoint pressure p1 or p2 for the first switching point.

12. Press the Enter key and select p1 or p2 with the UP or DOWN keys.
6.1bar 80°C
local mode
. . .
4. Set operating mode p1/p2 with the UP key or the DOWN key.
7 --- 77
Initial Start-up
7.6.8.3 Example of time settings for even loading

Requirement: two machines of the same capacity are to be equally cycled
A detailed description for configuring a clock or timer program can be
found in section 7.5.
Method A: daily cycling between p1 and p2 over 24 hours.

Condition: the system pressure setpoints p1/p2 are the same for both ma-
chines.
The compressor starts with pressure setpoint p2 at 0:00 hours. The p1/p2 changeover is
decided by the timer (local mode p1/p2 cycle):
The cycle is set up using the following switching points:
p1 cycling period: 24 h
p2 cycling period: 24 h
Start p2: 0:00 hours
Method B: equal duty cycle during the day
chines.
The p1/p2 changeover is decided by a clock program (local mode p1/p2 clock):
setpoint
01 Mon - Sun 00:00 p1 on
02 Mon - Sun 6:00 p2 on
03 Mon - Sun 12:00 p1 on
04 Mon - Sun 18:00 p2 on
Tab. 26 Example clock program for equal duty cycling during the day
Method C: equal duty cycling during the week

chines.
The p1/p2 changeover is decided by a clock program (local mode p1/p2 clock):
setpoint
01 Mon 00:00 p1 on
02 Mon 21:00 p2 on
03 Tue 18:00 p1 on
04 Wed 15:00 p2 on
05 Thu 12:00 p1 on
06 Fri 9:00 p2 on
07 Sat 06:00 p1 on
08 Sun 03:00 p2 on
Tab. 27 Example clock program for equal duty cycling during the week
7 --- 78
Initial Start-up
7.7 Configuring PC or Modem Output

The controller is provided with an RS 232 interface that can be used for connection to a PC
or a modem.
Overview
Configure the interface as follows:
Make the electrical connection (see electrical diagram for the machine)
Set the type of output
Saving the settings
7.7.1 RS 232 pin assignment


Connect the screening to the plug housings at both ends.
Pin Connections
1 spare
2 receive data RxD
3 receive data RxD
4 reserved
5 ground
6 spare
7 request to send RTS
8 clear to send CTS
9 spare
Tab. 28 RS 232 pin assignment
7.7.2 Configuring the RS 232 interface

6.1bar 80°C
RS232 <
RS485
3. Press Enter to select RS 232.
6.1bar 80°C
-> n.a. < Interface n(ot) a(ctive)

. . .
5. Press the UP key once or twice to select modem or data > PC.
6. Press the Enter key to accept the type of output.
7 --- 79
Initial Start-up
Saving the settings

7.8 Configuring the SMS

If, for example, a SIGMA TELE-CARE agreement has been signed, the controller can send
information to KAESER Service in SMS form to make possible a remote diagnosis. A
modem must be fitted that can be connected to the phone network.
Overview
Configure the SMS option as follows:
Activating the SMS function
Suppress repeat messages (filter)
Entering the modem’s phone number (modem)
Entering company data (site location)
Select the service centre (channel 1 (2))
Saving the settings
7.8.1 Activating the SMS function

3. Keep on pressing the DOWN key until SMS appears in the third line of the display.
6.1bar 80°C
mode: n.a. SMS inactive
buffer empty <
channel 1
6.1bar 80°C
*SMS status
mode: n.a. <
buffer empty
7. Press the UP key once or twice to select SMS 1x or SMS 5x.
8. Save the setting with the Enter key.
If 1st SMS is set the actual warning or alarm messages will be sent per
SMS.
If SMS 5x is set, an actual process image in binary format is sent in addi-
tion. Four further SMSs are needed for this function.
7 --- 80
Initial Start-up
7.8.2 Suppress repeat messages (filter)

To suppress messages repeating at short intervals, a period of 0 - 3.600 seconds can be
set during which a repeat of the same message is suppressed, i.e. is not sent.

the menu option configuration > SMS is selected
1. Keep on pressing the DOWN key until filter appears in the third line of the display.
3. Use the DOWN key or the UP key to set the required period and confirm by pressing
Enter.
7.8.3 Entering the modem’s phone number (modem)
Detailed information on standard settings and initialisation are given in the

service manual for SIGMA AIR MANAGER-short message service (SMS).
The modem phone number and modem initialisation must be entered to finalise configur-
ation of the modem.

the menu option configuration > SMS is selected.
1. Keep on pressing the DOWN key until modem appears in the third line of the display.
6.1bar 80°C
tel.modem
-> ******** < the first six numbers (not entered)
-> ******** further 12 numbers (not entered)
3. Use the DOWN key or the UP key to initially enter the first six numbers and confirm
each one by pressing Enter.
4. Scroll to the next line with the DOWN key and enter the remaining numbers in the
same way.
5. Scroll with the DOWN key until the following is displayed:
6.1bar 80°C
initialization
-> ATX3DTO < actual initialization
- - - - - - -
6. If required, set the initialization in the same way.
7 --- 81
Initial Start-up
7.8.4 Entering company data (site location)

The following information is entered in the location menu option:
Subsidiary: name of the KAESER subsidiary (for customers with a SIGMA TELE CARE
agreement this is already entered)
Customer: name of the company
Customer’s phone: phone number with which KAESER Service can call back
SMS language: the language of the SMS sent (select according to the KAESER Ser-
vice subsidiary)

the menu option configuration > SMS is selected
1. Keep on pressing the DOWN key until location appears in the third line of the dis-
play.
6.1bar 80°C
--------------
subsidiary
-> CBG name of the KAESER subsidiary
3. Scroll down with the DOWN key until customer appears in the second line.
5. Edit the company name with the UP or DOWNkey and confirm with the Enter key, use
the next line, if necessary
6. Enter the phone number in the menu option tel.customer in the same way.
7. Scroll down with the DOWN key until SMS appears in the second line.
8. Use the DOWN key or the UP key to select the SMS language and confirm by pressing
Enter.
7.8.5 Configuring selection of the Service Centre (channel)
Overview
The preset data entered by KAESER are displayed in menu option channel 1:
Phone number of the responsible call centre
Phone number of the SMS message
Selection of the SMS protocol
The following settings can be changed:
Number of auto re---dials
Duration of the interval between two calls

the menu option configuration > SMS is selected.
Ask your network provider for the number of the call centre.
7 --- 82
Initial Start-up
1. Keep on pressing the DOWN key until channel1 appears in the third line of the dis-
play.
6.1bar 80°C
tel. CallCenter
-> 017125 CallCenter number (first digits)
-> 21002 CallCenter number (following digits)
3. Scroll down with the DOWN key until auto re-dial appears in the second line.
5. Use the DOWN key or the UP key to set as required and confirm by pressing Enter.
6. Set up the duration of the interval in the same way.
The same settings can be made in the channel 2 menu option.
Saving the settings

7.9 Configuring input and output signals

The controller’s binary and analog inputs and outputs can be used for further require-
ments. This chapter deals with the various options in the following sections:
7.9.1: Outputting important operational machine states
7.9.2: Display of analog input values
7.9.3: Displaying additional binary input signals
7.9.4: Using machine pressure and temperature values as switches
7.9.5: Configuring analog outputs
The controller only allows assignment of spare inputs and outputs. If an

occupied input or output is assigned this will be rejected by the controller
(the display returns to n.a. when the Enter key is pressed).
The outputs DO 0.3 to DO 0.5 are left as spare at the factory. Further spare
outputs can be found in the machine circuit diagram.
7 --- 83
Initial Start-up
7.9.1 Outputting important operational states of the machine.

Important operational machine states can be made available as a binary signal via volt ---
free contacts.
The following messages can be outputted:
Message Explanation Output

controller ON Controller is powered up
Group alarm Alarm is activated
Motor running Motor running
Compressor ON The machine is switched on.
Group warning Warning message has appeared
Remote mode Remote mode is activated
IDLE The machine is in IDLE mode
LOAD The machine is in LOAD mode
Clock active The clock is activated
Clock contact The contact is closed
Emergency stop Emergency stop switch has been pressed
Tab. 29 Assigned output signals
Overview
The configuration is entered in menu option I/O periphery > DO functions:
Enter password for level 4
Select menu options configuration > I/O periphery > DO functions
Assigning a message to an output
7.9.1.1 Selecting menu options configuration > I/O periphery

3. Keep on pressing the DOWN key until I/O periphery appears in the third line of
the display.
6.1bar 80°C
DO functions < menu option for binary output functions

Show quantities menu option for showing quantities
Selecting the menu option ”DO functions”

A list of available messages and their assigned outputs is displayed.
6.1bar 80°C
controller ON controller ON message
-> n.a. < no output assigned
Group alarm group alarm message
7 --- 84
Initial Start-up
7.9.1.2 Assigning a message to an output

6. Select the required message with the DOWN key.
The cursor appears over inverse n.a. (or the assigned output).
Enter.
A message is now sent via the output assigned.
9. For clarity, enter the output in the table above
7.9.2 Displaying analog input values

Up to six pressure, temperature, etc. values from various sensors/transducers can be dis-
played at display level in the analog data menu.
Of these, two are assigned to pressure transducers and two to temperature sensors; two
further inputs can be assigned to freely selectable sensor types. A list of standard analog
data that can be displayed is found in chapter 8.6.
Overview
The configuration is entered in menu option I/O periphery > show quantities:
Select menu options configuration > I/O periphery > show quantities
Select display (display 1 - 6)
Assigning the analog input
Select the type of signal (4 - 20 mA/0 - 20 mA)
Allocating a value range to the measurement (calibration)
Editing sensor designation and unit of measure
Example:
The configuration is explained with the following example:
The signal quantity from an airflow measuring device is to be displayed in the analog data
menu. The sensor has a measurement range of 0 --- 50 m3/h and the signal ranges from
4 - 20 mA. The sensor is assigned to analog input AI5.
7.9.2.1 Selecting the menu option show quantities

an electrical connection has been made,
menu option configuration > I/O periphery is selected
(see section 7.9.1.1).
1. Keep pressing the DOWN key until show quantities appears in the third line of
the display.
6.1bar 80°C
display1 (p) < pressure display 1

display2 (p) pressure display 2
7 --- 85
Initial Start-up
7.9.2.2 Select display (display 1-6)

3. Keep pressing the DOWN key until display5 (I) appears in the third line of the
display and then confirm with the Enter key.
6.1bar 80°C
Mmmmmmmmmmmmm line for sensor designation
###### mmmmmm < line for unit designation
-> n.a. no input assigned
7.9.2.3 Assigning the analog input

4. Press the DOWN key once, to scroll n.a. into the third line of the display and then
press the Enter key.
5. Use the UP key to select input AI5 and confirm with the Enter key.
If the sensor was previously connected to the controller, a quantity is displayed.
7.9.2.4 Select the type of signal (4 - 20 mA/0 - 20 mA)

6. Press the DOWN key once to select the input signal.
As 4 - 20 mA is preset, no setting is needed.
7.9.2.5 Allocating a value range to the measurement (calibration)

The factory setting is a range from 0 - 10.000 that represents a signal current between
4 - 20 mA. This quantity range has to be adapted to represent the measurement range of
the sensor of 0 --- 50 m3/h.
6.1bar 80°C
calibration
20mA: 10000 < top of the signal range
4mA: 0 bottom of the signal range

9. Press and hold the DOWN key and to set the top of the range to 50.
The quantity reduces initially in steps of units, then tens, hundreds and finally in thou-
sands.
10. Using this method, reduce the quantity to 100 and then set to 50 with the DOWN key.
12. Set the bottom quantity for 4 mA in the same way.
7 --- 86
Initial Start-up
7.9.2.6 Editing sensor designation and unit of measure

13. Scroll up the display to the line for sensor designation with the UP key.
14. Press the Enter key and select characters from the character set with the UP and
DOWN keys to give the sensor signal a designation. There are 15 characters to
choose from.
15. Confirm the entry with the Enter key.
16. Enter the unit of measure in the line below in the same way.
The signal value from the sensor can now be displayed in the analog data menu (see
chapter 8.6).
7.9.3 Displaying additional binary input signals

As well as the defined alarm and warning messages there are six further freely selectable
input signals that can be used to display messages. Eine Liste der definierten Störungs-
und Wartungsmeldungen finden Sie in Kapitel 9. Information on spare inputs is given in the
machine circuit diagram.
An input signal can be classified as either an alarm, service or operational message. To
suppress any possible contact bounce or similar problems the input signal can be delayed
by an adjustable period. This ensures that the signal must be apparent for a minimum
period before it can be processed as a message.
If an input signal is classified as an alarm the controller goes into the alarm
state and shuts down the machine.
Overview
The configuration is entered in menu option I/O periphery > ext.messages:
Select menu options configuration > I/O periphery > ext. messages
Selecting the message number (0 - 5)
Selecting the message type (operational, alarm, warning)
Assign an input
Setting the time delay
Entering the message text
7.9.3.1 Selecting menu option ”ext. messages”

1. Keep pressing the DOWN key until ext. messages appears in the third line of the
display.
6.1bar 80°C
ext. message 0 < external message number 0

ext. message 1
7 --- 87
Initial Start-up
7.9.3.2 Selecting the message number (0-5)

3. Use the DOWN key to select a spare message number and confirm with the Enter key.
6.1bar 80°C
Mmmmmmmmmmmmm line for the message text
-> warning < selected message type
-> n.a. no input assigned
7.9.3.3 Selecting the message type (operational, alarm, warning)

5. Use the UP key to select the message type and confirm with the Enter key.
7.9.3.4 Assign an input

6. Press the DOWN key twice, then press the Enter key.
7. Use the UP key to select the input concerned and confirm with the Enter key.
7.9.3.5 Setting the time delay

8. Press the DOWN key twice, then press the Enter key.
The cursor appears inverse over the set time delay.
6.1bar 80°C
-> DI 2.0 selected input
td: 0.00s < set time delay
The period can be set between 0.01 and 600 seconds. The delay is counted down from
600 with the DOWN key and counted upwards from zero in 0.01 second steps with the UP
key.
9. Press the DOWN key to set a long time delay.
or
Press the UP key to set a short time delay.
10. Confirm the time delay setting with the Enter key.
7.9.3.6 Entering the message text

11. Using the UP key, scroll up the display to the line for the message text.
12. Press the Enter key and select characters from the character set with the UP and
DOWN keys to enter the message text. There are 15 characters to choose from.
13. Confirm the entry with the Enter key.
The input signal is now available as a message.
7 --- 88
Initial Start-up
7.9.4 Using machine pressure and temperature values as switches

The pressure transducers and temperature sensors connected to the controller (both in the
machine and on the user’s premises) can be also be used as switches:
If a set switching point SP is reached, a message can be triggered and/or a binary
output signal set until pressure falls below the switching differential SD again.
The message can be defined as an operational, warning or alarm message.
A delay period can be set to suppress constant on/off switching caused by fluctu-
ations around a switching point.
The following sensors can be used for the switching function:
pressure transducers:
--- local pressure transducer (pNloc)
--- external pressure transducer (pNext)
--- internal pressure transducer (pi)
--- two further pressure transducers (dis1 and dis2)
Temperature sensors
--- airend discharge temperature (ADT)
--- package discharge temperature (PDT)
--- motor temperature (mot T)
--- cooling water temperature cw T
--- two further temperature sensors (dis3 and dis4)
Overview
The configuration is entered in menu option I/O periphery > switch:
Select menu option configuration > I/O periphery > switch
Selecting the type of sensor
Selecting the sensor
Setting the switching point and switching differential
Entering the message text
Selecting the message type
Set the delay period
Assigning the switch to a binary output
7 --- 89
Initial Start-up
7.9.4.1 Selecting menu options configuration > I/O periphery

(see section 7.9.1.1)
1. Keep pressing the DOWN key until switch appears in the third line of the display.
6.1bar 80°C
p-switch menu option for the pressure switch

<
T switch menu option for the temperature switch
7.9.4.2 Selecting the type of sensor

3. Press Enter to select the pressure switch.
or
Press DOWN once to select the temperature switch. Confirm with the Enter key.
7.9.4.3 Selecting the sensor

6.1bar 80°C
p-switch pressure switch is selected
-> n.a. ########< no switch has been selected
SP: 0.00bar switching point

5. Use the UP key to select the required reference value and confirm with Enter.
7.9.4.4 Setting the switching point and switching differential

6. Press the DOWN key once and then press the Enter key.
7. Use the DOWN key or the UP key to set the value for the switching point as concerned
and confirm by pressing Enter.
8. Set the switching differential in the same way.
7.9.4.5 Entering the message text

9. Press the DOWN key once and then press the Enter key.
10. Enter the message text by selecting characters from the character set with the UP and
DOWN keys. There are 15 characters to choose from.
11. Save the text with the Enter key.
7.9.4.6 Selecting the message type

12. Press the DOWN key once and confirm with the Enter key.
13. Use the UP key to select the message type (operational, warning, alarm) and confirm
with the Enter key.
7 --- 90
Initial Start-up
7.9.4.7 Set the delay period

6.1bar 80°C
Operation selected message type
td: 0.00s < actual time delay
-> n.a. assigned output
The period can be set between 0.01 and 3,600 seconds. The delay is counted down from
3,600 with the DOWN key and counted upwards from zero in 0.01 second steps with the
UP key.
or
7.9.4.8 Assigning the switch to a binary output

17. Press the DOWN key once and then confirm with the Enter key.
The cursor appears over inverse n.a. (or the assigned output).
Enter.
Configuration of the switch is now complete.
7.9.5 Configuring analog outputs
A configurable analog output is only possible on a Sigma Control fitted with

an expander card. If the machine is fitted with variable frequency drive (fre-
quency converter) this output is possibly assigned.
Under the address AO1 the controller has provision for an analog output. An existing ana-
log input pressure or temperature signal can be connected to this output and calibrated for
further processing. The following input signals are available:
System pressure (pN)
Internal pressure (pi) in the oil separator
airend discharge temperature (ADT)
Further signals specific to the machine are on inputs AI2 - AI8
In addition, two actual machine parameters can be connected to the output:
Actual system pressure setpoint (p1 or p2)
or
Rate of increase of airend discharge temperature dT/dt ADT
It is not necessary to calibrate these parameters.
Overview
The configuration is entered in menu option I/O periphery > AO parameter:
Select menu options configuration > I/O periphery > AO parameter
Selecting the analog input signal
Select the type of signal (4 - 20 mA/0 - 20 mA)
Assign the quantity range (calibration, if required)
7 --- 91
Initial Start-up
7.9.5.1 Selecting ”AO parameter”

1. Keep pressing the DOWN key until AO parameter appears in the third line of the
display.
6.1bar 80°C
AO1 -> n.a. no signal set
-> 4 -20mA set signal type
<
0.0mA actual value
7.9.5.2 Selecting the analog input signal

3. Press the UP key once, to scroll n.a. into the third line of the display and then press
the Enter key.
4. Use the UP key to select required input and confirm with the Enter key.
7.9.5.3 Defining the type of analog signal (4-20 mA/0-20 mA)

If the sensor concerned has a signal range of 4 - 20 mA then move on to the next instruc-
tion.
5. To alter the signal range press the DOWN key once and confirm with the Enter key.
6. Use the UP key to change the value to 0 - 20 mA and confirm with Enter.
7.9.5.4 Allocating a value range to the measurement (calibration)

The following steps are dependent on the analog signal to be sent.
Actual setpoint values for the machine: no settings required
Input signal of a temperature sensor: see calibrating a temperature sensor
Input signal of a pressure transducer: see calibrating a pressure transducer
Calibrating a temperature sensor
For (0) 4 - 20 mA signals a range of 0 ˚ C - 120 ˚ C has been set at the factory. If the sensor
covers another temperature range then it must be calibrated.
6.1bar 80°C
. Pt100
20mA: 120°C < maximum value
4mA: 0°C minimum value
8. Press the Enter key to set the upper value.
9. Press and hold the DOWN key or the UP key to set the maximum value and confirm by
pressing Enter.
10. Set the minimum value in the same way.
7 --- 92
Initial Start-up
Calibrating the pressure range

For 0 - 20 mA or 4 - 20 mA signals a range of 0 - 16 bar has been set at the factory. If the
sensor covers another pressure range then it must be calibrated.
6.1bar 80°C
p1(2)
20mA: 16.0 bar < maximum value
4mA: 0.0 bar minimum value
12. Press the Enter key to set the upper value.

13. Press and hold the DOWN key or the UP key to set the maximum value and confirm by
pressing Enter.
14. Set the minimum value in the same way.
Configuration of the outputs is now complete.
7.10 Configuring the Package Discharge Air Temperature

In order to monitor the air discharge temperature from the compressor, e.g.
downstream of the air cooler, an appropriate sensor (PT100) must be in-
stalled there. Further information is given in the circuit diagram.
7.10.1 Compensating line resistance

To compensate for the increased line resistance of the temperature sensor caused by long
cable runs it is possible to correct (reduce) the temperature value displayed.
Overview
The correction can be made in the menu option components> PD temperature
Select menu option components > PD temperature
Entering the correction value
7.10.1.1 Select menu option components > PD temperature

3. Keep pressing the DOWN key until PD temperature appears in the third line of the
display.
6.1bar 80°C
PD temperature
-> AI8 55°C < actual analog input temperature
corr. -0.5°C compensation for line resistance
7 --- 93
Initial Start-up
7.10.2 Entering the correction value

5. Keep pressing the DOWN key until corr. -0.7 appears in the third line of the dis-
play.
A cursor appears inverse over the temperature value.
7. Select the correction value with the UP key or DOWNkey and confirm with Enter.
The package discharge temperature is compensated by the correction value.
7.10.3 Switching levels for the package discharge temperature

The package discharge temperature is monitored at five levels:
Minimum temperature --- alarm message
Low temperature --- warning message
Normal temperature --- no message
High temperature --- warning message
Maximum temperature --- alarm message
The temperatures for these monitoring levels can be set. Likewise the analog input to
which the temperature sensor is connected.
A delay period can be set to suppress constant on/off switching caused by fluctuations
around a switching point.
Overview
The configuration can be carried out in the menu option components > PD temperature
Select menu option components > PD temperature
Select the analog input, if necessary
Set the switching points and switching differentials for the five temperature levels
Set the delay period
7.10.3.1 Selecting the analog input

menu option components > PD temperature is selected
If an input has already been assigned, this section can be skipped.

6.1bar 80°C
PD temperature
-> AI8 55°C < actual analog input temperature
corr. -0.5°C compensation for line resistance
The cursor appears over inverse n.a. (or the assigned input).
2. Use the DOWN key or the UP key to select a spare input and confirm by pressing
Enter.
7 --- 94
Initial Start-up
7.10.3.2 Setting the switching point and switching differential

6.1bar 80°C
. . .
| -> SP: 80°C < maximum-temperature
| -> SP: 70°C high temperature

5. Select the correction value with the UP key or DOWNkey and confirm with Enter.
6. Set the high, low and minimum temperatures in the same way.
7.10.3.3 Set the delay period

7. Keep on pressing the DOWN key until td: 0.00s appears in the third line of the dis-
play.
6.1bar 80°C
. . .
td: 0.00s < actual time delay
The delay can be set between 0.01 and 300 seconds. The delay is counted down from 300
with the DOWN key and counted upwards from zero in 0.01 second steps with the UP key.
or
The settings for package discharge temperature monitoring are now configured.
7.11 Activating Remote Reset

When warning or alarm messages are routed to a remote control centre via an output it
makes sense to have these messages acknowledged and reset by the control centre.
To allow this, the remote reset and remote key have to be activated. In addition, a con-
troller input must be assigned to the reset signal.
Overview
Selecting menu option configuration > acknowledgement
Setting the remote reset function
Activating the remote key
Assign an input
Press remote key
7 --- 95
Initial Start-up
7.11.1 Selecting menu option configuration > acknowledgement
3. Keep pressing the DOWN key until acknowledgement appears in the third line of
the display.
6.1bar 80°C
remote mode
-> key < acknowledgement (reset) by key only
remote key: n remote key deactivated
7.11.2 Setting the remote reset function

key+RC appears in the display.
7. Press the Enter key to accept the setting.
7.11.3 Activating the remote key

The cursor appears over the y (active) or n (inactive).
The remote is now activated.
7.11.4 Assign an input

6.1bar 80°C
- - - - - - - -
RC -> n.a. < no remote contact input has been assigned

13. Use the UP key to select the required input and confirm with the Enter key.
The input has now been assigned.
14. Press the remote key to enable remote reset (acknowledgement).
Should a warning message occur, it can now be acknowledged from a control centre.
7 --- 96
Initial Start-up
7.12 Linking to an external pressure transducer

If the air system is operated with an air receiver, the pressure in the receiver can be regu-
lated by an external pressure transducer.
The sensor output can be linked in the following ways:
via a Profibus link (from a master controller). An input does not have to be assigned
via the USS protocol (from a pressure transducer linked to the frequency converter),
assigned to input FC USS
via a pressure transducer (0/4 ---20mA) linked to Sigma Control. Assignment to the
analog input is necessary.
The controller processes the options in the following sequence:
1. Profibus value,
2. Pressure according to the assigned external transducer,
3. Local system pressure, the local system pressure transducer remains activated.
Overview
Select menu option configuration > pressure settings > press.act.value
Assign an input
Select the type of analog signal (4 - 20 mA/0 - 20 mA), if necessary
7.12.1 Selecting menu option configuration > pressure settings > load control
press. settings appears in the third line of the display.
4. Keep pressing the DOWN key until press.act.value appears in the third line of
the display.
6.1bar 80°C
Press.act.value
->pNloc 6.1bar < local transducer
->4-20mA
7.12.2 Assign an input

7. A cursor appears over pNloc.
8. Select the input with the UP key or the DOWN key. For pressures measured via the
frequency controller select FC USS.
9. Confirm with the Enter key.
The input for the external transducer is now activated. If the transducer has a signal
range of 4 - 20 mA or is linked via USS, the configuration is complete.
7 --- 97
Initial Start-up
7.12.3 Defining the type of analog signal (4 - 20 mA/0 - 20 mA)

10. To alter the signal range press the DOWN key once and confirm with the Enter key.
11. Use the DOWN key to change the value to 0 - 20 mA and confirm with Enter.
7.13 Setting up the timer for condensate drainage

A solenoid valve can be activated at regular intervals for the drainage of condensate.
Overview
Selecting menu option configuration > timer
Setting the timer OFF and timer ON periods
Assigning an output to the solenoid valve
7.13.1 Selecting menu option configuration > timer
press. settings appears in the third line of the display.
3. Keep pressing the DOWN key until timer appears in the third line of the display.
6.1bar 80°C
Timer timer menu option
OFF 300s < timer off period of 300 seconds
ON 5.00 timer on period of 5 seconds
7.13.2 Setting the timer OFF and timer ON periods

5. To change the timer OFF period, press the DOWN key once and confirm with the Enter
key.
The cursor appears inverse over the set time delay. The period can be set between
0.01 and 3600 seconds.
6. Change the OFF period with the DOWN or UP keys.
8. Set the ON period for the drain valve in the same way.
7.13.3 Assigning an output to the solenoid valve

10. Use the UP key to select the required output and confirm with the Enter key.
7 --- 98
Initial Start-up
7.14 Activating the energy---saving mode for the refrigeration dryer

Continuous or timer modes can be activated for control of the refrigeration dryer. Using the
menu option ”timer” the dryer can be shut down under time control whenever no com-
pressed 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.
2. Keep pressing the DOWN key until control mode appears in the third line of the
display.
6.1bar 80°C
local mode actual operating mode
-> Dual <
Control mode
6.1bar 80°C
dryer
-> Continuous < continuous mode is activated
. . .
A cursor appears inverse over the mode.
6. Set the required control mode with the UP or DOWN keys.
7 --- 99
Initial Start-up
7.15 Initial Start---up

Before initial startup, check that the conditions listed in the service manual have been
met.
Checking the controller settings Section Done?

1 Language correctly set 7.1.2
2 Date and time correct 7.1.4
3 Display format correctly set 7.1.5
4 System pressure setpoint correctly set 7.2
Tab. 30 Checklist of installation conditions
Check and confirm all the items in the checklist before starting the machine.
When power is applied to the machine the controller boots and carries out a self test.
The display illuminates and power LED (8) lights up.
The actual system pressure and the airend discharge temperature are displayed in the
first line of the display.
6.1bar 50° C system pressure and airend discharge pressure
- - - - - - - -
off
- - - - - - - -
Press the LOAD/IDLE toggle key (13).
Too short a start period
CAUTION
Too short a start period can damage the machine.
Press the ON key and let the machine run for at least one minute in
IDLE, to allow sufficient oil to enter the pressure system.
Press the LOAD/IDLE toggle key.

The machine switches to the LOAD state and delivers compressed air.
7 --- 100
Operation
8 Operation
Fig. 10 Switching On and Off

1 ”Machine ON” LED (green) 6 ”LOAD” LED
2 ON key 7 ”IDLE” LED
3 OFF key 8 ’Power ON’ LED (green)
4 Clock key 13 Idlekey
5 Remote key
8.1 Switching the Machine On and Off
8.1.1 Switching on the machine in local mode
Damage can occur by switching on and off too frequently.
CAUTION Take the permissible motor switching frequency into account when
switching the machine on and off.
Further instructions with regard to switching on and off correctly:

1. Do not switch the compressor on and off with the main disconnect switch.
2. Always switch the machine on with the ON key and off with the OFF key.
Ensuring operational readiness
Before switching on, make sure that
--- nobody is working on the machine,
--- all panels are in place.
--- the access doors are closed,
--- the machine has warmed up to at least + 3 C.
Switching on the machine
Compressed air can cause injury!
CAUTION Ensure operational readiness
1. Switch on the main switch/supply disconnecting device.

The controller carries out a self---test and the green LED ’Power ON’ (8) lights.
2. Press the ON key (2).
The green ’Machine ON’ LED lights (1).
The compressor motor runs up as soon as the network pressure is lower than the sys-
tem pressure setpoint.
8 --- 101
Operation
Automatic restart
The automatic restart is activated at the factory. If the actual system pressure is lower than
the system pressure setpoint, the machine starts automatically after a power failure.
see chapter 7.3.5 for instructions on deactivating automatic restart.
Automatic starting!
There is danger of injury from the machine starting automatically or by re-

mote start command.
Isolate the machine from the mains and lock out all phases of the
power supply before opening any machine enclosure or guard.
If the Machine ON LED (1) is lit, but not the LOAD (6) and IDLE (7) LEDs,
the machine is at a standstill and ready to start.
The machine can start at any moment.
8.1.2 Switching off the machine in local mode

1. Press the Idle key (13).
The machine switches to IDLE and the LED (7) flashes.
2. After running in idle for 20 seconds, press the OFF key (3).
The ”Machine ON” LED goes out (1).
3. Switch off and lock out the main disconnect switch.
Switching off in an emergency
Press the EMERGENCY STOP key.
The EMERGENCY STOP pushbutton remains latched in.
The compressor is vented and the machine is prevented from re---starting.
Starting again after an emergency stop
1. Turn the EMERGENCY STOP button in the direction of the arrow to unlatch it.
2. Press the Reset key to delete any existing alarm messages.
3. Switch on the machine.
8.1.3 Remote on and off switching

Condition: a remote control centre is connected.
Press the remote key (5).

The LED (5) lights up. The machine can now be controlled from a remote control
centre.
The machine can still be switched on and off by the ON (2) or OFF (3) keys, if required.
8.1.4 Switching on and off with the clock

Condition: the clock program is entered,
the clock key is activated.
Press the Clock key (4).

The LED (4) lights up. The clock now has control of the machine.
8 --- 102
Operation
8.2 Resetting alarm messages
Fig. 11 Resetting warning and alarm messages
10 ”Warning” LED (yellow)

11 ”Alarm” LED (red)
12 Reset key
An alarm shuts the machine down automatically. The red ’Alarm’ LED blinks (11).
The last line in the display shows the actual fault causing the alarm. A table of possible
alarms occurring during operation are shown in section 9.1.
Condition: the fault has been removed
Press the Reset key (12).

The alarm LED goes out (11).
The machine is ready for operation again.
If the machine has been shut down with the EMERGENCY STOP pushbut-
ton:
Unlatch the EMERGENCY STOP pushbutton before pressing the reset

key
(turn the pushbutton in the direction of the arrow).
8 --- 103
Operation
8.3 Resetting warning messages
Fig. 12 Resetting warning and alarm messages
10 ”Warning” LED (yellow)

11 ”Alarm” LED (red)
12 Reset key
If maintenance work is to be carried out or if the warning is displayed before an alarm, the
yellow ”Warning” LED (10) flashes.
The last line in the display shows the actual warning.
A table of possible warning messages is shown in section 9.2.
Condition: the threat of an alarm is removed,

maintenance task has been completed.
Reset the warning message with the Reset key (12).

The warning LED (10) goes out.
8.4 Displaying the Actual Operating Mode

To display the actual operating mode, press the DOWN key once.
Example Explanation
6.1bar 80°C
idle
— — — — — — —
FC-on|p1-idle remote contact, switched on, system pressure setpoint p1,
idling
8 --- 104
Operation
The operating modes are shown using the following abbreviations:
e.g. key ---on ¦ p1 ---idle
Load control status:

idle idle
load On load
rdy Motor is off, but ready to run.
motor starts again if air is demanded
off motor is off
load controlled by:

p1 system pressure setpoint p1
p2 system pressure setpoint p2
pE increased system pressure pE (at a dubious load
signal)
RC remote contact (external load signal)
RB remote bus (external bus signal)
Machine status:
on switched on
off switched off
alm Alarm, there is a fault

machine switched on/off by:
key ON or OFF key on the control panel
clk Internal clock
RC remote contact (external contact)
RB remote bus (external bus signal)
UFK clock or remote contact (external contact)
hdy holidays (see chapter 7.3.2)
8 --- 105
Operation
8.5 Setting up Machine Pressure

A detailed explanation of all pressure parameter settings is given in chapter 7.2.
8.6 Displaying Messages

The following information can be called up in the status > messages menu option:
Event memory record of the last 100 events, these include alarm and warning mess-
ages
Last alarm
Last warning
Number of actual alarms
List of displayable information in a message

The information in a message is shown in three lines of the display. Message type and
status are shown abbreviated.
Example:
6.1bar 80°C
W a 16:10:31 warning message occurred at...
23.07.2004 on...
no pressure message text
build-up
W a 16:10:31 (example)
time of message occurrence

message status
c Message has come
g Message gone
a message reset
Type of message:
W Warning messages
A Alarm message
8.6.1 Selecting menu option status > messages

messages appears in the display.
event info appears in the display.
8 --- 106
Operation
Displaying event information

The last message (event) displayed appears in the display. The messages are dis-
played chronologically.
5. Scroll through past events with the DOWN key and back to actual events again with
the UP key.
Displaying the last alarm
1. Keep on pressing the DOWN key until last alarm: appears in the third line of the
display.
The last alarm is displayed.
Displaying the last warning
1. Keep on pressing the DOWN key until last warning: appears in the third line of
the display.
The last warning is displayed.
Displaying the number of current alarms or warnings
1. Keep on pressing the DOWN key until the number of alarms and warnings present ap-
pears.
8.7 Displaying status data, resetting and printing

The following information can be called up in the status > statistics menu option:
Machine duty cycle (relationship between load hours and overall operating hours) as a
percentage and from a defined day.
Max. and min. system pressure and max. internal pressure
Motor starts as from a defined day and the total number of motor starts
Motor starts per day and per hour
Last run under load, last run in idle, last motor stop
The status data can be displayed with the DOWN and UP keys.
Resetting status data
Some status data can be reset. The value displayed is deleted and evaluated anew from
the time of the reset. These are:
Motor starts as from a defined day
Max. and min. system pressure and max. internal pressure
Motor starts from a defined day onwards
8 --- 107
Operation
8.7.1 Displaying and resetting machine duty cycle

Status data are displayed, starting with machine duty cycle.
6.1bar 80°C
Duty cycle
* total duty cycle as from initial start ---up
85.2%
SFC RS485###% duty cycle for SFC
Resetting
1. Keep on pressing the DOWN key until reset: n appears in the third line of the dis-
play.
The actual date is taken as the starting date. The duty cycle is evaluated as from the
new starting date.
8 --- 108
Operation
8.7.2 Displaying and resetting further status data

1. In menu option status > statistics, press the DOWN key to display the following status
data:
Duty cycle from a defined day onwards
system pressure
--- max: maximum system pressure since last reset
--- min: minimum system pressure since the last reset
internal pressure
--- max: maximum internal pressure since last reset
motor starts
--- total number of motor starts
--- number of motor starts since last reset
motor starts /d
--- max. _ _ _ : permissible motor starts per day (this is specific to the machine)
--- number of detected starts over the last 24 hours
motor starts /h
--- max. _ _ _ : permissible motor starts per hour (this is specific to the machine)
--- number of detected starts over the last 60 minutes
motor starts T
--- number of detected motor starts below the minimum temperature
last load run
--- date and time of the last changeover from LOAD to IDLE mode
last idle run
--- date and time of the last changeover from IDLE to LOAD mode
motor OFF
--- date and time of the last shutdown
or the last changeover from IDLE mode to operational
2. Proceed as detailed in the previous section to carry out a reset.
8.7.3 Changing the permissible number of motor starts
The number of motor starts can be changed, e.g. in the case of an exchanged motor.
1. In menu option status > statistics keep pressing the DOWN key until motor starts
appears in the third line of the display.
The cursor appears inverse over the total number:
3. Use the DOWN key or the UP key to set the new value and confirm by pressing Enter.
8 --- 109
Operation
8.7.4 Transferring event memory data or parameter data to a PC

the interface is configured and
a PC is connected to the serial interface.
A condition for transfer of data is an online PC. Setting up the interface is described in
chapter 7.7.
3. Keep pressing the DOWN key until data>PC appears in the third line of the display.
5. Press the DOWN key or UP key untilevent info or data appears in the third line
of the display.
The data transfer starts. When the transfer is completed, the display changes back to
n. a. (not active).
8.8 Displaying analog data

The following information can be called up in the analog menu option:
Information
actual system pressure local ( pN loc )
actual system pressure external ( pN ext )*
actual internal pressure ( pi )*
actual cut ---out pressure ( p1 or p2) SP and SD
pressure differential across oil filter ( dp )*
airend discharge temperature (ADT)
airend discharge temperature before start
rate of rise of airend discharge temperature (dT/dt)
package discharge temperature*
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 data for actual pressure can be displayed in the configuration > press. settings >
press.act.value menu option.
Tab. 31 Displayed analog data
8 --- 110
Operation
Displaying analog data
1. In the main menu keep on pressing the DOWN key until analog data appears in
All the compressor’s analog data are displayed.
(example):
6.1bar 80°C
system pressure
pNloc 6.50bar local system pressure
. . .
3. Scroll with the DOWN key to display further analog data.
4. Scroll with the UP key to display own analog data.
8.9 Displaying operating data

The following information can be called up in the operating data menu option:
Operating hours
--- compressor run: total machine running hours
--- on load: machine on load running time
--- motor: motor running time (can be changed)
--- airend: airend running time (can be changed)
--- Sigma Control: controller’s hours of operation
--- mod. valve: modulating valve’s operational hours
Load valve ON frequency
Machine power consumption (according to type)
Displaying operating data

1. In the main menu keep pressing the DOWN key until operating data appears in
operating hours appears in the display.
3. Press the Enter key to display machine operating hours
or
scroll down with the DOWN key to display the load valve ON frequency and the power
consumption of the machine.
8 --- 111
Operation
Changing the operating hours

The motor and airend running times can be changed, e.g. in the case of an exchanged
motor.
1. In the main menu keep pressing the DOWN key until operating data appears in
operating hours appears in the display.
4. Press the DOWN key until motor (or airend) appears in the second line of the display.
6. Use the DOWN key or the UP key to set the required value and confirm by pressing
Enter.
8.10 Resetting maintenance interval hours counters

Maintenance interval counters register the operating hours between maintenance tasks.
The remaining hours in the respective maintenance interval counter can be individually
reset.
The controller registers the maintenance intervals for the following components:
Oil filter and oil separator
Oil change
Air filter
Belt change (blt.coup.chng.) and belt tension (blt.coup.insp.)
Coupling change (blt.coup.chng.) and coupling inspection (blt.coup.insp.)
Bearing change and bearing maintenance
Electrical equipment
Overview
Proceed as follows to reset a maintenance interval counter:
Selecting menu option maintenance > maintenance interval hours counter
Condition: maintenance task has been completed,

service message is reset,
password level 4 is activated.
8 --- 112
Operation

1. In the main menu, keep pressing the DOWN key until maintenance appears in the
A maintenance interval hours counter (e.g. oil filter) appears.
6.1bar 80°C
Oil filter name of the maintenance interval hours counter
6000h | 0150h < preset interval / remaining hours to maintenance
reset: n
3. Keep pressing the UP or DOWN key until the unit to be maintained appears in the sec-
ond line of the display.

The cursor appears inverse over reset: n.
The remaining interval hours now change to the total hours of the maintenance inter-
val, the reset parameter changes from y to n.
8.11 Setting the maintenance interval

Overview
Proceed as follows to set a maintenance interval:
Changing the maintenance interval

1. In the main menu, keep on pressing the DOWN key until maintenance appears in
3. A maintenance interval hours counter (e.g. oil filter) appears.
6.1bar 80°C
Oil filter name of the maintenance interval hours counter
6000h | 0150h < preset interval / remaining hours to maintenance
reset: n
4. Keep pressing the UP or DOWN key until the unit appears in the second line of the dis-
play.
8 --- 113
Operation
Changing the maintenance interval

The cursor appears over the preset maintenance interval.
6. Press the UP or DOWN key to change the interval hour by hour.
or
Press and hold the UP or DOWN key to change the interval by tens, hundreds or thou-
sands of hours.
7. Confirm with the Enter key.
8.12 Resetting annual maintenance messages

The annual maintenance message serves as a reminder of maintenance work and is not
related to actual machine operating hours.
The controller stores the actual data (time stamp) 100 hours after initial start up of the ma-
chine. If no maintenance has been carried out by the same date the following year or none
of the following maintenance interval counters have been reset, the message ”annual
maint” appears.
Oil filter
Oil separator
Oil change
Air filter

To reset the message, proceed as described in chapter 8.10.
The controller stores the actual date and starts the next annual interval.
8.13 Checking the pressure relief valve
This check may only be carried out

by specialists
by authorised KAESER service personnel.
Overview
Carrying out the check
Correct conclusion of the test
When check mode ”pressure relief valve” is activated, monitoring of inter-

nal pressure (blowoff protection) and regulation of the system pressure at
the setpoint is deactivated.
Danger of injury from pressurised components
CAUTION
The instructions listed below must be followed without fail.
8 --- 114
Operation

1. Note the opening pressure (or activating pressure) of the pressure relief valve from the
machine’s nameplate.
2. Press the OFF key to shut down the machine.
3. Close the shut ---off valve supplying the air main network from the machine.
4. Activate password level 4 in the controller (see section 7.1.3).
TÜV check appears in the display.
6.1bar 80°C
TÜV check
relief valve: n<
pRV: 16.00 bar activating pressure of pressure relief valve (example)

The cursor appears over relief valve: n.

The ”pressure relief valve” check mode is activated. Monitoring of internal pressure
and system setpoint pressure is deactivated!
10. Press the DOWN key once to display the internal pressure:
6.1bar 80°C
relief valve: y
pRV: 16.00 bar activating pressure of the pressure relief valve
pi: 7.30 bar actual internal pressure
11. Press and hold the ON key.

The machine switches to load, the internal pressure pi of the machine rises.
12. Keep an eye on the rise in pi on the display as long as the check is running.
13. If pi increases to more than 10 % of the opening pressure of the pressure relief valve
shut down the machine with the OFF key and change the valve.
Avoid oil mist:
Release the ON key as soon as the pressure relief valve opens to keep
build ---up of oil mist as low as possible.
If the pRV^ alarm appears in the display, the pressure relief valve is defec-
tive. The permissible internal pressure was exceeded by 2 bar.
Have the pressure relief valve replaced by an authorized KAESER Ser-

vice agent.
8 --- 115
Operation

The cursor appears over relief valve: y.
16. Use the DOWN key to select n and confirm with Enter.
The ”pressure relief valve” check mode is de---activated and the test ended.
18. Open the shut ---off valve from the machine again.
The machine is ready for operation.
8.14 Checking the Temperature Sensor and Overtemperature Shutdown

Function
This check may only be carried out

by specialists
by an authorised KAESER service agent.
The machine should shut down if the airend discharge temperature reaches a maximum of
110 ˚ C. A higher temperature is simulated to check this function. This is necessary to
evaluate and enter an offset value.
During the check mode this offset is added to the actual temperature to cause the machine
to shut down prematurely.
Overview
Ascertain and enter the offset
Shut down the machine and allow to cool down slightly
Ascertaining offset
1. Read off the airend discharge temperature under load (normal working temperature)
(first line in the display, e.g.: 80 ˚ C)
2. Offset = 110 ˚ C minus the airend discharge temperature
(offset in this case = 30 ˚ C)
3. Shut down the machine with the OFF key
4. Watch the first line of the display and wait until the airend discharge temperature has
dropped by about 5 ˚ C.
8 --- 116
Operation
Setting the offset

5. Activate password level 4 in the controller (see section 7.1.3).
”TÜV inspection” appears in the display.
6.1bar 80°C
ADT alarm: n
offset = 40 °C< offset value set (example)
ADT ^ : 0 °C
The cursor appears inverse over offset: 40 °C.
10. Use the DOWN key or the UP key to enter the calculated offset and confirm by pres-
sing Enter.
Condition: machine has cooled down by about 5 ˚ C
11. Press the UP key once so that ADT alarm: n appears in the third line of the dis-
play.
The cursor appears inverse over ADT alarm: n.
The ”overtemperature shutdown” check mode is activated.
14. Press the DOWN key once to display the operating temperature + offset:
6.1bar 73°C reduced operating temperature (73 ˚ C)
ADT alarm: y overtemperature shutdown
offset = 30 °C< offset value set (example)
ADT ^: 103 °C operating temperature + offset
15. Press the ON key to switch the machine to LOAD.

The machine goes on load and the airend discharge temperature rises to the operat-
ing temperature again.
As soon as a VET temperature of 110 ˚ C is reached, the machine shuts down and an
alarm is activated.
If the machine does not shut down:
Abort the check and contact KAESER Service as soon as possible.
8 --- 117
Operation

17. Reset the offset to 40 ˚ C and confirm with Enter.
18. Press the UP key once so that ADT alarm: y appears in the third line of the dis-
play.
20. Use the UP key to select and confirm with Enter.
The ”overtemperature shutdown” check mode is de---activated and the test ended.
8.15 Determining the optimal control mode.

Depending on the application, one of the three control modes, DUAL, VARIO or QUADRO
can be selected for the most economical duty cycle (relationship between hours on load to
total operating hours.
1. Enter password for level 4
2. Reset the ”duty cycle” setting in the statistics menu option
(see section 8.7)
3. select a control mode in the ”configuration” menu option
(see section 7.4)
4. Run the machine for an extended period (approx. one month or longer).
5. Note the ”duty cycle” value and then reset again.
6. Select another control mode.
7. Compare results after running the machine for the same period.
8. Repeat the procedure for the third control mode.
9. Select the control mode with the highest duty cycle percentage.
8 --- 118
Event Recognition and Fault Rectification
9 Fault Finding and Removal
KAESER Service
Do not attempt fault removal measures other than those given in this manual. Inform
KAESER Service if the fault cannot be removed with the measures suggested.
The messages valid for your machine are dependent on how the individual
machine is equipped.
There are three types of fault:
Description indicated by see

Alarm (with automatic shut ---down) red LED flashes 9.1
Warning (no shut ---down) yellow LED flashes 9.2
Other faults no indication 9.3
9.1 Alarm messages to the controller

(machine shut---down, red LED blinking)
Message Possible cause Remedy
access doors Door open with the machine Close the door(s).
running.

ADT Maximum airend discharge Ensure adequate ventila-
temperature exceeded. tion.
Ensure that the permissible
room temperature is not ex-
ceeded.
Clean the cooler.
Cooling air outlet of the ma-
chine too near a wall.
Check the cooling oil level.
ADT dT/dt Maximum rise rate of airend Check airend and piping to
discharge temperature airend.
(ADT) exceeded. Check the cooling oil level.
Check oil circulation.
AI 3/AI 4 error Line---break between the Check transducer connec-
analog input and the sen- tions and wiring.
sor.
Short circuit to earth.
AI 7/AI 8 error Line---break between the Check transducer connec-
analog input and the sen- tions and wiring.
sor.
Short circuit to earth.
airend rotation The drive motor is turning in Change over phase lines L1
the wrong direction. and L2.

air filter dp Air filter clogged. Clean or renew the filter el-
ement.
backpressure Back pressure in the oil Check venting line.
separator tank caused by
poor venting.
9 --- 119

Buscontroller Bus link via the Profibus DP Check line and settings.
interface
blowoff prot. The activating pressure of Change the oil separator
the pressure relief valve on cartridge.
the oil separator tank has Open the shut ---off valve in
been exceeded. the venting line.
Condensate drain Fault in condensate drainage. Check condensate drainage.
coolingwater low Cooling water pressure too Check cooling water supply.
low. Check the cooling water
stop valve position.
DO 0.6/DO 0.7 Short circuit in the line be- Check line and connec-
tween DO 0.6 / DO 0.7 out- tions.
puts and a consumer.
DO 1.6/DO 1.7 Short circuit in the line be- Check line and connec-
tween DO 1.6 / DO 1.7 out- tions.
puts and a consumer.
EMERGENCY-STOP Emergency-stop-button Unlatch the pushbutton.
pressed.
ext. message 0 Customer specific:
... No data
ext. message 5
fan M2 I Shutdown of 1st fan motor Investigate cause of shut-
because of overload. down.
Reset overload trip.
fan M3 I Shutdown of 2nd fan motor Investigate cause of shut-
fan M4 I Shutdown of 3rd fan motor Investigate cause of shut-
HT cell Fault in the high tension Contact KAESER service.
cell.
mains cont. on? The mains contactor does Check mains contactor and
not pull in despite ON com- wiring.
mand.
mains cont. off? The mains contactor does Check mains contactor and
not drop out despite OFF wiring.
command.
mains monitor Fault in mains power supply. Have the mains power sup-
ply checked.
mains voltage 2nd power failure Check power supply volt-
age.
Check door interlock.
Model Machine model uncertain Contact KAESER service.
9 --- 120

motor I Drive motor has been shut- Change the oil separator
down because of overload. cartridge.
Check minimum pressure/
check valve.
Investigate cause of shut-
down.
motor T Drive motor overheated. Ensure adequate ventila-
tion.
Install an extractor.
Clean the motor.
motor bearings Drive motor bearings over- Grease the motor bearings
heated. with the greasing device.
Neutral p ---switch Customer specific:
No data
Neutral T---switch Customer specific:
No data
no press.buildup Machine produces no com- Check the machine for
pressed air. leaks.
Working pressure stays Check coupling / V---belts
below 3.5 bar within a Contact KAESER service.
preset period.
oil p No changeover to load as Check oil circulation.
long as the minimum oil Check pressure switch, line
pressure is not reached. and connection.
PD temperature Package discharge tem- Contact KAESER service.
perature too low.
PD temperature Package discharge tem- Check the fan motor.
perature too high. Clean the cooler.
pRV The activating pressure of Replace the pressure relief
the pressure relief valve on valve.
the oil separator tank has
been exceeded.
RD compr. p Pressure switch for the re- Ensure adequate ventila-
frigerant compressor has tion.
activated.
Clean the refrigerant con-
denser.
Clean the cooler.
RD compr. T Temperature in the refriger- Clean the refrigerant con-
ant dryer too high. denser.
Ensure adequate ventila-
tion.
Install an extractor fan.
Clean the cooler
RD compr. T Temperature in refrigeration Contact KAESER service.
dryer too low.
separator dp Oil separator cartridge Replace the oil separator
clogged. cartridge.
9 --- 121

separator T Maximum air temperature Check the line to the trip
on oil separator tank outlet relay.
exceeded.
SFC Frequency converter faulty. Contact KAESER service.
SIGMA CONTROL T Maximum permissible Ensure adequate ventila-
temperature in SIGMA tion.
CONTROL housing ex- Ensure that the permissible
ceeded. room temperature is not ex-
ceeded.
Check control cabinet venti-
lator (filter mats).
sh.cct.AI 1/AI 2 The connection between Check transducer connec-
the sensor and the analog tions and wiring.
input is shorted.
sh.cct.AI 5/AI 6 The connection between Check transducer connec-
the sensor and the analog tions and wiring.
input is shorted.
soft start Fault in the soft start equip- Contact KAESER service.
ment.
Airend discharge tempera- Heat the compressor room.
Start ture (ADT) too low. Ambient
temperature below + 3˚ C.
V---belts broken The V---belts parted during Replace the belts.
operation.
Tab. 32 Alarm messages and actions
9.2 Warning messages on the controller (yellow LED flashes)

access doors Doors opened with the ma- Close access doors.
chine shut down.
ADT Maximum airend discharge Ensure sufficient ventilation
temperature will soon be re- Clean the cooler.
ached.
The machine’s cooling air
outlet is too near a wall.
Replace the oil filter.
air filter dp The pressure drop across Clean/replace the air filter
the air filter is too high. element.
Air filter element clogged.
air filter h The interval for the air filter Clean/replace the air filter
element check has expired. element.
annual maint. The maintenance interval Carry out necessary main-

counter was not reset within tenance and reset one of the
a year. following maintenance inter-
val counters: oil filter, oil
separator, oil change or air
filter.
9 --- 122

bearing maint. h The maintenance interval Grease the motor bearings.
for greasing the bearings
has expired.
blowoff prot. Warning Change the oil separator
The blowoff pressure of the cartridge.
pressure relief valve will Open the shut–off valve in
soon be reached. the venting line.
blt.coup.insp.h The maintenance interval Visually inspect and tension
for V–belt tension / coupling the V–belts.
inspection has expired.
blt.coup.chng. h V–belts / coupling worn. Change belts / coupling.
Buffer battery Battery for retention of data Replace the battery
is discharged.
bus alarm Bus link via Profibus DP in- Check bus highway and
terface interrupted plug.
Condensate drain Fault in condensate drain- Check condensate drain
age. and lines.
elect. equip. h The service interval for Reset the service interval
checking electrical equip- counter.
ment and installation has
expired.
error: RS 485 Wrong configuration or Check the link/interface
transmission error. connections between the
two controllers.
Check maximum cable
length and screening.
1 master and 1 slave confi-
gured.
ext.load signal? Dubious external load sig- Check settings of the exter-
nal nal controller.
Increased cut–out pressure Take the pressure drops
exceeded. across filters and dryer into
The external load control account.
has not switched to idle (off
load).
ext. message 0 Customer specific:
... No data
ext. message 5
flash memory Internal controller memory Contact KAESER service.
error.
FC mains Failure of power supply to Check power supply.
the frequency converter.
mains voltage 1. power failure: Check power supply volt-
Machine was re–started age.
automatically. Check door interlock.
modem problem SIGMA CONTROL does not Check the link between
recognise the modem. SIGMA control and the
modem.
9 --- 123

motor T Drive motor overheating. Ensure adequate ventila-
tion.
Install an extractor.
Clean the motor.
motorstarts /h The permissible number of Extend the idle period.
motor starts was exceeded Increase capacity of air re-
during the last 60 minutes. ceiver.
Increase cross–section of
piping between compressor
and air receiver.
motorstarts /d The permissible number of Extend the idle period.
motor starts was exceeded Increase capacity of air re-
during the last 24 hours. ceiver.
Increase cross–section of
piping between compressor
and air receiver.
motor bearings h The service interval for the Have an authorized
motor bearing change has KAESER technician replace
expired. the motor bearings.
Neutral p–switch Customer specific:
No data
Neutral T–switch Customer specific:
No data
no press.buildup The compressor cannot Check for air leaks.
build–up to working pres- Check the value for internal
sure.
pressure given in the ”ana-
log data” menu with the re-
ading on the oil separator
tank pressure gauge.
oil filter dp Oil filter clogged. Oil filter replacement
oil filter h The interval for the next oil Oil filter replacement
filter check has expired.
oil level Oil level too low. Top up the cooling oil.
oil T Cooling oil temperature too Increase room temperature.
low. Check the oil circuit.
Check temperature switch,
line and connection.
oil change h The service interval for the Change the cooling oil.
oil change has expired.
oil content Warning Check the scavenge tube in
The oil content limit for pure the oil separator cartridge.
air will soon be reached. Check the dirt trap strainer
in the scavenge line.
Check air treatment up-
stream of the measurement.
9 --- 124

oil content The oil content limit for pure Check the scavenge tube in
air has been exceeded. the oil separator cartridge.
Check the dirt trap strainer
in the scavenge line.
Check air treatment up-
stream of the measurement.
PD temperature Warning Contact KAESER service.
Compressor outlet (pack-
age discharge) temperature
is low.
PD temperature Warning Clean the cooler.
Compressor outlet (pack- Check the cooling oil level.
age discharge) temperature
too high.
RAM Internal RAM defective. Contact KAESER service.
set output The ’set output’ test func- Stop the ”set output” mode.
tion is activated.
separator dp Oil separator cartridge Change the oil separator
clogged. cartridge.
separator h The interval for the next oil Change the oil separator
separator cartridge check cartridge.
has expired.
system press. System pressure has fallen Check air demand.
below the ”sys.press. low” Check transducer connec-
value. tions and wiring.
Air consumption too high. Check ”sys.press. low” set-
ting.
system press. System pressure is above Check for air leaks.
(vacuum machines only) the ”sys.press. high” value. Check ”sys.press. high”
setting.
Check if the machine
switches to LOAD.
Tab. 33 Warning messages and actions
9.3 Other Alarms

Fault Possible cause Remedy
Drive motor overload Overload protection cutout Check setting.
protection cutout has is defective or incorrectly
tripped. set.
Oil separator cartridge Check pressure drop across
clogged. the separator cartridge.
Change the oil separator
cartridge if necessary.
The pressure system does Open the shut ---off valve in
not vent. the venting line.
Motor defective; bearing
damage or windings
shorted.
Airend defective.
9 --- 125
Fault Possible cause Remedy

Machine runs but produces Inlet valve not opening or
no compressed air. only opening partially.
Venting valve not closing.
Leaks in the pressure sys- Check pipework and con-
tem. nections for leaks and
tighten any loose fittings.
Air consumption is greater Check compressed air net-
than the capacity of the work for leaks.
compressor.
Shut down the consumer(s).
Hose coupling or mainten- Remove coupling or main-
ance hose still plugged into tenance hose.
the quick ---release coupling
on the oil separator tank.
Cooling oil runs out of the Oil level in the oil separator Drain off oil until the correct
air filter. tank too high. level is reached.
Inlet valve defective.
Compressor switches be- Air receiver too small.
tween load and idle (off Flow into the compressed Increase air pipe diameters.
load) more than twice per air network restricted.
minute. Check filter elements.
Switching difference too
small (e.g. p1 SD)
Cooling oil leaking into the Hose coupling or mainten- Remove coupling or main-
floor pan. ance hose still plugged into tenance hose.
the quick ---release coupling
on the oil separator tank.
Oil cooler leaking
Connections leaking. Tighten connection fittings.
Replace seals.
Cooling oil consumption too Unsuitable oil is being used. Use SIGMA FLUID cooling
high. oil.
Oil separator cartridge split. Change the oil separator
cartridge.
Oil level in the oil separator Drain off oil until the correct
tank too high. level is reached.
Oil return line clogged. Check dirt trap in the oil re-
turn line.
Tab. 34 Other faults and actions
9 --- 126
Maintenance
10 Maintenance
Maintenance work and work on electrical equipment may only be carried

out

by and under the supervision of a specialist,
by specialists,
by authorised KAESER service personnel.
10.1 Testing the controller
10.1.1 Displaying binary inputs and outputs

Binary inputs and outputs to and from the controller can be displayed as follows:
1. In the main menu keep pressing the UP key until package test appears in the
Displaying inputs
3. Press the DOWN key until DI test: n appears in the third line of the display.
The status of the inputs is shown.
6.1bar 80°C
- - - - - - - -
DI 0.76543210 input address 0.7... 0.0
10010101 status: 1= voltage, 0= no voltage)
Displaying outputs
5. In the package test option press the DOWN key until DO test appears in the
The status of the outputs is shown.
7. Press the DOWN key for further output addresses.
10 --- 127
Maintenance
10.1.2 Testing the LEDs on the controller

The LEDs on the controller are tested as follows:
1. In the main menu keep pressing the DOWN key until package test appears in the
3. Keep pressing the DOWN key until lamps test: n appears in the third line of the
display.
The cursor appears inverse over lamps test: n.
The lamps test is now activated. All LEDs start to flash. The test ends automatically
after 10 seconds.
6. If one or more of the LEDs does not flash, contact KAESER Service.
10 --- 128
Spares, Operating Materiels, Service
11 Spares, Operating Materials, Service
11.1 Note the nameplate

Please quote the data on the nameplate for all enquiries and spare parts orders.
11.2 Maintenance Contract

Sign a maintenance contract with an authorised KAESER service agent.
This ensures the utmost reliability and availability of your compressed air supply system.
11.3 Service Addresses

Addresses of KAESER agents are given at the end of the machine’s service manual.
11.4 Displaying the version number, machine model, material number and
serial number
6.1bar 80°C
general
pressure settings
<
control mode
3. Press the UP key and select general with the Enter key.
4. Press the DOWN key to display the following information:
6.1bar 80°C
type DS 171 machine model
PN: 7.7001.0 material number
SN 00234567 serial number
5. For further information on the hard and software press the UP key and then with the
Enter key select version no..
6.1bar 80°C
system 2.56 system version
software 72.15 software version
hardware 0.6 hardware version
11 --- 129
De-commissioning, Storage and Transport
12 Decommissioning, Storage and Transport
See service manual for the machine.
12 --- 130
Annex
13 Annex
13 --- 131
Main menu Menu level 1 Menu level 2 Menu level 3
Language
Communication RS232
RS485
Profibus
SMS
Package test TÜV check Pressure relief valve
ADT alarm
DI test
DO test
Lamps test
Components Motor
Booster
Air main charging
PD temperature
Configuration General
Pressure settings Pressure sensors
Compressor
Vacuum package
Press.act.value
Pressure settings Load control
Control mode Dual/Quadro/Vario...
Compressor start Compressor ON
Compressor OFF
Reset Remote reset
I/O periphery DO functions
Show quantities
Ext. messages
Switch
Timer
Clock Clock key
Time program
Password
Main menu
Status Messages
Statistics
Printer
Analog data All analog data
Operating data All operating data
Maintenance Maintenance
counters
Fold ---out: menu overview

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SERVICE MANUAL

Controller SIGMA CONTROL

KAESER KOMPRESSOREN GmbH

Symbol Item Description Symbol Item Description

13 Alarm 17 LOAD mode

2. Changing Display Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3. Entering the Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4. Adjusting System Pressure Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

5. Activating the Clock Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6. Activating the remote key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

7. Changing the Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

8. Outputting Important Operational States of the Machine. . . . . . . . . . . 7

9. Resetting Maintenance Interval Hours Counters . . . . . . . . . . . . . . . . . . . 8

10. Displaying Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

11. Testing the Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

12. Checking the Temperature Sensor and Shutdown Temperature Function 12

by persons trained on the machine/controller and persons instructed

2. Changing Display Language

3. Entering the Password

The following passwords are entered in the controller on delivery:

4. Adjusting System Pressure Setpoint

Select menu option configuration > pressure settings

Condition: password level 4 is activated.

Setting system pressure setpoint and switching difference for p1

5. Activating the Clock Key

Select the clock menu option

Condition: password level 4 is activated.

Activating the clock key

6. Activating the remote key

Further settings have to be made to allow the machine to be remotely con-

Select menu option configuration > pressure settings

7. Changing the Control Mode

Select menu option configuration > control mode

Condition: password level 4 is activated.

Changing the control mode

8. Outputting Important Operational States of the Machine.

Select menu options configuration > I/O periphery > DO functions

Condition: password level 4 is activated.

Assigning a message to an output

9. Resetting Maintenance Interval Hours Counters

Condition: maintenance task completed,

Resetting maintenance interval hours counters

10. Displaying Messages

Select menu options status > messages

11. Testing the Pressure Relief Valve

Compressed air is dangerous!

Preparation for the test

Carrying out the test

Avoiding oil mist:

Have the pressure relief valve replaced by an authorized KAESER Ser-

Due conclusion of the test

12. Checking the Temperature Sensor and Shutdown Temperature

The machine does not shut down:

Abort the test and contact KAESER Service as soon as possible.

Due conclusion of the test

1 Regarding this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

2 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 3

3 Safety and Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 4

4 Design and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 6

5 Installation and Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 20