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

1 SIGMA CONTROL 2 Quick installation guide

1.1 Operating elements .......................................................................................................... 1
1.2 Display elements .............................................................................................................. 2
1.3 Main menu – Overview ..................................................................................................... 2
1.4 Functions – Overview ....................................................................................................... 3
2 Regarding this document
2.1 Using this document ......................................................................................................... 5
2.2 Copyright .......................................................................................................................... 5
2.2.1 Software .............................................................................................................. 5
2.3 Certification ...................................................................................................................... 6
2.4 Updating the operating manual ........................................................................................ 6
2.5 Symbols and labels .......................................................................................................... 6
2.5.1 Warnings ............................................................................................................. 6
2.5.2 Potential damage warnings ................................................................................ 7
2.5.3 Other alert notes and their symbols .................................................................... 8
3 Technical Specifications
3.1 Controller SIGMA CONTROL 2 ....................................................................................... 9
3.1.1 User interface with display, CPU and interfaces ................................................. 9
3.1.2 Input/output module ............................................................................................ 11
3.1.3 Sensors ............................................................................................................... 12
3.2 Communication modules .................................................................................................. 12
3.2.1 PROFIBUS module ............................................................................................. 13
3.2.2 Modbus module .................................................................................................. 13
3.2.3 Modbus TCP module .......................................................................................... 14
3.2.4 DeviceNet module .............................................................................................. 15
3.2.5 PROFINET module ............................................................................................. 16
3.2.6 EtherNet/IP-Module ............................................................................................ 17
4 Safety and Responsibility
4.1 Basic instructions ............................................................................................................. 19
4.2 Specified use .................................................................................................................... 19
4.3 Improper use .................................................................................................................... 19
5 Design and Function
5.1 STC and OFC/SFC machine types .................................................................................. 20
5.2 The controller ................................................................................................................... 20
5.3 Operating panel ................................................................................................................ 22
5.3.1 Operating elements ............................................................................................ 22
5.3.2 Display elements ................................................................................................ 23
5.3.3 RFID reader ........................................................................................................ 23
5.4 Display ............................................................................................................................. 24
5.4.1 Operating mode .................................................................................................. 25
5.4.2 Main menu .......................................................................................................... 26
5.4.3 Setting parameters ............................................................................................. 26
5.4.4 Activating keys with check boxes ....................................................................... 27
5.5 Access rights .................................................................................................................... 27
5.6 KAESER CONNECT ........................................................................................................ 28
5.7 Menu overview ................................................................................................................. 29
5.7.1 Operating mode .................................................................................................. 29
5.7.2 Menu structure .................................................................................................... 30
5.8 Control modes .................................................................................................................. 41
5.8.1 Ready control mode ............................................................................................ 41
5.8.2 Operating control ................................................................................................ 42

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No.: 901700 10 E SIGMA CONTROL 2 BLOWER ≥ 2.5.3 i
 Contents

6 Installation and Operating Conditions

6.1 Maintaining ambient conditions ........................................................................................ 46
6.2 Installation conditions ....................................................................................................... 46
7 Installation
7.1 Reporting Transport Damage ........................................................................................... 47
7.2 Machine identification ....................................................................................................... 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

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ii SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 Contents

8.7.1 Overview of the different master operating modes ............................................. 102

8.7.2 SAM 4.0 mode ................................................................................................... 103
8.7.3 Master control via communication module ......................................................... 106
8.7.4 Master control of two machines in master/slave operation ................................. 115
8.8 Setting input and output signals ....................................................................................... 120
8.8.1 Output operational states of machine on digital outputs ..................................... 120
8.8.2 Output input signals on the display ..................................................................... 121
8.8.3 Switching and/or triggering messages with thresholds ....................................... 126
8.9 Activating remote acknowledgement ............................................................................... 130
8.9.1 Setting the remote acknowledgement function ................................................... 130
8.10 Error behaviour ................................................................................................................ 131
8.11 Commissioning the machine ............................................................................................ 132
9 Operation
9.1 Switching the machine on and off .................................................................................... 134
9.1.1 Switching on ....................................................................................................... 134
9.1.2 Switching off ....................................................................................................... 135
9.2 Switching off in an emergency ......................................................................................... 135
9.3 Acknowledging alarm and warning messages ................................................................. 136
9.4 Displaying messages ....................................................................................................... 137
9.4.1 Status – Messages menu ................................................................................... 138
9.5 Displaying analogue data ................................................................................................. 140
9.6 Displaying operating data ................................................................................................. 141
9.7 Setting the maintenance interval ...................................................................................... 143
9.8 Communication modules .................................................................................................. 143
9.8.1 Displays at the PROFIBUS module .................................................................... 143
9.8.2 Display at the Modbus module ........................................................................... 144
9.8.3 Displays at the Modbus TCP module ................................................................. 145
9.8.4 Display at the DeviceNet module ........................................................................ 146
9.8.5 Displays at the PROFINET module .................................................................... 146
9.8.6 Displays at the EtherNet/IP-Module .................................................................... 148
9.9 Save data ......................................................................................................................... 148
9.9.1 Format SD card .................................................................................................. 150
10 Fault Recognition and Rectification
10.1 Basic instructions ............................................................................................................. 151
10.2 Interpreting fault messages .............................................................................................. 151
10.3 Interpreting warning messages ........................................................................................ 155
10.4 Interpreting operation messages ...................................................................................... 160
10.5 Interpreting diagnostic messages .................................................................................... 162
10.6 Interpreting system messages ......................................................................................... 162
10.7 Communication modules .................................................................................................. 162
10.7.1 Troubleshooting, PROFIBUS module ................................................................. 162
10.7.2 Troubleshooting at the Modbus module ............................................................. 163
10.7.3 Troubleshooting Modbus TCP/EtherNet IP-Module ........................................... 164
10.7.4 Troubleshooting at the DeviceNet module .......................................................... 165
10.7.5 Troubleshooting, PROFINET module ................................................................. 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

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 Contents

13 Decommissioning, Storage and Transport

13.1 Decommissioning ............................................................................................................. 172
13.1.1 Temporary de-commissioning ............................................................................ 172
13.1.2 Long-term de-commissioning ............................................................................. 172
13.2 Packing ............................................................................................................................ 173
13.3 Storage ............................................................................................................................. 173
13.4 Transporting ..................................................................................................................... 173
13.5 Battery removal and disposal ........................................................................................... 173
13.5.1 Battery disposal in accordance with local environmental regulations. ................ 173

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iv SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 List of Illustrations

Fig. 1 Operating elements .................................................................................................................... 1

Fig. 2 Display elements ........................................................................................................................ 2
Fig. 3 MCS interfaces ........................................................................................................................... 10
Fig. 4 System structure ........................................................................................................................ 21
Fig. 5 Operating elements .................................................................................................................... 22
Fig. 6 Display elements ........................................................................................................................ 23
Fig. 7 RFID reader ................................................................................................................................ 24
Fig. 8 Operating mode .......................................................................................................................... 25
Fig. 9 KAESER CONNECT for SIGMA CONTROL 2 ........................................................................... 28
Fig. 10 Operating mode .......................................................................................................................... 30
Fig. 11 Operating mode .......................................................................................................................... 49
Fig. 12 Back of the RFID Equipment Card ............................................................................................ 51
Fig. 13 User log-on with RFID Equipment Card ..................................................................................... 51
Fig. 14 User log-in with RFID Equipment Card ...................................................................................... 52
Fig. 15 Manual user log-on ..................................................................................................................... 54
Fig. 16 Log-in mask ................................................................................................................................ 68
Fig. 17 KAESER CONNECT for SIGMA CONTROL 2 ........................................................................... 69
Fig. 18 Select language: window ............................................................................................................ 69
Fig. 19 System status menu ................................................................................................................... 70
Fig. 20 Main menu .................................................................................................................................. 70
Fig. 21 Graphs (illustration similar) ......................................................................................................... 71
Fig. 22 Control keys ............................................................................................................................... 72
Fig. 23 Messages (illustration similar) .................................................................................................... 73
Fig. 24 I/O display (illustration similar) ................................................................................................... 74
Fig. 25 User management menu ............................................................................................................ 75
Fig. 26 Log on for write access: window ................................................................................................ 75
Fig. 27 User management menu ............................................................................................................ 76
Fig. 28 Settings menu ............................................................................................................................ 77
Fig. 29 Backup menu ............................................................................................................................. 78
Fig. 30 Data recording menu .................................................................................................................. 79
Fig. 31 Direct connection of two SIGMA CONTROL 2 ........................................................................... 116
Fig. 32 Operating mode .......................................................................................................................... 133
Fig. 33 Switching the compressed air station on and off ........................................................................ 134
Fig. 34 Switching off in an emergency ................................................................................................... 135
Fig. 35 Acknowledging messages .......................................................................................................... 136
Fig. 36 PROFIBUS communication module – LEDs and interface ......................................................... 144
Fig. 37 Modbus communication module – LEDs and interface .............................................................. 144
Fig. 38 Modbus TCP communication module – LEDs and interface ...................................................... 145
Fig. 39 DeviceNet communication module – LEDs and interface .......................................................... 146
Fig. 40 PROFINET communication module – LEDs and interface ......................................................... 147
Fig. 41 EtherNet/IP communication module – LEDs and interface ........................................................ 148
Fig. 42 Battery labelling .......................................................................................................................... 174

Service Manual Controller

No.: 901700 10 E SIGMA CONTROL 2 BLOWER ≥ 2.5.3 v
 List of Illustrations

Service Manual Controller

vi SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 List of Tables

Tab. 1 Operating elements .................................................................................................................... 1

Tab. 2 Display elements ........................................................................................................................ 2
Tab. 3 Main menu – Overview ............................................................................................................... 2
Tab. 4 Functions – Overview ................................................................................................................. 3
Tab. 5 Danger levels and their definition (personal injury) .................................................................... 7
Tab. 6 Danger levels and their definition (damage to property) ............................................................ 7
Tab. 7 Formatting options ...................................................................................................................... 8
Tab. 8 User interface ............................................................................................................................. 9
Tab. 9 Display data ................................................................................................................................ 9
Tab. 10 MCS interfaces ........................................................................................................................... 10
Tab. 11 RFID ........................................................................................................................................... 10
Tab. 12 IOM 1 .......................................................................................................................................... 11
Tab. 13 Power supply specifications ....................................................................................................... 11
Tab. 14 Cable lengths ............................................................................................................................. 11
Tab. 15 Degree of protection, IOM .......................................................................................................... 12
Tab. 16 IOM dimensions ......................................................................................................................... 12
Tab. 17 Pressure transducer ................................................................................................................... 12
Tab. 18 Resistance thermometer ............................................................................................................ 12
Tab. 19 Technical specifications - PROFIBUS ........................................................................................ 13
Tab. 20 Assignment of PROFIBUS interface .......................................................................................... 13
Tab. 21 Technical Specifications - SIGMA CONTROL 2 interface .......................................................... 13
Tab. 22 Assignment of the SIGMA CONTROL 2 interface ...................................................................... 14
Tab. 23 Technical Specifications - Modbus TCP interface ...................................................................... 14
Tab. 24 Assignment of the Modbus TCP interface .................................................................................. 15
Tab. 25 Recommended conductors - Modbus TCP interface ................................................................. 15
Tab. 26 Technical specifications - SIGMA CONTROL 2 communication module ................................... 15
Tab. 27 Assignment of the SIGMA CONTROL 2 interface ...................................................................... 16
Tab. 28 Technical Specifications - SIGMA CONTROL 2 interface .......................................................... 16
Tab. 29 Assignment of the SIGMA CONTROL 2 interface ...................................................................... 16
Tab. 30 Recommended conductors - SIGMA CONTROL 2 interface ..................................................... 17
Tab. 31 Technical data EtherNet/IP-Interface ......................................................................................... 17
Tab. 32 Configuration of the EtherNet/IP-Interface ................................................................................. 17
Tab. 33 EtherNet/IP-Interface - Cabling recommendation ...................................................................... 18
Tab. 34 Operating elements .................................................................................................................... 22
Tab. 35 Display elements ........................................................................................................................ 23
Tab. 36 RFID reader ................................................................................................................................ 24
Tab. 37 Reset check box status .............................................................................................................. 27
Tab. 38 Check box status ........................................................................................................................ 27
Tab. 39 KAESER CONNECT functions ................................................................................................... 28
Tab. 40 Menu structure of main menu ..................................................................................................... 30
Tab. 41 Status menu ............................................................................................................................... 33
Tab. 42 Configuration menu .................................................................................................................... 34
Tab. 43 Communication menu ................................................................................................................ 37
Tab. 44 Connections menu ..................................................................................................................... 38
Tab. 45 Components menu ..................................................................................................................... 39
Tab. 46 SIGMA CONTROL 2 ready states .............................................................................................. 41
Tab. 47 Machine identification ................................................................................................................. 47
Tab. 48 Remote control identification ...................................................................................................... 47
Tab. 49 Machine identification ................................................................................................................. 47
Tab. 50 Supported languages ................................................................................................................. 50
Tab. 51 Date formats ............................................................................................................................... 57
Tab. 52 Possible settings for the time format .......................................................................................... 58
Tab. 53 Possible settings for the pressure unit ....................................................................................... 59
Tab. 54 Possible settings for the temperature unit .................................................................................. 59

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 List of Tables

Tab. 55 Display illumination ..................................................................................................................... 60

Tab. 56 Network parameters ................................................................................................................... 63
Tab. 57 E-mail parameters ...................................................................................................................... 65
Tab. 58 Control key functions .................................................................................................................. 72
Tab. 59 Blower characteristics ................................................................................................................ 80
Tab. 60 Settings for machine start and machine stop ............................................................................. 81
Tab. 61 User-defined clock programme machine ON/OFF ..................................................................... 82
Tab. 62 Example of a machine ON/OFF clock program .......................................................................... 83
Tab. 63 Delay time for automatic restart ................................................................................................. 86
Tab. 64 Overview of the different master controllers ............................................................................... 102
Tab. 65 Parameters for monitoring for communication malfunction ........................................................ 106
Tab. 66 Setting theStarttd parameter ...................................................................................................... 107
Tab. 67 Setting the Timeout parameter ................................................................................................... 108
Tab. 68 Setting theStarttd parameter ...................................................................................................... 109
Tab. 69 Setting the Timeout parameter ................................................................................................... 109
Tab. 70 Setting theStarttd parameter ...................................................................................................... 110
Tab. 71 Setting the Timeout parameter ................................................................................................... 110
Tab. 72 Setting theStarttd parameter ...................................................................................................... 111
Tab. 73 Setting the Timeout parameter ................................................................................................... 112
Tab. 74 Setting theStarttd parameter ...................................................................................................... 113
Tab. 75 Setting the Timeout parameter ................................................................................................... 113
Tab. 76 Setting theStarttd parameter ...................................................................................................... 114
Tab. 77 Setting the Timeout parameter ................................................................................................... 114
Tab. 78 Master-slave settings ................................................................................................................. 115
Tab. 79 Assigned output signals ............................................................................................................. 120
Tab. 80 Logic settings ............................................................................................................................. 124
Tab. 81 Available measured values ........................................................................................................ 126
Tab. 82 Check list for starting the machine ............................................................................................. 132
Tab. 83 Maximum permissible number of motor starts per hour ............................................................. 134
Tab. 84 Message sequence 1 ................................................................................................................. 136
Tab. 85 Message sequence 2 ................................................................................................................. 136
Tab. 86 Information of a message ........................................................................................................... 137
Tab. 87 Message abbreviations .............................................................................................................. 138
Tab. 88 PROFIBUS communication module – Interpretation of LEDs .................................................... 144
Tab. 89 Modbus communications module – Interpretation of LEDs ........................................................ 144
Tab. 90 Modbus TCP communications module – Interpretation of LEDs ................................................ 145
Tab. 91 DeviceNet communications module – Interpretation of LEDs .................................................... 146
Tab. 92 PROFINET communications module – Interpretation of LEDs ................................................... 147
Tab. 93 EtherNet/IP communication module – Interpretation of LEDs .................................................... 148
Tab. 94 Fault messages and remedies ................................................................................................... 151
Tab. 95 Warning messages and remedies .............................................................................................. 156
Tab. 96 Operational messages ............................................................................................................... 160
Tab. 97 System messages and remedies ............................................................................................... 162
Tab. 98 Com-Module communication error warning message ................................................................ 162
Tab. 99 Fault displays in the Communication – Com-Module menu. ...................................................... 163
Tab. 100 Com-Module communication error warning message ................................................................ 163
Tab. 101 Fault displays in the Communication – Com-Module menu. ...................................................... 164
Tab. 102 Com-Module communication error warning message ................................................................ 164
Tab. 103 Fault displays in the Communication – Com-Module menu. ...................................................... 165
Tab. 104 Com-Module communication error warning message ................................................................ 165
Tab. 105 Fault indications at the DeviceNet communication module ........................................................ 166
Tab. 106 Fault displays in the Communication – Com-Module menu. ...................................................... 166
Tab. 107 Com-Module communication error warning message ................................................................ 167
Tab. 108 Fault displays in the Communication – Com-Module menu. ...................................................... 167

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viii SIGMA CONTROL 2 BLOWER ≥ 2.5.3 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 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).

Tab. 1 Operating elements

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 1 SIGMA CONTROL 2 Quick installation guide
1.2 Display elements

1.2 Display elements

Fig. 2 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. 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 Continuous green light when voltage is applied to the controller.
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.

Tab. 2 Display elements

1.3 Main menu – Overview

Select the main menu with «Enter» key.
Menu No. Menu name Function
1 Status Displays messages, statistics and status information

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 1 SIGMA CONTROL 2 Quick installation guide
1.4 Functions – Overview

Menu No. Menu name 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

Tab. 3 Main menu – Overview

See Chapter 5.7.2 for the complete menu structure

1.4 Functions – Overview

Function Menu Steps Chapter
No.
Setting the con‐ Main Press and hold «Information» – «Up» / «Down» 8.2.12
trast menu
Setting the Main Press and hold «Information» – «Left» / «Right» 8.2.12
brightness menu
Setting the lan‐ Main «Enter» – «Up» – «Enter» – «Up» / «Down» 8.2.2
guage menu
Setting date, 5.1 <Configuration – General> 8.2.8
time and time
zone
Identification with – 8.2.4
RFID Equipment
Card

Displaying and 5.2 <Configuration – Blower properties – Altitude> 8.4

setting the blow‐
er properties
«Setting the» 6 <Time control – Setting timing program> 8.5.1
time control
Activating the 6 <Time control – Key time control – ☑> 8.5.1.3
«time control»
key
Activating – Activate the «Time control» key – Press «Time control» key 8.5.1.4
«time control»
Activate the 5.5 <Configuration – External DI / AII signal – Key remote – ☑> 8.2.13
«remote control» 8
key

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 1 SIGMA CONTROL 2 Quick installation guide
1.4 Functions – Overview

Function Menu Steps Chapter

No.
Activating the – Activate the «Remote» key – Press «Remote» key 8.2.13
«remote control»
Displaying oper‐ 3 <Operating data – Operating hours – Motor / Block> 9.6
ating data
Changing the op‐
erating hours
Setting the main‐ 4 <Maintenance – Setting the component maintenance interval > 9.7
tenance interval
Displaying mes‐ 1.1.1 Press the «Information» key. 9.4
sages
Acknowledging – Press the «Acknowledgement» key 9.3
messages
Fault messages 1.1.1 A fault message causes the machine to shut down. The Fault 10.2
LED flashes red. Fault messages are identified with the let‐
ter A. Example:
<0002 S k 31/12/2015 13:14:15 Overload blower motor>
Warning mes‐ 1.1.1 If maintenance work is to be carried out or if the warning is dis‐ 10.3
sages played before an alarm, the yellow warning LED flashes.
Warning messages are identified with the letter W.
Diagnostic mes‐ 1.1.1 A diagnostic message causes the machine to shut down. They 10.5
sages 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 A system message causes the machine to shut down. System 10.6
es messages are identified with the letter Y.

Tab. 4 Functions – Overview

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

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4 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:// <Hostname>/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.

Service Manual Controller

No.: 901700 10 E SIGMA CONTROL 2 BLOWER ≥ 2.5.3 5
 2 Regarding this document
2.3 Certification

2.3 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.

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6 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 Warns of imminent danger Will very likely result in death or severe injury
WARNING Warns of potentially imminent danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situa‐ May result in moderate physical injury
tion

Tab. 5 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.

Signal term Meaning Consequences of non-compliance
NOTE Warns of a potentially dangerous situation Damage to property is possible

Tab. 6 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.

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 2 Regarding this document
2.5 Symbols and labels

2.5.3 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.
Designation Formatting Example
Operating point UPPER CASE LOAD
Item number ... Open valve 4
Display italic ON LED
Key « ... » «ON» key
Menu option < ... > <Configuration>
Menu path <Menu 1 – Menu 2 – ...> <Configuration – Pressure control>
activated ... The minutes display flashes. 00:00:00

Tab. 7 Formatting options

This symbol identifies particularly important information.

Material Here you will find details on special tools, operating materials or spare parts.

Precondition Here you will find conditional requirements necessary to carry out the task.
The conditions relevant to safety shown here will help you to avoid dangerous situations.

➤ This 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 Further subjects are introduced here.

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8 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
■ Battery-buffered real-time clock
─ Battery service life: more than 10 years
─ Battery replaceable

3.1.1 User interface with display, CPU and interfaces

User interface

Characteristic Value
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 Input/output module

Tab. 8 User interface

Display

Characteristic Value
Graphical display [px] 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 Display data

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 3 Technical Specifications
3.1 Controller SIGMA CONTROL 2

Fig. 3 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, Module optional for:
slot for communications module 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 Value
Hardware on the SIGMA CONTROL 2 controller RFID reader
Hardware (external) RFID Equipment Card
Recognition distance [m] Max. 0.05
Frequency [MHz] 13.56
Emitted maximum transmitting power at 10 m dis‐ 11
tance [dB(µA/m)]

Tab. 11 RFID

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 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 Input/output module 1
Internal, in available in External, into
the control parallel on the machine
cabinet both sides 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 – – –

Tab. 12 IOM 1

3.1.2.1 Power supply specifications

Power is provided by the power supply unit within the machine.

Characteristic Value
Rated voltage (stabilised) [V DC] 24
Current consump‐ 2.4
tion SIGMA CONTROL 2 with IOM 1 [A]
IOM ≙ Input/Output module

Tab. 13 Power supply specifications

3.1.2.2 Maximum cable lengths

Input/Output Cable length [m]

Analogue input current (AII), ＜ 30
Analogue input resistor (AIR)
Analogue output current (AOI)
Digital input (DI), ＜ 100
Digital output relay (DOR)
Digital output transistor (DOT) ＜ 30

Tab. 14 Cable lengths

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 3 Technical Specifications
3.2 Communication modules

3.1.2.3 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

Tab. 15 Degree of protection, IOM

3.1.2.4 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 Two-core

Tab. 17 Pressure transducer

Resistance thermometer

Characteristic Value
Sensing resistance (to DIN IEC 751) PT100
Connection Two-core

Tab. 18 Resistance thermometer

3.2 Communication modules

SIGMA CONTROL 2 supports the following communication modules:
■ PROFIBUS (Option C41)
■ Modbus (Option C42)
■ DeviceNet (Option C43)
■ Modbus TCP (Option C44)
■ PROFINET (Option C45)
■ EtherNet/IP (Option C50)

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12 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 3 Technical Specifications
3.2 Communication modules

3.2.1 PROFIBUS module

Communications module

Feature Value
Controller SIGMA CONTROL 2 SIGMA AIR MANAGER 4.0
Bus PROFIBUS DP-V0 Slave, RS485
GSD file KAES0CEC.gsd KAKO0EFB.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, "Technical description "Technical description
see SIGMA CONTROL 2 process im‐ SIGMA AIR MANAGER 4.0 process im‐
age", document number age", document number 7_9696_PA.
7_7601_PA.

Tab. 19 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 SIGMA AIR MANAGER 4.0
Bus SIGMA CONTROL 2 or ASCII, RS485 or RS232, galvanically isolated
Baud rate Adjustable, possible baud rates:
[bps] 1200 / 2400 / 4800 / 9600 / 19200 / 38400 / 57600 / 76800 / 115200
Stop bits Possible settings 1 / 2
Parity Possible settings None / Even / Odd
Bold elements: Factory setting

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 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 64
[byte]
Output data 128 (process data) and 42 (diagnos‐ 128 (prozess data)
[byte] 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’ RS485 A (RxD/TxD negative)
Housing — — 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 SIGMA AIR MANAGER 4.0
Bus Modbus TCP server (Slave)
Connection 2x RJ45 ports (Cat5e, shielded), integrated 2-port switch, potential isolation
Baud 10/100, full duplex or half duplex
rate [Mbit/s]
Input data [byte] 64

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 3 Technical Specifications
3.2 Communication modules

Feature Value
Output data 128 (process data) and 42 (diagnos‐ 194 (process data)
[byte] 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.

Tab. 23 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 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. 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 "Technical description SIGMA CONTROL 2 process image", document number
7_7601xPA.

Tab. 26 Technical specifications - SIGMA CONTROL 2 communication module

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 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 Bus supply voltage negative 2)
2 CAN_L blue CAN Bus low
3 Shield non-isolated High-impedance (1 MOhm/47 nF) connection with functional
earthing (FE)
4 CAN_H White CAN Bus high
5 V+ Red Bus supply voltage positive 2)
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

Feature Value
Controller SIGMA CONTROL 2 SIGMA AIR MANAGER 4.0
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 100, full duplex
rate [Mbit/s]
GSD file GSDML-V2.25-Kaeser- GSDML-V2.3-Kaeser-SAM2-20150112
SC2-20120203.xml
Input data 64
[byte]
Output data 128 (process data)
[byte]
Data content, "Technical description "Technical description
see Document SIGMA CONTROL 2 process im‐ SIGMA AIR MANAGER 4.0 process im‐
No. age", document number age", document number 7_9696_PA.
7_7601xPA.

Tab. 28 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

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 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 SIGMA AIR MANAGER 4.0
Bus EtherNet/IP-Server (Slave)
Connection 2x RJ45 ports (Cat5e, shielded), integrated 2-port switch, potential isolation
Baud 10/100, full duplex or half duplex
rate [Mbit/s]
Input data [byte] 64
Output data 128 (process data) and 42 (diagnos‐ 194 (process data)
[byte] 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.

Tab. 31 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 RD- Blue Negative receive
* Position of pins 1 through 8, see chapter 9

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 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

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

Tab. 33 EtherNet/IP-Interface - Cabling recommendation

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 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.

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 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 frequency-
converter (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:

■ 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

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 5 Design and Function
5.2 The controller

Fig. 4 System structure

1 Machine enclosure 6 Inputs/outputs in the interior of the control
2 Control cabinet cabinet
3 Main Control System 7 Inputs/outputs in the interior of the blowers
4 Input/output module 8 Inputs/outputs for external sensors
5 I/O bus 9 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:

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

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 5 Design and Function
5.3 Operating panel

5.3 Operating panel

5.3.1 Operating elements

Fig. 5 Operating elements

Item Designation 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 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)
not for SXC

Tab. 34 Operating elements

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 5 Design and Function
5.3 Operating panel

5.3.2 Display elements

Fig. 6 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 Continuous green light when voltage is applied to the controller.
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.
12)
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.

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

Tab. 36 RFID reader

5.4 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.

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 5 Design and Function
5.4 Display

5.4.1 Operating mode

Fig. 8 Operating mode

1 Air filter 6 OFC/SFC: Speed compressor
2 Inlet pressure p1 7 Intake temperature T1
3 OFC/SFC: Drive motor’s duty cycle in % 8 Header
4 Final pressure p2 9 Cut-in period
5 Discharge temperature T2 10 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:
■ The hours during which the machine was activated
■ Remaining desiccant service life of the machine until the next maintenance.

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 5 Design and Function
5.4 Display

5.4.2 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.

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26 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.

Check box Status

☑ activated
☐ deactivated

Tab. 38 Check box status

5.5 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.

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 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)
not for SXC

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28 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
Messages ■ Current messages
■ Event history
I/O display Assignment of the input/output modules
User management ■ Creating and activating new user accounts
■ Modifying or deactivating existing user accounts
■ Changing passwords
Settings ■ Unit display format
■ Date display format
■ Time display format
Backup Saving data via KAESER CONNECT from SIGMA CONTROL 2 to a PC
12)
not for SXC

Tab. 39 KAESER CONNECT functions

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

5.7 Menu overview

5.7.1 Operating mode
When the power supply is switched on, details of the software are displayed (for example):
Compressor Machine model
PN: SN: Material number and serial number of the machine
EN: Equipment number of the machine

SIGMA CONTROL 2 – MCS MCS: Main Control System

PN: y.yyyyyy SN: x.xx.xx Material number and serial number of the controller
Software: ABC_V.V.V Software version

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

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 5 Design and Function
5.7 Menu overview

Fig. 10 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.
1)
Power switching with frequency converter (OFC/SFC)
2)
Screw blower

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 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)
3 Operating data ■ Operating hours
─ Blower package
─ On load
─ Motor
─ Block
─ SIGMA CONTROL 2
─ FC block drive
4 Maintenance ■ 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 For details of the Configuration menu, please
see table 42.
1)
Power switching with frequency converter (OFC/SFC)
2)
Screw blower

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 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.
1)
Power switching with frequency converter (OFC/SFC)
2)
Screw blower

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 5 Design and Function
5.7 Menu overview

Menu No./Designation Function/Sub-menu

11 Error behaviour ■ Communication
─ SAM 4.0
─ Com-Module
■ Sensor
─ AII1.02
1)
Power switching with frequency converter (OFC/SFC)
2)
Screw blower

Tab. 40 Menu structure of main menu

5.7.2.1 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)
only visible in the event of parametrisation error

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 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)
only visible in the event of parametrisation error

Tab. 41 Status menu

5.7.2.2 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)
Power switching with frequency converter (OFC/SFC)

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34 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)
Power switching with frequency converter (OFC/SFC)

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 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 ■ 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
1)
Power switching with frequency converter (OFC/SFC)

Tab. 42 Configuration menu

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 5 Design and Function
5.7 Menu overview

5.7.2.3 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:
■ PROFIBUS
■ Modbus
■ Modbus TCP
■ DeviceNet
■ PROFINET
■ EtherNet/IP

Tab. 43 Communication menu

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 5 Design and Function
5.7 Menu overview

5.7.2.4 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 Connections menu

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 5 Design and Function
5.7 Menu overview

5.7.2.5 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
1)
Power switching with frequency converter (OFC/SFC)
2)
Screw blower

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 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

■ Speed monitoring
■ Vibration monitoring
─ VSE Status
─ AII
─ ↑ V1
1)
Power switching with frequency converter (OFC/SFC)
2)
Screw blower

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40 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
1)
Power switching with frequency converter (OFC/SFC)
2)
Screw blower

Tab. 45 Components menu

5.8 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 On LED Alarm LED

OFF The machine is switched off. off on, off or
The machine cannot be started. flashing

ON The machine is switched on. on off

The machine can be started.
SWITCHING OFF Switching off is completed when flashes off
the run-on times of the motor
and fan have elapsed.

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 5 Design and Function
5.8 Control modes

Ready state Meaning On LED Alarm LED

ON/FAULT The machine is switched on but on on or flashing
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.

Tab. 46 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.

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42 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.
■ The IDLE LED lights green.

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 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

■ 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

5.8.2.1 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 SHUT-
DOWN state. This state is only left after the venting period has elapsed and the minimum run time
has been reached.

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44 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.

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 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.

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46 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 Machine identification

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 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:
■ 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

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48 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 8 Initial Start-up
8.2 Setting the controller

8.2.1 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 08:15:37AM current date and time

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 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:
Arabic Estonian Italian Norwegian Spanish
Bulgarian Finnish Japanese Polish Spanish
(South America)
Chinese French Korean Portuguese Czech
Danish French Croatian Romanian Turkish
(Canada)
German Greek Latvian Russian Hungarian
English Hebrew Lithuanian Swedish ...
English (USA) Indonesian Dutch Slovenian ...

Tab. 50 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---------------- 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

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50 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 The user interface is displayed in the set language.

8.2.3 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 Back of the RFID Equipment Card
2 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:
■ Read additional data
■ Change other settings

Fig. 13 User log-on with RFID Equipment Card

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 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 Any menu is displayed

Fig. 14 User log-in with RFID Equipment Card

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52 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 Header
Password changed 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.

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 8 Initial Start-up
8.2 Setting the controller

Fig. 15 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 You are now logged on to SIGMA CONTROL 2 with access level 2, having manually input your
user name and the password.

8.2.7 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.

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54 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
Registration successful The master RFID Equipment Card has been regis‐
tered
------------------------------
Name: E00017326
Level: 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 You have registered a master RFID Equipment Cards at the machine.

8.2.8 Checking/setting time and date

Precondition 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 <Configuration – General> menu.
2. Use «Up» or «Down» to select the Date/Time line.

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 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: XXXXXX set machine type (SC2 FLUID)
······························
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 <Configuration – General> 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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56 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 <Configuration – General> menu.

2. Use «Up» or «Down» to select the Date/Time line.
3. Press «Down» twice.
400mbar 08:15AM 80° C Header
5.1 General Menu
Model: 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:

Format Example
DD.MM.YY 30.07.16
YY-MM-DD 16–07–30
MM/DD/YY 07/30/16

Tab. 51 Date formats

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 8 Initial Start-up
8.2 Setting the controller

Precondition Access level 2 is activated.

1. Open the 5.1 <Configuration – General> menu.

2. Use «Up» or «Down» to select the Date format line.
400mbar 08:15AM 80° C Header
5.1 General Menu
Europe/London
······························
▶2 Time server
······························
Date format MM/DD/YY Date format
Time format hh:mm:ssAM/PM

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:

Format Example
hh:mm:ss 13:33:45
hh:mm 13:33
hh:mm:ssAM/PM 01:33:45PM
hh:mmAM/PM 01:33PM

Tab. 52 Possible settings for the time format

Precondition Access level 2 is activated.

1. Open the 5.1 <Configuration – General> menu.

2. Use «Up» or «Down» to select the Time format line.
400mbar 08:15AM 80° C Header
5.1 General Menu
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.

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58 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:

Format Example
bar 5.5bar
hPa 5523hPa
MPa 0.55MPa
psi 80psi
at 5.6at
"Hg 162"Hg
mbar 5500mbar

Tab. 53 Possible settings for the pressure unit

Precondition Access level 2 is activated.

1. Open the 5.1 <Configuration – General> menu.

2. Use «Up» or «Down» to select the Pressure unit line.
400mbar 08:15AM 80° C Header
5.1 General Menu
Time format hh:mm:ssAM/PM
······························
Pressure unit bar Unit of pressure
Temperature unit °C Unit of temperature
······························
Display illumination

3. Press «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:

Format Example
°C 46°C
K 319K

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 8 Initial Start-up
8.2 Setting the controller

Format Example
°F 114°F

Tab. 54 Possible settings for the temperature unit

Precondition Access level 2 is activated.

1. Open the 5.1 <Configuration – General> menu.

2. Use «Up» or «Down» to select the Temperature unit line.
400mbar 08:15AM 80° C Header
5.1 General Menu
Time format hh:mm:ssAM/PM
······························
Pressure unit bar Unit of pressure
Temperature unit °C Unit of temperature
······························
Display illumination

3. Press «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 1 2 3
Indication automatic on off
Function The illumination extin‐ Permanent setting Permanent setting
guishes after the time- Illumination "on" Illumination "off"
out has elapsed.

Tab. 55 Display illumination

Precondition Access level 2 is activated.

1. Open the 5.1 <Configuration – General> menu.

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

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60 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
5.1 General Menu
······························
Pressure unit bar Unit of pressure
Temperature unit °C 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 The display illumination is set for automatic operation with deactivation after one minute without
user intervention.

8.2.12 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 Contrast and brightness are set.

8.2.13 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.

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 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
8 Communication Menu
▶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
8 Communication Menu
▶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 SIGMA CONTROL 2 remote control is activated.

8.2.14 IP configuration
For the SIGMA CONTROL 2 to be connected to the network, you must set the IP configuration (for
KAESER CONNECT for example).
If you 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 <Communication – Ethernet/SIGMA NETWORK – IP configuration> menu.

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62 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 Setting value 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 – Activate the changed network parameters

Tab. 56 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.

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 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 <Communication – Ethernet/SIGMA NETWORK – E-mail> menu.

2. Use «Up» or «Down» to select the active: line.
400mbar 08:15AM 80° C Header
8.1.3 E-mail Menu
active: ☐ Activating/deactivating the e-mail function
Blower number: 1
Language: English GB Setting the language
Repeat cut-off time: 5min
Use SSL: ☑ 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.

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64 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 <Configuration - E-mail - Basic Set‐
tings> must be activated.

Parameter Setting Meaning

value
Blower This field displays the machine number that appears as the sender of e-
number: mails. 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 In this field, enter the time in minutes (repeat block time) that the system
time: 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 Enter the e-mail address of the sender in this field.
address:
Sender name: Enter the name of the sender in this field.
Contact In this field, enter a telephone number under which the air station opera‐
telephone: tor can be reached. This telephone number is sent with each e-mail.
Receiver The e-mail address of the recipient
address:
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.

Tab. 57 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.

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 8 Initial Start-up
8.2 Setting the controller

Precondition Access level 2 is activated.

1. Open the 8.1.3 <Communication – Ethernet/SIGMA NETWORK – E-mail> 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
8.1.3 E-mail Menu
active: ☐ Activating/deactivating the e-mail function
Blower number: 1
Language: English GB Setting the language
Repeat cut-off time: 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 Repeat cut-off time: is set.

8.2.16 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 <Configuration – General – Time server> menu.

2. Use «Up» or «Down» to select the IP address line.
400mbar 08:15AM 80° C Header
5.1.2 Time server Menu
active: ☐ Activating/deactivating the time server function
IP address 192.053.103.103 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.

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66 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
5.1.2 Time server Menu
active: ☑ The time server function is activated.
IP address 192.053.103.103 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.

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 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 Open KAESER CONNECT

Precondition The user name (see chapter 8.2.3) and password (see chapter 8.2.5) are known.
The controller's IP address is known, see chapters 8.2.14 and 8.7.4.

1. Use an Ethernet 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.

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Fig. 17 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 «Arrow key» Select language: 3 Setting the language
2 Select language: window 4 Selected language

7. Click to set the selected language 3 .

Result KAESER CONNECT is displayed in the set language.

8.3.2 System status menu

Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed.

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Fig. 19 System status menu

1. Click the System status menu element.

The System status menu is displayed

Fig. 20 Main menu

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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 automatically-
recorded 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.

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8.3.3.1 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 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

Tab. 58 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.

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8.3.4 Messages menu

The following messages types can be displayed:
■ Current messages
■ Blower messages
■ System messages
■ Diagnostic messages

Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed.

Fig. 23 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 KAESER CONNECT for SIGMA CONTROL 2 is displayed.

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Fig. 24 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:

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

Precondition The generated password is available.

KAESER CONNECT for SIGMA CONTROL 2 is displayed.

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Fig. 25 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

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8.3 KAESER CONNECT benefits

Fig. 27 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.

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Result The password for the existing user account is changed.

8.3.7 Settings menu

These settings are only required for access to KAESER CONNECT via web browser.

The following settings are possible.

■ Units
■ Date format
■ Time format

Fig. 28 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.

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8.3 KAESER CONNECT benefits

8.3.8 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:

■ Backup all
■ Log files
■ Settings
■ User information

Precondition 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 The data are downloaded to the Internet-capable device.

8.3.9 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.

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The following options are available:

■ 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

Precondition 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 The system displays a message confirming the successful logout.

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8.4 Displaying and setting the blower properties

8.4 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
■ Pressure
■ Vacuum
Maximum Display The machine is designed for this pressure (maximum working pres‐
pressure sure).
Design pressure Display The machine is configured for this pressure.
Minimum Display For design reasons, pressure can only be built up above this value
pressure (minimum working pressure).

Tab. 59 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 <Configuration – Blower properties> menu.
400mbar 08:15AM 80° C Header
5.2 Blower properties Menu
Altitude 65m Active line
Air pressure 1.006bar
Pressure version Pressure
Maximum pressure 0.40bar
Design pressure 0.30bar
Minimum pressure 0.20bar

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 <Configuration – Blower properties> menu.

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

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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 Header
5.2 Blower properties Menu
Altitude 00m Active line with set installation elevation
Air pressure 1.006bar
Pressure version Pressure
Maximum pressure 0.40bar
Design pressure 0.30bar
Minimum pressure 0.20bar

5. Press the «Enter» key.

The setting is applied.

Result The installation elevation is set.

8.5 Machine start and machine stop

➤ In addition to manually starting the machine locally, you have the following alternatives:

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

Tab. 60 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
■ Select menu Time control
■ Set clock program
■ Activating time control

8.5.1.1 Select the Time control menu

Precondition Access level 2 is activated.

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8.5 Machine start and machine stop

1. Open the 6<Time control> menu.

400mbar 08:15AM 80° C Header
6 Time control Menu
Key time control ☐ The time control key is activated
Reset ☐ All current switching points are reset
······························
01 n.a. 00:00AM off Active line
02 n.a. 00:00AM off
03 n.a. 00:00AM off

User-defined clock program

No.: Day Time Function
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20

Tab. 61 User-defined clock programme machine ON/OFF

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8.5.1.2 Setting the clock program (example)

When setting a clock programme for the first time, note first the switching times on the "User-
defined 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:

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

Tab. 62 Example of a machine ON/OFF clock program

Precondition Access level 2 is activated.

1. Open the 6<Time control> menu.

2. Use «Up» or «Down» to select the 01 line.
400mbar 08:15AM 80° C Header
6 Time control Menu
······························
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.

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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
6 Time control Menu
······························
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
05 Fri 03:00PM off Switching point 05 is set

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
6 Time control Menu
Key time control ☑ Active line with deactivated check box
Reset ☐
······························
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.

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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<Configuration – Pulse generator> menu.

400mbar 08:15AM 80° C Header
5.9 Pulse generator Menu
Activate ☐ 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.

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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
5.9 Pulse generator Menu
Activate ☑ The timer is activated
on : 01h:15m:00s Cut-in period
off : 01h:15m:00s Cut-out period
Function Load Mode

19. Press «Enter».

The setting is applied.

Result The machine is controlled by the timer.

8.5.3 "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 Start time [sec] Delay time [sec]

1 –– ––
2
3
4
5

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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 Delay time for automatic restart

Precondition Access level 2 is activated.

1. Open the 5.3 <Configuration – Restart> menu.

400mbar 08:15AM 80° C Header
5.3 Restart Menu
Automatic restart ☐ Automatic restart is deactivated
Delay 1s 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 You have adjusted the delay tome for the restart after a power supply failure from 1 s to 10 s.

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8.5 Machine start and machine stop

Activating/deactivating the "Automatic restart" function

Precondition Access level 2 is activated.

1. Open the 5.3 <Configuration – Restart> menu.

2. Use «Up» or «Down» to select the Automatic restart line.
400mbar 08:15AM 80° C Header
5.3 Restart Menu
Automatic restart ☐ Automatic restart is deactivated
Delay 10 s Set/expiring delay time

3. Press «Enter».
The setting mode is active.
4. Press the «Up» key.
The check box is activated.
400mbar 08:15AM 80° C Header
5.3 Restart Menu
Automatic restart ☑ Active line with deactivated check box
Delay 10 s Set/expiring delay time

5. Press the «Enter» key.

The setting is applied.

Result The "Automatic restart" function is activated.

8.5.4 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:

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■ 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.

8.5.4.1 Setting the load signal to remote mode

Precondition 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 <Configuration – External DI / AII signal> menu.

2. Use «Up» or «Down» to select the Load signal line.
400mbar 08:15AM 80° C Header
5.5 External DI / AII signal Menu
▶1 Current signal AII1.02
Load signal active line
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.

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10. Press «Enter».

The setting is applied.
ok is displayed.
400mbar 08:15AM 80° C Header
5.5 External DI / AII signal Menu
▶1 Current signal AII1.02
Load signal
DI1.04 ok ☑ Active line with deactivated check box
······························
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 <Configuration – External DI / AII signal> menu.

2. Use «Up» or «Down» to select the Idle signal line.
400mbar 08:15AM 80° C Header
5.5 External DI / AII signal Menu
▶1 Current signal AII1.02
Load signal
DI1.04 ☐
······························
Idle signal active line
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.

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8.6 Operating modes in frequency-controlled machines

10. Press «Enter».

The setting is applied.
ok is displayed.
400mbar 08:15AM 80° C Header
5.5 External DI / AII signal 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 SIGMA CONTROL 2 remote control is activated.

8.6 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
─ Target value:
→ Via parameters in the 5.4.1 Fixed speed menu

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No.: 901700 10 E 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:

■ 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.

8.6.1 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:

■ 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.

Precondition Access level 2 is activated.

The operating mode is displayed.
The Fixed speed or Pressure control mode is set in the 5.4 <Configuration – Operating modes>
menu.

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92 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 <Configuration – External DI / AII signal – Current signal AII1.02 > menu.
2. Use «Up» or «Down» to select the AII1.02 line.
400mbar 08:15AM 80° C Header
5.5.1 Current signal AII1.02 Menu
AII1.02 ☐ Active line
Value type 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 The function Current signal AII1.02 is activated. The machine can be controlled by an analogue
current signal at the AII1.02 input.

8.6.2 Setting the operating mode

Precondition Access level 2 is activated.
The operating mode is displayed.
AII1.02 current signal is set, see chapter 8.6.1

1. Open the 5.4 <Configuration – Operating modes> 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.

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No.: 901700 10 E 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 The currently selected operating mode is displayed in the 5.4 <Configuration – Operating modes>
menu.

8.6.3 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 <Configuration – Operating modes> 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.

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94 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
5.4.1 Fixed speed Menu
block speed
n_min 500/min
n_max 3600/min
------------------------------
Set speed 1760/min Active line
current 1750/min

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:
■ p1 (inlet pressure)/p2 (discharge pressure)
■ dp (differential pressure)
■ AII1.02 (Current signal AII1.02)

Precondition Access level 2 is activated.

1. Open the 5.4.2 <Configuration – Operating modes – Pressure control> menu.

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

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No.: 901700 10 E 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 Header
5.4.2 Pressure control Menu
Source actual pressure p1,p2 Active line
Source set pressure p1,p2
Local set pressure 1.0bar
KP 1.0rpm / mbar
KI 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 <Configuration – Operating modes – Pressure control> 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 Header
5.4.2 Pressure control Menu
Source actual pressure p1,p2
Source set pressure p1,p2
Local set pressure 1.0bar Active line
KP 1.0rpm / mbar
KI 1.00rpm / (mbar *s)
Set pressure rise time 0s

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

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96 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 <Configuration – Operating modes – Pressure control> menu.

2. Use «Up» or «Down» to select the Set pressure rise time line.
3. Press «Enter».
The setting mode is active.
400mbar 08:15AM 80° C Header
5.4.2 Pressure control Menu
Source actual pressure p1,p2
Source set pressure p1,p2
Local set pressure 1.0bar
KP 1.0rpm / mbar
KI 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)

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No.: 901700 10 E 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 <Configuration – Operating modes – Pressure control> menu.

2. Use «Up» or «Down» to select the KP line.
3. Press «Enter».
The setting mode is active.
400mbar 08:15AM 80° C Header
5.4.2 Pressure control Menu
Source actual pressure p1,p2
Source set pressure p1,p2
Local set pressure 1.0bar
KP 1.0rpm / mbar Active line
KI 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 Header
5.4.2 Pressure control Menu
Source actual pressure p1,p2
Source set pressure p1,p2
Local set pressure 1.0bar
KP 1.0rpm / mbar
KI 1.00rpm / (mbar *s) Active line
Set pressure rise time 0s

9. Press «Up» to incrementally increase the value for KI until the system (pressure) continuously
compensates.
10. Use «Down» to 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 The proportional and integral amplification are set.

8.6.5 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.

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98 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 8 Initial Start-up
8.6 Operating modes in frequency-controlled machines

Precondition 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 <Configuration – External DI / AII signal – Current signal AII1.02> menu.
2. Use «Up» or «Down» to select the 4mA line.
400mbar 08:15AM 80° C Header
5.5.1 Current signal AII1.02 Menu
AII1.02 ☑
Value type Speed
Decimal places 0
Unit 1/min
4mA 1500/min Active line
20mA 2000/min

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:

■ xA (permanently)
■ xB (permanently)

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No.: 901700 10 E 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
<Configuration – External DI / AII signal – Current signal AII1.02> menu

1. Open the 5.4 <Configuration – Operating modes> 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.

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100 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
5.4.3 External values control Menu
▶1 Controller settings
Load control
off
------------------------------
xA active line
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 <Configuration – Operating modes – External values control – Controller
settings> menu.
400mbar 08:15AM 80° C Header
5.4.3.1 Controller settings Menu
KP 1rpm/% active line
KI 10rpm/s/%
Set value 0%
Actual value 0%
Set value ramp-up time 0s

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

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No.: 901700 10 E SIGMA CONTROL 2 BLOWER ≥ 2.5.3 101
 8 Initial Start-up
8.7 Setting the machine for master control operation

8.6.7 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 <Configuration – Operating modes> menu.

400mbar 08:15AM 80° C Header
5.4 Operating modes Menu
▶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 The change speed for the speed is set.

8.7 Setting the machine for master control operation

8.7.1 Overview of the different master operating modes
The controller offers several possibilities to work together with other controllers:

Method Description Section

SIGMA AIR You must modify the settings in SIGMA CONTROL 2 for the op‐ 8.7.2
MANAGER 4.0 mode eration via SIGMA NETWORK using the
KAESER SIGMA AIR MANAGEMENT SYSTEM (SIGMA AIR
MANAGER 4.0).

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102 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).
Master control via re‐ The machine is controlled by signals from a master controller. 8.5.4
mote contact
Master control of two The two SIGMA CONTROL 2 controllers operate as master and 8.7.4
machines in master/ slave.
slave operation

Tab. 64 Overview of the different master controllers

8.7.1.1 Priorities in master control operation

These priorities are valid in master control operation:

■ Bus (top priority)
■ External contacts (load contact)
■ Master/slave operation
■ Timer control (lowest priority)

8.7.2 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 <Communication – Ethernet/SIGMA NETWORK – IP configuration> menu.

2. Use «Up» or «Down» to select the IP address line.
400mbar 08:15AM 80° C Header
8.1.1 IP configuration Menu
IP address 169.254.100.103 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).

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No.: 901700 10 E 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 <Communication – Ethernet/SIGMA NETWORK – Connections – SAM 4.0>

menu.
2. Use «Up» or «Down» to select the SAM 4.0 active: line.
400mbar 08:15AM 80° C Header
8.1.2.2 SAM 4.0 Menu
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
8.1.2.2 SAM 4.0 Menu
Status Counter 0
No error
------------------------------
SAM 4.0 active: ☑
Send/Receive Active line
IP address : 169.254.100.100

9. Press the «Enter» key.

The setting is applied.

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104 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 Header
8.1.2.2 SAM 4.0 Menu
IP address : 169.254.100.100
Port : 2000
······························
Communication error : ☑
Start td: 15s active line
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 Header
8.1.2.2 SAM 4.0 Menu
IP address : 169.254.100.100
Port : 2000
······························
Communication error : ☑
Start td: 30s active line
Timeout : 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.

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 8 Initial Start-up
8.7 Setting the machine for master control operation

400mbar 08:15AM 80° C Header

8.1.2.2 SAM 4.0 Menu
IP address : 169.254.100.100
Port : 2000
······························
Communication error : ☑ active line
Start td 30s
Timeout : 5s ☑

Settings for connection to SAM 4.0.

Parameters Factory setting Set value

Check box Communication error Check box ☑ activated 1)

Start td 30 s
Timeout 5s
Check box Timeout Check box ☑ activated
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:
■ 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

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 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 <Communication – Com-Module> 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.

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 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:

Parameters Factory setting Set value

Timeout 5s 5s
Monitoring Check box ☑ activated Check box ☑ activated

Tab. 67 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 <Communication – Com-Module> 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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108 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 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.

Parameters Factory setting Set value

Start td 15 s

Tab. 68 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.

Parameters Factory setting Set value

Timeout 5s
Monitoring Check box ☑ activated

Tab. 69 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 <Communication – Com-Module> 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.

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 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 2. Set IP address.
apply the IP-Parameter. 3. Set Subnet mask.
The communication module is started with
4. Set the Gateway address.
the set parameters.
5. DNS Server 1-Setting address (optional).
Communication with the bus master is run‐
ning. 6. DNS Server 2-Setting address (optional).
Time-out at bus fault is activated. 7. Activate the Use IP settings check box to
apply the IP-Parameter.
Bus communication is now monitored. The
The communication module is started with
number behind Status Counter (Run) con‐
the set parameters.
tinuously changes during communication.
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.

Parameters Factory setting Set value

Start td 15 s

Tab. 70 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.

Parameters Factory setting Set value

Timeout 5s
Monitoring Check box ☑ activated

Tab. 71 Setting the Timeout parameter

➤ Enter the required settings, as described above.

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110 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 8 Initial Start-up
8.7 Setting the machine for master control operation

8.7.3.5 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 <Communication – Com-Module> 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.

Parameters Factory setting Set value

Start td 15 s

Tab. 72 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.

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 8 Initial Start-up
8.7 Setting the machine for master control operation

Parameters Factory setting Set value

Timeout 5s
Monitoring Check box ☑ activated

Tab. 73 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 <Communication – Com-Module> 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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112 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.

Parameters Factory setting Set value

Timeout 5s
Monitoring Check box ☑ activated

Tab. 75 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 <Communication – Com-Module> 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.

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 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 2. Set IP address.
apply the IP-Parameter. 3. Set Subnet mask.
The communication module is started with
4. Set the Gateway address.
the set parameters.
5. DNS Server 1-Setting address (optional).
Communication with the bus master is run‐
ning. 6. DNS Server 2-Setting address (optional).
Time-out at bus fault is activated. 7. Activate the Use IP settings check box to
apply the IP-Parameter.
Bus communication is now monitored. The
The communication module is started with
number behind Status Counter (Run) con‐
the set parameters.
tinuously changes during communication.
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.

Parameters Factory setting Set value

Start td 15 s

Tab. 76 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.

Parameters Factory setting Set value

Timeout 5s
Monitoring Check box ☑ activated

Tab. 77 Setting the Timeout parameter

➤ Enter the required settings, as described above.

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114 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 8 Initial Start-up
8.7 Setting the machine for master control operation

8.7.3.8 Activating the remote control

➤ Activate remote control see chapter 8.2.13.

Result SIGMA CONTROL 2 remote control is activated.

8.7.4 Master control of two machines in master/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:

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

Tab. 78 Master-slave settings

8.7.4.1 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.

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 8 Initial Start-up
8.7 Setting the machine for master control operation

Fig. 31 Direct connection of two SIGMA CONTROL 2

1 Controller machine 1 (Master mode) 4 Controller machine 2 (Slave mode)
2 Ethernet interface X1 5 Ethernet interface X1
3 Ethernet cable, cross-linked

➤ 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 Setting the controller of machine 1 as master

Precondition The electrical connection is made.

Access level 2 is activated.

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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:
■ IP addressController machine 1 (Master mode): 169.254.100.101
■ IP address Controller machine 2 (Slave): 169.254.100.102

Precondition The electrical connection is made.

Access level 2 is activated.

1. Set IP address for the 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 <Communication – Ethernet/SIGMA NETWORK – Connections – SIGMA
CONTROL 2> 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 Header
8.1.2.1 SIGMA CONTROL 2 Menu
Status Run 1¦Error 0
------------------------------
Mode : Master Active line
Port : 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 (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.

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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:
■ IP addressController machine 1 (Master mode): 169.254.100.101
■ IP address Controller machine 2 (Slave): 169.254.100.102

Precondition The electrical connection is made.

Access level 2 is activated.

1. Set IP address for the slave; see chapter 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 <Communication – Ethernet/SIGMA NETWORK – Connections – SIGMA
CONTROL 2> 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 Header
8.1.2.1 SIGMA CONTROL 2 Menu
Status Run 1¦Error 0
------------------------------
Mode : Slave Active line
Port : 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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 8 Initial Start-up
8.7 Setting the machine for master control operation

8.7.4.4 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 <Maintenance – Load balancing> menu.

2. Use «Up» or «Down» to select the Load balancing line.
400mbar 08:15AM 80° C Header
4.1 Load balancing
Load balancing ☐ Active line with inactive check box
dt maintenance hours 5h
Maintenance Master 1h
Maintenance Slave 1h
Master state ready
Slave state ready

3. Press «Enter».
The setting mode is active.
400mbar 08:15AM 80° C Header
4.1 Load balancing
Load balancing ☑ Active line with activated check box
dt maintenance hours 5h
Maintenance Master 1h
Maintenance Slave 1h
Master state ready
Slave state ready

4. Press the «Up» key.

The check box is activated.
5. Press «Enter».
The setting is applied.

Result Load balancing is activated.

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 8 Initial Start-up
8.8 Setting input and output signals

8.8 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:

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

Tab. 79 Assigned output signals

8.8.1.1 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 <Configuration – I/O periphery – DO-functions> menu.

A menu containing a list of available messages and their assigned outputs is displayed.
400mbar 08:15AM 80° C 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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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
5.10.1 DO-functions Menu
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.
■ Enter the message text
■ Assign and activate the input

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 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.

8.8.2.1 External messages menu

Precondition The electrical connection has been made.

Access level 2 is activated.

1. Open the 5.10.2 <Configuration – I/O periphery – External messages> menu.

The External messages menu is displayed.
400mbar 08:15AM 80° C 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 ☐ No input assigned
td: 0s ¦ Logic : + Logic
DOR1.04 ☐
Warning ☑ 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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122 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
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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 : + Logic
DOR1.04 ☐
Warning ☑ 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 08:15AM 80° C Header
5.10.2.1 External message 1 Menu
External message 1 Message text
DI1.07 ok ☑ Input selected
td: 0s ¦ Logic : + Logic
DOR1.04 ☐
Warning ☑ 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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 8 Initial Start-up
8.8 Setting input and output signals

2. Press «Enter».
The td delay time flashes.
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5.10.2.1 External message 1 Menu
External message 1 Message text
DI1.07 ok ☑ Input selected
td: 0s ¦ Logic : + set time delay td
DOR1.04 ☐
Warning ☑ 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 Sign
24 V +
0V -

Tab. 80 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 ok ☑ Input selected
td: 0s ¦ Logic : + active line, set logic control field
DOR1.04 ☐
Warning ☑ 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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124 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 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 ok ☑ Input selected
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 ok ☑ Input selected
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 The signal at the DI digital input is available as External message 1 and as output signal at the
selected DOR output.

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 8 Initial Start-up
8.8 Setting input and output signals

8.8.3 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 # Output
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 control- 0097 O
end (rotary screw blower)) 0098 W
0097 A
T_S Threshold for temperature T_S (temperature underneath 0098 O
sound enclosure) 0099 W
0098 A
block speed 1) Threshold for the airend speed 0096 O/W/A
1)
Power switching with frequency converter (OFC/SFC)

Tab. 81 Available measured values

Example: Setting for the inlet pressure p1.

Precondition Access level 2 is activated

1. Open the 5.10.3 <Configuration – I/O periphery – Switch> 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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126 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 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
5.10.3.1 p1 Menu
active: ☐ active line with check box
······························
SP: 0.40bar ¦ SD: 0.0bar Switching point (SP) and switching differential (SD)
td 0s ¦ Logic + Delay (td) and logic
DOR1.01 ☐ Output DOR
DOT1.01 ☐ Output DOT

8.8.3.1 Setting the switching point and switching differential

1. Use «Up» or «Down» to select the SP line.

400mbar 08:15AM 80° C Header
5.10.3.1 p1 Menu
active: ☐
······························
SP: 0.40bar ¦ SD: −0.2bar Switching point (SP) and switching differential (SD)
td 0s ¦ Logic + 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
5.10.3.1 p1 Menu
active: ☐
······························
SP: 0.40bar ¦ SD: −0.2bar Switching point (SP) and switching differential (SD)
td 120s ¦ Logic + Delay (td) and logic
DOR1.01 ☐ Output DOR
DOT1.01 ☐ Output DOT

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
5.10.3.1 p1 Menu
active: ☐
······························
SP: 0.40bar ¦ SD: −0.2bar Switching point (SP) and switching differential (SD)
td 120s ¦ Logic + Delay (td) and logic
DOR1.03 ok ☑ Output DOR
DOT1.01 ☐ Output DOT

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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128 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 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
5.10.3.1 p1 Menu
······························
SP: 0.40bar ¦ SD: −0.2bar Switching point (SP) and switching differential (SD)
td 120s ¦ Logic + Delay (td) and 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
5.10.3.1 p1 Menu
active: ☑ active line with check box
······························
SP: 0.40bar ¦ SD: −0.2bar Switching point (SP) and switching differential (SD)
td 120s ¦ Logic + Delay (td) and logic
DOR1.03 ok ☑ Output DOR
DOT1.01 ☐ Output DOT

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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 8 Initial Start-up
8.9 Activating remote acknowledgement

8.9 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 Setting the remote acknowledgement function

Precondition 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 <Configuration – External DI / AII signal> menu.

2. Use «Up» or «Down» to select the Acknowledge messages line.
400mbar 08:15AM 80° C Header
5.5 External DI / AII signal 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 Header
5.5 External DI / AII signal 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 Access level 2 is activated.

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 8 Initial Start-up
8.11 Commissioning the machine

1. Open the 11.1.1 <Error behaviour – Communication – SAM 4.0> menu.

400mbar 08:15AM 80° C Header
11.1.1 SAM 4.0 Menu
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 Commissioning the machine

Checking the controller settings Section Confirmed?
➤ 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

Tab. 82 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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132 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 8 Initial Start-up
8.11 Commissioning the machine

Fig. 32 Operating mode

2. Continue the commissioning process as described in chapter "Commissioning" of the ma‐

chine's operating manual.

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

Fig. 33 Switching the compressed air station on and off

7 «ON» key 14 IDLE LED
8 «OFF» key 15 LOAD LED
13 «Load/Idle» toggle key 16 Voltage applied to controller LED

9.1.1 Switching on
Precondition 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
<10 s 6
≥10 s 4
In screw blowers plus 2 minutes pause between OFF and ON

Tab. 83 Maximum permissible number of motor starts per hour

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 9 Operation
9.2 Switching off in an emergency

Automatic restart

If a power failure occurs, the machine is not prevented from automatically re-starting when power is
resumed.
It can automatically re-start as soon as power is restored.
➤ The "Automatic restart" function is deactivated by default.
See chapter 8.5.3 for setting this function.

9.1.2 Switching off

1. Press the «OFF» key.
When the machine switches to IDLE (as per configuration), and during the fan run-on time,
the On LED flashes. The ON LED extinguishes as soon as the automatic shut-off action is
completed.
2. Switch off and lock out the power supply isolating device.

Result The Voltage applied to controller LED extinguishes. The machine is switched off and disconnected
from the power supply.

In rare cases, you may want to shut down the machine immediately and cannot wait until the
automatic shut-down process is finished?
➤ Press the «OFF» key a second time.
The compressor drive and the sound enclosure fan are immediately switched off.

9.2 Switching off in an emergency

The EMERGENCY STOP command device is located below or to the right of the controller.

Fig. 34 Switching off in an emergency

22 EMERGENCY STOP command device

Switching off

➤ Press the EMERGENCY STOP command device.

After actuating the EMERGENCY STOP command device, the machine is shut down. How‐
ever, the machine is still connected to the electrical mains supply.

Result The EMERGENCY STOP command device remains latched after actuation.
The machine is secured against an automatic restart.

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 9 Operation
9.3 Acknowledging alarm and warning messages

Switching on

Precondition The fault has been rectified

1. Turn the EMERGENCY STOP command device in the direction of the arrow to unlatch it.
2. Acknowledge any existing alarm messages.

Result The machine can now be started again.

9.3 Acknowledging alarm and warning messages

Messages are displayed on the "new value" principle. You can acknowledge warning or fault mes‐
sages immediately after Message coming or Message going. However, warning and fault messag‐
es can be acknowledged only following a successful elimination of the corresponding fault.
Message sequence 1 Display
Message coming LED flashes
Message acknowledged LED illuminates
Message going LED off

Tab. 84 Message sequence 1

Message sequence 2 Display

Message coming LED flashes
Message going LED flashes
Message acknowledged LED off

Tab. 85 Message sequence 2

Fig. 35 Acknowledging messages

17 Warning LED (yellow)
20 Alarm LED (red)
21 «Acknowledge» key

Fault message

A fault message shuts the machine down automatically.

The red Fault LED flashes.

Precondition The fault has been rectified

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136 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 9 Operation
9.4 Displaying messages

➤ Press the «Acknowledgement» key to acknowledge the fault message.

Alarm LED extinguishes. The machine is ready to start again.
The machine has been stopped with the EMERGENCY STOP command device.
➤ First turn the EMERGENCY STOP command device in the direction of the arrow to un‐
lock it.
➤ Then acknowledge the fault message.

Further information A list of possible fault messages occurring during operation are shown in chapter 10.2.

Warning message

If maintenance work is to be carried out or if the warning is displayed before a fault, the yel‐
low warning LED flashes.

Precondition The risk of a fault has been eliminated

Maintenance has been carried out

➤ Press the «Acknowledgement» key to acknowledge the warning message.

The Maintenance LED extinguishes. The machine is ready to start again.

Further information A list of possible warning messages occurring during operation are shown in chapter 10.3.

9.4 Displaying messages

The following information can be accessed in the 1.1 <Status – Messages> menu:
■ Current messages
─ Last alarm
─ Last warning
─ Number of currently registered fault and/or warnings
■ Messages history: The last 1000 events, these include fault and warning messages
─ Blower messages
─ Diagnostic messages
─ System messages

The information (message) is shown in three lines of the display.

Line Submenu/Segment/Text
1 Selected submenu:
■ Blower messages
■ Diagnostic messages
■ System messages
2 Segment:
■ Message number
■ Type of message
■ Message status
■ Message date
■ Message time

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 9 Operation
9.4 Displaying messages

Line Submenu/Segment/Text
3 Text:
■ Message text
■ –

Tab. 86 Information of a message

Message type and status are shown abbreviated.

Segment Display Meaning
Message number 0059 (example) Message 0059
Type of message W Warning and maintenance message
A Alarm
Message status c Message has come
g Message gone
a Message acknowledged
Date 04/13/20 (example) Date
Time 08:15:37AM (example) Time

Tab. 87 Message abbreviations

9.4.1 Status – Messages menu

1. Open the 1.1 <Status – Messages > menu.
The Messages menu is displayed
The number of current faults and warnings is displayed in the two bottom lines.
400mbar 08:15AM 80° C Header
1.1 Messages Menu
▶1 Current messages active line
▶2 Messages history
▶3 Address error
------------------------------
current Alarms 2 Number of currently registered faults
Warnings 1 Number of currently registered warnings

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 9 Operation
9.4 Displaying messages

Displaying the last fault/warning

1. Open the 1.1.1 <Status – Messages – Current messages> menu.

The third line displays the last fault or warning message.
400mbar 08:15AM 80° C Header
1.1.1 Current messages Menu
0002 A c 04/16/20 01:32:49PM Last message
Overload blower motor
0015 W a 04/16/20 01:06:43PM Second to last message
Bus alarm
0005 W c 04/13/20 08:15:37AM
T1 ↑

2. Press «Escape» repeatedly to leave this menu.

Displaying the message history

1. Open the 1.1.2 <Status – Messages – Messages history> menu.

400mbar 08:15AM 80° C Header
1.1.2 Messages history Menu
▶1 Blower messages Active line with sub-menu: Blower messages
▶2 Diagnostic messages Diagnostic messages
▶3 System messages System messages

2. Press «Enter».
The 1.1.2.1 Blower messages menu is displayed.
The third line displays the last fault or warning message.
400mbar 08:15AM 80° C Header
1.1.2.1 Blower messages Menu
0002 A c 04/16/20 01:32:49PM Last message
Overload blower motor Message text for message 0002
0015 W a 04/16/20 01:06:43PM
Bus alarm Message text for message 0015
0005 W c 04/16/20 08:15:37AM
T1 ↑ Message text for message 0005

3. Press «Escape» repeatedly to leave this menu.

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 9 Operation
9.5 Displaying analogue data

9.5 Displaying analogue data

The following information can be called up in the Performance data menu:
■ Pressures
─ Inlet pressure p1
─ Discharge pressure p2
─ Differential pressure dp
─ Pressure ratio π = p2_a / p1_a
─ Drag indicator p1 min
─ Drag indicator p2 max
■ Temperatures
─ Inlet temperature T1
─ Discharge temperature T2
─ Temperature difference dT
─ Oil temperature, control side T3 (screw blower)
─ Sound enclosure temperature T_S
─ Internal temperature, controller MCS
─ Internal temperature, I/O module First IOM
■ Speeds
─ Motor
─ Block
■ External values
─ Pressure at input AII1.02
─ Speed at input AII1.02
─ Value at input AII1.02
─ Value (with one decimal place) at the input AII1.02
─ Value (with two decimal places) at the input AII1.02
■ Curves
─ Inlet pressure/inlet temperature p1/T1 curve
─ Discharge pressure/discharge temperature p2/T2 curve
─ Sound enclosure temperature/inlet temperature T_S/T1 curve
─ Discharge pressure/speed p2/f curve
─ Pressure ratio/oil temperature π/T3 curve
─ Inlet pressure/speed p1/f curve
■ Frequency converter
─ Speed
─ Current
─ DC link voltage DC link voltage
─ Torque

Displaying analogue data

Precondition The operating mode is displayed.

1. Open the 2 <Performance data> menu.

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9.6 Displaying operating data

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

400mbar 08:15AM 80° C Header
2 Performance data Menu
▶1 Pressures Active line
▶2 Temperatures
▶3 Speeds
▶4 External values
▶5 Curves
▶6 Frequency converter

3. Press «Enter».
The analogue data for pressures are displayed.
400mbar 08:15AM 80° C Header
2.1 Pressures Menu
p1 0.0bar Active line with inlet pressure
p2 0.0bar
dp 0.0bar
π = p2_a / p1_a 0.0
------------------------------
Drag indicator

4. Press «Escape» repeatedly to leave this menu.

➤ Display other analogue values in the same manner.

9.6 Displaying operating data

The following information can be called up in the Operating data menu:
■ Operating hours
─ Blower package: Total machine running time
─ On load: Machine running time in LOAD mode
─ Motor: Running time of drive motor (adjustable)
─ Block: Running time of blower block (adjustable)
─ SIGMA CONTROL 2: Controller running time
─ OFC/SFC: FC block drive: Running time of the frequency converter

Display the operating hours

Precondition The operating mode is displayed.

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9.6 Displaying operating data

1. Open the 3.1 <Operating data – Operating hours> menu.

The Operating hours menu is displayed
400mbar 08:15AM 80° C Header
3.1 Operating hours Menu
Blower package 3050h active line
On load 3050h
Motor 3050h
Block 3050h
SIGMA CONTROL 2 3050h
FC block drive 3050h

Changing the operating hours

You can adjust the running times of the drive motor (Motor) and the compressor. This may be re‐
quired after a replacement, for example.

Precondition Access level 2 is activated.

1. Open the 3.1 <Operating data – Operating hours> menu.

400mbar 08:15AM 80° C Header
3.1 Operating hours Menu
Blower package 3050h
On load 3050h
Motor 3050h active line
Block 3050h
SIGMA CONTROL 2 3050h
FC block drive 3050h

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

3. Press «Enter».
The display of the running time flashes (e.g., 3050 h).
400mbar 08:15AM 80° C Header
3.1 Operating hours Menu
Blower package 3050h
On load 3050h
Motor 0h active line
Block 3050h
SIGMA CONTROL 2 3050h
FC block drive 3050h

4. Use «Down» or «Up» key to set the value for operating hours to zero.
5. Press the «Enter» key.
The setting is applied.
6. Press «Escape» repeatedly to leave this menu.

Result The operating hours for the new drive motor are set to 0 h.

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9.7 Setting the maintenance interval

9.7 Setting the maintenance interval

Example: Changing the lubricating oil change maintenance interval.

Precondition Access level 2 is activated.

The operating mode is displayed.

1. Open the 4 <Maintenance> menu.

2. Use «Up» or «Down» to select the line displaying the maintenance interval to be set.
400mbar 08:15AM 80° C Header
4 Maintenance
▶1 Load balancing
Change block oil Maintenance interval description
3000h ¦ 2799h Reset ☐ Active line, factory-defined interval 3000 h
······························
Change belt

3. Press «Enter».
The maintenance interval display flashes.
4. Use «Up» or «Down» to set the new value for the maintenance interval.
Keep the «Up» or «Down» key pressed to quickly change the maintenance interval in incre‐
ments of 10, 100 or 1000.

5. Press «Enter».
The setting is applied.
6. Press the «Right» arrow twice.
7. Press «Enter».
The check box will flash.
8. Press the «Up» key.
The check box is activated.
9. Press the «Enter» key.
The counter for the maintenance interval is reset.
10. Press «Escape» repeatedly to leave this menu.

9.8 Communication modules

9.8.1 Displays at the PROFIBUS module

The communication module features LEDs providing information about the module status.

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9.8 Communication modules

Fig. 36 PROFIBUS communication module – LEDs and interface

1 PROFIBUS communication module 3 LED ST: Status
2 LED OP: Operating mode 4 Sub-D port, 9 poles

LED Colour State Meaning

OP off Module without voltage/not connected to bus
Green flashes Module connected to bus
illuminates continuously Module connected to bus, communication is running
Red flashes 1:1 (on:off) Parametrisation error
flashes 2:1 (on:off) PROFIBUS configuration error
ST off Module without voltage/deactivated
Green illuminates continuously Module in operation
flashes Module in operation, internal diagnosis available
Red illuminates continuously Error

Tab. 88 PROFIBUS communication module – Interpretation of LEDs

9.8.2 Display at the Modbus module

The communication module features LEDs providing information about the module status.

Fig. 37 Modbus communication module – LEDs and interface

1 Communications module 3 LED DS: Device Status
2 LED Common rail system: Communication 4 Sub-D port, 9 poles

LED Colour State Meaning

Common rail off Module without voltage or no communication
system Yellow illuminates continuously Module connected to bus, communication is
running
Red illuminates continuously Error

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9.8 Communication modules

LED Colour State Meaning

DS off Module without voltage/deactivated
Green illuminates continuously Module in operation
Red illuminates continuously Error
flashes 1:1 (on:off) Configuration fault
flashes 2:1 (on:off) Module in operation, internal diagnosis availa‐
ble

Tab. 89 Modbus communications module – Interpretation of LEDs

9.8.3 Displays at the Modbus TCP module

The communication module features LEDs providing information about the module status.

Fig. 38 Modbus TCP communication module – LEDs and interface

1 Communications module 5 Modbus TCP Port 2
2 LED NS: Network status 6 LED connection status Port 1
3 LED MS: Module status 7 LED connection status Port 2
4 Modbus TCP Port 1

LED Colour State Meaning

2 NS off Module without voltage or IP address not available
Green illuminates continuously Module in operation, active or idle
flashes Module waits for connection
Red illuminates continuously Duplicate IP address or internal fault
flashes Monitoring time exceeded (time-out)
3 MS off Module without voltage
Green illuminates continuously Module in operation
Red illuminates continuously Internal fault, module in "EXCEPTION" status
flashes Fault in diagnostic object or IP address conflict

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9.8 Communication modules

LED Colour State Meaning

6, 7 off No connection.
Green illuminates continuously Connection established, 100 Mbit/s
flashes Communication running, 100 Mbit/s
Yellow illuminates continuously Connection established, 10 Mbit/s
flashes Communication running, 10 Mbit/s

Tab. 90 Modbus TCP communications module – Interpretation of LEDs

9.8.4 Display at the DeviceNet module

The communication module features LEDs providing information about the module status.

Fig. 39 DeviceNet communication module – LEDs and interface

1 Communications module 3 LED MS: Module status
2 LED NS: Network status 4 DeviceNet connection plug

LED Colour State Meaning

NS off Module without voltage/not connected to bus
Green flashes Module connected to bus
illuminates continuously Module connected to bus, communication is running
Red flashes Time-out, communication interrupted
illuminates continuously Connection fault
Red/Green alternating Self test
MS off Module without voltage/deactivated
Green illuminates continuously Module in operation
flashes Incomplete configuration, commissioning required
Red flashes Recoverable error
illuminates continuously Unrecoverable error
Red/Green alternating Self test

Tab. 91 DeviceNet communications module – Interpretation of LEDs

9.8.5 Displays at the PROFINET module

The communication module features LEDs providing information about the module status.

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9.8 Communication modules

Fig. 40 PROFINET communication module – LEDs and interface

1 Communications module 5 PROFINET Port 2
2 LED NS: Network status 6 LED connection status Port 1
3 LED MS: Module status 7 LED connection status Port 2
4 PROFINET Port 1

LED Colour State Meaning

2 NS off Offline

■ Module without voltage

■ No communication with the IO controller
Green illuminates continuously Online (RUN)

■ Module connected to bus, communication is running

■ IO controller in RUN mode
flashes Online (STOP)

■ Module connected to bus, communication is running

■ IO controller in STOP mode
3 MS off Not initialised

■ Module without voltage

■ Module in "Setup" status
■ Module in "NW-INIT" status
Green illuminates continuously Module in operation
flashes 1:1 (on:off) Diagnostic data available
flashes 2:1 (on:off) Is used by Engineering Tools to identify the network node
Red illuminates continuously Module in "EXCEPTION" status
flashes 1:1 (on:off) Configuration fault
flashes 2:1 (on:off) IP address not set
flashes 3:1 (on:off) Station name not set
flashes 4:1 (on:off) Internal error
6, 7 off No connection.
Green illuminates continuously Connection established, no communication
flashes Communication in operation

Tab. 92 PROFINET communications module – Interpretation of LEDs

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9.9 Save data

9.8.6 Displays at the EtherNet/IP-Module

The communication module features LEDs providing information about the module status.

Fig. 41 EtherNet/IP communication module – LEDs and interface

1 Communications module 5 EtherNet/IP Port 2
2 LED NS: Network status 6 LED connection status Port 1
3 LED MS: Module status 7 LED connection status Port 2
4 EtherNet/IP Port 1

LED Colour State Meaning

2 NS off Module without voltage or IP address not available
Green illuminates continuously Module in operation, connection has been made
flashes Module waits for connection
Red illuminates continuously Duplicate IP address or internal fault
flashes Monitoring time exceeded (time-out)
3 MS off Module without voltage
Green illuminates continuously Module in operation, master communicates (scanner in
run status)
flashes Module not configured or master in idle (scanner in idle
status)
Red illuminates continuously Internal fault, module in "EXCEPTION" status
flashes The currently used settings do not correspond to the
saved settings
6, 7 off No connection.
Green illuminates continuously Connection established, 100 Mbit/s
flashes Communication running, 100 Mbit/s
Yellow illuminates continuously Connection established, 10 Mbit/s
flashes Communication running, 10 Mbit/s

Tab. 93 EtherNet/IP communication module – Interpretation of LEDs

9.9 Save data

SIGMA CONTROL 2 settings can be backed up to an SD card.

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9.9 Save data

Precondition An SD card with compatible file system (FAT32) and minimum 50 MB free memory is plugged into
the SD card slot X5 of SIGMA CONTROL 2
The write protection of the SD card has been deactivated.
Access level 2 is activated.

1. Open the 5.6 <Configuration – Save data> menu.

2. Use «Up» or «Down» to select the Language: line.
400mbar 08:15AM 80° C Header
5.6 Save data Menu
Language: en_GB English Active line
······························
Save data :☐
······························
Eject SD card :☐
Status recognised

3. Press «Enter».
The display for the set language flashes.
4. Use «Up» or «Down» to select the desired language.
5. Press «Enter».
The setting is applied.
6. Use «Up» or «Down» to select the Save data line.
400mbar 08:15AM 80° C Header
5.6 Save data Menu
Language: en_GB English
······························
Save data :☑ Active line
······························
Eject SD card :☐
Status recognised

7. Press «Enter».
The check box Save data will flash.
8. Press «Up».
The check box is activated.
9. Press «Enter».
A security query is displayed.
10. Press «Enter».

Result The settings are saved on the SD card.

Safely remove the SD card.

1. Use «Up» or «Down» to select the Eject SD card line.

2. Press «Enter».
The check box Eject SD card will flash.

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 9 Operation
9.9 Save data

3. Press «Up».
The check box is activated.
400mbar 08:15AM 80° C Header
5.6 Save data Menu
Language: en_GB English
······························
Save data :☑
······························
Eject SD card :☑ Active line
Status recognised

4. Press the «Enter» key.

A security query is displayed.
5. Press «Enter».

Result The SD card is securely logged off from the electronic control and can be removed without the risk
of data loss.

9.9.1 Format SD card

Precondition The operating mode is displayed
The machine has been switched off with the «OFF» key
The EMERGENCY STOP command device has been actuated

1. Open the 5.6 <Configuration – Save data> menu.

2. Use «Up» or «Down» to select the Format SD card line.
3. Press «Enter».
The check box Format SD card will flash.
4. Press «Up».
The check box is activated.
400mbar 08:15AM 80° C Header
5.6 Save data Menu
Save data :☑
······························
Eject SD card :☐
Status recognised
······························
Format SD card :☑ Active line

5. Press the «Enter» key.

A security query is displayed.
6. Press «Enter».
SD card being formatted.

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 10 Fault Recognition and Rectification
10.1 Basic instructions

10 Fault Recognition and Rectification

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

SIGMA CONTROL 2 will indicate three types of faults:

■ Fault on the machine:
The red LED flashes, the machine is shut down, see chapters 10.2 and 10.5.
■ Fault on the controller:
The machine is shut down, see chapter 10.6.
■ Warning:
The yellow LED illuminates, the machine is not shut down, see chapter 10.3.

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

10.2 Interpreting fault messages

If an input signal is classified as a fault, the controller will display the fault upon the signal's
arrival.

Consequences:
■ The red LED flashes:
■ The controller switches the machine off.
Fault messages are identified with the letter A.
The message numbers are not numbered consecutively.
In this table, you will see "%d" for a variable value, e.g. a number, duration or I/O address.

1)
Messages 0021, 0074–0075 and 0092-0096 are customer-specific.
Complete possible causes and remedies for your defined message text (see chapter 8.8).

Message Possible cause Remedy

0001 A EMERGENCY STOP com‐ Check operational safety.
Emergency stop mand device actuated. Unlatch the push button.
0002 A Overload shut-down of the Investigate cause of shut-down.
Overload blower motor drive motor. Check the drive motor.
Check operating conditions.
0003 A Current draw of the fan Check fan
Fan motor motor too high. Check operating conditions.
Defective fan motor.
Fan wheel is jammed or
damaged.

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 10 Fault Recognition and Rectification
10.2 Interpreting fault messages

Message Possible cause Remedy

0004 A Mains contactor does not Call KAESER SERVICE.
Mains contactor pull in.
feedback signal Mains contactor welded.
Reset spring at the mains
contactor defective.
Feedback contact defec‐
tive.
I/O wiring defective.
0005 A Fault in drive system. Check drive motor and belt drive.
Motor stop
0006 A Electric feed has incorrect Ensure right-hand rotation.
Phase error blower phase sequence. Check presence of all three phases.
motor
0007 A Vibration Check the removal of the transport securing
Vibration alarm device.
Check the vibration isolation of the connect‐
ing line.
Call KAESER SERVICE.
0008 A Lubricant level at the blow‐ Replenish with lubricating oil.
Oil level side A er block drive side too low.
0009 A Inlet pressure too low. Check operating conditions.
p1 ⇟ Inlet filter clogged. Check all feed lines, the inlet silencer at the
blower block and the inlet filter.
0010 A Discharge pressure too Check operating conditions.
p2 ⇞ high. Check all discharge lines, the discharge si‐
lencer and the blower block.
0011 A Differential pressure too Check operating conditions.
dp ⇞ high. Check all feed lines, discharge lines, the in‐
let and the discharge silencers and the
blower block.
0012 A Discharge temperature too Check ambient conditions.
T2 ⇞ high. Check the sound enclosure fan function.
0013 A Sound enclosure tempera‐ Keep ambient conditions within specified
T_S ⇞ ture too high. limits.
Check the sound enclosure fan function.
0014 A Sound enclosure tempera‐ Check function of the machine heating sys‐
T_S ⇟ ture too low. tem.
Keep ambient conditions within specified
limits.
0015 A Inlet temperature too high. Check operating conditions.
T1 ⇞ Check all feed lines, the inlet silencer and
the blower block.
Check ambient conditions.
0016 A Drive motor temperature is Check the ambient and operating condi‐
T_M ⇞ too high. tions.

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152 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 10 Fault Recognition and Rectification
10.2 Interpreting fault messages

Message Possible cause Remedy

0017 A T2/T1 temperature differ‐ Check operating conditions.
dT ⇞ ence too high. Check all feed lines, discharge lines, the in‐
let and the discharge silencers and the
blower block.
0018 A Inlet filter clogged. Replace the inlet filter.
Filter blocked
0019 A Internal fault, frequency Call KAESER SERVICE.
FC error %d converter.
0020 A Lubricant level at the blow‐ Replenish with lubricating oil.
Oil level side B er block control side too
low.
0021 A 1)

External message 1
0022 A Current draw of the fan Check fan
Aftercooler motor too high. Check operating conditions.
Temperature too high. Clean the aftercooler.
Aftercooler clogged.
0023 A A fault occurred in the data Call KAESER SERVICE.
USS bus transmission between con‐
communication error troller and the FC of the
compressor drive.
0024 A A diagnostic message has For more details, see the text of the diag‐
Diagnostics group alarm occurred. nostic message.
Call KAESER SERVICE.
0025 A Oil temperature is very Check the ambient and operating condi‐
T3 ⇞ high. tions.
0026 A Pressure ratio across the Inlet conditions (pressure) or back pressure
π=p2_a/p1_a ⇞ block is too high - fault. is too high.
Check filter.
Check the position of the process valves.
0027 A Inlet temperature is too Check the inlet conditions (pipe, space) -
T1 ⇟ low – Fault T1 very low. Check the ambient and operating condi‐
tions.
0028 A Blower USS bus fault Check connection and line path.
Error USS handler %d
0029 A USS Communication fault Check connection and line path.
PKW requests
failed %d %d
0030 A Error while activating the Call KAESER SERVICE.
Error FC ramp up FC.
0031 A Frequency converter fault Call KAESER SERVICE.
Motor: n min not
reached
0032 A Frequency converter fault Call KAESER SERVICE.
Heavy load monitoring
triggered

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 10 Fault Recognition and Rectification
10.2 Interpreting fault messages

Message Possible cause Remedy

0033 A Fault STO channels Check STO channels
Blower motor FC: STO-
function inactive
0034 A Fault STO channels Check STO channels
Blower motor FC off -
STO?
0035 A Working pressure very Check operating conditions.
dp ⇟ low. Check all feed lines, discharge lines, the in‐
let and the discharge silencers and the
blower block.
0036 A The drive motor is turning Changeover phase lines L1 and L2.
Rotational direction in the wrong direction.
block
0037 A The safety valve does not Call KAESER SERVICE.
pRV ⇞ open
0038 A Pressure peaks in the vac‐ Check operating conditions.
Drag indicator p1 ⇟ uum network
0039 A Pressure peaks in the Check operating conditions.
Drag indicator p2 ⇞ compressed air network
0040 A Over voltage in the power Check power supply.
Surge arrester supply (only in version for Call KAESER SERVICE.
Canada)
0050 A Fault in re-lubrication de‐ Contact KAESER SERVICE.
Greasing system vice
0057 A Compressor model uncer‐ Call KAESER SERVICE.
Model? tain.
0074 A 1)

External message 2
0075 A 1)

External message 3
0080 A Alarm from vibration moni‐ Call KAESER SERVICE.
Vibration monitoring toring
VSE ⇞
0092 A 1)

Switch p1
0093 A 1)

Switch p2
0094 A 1)

Switch T1
0095 A 1)

Switch T2
0096 A 1)

Switch block speed

0097 A 1)

Switch T3

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154 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 10 Fault Recognition and Rectification
10.3 Interpreting warning messages

Message Possible cause Remedy

0098 A 1)

Switch T_S
0100 A Fault of frequency convert‐ Check the manual of frequency converter
Frequency converter er provided by the custom‐ provided by the customer
group alarm er
0101 A Fault when switching on Check parametrisation of frequency convert‐
Error FC ramp up frequency converter provi‐ er provided by the customer
ded by the customer
0102 A The blower motor has not Check parametrisation of frequency convert‐
Motor: n min not reached the minimum er provided by the customer
reached speed
0103 A Difference between the Check parametrisation of frequency convert‐
Target / Actual speed target and actual speed of er provided by the customer or speed meas‐
deviation ⇞ the blower motor is too urement
much
0104 A Difference between the Check parametrisation of frequency convert‐
block speed measured and calculated er provided by the customer or speed meas‐
speed of the block is too urement
much
0140 A AFxM- valve actuator Check the actuator of the AFxM valve.
AFxM-valve actuator fault.. Check the wiring between IOM and the
error AFxM valve actuator
0141 A Control cabinet fan actua‐ Check the control cabinet fan for jamming.
Enclosure fan actuator tor fault. Check the wiring to the drive of the control
alarm cabinet fan.
Check the drive of the control cabinet fan.
0142 A AFxM- valve actuator Check the actuator of the AFxM valve.
AFxM-valve actuator fault.. Check the wiring between IOM and the
error AFxM valve actuator.
0500 A An I/O address has been Have the menu with the incorrect parametri‐
I/O parameterisation assigned more than once. sation displayed in the 1.1.3Address error
incorrect in module %d! menu and correct the parameter in there

Tab. 94 Fault messages and remedies

10.3 Interpreting warning messages

If an input signal is classified as a warning, the controller will display the warning upon the
signal's arrival.

Consequences:
■ The yellow LED flashes.
■ The controller does not switch off the machine.
Warning messages are identified with the letter W.
The message numbers are not numbered consecutively.

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 10 Fault Recognition and Rectification
10.3 Interpreting warning messages

In this table, you will see "%d" for a variable value, e.g. a number, duration or I/O address.

Messages 0021, 0074–0075 and 0092-0096 are customer-specific.

1)

Complete possible causes and remedies for your defined message text (see chapter 8.8).

Message Possible cause Remedy

0001 W Equipment number entered incom‐ Call KAESER SERVICE.
Equipment number pletely or not at all.
incomplete
0002 W Discharge pressure too high. Check operating conditions.
p2 ↑ Check all discharge lines, the dis‐
charge silencer and the blower
block.
0003 W Differential pressure too high. Check operating conditions.
dp ↑ Check all feed lines, discharge lines,
the inlet and the discharge silencers
and the blower block.
0004 W Ambient temperature too low. Check ambient conditions.
T_S ↓
0005 W Inlet temperature too high. Check operating conditions.
T1 ↑ Check all feed lines, the inlet silenc‐
er and the blower block.
Check ambient conditions.
0006 W Discharge temperature too high. Check ambient conditions.
T2 ↑ Check the sound enclosure fan func‐
tion.
0007 W T2/T1 temperature difference too Check operating conditions.
dT ↑ high. Check all feed lines, discharge lines,
the inlet and the discharge silencers
and the blower block.
0008 W Maximum number of switching cy‐ Call KAESER SERVICE.
Exchange mains cles for the mains contactor
contactor reached.
0009 W Sound enclosure temperature too Check ambient conditions.
T_S ↑ high. Check the sound enclosure fan func‐
tion.
0010 W Lubricant level at the blower block Replenish with lubricating oil.
Oil level side A drive side too low.
0011 W Lubricant level at the blower block Replenish with lubricating oil.
Oil level side B control side too low.
0012 W Inlet filter clogged. Replace the inlet filter.
Filter blocked
0013 W Differential pressure too low. Check operating conditions.
dp ↓ Check all feed lines, discharge lines,
the inlet and the discharge silencers
and the blower block.

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 10 Fault Recognition and Rectification
10.3 Interpreting warning messages

Message Possible cause Remedy

0014 W 1)

External message 1
0015 W The bus link via Com module inter‐ Check bus conduits and plug.
Com-Module face is interrupted.
communication error
0016 W Oil temperature T3 too low Check ambient conditions.
T3 ↓
0017W Oil temperature T3 too high (only Check the operating conditions
T3 ↑ when used in screw blowers) → oil (max. speed/pressure)
temperature Ambient temperature too high
Cooling air feed clogged
Check the direction of rotation for
the sound enclosure fan.
Call KAESER SERVICE.
0018W Pressure ratio across the block is Inlet conditions (pressure) or back
π=p2_a/p1_a ↑ too high - warning. pressure is too high.
Check filter.
Check the position of the process
valves.
0019W Inlet temperature too low – warning. Check the inlet conditions (pipe,
T1 ↓ room)
Check the climatic conditions in the
machine environment
0020W Compressor drive motor overhea‐ Keep ambient conditions within
T_M ↑ ted. specified limits.
Check the cooling air supply.
Clean the motor.
0021W Inlet pressure too low – warning. Check the inlet conditions (pipe,
p1 ↓ room)
Check the position of the process
valves.
Severe clogging of the inlet louvre.
0022W Max. switching frequency / h excee‐ Check the operating conditions
Motor starts ↑ ded. and/or operating mode.
0023W The numerical value is the fault Call KAESER SERVICE.
FC error %d code of the frequency converter.
0024W FC in service mode Deactivate the service mode in
FC service mode menu 10.1.1.2
activated
0025W STO channels must be tested. Switch off the FC.
Test of cut-of paths
required
0026W The test operation is active. Conclude the test operation.
Machine test
measurement of block
speed active

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 10 Fault Recognition and Rectification
10.3 Interpreting warning messages

Message Possible cause Remedy

0027W Relevant only for commissioning Call KAESER SERVICE.
Machine test safety
valve active
0038W Pressure peaks in the vacuum net‐ Check operating conditions.
Drag indicator p1 ⇟ work
0039W Pressure peaks in the compressed Check operating conditions.
Drag indicator p2 ⇞ air network
0040W Over voltage in the power supply Check power supply.
Surge arrester (only in version for Canada) Call KAESER SERVICE.
0045 W Test operation for the manual actua‐ Call KAESER SERVICE.
DO test active tion of individual outputs is active.
0050 W Fault in re-lubrication device Call KAESER SERVICE.
Greasing system
0058 W The electrical connection is interrup‐ Check the electrical connections.
SC2 <=> SC2 ted. Check the IP configuration.
communication error IP configuration incorrect
0074 A 1)

External message 2
0075 W 1)

External message 3
0080 W Alarm from vibration monitoring Check operating conditions.
Vibration monitoring
VSE ⇞
0081 W Warning from vibration monitoring Check operating conditions.
Vibration monitoring
VSE ↑
0082 W High vibration values Call KAESER SERVICE.
Vibration monitoring
sum signal ↑
0092 W 1)

Switch p1
0093 W 1)

Switch p2
0094 W 1)

Switch T1
0095 W 1)

Switch T2
0096 W 1)

Switch block speed

0097 W Bus link via SIGMA NETWORK in‐ Check bus lines and plug.
SAM 4.0 terrupted
communication error
0098 W 1)

Switch T3

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10.3 Interpreting warning messages

Message Possible cause Remedy

0099 W 1)

Switch T_S
0100 W The frequency converter provided Deactivate the service mode in
FC service mode by the customer is in service mode menu 10.1.1.3
activated
0200 W Lubricating oil: Change the lubricating oil.
Change lube h ↑ Maintenance interval has elapsed.
0201 W V-belt: Call KAESER SERVICE.
Change belt h ↑ Maintenance interval has elapsed.
0202 W Inlet filter: Replace the inlet filter.
Change filter h ↑ Maintenance interval has elapsed.
0203 W Air filter: Change the filter mat.
Change filter mat h ↑ Maintenance interval has elapsed.
0204 W Motor bearing of drive motor: Re-lubricate the motor bearing of
Motor bearings lube h Maintenance interval has elapsed. drive motor.
↑
0205 W Motor bearing of drive motor inspec‐ Check the motor bearing of drive
Check motor bearings tion. motor.
h↑
0206 W Motor bearing of drive motor: Call KAESER SERVICE.
Change motor Maintenance interval has elapsed.
bearings h ↑
0207 W Motor bearing of sound enclosure Call KAESER SERVICE.
Check motor bearings fan motor:
encl. fan h ↑ Maintenance interval has elapsed.
0208 W Motor bearing of control cabinet fan Call KAESER SERVICE.
Check control cabinet motor:
fan h ↑ Maintenance interval has elapsed.
0209 W Motor bearing of frequency convert‐ Call KAESER SERVICE.
Check FC fan h ↑ er fan motor:
Maintenance interval has elapsed.
0210 W Last maintenance was 1 year ago. Carry out the necessary mainte‐
Annual maintenance nance tasks and reset the corre‐
due sponding maintenance interval
counters.
0211 W Maintenance interval has elapsed Change the filter
Filter change
transmission venting h
↑
0212 W Maintenance interval has elapsed Carry out the necessary mainte‐
Electrical equipment h nance tasks and reset the corre‐
⇞ sponding maintenance interval
counters.
0300 W Fault while writing data to SD card. Call KAESER SERVICE.
SD card write error

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 10 Fault Recognition and Rectification
10.4 Interpreting operation messages

Message Possible cause Remedy

0868 W No continuity in line for ext. sensor Check cable runs and sensor con‐
AII%d.0%d - open at analogue input. nections.
circuit
0869 W Short circuit in line for ext. sensor at Check cable runs and sensor con‐
AII%d.0%d - short- analogue input. nections.
circuit
0874 W No continuity in line for ext. sensor Check cable runs and sensor con‐
AII%d.0%d - open at analogue input. nections.
circuit
0875 W Short circuit in line for ext. sensor at Check cable runs and sensor con‐
AII%d.0%d - short- analogue input. nections.
circuit
0880 W No continuity in line for ext. sensor Check cable runs and sensor con‐
AII%d.0%d - open at analogue input. nections.
circuit
0881 W Short circuit in line for ext. sensor at Check cable runs and sensor con‐
AII%d.0%d - short- analogue input. nections.
circuit
1000 W RFID reader fault Switch on the power supply and
RFID error: switch subsequently off again.
SIGMA CONTROL Contact KAESER SERVICE if the
power supply OFF → problem persists
ON!

Tab. 95 Warning messages and remedies

10.4 Interpreting operation messages

The controller will automatically display operation messages, informing you about the current op‐
erational state of the machine.
Operational messages are identified with the letter O.
The message numbers are not numbered consecutively.
In this table, you will see "%d" for a variable value, e.g. a number, duration or I/O address.

Messages 0092-0096 are customer-specific.

1)

Complete possible causes and remedies for your defined message text (see chapter 8.8).

Message Meaning
0011 O The optional heating has not yet heated the blower suffi‐
Waiting for cold start enabling ciently

0012 O The solenoid valve for the gear ventilation has opened
Oil return started
0013 O Currently the oil level is low. Wait for oil return, this may
Oil deficiency remedy the low oil level
Please wait for oil return

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 10 Fault Recognition and Rectification
10.4 Interpreting operation messages

Message Meaning
0014 O The restart inhibitor is still activated. Wait until the blow‐
Restart lock-out active er starts

0027 O The control has been switched on

Power OFF → ON
0038 O Pressure peaks in the vacuum network
Drag indicator p1 ⇟
0039 O Pressure peaks in the compressed air network
Drag indicator p2 ⇞
0073 O 1)

External message 1
0074 O 1)

External message 2
0075 O 1)

External message 3
0080 O Warning from vibration monitoring
Vibration monitoring VSE ↑
0081 O Increased vibration values
Vibration monitoring sum signal ⇡
0092 O 1)

Switch p1
0093 O 1)

Switch p2
0094 O 1)

Switch T1
0095 O 1)

Switch T2
0096 O 1)

Switch block speed

0097 O 1)

Switch T3
0098 O 1)

Switch T_S
0300 O Service information
Cycle-exact data recording active
1000 O You successfully registered 2 RFID Equipment Cards at
2 RFID Equipment Cards successfully the controller.
registered

Tab. 96 Operational messages

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 10 Fault Recognition and Rectification
10.5 Interpreting diagnostic messages

10.5 Interpreting diagnostic messages

A diagnostic message causes the machine to shut down.

Diagnostic messages are identified with the letter D.

They provide information on the status of the controller, the connected input and output modules
and support the KAESER SERVICE in trouble-shooting.

10.6 Interpreting system messages

A system message causes the machine to shut down.

System messages are identified with the letter Y.

The message numbers are not numbered consecutively.

Message Possible cause Remedy

0001 Y System error Call KAESER SERVICE.
Hardware watchdog reset
0002 Y System error Call KAESER SERVICE.
Internal software error
0003 Y System error Call KAESER SERVICE.
Filesystem Read/Write failure
0004 Y System error Call KAESER SERVICE.
CPU load too high
0005 Y System error Call KAESER SERVICE.
RAM out of memory

Tab. 97 System messages and remedies

10.7 Communication modules

10.7.1 Troubleshooting, PROFIBUS module
10.7.1.1 Machine and SIGMA CONTROL 2

In the event of a fault in the bus communication, the red "Communication" and the yellow "Warn‐
ing" LEDs flash at the SIGMA CONTROL 2. The system displays the following warning message:

Message Possible cause Measure

0015 W Com-Module Bus coupling via communication module Check bus lines and plug.
communication error is interrupted.
Incorrect or faulty communication mod‐ Check communication
ule module, see below.

Tab. 98 Com-Module communication error warning message

In addition to the 0015 W Com-Module communication error warning message, the system dis‐
plays the following information for troubleshooting:

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 10 Fault Recognition and Rectification
10.7 Communication modules

1. For displays on the communication module, see chapter 9.

Please contact KAESER Service if one or both of the LEDs are lit up or flash red.
2. Displays in the <Communication – Com-Module> menu.
In the 8.2 <Communication – Com-Module> menu, communication faults are displayed as text
beneath the line Status or as a number after the term Error.

No.: Fault text Possible cause Measure

1 COM Module fault Defective module. Call KAESER SERVICE.
2 Communication Bus coupling via commu‐ Check bus conduits and plug.
error nication module is inter‐
rupted.
Incorrect slave address of Set the slave address at the
the module. SIGMA CONTROL 2 as parametrised at
the bus master.
3 Firmware error Defective module. Call KAESER SERVICE.
4 COM Module Module is not activated. Start the communication, see chapter 8.
deactivated
5 COM Module not No KAESER communica‐ Use only original KAESER communication
identified tion module. module.
90 Error Bus Bus master does not re‐ ■ Check the software of the bus master.
monitoring turn the toggle bit within Check the time-out time, see chapter
the monitoring interval. 8.
■ Deactivate monitoring if it has been ac‐
tivated inadvertently. See chapter 8.

Tab. 99 Fault displays in the Communication – Com-Module menu.

Result The bus communication is automatically continued as soon as the cause of the fault is remedied.

10.7.2 Troubleshooting at the Modbus module

10.7.2.1 Machine and SIGMA CONTROL 2

In the event of a fault in the bus communication, the red "Communication" and the yellow "Warn‐
ing" LEDs flash at the SIGMA CONTROL 2. The system displays the following warning message:

Message Possible cause Measure

0015 W Com-Module Bus coupling via communication module Check bus lines and plug.
communication error is interrupted.
Incorrect or faulty communication mod‐ Check communication
ule module, see below.

Tab. 100 Com-Module communication error warning message

In addition to the 0015 W Com-Module communication error warning message, the system dis‐
plays the following information for troubleshooting:
1. See chapter 9 for display on the communication module.
If one or both LEDs are illuminated red or blink red, contact KAESER SERVICE.

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 10 Fault Recognition and Rectification
10.7 Communication modules

2. Displays in the <Communication – Com-Module> menu.

In the 8.2 <Communication – Com-Module> menu, communication faults are displayed as text
beneath the line Status or as a number after the term Error.

No.: Fault text Possible cause Measure

1 COM Module fault Defective module. Call KAESER SERVICE.
2 Communication Bus coupling via communi‐ Check bus lines and plug.
error cation module is interrup‐
ted.
Incorrect address settings Set the values at SIGMA CONTROL 2 as
or bus parameters in the parametrised at the bus master.
module.
3 Firmware error Defective module. Call KAESER SERVICE.
4 COM Module Module is not activated. Start the communication, see chapter 8.
deactivated
5 COM Module not No KAESER communica‐ Use only original KAESER communica‐
identified tion module. tion module.
90 Error Bus Bus master does not return ■ Check bus master software.
monitoring the toggle bit within the ■ Check the time-out time, see chapter
monitoring interval. 8.
■ Deactivate monitoring if it has been
activated inadvertently. See chap‐
ter 8.

Tab. 101 Fault displays in the Communication – Com-Module menu.

Result The bus communication is automatically continued as soon as the cause of the fault is remedied.

10.7.3 Troubleshooting Modbus TCP/EtherNet IP-Module

10.7.3.1 Machine and SIGMA CONTROL 2

In the event of a fault in the bus communication, the red "Communication" and the yellow "Warn‐
ing" LEDs flash at the SIGMA CONTROL 2. The system displays the following warning message:

Message Possible cause Remedy

0015 W Com-Module Bus coupling via communication module Check bus lines and plug.
communication error is interrupted.
Incorrect or faulty communication mod‐ Check communication
ule module, see below.

Tab. 102 Com-Module communication error warning message

In addition to the 0015 W Com-Module communication error warning message, the system dis‐
plays the following information for troubleshooting:
1. See chapter 9 for display on the communication module.
If one or both LEDs are illuminated red or blink red, contact KAESER SERVICE.

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 10 Fault Recognition and Rectification
10.7 Communication modules

2. Displays in the <Communication – Com-Module> menu.

In the 8.2 <Communication – Com-Module> menu, communication faults are displayed as text
beneath the line Status or as a number after the term Error.

No.: Fault text Possible cause Remedy

1 COM Module fault Defective module. Call KAESER SERVICE.
2 Communication error Bus coupling via communi‐ Check bus lines and plug.
cation module is interrup‐
ted.
Incorrect address settings Set the values at SIGMA CONTROL 2 as
or bus parameters in the parametrised at the bus master.
module.
3 Firmware fault. Defective module. Call KAESER SERVICE.
4 COM Module Module is not activated. Start the communication, see chapter 8.
deactivated
5 COM Module not No KAESER communica‐ Use only original KAESER communica‐
identified tion module. tion module.
90 Fault bus monitoring Bus master does not return ■ Check bus master software.
the toggle bit within the ■ Check the time-out time, see chapter
monitoring interval. 8.
■ Deactivate monitoring if it has been
activated inadvertently. See chap‐
ter 8.

Tab. 103 Fault displays in the Communication – Com-Module menu.

Result The bus communication is automatically continued as soon as the cause of the fault is remedied.

10.7.4 Troubleshooting at the DeviceNet module

10.7.4.1 Machine and SIGMA CONTROL 2

In the event of a fault in the bus communication, the red "Communication" and the yellow "Warn‐
ing" LEDs flash at the SIGMA CONTROL 2. The system displays the following warning message:

Message Possible cause Measure

0015 W Com-Module Bus coupling via communication module Check bus lines and plug.
communication error is interrupted.
Incorrect or faulty communication mod‐ Check communication
ule module, see below.

Tab. 104 Com-Module communication error warning message

In addition to the 0015 W Com-Module communication error warning message, the system dis‐
plays the following information for troubleshooting:

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 10 Fault Recognition and Rectification
10.7 Communication modules

1. For displays on the communication module, see chapter 9.

LED Error Possible cause Measure

NS flashes red Time-out, com‐ Bus problem ■ Check communication.
munication inter‐ ■ Synchronise the module.
rupted.
illuminates Connection fault.
red
MS flashes red Recoverable er‐ ■ Synchronise the module.
ror.
illuminates Unrecoverable Defective mod‐ ■ Call KAESER SERVICE.
red error. ule. ■ Install a new module.
MS illuminates green Module connec‐ Master deacti‐ Activate the master.
and ted to bus, no vated.
NS flashes green communication Incorrect slave Set the slave address at the
(software). address of the SIGMA CONTROL 2 as parametr‐
module. ised at the bus master. See chapter8
for the setting.
MS illuminates of flash‐ Module connec‐ Bus connec‐ ■ Check bus conduits and plug.
es green and NS is off ted to bus, no tion interrupted ■ Check the bus supply voltage.
communication Bus supply
(hardware). voltage absent.

Tab. 105 Fault indications at the DeviceNet communication module

2. Displays in the <Communication – Com-Module> menu.

In the 8.2 <Communication – Com-Module> menu, communication faults are displayed as text
beneath the line Status or as a number after the term Error.

No.: Fault text Possible cause Measure

1 COM Module fault Defective module. Call KAESER SERVICE.
2 Communication Bus coupling via commu‐ Check bus conduits and plug.
error nication module is inter‐
rupted.
Incorrect slave address of Set the slave address at the
the module. SIGMA CONTROL 2 as parametrised at
the bus master. See chapter 8 for the set‐
ting.
3 Internal software Defective module. Call KAESER SERVICE.
error
4 COM Module Module is not activated. Start the communication, see chapter 8.
deactivated
5 COM Module not No KAESER communica‐ Use only original KAESER communication
identified tion module. module.

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 10 Fault Recognition and Rectification
10.7 Communication modules

No.: Fault text Possible cause Measure

90 Error Bus Bus master does not re‐ ■ Check bus master software.
monitoring turn the toggle bit within ■ Check the time-out time, see chapter 8.
the monitoring interval.
■ Deactivate monitoring if it has been ac‐
tivated inadvertently. See chapter 8.

Tab. 106 Fault displays in the Communication – Com-Module menu.

Result The bus communication is automatically continued as soon as the cause of the fault is remedied.

10.7.5 Troubleshooting, PROFINET module

10.7.5.1 Machine and SIGMA CONTROL 2

In the event of a fault in the bus communication, the red "Communication" and the yellow "Warn‐
ing" LEDs flash at the SIGMA CONTROL 2. The system displays the following warning message:

Message Possible cause Measure

0015 W Com-Module Bus coupling via communication module Check bus lines and plug.
communication error is interrupted.
Incorrect or faulty communication mod‐ Check communication
ule module, see below.

Tab. 107 Com-Module communication error warning message

In addition to the 0015 W Com-Module communication error warning message, the system dis‐
plays the following information for troubleshooting:
1. For displays on the communication module, see chapter 9.
Please contact KAESER SERVICE techician if the LED MS illuminates red or flashes in a 4:1
rhythm.
2. Displays in the <Communication – Com-Module> menu.
In the 8.2 <Communication – Com-Module> menu, communication faults are displayed as text
beneath the line Status or as a number after the term Error.

No.: Fault text Possible cause Measure

1 COM Module fault Defective module. Call KAESER SERVICE.
2 Communication Bus coupling via communi‐ Check bus conduits and plug.
error cation module is interrup‐
ted.
Incorrect IP address set‐ Set the values at the
tings or bus parameters in SIGMA CONTROL 2 as parametrised at
the module. the bus master.
3 Firmware error Defective module. Call KAESER SERVICE.
4 COM Module Module is not activated. Start the communication, see chapter 8.
deactivated
5 COM Module not No KAESER communica‐ Use only original KAESER communica‐
identified tion module. tion module.

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 10 Fault Recognition and Rectification
10.7 Communication modules

No.: Fault text Possible cause Measure

90 Error Bus Bus master does not return ■ Check bus master software.
monitoring the toggle bit within the ■ Check the time-out time, see chapter
monitoring interval. 8.
■ Deactivate monitoring if it has been
activated inadvertently. See chap‐
ter 8.

Tab. 108 Fault displays in the Communication – Com-Module menu.

Result The bus communication is automatically continued as soon as the cause of the fault is remedied.

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168 SIGMA CONTROL 2 BLOWER ≥ 2.5.3 No.: 901700 10 E
 11 Maintenance
11.1 Changing the battery

11 Maintenance
11.1 Changing the battery
If the time and date are no longer up-to-date after you switch the supply voltage back on, the inte‐
grated battery for buffering the real-time clock is discharged and must be replaced. Contact
KAESER SERVICE. With a discharged battery, the date and time of the controller always restarts
on the 1st of January 1970 at 01:00:00 in the time zone Europe/Berlin.

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 12 Spares, Operating Materials, Service
12.1 Note the nameplate

12 Spares, Operating Materials, Service

12.1 Note the nameplate
The nameplate contains all information to identify your machine. This information is essential to us
in order to provide you with optimal service.
➤ Please give the information from the nameplate with every enquiry and order for spares.

12.2 KAESER AIR SERVICE

KAESER AIR SERVICE offers:
■ Authorised service technicians with KAESER factory training
■ Increased operational reliability ensured by preventive maintenance
■ Energy savings achieved by avoidance of pressure losses
■ optimum conditions for operation of the compressed air system,
■ The security of genuine KAESER spares.
■ Increased legal certainty as all regulations are kept to.

➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement.

Your advantage:
lower costs and higher compressed air availability.

12.3 Displaying the version number, machine model, material number

and serial number
1. Open the 5.1.1 <Configuration – General – System information> menu.
2. Use «Up» or «Down» to select the SIGMA CONTROL 2 - MCS line.
400mbar 08:15AM 80° C Header
5.1.1 System information Menu
▶1 SIGMA CONTROL 2 - MCS active line
▶2 Blower package
▶3 IO modules
▶4 FC information

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 12 Spares, Operating Materials, Service
12.3 Displaying the version number, machine model, material number and serial number

3. Press «Enter».
The 5.1.1.1 SIGMA CONTROL 2 - MCS menu is displayed.
400mbar 08:15AM 80° C Header
5.1.1.1 SIGMA CONTROL 2 - MCS Menu
Software blow_2.X.X Software version
······························
KAESER
PN 7.7601.0 Material number
SN 123456 Serial number
······························

4. Repeatedly press «Up» or «Down» to display further information.

400mbar 08:15AM 80° C Header
5.1.1.1 SIGMA CONTROL 2 - MCS Menu
SN 123456 Serial number
······························
Prodrive
PN 6309.1001.7401 Material number
SN 12.32.009.558 Serial number
MFGDT 2016/08 Manufacturing date

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 13 Decommissioning, Storage and Transport
13.1 Decommissioning

13 Decommissioning, Storage and Transport

13.1 Decommissioning
De-commissioning is necessary, for example, under the following circumstances:
■ The machine is (temporarily) not needed.
■ The machine is to be moved to another location.
■ The machine is to be scrapped.

➤ The following tasks must be carried out only by authorised personnel.

13.1.1 Temporary de-commissioning

Precondition The machine can be started at regular intervals.

➤ Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protec‐
tion against corrosion.

13.1.2 Long-term de-commissioning

Precondition Immediately prior to de-commissioning, run the machine under LOAD for at least 30 minutes.

13.1.2.1 Draining condensate

If the machine is equipped with one or more condensate drain(s), drain condensate from every
condensate drain.

Precondition The machine is switched off.

1. Drain condensate from all condensate drains and dispose according to applicable environment
protection regulations.
2. Remove the user-supplied condensate conduits.
The condensate drains are not supplied with power when the machine is switched off?
➤ Detach and drain the condensate drains.

13.1.2.2 Isolating the machine from supply lines

Precondition The power supply isolating device is switched off,

it has been locked off against unintentional reactivation and
the absence of voltage has been verified.
The machine is fully vented.
The user's shut-off valve to the compressed air network is closed or the compressed air network
has been fully vented.

1. Allow the machine to completely cool down.

2. Detach the power supply and connecting line to the compressed air network at the user side.
3. Option K2/K9:
Detach the user connecting lines and use compressed air (<2 bar) to blow out the cooling wa‐
ter system until liquid no longer escapes.

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 13 Decommissioning, Storage and Transport
13.2 Packing

4. Option W2/W3:
Detach the user connecting lines and use compressed air (<2 bar) to blow out the heat recov‐
ery system until liquid no longer escapes.
5. Properly close all open connecting ports.

13.2 Packing
➤ Follow the instructions in the machine's service manual.

13.3 Storage
➤ Follow the instructions in the machine's service manual.

13.4 Transporting
➤ Follow the instructions in the machine's service manual.

13.5 Battery removal and disposal

Precondition SIGMA CONTROL 2 is de-commissioned.

1. Disconnect SIGMA CONTROL 2 from all connections.

2. If necessary, use a tool to forcefully remove the rear enclosure panel.
3. If necessary, use a tool to forcefully remove the board from the housing.
4. Use a suitable tool to remove the internally installed battery.
5. Battery disposal in accordance with environmental guidelines.
6. Hand the SIGMA CONTROL 2 over to an authorised disposal expert.

Further information Refer to the machine’s Operating Manual for details regarding the battery’s environmentally sound
disposal.

13.5.1 Battery disposal in accordance with local environmental regulations.

Batteries contain substances that are harmful to living beings and the environment. For this reason,
batteries must not be disposed of with unsorted residential waste. They must be delivered to the
national battery collection system. This procedure facilitates the handling and recycling of batteries.
In EU Member States, as per Directive 2006/66 / EC, used batteries must be returned to the point
of sale or to a disposal system (free of charge). These disposal facilities may be local recycling
yards for used electric and electronic devices and their points of sale.
The SIGMA CONTROL 2controller’s enclosure houses a battery.

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 13 Decommissioning, Storage and Transport
13.5 Battery removal and disposal

Fig. 42 Battery labelling

1 Do not dispose of batteries with residential waste.
2 Battery contains lead (if applicable)

➤ Comply with national disposal regulations and dispose of batteries in an environmentally-

friendly manner.
You actively contribute to the protection of our environment when you bring used batteries to
the appropriate recycling system.

Further information Refer to the SIGMA CONTROL 2user manual for details regarding battery removal and replace‐
ment.

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