KAESER KOMPRESSOREN SIGMA CONTROL 2, Service Manual

Page 1: ...Service Manual Controller SIGMA CONTROL 2 BLOWER 4 0 X No 901700 14 E Manufacturer KAESER KOMPRESSOREN SE 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 www kaeser com...

Page 2: ...KKW SSC 2 15 en IBA SIGMA CONTROL BLOWER KKW SSC 2 15 20220810 080650...

Page 3: ...ule 13 3 2 2 Modbus module 13 3 2 3 Modbus TCP module 14 3 2 4 DeviceNet module 15 3 2 5 PROFINET module 16 3 2 6 EtherNet IP Module 17 4 Safety and Responsibility 4 1 Basic instructions 19 4 2 Specif...

Page 4: ...rver 66 8 3 KAESER CONNECT benefits 67 8 3 1 Open KAESER CONNECT 68 8 3 2 System status menu 69 8 3 3 Graphs menu 71 8 3 4 Messages menu 73 8 3 5 I O display menu 73 8 3 6 User management menu 74 8 3...

Page 5: ...kWh counter 145 9 7 Setting the maintenance interval 145 9 8 External Maintenance counter 146 9 9 Communication modules 149 9 9 1 Displays at the PROFIBUS module 149 9 9 2 Display at the Modbus module...

Page 6: ...ioning 175 13 1 1 Temporary de commissioning 175 13 1 2 Long term de commissioning 175 13 2 Packing 176 13 3 Storage 176 13 4 Transporting 176 13 5 Battery removal and disposal 176 13 5 1 Battery disp...

Page 7: ...73 Fig 24 I O display illustration similar 74 Fig 25 User management menu 75 Fig 26 Log on for write access window 75 Fig 27 User management menu 76 Fig 28 Settings menu 77 Fig 29 Backup menu 78 Fig...

Page 8: ...List of Illustrations vi Service Manual Controller SIGMA CONTROL 2 BLOWER 4 0 X No 901700 14 E...

Page 9: ...5 Tab 27 Assigning the DeviceNet interface 16 Tab 28 DeviceNet interface cabling recommendation 16 Tab 29 Technical Specifications SIGMA CONTROL 2 interface 16 Tab 30 Assignment of the SIGMA CONTROL 2...

Page 10: ...rting the machine 135 Tab 85 Maximum permissible number of motor starts per hour 136 Tab 86 Message sequence 1 138 Tab 87 Message sequence 2 138 Tab 88 Information of a message 139 Tab 89 Message abbr...

Page 11: ...9 Com Module communication error warning message 172 Tab 110 Fault indicators in the Communication Com Module menu 172 List of Tables No 901700 14 E Service Manual Controller SIGMA CONTROL 2 BLOWER 4...

Page 12: ...List of Tables x Service Manual Controller SIGMA CONTROL 2 BLOWER 4 0 X No 901700 14 E...

Page 13: ...elected sub menu option Exits editing mode and saves 7 ON Switches the machine on 8 OFF Switches the machine off 10 RFID RFID reader for logging user in via RFID Equipment Card 11 Time control Switche...

Page 14: ...essed 15 LOAD Illuminates continuously in green when the machine is running in LOAD 16 Voltage applied to controller Illuminates continuously in green when voltage is supplied to the con troller 17 Wa...

Page 15: ...iew See chapter 5 7 2 for the complete menu structure 1 4 Functions overview Function Menu no Action steps Chapter Set contrast Main menu Press and hold down Information Up Down 8 2 12 Set brightness...

Page 16: ...r 10 2 Warning mes sages 1 1 1 If maintenance work needs to be carried out or if the warning is displayed before a fault the yellow Warning LED flashes Warning messages are identified by the letter W...

Page 17: ...TROL 2 contains copyright protected software packages which are licensed as Open Source A copy of these licenses is contained in SIGMA CONTROL 2 Display the licenses by pointing your browser to the CO...

Page 18: ...C rules The operation is subject to the following two conditions this device may not cause harmful interference and this device must accept any interference received including interference that may ca...

Page 19: ...ocedure and numbered as a step Example 1 WARNING The type and source of the imminent danger is shown here The possible consequences of ignoring a warning are shown here The word WARNING indicates that...

Page 20: ...s or spare parts Precondition Here you will find conditional requirements necessary to carry out the task The conditions relevant to safety shown here will help you to avoid dangerous situations This...

Page 21: ...Number of membrane keys 13 Number of LEDs 9 Degree of protection control cabinet exterior IP 54 Degree of protection control cabinet interior IP 20 Voltage V DC 24 Current A 0 3 Voltage source Input...

Page 22: ...6 FE Functional earth FE The positions of the interfaces X1 X6 are marked on the rear of the controller Tab 10 MCS interfaces Identification with RFID Equipment Card Characteristic Value Hardware on t...

Page 23: ...50 VAC 8 A 8 Digital output transistor DOT 24 VDC 0 5 A 2 1 Analogue output current AOI 0 20 mA Tab 12 IOM 1 3 1 2 1 Power supply specifications Power is provided by the power supply unit within the m...

Page 24: ...racteristic Value Output signal mA 0 4 20 Connection Two core Tab 17 Pressure transducer Resistance thermometer Characteristic Value Sensing resistance to DIN IEC 751 PT100 Connection Two core Tab 18...

Page 25: ...2 7 9 3 B RxD TxD positive RS485 Level 4 RTS Send request 5 GND for terminator data delivery isolated 6 VP 5 V for terminating resistor isolated short circuit proof max 10 mA 8 A RxD TxD negative RS48...

Page 26: ...tential isolated RS485 Bus polarisation for terminating resistor pull down 2 Output VP 5V DC isolated max 10mA RS485 Bus polarisation 5V for terminating resistor pull up 3 Input PMC To use RS232 conne...

Page 27: ...24 Assignment of the Modbus TCP interface Recommended conduit Feature Value Conductor Network conductor CAT5 shielded CU for example 7 7629 0 Plug Bus plug RJ45 IP20 for example 7 7628 0 Maximum cable...

Page 28: ...path Within buildings Tab 28 DeviceNet interface cabling recommendation NOTICE Overvoltage can destroy the communications module Comply with the routing path and maximum cable length 3 2 5 PROFINET m...

Page 29: ...8 see chapter 9 Tab 30 Assignment of the SIGMA CONTROL 2 interface Recommended conduit Feature Value Conductor PROFINET conductor CAT5 shielded CU for example 7 7629 0 Plug Bus plug RJ45 IP20 for exa...

Page 30: ...smit 3 RD White Positive receive 4 5 7 8 6 RD Blue Negative receive Housing Cable shield High impedance 1 MOhm 47 nF connection with func tional earthing FE Position of pins 1 through 8 see chapter 9...

Page 31: ...am ages that may result from incorrect use The user alone is liable for any risks incurred Adhere to the specifications given in these operating instructions and the machine s service manual Operate t...

Page 32: ...e controller SIGMA CONTROL 2 controls regulates monitors and protects the machine All parameters needed to operate KAESER blowers can be set and displayed using the controller Various user dependent p...

Page 33: ...e drive motor in relation to the user s actual air demand Automatic restart of the machine after a power failure can be activated The monitoring function allows Supervision of all maintenance relevant...

Page 34: ...sub menu option Exits editing mode and saves 7 ON Switches the machine on 8 OFF Switches the machine off 10 RFID RFID reader for logging user in via RFID Equipment Card 11 Time control Switches time...

Page 35: ...y is pressed 15 LOAD Illuminates continuously in green when the machine is running in LOAD 16 Voltage applied to controller Illuminates continuously in green when voltage is supplied to the con trolle...

Page 36: ...ve This plastic sleeve is attached to the rear of the controller in the control cabinet Fig 7 RFID reader Position Designation Function 24 RFID RFID reader for communication with a RFID Equipment Card...

Page 37: ...n a dark background The following parameters are permanently displayed in the header Final pressure p2 Time Airend discharge temperature T2 Lines 2 to 7 Piping and instrumentation diagram Lines 2 to 7...

Page 38: ...ay be visible Subordinate menus can be recognised in the menu structure by the number preceding their desig nation The menu structure is detailed in chapter 5 7 2 Active line The active line 2 8 is al...

Page 39: ...ox flashes Press the Up key The check box is activated and flashes To save the settings press the Enter key again The display line ceases flashing and the key is activated Follow the same steps to dea...

Page 40: ...of the control ler This enables for example the operating and energy efficiency of your machine to be checked remotely To do so you must generate a one time password see Chapter 8 2 5 KAESER CONNECT d...

Page 41: ...to a PC via KAESER CONNECT 12 not on SXC Tab 40 KAESER CONNECT functions Further information For accessing KAESER CONNECT logging in and other procedures please see Chapter 8 3 5 7 Menu overview 5 7 1...

Page 42: ...main menu In the main menu you can Retrieve displayed information Enter customer specific settings The menus shown require access level 2 Main menu Menu No Designation Function Sub menu 1 Status Messa...

Page 43: ...ck oil Oil service 1 Change belt not screw blowers Change filter Change filter mat FC 1 Motor bearings grease Check motor bearings Change motor bearings Check motor bearings encl fan Check control cab...

Page 44: ...witching point 16 Switching point 17 Switching point 18 Switching point 19 Switching point 20 7 User Name Password Current access level 8 Communication Ethernet SIGMA NETWORK Com Module Key remote For...

Page 45: ...ssages Messages history Blower messages Diagnostic messages System messages Address error Incorrect parameterisation in 3 current Alarms current Warnings 1 2 Statistics Load hours since Reset Load FAD...

Page 46: ...mation SIGMA CONTROL 2 MCS Software KAESER PN SN Controller manufacturer PN SN MFGDT Manufacturing date Blower package EN Equipment number PN Material number SN Serial number Speed stage IO modules Fi...

Page 47: ...al pressure Source set pressure Local set pressure KP KI Set pressure rise time Ignore bus actual pressure External values control 1 Controller settings Load control xA Load on Load off xB Load on Loa...

Page 48: ...5 9 Pulse generator Activate on off Function 5 10 I O periphery DO functions On load Controller on Collective error Collective warning Remote mode Time control active External messages External messa...

Page 49: ...lower number Language Sender address Sender name Contact telephone Receiver address SMTP server User name Password Port Timeout Repeat cut off time MAC MAC address 8 2 Com Module The content of the me...

Page 50: ...r IP address Communication error Start td Timeout SAM 4 0 Status Master SAM 4 0 active Send Receive Send IP address Port Communication error Start td Timeout Load signal Restart Timeout Cycle time Tab...

Page 51: ...mics STO1 FC contact n_Motor Motor temperature Collection AIR Greasing system 2 DOR DI Interval Target Actual Alarm td Actual Motor type 1 Power switching with frequency converter OFC SFC 2 Screw blow...

Page 52: ...Filter Message type Method Reset reference value p1 Cold start T3 Collection AIR SP DI T_S DOR DOT n_ref p Speed monitoring Vibration monitoring VSE Status AII V1 1 Power switching with frequency con...

Page 53: ...ng with each other 5 8 1 Ready control mode The ready control mode specifies whether individual machines or machines under master control can be activated It evaluates the On and Off keys The software...

Page 54: ...n stops 5 8 1 1 Ready control without remote acknowledgement If the ready control is in ON or SWITCH OFF ready mode and a fault occurs the ready control switches to OFF ready mode If the Remote acknow...

Page 55: ...ge applied to controller LED lights green The ON LED is extinguished The IDLE LED is extinguished The LOAD LED is extinguished The drive motor is stopped The sound enclosure s fan stops READY The mach...

Page 56: ...no longer present the READY operating state is assumed and the drive motor is stopped If the operating control is in READY MOTOR START or LOAD mode and the shut down command is present the operation c...

Page 57: ...te is only left when the run on time has elapsed and the minimum run time has been reached The Stop command or the end of the shut down switches the control to the STOP state 5 Design and Function 5 8...

Page 58: ...d the machine into which the controller is installed NOTICE UV radiation Direct sunlight UV radiation can destroy the display screen Do not allow the display screen to be subjected to direct sunlight...

Page 59: ...ommencing any work on the machine Tab 48 Machine identification Label the starting device in the remote control centre as follows suggestions Remote control Risk of injury caused by unexpected startin...

Page 60: ...CONTROL 2 The quick installation guide at the beginning of this operating manual provides an overview of the essential indicator and operating elements the main menu and important functions Perform se...

Page 61: ...erformance data Submenu 3 Operating data Submenu 4 Maintenance Submenu 5 Configuration Active line 3 Using the Up or Down key select the line Configuration 4 Press the Enter key The Configuration menu...

Page 62: ...omatically adjust the units and the time and date formats based on the selected language These settings can be changed manually see chapter 8 2 10 Precondition The operating display is shown 1 Press t...

Page 63: ...ment Card number 1 Note down the username RFID Equipment Card number 2 Keep the note in a secure location Should your RFID Equipment Card get damaged or lost If you know your username and password you...

Page 64: ...MA CONTROL 2 manually A password is also required in order to log in to the SIGMA CONTROL 2 via KAESER CONNECT see chapter 8 3 Prerequisite for this is that Name Password You have noted down your user...

Page 65: ...that you can log in manually without the RFID Equipment Card if necessary 5 Press the Enter key The setting is applied accordingly 8 2 6 Logging in manually In the event that your RFID Equipment Card...

Page 66: ...key to select the Login line 12 Press the Enter key Current access level 2 is displayed Result You are now logged in to the SIGMA CONTROL 2 with access level 2 via manual input of your username and pa...

Page 67: ...hould you wish to register the master RFID Equipment Card for the other machines repeat the above steps in each machine Result You have now registered a master RFID Equipment Card in the machine 8 2 8...

Page 68: ...ss the Enter key The setting is applied accordingly 12 Press the Escape key repeatedly to exit the menu Checking setting the date Precondition Access level 2 is activated 1 Open the menu 5 1 Configura...

Page 69: ...Date Time 3 Press the Down key twice 400mbar 08 15AM 80 C Header 5 1 General Menu Model XXXXXX Specified machine type Date Time 04 13 22 08 15 37AM Europe London Time zone 4 Press the Enter key The ti...

Page 70: ...tor flashes 4 Use the Up or Down key to set the date format 5 Press the Enter key The setting is applied accordingly 6 Press the Escape key repeatedly to exit the menu Setting the time format Set the...

Page 71: ...he pressure display Set the units for the pressure display Format Example bar 5 5bar hPa 5523hPa MPa 0 55MPa psi 80psi at 5 6at Hg 162 Hg mbar 5500mbar Tab 54 Settings options for the pressure units P...

Page 72: ...eader 5 1 General Menu Time format hh mm ssAM PM Pressure unit bar Unit of pressure Temperature unit C Unit of temperature Display illumination 3 Press the Enter key The display for the selected unit...

Page 73: ...nation is set to automatic mode with deactivation after one minute in the absence of any key being pressed 8 2 12 Setting the contrast and the brightness Contrast and brightness are factory set to nor...

Page 74: ...ult SIGMA CONTROL 2 remote control is activated 8 2 14 IP configuration For the SIGMA CONTROL 2 to be connected to the network you must set the IP configuration for KAESER CONNECT for example If you u...

Page 75: ...is displayed 10 Set the remaining network parameters as described above Parameters Setting value Meaning IP address IP address of the interface X1 Ethernet Subnet mask Subnet mask of the network Gate...

Page 76: ...il parameters are known Request the required information from the IT department 1 Open the 8 1 3 Communication Ethernet SIGMA NETWORK E mail menu 2 Use Up or Down to select the active line 400mbar 08...

Page 77: ...this field Contact telephone In this field enter a telephone number under which the air station opera tor can be reached This telephone number is sent with each e mail Receiver address The e mail add...

Page 78: ...rver available in the Internet or a local Intranet SIGMA CONTROL 2 then automatically imports the date and time settings and ensures continuous synchronisation of the internal clock with the exter nal...

Page 79: ...Example address time server 11 Press Enter 12 Press Escape repeatedly to leave this menu Result Access to the selected time server is active The internal clock of SIGMA CONTROL 2 is permanently synchr...

Page 80: ...8 3 1 Open KAESER CONNECT Precondition The user name see chapter 8 2 3 and password see chapter 8 2 5 are known The controller s IP address is known see chapters 8 2 14 and 8 7 4 1 Use an Ethernet ca...

Page 81: ...language 2 Select language window 3 Setting the language 4 Selected language 7 Click to set the selected language 3 Result KAESER CONNECT is displayed in the set language 8 3 2 System status menu Pre...

Page 82: ...s menu 1 Click the System status menu element The System status menu is displayed Fig 20 Main menu 8 Initial Start up 8 3 KAESER CONNECT benefits 70 Service Manual Controller SIGMA CONTROL 2 BLOWER 4...

Page 83: ...achine data for any time in the past Moving the mouse pointer across the graph calls up a ruler The time selected with the ruler and the associated values are displayed in the legend above the graph W...

Page 84: ...he SD card and displayed 2 Click the Scroll right 4 arrow key The display area is shifted to the right by 1 3 3 With the mouse button pressed draw a rectangle around the selected area 4 Release the mo...

Page 85: ...menu is displayed 2 Click the required message type 3 Check messages 8 3 5 I O display menu The measured values of the analogue inputs and the states of the digital inputs and outputs are displayed in...

Page 86: ...ord Subsequently the write mode is activated see Chapter 8 2 5 The write mode is granted only to one person at a time If a second user attempts to log on in write mode he will be refused by the system...

Page 87: ...or write access window is displayed Fig 26 Log on for write access window 3 Enter your user name in the User name field 4 Enter your password in the Password field 5 Click OK The User management menu...

Page 88: ...ted and activated Editing a user account You can edit existing user accounts Changing the password Changing the access level Changing the status Example Change the password for an existing user accoun...

Page 89: ...NNECT for SIGMA CONTROL 2 is displayed 1 Click the Settings menu element 2 Click the arrow key for the unit of pressure A selection list of units of pressure is displayed 3 Set the appropriate pressur...

Page 90: ...he Backup menu element Fig 29 Backup menu 2 Set the required backup type in the Select source option 3 Click Backup Result The data are downloaded to the Internet capable device 8 3 9 Data recording m...

Page 91: ...Fig 30 Data recording menu 2 Select the option Hour file or Start time 3 Set the desired time in the fields MM DD YY and HH 00 4 Click on Get Data Result The data is downloaded onto the device The dow...

Page 92: ...is configured for this pressure Minimum pressure Display For design reasons pressure can only be built up above this value minimum working pressure Tab 60 Blower characteristics Set the installation...

Page 93: ...tion State on delivery setting See Automatic start stop in timer mode No clock time program set 8 5 1 Automatic start stop with timer Deactivated 8 5 2 Automatic restart function Deactivated 8 5 3 Con...

Page 94: ...are reset 01 n a 00 00AM off Active line 02 n a 00 00AM off 03 n a 00 00AM off User defined clock program No Day Time Function 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 Tab 62 User d...

Page 95: ...ri 01 00PM on 04 Mon Thu 05 00PM off 05 Fri 03 00PM off Tab 63 Example of a machine ON OFF clock program Precondition Access level 2 is activated 1 Open the 6 Time control menu 2 Use Up or Down to sel...

Page 96: ...ion on 16 Press the Enter key The setting is applied The on action is set for the first switching point 17 Set the other switching points in the same manner Result Weekdays time and the actions on off...

Page 97: ...and READY Valid setting values for the cutting in and out duration are between 24 h t 15 m Precondition Access level 2 is activated 1 Open the 5 9 Configuration Pulse generator menu 400mbar 08 15AM 8...

Page 98: ...fter power failure If you want to activate the Automatic restart function you can set a delay time for the machine restart You ensure so that the electrical system is not overly stressed due to a simu...

Page 99: ...se Up or Down to select the Delay line 3 Press Enter The setting mode is active 4 Use Up or Down to set the delay time value 400mbar 08 15AM 80 C Header 5 3 Restart Menu Automatic restart Automatic re...

Page 100: ...Set expiring delay time 5 Press the Enter key The setting is applied Result The Automatic restart function is activated 8 5 4 Controlling the machine remotely If the machine is to be shut down and sw...

Page 101: ...e of the Remote On signal the blower will be prevented from starting remotely regardless of the op erating mode selected When the Blower on function is deactivated the Remote On signal remains on perm...

Page 102: ...the menu 5 5 Configuration External DI AII signal 2 Using the Up or Down key select the line Load signal 400mbar 08 15AM 80 C Header 5 5 External DI AII signal Menu Load signal Active line DI1 04 Logi...

Page 103: ...is displayed 1 Open the menu 5 5 Configuration External DI AII signal 2 Using the Up or Down key select the line Idle signal 400mbar 08 15AM 80 C Header 5 5 External DI AII signal Menu Load signal Act...

Page 104: ...g modes The options available for the operating modes are de pendent upon the configuration of the AII1 02 current signal The current signal is set in the menu 5 5 1 Current signal AII1 02 see chapter...

Page 105: ...n the AII1 02 external analogue output is active and the variable type Speed has been set The External values control operating mode can only be selected when the AII1 02 external analogue input is ac...

Page 106: ...an be controlled by an analogue current signal at the AII1 02 input 8 6 2 Setting the operating mode Precondition Access level 2 is activated The operating mode is displayed AII1 02 current signal is...

Page 107: ...e In the MOTOR START and IDLE operating modes the blower block always runs at minimum speed Precondition Access level 2 is activated The operating mode is displayed 1 Open the 5 4 Configuration Operat...

Page 108: ...and thereby the blower block indirect The blower block speed determines the flow rate By changing the speed the frequency converter adjusts the flow rate to the consumption and constantly maintains t...

Page 109: ...of the I portion anti wind up reset If the operation control is in STOP READY SHUT DOWN or MOTOR START operating mode the effective target pressure is 0 bar At the end of the motor start the effective...

Page 110: ...e control menu 2 Use Up or Down to select the Set pressure rise time line 3 Press Enter The setting mode is active 400mbar 08 15AM 80 C Header 5 4 2 Pressure control Menu Source actual pressure p1 p2...

Page 111: ...e 1 0bar KP 1 0rpm mbar KI 1 00rpm mbar s Active line Set pressure rise time 0s 9 Press Up to incrementally increase the value for KI until the system pressure continuously compensates 10 Use Down to...

Page 112: ...t on the load con trol The two point controller is activated in the menu 5 4 3 1 Controller settingsvia the Load control check box The two parameters Load on and Load off only affect the two point con...

Page 113: ...ed between xA xB The blower with the highest number of hours to go until the next maintenance runs at xA Common to all operating modes is that the setpoint pair xA is used in the event of a fault I O...

Page 114: ...n set the percentage value for the cut in threshold 15 Press the Enter key The setting is applied accordingly 16 Set the percentage value for Load off in the same manner 17 Press the Escape key repeat...

Page 115: ...able Parameter Available settings Reference Intake conditions Standard conditions Set value source Local AII1 02 Tab 65 Parameters for the flow rate Precondition The operating display is shown Access...

Page 116: ...Intake conditions Active line 14 Press the Down key 15 Press the Enter key The indicator flashes for the reference currently selected 16 Use the Up or Down key to select the desired reference 17 Press...

Page 117: ...operating modes The controller offers several possibilities to work together with other controllers Method Description Section SIGMA AIR MANAGER 4 0 mode You must modify the settings in SIGMA CONTROL...

Page 118: ...tion 1 Open the 8 1 1 Communication Ethernet SIGMA NETWORK IP configuration menu 2 Use Up or Down to select the IP address line 400mbar 08 15AM 80 C Header 8 1 1 IP configuration Menu IP address 169 2...

Page 119: ...or Down to set the Send Receive value 400mbar 08 15AM 80 C Header 8 1 2 2 SAM 4 0 Menu Status Counter 0 No error SAM 4 0 active Send Receive Active line IP address 169 254 100 100 9 Press the Enter ke...

Page 120: ...to 30 s SIGMA CONTROL 2 can monitor the bus communication at user level For this purpose the bus master reads a value toggle bit that changes with every bus cycle and returns it without change SIGMA...

Page 121: ...ssioning the communications module The communications module is correctly installed and connected The bus cabling is connected to the bus master The machine is parametrised as a slave in the bus maste...

Page 122: ...n the time passing at the bus master between return of voltage and start of communication via the bus Parameters Factory setting Set value Start td 15 s SIGMA AIR MANAGER without SIGMA AIR CONTROL plu...

Page 123: ...d with the set parameters Communication with the bus master is running 9 Time out at bus fault is activated Bus communication is now monitored The number behind Status Counter Run continuously changes...

Page 124: ...bus fault 5 Set IP Parameter as described below Use DHCP Do not use DHCP 1 Activate the DHCP check box 2 Activate the Use IP settings check box to apply the IP Parameter The communication module is s...

Page 125: ...out parameter Enter the required settings as described above 8 7 3 5 Commissioning the DeviceNet module Machine Precondition Access level 2 is activated The network parameters are known Request the re...

Page 126: ...or Master modes SIGMA CONTROL 2 can monitor Com Module the bus com munication at user level For this purpose the bus master reads a value toggle bit that changes with every bus cycle and returns it wi...

Page 127: ...n Reaction in a bus fault Only for machines After switching on the power supply the bus alarm can be suppressed for a definable period of time The setting depends on the time passing at the bus master...

Page 128: ...fault 5 Set IP Parameter as described below Use DHCP Do not use DHCP 1 Activate the DHCP check box 2 Activate the Use IP settings check box to apply the IP Parameter The communication module is starte...

Page 129: ...as described above 8 7 3 8 Activating the remote control Activate remote control see chapter 8 2 13 Result SIGMA CONTROL 2 remote control is activated 8 7 4 Master control of two machines in master sl...

Page 130: ...250 01870 Install the Ethernet cable Use a cross linked Ethernet cable for the direct connection of two machines Fig 31 Direct connection of two SIGMA CONTROL 2 1 Controller machine 1 Master mode 2 Et...

Page 131: ...lers of both machines are linked directly they must be given different IP addresses Example IP addressController machine 1 Master mode 169 254 100 101 IP address Controller machine 2 Slave 169 254 100...

Page 132: ...Master mode 169 254 100 101 IP address Controller machine 2 Slave 169 254 100 102 Precondition The electrical connection is made Access level 2 is activated 1 Set IP address for the slave see chapter...

Page 133: ...th machines 8 7 4 5 Load balancing You can optionally set load balancing for both machines Without load balancing being active the machines will operate in fault actuated changeover mode redundancy op...

Page 134: ...hing and or triggering messages with thresholds The controller only allows assignment of spare inputs and outputs Any assignment of a pre assigned input or output is discarded by the controller Spare...

Page 135: ...Press Enter The output of the selected message flashes 400mbar 08 15AM 80 C Header 5 10 1 DO functions Menu On load DOR1 05 ok Logic Active line with assigned output Controller on DOR1 03 Logic 4 Sel...

Page 136: ...is classified as fault the controller goes into the alarm state and shuts down the machine Overview Use the External messages menu for specifying the settings Enter the message text Assign and activa...

Page 137: ...ing characters of the message text in the same manner 7 Press Enter The message text has been entered 8 Press Enter The setting is applied 8 8 2 3 Assign and activate the input 1 Use Up or Down to sel...

Page 138: ...1 second increments with the UP key 1 Use Up or Down to select the td line 2 Press Enter The td delay time flashes 400mbar 08 15AM 80 C Header 5 10 2 1 External message 1 Menu External message 1 Mess...

Page 139: ...lect the message type line with the Up and Down keys 2 Press Enter The display for the message type flashes 3 Use Up or Down to set the message type 400mbar 08 15AM 80 C Header 5 10 2 1 External messa...

Page 140: ...ssages and or other switching functions The following measured values are available Measured value Explanation Message Output p1 Threshold for pressure p1 inlet pressure 0092 O W A p2 Threshold for pr...

Page 141: ...R DOT1 01 Output DOT 8 8 3 1 Setting the switching point and switching differential 1 Use Up or Down to select the SP line 400mbar 08 15AM 80 C Header 5 10 3 1 p1 Menu active SP 0 40bar SD 0 2bar Swit...

Page 142: ...The td delay time has been set 8 8 3 3 Assign and activate the output Once the threshold has been reached you can switch a digital output DOR 1 Use Up or Down to select the DOR line 2 Press Enter The...

Page 143: ...Right arrow 6 Press Enter The check box assigned to the message type flashes 7 Press Up key The message is activated 8 Press Enter Result The message type is set and activated 8 8 3 5 Activating the...

Page 144: ...ead to machine damage Safety relevant EMERGENCY STOP control device and Mains contactor feedback mes sages cannot be acknowledged remotely The following conditions must be fulfilled The Remote acknowl...

Page 145: ...nput flashes 9 Press the Up key The check box is activated 10 Press Enter The setting is applied ok is displayed 400mbar 08 15AM 80 C Header 5 5 External DI AII signal Menu Idle signal DI1 09 Acknowle...

Page 146: ...d Option Load 2 Use Up or Down to select the topmost line 3 Press Enter The setting mode is active 4 Use Up or Down key to set the Send Receive option 5 Press Enter The setting is applied 6 Use the Up...

Page 147: ...lied to the machine the controller boots and carries out a self test The display and the Controller on LED illuminate The actual working pressure the time and the airend discharge temperature are disp...

Page 148: ...n Chapter Installation and Operating Conditions are met 1 Switch on the user s power supply isolating device 2 Switch on the machine and wait for SIGMA CONTROL 2 to start The voltage applied to contro...

Page 149: ...er supply In rare cases you may want to shut down the machine immediately and cannot wait until the automatic shut down process is finished Press the OFF key a second time The compressor drive and the...

Page 150: ...wing a successful elimination of the corresponding fault Message sequence 1 Display Message coming LED flashes Message acknowledged LED illuminates Message going LED off Tab 86 Message sequence 1 Mess...

Page 151: ...owledge the warning message The Maintenance LED extinguishes The machine is ready to start again Further information A list of possible warning messages occurring during operation are shown in chapter...

Page 152: ...8 15 37AM example Time Tab 89 Message abbreviations 9 4 1 Status Messages menu 1 Open the 1 1 Status Messages menu The Messages menu is displayed The number of current faults and warnings is displayed...

Page 153: ...1 1 2 Messages history Menu 1 Blower messages Active line with sub menu Blower messages 2 Diagnostic messages Diagnostic messages 3 System messages System messages 2 Press Enter The 1 1 2 1 Blower me...

Page 154: ...at input AII1 02 Speed at input AII1 02 Value at input AII1 02 Value with one decimal place at the input AII1 02 Value with two decimal places at the input AII1 02 Curves Inlet pressure inlet temperat...

Page 155: ...play other analogue values in the same manner 9 6 Displaying operating data The following information can be called up in the Operating data menu Operating hours Blower package Total machine running t...

Page 156: ...nu Blower package 3050h On load 3050h Motor 3050h active line Block 3050h SIGMA CONTROL 2 3050h FC block drive 3050h 2 Using the Up or Down key select the line Motor 3 Press the Enter key The display...

Page 157: ...e input currently set 4 Using the Up or Down key open the input to which the power meter is connected 5 Press the Enter key The input has now been assigned Pulses sent to the selected digital input wi...

Page 158: ...nter key The setting is applied accordingly 6 Press the Right key twice 7 Press the Enter key The check box flashes 8 Press the Up key The check box is activated 9 Press the Enter key The maintenance...

Page 159: ...5 Press the Enter key The cursor is located at the first character of the text A column containing a selection of characters is displayed The selected character flashes 6 Select the required character...

Page 160: ...er 1 for example 2 Press the Down key twice 3 Press the Enter key The setting mode is active 400mbar 08 15AM 80 C Header 4 1 External counter External counter 1 Motor running 3000h 2319h Reset Active...

Page 161: ...Parametrisation error flashes 2 1 on off PROFIBUS configuration error ST off Module without voltage deactivated Green illuminates continuously Module in operation flashes Module in operation internal...

Page 162: ...s TCP communication module LEDs and interface 1 Communications module 2 LED NS Network status 3 LED MS Module status 4 Modbus TCP Port 1 5 Modbus TCP Port 2 6 LED connection status Port 1 7 LED connec...

Page 163: ...Module without voltage not connected to bus Green flashes Module connected to bus illuminates continuously Module connected to bus communication is running Red flashes Time out communication interrup...

Page 164: ...ialised Module without voltage Module in Setup status Module in NW INIT status Green illuminates continuously Module in operation flashes 1 1 on off Diagnostic data available flashes 2 1 on off Is use...

Page 165: ...ring time exceeded time out 3 MS off Module without voltage Green illuminates continuously Module in operation master communicates scanner in run status flashes Module not configured or master in idle...

Page 166: ...e flashes 4 Use Up or Down to select the desired language 5 Press Enter The setting is applied 6 Use Up or Down to select the Save data line 400mbar 08 15AM 80 C Header 5 6 Save data Menu Language en_...

Page 167: ...isplayed The machine has been switched off with the OFF key The EMERGENCY STOP command device has been actuated 1 Open the 5 6 Configuration Save data menu 2 Use Up or Down to select the Format SD car...

Page 168: ...ice partner 10 2 Interpreting alarm messages If an input signal is classified as a fault the controller will display an alarm upon receiving the signal Consequences The red LED flashes The controller...

Page 169: ...vel at airend drive end too low Replenish lubricating oil 0009 A p1 Inlet pressure too low Inlet filter clogged Check operating conditions Check all supply lines airend inlet silenc er and inlet filte...

Page 170: ...sion between con troller and compressor drive FC Contact an authorised service partner 0024 A Diagnostics group alarm A diagnostic message has been triggered For more details see diagnostic mes sage t...

Page 171: ...ks in vacuum network Check operating conditions 0039 A Drag indicator p2 Pressure peaks in com pressed air network Check operating conditions 0040 A Surge arrester Overvoltage in the power supply Cana...

Page 172: ...ation incorrect in module d An I O address has been as signed more than once Display incorrect parametrisation in menu 1 1 3Address error and correct parameter there Tab 96 Alarm messages and remedies...

Page 173: ...nge mains contactor Maximum number of switching cycles for mains contactor reached Contact an authorised service partner 0009 W T_S Sound enclosure temperature too high Check ambient conditions Check...

Page 174: ...room Check position of process valves Severe clogging of inlet louvre 0022W Motor starts Max switching frequency h exceeded Check operating conditions and or operating mode 0023W FC error d Numerical...

Page 175: ...ing Check operating conditions 0081 W Vibration monitoring VSE Warning from vibration monitoring Check operating conditions 0082 W Vibration monitoring sum signal High vibration values Contact an auth...

Page 176: ...Check FC fan h Frequency converter fan motor bear ings Maintenance interval expired Contact an authorised service partner 0210 W Annual maintenance due Last maintenance was 1 year ago Carry out the ne...

Page 177: ...achine Operating messages are identified with the letter O Operating messages are not numbered consecutively In this table d represents a variable value e g a number period of time or I O address 1 Me...

Page 178: ...1 0096 O Switch block speed 1 0097 O Switch T3 1 0098 O Switch T_S 1 0300 O Cycle exact data recording active Service information 0301 O SD card defective Service information 1000 O 2 RFID Equipment...

Page 179: ...unication modules 10 7 1 Troubleshooting the PROFIBUS module 10 7 1 1 Machine and SIGMA CONTROL 2 In the event of a bus communications fault the red Communication LED and the yellow Warning LED will f...

Page 180: ...rtently See chapter 8 Tab 101 Fault indicators in the Communication Com Module menu Result Bus communications will be resumed automatically as soon as the cause of the fault has been remedied 10 7 2 T...

Page 181: ...tently See chapter 8 Tab 103 Fault indicators in the Communication Com Module menu Result Bus communications will be resumed automatically as soon as the cause of the fault has been remedied 10 7 3 Tr...

Page 182: ...tware Check the timeout interval see chapter 8 Deactivate monitoring if activated inad vertently See chapter 8 Tab 105 Fault indicators in the Communication Com Module menu Result Bus communications w...

Page 183: ...le In the menu 8 2 Communication Com Module communications errors are displayed as text under the line Status or as a number after the word Error No Fault text Possible cause Action 1 COM Module fault...

Page 184: ...e communications errors are displayed as text under the line Status or as a number after the word Error No Fault text Possible cause Action 1 COM Module fault Defective module Contact an authorised se...

Page 185: ...for the real time clock is discharged and must be replaced Contact an authorised service partner When the battery is discharged the date and time of the controller will always re set to 01 01 1970 at...

Page 186: ...r 5 1 1 System information Menu 1 SIGMA CONTROL 2 MCS active line 2 Blower package 3 IO modules 4 FC information 3 Press Enter The 5 1 1 1 SIGMA CONTROL 2 MCS menu is displayed 400mbar 08 15AM 80 C He...

Page 187: ...ndensate from all condensate drains and dispose according to applicable environment protection regulations 2 Remove the user supplied condensate conduits The condensate drains are not supplied with po...

Page 188: ...Hand the SIGMA CONTROL 2 over to an authorised disposal expert Further information Refer to the machine s Operating Manual for details regarding the battery s environmentally sound disposal 13 5 1 Bat...

Page 189: ...riendly manner You actively contribute to the protection of our environment when you bring used batteries to the appropriate recycling system Further information Refer to the SIGMA CONTROL 2user manua...

Page 190: ...13 Decommissioning Storage and Transport 13 5 Battery removal and disposal 178 Service Manual Controller SIGMA CONTROL 2 BLOWER 4 0 X No 901700 14 E...