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Service Manual Controller SIGMA CONTROL 2

BLOWER ≥ 2.5.3

No.: 901700 10 E

Manufacturer:

KAESER KOMPRESSOREN SE 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 www.kaeser.com

/KKW/SSC 2.11 en IBA-SIGMA CONTROL BLOWER /KKW/SSC 2.11 20200824 081558

Contents

No.: 901700 10 E

1

SIGMA CONTROL 2 Quick installation guide 1.1 Operating elements .......................................................................................................... 1.2 Display elements .............................................................................................................. 1.3 Main menu – Overview ..................................................................................................... 1.4 Functions – Overview .......................................................................................................

1 2 2 3

2

Regarding this document 2.1 Using this document ......................................................................................................... 2.2 Copyright .......................................................................................................................... 2.2.1 Software .............................................................................................................. 2.3 Certification ...................................................................................................................... 2.4 Updating the operating manual ........................................................................................ 2.5 Symbols and labels .......................................................................................................... 2.5.1 Warnings ............................................................................................................. 2.5.2 Potential damage warnings ................................................................................ 2.5.3 Other alert notes and their symbols ....................................................................

5 5 5 6 6 6 6 7 8

3

Technical Specifications 3.1 Controller SIGMA CONTROL 2 ....................................................................................... 3.1.1 User interface with display, CPU and interfaces ................................................. 3.1.2 Input/output module ............................................................................................ 3.1.3 Sensors ............................................................................................................... 3.2 Communication modules .................................................................................................. 3.2.1 PROFIBUS module ............................................................................................. 3.2.2 Modbus module .................................................................................................. 3.2.3 Modbus TCP module .......................................................................................... 3.2.4 DeviceNet module .............................................................................................. 3.2.5 PROFINET module ............................................................................................. 3.2.6 EtherNet/IP-Module ............................................................................................

9 9 11 12 12 13 13 14 15 16 17

4

Safety and Responsibility 4.1 Basic instructions ............................................................................................................. 4.2 Specified use .................................................................................................................... 4.3 Improper use ....................................................................................................................

19 19 19

5

Design and Function 5.1 STC and OFC/SFC machine types .................................................................................. 5.2 The controller ................................................................................................................... 5.3 Operating panel ................................................................................................................ 5.3.1 Operating elements ............................................................................................ 5.3.2 Display elements ................................................................................................ 5.3.3 RFID reader ........................................................................................................ 5.4 Display ............................................................................................................................. 5.4.1 Operating mode .................................................................................................. 5.4.2 Main menu .......................................................................................................... 5.4.3 Setting parameters ............................................................................................. 5.4.4 Activating keys with check boxes ....................................................................... 5.5 Access rights .................................................................................................................... 5.6 KAESER CONNECT ........................................................................................................ 5.7 Menu overview ................................................................................................................. 5.7.1 Operating mode .................................................................................................. 5.7.2 Menu structure .................................................................................................... 5.8 Control modes .................................................................................................................. 5.8.1 Ready control mode ............................................................................................ 5.8.2 Operating control ................................................................................................

20 20 22 22 23 23 24 25 26 26 27 27 28 29 29 30 41 41 42

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

i

Contents

ii

6

Installation and Operating Conditions 6.1 Maintaining ambient conditions ........................................................................................ 6.2 Installation conditions .......................................................................................................

46 46

7

Installation 7.1 Reporting Transport Damage ........................................................................................... 7.2 Machine identification .......................................................................................................

47 47

8

Initial Start-up 8.1 Outline .............................................................................................................................. 48 8.2 Setting the controller ........................................................................................................ 48 8.2.1 Selecting menu options ...................................................................................... 49 8.2.2 Setting the language ........................................................................................... 50 8.2.3 Noting the user name ......................................................................................... 51 8.2.4 User log-on with RFID Equipment Card ............................................................. 51 8.2.5 Generating a password ....................................................................................... 52 8.2.6 Manual user log-on ............................................................................................. 53 8.2.7 Create the master RFID Equipment Card ........................................................... 54 8.2.8 Checking/setting time and date .......................................................................... 55 8.2.9 Set the time zone ................................................................................................ 57 8.2.10 Set display formats ............................................................................................. 57 8.2.11 Setting the display illumination ........................................................................... 60 8.2.12 Setting the contrast and the brightness .............................................................. 61 8.2.13 Activating the remote control .............................................................................. 61 8.2.14 IP configuration .................................................................................................. 62 8.2.15 Setting the e-mail function .................................................................................. 64 8.2.16 Setting the time server ....................................................................................... 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 8.3.7 Settings menu ..................................................................................................... 77 8.3.8 Save data menu .................................................................................................. 78 8.3.9 Data recording menu .......................................................................................... 78 8.3.10 KAESER CONNECT exit .................................................................................... 79 8.4 Displaying and setting the blower properties ................................................................... 80 8.4.1 Displaying the blower properties ......................................................................... 80 8.4.2 Setting the installation elevation ......................................................................... 80 8.5 Machine start and machine stop ...................................................................................... 81 8.5.1 Automatic start/stop in timer mode ..................................................................... 81 8.5.2 Automatic start/stop with timer ............................................................................ 85 8.5.3 "Automatic restart" function ................................................................................ 86 8.5.4 Controlling machine from a remote location ....................................................... 88 8.6 Operating modes in frequency-controlled machines ........................................................ 91 8.6.1 Current signal AII1.02 ......................................................................................... 92 8.6.2 Setting the operating mode ................................................................................. 93 8.6.3 Constant speed ................................................................................................... 94 8.6.4 Pressure control .................................................................................................. 95 8.6.5 External speed definition .................................................................................... 98 8.6.6 Control with external variable ............................................................................. 99 8.6.7 SFC acceleration time ........................................................................................ 102 8.7 Setting the machine for master control operation ............................................................ 102

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

Contents

No.: 901700 10 E

8.7.1 Overview of the different master operating modes ............................................. 8.7.2 SAM 4.0 mode ................................................................................................... 8.7.3 Master control via communication module ......................................................... 8.7.4 Master control of two machines in master/slave operation ................................. 8.8 Setting input and output signals ....................................................................................... 8.8.1 Output operational states of machine on digital outputs ..................................... 8.8.2 Output input signals on the display ..................................................................... 8.8.3 Switching and/or triggering messages with thresholds ....................................... 8.9 Activating remote acknowledgement ............................................................................... 8.9.1 Setting the remote acknowledgement function ................................................... 8.10 Error behaviour ................................................................................................................ 8.11 Commissioning the machine ............................................................................................

102 103 106 115 120 120 121 126 130 130 131 132

9

Operation 9.1 Switching the machine on and off .................................................................................... 9.1.1 Switching on ....................................................................................................... 9.1.2 Switching off ....................................................................................................... 9.2 Switching off in an emergency ......................................................................................... 9.3 Acknowledging alarm and warning messages ................................................................. 9.4 Displaying messages ....................................................................................................... 9.4.1 Status – Messages menu ................................................................................... 9.5 Displaying analogue data ................................................................................................. 9.6 Displaying operating data ................................................................................................. 9.7 Setting the maintenance interval ...................................................................................... 9.8 Communication modules .................................................................................................. 9.8.1 Displays at the PROFIBUS module .................................................................... 9.8.2 Display at the Modbus module ........................................................................... 9.8.3 Displays at the Modbus TCP module ................................................................. 9.8.4 Display at the DeviceNet module ........................................................................ 9.8.5 Displays at the PROFINET module .................................................................... 9.8.6 Displays at the EtherNet/IP-Module .................................................................... 9.9 Save data ......................................................................................................................... 9.9.1 Format SD card ..................................................................................................

134 134 135 135 136 137 138 140 141 143 143 143 144 145 146 146 148 148 150

10

Fault Recognition and Rectification 10.1 Basic instructions ............................................................................................................. 10.2 Interpreting fault messages .............................................................................................. 10.3 Interpreting warning messages ........................................................................................ 10.4 Interpreting operation messages ...................................................................................... 10.5 Interpreting diagnostic messages .................................................................................... 10.6 Interpreting system messages ......................................................................................... 10.7 Communication modules .................................................................................................. 10.7.1 Troubleshooting, PROFIBUS module ................................................................. 10.7.2 Troubleshooting at the Modbus module ............................................................. 10.7.3 Troubleshooting Modbus TCP/EtherNet IP-Module ........................................... 10.7.4 Troubleshooting at the DeviceNet module .......................................................... 10.7.5 Troubleshooting, PROFINET module .................................................................

151 151 155 160 162 162 162 162 163 164 165 167

11

Maintenance 11.1 Changing the battery ........................................................................................................ 169

12

Spares, Operating Materials, Service 12.1 Note the nameplate .......................................................................................................... 170 12.2 KAESER AIR SERVICE ................................................................................................... 170 12.3 Displaying the version number, machine model, material number and serial number ..... 170

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

iii

Contents

13

iv

Decommissioning, Storage and Transport 13.1 Decommissioning ............................................................................................................. 13.1.1 Temporary de-commissioning ............................................................................ 13.1.2 Long-term de-commissioning ............................................................................. 13.2 Packing ............................................................................................................................ 13.3 Storage ............................................................................................................................. 13.4 Transporting ..................................................................................................................... 13.5 Battery removal and disposal ........................................................................................... 13.5.1 Battery disposal in accordance with local environmental regulations. ................

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

172 172 172 173 173 173 173 173

No.: 901700 10 E

List of Illustrations

Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 Fig. 6 Fig. 7 Fig. 8 Fig. 9 Fig. 10 Fig. 11 Fig. 12 Fig. 13 Fig. 14 Fig. 15 Fig. 16 Fig. 17 Fig. 18 Fig. 19 Fig. 20 Fig. 21 Fig. 22 Fig. 23 Fig. 24 Fig. 25 Fig. 26 Fig. 27 Fig. 28 Fig. 29 Fig. 30 Fig. 31 Fig. 32 Fig. 33 Fig. 34 Fig. 35 Fig. 36 Fig. 37 Fig. 38 Fig. 39 Fig. 40 Fig. 41 Fig. 42

No.: 901700 10 E

Operating elements .................................................................................................................... Display elements ........................................................................................................................ MCS interfaces ........................................................................................................................... System structure ........................................................................................................................ Operating elements .................................................................................................................... Display elements ........................................................................................................................ RFID reader ................................................................................................................................ Operating mode .......................................................................................................................... KAESER CONNECT for SIGMA CONTROL 2 ........................................................................... Operating mode .......................................................................................................................... Operating mode .......................................................................................................................... Back of the RFID Equipment Card ............................................................................................ User log-on with RFID Equipment Card ..................................................................................... User log-in with RFID Equipment Card ...................................................................................... Manual user log-on ..................................................................................................................... Log-in mask ................................................................................................................................ KAESER CONNECT for SIGMA CONTROL 2 ........................................................................... Select language: window ............................................................................................................ System status menu ................................................................................................................... Main menu .................................................................................................................................. Graphs (illustration similar) ......................................................................................................... Control keys ............................................................................................................................... Messages (illustration similar) .................................................................................................... I/O display (illustration similar) ................................................................................................... User management menu ............................................................................................................ Log on for write access: window ................................................................................................ User management menu ............................................................................................................ Settings menu ............................................................................................................................ Backup menu ............................................................................................................................. Data recording menu .................................................................................................................. Direct connection of two SIGMA CONTROL 2 ........................................................................... Operating mode .......................................................................................................................... Switching the compressed air station on and off ........................................................................ Switching off in an emergency ................................................................................................... Acknowledging messages .......................................................................................................... PROFIBUS communication module – LEDs and interface ......................................................... Modbus communication module – LEDs and interface .............................................................. Modbus TCP communication module – LEDs and interface ...................................................... DeviceNet communication module – LEDs and interface .......................................................... PROFINET communication module – LEDs and interface ......................................................... EtherNet/IP communication module – LEDs and interface ........................................................ Battery labelling ..........................................................................................................................

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

1 2 10 21 22 23 24 25 28 30 49 51 51 52 54 68 69 69 70 70 71 72 73 74 75 75 76 77 78 79 116 133 134 135 136 144 144 145 146 147 148 174

v

List of Illustrations

vi

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

List of Tables

Tab. 1 Tab. 2 Tab. 3 Tab. 4 Tab. 5 Tab. 6 Tab. 7 Tab. 8 Tab. 9 Tab. 10 Tab. 11 Tab. 12 Tab. 13 Tab. 14 Tab. 15 Tab. 16 Tab. 17 Tab. 18 Tab. 19 Tab. 20 Tab. 21 Tab. 22 Tab. 23 Tab. 24 Tab. 25 Tab. 26 Tab. 27 Tab. 28 Tab. 29 Tab. 30 Tab. 31 Tab. 32 Tab. 33 Tab. 34 Tab. 35 Tab. 36 Tab. 37 Tab. 38 Tab. 39 Tab. 40 Tab. 41 Tab. 42 Tab. 43 Tab. 44 Tab. 45 Tab. 46 Tab. 47 Tab. 48 Tab. 49 Tab. 50 Tab. 51 Tab. 52 Tab. 53 Tab. 54

No.: 901700 10 E

Operating elements .................................................................................................................... Display elements ........................................................................................................................ Main menu – Overview ............................................................................................................... Functions – Overview ................................................................................................................. Danger levels and their definition (personal injury) .................................................................... Danger levels and their definition (damage to property) ............................................................ Formatting options ...................................................................................................................... User interface ............................................................................................................................. Display data ................................................................................................................................ MCS interfaces ........................................................................................................................... RFID ........................................................................................................................................... IOM 1 .......................................................................................................................................... Power supply specifications ....................................................................................................... Cable lengths ............................................................................................................................. Degree of protection, IOM .......................................................................................................... IOM dimensions ......................................................................................................................... Pressure transducer ................................................................................................................... Resistance thermometer ............................................................................................................ Technical specifications - PROFIBUS ........................................................................................ Assignment of PROFIBUS interface .......................................................................................... Technical Specifications - SIGMA CONTROL 2 interface .......................................................... Assignment of the SIGMA CONTROL 2 interface ...................................................................... Technical Specifications - Modbus TCP interface ...................................................................... Assignment of the Modbus TCP interface .................................................................................. Recommended conductors - Modbus TCP interface ................................................................. Technical specifications - SIGMA CONTROL 2 communication module ................................... Assignment of the SIGMA CONTROL 2 interface ...................................................................... Technical Specifications - SIGMA CONTROL 2 interface .......................................................... Assignment of the SIGMA CONTROL 2 interface ...................................................................... Recommended conductors - SIGMA CONTROL 2 interface ..................................................... Technical data EtherNet/IP-Interface ......................................................................................... Configuration of the EtherNet/IP-Interface ................................................................................. EtherNet/IP-Interface - Cabling recommendation ...................................................................... Operating elements .................................................................................................................... Display elements ........................................................................................................................ RFID reader ................................................................................................................................ Reset check box status .............................................................................................................. Check box status ........................................................................................................................ KAESER CONNECT functions ................................................................................................... Menu structure of main menu ..................................................................................................... Status menu ............................................................................................................................... Configuration menu .................................................................................................................... Communication menu ................................................................................................................ Connections menu ..................................................................................................................... Components menu ..................................................................................................................... SIGMA CONTROL 2 ready states .............................................................................................. Machine identification ................................................................................................................. Remote control identification ...................................................................................................... Machine identification ................................................................................................................. Supported languages ................................................................................................................. Date formats ............................................................................................................................... Possible settings for the time format .......................................................................................... Possible settings for the pressure unit ....................................................................................... Possible settings for the temperature unit ..................................................................................

1 2 2 3 7 7 8 9 9 10 10 11 11 11 12 12 12 12 13 13 13 14 14 15 15 15 16 16 16 17 17 17 18 22 23 24 27 27 28 30 33 34 37 38 39 41 47 47 47 50 57 58 59 59

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

vii

List of Tables

Tab. 55 Tab. 56 Tab. 57 Tab. 58 Tab. 59 Tab. 60 Tab. 61 Tab. 62 Tab. 63 Tab. 64 Tab. 65 Tab. 66 Tab. 67 Tab. 68 Tab. 69 Tab. 70 Tab. 71 Tab. 72 Tab. 73 Tab. 74 Tab. 75 Tab. 76 Tab. 77 Tab. 78 Tab. 79 Tab. 80 Tab. 81 Tab. 82 Tab. 83 Tab. 84 Tab. 85 Tab. 86 Tab. 87 Tab. 88 Tab. 89 Tab. 90 Tab. 91 Tab. 92 Tab. 93 Tab. 94 Tab. 95 Tab. 96 Tab. 97 Tab. 98 Tab. 99 Tab. 100 Tab. 101 Tab. 102 Tab. 103 Tab. 104 Tab. 105 Tab. 106 Tab. 107 Tab. 108

viii

Display illumination ..................................................................................................................... Network parameters ................................................................................................................... E-mail parameters ...................................................................................................................... Control key functions .................................................................................................................. Blower characteristics ................................................................................................................ Settings for machine start and machine stop ............................................................................. User-defined clock programme machine ON/OFF ..................................................................... Example of a machine ON/OFF clock program .......................................................................... Delay time for automatic restart ................................................................................................. Overview of the different master controllers ............................................................................... Parameters for monitoring for communication malfunction ........................................................ Setting theStarttd parameter ...................................................................................................... Setting the Timeout parameter ................................................................................................... Setting theStarttd parameter ...................................................................................................... Setting the Timeout parameter ................................................................................................... Setting theStarttd parameter ...................................................................................................... Setting the Timeout parameter ................................................................................................... Setting theStarttd parameter ...................................................................................................... Setting the Timeout parameter ................................................................................................... Setting theStarttd parameter ...................................................................................................... Setting the Timeout parameter ................................................................................................... Setting theStarttd parameter ...................................................................................................... Setting the Timeout parameter ................................................................................................... Master-slave settings ................................................................................................................. Assigned output signals ............................................................................................................. Logic settings ............................................................................................................................. Available measured values ........................................................................................................ Check list for starting the machine ............................................................................................. Maximum permissible number of motor starts per hour ............................................................. Message sequence 1 ................................................................................................................. Message sequence 2 ................................................................................................................. Information of a message ........................................................................................................... Message abbreviations .............................................................................................................. PROFIBUS communication module – Interpretation of LEDs .................................................... Modbus communications module – Interpretation of LEDs ........................................................ Modbus TCP communications module – Interpretation of LEDs ................................................ DeviceNet communications module – Interpretation of LEDs .................................................... PROFINET communications module – Interpretation of LEDs ................................................... EtherNet/IP communication module – Interpretation of LEDs .................................................... Fault messages and remedies ................................................................................................... Warning messages and remedies .............................................................................................. Operational messages ............................................................................................................... System messages and remedies ............................................................................................... Com-Module communication error warning message ................................................................ Fault displays in the Communication – Com-Module menu. ...................................................... Com-Module communication error warning message ................................................................ Fault displays in the Communication – Com-Module menu. ...................................................... Com-Module communication error warning message ................................................................ Fault displays in the Communication – Com-Module menu. ...................................................... Com-Module communication error warning message ................................................................ Fault indications at the DeviceNet communication module ........................................................ Fault displays in the Communication – Com-Module menu. ...................................................... Com-Module communication error warning message ................................................................ Fault displays in the Communication – Com-Module menu. ......................................................

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

60 63 65 72 80 81 82 83 86 102 106 107 108 109 109 110 110 111 112 113 113 114 114 115 120 124 126 132 134 136 136 137 138 144 144 145 146 147 148 151 156 160 162 162 163 163 164 164 165 165 166 166 167 167

No.: 901700 10 E

1

SIGMA CONTROL 2 Quick installation guide

1.1

Operating elements

1 SIGMA CONTROL 2 Quick installation guide 1.1

Operating elements

Fig. 1

Operating elements Item Designation

Tab. 1

No.: 901700 10 E

Function

1

«Up»

Scrolls up the menu options. Increases a parameter value.

2

«Left»

Jumps to the left. Moves the cursor position to the left.

3

«Right»

Jumps to the right. Moves the cursor position to the right.

4

«Down»

Scrolls down the menu options. Reduces a parameter value.

5

«Escape»

Returns to the next higher menu option level. Exits the edit mode without saving.

6

«Enter»

Jumps to the selected submenu option. Exits the edit mode and saves.

7

«ON»

Switches the machine on.

8

«OFF»

Switches the machine off.

10

RFID

RFID reader for user log-in with RFID Equipment Card.

11

«Time control»

Switches the time control on and off.

12

«Remote control»

Switches the remote control on and off.

13

«LOAD/IDLE»

Toggles between the LOAD and IDLE modes.

19

«Information»

Displays the event memory.

21

«Acknowledgement»

Confirms/acknowledges alarms and warning messages. If permissible: Resets the fault counter (RESET).

Operating elements

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

1

1

SIGMA CONTROL 2 Quick installation guide

1.2

Display elements

1.2

Display elements

Fig. 2

Display elements Item Designation

Tab. 2

1.3

Function

7

ON

Display illuminates green when the machine switched on.

9

Display

Graphic display with 8 lines and 30 characters per line.

11

Time control

Continuous green light when the machine is controlled by the timer.

12

Remote control

Continuous green light when the machine is in remote control.

14

IDLE

Continuous green light when the machine is running in IDLE. Flashes when the «LOAD/IDLE» toggle key is pressed.

15

LOAD

Continuous green light when the machine is running in LOAD.

16

Voltage applied to controller

Continuous green light when voltage is applied to the controller.

17

Warning

Flashes in yellow in the following events: ■

Maintenance necessary

■

Warning message

18

Communications error Continuous red light to indicate a faulty communication connection without machine shut-down.

20

Fault

Flashes red to indicate a machine fault. Continuous red light after acknowledgement.

Display elements

Main menu – Overview Select the main menu with «Enter» key.

2

Menu No. Menu name

Function

1

Displays messages, statistics and status information

Status

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

1

SIGMA CONTROL 2 Quick installation guide

1.4

Functions – Overview

Menu No. Menu name

Tab. 3

Function

2

Performance data Displays measured data of the machine and its components (e.g., motors)

3

Operating data

Displays operating hours of the machine and its components

4

Maintenance

Displays maintenance data of the machine and its components

5

Configuration

Machine parameters setting

6

Time control

Setting the time control

7

User

Manual user log-in and password administration

8

Communication

Setting the IP configuration, port and e-mail

10

Components

Setting the machine components

Main menu – Overview See Chapter 5.7.2 for the complete menu structure

1.4

Functions – Overview Function

Menu Steps No.

Chapter

Setting the con‐ trast

Main Press and hold «Information» – «Up» / «Down» menu

8.2.12

Setting the brightness

Main Press and hold «Information» – «Left» / «Right» menu

8.2.12

Setting the lan‐ guage

Main «Enter» – «Up» – «Enter» – «Up» / «Down» menu

8.2.2

Setting date, time and time zone

5.1

Identification with – RFID Equipment Card

8.2.4

Displaying and 5.2 setting the blow‐ er properties

8.4

«Setting the» time control

6

8.5.1

Activating the «time control» key

6

8.5.1.3

Activating «time control»

–

Activate the «Time control» key – Press «Time control» key

8.5.1.4

8.2.13

Activate the 5.5 «remote control» 8 key

No.: 901700 10 E

8.2.8

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

3

1

SIGMA CONTROL 2 Quick installation guide

1.4

Functions – Overview

Function

Menu Steps No.

Chapter

Activating the – «remote control»

Activate the «Remote» key – Press «Remote» key

8.2.13

Displaying oper‐ ating data

9.6

3

Changing the op‐ erating hours

Tab. 4

Setting the main‐ 4 tenance interval

9.7

Displaying mes‐ sages

1.1.1

Press the «Information» key.

9.4

Acknowledging messages

–

Press the «Acknowledgement» key

9.3

Fault messages

1.1.1

A fault message causes the machine to shut down. The Fault LED flashes red. Fault messages are identified with the let‐ ter A. Example:

10.2

Warning mes‐ sages

1.1.1

If maintenance work is to be carried out or if the warning is dis‐ 10.3 played before an alarm, the yellow warning LED flashes. Warning messages are identified with the letter W.

Diagnostic mes‐ sages

1.1.1

A diagnostic message causes the machine to shut down. They 10.5 provide information on the status of the controller, the connec‐ ted input and output modules and support the KAESER SERVICE in trouble-shooting. Diagnostic messages are identified with the letter D.

System messag‐ 1.1.1 es

A system message causes the machine to shut down. System 10.6 messages are identified with the letter Y.

Functions – Overview Settings can be made after log-in with the RFID Equipment Card and access level 2.

4

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

2

Regarding this document

2.1

Using this document

2 Regarding this document 2.1

Using this document The operating manual contains important information to the entire life cycle of SIGMA CONTROL 2. The operating manual is a component of the product. ➤ Keep the manual in a safe place throughout the life of SIGMA CONTROL 2. ➤ Pass the manual on to the next owner/user of the machine. ➤ Ensure that all amendments received are inserted into the operating manual.

2.2

Copyright This operating manual is protected by copyright. Any queries regarding the use or duplication of this documentation should be referred to KAESER. Correct use of information will be fully suppor‐ ted.

2.2.1

Software The software used in SIGMA CONTROL 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 "COPYING" file in the root directory of SIGMA CONTROL 2. URL: http:// /COPYING The licenses can be also found under these addresses: http://www.gnu.org/licenses http://code.google.com/p/curve25519-donna/ Within three years from receipt of SIGMA CONTROL 2, you may obtain the complete source code of the copyright-protected software packages by sending a corresponding order to the following ad‐ dress: Technical Office Electrical Design KAESER KOMPRESSOREN SE 96450 Coburg, Postfach 2143 Germany This offer is valid for anybody having this information.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

5

2.3

2

Regarding this document

2.3

Certification

Certification This product has the following approvals: ■

■

■

This equipment has been tested and found to comply with the limits for a Class B digital de‐ vice, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: ─

Reorient or relocate the receiving antenna.

─

Increase the separation between the equipment and receiver.

─

Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

─

Consult the dealer or an experienced radio/TV technician for help.

This device complies with part 15 of the FCC 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 cause undesired operation.

This device fulfils the provisions of the Industry Canada Licence, with the exception of the RSS 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 cause undesired operation. In order to ensure permanent compliance with the FCC rules, unless explicitly approved by the authority responsible for compliance with the provisions, no changes must be carried out (for example: when connecting to computers or peripheral equipment use shielded cables on‐ ly).

2.4

Updating the operating manual Go to our website http://www.kaeser.com/sc2manual to find the latest version of the operating manual. ➤ Download the desired operating manual from our server and forward it to your operators.

2.5

Symbols and labels ➤ Please note the symbols and labels used in this document.

2.5.1

Warnings Warnings indicate danger potentially resulting in personal injury, if the measures specified are not taken.

6

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

2

Regarding this document

2.5

Symbols and labels

Warning notices indicate three levels of danger identified by the corresponding signal word: Signal term Meaning

Consequences of non-compliance

DANGER

Will very likely result in death or severe injury

Warns of imminent danger

WARNING Warns of potentially imminent danger CAUTION Tab. 5

May result in death or severe injury

Warns of a potentially dangerous situa‐ May result in moderate physical injury tion

Danger levels and their definition (personal injury) Warning notices preceding a chapter apply to the entire chapter, including all sub-sections. Example: DANGER The type and source of the imminent danger is shown here! The possible consequences of ignoring a warning are shown here. The word "DANGER" indicates that death or severe injury can very likely result from ignoring the warning. ➤ The measures required to protect yourself from danger are shown here. Warning notes referring to a sub-section or the subsequent step are integrated into the procedure 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 death or severe injury may result from ignoring the warn‐ ing. ➤ The measures required to protect yourself from danger are shown here. 2. Always read and comply with warning instructions.

2.5.2

Potential damage warnings Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐ jury. Warning notices for damages are identified by their signal term.

Tab. 6

Signal term Meaning

Consequences of non-compliance

NOTE

Damage to property is possible

Warns of a potentially dangerous situation

Danger levels and their definition (damage to property) Example:

NOTICE The type and source of the imminent danger is shown here! Potential effects when ignoring the warning are indicated here. ➤ The protective measures against the damages are shown here. ➤ Carefully read and fully comply with warnings against damages.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

7

2.5.3

2

Regarding this document

2.5

Symbols and labels

Other alert notes and their symbols The meaning of names is emphasised by different formatting. Depending on the font, not all for‐ matting options can be realised.

Tab. 7

Designation

Formatting

Example

Operating point

UPPER CASE

LOAD

Item number

...

Open valve 4

Display

italic

ON LED

Key

« ... »

«ON» key

Menu option

< ... >

Menu path



activated

...

The minutes display flashes. 00:00:00

Formatting options This symbol identifies particularly important information.

Material Precondition

Here you will find details on special tools, operating materials or spare parts. 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 symbol denotes lists of actions comprising one stage of a task. Operating instructions with several steps are numbered in the sequence of the operating steps. Information referring to potential problems is identified by a question mark. The cause is specified in the help text ... ➤ ... as is a solution. This symbol identifies important information or measures regarding the protection of the envi‐ ronment.

Further information

8

Further subjects are introduced here.

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

3

Technical Specifications

3.1

Controller SIGMA CONTROL 2

3 Technical Specifications 3.1

Controller SIGMA CONTROL 2 Industrial PC ■

Internal temperature monitoring

■

Internal undervoltage monitoring

■

3.1.1

Battery-buffered real-time clock ─

Battery service life: more than 10 years

─

Battery replaceable

User interface with display, CPU and interfaces User interface Characteristic Material

Plastics

Width [mm]

190

Height [mm]

130

Depth [mm]

45

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 Tab. 8

Value

Input/output module

User interface Display Characteristic Graphical display [px]

Value 255 x 128

Width [mm]

82

Height [mm]

41

Maximum number of lines/characters

8/30

Colours

Black/white with grey scale

Lighting

LED backlit

px ≙ pixel Tab. 9

No.: 901700 10 E

Display data

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

9

Fig. 3

3

Technical Specifications

3.1

Controller SIGMA CONTROL 2

MCS interfaces Identification

Interface

Connection

X1

Ethernet 10/100 Base T

RJ 45 socket

X2

I/O bus

9-pole SUB-D pins

X3

RS485–FC (USS interface)

9-pole SUB-D socket

X4

Com modules, slot for communications module

Module optional for: PROFIBUS, PROFINET, Modbus RTU, Modbus TCP, DeviceNet, EtherNet/IP

X5

SD card, SD card slot

SD/SDHC card

X6

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 Hardware on the SIGMA CONTROL 2 controller Hardware (external) Recognition distance [m] Frequency [MHz] Emitted maximum transmitting power at 10 m dis‐ tance [dB(µA/m)]

Tab. 11

10

Value RFID reader RFID Equipment Card Max. 0.05 13.56 11

RFID

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

3

Technical Specifications

3.1

Controller SIGMA CONTROL 2

The RFID read/write device transmits at a frequency of 13.56 MHz and is permitted for use in EU member states.

3.1.2

Input/output module The input/output module features: ■

Internal temperature monitoring

■

Internal undervoltage monitoring

■

LED indication of operational status

IOM 1 Input/Output

Tab. 12 3.1.2.1

Input/output module 1 Internal, in the control cabinet

available in parallel on both sides

External, into the machine interior

Digital input (DI), 24 VDC

4

10

2

Analogue input current (AII), 0–20 mA

–

1

2

Analogue input resistor (AIR), PT100

–

1

3

Digital output relay (DOR), 250 VAC, 8 A

8

–

–

Digital output transistor (DOT), 24 VDC, 0.5 A

–

2

1

Analogue output current (AOI), 0–20 mA

–

–

–

IOM 1 Power supply specifications Power is provided by the power supply unit within the machine. Characteristic

Value

Rated voltage (stabilised) [V DC]

24

Current consump‐ tion SIGMA CONTROL 2 with IOM 1 [A]

2.4

IOM ≙ Input/Output module Tab. 13 3.1.2.2

Power supply specifications Maximum cable lengths Input/Output

Tab. 14

No.: 901700 10 E

Cable length [m]

Analogue input current (AII), Analogue input resistor (AIR) Analogue output current (AOI)

＜ 30

Digital input (DI), Digital output relay (DOR)

＜ 100

Digital output transistor (DOT)

＜ 30

Cable lengths

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

11

3.1.2.3

Tab. 15 3.1.2.4

3

Technical Specifications

3.2

Communication modules

Degree of protection, input/output module Characteristic

Value

Degree of protection within the machine

IP 54

Degree of protection within the control cabinet

IP 20

Degree of protection, IOM Dimensions, input/output module Characteristic

Value

Width [mm]

125

Height [mm]

250

Depth [mm]

44

Tab. 16

IOM dimensions

3.1.3

Sensors Pressure transducer Characteristic

Value

Output signal [mA]

0/4–20

Connection Tab. 17

Two-core

Pressure transducer Resistance thermometer Characteristic

Value

Sensing resistance (to DIN IEC 751)

PT100

Connection Tab. 18

3.2

Two-core

Resistance thermometer

Communication modules SIGMA CONTROL 2 supports the following communication modules:

12

■

PROFIBUS (Option C41)

■

Modbus (Option C42)

■

DeviceNet (Option C43)

■

Modbus TCP (Option C44)

■

PROFINET (Option C45)

■

EtherNet/IP (Option C50)

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

3.2.1

3

Technical Specifications

3.2

Communication modules

PROFIBUS module Communications module

Tab. 19

Feature

Value

Controller

SIGMA CONTROL 2

Bus

PROFIBUS DP-V0 Slave, RS485

GSD file

KAES0CEC.gsd

Baud rate

Automatic recognition, possible baud rates: [kbps]: 9.6/19.2/45.45/93.75/187.5/ 500 [Mbps]: 1.5/3/6/12

Input data

64 byte

Output data

128 byte

Diagnostic data

31 byte

—

Data content, see

"Technical description SIGMA CONTROL 2 process im‐ age", document number 7_7601_PA.

"Technical description SIGMA AIR MANAGER 4.0 process im‐ age", document number 7_9696_PA.

SIGMA AIR MANAGER 4.0 KAKO0EFB.gsd

Technical specifications - PROFIBUS Assignment of bus interface (Sub-D port, 9 poles, screw locking) Pin

Signal

Description

1, 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, RS485 Level

Housing Cable shield Compliant with PROFIBUS standard, connected internally via filter to func‐ tion earth (FE) Tab. 20

Assignment of PROFIBUS interface

3.2.2

Modbus module Communications module Feature

Value

Controller

SIGMA CONTROL 2

Bus

SIGMA CONTROL 2 or ASCII, RS485 or RS232, galvanically isolated

Baud rate [bps]

Adjustable, possible baud rates: 1200 / 2400 / 4800 / 9600 / 19200 / 38400 / 57600 / 76800 / 115200

Stop bits

Possible settings 1 / 2

Parity

Possible settings None / Even / Odd

SIGMA AIR MANAGER 4.0

Bold elements: Factory setting

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

13

3

Technical Specifications

3.2

Communication modules

Feature

Value

Time-out [ms] Possible settings 0...2000 ... 99999 Data bits:

RTU: 8, ASCII: 7

Mode

Possible settings RTU / ASCII

Input data [byte]

64

Output data [byte]

128 (process data) and 42 (diagnos‐ 128 (prozess data) tic data)

Data content

"Technical description "Technical description SIGMA CONTROL 2 process image", SIGMA AIR MANAGER 4.0 process im‐ document number 7_7601xPA. age", document number 7_9696_PA.

Bold elements: Factory setting Tab. 21

Technical Specifications - SIGMA CONTROL 2 interface Assignment of the SIGMA CONTROL 2 interface The Modbus interface is galvanically isolated and features RS485 and RS2232 signals. To use the RS232 interface, connect Pin 2 with Pin 3. Pin

Direction

Signal Description

1

—

GND

Data reference potential (isolated),

C/C’

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, connect with Pin 2. To use RS485, keep open.

5

Bi-directional B/B’

RS485 B (RxD/TxD positive)

7

Input

RxD

RS232 Receive data

8

Output

TxD

RS232 Send data

9

Bi-directional A/A’

Housing —

—

RS485 A (RxD/TxD negative) Internally connected to functional earthing (FE)

Tab. 22

Assignment of the SIGMA CONTROL 2 interface

3.2.3

Modbus TCP module Modbus TCP-Interface Feature

Value

Controller

SIGMA CONTROL 2

Bus

Modbus TCP server (Slave)

Connection

2x RJ45 ports (Cat5e, shielded), integrated 2-port switch, potential isolation

Baud rate [Mbit/s]

10/100, full duplex or half duplex

SIGMA AIR MANAGER 4.0

Input data [byte] 64

14

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

Tab. 23

3

Technical Specifications

3.2

Communication modules

Feature

Value

Output data [byte]

128 (process data) and 42 (diagnos‐ 194 (process data) tic data)

Data content

"Technical description "Technical description SIGMA CONTROL 2 process im‐ SIGMA AIR MANAGER 4.0 process im‐ age", document number 7_7601xPA. age", document number 7_9696_PA.

Technical Specifications - Modbus TCP interface Assignment of the Modbus TCP interface Pin *

Signal

Conductor colour Description

1

TD+

Yellow

Send positive (positive transmit)

2

TD–

Orange

Send negative (negative Transmit)

3

RD+

White

Positive receive

4, 5, 7, 8 —

—

—

6

Blue

Negative receive

RD-

Housing Cable shield —

High-impedance (1 MOhm/47 nF) connection with func‐ tional earthing (FE)

* Position of pins 1 through 8, see chapter 9 Tab. 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 length [m]

100

Tab. 25

Recommended conductors - Modbus TCP interface

3.2.4

DeviceNet module Communication module Feature

Value

Bus

DeviceNet adapter (Slave), galvanically isolated

EDS file

324-8172-EDS_ABCC_DEV_V_2_3_1.eds

Functions

Implicit and explicit messaging, UCMM, change-of-state, cyclic IO, polled IO

Baud rate [kbps]

Automatic recognition, possible baud rates: 125–500

Input data [byte]

64

Output data [byte] 128 Data content Tab. 26

No.: 901700 10 E

"Technical description SIGMA CONTROL 2 process image", document number 7_7601xPA.

Technical specifications - SIGMA CONTROL 2 communication module

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

15

3

Technical Specifications

3.2

Communication modules

Assignment of bus interface (plug-in terminal strip, 5 poles) Pin Signal

Conductor colour 1) Description

1

V−

Black

2

CAN_L blue

CAN Bus low

3

Shield

High-impedance (1 MOhm/47 nF) connection with functional earthing (FE)

4

CAN_H White

CAN Bus high

5

V+

Bus supply voltage positive 2)

Bus supply voltage negative 2)

non-isolated

Red

1)

Conductor colour to ODVA specification

2)

Voltage range: 11–25 V, maximum power consumption 36–38 mA

Tab. 27

Assignment of the SIGMA CONTROL 2 interface

3.2.5

PROFINET module PROFINET-interface

Tab. 28

Feature

Value

Controller

SIGMA CONTROL 2

Bus

SIGMA CONTROL 2 device (Slave) with RT classification, conformity class B, topology detection (LLDP), network management (SNMP), redundancy, MRP protocol

Connection

2x RJ45 ports (Cat5e), 2-port switch, potential isolation

Baud rate [Mbit/s]

100, full duplex

GSD file

GSDML-V2.25-KaeserSC2-20120203.xml

Input data [byte]

64

Output data [byte]

128 (process data)

Data content, see Document No.

"Technical description SIGMA CONTROL 2 process im‐ age", document number 7_7601xPA.

SIGMA AIR MANAGER 4.0

GSDML-V2.3-Kaeser-SAM2-20150112

"Technical description SIGMA AIR MANAGER 4.0 process im‐ age", document number 7_9696_PA.

Technical Specifications - SIGMA CONTROL 2 interface Assignment of PROFINET interface Pin *

Signal

Conductor colour Description

1

TD+

Yellow

Send positive (positive transmit)

2

TD–

Orange

Send negative (negative Transmit)

3

RD+

White

Positive receive

—

—

4, 5, 7, 8 —

* Position of pins 1 through 8, see chapter 9

16

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

3

Technical Specifications

3.2

Communication modules

Pin *

Signal

Conductor colour Description

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 Tab. 29

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 example: 7.7628.0 or 7.7628.1

Maximum cable length [m]

100

Tab. 30

Recommended conductors - SIGMA CONTROL 2 interface

3.2.6

EtherNet/IP-Module EtherNet/IP-Interface Feature

Value

Controller

SIGMA CONTROL 2

Bus

EtherNet/IP-Server (Slave)

Connection

2x RJ45 ports (Cat5e, shielded), integrated 2-port switch, potential isolation

Baud rate [Mbit/s]

10/100, full duplex or half duplex

SIGMA AIR MANAGER 4.0

Input data [byte] 64

Tab. 31

Output data [byte]

128 (process data) and 42 (diagnos‐ 194 (process data) tic data)

Data content

"Technical description "Technical description SIGMA CONTROL 2 process image", SIGMA AIR MANAGER 4.0 process im‐ document number 7_7601xPA. age", document number 7_9696_PA.

Technical data EtherNet/IP-Interface Configuration of the EtherNet/IP-Interface Pin *

Signal

Conductor colour Description

1

TD+

Yellow

Send positive (positive transmit)

2

TD–

Orange

Send negative (negative Transmit)

3

RD+

White

Positive receive

4, 5, 7, 8 —

—

—

6

Blue

Negative receive

RD-

* Position of pins 1 through 8, see chapter 9

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

17

3

Technical Specifications

3.2

Communication modules

Pin *

Signal

Conductor colour Description

Housing Cable shield —

High-impedance (1 MOhm/47 nF) connection with func‐ tional earthing (FE)

* Position of pins 1 through 8, see chapter 9 Tab. 32

Configuration of the EtherNet/IP-Interface Recommended conduit

Tab. 33

18

Feature

Value

Conductor

Network conductor, CAT5 shielded, CU, for example: 7.7629.0

Plug

Bus plug RJ45, IP20, for example: 7.7628.1

Maximum cable length [m]

100

EtherNet/IP-Interface - Cabling recommendation

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

4

Safety and Responsibility

4.1

Basic instructions

4 Safety and Responsibility 4.1

Basic instructions SIGMA CONTROL 2 is manufactured to the latest engineering standards and acknowledged safety regulations. The safety regulations of the machine in which SIGMA CONTROL 2 is installed apply.

4.2

Specified use SIGMA CONTROL 2 is solely intended for the control of machines in which SIGMA CONTROL 2 is factory-installed. Any other use is considered incorrect. The manufacturer is not liable for any dam‐ 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 the machine only within its performance limits and under the permitted ambient condi‐ tions.

4.3

Improper use Improper usage can cause damage to property and/or (severe) injuries. ➤ Use SIGMA CONTROL 2 only as intended. ➤ Do not use SIGMA CONTROL 2 to control other machines or products for which SIGMA CONTROL 2 is not intended.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

19

5

Design and Function

5.1

STC and OFC/SFC machine types

5 Design and Function 5.1

STC and OFC/SFC machine types STC: Machine with star-delta start Machines with star-delta start operate at mains frequency with a speed determined by the belt drive translation. The flow rate depends on the working pressure and, possibly, the options of the specific machine. OFC/SFC: Machine with frequency converters Machines with frequency converters (FC) operate with variable speeds, regardless of the mains frequency applied. The flow rate depends on the respective speed, the working pressure and, pos‐ sibly, the options of the specific machine. STC: Sections of this manual with this symbol apply solely to machines with star-delta start. OFC/SFC: Sections of this manual with this symbol apply solely to machines with frequencyconverter (FC). All other sections apply to both machine types.

5.2

The 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 password mechanisms protect the parameters. Components SIGMA CONTROL 2 has the following components: ■

■

20

Main Control System (MCS): ─

Industrial PC

─

Software for the control, regulation, and monitoring of the machine, for the display and mod‐ ification of settings and for communication.

─

User interface with backlit display, touch keys, LEDs, and interfaces.

─

Radio Frequency Idenfication (RFID): Identification with RFID Equipment Card

─

Slot for customer interface; optional communications module

─

SD card slot for SD/SDHC cards: Manual loading of updates with an SC card, reading or recording process data

Input-Output-Module (IOM): Modules with digital and analogue inputs and outputs with autonomous power supply

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

Fig. 4

5

Design and Function

5.2

The controller

System structure 1 2 3 4 5

Machine enclosure Control cabinet Main Control System Input/output module I/O bus

6 7 8 9

Inputs/outputs in the interior of the control cabinet Inputs/outputs in the interior of the blowers Inputs/outputs for external sensors Compressor

Function The control and regulating function allows: ■

Automatic changeover of the machine from LOAD to IDLE or READY.

■

OFC/SFC: Optimum utilisation of the 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 components via the maintenance interval counters.

■

Display of warning and maintenance messages for due maintenance on the display of the SIGMA CONTROL 2.

The protective function allows: ■

No.: 901700 10 E

Automatic machine shutdown on alarms that may lead to damage to the machine, e.g. overcur‐ rent, overpressure, overtemperature.

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

21

5

Design and Function

5.3

Operating panel

5.3

Operating panel

5.3.1

Operating elements

Fig. 5

Operating elements Item Designation 1

«Up»

Scrolls up the menu options. Increases a parameter value.

2

«Left»

Jumps to the left. Moves the cursor position to the left.

3

«Right»

Jumps to the right. Moves the cursor position to the right.

4

«Down»

Scrolls down the menu options. Reduces a parameter value.

5

«Escape»

Returns to the next higher menu option level. Exits the edit mode without saving.

6

«Enter»

Jumps to the selected submenu option. Exits the edit mode and saves.

7

«ON»

Switches the machine on.

8

«OFF»

Switches the machine off.

10

RFID

RFID reader for user log-in with RFID Equipment Card.

11

«Time control»

Switches the time control on and off.

12

«Remote control»

Switches the remote control on and off.

13

«LOAD/IDLE»

Toggles between the LOAD and IDLE 12) operating points.

19

«Information»

Displays the event memory.

21

«Acknowledgement»

Confirms/acknowledges alarms and warning messages. If permissible: Resets the fault counter (RESET).

12)

Tab. 34

22

Function

not for SXC

Operating elements

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

5.3.2

Fig. 6

5

Design and Function

5.3

Operating panel

Display elements

Display elements Item Designation

Function

7

ON

Display illuminates green when the machine switched on.

9

Display

Graphic display with 8 lines and 30 characters per line.

11

Time control

Continuous green light when the machine is controlled by the timer.

12

Remote control

Continuous green light when the machine is in remote control.

14

IDLE

Continuous green light when the machine is running in IDLE. Flash‐ es when the «LOAD/IDLE» 12) toggle key is pressed.

15

LOAD

Continuous green light when the machine is running in LOAD.

16

Voltage applied to controller

Continuous green light when voltage is applied to the controller.

17

Warning

Flashes in yellow in the following events: ■

Maintenance necessary

■

Warning message

18

Communications error Continuous red light to indicate a faulty communication connection without machine shut-down.

20

Fault

12)

Flashes red to indicate a machine fault. Continuous red light after acknowledgement.

not for SXC

Tab. 35

Display elements

5.3.3

RFID reader RFID is the abbreviation for “Radio Frequency Identification” and makes possible to identify per‐ sons and objects. Placing a suitable transponder in front of the RFID reader of the controller will automatically acti‐ vate the communication between transponder and SIGMA CONTROL 2.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

23

5

Design and Function

5.4

Display

A suitable transponder is the RFID Equipment Card. Two of them have been provided with the ma‐ chine. Typical application: ■

Operators log on at the machine. (Manual input of the password not required) The RFID Equipment Cards are carefully packed in a plastic sleeve. This plastic sleeve is attached to the rear of the controller in the control cabinet.

Fig. 7

RFID reader Position Designation Function 24

Tab. 36

5.4

RFID

RFID reader for the communication with a RFID Equipment Card or RFID Key.

RFID reader

Display Use the display to read information and to check entered data. The display comprises 8 lines, each of 30 characters. During operation, the operation mode is displayed as a pipe and instrument diagram. Press «Enter» or one of the arrow keys to open the main menu. Here, you can set the language to be used for the display of texts or open the various submenus.

24

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

5.4.1

Fig. 8

5

Design and Function

5.4

Display

Operating mode

Operating mode 1 2 3 4 5

Air filter Inlet pressure p1 OFC/SFC: Drive motor’s duty cycle in % Final pressure p2 Discharge temperature T2

6 7 8 9 10

OFC/SFC: Speed compressor Intake temperature T1 Header Cut-in period Time until the next maintenance

Header The header 8 is the topmost line on the display. It is always shown as white text on a black back‐ ground. The following parameters are displayed permanently in the header: ■

Final pressure p2

■

Time

■

Discharge temperature T2

Lines 2 to 7: Pipe and instrument flow diagram Display lines 2 to 7 display the current machine state as a pipe and instrument diagram (see Fig. 8) or a menu text. Line 8: Machine state The following parameters with their current values are displayed in line 8:

No.: 901700 10 E

■

The hours during which the machine was activated

■

Remaining desiccant service life of the machine until the next maintenance.

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

25

5.4.2

5

Design and Function

5.4

Display

Main menu 400mbar

08:15AM

80° C

Header

Main menu ----------------English GB----------------

Current language

▶1 Status

Active line

▶2 Performance data

Submenu

▶3 Operating data

Submenu

▶4 Maintenance

Submenu

▶5 Configuration

Submenu

Representation The main menu is the top menu level. You open the individual submenus in the main menu. A scrollbar appears at the right side of the display if you open a menu with more than 6 lines. It represents the currently visible portion of the menu. A short scrollbar thus indicates that the opened menu is very long as only a small portion can be displayed. The image above provides an example for the appearance of the main menu (without scrollbar). Numbering Each menu is numbered. Not all menus may be displayed because the access to certain menus is restricted by the access level, and some menus are displayed or hidden due to specific settings or options. For example, you can recognise subordinate menus in the menu structure by the number preced‐ ing their designation. The menu structure is explained in chapter 5.7.2. Active line The active line (2–8) is always shown as white text on a dark background. In deviation of this, the header is also shown as white text on a dark background, but cannot be selected. Press «Enter» to open a menu in the active line. This opens the selected menu. You change parameters in Setting mode.

5.4.3

Setting parameters In order to set a parameter in the active line of the selected menu, you must always switch to setting mode. Setting parameters Press «Enter». The value of the parameter will flash indicating that it can be changed. The «Enter» key affects only the active line. In some lines, you can change more than one parameter. In this case, you must first select the specific parameter with the «Left» or «Right» keys.

26

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

5

Design and Function

5.5

Access rights

Resetting current parameters In order to reset current parameters to Zero, activate the check box for Reset in the active line of the display. First, press «Enter» to switch into setting mode. The check box Reset flashes. You then press «Up». The check box is activated and flashes. Press «Enter» to save the settings. The display no longer flashes and the parameters are reset. The check box for Reset is again de‐ activated.

Reset check box

Status

☑

activated

☐

deactivated

Tab. 37

Reset check box status

5.4.4

Activating keys with check boxes Certain keys of the SIGMA CONTROL 2 are locked by default. Activate the corresponding check boxes in the active line of the display to unlock these keys. First, press «Enter» to switch into setting mode. The check box will flash. You then press «Up». The check box is activated and flashes. Press again «Enter» to save the settings. The display line no longer flashes and the key is activated. Proceed correspondingly to deactivate a key. Some modifications require access level 2, see chapter 5.5.

Tab. 38

5.5

Check box

Status

☑

activated

☐

deactivated

Check box status

Access rights Access to the controller is governed by the user name combined with a password. Users log on using an RFID Equipment Card by default. Alternatively, you can manually enter the user name and the password. When the controller is switched on, the lowest level of access (level 0) is activated. You have access to a further level: Access level 2 Access level 2 allows you to display and adjust further parameters. The access level will automatically return to level 0 after 10 minutes without any key being pressed.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

27

5

Design and Function

5.6

KAESER CONNECT

Secure storage of the RFID Equipment Cards You will receive 2 RFID Equipment Cards with each machine. They are stored in a plastic sleeve. This plastic sleeve is attached at the rear of the controller in the control cabinet. If you lose both RFID Equipment Cards, you can register a new RFID Equipment Card only after having entered the user name and the password. A new RFID Equipment Card may be registered by the KAESER Service subject to a fee, if the user name and the password are lost.

5.6

KAESER CONNECT Using an Internet-capable device with web browser, you can open a visualisation of the controller. This enables remote checking of, for example, the operating and energy efficiency of your ma‐ chine. For this purpose, you must generate a password once (see Chapter 8.2.5). KAESER CONNECT does not require additional software to do so. The display language of KAESER CONNECT can be set independently to the language used with SIGMA CONTROL 2.

Fig. 9

KAESER CONNECT for SIGMA CONTROL 2 KAESER CONNECT functions: Operating element Meaning read => write

Switching from read-only to read/write mode To create users and acknowledge messages

write => read

Switching from read/write to read-only mode

Logout

Log out user

Contact/Service

Displaying the contact information for KAESER SERVICE

12)

28

not for SXC

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

5

Design and Function

5.7

Menu overview

Operating element Meaning Select language:

Setting the display language for KAESER CONNECT

System status

Menu representation on local display

Graphs

■

Pressures and temperatures are displayed in different graphs

■

Graphic representation of the machine status (STOP, IDLE, 12), LOAD) and speed over the time line

■

Current messages

■

Event history

Messages I/O display

Assignment of the input/output modules

User management ■

Settings

Backup 12)

Tab. 39 Further information

5.7 5.7.1

Creating and activating new user accounts

■

Modifying or deactivating existing user accounts

■

Changing passwords

■

Unit display format

■

Date display format

■

Time display format

Saving data via KAESER CONNECT from SIGMA CONTROL 2 to a PC

not for SXC

KAESER CONNECT functions For opening KAESER CONNECT, login and other procedures, please see chapter 8.3.

Menu overview Operating mode When the power supply is switched on, details of the software are displayed (for example): Machine model

Compressor PN:

Material number and serial number of the machine

SN:

Equipment number of the machine

EN: SIGMA CONTROL 2 PN: y.yyyyyy

–

MCS

SN: x.xx.xx

Software: ABC_V.V.V

MCS: Main Control System Material number and serial number of the controller Software version

Subsequently, the software is loaded and the current operating mode is displayed as a pipe and instrument diagram. Example:

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

29

Fig. 10

5

Design and Function

5.7

Menu overview

Operating mode The following parameters are displayed: ■

Operating mode of the machine

■

Information about pressures, temperatures and speeds

■

Number of operating hours

The operating display provides the most important parameters during the machine's operation.

5.7.2

Menu structure Press «Enter» or one of the arrow keys to open the 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

■

Messages ─

Current messages

─

Messages history

─

Address error

■

Statistics

■

DI/DO display

■

Current operating mode

For details of the Status menu, please see ta‐ ble 41.

30

1)

Power switching with frequency converter (OFC/SFC)

2)

Screw blower

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

5

Design and Function

5.7

Menu overview

Menu No./Designation

Function/Sub-menu

2 Performance data

■

Pressures

■

Temperatures

■

Speeds

■

External values

■

Curves

■

Frequency converter 1)

■

Operating hours

3 Operating data

4 Maintenance

■

─

Blower package

─

On load

─

Motor

─

Block

─

SIGMA CONTROL 2

─

FC block drive

Load balancing

Change block 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 cabinet fan 1) Check FC fan 1) Filter transmission venting 2) Electrical equipment Annual maintenance due on 5 Configuration

No.: 901700 10 E

For details of the Configuration menu, please see table 42.

1)

Power switching with frequency converter (OFC/SFC)

2)

Screw blower

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

31

5

Design and Function

5.7

Menu overview

Menu No./Designation

Function/Sub-menu

6 Time control

Key time control Reset Switching point 01 Switching point 02 Switching point 03 Switching point 04 Switching point 05 Switching point 06 Switching point 07 Switching point 08 Switching point 09 Switching point 10 Switching point 11 Switching point 12 Switching point 13 Switching point 14 Switching point 15 Switching 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 details of the Communication menu, please see table 43. 10 Components

■

Motor

■

Block

■

Sound enclosure cooling

■

AFxM-valve

■

Aftercooler

For details of the Components menu, please see table 45.

32

1)

Power switching with frequency converter (OFC/SFC)

2)

Screw blower

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

5

Design and Function

5.7

Menu overview

Menu No./Designation

Function/Sub-menu

11 Error behaviour

■

■

Communication ─

SAM 4.0

─

Com-Module

Sensor ─

Tab. 40 5.7.2.1

1)

Power switching with frequency converter (OFC/SFC)

2)

Screw blower

AII1.02

Menu structure of main menu

Status menu Menu No./Designation

Function/Sub-menu

1.1 Messages

■

Current messages

■

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) since/Reset Motor starts total since/Reset Motor starts /h Motor starts /d

1.3 DI/DO display

1st I/O module DI/DO display

3)

No.: 901700 10 E

only visible in the event of parametrisation error

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

33

5

Design and Function

5.7

Menu overview

Menu No./Designation

Function/Sub-menu

1.4 Current operating mode

Idle time Rest Load signal Source/value Acknowledge messages Set pressure Actual pressure Set speed Set value Actual value

3)

Tab. 41 5.7.2.2

only visible in the event of parametrisation error

Status menu Configuration menu Menu No./Designation

Function/Sub-menu

5.1 General

■

System information ─

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 First IOM Second IOM

─

FC information

─

IOM type selection

Model: Date/Time Time zone ■

Time server ─

active:

─

IP address

Date format Time format Pressure unit Temperature unit Display illumination 1)

34

Power switching with frequency converter (OFC/SFC)

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

5

Design and Function

5.7

Menu overview

Menu No./Designation

Function/Sub-menu

5.2 Blower properties

Altitude Air pressure Pressure version Maximum pressure Design pressure Minimum pressure

5.3 Restart

Automatic restart Delay

5.4 Operating modes

Current operating mode ■

■

■

Fixed speed 1) ─

n_min/n_max

─

Set speed

─

Actual speed

Pressure control 1) ─

Source actual 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/Load off

─

xA/xB Clock xA/xB RC dt maintenance hours

Ramp up time Ramp down time: 1)

No.: 901700 10 E

Power switching with frequency converter (OFC/SFC)

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

35

5

Design and Function

5.7

Menu overview

Menu No./Designation

Function/Sub-menu

5.5 External DI / AII signal

■

Current signal AII1.02 ─

AII1.02

─

Value type

─

Decimal places

─

Unit

─

4mA/20mA

Load signal Idle signal Acknowledge messages Key remote 5.6 Save data

Language: Save data Eject SD card Status Format SD card

5.9 Pulse generator

Activate on off Function

5.10 I/O periphery

■

■

■

1)

Tab. 42

36

DO-functions ─

On load

─

Controller on

─

Collective error

─

Collective warning

─

Remote mode

─

Time control active

External messages ─

External message 1

─

External message 2

─

External message 3

Switch ─

p1

─

p2

─

T1

─

T2

─

T3

─

T_S

─

block speed

Power switching with frequency converter (OFC/SFC)

Configuration menu

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

5.7.2.3

5

Design and Function

5.7

Menu overview

Communication menu Menu No./Designation

Function/Sub-menu

8.1 Ethernet/SIGMA NETWORK

■

■

IP configuration ─

IP address

─

Subnet mask

─

Gateway

─

DNS Server 1

─

DNS Server 2

─

Restart network

Connections ─

SIGMA CONTROL 2

─

SAM 4.0

Restart Timeout Cycle time For details of the Connections menu, please see table 44. ■

E-mail ─

active: Blower 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 menu depends on the type of the communication module identified. The following KAESER communications mod‐ ules may be used:

Tab. 43

No.: 901700 10 E

■

PROFIBUS

■

Modbus

■

Modbus TCP

■

DeviceNet

■

PROFINET

■

EtherNet/IP

Communication menu

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

37

5.7.2.4

5

Design and Function

5.7

Menu overview

Connections menu Menu No./Designation

Function/Sub-menu

8.1.2 Connections

■

■

SIGMA CONTROL 2 ─

Status

─

Mode

─

Port

─

Communication partner

─

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. 44

38

Connections menu

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

5.7.2.5

5

Design and Function

5.7

Menu overview

Components menu Menu No./Designation

Function/Sub-menu

10.1 Motor

■

■

■

Power switching ─

Drive type

─

Star-Delta

─

Sinamics STO1)

─

FC contact

─

n_Motor

Motor temperature ─

Collection

─

AIR

Greasing system 2) ─

DOR

─

DI

─

Interval

─

Target/Actual

─

Alarm

─

td/Actual

Motor type

No.: 901700 10 E

1)

Power switching with frequency converter (OFC/SFC)

2)

Screw blower

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

39

5

Design and Function

5.7

Menu overview

Menu No./Designation

Function/Sub-menu

10.2 Block

■

■

■

■

■

Pressures ─

p1

─

p2

─

dp

─

π = p2_a / p1_a

Temperatures ─

T1

─

T2

─

T3

─

dT

Oil level monitoring ─

DI

─

DI

─

Message type

Filter ─

Message type

─

Method

─

Reset reference value p1

Cold start ─

T3 Collection

─

AIR

─

SP

─

DI

─

T_S

─

DOR

─

DOT

n_ref, p ■ ■

40

Speed monitoring Vibration monitoring ─

VSE Status

─

AII

─

↑ V1

1)

Power switching with frequency converter (OFC/SFC)

2)

Screw blower

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

5

Design and Function

5.8

Control modes

Menu No./Designation

Function/Sub-menu

10.3 Sound enclosure cooling

■

Fan

Collection AIR ⇞ ↑ ↓ ⇞ DI 10.4 AFxM-valve

AFxM-valve Control type Type Idle time

10.5 Aftercooler

Aftercooler

10.6 Transmission venting

Oil return/DOT vacuum pump/DOT Interval Target/Actual Trigger time Target/Actual

Tab. 45

5.8

1)

Power switching with frequency converter (OFC/SFC)

2)

Screw blower

Components menu

Control modes The behaviour of machines with SIGMA CONTROL 2 is determined by three software control modes interacting 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 checks whether all faults are inactive. The following ready states are identified: Ready state

Meaning

OFF

The machine is switched off.

On LED off

on, off or flashing

on

off

flashes

off

The machine cannot be started. ON

The machine is switched on.

Alarm LED

The machine can be started. SWITCHING OFF

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

Switching off is completed when the run-on times of the motor and fan have elapsed.

41

Tab. 46

5

Design and Function

5.8

Control modes

Ready state

Meaning

ON/FAULT

The machine is switched on but there is at least one fault with active cause or still requiring ac‐ knowledgement. This state is assumed only when the Remote acknowledgement function is active.

On LED on

Alarm LED on or flashing

SIGMA CONTROL 2 ready states When the operating voltage is applied to the SIGMA CONTROL 2 controller, the operating control is in OFF mode. If all faults are inactive, pressing «ON» produces the ON ready mode. If remote control is active, the remote load demand and remote idle demand signals are evaluated. When the remote control is deactivated, the system switches to Local mode. The load signal is generated by the «ON» key or the two-point controller. Pressing the «OFF» key produces the SWITCH OFF ready mode. The machine is shut down un‐ der control. The sound enclosure's fan will run on to prevent a heating up of the interior caused by pent up heat. If «ON» is pressed during the control shut-down process, the ready control returns to ON mode. You can interrupt the controlled machine shut-down by pressing «OFF» a second time. The ready control changes to OFF ready mode. The sound enclosure's fan 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 acknowledgement function is inactive, the machine cannot be operated until the fault is corrected. When all fault causes have been corrected and all faults have been acknowledged, you must again press «ON».

5.8.1.2

Ready control with remote acknowledgement If the ready control is in ON ready mode and a fault occurs or is active, the ready control switches to ON/FAULT ready mode but not OFF ready mode. In the ON/FAULT ready mode, the machine behaves similar to the OFF ready mode. When all fault causes have been corrected and all faults are acknowledged, the ready control re‐ turns to ON ready mode and the drive motor starts. You don't need to press «ON» a second time. If the ready control is in ON/FAULT ready mode, you must expect at any time that a remote acknowledgement may switch the machine to ON ready mode and the drive motor is started.

5.8.2

Operating control The operating control mode specifies whether individual machines or machines under master con‐ trol are activated. It evaluates the Load run command and Idle run command signals.

42

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

5

Design and Function

5.8

Control modes

The operating control works with two periods: ■

Minimum running period: It is calculated from the motor's starting frequency and is only used for blowers with idle valve. This parameter cannot be set by customers and is only active with machine type STC.

■

Venting period: In the Local mode, the venting period is always 0 s. In the remote mode, this time depends on the setting in menu 10.4. In machines without idle valve, it is at most 1 s.

Objective of the venting period: Preventing undesirable switching processes of the motor due to signal faults. Reducing the response time for load demand when the blower is still in idle mode. The following operational states are identified: STOP The machine is connected to the power supply. The machine is switched off. ■

The voltage 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 machine has been activated with «ON»: ■

The ON LED lights green.

■

The IDLE LED is extinguished.

■

The LOAD LED is extinguished.

■

The drive motor is stopped.

■

The fan of the sound enclosure may still run.

In addition, timing and/or remote control may affect the start of the drive motor. MOTOR START The machine has been activated with «ON»: ■

The ON LED lights green.

■

The IDLE LED lights green.

■

The LOAD LED is extinguished.

■

The drive motor is started

■

The sound enclosure's fan runs

■

The Load/Idle valve is open.

IDLE 1) The air generated by the compressor is vented into the atmosphere. The drive motor runs unloaded and consumes very little power. ■

No.: 901700 10 E

The IDLE LED lights green.

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

43

5

Design and Function

5.8

Control modes

■

The LOAD LED is extinguished.

■

The sound enclosure's fan runs

■

The Load/Idle valve is open.

No air is transported. 1)

Only in combination with the optional idle valve.

LOAD The drive motor runs under load: ■

The IDLE LED is extinguished.

■

The LOAD LED lights green.

■

The sound enclosure's fan runs

■

The Load run/Idle run valve is closed

Air is transported. SHUT-DOWN

5.8.2.1

■

The IDLE LED lights green.

■

The LOAD LED is extinguished.

■

The remaining idle time is displayed in menu 1.4

■

The drive motor is running

■

The Idle valve is open

■

The sound enclosure's fan runs

Operating control without load/idle valve When the operating voltage is applied to SIGMA CONTROL 2, the operation control is in STOP operating mode and then switches to READY mode. Triggered by the Load run command, the drive motor starts via the MOTOR START operating mode and switches to LOAD operating mode. When the Load run command is 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 control switches to the SHUT-DOWN operating state. As soon as the shut-down process is completed or the stop command is issued, the operating con‐ trol switches to the STOP operating state after the venting period has elapsed (menu 10.4 -> max. 1 s).

5.8.2.2

Operating control with load/idle valve If the Load or Idle run command is present, the drive motor starts via the MOTOR START operat‐ ing state. If the Load run command is present, the machine will switch to LOAD after the motor start is com‐ pleted. If the Idle command is present, the operation control remains in IDLE. If there is no Load run nor Idle command present, the operating control switches to the SHUTDOWN state. This state is only left after the venting period has elapsed and the minimum run time has been reached.

44

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

5

Design and Function

5.8

Control modes

If the Shut-down command is present, the control switches to the SHUT-DOWN state. This state 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.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

45

6

Installation and Operating Conditions

6.1

Maintaining ambient conditions

6 Installation and Operating Conditions 6.1

Maintaining ambient conditions ➤ Follow the instructions in the machine's service manual.

6.2

Installation conditions The installation and operating conditions depend 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. ➤ See the machine's operating manual for required conditions.

46

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

7

Installation

7.1

Reporting Transport Damage

7 Installation 7.1

Reporting Transport Damage 1. Check the machine for visible and hidden transport damage. 2. Inform the carrier and the manufacturer in writing of any damage without delay.

7.2

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. ➤ Attach the following notice to warn of remote machine operation (suggestion):

Remote control: Risk of injury caused by unexpected starting! ➤ Make sure the power supply disconnecting device is switched off before commencing any work on the machine. Tab. 47

Machine identification ➤ Label the starting device in the remote control centre as follows (suggestions):

Remote control: Risk of injury caused by unexpected starting! ➤ Before starting, make sure that no one is working on the machine and that it can be safely started. Tab. 48

Remote control identification Identifying the machine for time control (clock mode operation) ➤ Attach the following notice to indicate the ON/OFF timer program machine operation (sugges‐ tion):

Time control: Risk of injury caused by unexpected starting! ➤ Make sure the power supply disconnecting device is switched off before commencing any work on the machine. Tab. 49

No.: 901700 10 E

Machine identification

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

47

8

Initial Start-up

8.1

Outline

8 Initial Start-up 8.1

Outline SIGMA CONTROL 2 was designed and developed for a number of applications. The settings that can be made are correspondingly varied. It is possible that only a few of these settings are needed for the initial start-up. This depends on the application. 8.2: Setting the controller (display format, units, languages, etc.) 8.3: KAESER CONNECT benefits 8.4: Displaying and setting the blower properties 8.5: Machine start and stop 8.6: Operating modes in frequency-controlled machines 8.7: Setting the machine for master control operation 8.8: Setting the external input signal 8.9: Activating remote acknowledgement 8.10: Error behaviour 8.11: Commissioning the machine

8.2

Setting the controller The following chapters describe in detail the basic settings for the SIGMA CONTROL 2. The quick installation guide at the beginning of this operating manual provides an overview of the essential displays and operating elements, the main menu and important functions. ➤ Carry out settings as required:

48

■

8.2.1: Selecting menu options (introduction)

■

8.2.2: Setting the language

■

8.2.3: Noting the user name

■

8.2.4: User log-in with RFID Equipment Card

■

8.2.5: Generating a password

■

8.2.6: Manual user log-in

■

8.2.7: Create the master RFID Equipment Card

■

8.2.8: Checking/Setting time and date

■

8.2.9: Setting the time zone (daylight saving time/winter time)

■

8.2.10: Set display formats (date, time, units of pressure and temperature)

■

8.2.11: Setting the display illumination

■

8.2.12: Setting the contrast and the brightness

■

8.2.13: Activating the remote control

■

8.2.14: IP configuration

■

8.2.15: Setting the e-mail function

■

8.2.16: Setting the time server

■

8.3.6: Creating a user account

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8.2.1

8

Initial Start-up

8.2

Setting the controller

Selecting menu options All menu options can be selected with the «Down», «Up» and «Enter» keys. Example: Select the < Configuration – General > menu option 1. Switch on the machine and wait for SIGMA CONTROL 2 to start. The operating mode is displayed.

Fig. 11

Operating mode 2. Press «Enter». The Main menu is displayed. 400mbar

08:15AM

80° C

Header

Main menu ----------------English GB----------------

Current language

▶1 Status

Sub-menu

▶2 Performance data

Sub-menu

▶3 Operating data

Sub-menu

▶4 Maintenance

Sub-menu

▶5 Configuration

Active line

3. Use «Up» or «Down» to select the Configuration line. 4. Press «Enter». The Configuration menu is displayed 5. Use «Up» or «Down» to select the General line. 6. Press «Enter». The General menu is displayed 400mbar

08:15AM

80° C

Header

5.1 General

Menu

▶1 System information

Sub-menu

······························ Model:

XXXXXX

set machine type

······························ Date/Time 04/13/20

No.: 901700 10 E

08:15:37AM

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

current date and time

49

8

Initial Start-up

8.2

Setting the controller

7. Use «Up» or «Down» to select a menu item in the General sub-menu such as System information. 8. Press «Escape» repeatedly to leave this menu.

8.2.2

Setting the language You can set the user interface to one of these languages:

Tab. 50

Arabic

Estonian

Italian

Norwegian

Spanish

Bulgarian

Finnish

Japanese

Polish

Spanish (South America)

Chinese

French

Korean

Portuguese

Czech

Danish

French (Canada)

Croatian

Romanian

Turkish

German

Greek

Latvian

Russian

Hungarian

English

Hebrew

Lithuanian

Swedish

...

English (USA)

Indonesian

Dutch

Slovenian

...

Supported languages Depending on the selected language, the system automatically sets the units and the time and date formats. You can manually change these settings (see chapter 8.2.10).

Precondition

The operating mode is displayed. 1. Press «Enter». The Main menu is displayed. 400mbar

08:15AM

80° C

Header

Main menu ----------------English GB----------------

Current language

▶1 Status

active line

▶2 Performance data

Sub-menu

▶3 Operating data

Sub-menu

▶4 Maintenance

Sub-menu

▶5 Configuration

Sub-menu

2. Press «Up» key. The currently set language is displayed. 400mbar

08:15AM

80° C

Header

Main menu ----------------English GB----------------

50

Active line with current set language

▶1 Status

Sub-menu

▶2 Performance data

Sub-menu

▶3 Operating data

Sub-menu

▶4 Maintenance

Sub-menu

▶5 Configuration

Sub-menu

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.2

Setting the controller

3. Press «Enter». The currently set language flashes. 4. Use «Up» or «Down» to select the desired language. 5. Press «Enter». Result

8.2.3

The user interface is displayed in the set language.

Noting the user name The number on the back of your RFID Equipment Card is identical to the user name dis‐ played on SIGMA CONTROL 2 after you have successfully logged on using your RFID Equipment Card.

Fig. 12

Back of the RFID Equipment Card 1 2

Back of the RFID Equipment Card Number of the RFID Equipment Card

1. Note the user name (= number of the RFID Equipment Card). 2. Keep the note at a secure location. If your RFID Equipment Card gets damaged or can no longer be found? ➤ If you know your user name and password, you can manually log on to SIGMA CONTROL 2 (see chapter 8.2.5).

8.2.4

User log-on with RFID Equipment Card The RFID Equipment Card enables you to easily and quickly log on at SIGMA CONTROL 2. It au‐ thorises you to access advanced functions of the controller. Advanced access rights allow you to:

Fig. 13

No.: 901700 10 E

■

Read additional data

■

Change other settings

User log-on with RFID Equipment Card

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

51

8

Initial Start-up

8.2

Setting the controller

1. Hold the RFID Equipment Card in front of the RFID reader. Your user name and access level will be displayed. 400mbar

08:15AM

80° C

Header

Log-in successful

Menu

Button to change password

Prompt, whether the password is to be changed

------------------------------

Name:

E00019895

Level:

2

2. Press «Enter». The access right is confirmed. The RFID Equipment Card is damaged or lost? ➤ Manually enter the user name and password, see chapter 8.2.6.

8.2.5

Generating a password In the event that your RFID Equipment Card is damaged or lost, you must manually log on to SIGMA CONTROL 2. A password is also required to use KAESER CONNECT to log on at SIGMA CONTROL 2 (see chapter 8.3). Prerequisite for this is that you know your ■

Name

■

Password

You have noted your user name and stored it at a suitable location (see chapter 8.2.3). You now generate a password at the SIGMA CONTROL 2. Note this generated password as well, and store it a suitable location. If your RFID Equipment Card is damaged or lost, the card won't be necessary to manually log on to SIGMA CONTROL 2 when you have these two pieces of information. Precondition

Fig. 14

52

Any menu is displayed

User log-in with RFID Equipment Card

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.2

Setting the controller

1. Hold the RFID Equipment Card in front of the RFID reader. Users are always logged on with access level 2. 400mbar

08:15AM

80° C

Header

Log-in successful

Menu

Button to change password

Prompt, whether the password is to be changed

------------------------------

Name:

E00019895

Level:

2

2. Press the «Right» key within five seconds. The new Password is displayed. 400mbar

08:15AM

80° C

Password changed

Header Menu

-----------------------------Please take note of your new password: xFNDQRCnDn

New password

3. Note the new password. 4. Store the password at a suitable location, if it should become necessary to manually log-on without the RFID Equipment Card. 5. Press the «Enter» key. The setting is applied.

8.2.6

Manual user log-on In the event that your RFID Equipment Card is damaged or lost, you can manually log on to SIGMA CONTROL 2.

Precondition

The user name (see chapter 8.2.3) and password (see chapter 8.2.5) are known. The operating mode is displayed. 1. Open the 7 User menu. 2. Use «Up» or «Down» to select the Name line. 3. Press «Enter». The setting mode is active. A column with alphanumeric characters is displayed. The selected character flashes.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

53

Fig. 15

8

Initial Start-up

8.2

Setting the controller

Manual user log-on 4. Select the required character with the «Up» or «Down» keys. 5. Press the «Right» arrow. The cursor jumps to the next position of the user name. 6. Enter the remaining characters of the user name in the same manner. 7. Press «Enter». The user name is entered. 8. Use «Up» or «Down» to select the Password line. 9. Press «Enter». Enter the remaining letters and digits of the password in the same manner. The password is case sensitive! 10. Press «Enter». The password is entered. 11. Use «Up» or «Down» to select the [Login] line. 12. Press «Enter».

Current access level 2 is displayed. Result

8.2.7

You are now logged on to SIGMA CONTROL 2 with access level 2, having manually input your user name and the password.

Create the master RFID Equipment Card If you are running several KAESER machines with the SIGMA CONTROL 2 control it may make sense to create a master RFID Equipment Card with which you can log onto all machines.

Precondition

The RFID Equipment Card delivered with the machine and at least one additional teachable RFID Equipment Card are available. The operating mode is displayed.

54

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.2

Setting the controller

1. Hold the RFID Equipment Card delivered with the machine in front of the RFID reader. Users are always logged on with access level 2. 400mbar

08:15AM

80° C

Header

Log-in successful

Menu

Button to change password

Prompt, whether the password is to be changed

------------------------------

Name:

E00019895

Level:

2

2. Within 10 minutes, hold the master RFID Equipment Card to be taught in front of the RFID reader. The master RFID Equipment Card is not registered at the machine. 400mbar

08:15AM

80° C

Header The master RFID Equipment Card has been regis‐ tered

Registration successful -----------------------------Name: Level:

E00017326 2

3. Repeat the above steps at the next machine if the master RFID Equipment Card is to be regis‐ tered at other machines. Result

8.2.8 Precondition

You have registered a master RFID Equipment Cards at the machine.

Checking/setting time and date Access level 2 is activated. Check and set time ➤ When operating the machine with a timer program, check the time settings at least once a year. ➤ You can automatically synchronise date and time using a time server. Manual setting of the time is no longer required in this case. See chapter 8.2.16. 1. Open the 5.1 menu. 2. Use «Up» or «Down» to select the Date/Time line.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

55

8

Initial Start-up

8.2

Setting the controller

3. Press the «DOWN» key. 400mbar

08:15AM

80° C

Header

5.1 General

Menu

▶1 System information

Sub-menu

······························ Model:

set machine type (SC2 FLUID)

XXXXXX ······························

Date/Time 04/13/20

08:15:37AM

current date and time

4. Press the «Right» key. 5. Press «Enter». The display for hours 00:00:00 flashes. 6. Use «Up» or «Down» to set the hours. 7. Press the «Right» arrow. The display for minutes 00:00:00 flashes. 8. Use «Up» or «Down» to set the minutes. 9. Press the «Right» arrow. The display for seconds 00:00:00 flashes. 10. Use «Up» or «Down» to set the seconds. 11. Press «Enter». The setting is applied. 12. Press «Escape» repeatedly to leave this menu. Check/set the date Precondition

Access level 2 is activated. 1. Open the 5.1 menu. 2. Use «Up» or «Down» to select the Date/Time line. 3. Press the «DOWN» key. 400mbar

08:15AM

80° C

Header

5.1 General

Menu

▶1 System information

Sub-menu

······························ Model:

XXXXXX

set machine type (SC2 FLUID)

······························ Date/Time 04/13/20

08:15:37AM

current date and time

4. Press «Enter». The display for days 00.00.00 flashes. 5. Use «Up» or «Down» to set the day. 6. Press the «Right» arrow. The display for months 00.00.00 flashes.

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Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.2

Setting the controller

7. Use «Up» or «Down» to set the month. 8. Press the «Right» arrow. The display for years 00.00.00 flashes. 9. Use «Up» or «Down» to set the years. 10. Press «Enter». The setting is applied. 11. Press «Escape» repeatedly to leave this menu.

8.2.9

Set the time zone Set the time zone for the SIGMA CONTROL 2 to ensure the timely automatic conversion from win‐ ter time (standard time) to daylight savings time, for example.

Precondition

Access level 2 is activated. 1. Open the 5.1 menu. 2. Use «Up» or «Down» to select the Date/Time line. 3. Press «Down» twice. 400mbar

08:15AM

80° C

5.1 General Model:

Header Menu

XXXXXX

set machine type

······························ Date/Time 04/13/20

08:15:37AM Europe/London

Time zone

······························

4. Press «Enter». The time zone display flashes. 5. Use «Up» or «Down» to set the time zone. 6. Press «Enter». The setting is applied. 7. Press «Escape» repeatedly to leave this menu.

8.2.10

Set display formats Depending on the selected language, the system automatically sets the units and the time and date formats. You can manually change these settings. Setting the date format Set the display for the date format:

Tab. 51

No.: 901700 10 E

Format

Example

DD.MM.YY

30.07.16

YY-MM-DD

16–07–30

MM/DD/YY

07/30/16

Date formats

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

57

Precondition

8

Initial Start-up

8.2

Setting the controller

Access level 2 is activated. 1. Open the 5.1 menu. 2. Use «Up» or «Down» to select the Date format line. 400mbar

08:15AM

80° C

Header Menu

5.1 General Europe/London ······························ ▶2 Time server ······························ Date format

MM/DD/YY

Time format

hh:mm:ssAM/PM

Date format

3. Press «Enter». The MM/DD/YY display flashes. 4. Use «Up» or «Down» to set the date format. 5. Press «Enter». The setting is applied. 6. Press «Escape» repeatedly to leave this menu. Setting the time format Set the display for the time format:

Tab. 52 Precondition

Format

Example

hh:mm:ss

13:33:45

hh:mm

13:33

hh:mm:ssAM/PM

01:33:45PM

hh:mmAM/PM

01:33PM

Possible settings for the time format Access level 2 is activated. 1. Open the 5.1 menu. 2. Use «Up» or «Down» to select the Time format line. 400mbar

08:15AM

80° C

Header Menu

5.1 General Europe/London ······························ ▶2 Time server ······························ Date format

MM/DD/YY

Time format

hh:mm:ssAM/PM

time format

3. Press «Enter». The hh:mm:ssAM/PM indication flashes.

58

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.2

Setting the controller

4. Use «Up» or «Down» to set the time format. 5. Press «Enter». The setting is applied. 6. Press «Escape» repeatedly to leave this menu. Setting the pressure display units Set the pressure unit for display:

Tab. 53 Precondition

Format

Example

bar

5.5bar

hPa

5523hPa

MPa

0.55MPa

psi

80psi

at

5.6at

"Hg

162"Hg

mbar

5500mbar

Possible settings for the pressure unit Access level 2 is activated. 1. Open the 5.1 menu. 2. Use «Up» or «Down» to select the Pressure unit line. 400mbar

08:15AM

80° C

Menu

5.1 General Time format

Header

hh:mm:ssAM/PM

······························ Pressure unit Temperature unit

bar °C

Unit of pressure Unit of temperature

······························ Display illumination

3. Press «Enter». The display for the set unit flashes. 4. Use «Up» or «Down» to set the unit. 5. Press «Enter». The setting is applied. 6. Press «Escape» repeatedly to leave this menu. Setting the temperature display units Set the temperature unit for display:

No.: 901700 10 E

Format

Example

°C

46°C

K

319K

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

59

Tab. 54 Precondition

8

Initial Start-up

8.2

Setting the controller

Format

Example

°F

114°F

Possible settings for the temperature unit Access level 2 is activated. 1. Open the 5.1 menu. 2. Use «Up» or «Down» to select the Temperature unit line. 400mbar

08:15AM

80° C

Menu

5.1 General Time format

Header

hh:mm:ssAM/PM

······························ Pressure unit

bar

Temperature unit

°C

Unit of pressure Unit of temperature

······························ Display illumination

3. Press «Enter». The display for the set unit flashes. 4. Use «Up» or «Down» to set the unit. 5. Press «Enter». The setting is applied. 6. Press «Escape» repeatedly to leave this menu.

8.2.11

Setting the display illumination Set the display lighting mode: Mode

Tab. 55 Precondition

1

2

3

Indication

automatic

on

off

Function

The illumination extin‐ guishes after the timeout has elapsed.

Permanent setting Illumination "on"

Permanent setting Illumination "off"

Display illumination Access level 2 is activated. 1. Open the 5.1 menu. 2. Use «Up» or «Down» to select the Display illumination line.

60

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.2

Setting the controller

3. Press the «DOWN» key. The Mode line is displayed. 400mbar

08:15AM

80° C

Header Menu

5.1 General ······························ Pressure unit

bar

Temperature unit

°C

Unit of pressure Unit of temperature

······························ Display illumination Mode

auto.¦

Timeout:

1min

Active line

4. Press «Enter». The display for the set mode flashes. 5. Use the «Up» or «Down» keys to set the auto. mode. 6. Press «Enter». The setting is applied. 7. Press the «Right» key. 8. Set the value for the Timeout in the same manner: 1 min, for example. 9. Press «Enter». 10. Press «Escape» repeatedly to leave this menu. Result

8.2.12

The display illumination is set for automatic operation with deactivation after one minute without user intervention.

Setting the contrast and the brightness Contrast and brightness are factory set to normal light conditions. You can manually set contrast and brightness for different lighting conditions.

Precondition

The operating mode is displayed. 1. Press and hold the «Information» key. 2. Use «Up» or «Down» to set the contrast. 3. Use «Left» or «Right» to set the brightness.

Result

8.2.13

Contrast and brightness are set.

Activating the remote control The «remote control» key on the operating panel of the SIGMA CONTROL 2 can be activated or deactivated. Various menus offer check boxes for this setting.

Precondition

Access level 2 is activated. The operating mode is displayed. 1. Open the menu, e.g. 8 Communication menu. 2. Use «Up» or «Down» to select the Key remote line.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

61

8

Initial Start-up

8.2

Setting the controller

3. Press «Enter». The check box Key remote will flash. 400mbar

08:15AM

80° C

Header Menu

8 Communication ▶1 Ethernet/SIGMA NETWORK ▶2 Com-Module Key remote

☐

Active line with deactivated check box

4. Press the «Up» key. The check box is activated. 5. Press the «Enter» key. The «Remote control» key is activated. 400mbar

08:15AM

80° C

Header Menu

8 Communication ▶1 Ethernet/SIGMA NETWORK ▶2 Com-Module Key remote

☑

Active line with deactivated check box

6. Press «Escape» repeatedly to leave this menu. Proceed in the same manner to deactivate the «remote control» key. 7. Press «Remote control» key on the operating panel of SIGMA CONTROL 2. Result

8.2.14

SIGMA CONTROL 2 remote control is activated.

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 use SIGMA CONTROL 2 as the master control of two machines, you set other network parameters in the IP configuration menu (see chapter 8.7.4). The network parameters for the IP configuration must be specified manually. You cannot use DHCP for an automatic IP configuration.

Precondition

Access level 2 is activated. The network parameters are known. Request the required information from your IT department. 1. Connect SIGMA CONTROL 2 to the network using an Ethernet cable. 2. Open the 8.1.1 menu.

62

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.2

Setting the controller

3. Use «Up» or «Down» to select the IP address line. 400mbar

08:15AM

80° C

Header

8.1.1 IP configuration

Menu

IP address

169.254.100.101

active line, factory setting

Subnet mask

255.255.000.000

Gateway

169,254,100.97

DNS Server 1

169,254,100.97

DNS Server 2

169,254,100.97

Restart network

☐

4. Press «Enter». The first group of numbers of the IP address flashes 169.254.100.101. 5. Use «Up» or «Down» to set the first group of numbers of the IP address. 6. Press the «Right» key. The SECOND group of numbers of the IP address flashes 192.168.100.101. 7. Use «Up» or «Down» to set the second, third and fourth group of numbers of the IP address. The IP address is correctly set. 8. Press «Enter». The setting is applied. 9. Press «Down». The Subnet mask line is displayed. 10. Set the remaining network parameters as described above: Parameters

Meaning

IP address

IP address of the interface X1 Ethernet

Subnet mask

Subnet mask of the network

Gateway

Gateway address of the network

DNS Server 1

DNS server 1 address

DNS Server 2

DNS server 2 address

Restart network Tab. 56

Setting value

–

Activate the changed network parameters

Network parameters 11. Use «Up» or «Down» to select the Restart network line. 400mbar

08:15AM

80° C

Header

8.1.1 IP configuration

Menu

IP address

192.168.001.010

Example address

Subnet mask

255.255.255.000

Example address

Gateway

192.168.001.001

Example address

DNS Server 1

008.008.008.008

Example address

DNS Server 2

008.008.004.004

Example address

Restart network

☐

Active line

12. Press «Enter». The check box Restart network will flash.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

63

8

Initial Start-up

8.2

Setting the controller

13. Press the «Up» key. The check box is activated. 14. Press «Enter». Result

The network is restarted. The set network parameters are active.

8.2.15

Setting the e-mail function SIGMA CONTROL 2 is able to send messages via e-mail. For this purpose, a network connection with an SMTP server is required. Setting e-mail parameters

Precondition

Access level 2 is activated. IP configuration is set; see chapter 8.2.14. An SMTP server is active in the network. The e-mail parameters are known. Request the required information from the IT department. 1. Open the 8.1.3 menu. 2. Use «Up» or «Down» to select the active: line. 400mbar

08:15AM

80° C

Menu

8.1.3 E-mail active:

☐

Blower number:

1

Language:

Header

English GB

Repeat cut-off time: Use SSL:

Activating/deactivating the e-mail function Setting the language

5min ☑

Encryption option

------------------------------

3. Press «Enter». The check box active: will flash. 4. Press «Up». The check box is deactivated. 5. Press «Enter». The e-mail function is deactivated.

64

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.2

Setting the controller

6. Set the e-mail parameters as described above: If SIGMA CONTROL 2 is connected via SIGMA NETWORK to SAM 4.0 and emails are to be forwarded via SAM 4.0, then enter the IP address of interface X6 of SAM 4.0 in the SMTP server: field. 169.254.100.100 (see also chapter 8.7.2). Enter at port address of the SMTP server: 25. For SAM 4.0 the option Data Forwarding in the menu must be activated. Parameter

Tab. 57

Setting Meaning value

Blower number:

This field displays the machine number that appears as the sender of emails. The recipient is thus able to identify the different machines send‐ ing mails.

Language:

Use this field to define the language for the message texts. This setting is independent from the language setting in SIGMA CONTROL 2 (see chapter 8.2.2).

Repeat cut-off time:

In this field, enter the time in minutes (repeat block time) that the system must wait in order not to send multiple recurring messages in short time intervals.

Use SSL:

E-mail sending is encrypted if the check box is ticked.

Sender address:

Enter the e-mail address of the sender in this field.

Sender name:

Enter the name of the sender in 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 address of the recipient

SMTP server:

IP address of the SMTP server receiving and forwarding the e-mails

User name:

Log-in user name for logging on to the SMTP server

Password:

Log-in password for logging on to the SMTP server

Port

Port address of the SMTP server

Timeout

In this field, enter the seconds for SIGMA CONTROL 2 to wait for a reply by the SMTP server before e-mail sending is cancelled.

Resend after:

In this field, enter the time in seconds for the system to wait after a failed e-mail sending operation before it again attempts to send the mail.

E-mail parameters 7. Activating the e-mail function: Activate the active: check box as described above. 8. Press «Escape» repeatedly to leave this menu.

Result

The e-mail parameters are set and the e-mail function is activated. Suppressing repeat messages To suppress messages repeating at short intervals, a period of 0–999 minutes can be set during which a repeat of the same message is suppressed, i.e. is not sent. This prevents the sending of identical messages.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

65

Precondition

8

Initial Start-up

8.2

Setting the controller

Access level 2 is activated. 1. Open the 8.1.3 menu. 2. Use «Up» or «Down» to select the Repeat cut-off time: line. 3. Press «Enter». The set value for Repeat cut-off time: in minutes flashes. 400mbar

08:15AM

80° C

Header Menu

8.1.3 E-mail active:

☐

Blower number:

1

Language:

English GB

Repeat cut-off time:

Activating/deactivating the e-mail function Setting the language

5min

Use SSL:

☑

Encryption option

------------------------------

4. Use «Up» or «Down» to set the value for Repeat cut-off time:. 5. Press «Enter». The setting is applied. 6. Press «Escape» repeatedly to leave this menu. Result

8.2.16

Repeat cut-off time: is set.

Setting the time server If SIGMA CONTROL 2 is connected to the network, you can set the access to an SNTP server 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 time server.

Precondition

Access level 2 is activated. IP configuration is set; see chapter 8.2.14. The time server's IP address is known. Request the required information from your IT department. 1. Open the 5.1.2 menu. 2. Use «Up» or «Down» to select the IP address line. 400mbar

08:15AM

80° C

Menu

5.1.2 Time server active: IP address

Header

☐ 192.053.103.103

Activating/deactivating the time server function Example address, time server

3. Press «Enter». The first group of numbers of the IP address flashes 192.053.103.103. 4. Use «Up» or «Down» to set the first group of numbers of the IP address.

66

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.3

KAESER CONNECT benefits

5. Press the «Right» key. The second group of numbers of the IP address flashes 192.053.103.103. 6. Use «Up» or «Down» to set the second, third and fourth group of numbers of the IP address. The IP address is correctly set. 7. Press «Enter». The setting is applied. 8. Use «Up» or «Down» to select the active: line. 9. Press «Enter». The check box active: will flash. 10. Press the «Up» key. The check box is activated. 400mbar

08:15AM

80° C Menu

5.1.2 Time server active: IP address

☑ 192.053.103.103

The time server function is activated. 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 synchronised.

8.3

KAESER CONNECT benefits Using an Internet-capable device with web browser, you can use KAESER CONNECT to remotely display these SIGMA CONTROL 2 menus: ■

System status

■

Graphs

■

Messages

■

I/O display

■

User management

■

Settings

■

Backup

■

Data recording

Thus, KAESER CONNECT provides an excellent option for an easy and quick check of the econo‐ my and energy efficiency of your machines.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

67

8

Initial Start-up

8.3

KAESER CONNECT benefits

The following functions are not implemented with KAESER CONNECT: ■

Remotely starting the machine

■

Remotely setting parameters

For KAESER CONNECT to be able to use the Internet-capable device, it must be registered in the same network as SIGMA CONTROL 2. To be able to use KAESER CONNECT, the browser installed on the Internet-capable device must be able to display HTML5 content. For security reasons, we strongly recommend to use only up-to-date browser versions.

8.3.1 Precondition

Open KAESER CONNECT 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 cable to connect SIGMA CONTROL 2 to the Internet-capable device or net‐ work. 2. In the web browser, enter the IP address of the controller. The log-in mask is displayed.

Fig. 16

Log-in mask 3. Enter your user name in the User name: field. 4. Enter your password in the Password: field. 5. Click Login. KAESER CONNECT for SIGMA CONTROL 2 is displayed.

68

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

Fig. 17

8

Initial Start-up

8.3

KAESER CONNECT benefits

KAESER CONNECT for SIGMA CONTROL 2 6. Click the arrow key 1 to open Select language:. The Select language: window is displayed.

Fig. 18

Select language: window 1 2

«Arrow key» Select language: Select language: window

3 4

Setting the language Selected language

7. Click to set the selected language 3 . Result

8.3.2 Precondition

No.: 901700 10 E

KAESER CONNECT is displayed in the set language.

System status menu KAESER CONNECT for SIGMA CONTROL 2 is displayed.

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

69

Fig. 19

8

Initial Start-up

8.3

KAESER CONNECT benefits

System status menu 1. Click the System status menu element. The System status menu is displayed

Fig. 20

70

Main menu

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.3

KAESER CONNECT benefits

2. Click in the SIGMA CONTROL 2 display. The Main menu is displayed. 3. Click the numbered lines. The system displays the corresponding sub-menus. 4. Press ESC repeatedly to leave this menu.

8.3.3

Graphs menu When starting the Graphs menu, the recorded machine data from the last 20 minutes are displayed as diagram. The system updates the graph every ten seconds whilst the current time is displayed. If an SD card is provided in the X5 SD card slot, you can retrieve and display the automaticallyrecorded machine 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. When the ruler is hidden, the time and associated values are displayed at the right edge of the graph. The graph content depends on the machine type. The Speed display is implemented only for machines with frequency converter.

Precondition

KAESER CONNECT for SIGMA CONTROL 2 is displayed. 1. Click the Graphs menu element.

Fig. 21

Graphs (illustration similar) 2. Check the displayed data.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

71

8.3.3.1

8

Initial Start-up

8.3

KAESER CONNECT benefits

Zoom function Use the Zoom function to enlarge significant curve developments: Highlight a specific area within the graph by drawing a rectangle with the mouse pointer pressed. The selected area will be enlarged as soon as the mouse pointer is released.

Fig. 22

Tab. 58

Control keys Item Description

Function

1

«Start»

Display the oldest data in the cache memory or load the data from the previ‐ ous 20 minutes from the SD card

2

«Scroll left»

Shift the display area by 1/3 to the left

3

«Zoom-out» Time range is enlarged

4

«Scroll right» Shift the display area by 1/3 to the right

5

«End»

Display the current data

6

«Refresh»

Load and display the entered machine data from start time to end time

Control key functions 1. Click the «Start» 1 arrow key. The oldest data in the cache memory or the data of the last 20 minutes are loaded form the 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 mouse button. The selected area is enlarged (zoom-in function). 5. Click the «Zoom-out» 3 arrow key. The time range is enlarged (zoom-out function).

8.3.3.2

Display past machine data You can display the automatically-recorded machine data for any time in the past.

Precondition

An SD card with sufficient free memory is inserted in the X5 SD card slot The SD card was inserted for the entire operating time of the machine. The SIGMA CONTROL 2 data recorder function is activated. 1. Enter the date and time for the start time in the required time period in Start:. 2. Enter the date and time for the end time in the required time period in End:. 3. Click 6 . The machine data for the specified time interval are loaded and displayed.

72

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8.3.4

8

Initial Start-up

8.3

KAESER CONNECT benefits

Messages menu The following messages types can be displayed:

Precondition

Fig. 23

■

Current messages

■

Blower messages

■

System messages

■

Diagnostic messages

KAESER CONNECT for SIGMA CONTROL 2 is displayed.

Messages (illustration similar) 1. Click the Messages menu element. The Messages 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 the I/O display menu. Depending on the machine options, you may select from further IOM module tabs.

Precondition

No.: 901700 10 E

KAESER CONNECT for SIGMA CONTROL 2 is displayed.

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

73

Fig. 24

8

Initial Start-up

8.3

KAESER CONNECT benefits

I/O display (illustration similar) ➤ Click the I/O display menu element. The current measured data and states of the input/output modules are displayed.

8.3.6

User management menu Use the User management menu to create additional user accounts for other employees. In order to be able to create user accounts, you must activate the write mode. The system will prompt you to enter and confirm your user name and your password. 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. The system will return an error message. String length for personally created user names and passwords:

Precondition

■

User name: 6 to 16 characters, the second character must not be a number

■

Password: 6 to 16 characters

The generated password is available. KAESER CONNECT for SIGMA CONTROL 2 is displayed.

74

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

Fig. 25

8

Initial Start-up

8.3

KAESER CONNECT benefits

User management menu 1. Click the User management menu element. 2. Click read => write to activate the read/write mode. The Log on for 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 is displayed

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

75

Fig. 27

8

Initial Start-up

8.3

KAESER CONNECT benefits

User management menu 6. Enter a new user name in the User name: field. 7. Enter a new password in the Password: field. 8. Re-enter the same new password in the Repeat password: field. 9. Set Level 2 in the Access level: field. 10. Set the State: option in the Enabled field. 11. Click Add. The new user name has been added to the user list.

Result

A new user account has been created 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 account. Precondition

The User management menu is displayed Write mode is activated. 1. Click the required user account in the list. 2. Enter a new password in the Password: field. 3. Re-enter the same new password in the Repeat password: field. 4. Click Update user.

76

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

Result

8.3.7

8

Initial Start-up

8.3

KAESER CONNECT benefits

The password for the existing user account is changed.

Settings menu These settings are only required for access to KAESER CONNECT via web browser. The following settings are possible.

Fig. 28

■

Units

■

Date format

■

Time format

Settings menu For example, you want to convert your units to US values:

Precondition

KAESER CONNECT 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 pressure unit (psi). 4. Click the arrow key for the unit of temperature. A selection list of units of temperature is displayed. 5. Set the appropriate temperature unit (°F). 6. Set additional units and date and time formats.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

77

8.3.8

8

Initial Start-up

8.3

KAESER CONNECT benefits

Save data menu The Backup menu allows you to download data from SIGMA CONTROL 2 to the Internet-capable device. The following backup types are available:

Precondition

■

Backup all

■

Log files

■

Settings

■

User information

KAESER CONNECT for SIGMA CONTROL 2 is displayed. 1. Click the Backup menu element.

Fig. 29

Backup menu 2. Set the required backup type in the Select source: option. 3. Click Backup.

Result

8.3.9

The data are downloaded to the Internet-capable device.

Data recording menu The Data recording menu allows you to download machine data that has been recorded to the SD card from SIGMA CONTROL 2 to the Internet-capable device.

78

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.3

KAESER CONNECT benefits

The following options are available:

Precondition

■

Hour file: Recorded machine data from the last 60 min

■

Time period range: Recorded machine data between the time period of Start time and End time

KAESER CONNECT for SIGMA CONTROL 2 is displayed An SD card with sufficient free memory has been inserted in the X5 SD card slot of SIGMA CONTROL 2 during the machine running time 1. Click the Data recording menu element.

Fig. 30

Data recording menu 2. Select the Hour file or Start time option. 3. Set the requested time in the MM/DD/YY and HH:00 field. 4. Click Get Data.

Result

The data is downloaded to the Internet-capable device. The downloaded data can be sent to KAESER SERVICE for evaluation and service support.

8.3.10

KAESER CONNECT exit In order to close KAESER CONNECTfor SIGMA CONTROL 2, click Logout in the header. ➤ Click Logout.

Result

No.: 901700 10 E

The system displays a message confirming the successful logout.

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

79

8.4

8

Initial Start-up

8.4

Displaying and setting the blower properties

Displaying and setting the blower properties This section contains instruction about the display of the blower properties and their settings for the machine's specific installation elevation. "Display" means that the parameter will only be shown. "Setting:" means that the parameter can also be changed. Parameters

Type

Explanation

Altitude

Setting Input the current installation elevation above base height level (mean height above sea level).

Air pressure

Display The system calculates the value for the air pressure according to the installation elevation.

Pressure version Display Machine operating mode

Tab. 59

■

Pressure

■

Vacuum

Maximum pressure

Display The machine is designed for this pressure (maximum working pres‐ sure).

Design pressure

Display The machine is configured for this pressure.

Minimum pressure

Display For design reasons, pressure can only be built up above this value (minimum working pressure).

Blower characteristics ➤ Set the installation elevation as shown in chapter 8.4.2.

8.4.1

Displaying the blower properties 1. Open the 5.2 menu. 400mbar

08:15AM

80° C

Menu

5.2 Blower properties Altitude

Header

65m

Air pressure

1.006bar

Pressure version

Pressure

Maximum pressure

0.40bar

Design pressure

0.30bar

Minimum pressure

0.20bar

Active line

2. Use «Up» or «Down» to select the line.

8.4.2

Setting the installation elevation The installation elevation can be set within certain limits:

Precondition

Access level 2 is activated. 1. Open the 5.2 menu. 2. Use «Up» or «Down» to select the Altitude line.

80

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.5

Machine start and machine stop

3. Press «Enter». The setting mode is active. 4. Use «UP» or «DOWN» to set the value for installation elevation. 400mbar

08:15AM

80° C

Menu

5.2 Blower properties Altitude

Header

00m

Air pressure

1.006bar

Pressure version

Pressure

Maximum pressure

0.40bar

Design pressure

0.30bar

Minimum pressure

0.20bar

Active line with set installation elevation

5. Press the «Enter» key. The setting is applied. Result

8.5

The installation elevation is set.

Machine start and machine stop ➤ In addition to manually starting the machine locally, you have the following alternatives:

Tab. 60

Function

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

Controlling machine from a remote location

Deactivated

8.5.4

Settings for machine start and machine stop You can select either Time control or Pulse generator operating mode. The operating modes cannot be used simultaneously.

8.5.1

Automatic start/stop in timer mode Overview

8.5.1.1 Precondition

No.: 901700 10 E

■

Select menu Time control

■

Set clock program

■

Activating time control

Select the Time control menu Access level 2 is activated.

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

81

8

Initial Start-up

8.5

Machine start and machine stop

1. Open the 6 menu. 400mbar

08:15AM

80° C

Header Menu

6 Time control Key time control

☐

The time control key is activated

Reset

☐

All current switching points are reset

······························ 01

n.a.

00:00AM

off

02

n.a.

00:00AM

off

03

n.a.

00:00AM

off

Active line

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. 61

82

User-defined clock programme machine ON/OFF

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8.5.1.2

8

Initial Start-up

8.5

Machine start and machine stop

Setting the clock program (example) When setting a clock programme for the first time, note first the switching times on the "Userdefined clock programme" table for example. In addition to individual weekdays, the controller has the following cycles: ■

Mon-Thu

■

Mon-Fri

■

Mon-Sat

■

Mon-Sun

■

Sat-Thu

■

Sun-Thu

Example ■

Machine ON: On weekdays 06:30AM – 05:00PM, Fridays 06:30AM – 03:00PM

■

Machine OFF: Sat – Sun and during midday break 12:00PM – 01:00PM

The following switching points result:

Tab. 62 Precondition

No.:

Day

Time

Function

01

Mon-Fri

06:30AM

on

02

Mon-Fri

12:00PM

off

03

Mon-Fri

01:00PM

on

04

Mon-Thu

05:00PM

off

05

Fri

03:00PM

off

Example of a machine ON/OFF clock program Access level 2 is activated. 1. Open the 6 menu. 2. Use «Up» or «Down» to select the 01 line. 400mbar

08:15AM

80° C

Header Menu

6 Time control ······························ 01

n.a.

00:00AM

off

Active line with switching point 01

02

n.a.

00:00AM

off

Switching point 02

03

n.a.

00:00AM

off

Switching point 03

04

n.a.

00:00AM

off

Switching point 04

05

n.a.

00:00AM

off

Switching point 05

3. Press «Enter». The n.a. indication flashes. 4. Use «Up» or «Down» to set the weekdays. 5. Press the «Enter» key. The setting is applied. 6. Press the «Right» key.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

83

8

Initial Start-up

8.5

Machine start and machine stop

7. Press «Enter». The display for hours, 00:00 flashes. 8. Use «Up» or «Down» to set the hours. 9. Press the «Right» arrow. 10. The display for minutes, 00:00 flashes. 11. Use «Up» or «Down» to set the minutes. 12. Press the «Enter» key. The setting is applied. 400mbar

08:15AM

80° C

Header Menu

6 Time control ······························ 01

Mon-Fri

06:30AM

on

Switching point 01 is set

02

Mon-Fri

12:00PM

off

Switching point 02 is set

03

Mon-Fri

01:00PM

on

Switching point 03 is set

04

Mon-Thu

05:00PM

off

Switching point 04 is set

off

Switching point 05 is set

05

Fri

03:00PM

13. Press the «Right» arrow. 14. Press «Enter». The on/off indicator flashes. 15. Use «Up» or «Down» key to set the action 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 are set for all switching points of the user-defined clock program.

8.5.1.3

Activating the «Time control» key 1. Use «Up» or «Down» to select the Key time control line. 2. Press «Enter». The check box Key time control will flash. 400mbar

08:15AM

80° C

Header Menu

6 Time control Key time control

☑

Reset

☐

Active line with deactivated check box

······························ 01

Mon-Fri

06:30AM

on

Switching point 01:

02

Mon-Fri

12:00PM

off

Switching point 02

03

Mon-Fri

01:00PM

on

Switching point 03

3. Press the «Up» key. The check box is activated.

84

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.5

Machine start and machine stop

4. Press «Enter». The setting is applied. 5. Press «Escape» repeatedly to leave this menu. Result

The «Time control» key is activated.

8.5.1.4

Activating time control

Precondition

The «Time control» key is activated; see chapter 8.5.1.3. ➤ Press the «Time control» key on the SIGMA CONTROL 2 operating panel to activate the time control.

Result

The Time control LED on the operating panel of the SIGMA CONTROL 2 signalises with green continuous light that the machine is operated with activated time control. The time control of SIGMA CONTROL 2 switches the machine according to the defined switching points of the time program.

8.5.2

Automatic start/stop with timer You can use the timer for the machine cutting in and out between LOAD 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 menu. 400mbar

08:15AM

80° C

Menu

5.9 Pulse generator Activate

Header

☐

The timer is deactivated

on :

00h:00m:00s

Cut-in period

off :

00h:00m:00s

Cut-out period

Function

Load

Mode

2. Use «Up» or «Down» to select the on line. 3. Press «Enter». The setting mode is active. The display for hours 00h:00m:00s flashes. 4. Use «Up» or «Down» to set the hours. 5. Press the «Right» key. The display for minutes 01h:00m:00s flashes. 6. Use «Up» or «Down» to set the minutes. 7. Press the «Right» key. The display for seconds 01h:15m:00s flashes. 8. Use «Up» or «Down» to set the seconds. 9. Press «Enter». The setting is applied. 10. Use «Up» or «Down» to select the off line.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

85

8

Initial Start-up

8.5

Machine start and machine stop

11. Proceed in the same manner to set the cut-out period. 12. Use the «Up» or «Down» keys to select the Function line. 13. Press «Enter» to switch into setting mode. 14. Use «Up» or «Down» to set the desired on or Load option. 15. Press the «Enter» key. The setting is applied. 16. Use the «Up» or «Down» keys to select the Activate line. 17. Press «Enter». The check box flashes in the active line. 18. Press the «Up» key. The check box is activated. 400mbar

08:15AM

80° C

Header Menu

5.9 Pulse generator Activate

The timer is activated

☑

on :

01h:15m:00s

Cut-in period

off :

01h:15m:00s

Cut-out period

Function

Mode

Load

19. Press «Enter». The setting is applied. Result

8.5.3

The machine is controlled by the timer.

"Automatic restart" function The "Automatic restart" function is deactivated after 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 simultaneous start of multiple machines. Setting the automatic restart delay period If you operate several machines, it is better to start them in sequence. Use the "Delay time for automatic restart" table to plan the time-delayed machine start. In the "Start period" column, enter for each individual machine the real time required for the first possible LOAD. Cumulatively add these values in the "Delay time" column. Enter the value of the delay time of each machine in the corresponding controller. The first machine may start immediately and does not require a delay time. Machine number 1

Start time [sec]

Delay time [sec]

––

––

2 3 4 5

86

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.5

Machine start and machine stop

Machine number

Start time [sec]

Delay time [sec]

6 7 8 9 10 11 12 13 14 15 16 Tab. 63 Precondition

Delay time for automatic restart Access level 2 is activated. 1. Open the 5.3 menu. 400mbar

08:15AM

80° C

Header Menu

5.3 Restart Automatic restart Delay

☐ 1s

Automatic restart is deactivated Set/expiring delay time

2. Use «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 restart is deactivated

Delay

☐ 10 s

Set/expiring delay time

5. Press the «Enter» key. The setting is applied. Result

No.: 901700 10 E

You have adjusted the delay tome for the restart after a power supply failure from 1 s to 10 s.

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

87

8

Initial Start-up

8.5

Machine start and machine stop

Activating/deactivating the "Automatic restart" function Precondition

Access level 2 is activated. 1. Open the 5.3 menu. 2. Use «Up» or «Down» to select the Automatic restart line. 400mbar

08:15AM

80° C

Header Menu

5.3 Restart Automatic restart Delay

☐

Automatic restart is deactivated

10 s

Set/expiring delay time

80° C

Header

3. Press «Enter». The setting mode is active. 4. Press the «Up» key. The check box is activated. 400mbar

08:15AM

Menu

5.3 Restart Automatic restart Delay

☑ 10 s

Active line with deactivated check box Set/expiring delay time

5. Press the «Enter» key. The setting is applied. Result

8.5.4

The "Automatic restart" function is activated.

Controlling machine from a remote location If the machine is to be started and stopped from a remote control centre, provide the following set‐ tings: Overview ■

Setting the load signal to remote mode

■

Setting the idle signal to remote mode

■

If necessary, activate the «Time control» key and configure the clock program (see chap‐ ter 8.5.1.2).

■

Activating the remote control

■

Press the «ON »key. The On LED lights green.

Two methods are available to start the machine remotely from a control centre:

88

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8.5.4.1 Precondition

8

Initial Start-up

8.5

Machine start and machine stop

■

Variant A: Starting the machine with the input signal from the remote control centre.

■

Variant B: Starting the machine from the remote control centre in addition to a configured ON/OFF clock program. The machine can be started from the remote control centre even though the time control is ac‐ tivated and the ON/OFF program has selected OFF at this point in time.

Setting the load signal to remote mode Electric connection via DI 1.04 – terminal -X15: 5+6 is made Access level 2 is activated. The operating mode is displayed. 1. Open the 5.5 menu. 2. Use «Up» or «Down» to select the Load signal line. 400mbar

08:15AM

80° C

5.5 External DI / AII signal

Header Menu

▶1 Current signal AII1.02

active line

Load signal DI1.04

☐ ······························

Idle signal DI1.09

☐

3. Press the «DOWN» key. The input DI has been selected. 4. Press «Enter». The display for the currently set input flashes. 5. Select the input DI1.04 with the «Up» or «Down» key. 6. Press «Enter». The setting is applied. 7. Press the «Right» key. 8. Press «Enter». The check box assigned to the input flashes. 9. Press the «Up» key. The check box is activated.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

89

8

Initial Start-up

8.5

Machine start and machine stop

10. Press «Enter». The setting is applied.

ok is displayed. 400mbar

08:15AM

80° C

Header Menu

5.5 External DI / AII signal ▶1 Current signal AII1.02 Load signal DI1.04

Active line with deactivated check box

ok ☑ ······························

Idle signal DI1.09

☐

11. Press «Escape» repeatedly to leave this menu. Result

The load signal is set to remote operation.

8.5.4.2

Setting the idle signal to remote mode

Precondition

The Load/Idle run valve is installed Electric connection via DI 1.09 – terminal -X15: 11+12 is made Access level 2 is activated. The operating mode is displayed. 1. Open the 5.5 menu. 2. Use «Up» or «Down» to select the Idle signal line. 400mbar

08:15AM

80° C

5.5 External DI / AII signal

Header Menu

▶1 Current signal AII1.02 Load signal DI1.04

☐ ······························

active line

Idle signal DI1.09

☐

3. Press the «DOWN» key. The input DI has been selected. 4. Press «Enter». The display for the currently set input flashes. 5. Select the input DI1.09 with the «Up» or «Down» key. 6. Press «Enter». The setting is applied. 7. Press the «Right» key. 8. Press «Enter». The check box assigned to the input flashes. 9. Press the «Up» key. The check box is activated.

90

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.6

Operating modes in frequency-controlled machines

10. Press «Enter». The setting is applied.

ok is displayed. 400mbar

08:15AM

80° C

5.5 External DI / AII signal

Header Menu

▶1 Current signal AII1.02 Load signal DI1.04

☐ ······························

Idle signal DI1.09

ok ☑

Active line with deactivated check box

11. Press «Escape» repeatedly to leave this menu. Result

The idle signal is set to remote operation. The conveyed air escapes through the Load/Idle run valve.

8.5.4.3

Activating the remote control ➤ Activate remote control see chapter 8.2.13.

Result

8.6

SIGMA CONTROL 2 remote control is activated.

Operating modes in frequency-controlled machines You can set various operating modes in frequency-controlled machines. Use the 5.4 Operating modes menu for specifying the settings. The selection options for the operating modes depend on the configuration of the AII1.02 current signal. Set the current signal in the 5.5.1 Current signal AII1.02 menu (see chapter 8.6.1). Possible operating modes: ■

Fixed speed

■

Pressure control

■

External speed control

■

External values control

The Fixed speed and Pressure control operating modes can always be selected, regardless of the setting of the AII1.02 current signal. The External speed control and External values control operating modes are only available if the AII1.02 current signal has been correspondingly defined. Relationships concerning operating modes: ■

Fixed speed ─

No.: 901700 10 E

Target value: → Via parameters in the 5.4.1 Fixed speed menu

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

91

8

Initial Start-up

8.6

Operating modes in frequency-controlled machines

■

■

Pressure control ─

Target value: → Via bus, if the activation bit is set → Via parameters in the 5.4.2 Pressure control menu→ Via AII1.02, if set in the 5.5.1 Current signal AII1.02 menu

─

Actual value: → Via bus, if the activation bit is set → Via AII1.02 if Current signal AII1.02 is set in the 5.5.1 menu and Pressure control is selected in the 5.4.2 menu → p1, p2 gauge or vacuum pressure version, if Pressure control is selected in the 5.4.2 menu → dp, if Pressure control is selected in the 5.4.2 menu

External speed control ─

■

Target value: → Via bus, if the activation bit is set → Via AII1.02 if Current signal AII1.02 is set in the 5.5.1 menu

External values control ─

Target value: → Via bus, if the activation bit is set → Via parameters in the 5.4.3 External values control menu

─

Actual value: → Via AII1.02 if Current signal AII1.02 is set in the 5.5.1 menu

Locking the operating modes:

8.6.1

■

The Fixed speed and Pressure control operating modes can always be selected, regardless of the setting of the AII1.02 current signal

■

External speed control operating mode can be only selected when the AII1.02 external ana‐ logue output is active and the Speed variable type is set

■

External values control operating mode can only be selected when the AII1.02 external ana‐ logue input is active and the Other variable type is set. If the operating mode can be selected, the system displays the 5.4.3 External values control menu

■

Settings in the 5.5.1 Current signal AII1.02 menu are only possible when the signal is not used in the currently selected operating mode.

Current signal AII1.02 The machine can be controlled by a current signal at the AII1.02 analogue input. This current sig‐ nal may represent the Pressure, Speed and Other values. For the Other value, you can set signal scale and its resolution. Locking the AII1.02 current signal: ■

Precondition

You can deactivate or modify AII1.02 only when the AII1.02 current input is not actually used in a control mode. ─

Neither External speed control nor External values control operating mode are set.

─

Pressure control and AII1.02 are not set as source.

Access level 2 is activated. The operating mode is displayed. The Fixed speed or Pressure control mode is set in the 5.4 menu.

92

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.6

Operating modes in frequency-controlled machines

1. Open the 5.5.1 menu. 2. Use «Up» or «Down» to select the AII1.02 line. 400mbar

08:15AM

80° C

Menu

5.5.1 Current signal AII1.02 AII1.02

☐

Value type

Header Active line

Other

Decimal places

1

Unit

bar

4mA

0.40bar

20mA

1.0bar

3. Press «Enter». The check box AII1.02 will flash. 4. Press the «Up» key. The check box is activated. 5. Press «Enter». The setting is applied. 6. If necessary, specify settings for Value type, Decimal places, Unit, Scaling 4mA / 20mA. 7. Press «Escape» repeatedly to leave this menu. Result

8.6.2 Precondition

The function Current signal AII1.02 is activated. The machine can be controlled by an analogue current signal at the AII1.02 input.

Setting the operating mode Access level 2 is activated. The operating mode is displayed. AII1.02 current signal is set, see chapter 8.6.1 1. Open the 5.4 menu. 400mbar

08:15AM

80° C

Header

5.4 Operating modes

Menu

Fixed speed

Currently set operating mode

-----------------------------▶1 Fixed speed

Submenu

▶2 Pressure control

Submenu

▶3 External values control

Submenu

------------------------------

2. Use «Up» or «Down» to select the topmost line. 3. Press «Enter». The setting mode is active. The currently set language flashes. 4. Use «Up» or «Down» to set the required operating mode. 5. Press «Enter». The setting is applied.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

93

8

Initial Start-up

8.6

Operating modes in frequency-controlled machines

6. Use «Up» or «Down» to configure the details for the set operating mode. Open the required sub-menus 1–3. 7. Press «Enter». The setting mode is active. 8. Enter settings. 9. Press «Escape» repeatedly to leave this menu. Result

8.6.3

The currently selected operating mode is displayed in the 5.4 menu.

Constant speed In the Fixed speed operating mode, the machine runs with a set target speed for the blower block. The target speed can be freely selected in the range between the minimum and maximum permis‐ sible blower block speed and affects only the LOAD operating mode. 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 menu. 2. Press «Enter». The currently set language flashes. 400mbar

08:15AM

80° C

Header

5.4 Operating modes

Menu

Fixed speed

Currently set operating mode

-----------------------------▶1 Fixed speed

Submenu

▶2 Pressure control

Submenu

▶3 External values control

Submenu

------------------------------

3. Use «Up» or «Down» to set the Fixed speed operating mode. 4. Press «Enter». The setting is applied. 5. Use «Up» or «Down» to select the ▶1Fixed speed line. 6. Press «Enter». The 5.4.1 Fixed speed menu is displayed.

94

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.6

Operating modes in frequency-controlled machines

7. Use «Up» or «Down» to select the Set speed line. 400mbar

08:15AM

80° C

Header Menu

5.4.1 Fixed speed block speed n_min

500/min

n_max

3600/min ------------------------------

Set speed

1760/min

current

1750/min

Active line

8. Press «Enter». The setting mode is active. 9. Use «Up» or «Down» to set the Set speed value. 10. Press «Enter». The setting is applied. Result

The Fixed speed mode is set. Pressure peaks caused by an excessively fast run-up of the speed ➤ Set the change speed for the speed (see chapter 8.6.7).

8.6.4

Pressure control When the machine runs in Pressure control operating mode, the frequency converter automatically compensates for deviations between the target pressure and the actual pressure by changing the speed of the drive motor (direct) 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 the system pressure within the regulating range of the machine between minimum and maximum flow rate and minimum and maximum speed.

8.6.4.1

Setting the controlled variable In the 5.4.2 Pressure control menu, select the signal for the Source actual pressure parameter that the system uses to regulate:

Precondition

■

p1 (inlet pressure)/p2 (discharge pressure)

■

dp (differential pressure)

■

AII1.02 (Current signal AII1.02)

Access level 2 is activated. 1. Open the 5.4.2 menu. 2. Use «Up» or «Down» to select the Source actual pressure line.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

95

8

Initial Start-up

8.6

Operating modes in frequency-controlled machines

3. Press «Enter». The setting mode is active. 400mbar

08:15AM

80° C

Menu

5.4.2 Pressure control Source actual pressure

p1,p2

Source set pressure

p1,p2

Local set pressure KP KI

Header Active line

1.0bar 1.0rpm / mbar

1.00rpm / (mbar *s)

Set pressure rise time

0s

4. Select the required source with «Up» or «Down». 5. Press «Enter». The setting is applied. 6. Press «Escape» repeatedly to leave this menu. Result

The source for the actual pressure is specified.

8.6.4.2

Setting the required working pressure A PI controller with anti-wind-up reset and upstream target value delay is used for controlling the pressure. The speed calculated by the PI controller is limited to the minimum and maximum speeds permissi‐ ble for the specific blower block. The difference of the speed upstream or downstream of the speed limitation is used for the correction 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 target pressure of 0 bar starts to rise to the target pressure set in the menu. The effective target pressure rises linearly. The target pressure is limited by the maximum working pressure of the machine.

Precondition

Access level 2 is activated. 1. Open the 5.4.2 menu. 2. Use «Up» or «Down» to select the Local set pressure line. 3. Press «Enter». The setting mode is active. 400mbar

08:15AM

80° C

Menu

5.4.2 Pressure control Source actual pressure

p1,p2

Source set pressure

p1,p2

Local set pressure KP KI

Header

1.0bar

Active line

1.0rpm / mbar 1.00rpm / (mbar *s)

Set pressure rise time

0s

4. Use «Up» or «Down» to set the value for Local set pressure.

96

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.6

Operating modes in frequency-controlled machines

5. Press «Enter». The setting is applied. 6. Press «Escape» repeatedly to leave this menu. Result

The target pressure is set. ➤ Adjust the target pressure rise time as required.

8.6.4.3

Setting the target pressure rise time The target pressure is increased linear to prevent the controller output from immediately reaching the full speed. This gives the system time to build up the actual pressure. If the full target pressure would be instantly used, the system and hence the actual pressure could overcompensate. To avoid an over-compensation of the actual pressure during machine start, you can set a delay beyond the target pressure rise time (0 s to 99 s). The target pressure delay is inactive if 0 s is set as target pressure rise time.

Precondition

Access level 2 is activated. 1. Open the 5.4.2 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

5.4.2 Pressure control Source actual pressure

p1,p2

Source set pressure

p1,p2

Local set pressure KP KI

Header Menu

1.0bar 1.0rpm / mbar

1.00rpm / (mbar *s)

Set pressure rise time

60s

Active line

4. Use «Up» or «Down» to set the value for Set pressure rise time. 5. Press «Enter». The setting is applied. 6. Press «Escape» repeatedly to leave this menu. Result

The target pressure rise time is set.

8.6.4.4

Setting the proportional and integral amplification Set the following values for the target pressure. Setting the KP (proportional amplification) and KI (integral amplification) values is used to activate the PI controller and is performed empirically.

Precondition

Access level 2 is activated. Starting value KP: 0.1 rpm / mbar Starting value KI: 0.01 rpm / (mbar *s)

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

97

8

Initial Start-up

8.6

Operating modes in frequency-controlled machines

1. Open the 5.4.2 menu. 2. Use «Up» or «Down» to select the KP line. 3. Press «Enter». The setting mode is active. 400mbar

08:15AM

80° C

5.4.2 Pressure control Source actual pressure

p1,p2

Source set pressure

p1,p2

Local set pressure KP KI

Header Menu

1.0bar 1.0rpm / mbar

Active line

1.00rpm / (mbar *s)

Set pressure rise time

0s

4. Press «Up» to incrementally increase the value for KP and to slightly change the actual pres‐ sure until the system (pressure) continuously compensates. 5. Use «Down» to reduce the KP value to approximately 40 - 50 % of the currently set value. 6. Press «Enter». The setting is applied. 7. Use «Up» or «Down» to select the KI line. 8. Press «Enter». The setting mode is active. 400mbar

08:15AM

80° C

Menu

5.4.2 Pressure control Source actual pressure

p1,p2

Source set pressure

p1,p2

Local set pressure KP KI

Header

1.0bar 1.0rpm / mbar

1.00rpm / (mbar *s)

Set pressure rise time

Active line

0s

9. Press «Up» to incrementally increase the value for KI until the system (pressure) continuously compensates. 10. Use «Down» to reduce the KI value to approximately 70 - 80 % of the currently set value. 11. Press «Enter». The setting is applied. 12. Press «Escape» repeatedly to leave this menu. Result

8.6.5

The proportional and integral amplification are set.

External speed definition If the machine runs in External speed control operating mode, the speed of the drive motor (direct) and the blower block (indirect) are regulated by an external analog signal in the programmed speed range between nmin and nmax according to the machine's design. Use the 5.5.1 Current signal AII1.02 menu to set the scaling of the 4–20 mA signal. The galvanic decoupling of the signal is performed via a buffer amplifier installed in the control cabinet.

98

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

Precondition

8

Initial Start-up

8.6

Operating modes in frequency-controlled machines

Access level 2 is activated. The operating mode is displayed. The electrical connection via -X16: 5 (+) and -X16: 6 (−) has been made (external analog signal). 1. Open the 5.5.1 menu. 2. Use «Up» or «Down» to select the 4mA line. 400mbar

08:15AM

80° C

Header Menu

5.5.1 Current signal AII1.02 AII1.02

☑

Value type

Speed

Decimal places

0

Unit

1/min

4mA

1500/min

20mA

2000/min

Active line

3. Press «Enter». The setting mode is active. 4. Use «Up» or «Down» to set the speed. 5. Press the «Enter» key. The setting is applied. 6. Adjust the switching differential for the 20mA parameter in the same manner. Result

The External speed control mode is set. Pressure peaks caused by an excessively fast run-up of the speed ➤ Set the change speed for the speed (see chapter 8.6.7).

8.6.6

Control with external variable You can use up to two controllers in External values control operating mode. This variable is dis‐ played as a percentage with adjustable number of decimal places (e.g., the measured value for oxygen content). The two-point controller always acts on load control. The two-point controller is activated in the 5.4.3.1 Controller settings menu with checkbox Load control). The two Load on and Load off parameters affect only the two-point control. In frequency-controlled machines, you automatically activate the PI controller when you preselect the External values control operating mode. It controls the actual value which is captured with the AII 1.02 current signal. Speed is the setting variable in this case. You can specify the target value in the 5.4.3.1Controller settings menu or via bus after you have set the activation bit XBS49=1 (see process map): 7_7601_BLOW_PA). You configure only the PI controller in the 5.4.3.1Controller settings menu. Using a two-point controller, you can influence the load command of the blower depending on the external value. Target value pairs xA and xB are available for this purpose. Each target value pair includes a switching-on threshold Load on and a switching-off threshold Load off. Both target value pairs are used depending on the set operating mode. In addition to off, the following operating modes are available:

No.: 901700 10 E

■

xA (permanently)

■

xB (permanently)

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

99

8

Initial Start-up

8.6

Operating modes in frequency-controlled machines

■

xA/xB Clock

■

xA/xB SC2

■

xA/xB RC

■

xA/xB Load balancing

In operating mode xA/xB Clock the target value is switched via a separate timer with 20 switching points. You set the timer in the 5.4.3.2xA/xB Clock menu. Please note the minimum run time for limiting the starting frequency (see chapter 9.1.1). Operating mode xA/xB SC2 is a master/slave operating mode. First of all, the master/slave com‐ munication (see chapter 8.7.4), and the remote control operating mode (see chapter 8.2.13) must be activated. This operating mode is intended for the slave. The slave uses xA, if the master uses xB and vice versa. In the xA/xB RC operating mode, it switches between xA and xB with a signal to the digital input. Set the digital input in the 5.4.3External values control menu. Also, the remote control operating mode is activated. In the xA/xB Load balancing operating mode, the master/slave communication and the remote con‐ trol operating mode is activated. This operating mode is only used for the master. The master pur‐ sues the set target. Set a maintenance hour offset for this purpose. Depending on the number of hours until the next maintenance, the target value is switched between xA/xB. The blower with the higher number of hours until the next maintenance, runs at xA. All operating modes have in common that the target value pair xA is used in the event of an error (faulty I/O parametrisation or communication malfunction). For the master/slave operating modes, xA is used if the partner is currently not operational. In addition, the target value pair can be switched by means of the bus. Use the activation bit “xBS30” and the selection bit “xBS31“ (0 = xA, 1 = xB) for this purpose. Precondition

Access level 2 is activated. The remote control operating mode is activated (see chapter 8.2.13) The operating mode is displayed. The Other variable type is set and the Current signal AII1.02 check box is activated in the 5.5.1 menu 1. Open the 5.4 menu. 2. Press «Enter». The currently set language flashes. 400mbar

08:15AM

80° C

Header

5.4 Operating modes

Menu

Fixed speed

Currently set operating mode

▶1 Fixed speed

Sub-menu

▶2 Pressure control

Sub-menu

▶3 External values control

Sub-menu

-----------------------------Ramp up time

3. Use «Up» or «Down» to set the External values control operating mode. 4. Press «Enter». The setting is applied.

100

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.6

Operating modes in frequency-controlled machines

5. Use «Up» or «Down » to select the ▶3 External values control line. 6. Press «Enter». The 5.4.3 External values control menu is displayed. 400mbar

08:15AM

80° C

Header Menu

5.4.3 External values control ▶1 Controller settings Load control off ------------------------------

active line

xA Load on

40%

7. Use the «Up» or «Down» keys to select the Load control line. 8. Press the «Down» key. 9. Press «Enter». The currently active operating mode flashes. 10. Use «Up» or «Down» to set the required operating mode for the Load control. 11. Press «Enter». The setting is applied. 12. Use the «Up» or «Down» keys to select the Load on line. 13. Press «Enter». The setting mode is active. 14. Use «Up» or «Down» to set the percentage value for the cut-in threshold. 15. Press «Enter». The setting is applied. 16. Set the percentage value for Load off in the same manner. 17. Press «Escape» repeatedly to leave this menu. Result

The load control of the machine is controlled by the measured value of the external variable.

8.6.6.1

Controller settings in frequency-controlled machines 1. Open the 5.4.3.1 menu. 400mbar

08:15AM

80° C

Menu

5.4.3.1 Controller settings KP KI

1rpm/%

active line

10rpm/s/%

Set value

0%

Actual value

0%

Set value ramp-up time

Header

0s

2. Set the control parameters for the PI controller. See chapter 8.6.4 Pressure control for the set‐ ting.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

101

8.6.7

8

Initial Start-up

8.7

Setting the machine for master control operation

SFC acceleration time In frequency-controlled machines, you can set the change speed for the speed in the Fixed speed and External speed control operating modes. This will prevent pressure peaks caused by an ex‐ cessively fast acceleration of the speed.

Ramp up time is the time from minimum speed to reaching the machine-specific maximum speed. The values for Ramp up time and Ramp down time: which can be set at SIGMA CONTROL 2 are added to the similar parameters that have already been set in the FC. Precondition

Access level 2 is activated. The operating mode is displayed. 1. Open the 5.4 menu. 400mbar

08:15AM

80° C

Header Menu

5.4 Operating modes ▶3 External values control -----------------------------Ramp up time 7s

Active line

Ramp down time: 7s

2. Use «Up» or «Down» to select the Ramp up time line. 3. Press «Enter». The setting mode is active. 4. Use «Up» or «Down» to set the time in seconds. You can set this parameter in a range of 0–600 seconds. 5. Press the «Enter» key. The setting is applied. 6. Set the value for the Ramp down time: in the same manner. 7. Press «Escape» repeatedly to leave this menu. Result

8.7 8.7.1

The change speed for the speed is set.

Setting the machine for master control operation Overview of the different master operating modes The controller offers several possibilities to work together with other controllers:

102

Method

Description

Section

SIGMA AIR MANAGER 4.0 mode

You must modify the settings in SIGMA CONTROL 2 for the op‐ eration via SIGMA NETWORK using the KAESER SIGMA AIR MANAGEMENT SYSTEM (SIGMA AIR MANAGER 4.0).

8.7.2

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.7

Setting the machine for master control operation

Method

Description

Section

Master control via For example, the controller (and therefore the machine) receives 8.7.3 communication module the instruction LOAD or IDLE via the PROFIBUS master (e.g. SIGMA AIR MANAGER).

Tab. 64 8.7.1.1

Master control via re‐ mote contact

The machine is controlled by signals from a master controller.

8.5.4

Master control of two machines in master/ slave operation

The two SIGMA CONTROL 2 controllers operate as master and slave.

8.7.4

Overview of the different master controllers Priorities in master control operation These priorities are valid in master control operation:

8.7.2

■

Bus (top priority)

■

External contacts (load contact)

■

Master/slave operation

■

Timer control (lowest priority)

SAM 4.0 mode You must modify the settings in SIGMA CONTROL 2 for the operation via SIGMA NETWORK us‐ ing, for example, the KAESER SIGMA AIR MANAGER 4.0 (SAM 4.0).

Precondition

SIGMA CONTROL 2 is connected to SAM 4.0 via SIGMA NETWORK and ready for operation (see the SAM 4.0 operating manual in the chapter “Installation”) Network pressure pB is set as the pressure for the “SAM 4.0 manual mode". Access level 2 is activated. The remote control is activated (see chapter 8.2.13) Setting the IP configuration 1. Open the 8.1.1 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

169.254.100.103

active line, factory setting

Subnet mask

255.255.000.000

Gateway

169,254,100.97

DNS Server 1

169,254,100.97

DNS Server 2

169,254,100.97

Restart network

☐

3. Set the IP address for SIGMA CONTROL 2 using the following pattern: 169.254.100.(SAM 4.0 machine number +102) (for the setting see chapter 8.2.14).

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

103

8

Initial Start-up

8.7

Setting the machine for master control operation

Setting SAM 4.0 mode The IP address for SAM 4.0 has been set on SIGMA CONTROL 2 at the factory: 169.254.100.100 and must not be changed. The same applies to Port 2000. 1. Open the 8.1.2.2 menu. 2. Use «Up» or «Down» to select the SAM 4.0 active: line. 400mbar

08:15AM

80° C

Header Menu

8.1.2.2 SAM 4.0 Status

Counter 0 No error ------------------------------

SAM 4.0 active:

☑

Active line

Send IP address

:

169.254.100.100

3. Press «Enter». The SAM 4.0 active: check box flashes. 4. Press «UP». The check box is activated. 5. Press «Enter». The setting is applied. 6. Press the «DOWN» key. 7. Press «Enter». The currently active operating mode flashes. 8. Use «Up» or «Down» to set the Send/Receive value. 400mbar

08:15AM

80° C

Header Menu

8.1.2.2 SAM 4.0 Status

Counter 0 No error ------------------------------

SAM 4.0 active:

☑ Send/Receive

IP address

:

Active line

169.254.100.100

9. Press the «Enter» key. The setting is applied.

104

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.7

Setting the machine for master control operation

10. Use «Up» or «Down» to select the Starttd line. 400mbar

08:15AM

80° C

Menu

8.1.2.2 SAM 4.0 IP address

:

Port

Header

169.254.100.100 :

2000

······························ Communication error :

☑

Start td:

active line

15s

Timeout :

5s

☑

11. Press «Enter». The setting mode is active. 12. Use «Up» or «Down» to set the Start td value to 30 s. 400mbar

08:15AM

80° C

Menu

8.1.2.2 SAM 4.0 IP address Port

Header

:

169.254.100.100 :

2000

······························ Communication error :

☑

Start td: Timeout :

active line

30s 5s

☑

13. Press the «Enter» key. The setting is applied. Result

SIGMA CONTROL 2 communicates with SAM 4.0 via SIGMA NETWORK. The communication is working smoothly when neither SIGMA CONTROL 2 nor SAM 4.0 report any communication fault.

8.7.2.1

Reaction in the event of a communication malfunction After switching on the power supply, monitoring for communication malfunctions is suppressed for a period of time which can be defined by means of the Start td parameter. The setting depends on the time passing at the bus master between return of voltage and start of communication via the bus. For the communication with SAM 4.0, the value of Start td must be set 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 CONTROL 2 returns a communication malfunction if the value does not change for a time longer than set (Timeout). Monitoring for communication malfunction can be activated if needed. For this purpose, the Send/Receive option must be set for the data exchange. Activate the Communication error check box to enable monitoring for communication malfunctions.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

105

8

Initial Start-up

8.7

Setting the machine for master control operation

400mbar

08:15AM

80° C

Menu

8.1.2.2 SAM 4.0 IP address

:

Port

Header

169.254.100.100 :

2000

······························ Communication error :

☑

Start td Timeout :

active line

30s 5s

☑

Settings for connection to SAM 4.0. Parameters

Factory setting

Check box Communication error

Check box ☑ activated

Start td

30 s

Timeout

5s

Check box Timeout

Check box ☑ activated

1)

Set value 1)

Prerequisite: The Send/Receive option has been set

Tab. 65

Parameters for monitoring for communication malfunction

8.7.3

Master control via communication module

8.7.3.1

Overview SIGMA CONTROL 2 can use an optional communication module to communicate with a master controller or a control centre. Depending on the selected machine type, this communication module has been factory-installed or can be added with a retrofit kit. In both cases, the communication module must be set for the actual application in the menu of SIGMA CONTROL 2. SIGMA CONTROL 2 supports the following KAESER communication modules: ■

PROFIBUS (Option C41)

■

Modbus (Option C42)

■

DeviceNet (Option C43)

■

Modbus TCP (Option C44)

■

PROFINET (Option C45)

■

EtherNet/IP (Option C50)

The following requirements must be met before commissioning the communication module:

106

■

The communication module is correctly installed and connected

■

The bus wiring to the bus master is ready

■

The machine is parametrised as a slave in the bus master

■

The bus master is operational

■

The machine's voltage supply is activated

■

The machine has been activated with «ON»

■

OFC/SFC: The Constant pressure control operating mode is set

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.7

Setting the machine for master control operation

When all requirements are met, perform the commissioning process for each communication module as shown below. The following description concerning the parametrisation refers to current SIGMA CONTROL 2 software versions. Please contact KAESER SERVICE if the settings in the machine deviate. 8.7.3.2

Commissioning the PROFIBUS module Machine 1. Open the 8.2 menu. 2. Activate the Com-Module Start check box. The communication module is activated. The system detects the communication module type and displays it in the Type line. 3. Select the data exchange direction: ► SIGMA CONTROL 2 ⇆ Bus master (SIGMA CONTROL 2 sends process data and receives control data): Send/Receive or Master: Set Com-Module. ► SIGMA CONTROL 2 → Bus master (SIGMA CONTROL 2 sends process data): Send or Master: Setting SAM/JSON-RPC. For connection to a SIGMA AIR MANAGER: Send/Receive or Master: Set Com-Module. 4. Set the slave address (Slave No.:). The permissible address length is between 3 and 126. For connection to a SIGMA AIR MANAGER: Slave address = compressor number + 102. 5. Set the required reaction in the event of a bus fault (see next chapter, “Reaction in a PROFI‐ BUS bus fault”). 6. Start the communication module with the set parameters. Activate the Reset check box. The communication module is started with the set parameters. 7. Time-out at bus fault is activated. Bus communication is now monitored. The number behind Status Counter (Run) continuously changes during communication. 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 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 plus 30 s SIGMA AIR MANAGER with SIGMA AIR CONTROL plus 40 s

Tab. 66

Setting theStarttd parameter SIGMA CONTROL 2 monitors the bus communication at log level (PROFIBUS). If there is a check box behind Communication error, this monitoring in the Send mode can be switched off by deacti‐ vating the check box.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

107

8

Initial Start-up

8.7

Setting the machine for master control operation

In Send/Receive 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 without change. SIGMA CONTROL 2 returns a bus alarm if the bit does not change for a time longer than set (Timeout). Activate monitoring by setting a check mark ☑. For the connection to a SIGMA AIR MANAGER, set the following:

Tab. 67

Parameters

Factory setting

Set value

Timeout

5s

5s

Monitoring

Check box ☑ activated

Check box ☑ activated

Setting the Timeout parameter ➤ Enter the required settings, as described above.

8.7.3.3

Commissioning the Modbus module Machine

Precondition

Access level 2 is activated. The network parameters are known. Request the required information from your IT department. 1. Open the 8.2 menu. 2. Activate the Com-Module Start check box. The communication module is activated. The system detects the communication module type and displays it in the Type line. 3. Select the data exchange direction: ► SIGMA CONTROL 2 ⇆ Bus master (SIGMA CONTROL 2 sends process data and receives control data): Send/Receive or Master: Set Com module. ► SIGMA CONTROL 2 → Bus master (SIGMA CONTROL 2 sends process data): Send or Master: Setting SAM/JSON-RPC. 4. Set the slave address (Slave No.:). 5. Set the required reaction in the event of a bus fault (see next chapter, “Reaction in a PROFI‐ BUS bus fault”). 6. Set the bus parameters. Set the baud rate, number of stop bits, parity, time-out and mode as required by the bus mas‐ ter. See chapter 2 for the setting options and the default settings. 7. Start the communication module with the set parameters: 8. Activate the Reset check box. The communication module is started 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 during communication. Reaction in a bus fault Only for machines.

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Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

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8

Initial Start-up

8.7

Setting the machine for master control operation

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 between return of voltage and start of communication via the bus.

Tab. 68

Parameters

Factory setting

Start td

15 s

Set value

Setting theStarttd parameter SIGMA CONTROL 2 monitors the bus communication at log level (Modbus). If there is a check box behind Communication error, this monitoring in the Send mode can be switched off by deactivating the check box. In Send/Receive 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 without change. SIGMA CONTROL 2 returns a bus alarm if the bit does not change for a time longer than set (Timeout). Activate the check box to enable monitor‐ ing.

Tab. 69

Parameters

Factory setting

Timeout

5s

Monitoring

Check box ☑ activated

Set value

Setting the Timeout parameter ➤ Enter the required settings, as described above.

8.7.3.4

Commissioning the Modbus TCP module Machine

Precondition

Access level 2 is activated. The network parameters are known. Request the required information from your IT department 1. Open the 8.2 menu. 2. Activate the Com-Module Start check box. The communication module is activated. The system detects the communication module type and displays it in the Type line. 3. Select the data exchange direction: ► SIGMA CONTROL 2 ⇆ Bus master (SIGMA CONTROL 2 sends process data and receives control data): Send/Receive or Master: Set Com module. ► SIGMA CONTROL 2 → Bus master (SIGMA CONTROL 2 sends process data): Send or Master: Setting SAM/JSON-RPC. 4. Set the required reaction in the event of a bus fault (see next chapter, “Reaction in a PROFI‐ BUS bus fault”). 5. Set IP-Parameter as described below.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

109

8

Initial Start-up

8.7

Setting the machine for master control operation

Use DHCP

Do not use DHCP

1. Activate the DHCP check box.

1. Deactivate the DHCP check box.

2. Activate the Use IP settings check box to apply the IP-Parameter. The communication module is started with the set parameters.

3. Set Subnet mask.

Communication with the bus master is run‐ ning. Time-out at bus fault is activated. Bus communication is now monitored. The number behind Status Counter (Run) con‐ tinuously changes during communication.

2. Set IP address. 4. Set the Gateway address. 5. DNS Server 1-Setting address (optional). 6. DNS Server 2-Setting address (optional). 7. Activate the Use IP settings check box to apply the IP-Parameter. The communication module is started with the set parameters. Communication with the bus master is run‐ ning. Time-out at bus fault is activated. Bus communication is now monitored. The number behind Status Counter (Run) con‐ tinuously changes during communication.

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 between return of voltage and start of communication via the bus.

Tab. 70

Parameters

Factory setting

Start td

15 s

Set value

Setting theStarttd parameter SIGMA CONTROL 2 monitors the bus communication at log level (Modbus TCP). If there is a check box behind Communication error, this monitoring in the Send mode can be switched off by deactivating the check box. In Send/Receive 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 without change. SIGMA CONTROL 2 returns a bus alarm if the bit does not change for a time longer than set (Timeout). Activate the check box to enable monitor‐ ing.

Tab. 71

Parameters

Factory setting

Timeout

5s

Monitoring

Check box ☑ activated

Set value

Setting the Timeout parameter ➤ Enter the required settings, as described above.

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Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8.7.3.5

8

Initial Start-up

8.7

Setting the machine for master control operation

Commissioning the DeviceNet module Machine

Precondition

Access level 2 is activated. The network parameters are known. Request the required information from your IT department. 1. Open the 8.2 menu. 2. Activate the Com-Module Start check box. The communication module is activated. The system detects the communication module type and displays it in the Type line. 3. Select the data exchange direction: ► SIGMA CONTROL 2 ⇆ Bus master (SIGMA CONTROL 2 sends process data and receives control data): Send/Receive or Master: Set Com module. ► SIGMA CONTROL 2 → Bus master (SIGMA CONTROL 2 sends process data): Send or Master: Setting SAM/JSON-RPC. 4. Set the slave address (Slave No.:). 5. Set the required reaction in the event of a bus fault (see next chapter, “Reaction in a PROFI‐ BUS bus fault”). 6. Start the communication module with the set parameters. 7. Activate the Reset check box. The communication module is started with the set parameters. Communication with the bus master is running. 8. Time-out at bus fault is activated. Bus communication is now monitored. The number behind Status Counter (Run) continuously changes during communication. Change the baud rate at the bus master during operation. ➤ Activate the Reset check box to synchronise the communication module. 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 between return of voltage and start of communication via the bus.

Tab. 72

Parameters

Factory setting

Start td

15 s

Set value

Setting theStarttd parameter SIGMA CONTROL 2 monitors the bus communication at log level (SIGMA CONTROL 2). If there is a check box behind Communication error, this monitoring in the Send mode can be switched off by deactivating the check box. In Send/Receive 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 without change. SIGMA CONTROL 2 returns a bus alarm if the bit does not change for a time longer than set (Timeout). Activate the check box to enable monitor‐ ing.

No.: 901700 10 E

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111

Tab. 73

8

Initial Start-up

8.7

Setting the machine for master control operation

Parameters

Factory setting

Timeout

5s

Monitoring

Check box ☑ activated

Set value

Setting the Timeout parameter ➤ Enter the required settings, as described above.

8.7.3.6

Commissioning the PROFINET module Machine

Precondition

Access level 2 is activated. The network parameters are known. Request the required information from your IT department. 1. Open the 8.2 menu. 2. Activate the Com-Module Start check box. The communication module is activated. The system detects the communication module type and displays it in the Type line. 3. Select the data exchange direction: ► SIGMA CONTROL 2 ⇆ Bus master (SIGMA CONTROL 2 sends process data and receives control data): Send/Receive or Master: Set Com module. ► SIGMA CONTROL 2 → Bus master (SIGMA CONTROL 2 sends process data): Send or Master: Setting SAM/JSON-RPC. 4. Enter the station name. By means of the station name the bus master identifies SIGMA CONTROL 2. 5. Remove the check mark after Use IP settings to deactivate the IP settings. The IP address is defined by the bus master and only shown on SIGMA CONTROL 2. 6. Set the required reaction in the event of a bus fault (see next chapter, “Reaction in a PROFI‐ BUS bus fault”). 7. Start the communication module with the set parameters: 8. Activate the Reset check box. The communication module is started with the set parameters. Communication with the bus master is running. The IP address defined by the bus master is shown on SIGMA CONTROL 2. 9. Time-out at bus fault is activated. Bus communication is now monitored. The number behind Status Counter (Run) continuously changes during communication. 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 between return of voltage and start of communication via the bus.

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Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8

Initial Start-up

8.7

Setting the machine for master control operation

Parameters

Factory setting

Set value

Start td

15 s

SIGMA AIR MANAGER without SIGMA AIR CONTROL plus 30 s SIGMA AIR MANAGER with SIGMA AIR CONTROL plus 40 s

Tab. 74

Setting theStarttd parameter SIGMA CONTROL 2 monitors the bus communication at log level (PROFINET). If there is a check box behind Communication error, this monitoring in the Send mode can be switched off by deacti‐ vating the check box. In Send/Receive 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 without change. SIGMA CONTROL 2 returns a bus alarm if the bit does not change for a time longer than set (Timeout). Activate the check box to enable monitor‐ ing.

Tab. 75

Parameters

Factory setting

Timeout

5s

Monitoring

Check box ☑ activated

Set value

Setting the Timeout parameter ➤ Enter the required settings, as described above.

8.7.3.7

Commissioning the EtherNet/IP-Module Machine

Precondition

Access level 2 is activated. The network parameters are known. Request the required information from your IT department 1. Open the 8.2 menu. 2. Activate the Com-Module Start check box. The communication module is activated. The system detects the communication module type and displays it in the Type line. 3. Select the data exchange direction: ► SIGMA CONTROL 2 ⇆ Bus master (SIGMA CONTROL 2 sends process data and receives control data): Send/Receive or Master: Set Com module. ► SIGMA CONTROL 2 → Bus master (SIGMA CONTROL 2 sends process data): Send or Master: Setting SAM/JSON-RPC. 4. Set the required reaction in the event of a bus fault (see next chapter, “Reaction in a PROFI‐ BUS bus fault”). 5. Set IP-Parameter as described below.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

113

8

Initial Start-up

8.7

Setting the machine for master control operation

Use DHCP

Do not use DHCP

1. Activate the DHCP check box.

1. Deactivate the DHCP check box.

2. Activate the Use IP settings check box to apply the IP-Parameter. The communication module is started with the set parameters.

3. Set Subnet mask.

Communication with the bus master is run‐ ning. Time-out at bus fault is activated. Bus communication is now monitored. The number behind Status Counter (Run) con‐ tinuously changes during communication.

2. Set IP address. 4. Set the Gateway address. 5. DNS Server 1-Setting address (optional). 6. DNS Server 2-Setting address (optional). 7. Activate the Use IP settings check box to apply the IP-Parameter. The communication module is started with the set parameters. Communication with the bus master is run‐ ning. Time-out at bus fault is activated. Bus communication is now monitored. The number behind Status Counter (Run) con‐ tinuously changes during communication.

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 between return of voltage and start of communication via the bus.

Tab. 76

Parameters

Factory setting

Start td

15 s

Set value

Setting theStarttd parameter SIGMA CONTROL 2 monitors the bus communication at log level (SIGMA CONTROL 2). If there is a check box behind Communication error, this monitoring in the Send mode can be switched off by deactivating the check box. In Send/Receive 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 without change. SIGMA CONTROL 2 returns a bus alarm if the bit does not change for a time longer than set (Timeout). Activate the check box to enable monitor‐ ing.

Tab. 77

Parameters

Factory setting

Timeout

5s

Monitoring

Check box ☑ activated

Set value

Setting the Timeout parameter ➤ Enter the required settings, as described above.

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Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

8.7.3.8

8

Initial Start-up

8.7

Setting the machine for master control operation

Activating the remote control ➤ Activate remote control see chapter 8.2.13.

Result

8.7.4

SIGMA CONTROL 2 remote control is activated.

Master control of two machines in master/slave operation Two machines with SIGMA CONTROL 2 work as master/slave in the same air network. The mas‐ ter controls the machine with the controller configured as slave. For both machines to work in redundancy operation, the electrical connections and the set‐ tings at both controllers must be identically created and configured. If two machines with SIGMA CONTROL 2 are to work in master-slave mode, their controllers must have the same software version. ➤ Follow the configuration steps as described in table 78:

Tab. 78 8.7.4.1

Controller

Procedure

Chapter

Both

Establishing the electrical connection

8.7.4.1

Both

Set IP addresses for Ethernet

8.7.4.2 and 8.7.4.3

Both

Setting the controller as master or slave

8.7.4.2 and 8.7.4.3

Both

Set the target pressures for both.

8.7.4.2 and 8.7.4.3

Slave

Activating the remote control

8.7.4.2 and 8.7.4.3

Both

Setting the load balancing

8.7.4.5

Master-slave settings Establishing the electrical connection You need the following accessories to create the network connection with SIGMA NETWORK or Ethernet: ■

SIGMA NETWORK cable (7.9679.0) or Ethernet cable with a maximum connection length of 100 m each

■

For each machine with SIGMA CONTROL 2: ─

■

Retrofit kit LAN RJ45 (7.5250.01870)

For connecting the machines to a network (LAN) or switch: ─

2x RJ45 plug (7.7628.1)

➤ Create the electrical connection according to the local condition. For more information, see the installation manual for the retrofit kit LAN RJ45 (7.5250.01870) Install the Ethernet cable Use a cross-linked Ethernet cable for the direct connection of two machines.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

115

Fig. 31

8

Initial Start-up

8.7

Setting the machine for master control operation

Direct connection of two SIGMA CONTROL 2 1 2 3

Controller machine 1 (Master mode) Ethernet interface X1 Ethernet cable, cross-linked

4 5

Controller machine 2 (Slave mode) Ethernet interface X1

➤ Install the Ethernet cable between the two machines. When you connect the machines to a network (LAN) or switch (when using KAESER CONNECT for example). ➤ Install the Ethernet cable from each machine to the LAN connection or switch. Connect the Ethernet cable with the machine For each machine: 1. Insert the Ethernet cable into the machine and the machine's control cabinet, using an EMC connection. 2. Lead the Ethernet cable through the cable ducts to SIGMA CONTROL 2. Use the wiring path in the 24V range (blue wiring) of the ducts. 3. Attach the RJ45-plug to the cable end. 4. Plug the RJ45 plug into the Ethernet interface X1 of the SIGMA CONTROL 2 until it latches. For connecting the machines to a network (LAN) or switch: Connect the Ethernet cable for each machine to the LAN connection or switch. 1. Attach the RJ45-plug to the cable end. 2. Plug the RJ45plug into the network socket until it latches. 8.7.4.2 Precondition

Setting the controller of machine 1 as master The electrical connection is made. Access level 2 is activated.

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Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

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8

Initial Start-up

8.7

Setting the machine for master control operation

Master IP configuration If the controllers of both machines are linked directly, they must be given different IP addresses. Example:

Precondition

■

IP addressController machine 1 (Master mode): 169.254.100.101

■

IP address Controller machine 2 (Slave): 169.254.100.102

The electrical connection is made. Access level 2 is activated. 1. Set IP address for the master see chapter 8.2.14,IP address see above example. The IP address of machine 1 (master) is set correctly. 2. Open the 8.1.2.1 menu. 3. Use «Up» or «Down» to select the Mode line. 4. Press «Enter». The setting mode is active. 5. Use «Up» or «Down» to set Machine 1 Master operating mode. 400mbar

08:15AM

80° C

Menu

8.1.2.1 SIGMA CONTROL 2 Status

Run

Header

1¦Error

0

-----------------------------Mode

:

Master

Port

:

2.001

Active line

······························ Communication partner

6. Press the «Enter» key. The setting is applied. 7. Use «Up» or «Down» to select the IP address line. 8. Press «Enter». The setting mode is active. 9. Set the IP address of the communication partner (slave, see above example). 10. Press «Enter». The IP address of machine 2 (slave) is set correctly. Setting the load balancing ➤ Setting the load balancing (see chapter 8.7.4.5). Result

The controller of machine 1 is set as master.

8.7.4.3

Setting the machine 2 controller as slave

Precondition

The electrical connection is made. Access level 2 is activated.

No.: 901700 10 E

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

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8

Initial Start-up

8.7

Setting the machine for master control operation

Slave IP configuration If the controllers of both machines are linked directly, they must be given different IP addresses. Example:

Precondition

■

IP addressController machine 1 (Master mode): 169.254.100.101

■

IP address Controller machine 2 (Slave): 169.254.100.102

The electrical connection is made. Access level 2 is activated. 1. Set IP address for the slave; see chapter 8.2.14, IP address see above example. The IP address of machine 2 (slave) is set correctly. 2. Open the 8.1.2.1 menu. 3. Use «Up» or «Down» to select the Mode line. 4. Press «Enter». The setting mode is active. 5. Use «Up» or «Down» to set Machine 2 Slave operating mode. 400mbar

08:15AM

80° C

Menu

8.1.2.1 SIGMA CONTROL 2 Status

Run

Header

1¦Error

0

-----------------------------Mode

:

Port

:

Slave

Active line

2.001

······························ Communication partner

6. Press the «Enter» key. The setting is applied. 7. Use «Up» or «Down» to select the IP address line. 8. Press «Enter». The setting mode is active. 9. Set the IP address of the communication partner (master, see above example). 10. Press «Enter». The IP address of machine 1 (master) is set correctly. Setting the load balancing ➤ Setting the load balancing (see chapter 8.7.4.5). Activating the remote control ➤ Activate remote control see chapter 8.2.13. Result

The remote control is activated. The controller of machine 2 is set as slave.

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Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

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8.7.4.4

8

Initial Start-up

8.7

Setting the machine for master control operation

Switching on both machines ➤ Press «ON» on both machines. The on LED lights green on both 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 operation). Load balancing is activated only on machine 1 (master).

Setting load balancing for machines 1 and 2 1. Open the 4.1 menu. 2. Use «Up» or «Down» to select the Load balancing line. 400mbar

08:15AM

80° C

Header

4.1 Load balancing Load balancing

☐

dt maintenance hours

5h

Maintenance Master

1h

Maintenance Slave

1h

Master state

ready

Slave state

ready

Active line with inactive check box

3. Press «Enter». The setting mode is active. 400mbar

08:15AM

80° C

Header

4.1 Load balancing Load balancing

☑

dt maintenance hours

5h

Maintenance Master

1h

Maintenance Slave

1h

Master state

ready

Slave state

ready

Active line with activated check box

4. Press the «Up» key. The check box is activated. 5. Press «Enter». The setting is applied. Result

No.: 901700 10 E

Load balancing is activated.

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

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8.8

8

Initial Start-up

8.8

Setting input and output signals

Setting input and output signals The controller's analogue and digital inputs and outputs can be used for customised messages and/or other functions. The various options are explained in the following chapters: ■

8.8.1: Output operational states of machine on digital outputs

■

8.8.2: Output input signals on the display

■

8.8.3: Switching 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 outputs can be found in the machine circuit diagram.

➤ Set the inputs and outputs as described below.

8.8.1

Output operational states of machine on digital outputs Important operational machine states can be made available as digital signals via floating contacts. Each output can be assigned only once. The following messages can be output:

Tab. 79 8.8.1.1

Message

Explanation

Output

Controller on

Controller is powered up

ON LOAD

The machine is running in LOAD mode

Collective error

Fault has occurred

Collective warning

Warning message has appeared

Assigned output signals DO-functions menu The requested message can be assigned to a free digital output (DOR orDOT).

Precondition

Access level 2 is activated. 1. Open the 5.10.1 menu. A menu containing a list of available messages and their assigned outputs is displayed. 400mbar

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Header

5.10.1 DO-functions

Menu

On load

Active line

DOR1.05

☐ ¦ Logic :

+

······························ Controller on DOR1.03

☐ ¦ Logic :

+

······························

8.8.1.2

Assigning a message to an output 1. Select the required message with the «Up» or «Down» keys.

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Initial Start-up

8.8

Setting input and output signals

2. Press the «Down» key once. Output DOR has been selected 3. Press «Enter». The output of the selected message flashes. 400mbar

08:15AM

80° C

Header Menu

5.10.1 DO-functions On load DOR1.05

ok

☐ ¦ Logic :

+

Active line with assigned output

······························ Controller on DOR1.03

☐ ¦ Logic :

+

······························

4. Select a free output with the «Up» or «Down» key. 5. Press «Enter». The setting is applied. 6. Press the «Right» key. 7. Press «Enter». The check box will flash. 8. Press «Up» key. The check box associated to the output is activated. 9. Press «Enter». If the message is correctly assigned to the output and activated, ok is displayed. 10. If necessary, set the Logic option. Result

A message about the operational state is now sent via the assigned digital output. You are missing an organised display of assigned output signals? ➤ Enter the selected output in table 7981.

8.8.2

Output input signals on the display In addition to the defined alarm and warning messages there are three further freely selectable in‐ put signals that can be used to display messages. A list of the alarm and warning messages is pro‐ vided in chapters 10.2 and 10.3. Please see the machine's wiring diagram for information on free inputs. An input signal can be classified as either a fault, a warning or an operational message. To sup‐ press any possible contact bounce or similar problems, the input signal can be delayed by an ad‐ justable 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 fault, the controller goes into the alarm state and shuts down the machine. Overview Use the External messages menu for specifying the settings.

No.: 901700 10 E

■

Enter the message text

■

Assign and activate the input

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8.8.2.1 Precondition

8

Initial Start-up

8.8

Setting input and output signals

■

Set the time delay

■

Setting the logic

■

Assign and activate the output

■

Selecting the message type

■

Activate the message.

External messages menu The electrical connection has been made. Access level 2 is activated. 1. Open the 5.10.2 menu. The External messages menu is displayed. 400mbar

08:15AM

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Header

5.10.2 External messages

Menu

▶1 External message 1

Active line with external message No. 1

▶2 External message 2 ▶3 External message 3

8.8.2.2

Enter the message text In the below example we select External message 1. 1. Use «Up» or «Down» to select the External message 1 line. 2. Press «Enter». The External message 1 menu is displayed. 400mbar

08:15AM

80° C

Header

5.10.2.1 External message 1

Menu

External message 1

Message text

DI1.06 td:

No input assigned

☐ 0s ¦ Logic :

+

DOR1.04

☐

Warning

☑

Logic Message type (operational, alarm, warning)

3. Press «Enter». The cursor is located at the first character of the message text. A column with alphanumeric characters is displayed. The selected character flashes. 4. Select the required character with the «Up» or «Down» keys. 5. Press the «Right» arrow. The cursor jumps to the next position of the message text. 6. Enter the remaining characters of the message text in the same manner.

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8

Initial Start-up

8.8

Setting input and output signals

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 select the DI line. 2. Press «Enter». The display for the currently set input flashes. 3. Use «Up» or «Down» to select the input. 4. Press «Enter». The setting is applied. 400mbar

08:15AM

80° C

Header

5.10.2.1 External message 1

Menu

External message 1

Message text

DI1.07

The output has been selected.

☐

td:

0s ¦ Logic :

+

DOR1.04

☐

Warning

☑

Logic Message type (operational, alarm, warning)

5. Press the «Right» key. 6. Press «Enter». The check box assigned to the input flashes. 7. Press the «Up» key. The check box is activated. 400mbar

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80° C

Header

5.10.2.1 External message 1

Menu

External message 1

Message text

DI1.07

Input selected

td:

ok ☑ 0s ¦ Logic :

+

DOR1.04

☐

Warning

☑

Logic Message type (operational, alarm, warning)

8. Press «Enter».

ok is displayed. The input is assigned and activated. 8.8.2.4

Set the time delay The delay can be set between 0 and 600 seconds. The delay is counted down from 600 in 1 second increments with the «DOWN» key and counted upwards from 0 (zero) in 1 second increments with the «UP» key. 1. Use «Up» or «Down» to select the td line.

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123

8

Initial Start-up

8.8

Setting input and output signals

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

Message text

DI1.07

Input selected

ok ☑

td:

0s ¦ Logic :

+

DOR1.04

☐

Warning

☑

set time delay td Message type (operational, alarm, warning)

3. Use «Up» or «Down» to set the time delay in seconds. 4. Press «Enter». Result

The td delay time has been set.

8.8.2.5

Setting the logic Possible logic settings Message at

Tab. 80

Sign

24 V

+

0V

-

Logic settings 1. Use «Up» or «Down» to select the td line. 2. Press the «Right» arrow. 3. Press «Enter». The control field Logic flashes. 4. Use «UP» or «Down» to set the desired behaviour, see table 80. 400mbar

08:15AM

80° C

Header

5.10.2.1 External message 1

Menu

External message 1

Message text

DI1.07

Input selected

ok ☑

td:

0s ¦ Logic :

+

DOR1.04

☐

Warning

☑

active line, set logic control field Message type (operational, alarm, warning)

5. Press «Enter». Result

For messages at 24 V, the logic is set with the + symbol.

8.8.2.6

Setting the message type 1. Select the message type line with the «Up» and «Down» keys.

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8

Initial Start-up

8.8

Setting input and output signals

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 message 1

Menu

External message 1

Message text

DI1.07

Input selected

ok ☑

td:

0s ¦ Logic :

+

DOR1.04

☐

Warning

☑

Example: Warning message type

4. Press «Enter». The message type is set. 8.8.2.7

Assign and activate the output 1. Use «Up» or «Down» to select the DOR line. 2. Press «Enter». The DOR output display flashes. 3. Select the output with the «Up» and «Down» keys. 4. Press «Enter». The setting is applied. 400mbar

08:15AM

80° C

Header

5.10.2.1 External message 1

Menu

External message 1

Message text

DI1.07

Input selected

ok ☑

td:

0s ¦ Logic : DOR1.04

☑

Output is selected and activated

Warning

☑

Example: Warning message type

5. Press the «Right» key. 6. Press «Enter». The check box assigned to the output flashes. 7. Press the «Up» key. The check box is activated. 8. Press «Enter». The output is assigned and activated. Result

No.: 901700 10 E

The signal at the DI digital input is available as External message 1 and as output signal at the selected DOR output.

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

125

8.8.3

8

Initial Start-up

8.8

Setting input and output signals

Switching and/or triggering messages with thresholds Some measured values of the controller can be used for customised messages and/or other switching functions. The following measured values are available: Measured value Explanation

Message #

p1

Threshold for pressure p1 (inlet pressure)

0092 O/W/A

p2

Threshold for pressure p2 (discharge pressure)

0093 O/W/A

T1

Threshold for temperature T1 (inlet temperature)

0094 O/W/A

T2

Threshold for temperature T2 (discharge temperature)

0095 O/W/A

T3

Threshold for temperature T3 (oil temperature at controlend (rotary screw blower))

0097 O

Output

0098 W 0097 A

Threshold for temperature T_S (temperature underneath sound enclosure)

T_S

0098 O 0099 W 0098 A

block speed 1)

Tab. 81

1)

Threshold for the airend speed

0096 O/W/A

Power switching with frequency converter (OFC/SFC)

Available measured values Example: Setting for the inlet pressure p1.

Precondition

Access level 2 is activated 1. Open the 5.10.3 menu. A menu containing a list of available measured values is displayed. 400mbar

08:15AM

80° C

Header

5.10.3 Switch

Menu

▶1 p1

Active line

▶2 p2 ▶3 T1 ▶4 T2 ▶5 T3 ▶6 T_S

2. Use «Up» or «Down» to select the measured value.

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8

Initial Start-up

8.8

Setting input and output signals

3. Press «Enter». The menu for the selected measured value (in the example p1) is displayed. 400mbar

08:15AM

80° C

Header Menu

5.10.3.1 p1 active:

active line with check box

☐ ······························

SP: td

8.8.3.1

0.40bar ¦ SD:

0.0bar

Switching point (SP) and switching differential (SD)

+

Delay (td) and logic

DOR1.01

☐

Output DOR

DOT1.01

☐

Output DOT

0s ¦ Logic

Setting the switching point and switching differential 1. Use «Up» or «Down» to select the SP line. 400mbar

08:15AM

80° C

Header Menu

5.10.3.1 p1 active:

☐ ······························

SP:

0.40bar ¦ SD:

td

0s ¦ Logic

−0.2bar

Switching point (SP) and switching differential (SD)

+

Delay (td) and logic

DOR1.01

☐

Output DOR

DOT1.01

☐

Output DOT

2. Press «Enter». The display for the current threshold of the switching point flashes. 3. Use the «Up» or «Down» keys to set the SP threshold. 4. Press «Enter». The setting is applied. 5. If necessary, adjust the value for the SD switching differential in the same way. Result

The threshold for the SP switching point and the SD switching differential are set.

8.8.3.2

Set the time delay The delay can be set between 0 and 600 seconds. The delay is counted down from 600 in 1 second increments with the «DOWN» key and counted upwards from 0 (zero) in 1 second increments with the «UP» key. 1. Use «Up» or «Down» to select the td line.

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8

Initial Start-up

8.8

Setting input and output signals

2. Press «Enter». The td delay time flashes. 400mbar

08:15AM

80° C

Header Menu

5.10.3.1 p1 active:

☐ ······························

SP: td

0.40bar ¦ SD:

−0.2bar

Switching point (SP) and switching differential (SD)

+

Delay (td) and logic

DOR1.01

☐

Output DOR

DOT1.01

☐

Output DOT

120s ¦ Logic

3. Use «Up» or «Down» to set the time delay in seconds. 4. Press «Enter». Result

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 DOR output display flashes. 3. Select the output with the «Up» and «Down» keys. 4. Press «Enter». The setting is applied. 400mbar

08:15AM

80° C

Header Menu

5.10.3.1 p1 active:

☐ ······························

SP: td

0.40bar ¦ SD:

−0.2bar

Switching point (SP) and switching differential (SD) Delay (td) and logic

120s ¦ Logic

+

DOR1.03

ok ☑

Output DOR

☐

Output DOT

DOT1.01

5. Press the «Right» key. 6. Press «Enter». The check box assigned to the output flashes. 7. Press the «Up» key. The check box is activated. 8. Press «Enter». The output is assigned and activated.

ok is displayed. 8.8.3.4

Setting the message type 1. Select the message type line with the «Up» and «Down» keys.

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8

Initial Start-up

8.8

Setting input and output signals

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 Menu

5.10.3.1 p1 ······························ SP: td

0.40bar ¦ SD:

−0.2bar

Switching point (SP) and switching differential (SD) Delay (td) and logic

120s ¦ Logic

+

DOR1.03

ok ☑

Output DOR

DOT1.01

☐

Output DOT

Warning

☑

Type of message

4. Press «Enter». 5. Press the «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 threshold 1. Use «Up» or «Down» to select the active: line. 2. Press «Enter». The check box will flash. 400mbar

08:15AM

80° C

Header Menu

5.10.3.1 p1 active:

active line with check box

☑ ······························

SP: td

0.40bar ¦ SD:

−0.2bar

Switching point (SP) and switching differential (SD) Delay (td) and logic

120s ¦ Logic

+

DOR1.03

ok ☑

Output DOR

☐

Output DOT

DOT1.01

3. Press the «Up» key. The check box is activated. 4. Press the «Enter» key. The threshold is selected and activated. Result

In the above example the switching point for p1 has been set and is active. If the pressure is reached or exceeded and remains longer than the set time delay td, the message is triggered with the set message type and the set output DOR is switched. If the pressure falls below the threshold SP + switching differential SD, the message and output are reset. The switching behaviour is inver‐ ted by setting "-" of Logic parameter. The settings for the other measured values are carried out in the same manner.

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129

8.9

8

Initial Start-up

8.9

Activating remote acknowledgement

Activating remote acknowledgement When fault or warning messages are routed to a remote control centre via an output it makes sense to have these messages acknowledged by the control centre. Acknowledging the message without correcting the cause, however, can lead 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 acknowledgement" function is activated.

■

The remote control is activated CAUTION Machine damage can result from acknowledging a fault message without remedying its cause! ➤ Find the failure cause. DANGER Risk of injury due to sudden machine start. ➤ If the controller is in ON/FAULT operating mode when Remote acknowledgement is ac‐ tive, it must be assumed that, an any time, a remote acknowledgement may switch the machine to ON and the blower motor is started. See chapter 5.8.

8.9.1 Precondition

Setting the remote acknowledgement function Electric connection via DI 1.045– terminal -X15: 7+8 is made Access level 2 is activated. The operating mode is displayed. 1. Open the 5.5 menu. 2. Use «Up» or «Down» to select the Acknowledge messages line. 400mbar

08:15AM

80° C

5.5 External DI / AII signal

Header Menu

Idle signal DI1.09

☐ ······························

Acknowledge messages DI1.05

☐ ······························

3. Press the «DOWN» key. The input DI has been selected. 4. Press «Enter». The display for the currently set input flashes. 5. Select the input DI1.05 with the «Up» or «Down» key.

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8

Initial Start-up

8.10

Error behaviour

6. Press the «Enter» key. The setting is applied. 7. Press the «Right» key. 8. Press «Enter». The check box assigned to the input 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

5.5 External DI / AII signal

Header Menu

Idle signal DI1.09

☐ ······························

Acknowledge messages DI1.05

ok ☑

Active line with deactivated check box

······························

Result

The Remote acknowledgement function is activated. Activating the remote control ➤ Activate remote control see chapter 8.2.13.

Result

The remote control is activated.

Result

Should a message occur, it can now be acknowledged from a control centre.

8.10

Error behaviour The behaviour in the event of a fault during the communication in master control mode or when receiving measured values from external sensors can be set. The following options can be displayed and set: ■

■

Communication ─

SAM 4.0

─

Com-Module

Sensor ─

AII1.02 (with access level 2 dispay only)

In the following example, the behaviour in master control mode is set with SAM 4.0. Precondition

No.: 901700 10 E

Access level 2 is activated.

Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

131

8

Initial Start-up

8.11

Commissioning the machine

1. Open the 11.1.1 menu. 400mbar

08:15AM

80° C

Header Menu

11.1.1 SAM 4.0 Send/Receive

Active line

Load signal Load

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» or «Down» keys to select the Load signal line. 7. Press the «DOWN» key. 8. Press «Enter». The setting mode is active. 9. Use «Up» or «Down» to set the Load or ready option. 10. Press the «Enter» key. The setting is applied. Result

If a communication fault occurs during the master control mode and no external load signal has been parametrised, the blower switches to the operating state that has been set in this menu. ➤ The settings for Com-Module are carried out in the same manner.

8.11

Tab. 82

Commissioning the machine Checking the controller settings

Section

➤ Language correctly set?

8.2.2

➤ Date and time correctly set?

8.2.8

➤ Display format correctly set?

8.2.10

➤ OFC/SFC: Operating mode correctly set?

8.6

Confirmed?

Check list for starting the machine 1. Check and confirm all the items in the check list before first start-up of the machine. When power is applied 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 displayed in the first line of the display. The operating mode is mapped as a pipe and instrument diagram on the display.

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Service Manual Controller SIGMA CONTROL 2 BLOWER ≥ 2.5.3

No.: 901700 10 E

Fig. 32

8

Initial Start-up

8.11

Commissioning the machine

Operating mode 2. Continue the commissioning process as described in chapter "Commissioning" of the ma‐ chine's operating manual.

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133

9

Operation

9.1

Switching the machine on and off

9 Operation 9.1

Switching the machine on and off Always switch the machine on with the «ON» key and off with the «OFF» key.

Precondition

Fig. 33

A power supply isolating device has been installed by the user.

Switching the compressed air station on and off 7 8 13

9.1.1 Precondition

«ON» key «OFF» key «Load/Idle» toggle key

14 15 16

IDLE LED LOAD LED Voltage applied to controller LED

Switching on No personnel are working on the machine. All maintenance doors and removable panels are in place and secured. The ambient conditions as described in 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 controller LED 16 lights green. 3. Press the «On» 7 key. The On LED lights green. The minimum run time for limiting the starting frequency is active in the Remote control and Local operating modes. The starting frequency is used only by star-delta machines. Star period

Motor starts per hour