Esd 442 SFC

Project: Florence12 / L.
00478
Order-No.: 10357405
Technical Documentation
Compressor-Typ: ESD 442 SFC / 14 bar (a), ac, Helium

Compressor-No.: ESD.2C / Serial-No.: 1205
Table of Contents
1. Dimensional drawing
2. Electrical diagram
3. Service manual compressor
4. Service manual Sigma Control
5. Spare Parts List
6. Performance test by helium #100714
7. Measurement record for units with suction side gas
supply
8. Quality-Dimensions-Material-Surface #100713
Project: Florence12 / L.00478
Order-No.: 10357405

1. Dimensional drawing
Die Zeichnung bleibt unser ausschließliches Eigentum. Sie wird nur zu dem vereinbarten Zweck anvertraut und darf zu keinem anderen Drawings remain our exclusive property. They are entrusted only for the agreed purpose. Copies or any other Entwicklungsbedingte
Zweck verwendet werden. Kopien oder sonstige Vervielfältigungen einschließlich Speicherung, Verarbeitung oder Verbreitung unter reproduction, including storage, treatment and dissemination by use of electronic systems must not be made for any Änderungen vorbehalten.
Verwendung elektronischer Systeme dürfen nur zu dem vereinbarten Zweck angefertigt werden. Weder Original noch Vervielfältigungen other than the agreed purpose. Neither originals nor reproductions may be given to or made available to third parties. Zeichnung darf nur über
dürfen Dritten ausgehändigt oder in sonstiger Weise zugänglich gemacht werden. CAD geändert werden.
Option:
37 3/4 40 1/2
Air cooling
1/2
Machine mountings
Gas discharge
ANSI 3" / 300lbs
Z
1/8
25 7/8
8 3/8
7 1/8
11 3/8 1 7/8
A
H1
5 1/4
3 7/8
4 5/8
Cooling air outlet
64 5/8
67
H1
K1
Code:
CG
ATTENTION!
33 1/2
CG : Centre of gravity
78 23 5/8
CG
35 1/4 17 1/4
position marginally dependent on design

2
Z
30 5/8
Minimum width of door is total width of unit + 100 mm

14 3/4 9 7/8
Gas inlet
19 7/8 ±0,4
ANSI 4" / 150lbs
Demounting height for separating cartridge
90
°
122
CG
72 7/8
Oil return line
90
°
33 1/2
for motor bearings

Swagelok SS 400-1-2
Relubrication equipment
62 1/4
70 1/8 ±0,4
9 7/8
Y
B
90
90
°
°
84 1/8
5 1/8
90
86 3/8 °
24 1/4
90 1/8
32 1/2
38 1/4 35 3/8
16
Status
11
10248151 D 00
Dokument TZD
Dokument TZM
10248151 USE 00
FREIGEGEBEN
13 3/4
40
A2
5
Original
Änderungs-Nr. Projektion Maßstab
Bezeichnung
79
Gez.
Bearb.
24 7/8 11 3/4
ESD.2C SFC K1
Y
Dimension and connection dim.

Datum
as required
2 x dia.75
1 5/8
7 1/8
1 5/8
5 3/4
30.08.2013 MALTER1
23.05.2013 MALTER1
B
Freigeg. 03.09.2013 DRESSEL4

4 x dia.26
Electrical connections
Name
USE
5 7/8
2 1/2
3 7/8
Sprache
A
29 1/8 3 7/8
2 x dia.75
Electrical connections as required
Blatt
1 von 1
Cooling air inlet
Stand 12.11.2012
Order-No.: 10357405

2. Electrical diagram
Order-No.: 10357405

3. Service manual compressor

Service Manual
Screw Compressor
ESD 442/14 bar (abs) SFC SIGMA CONTROL 2

ESD_2C_10357405_10–LIN_00 E
Manufacturer:
KAESER KOMPRESSOREN
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
Original instructions
/KKW/SESD 2.02 en 05 ESD_2C_10357405_10-000_00
/KKW/SSC 2.02 05
20130903 095638
Contents
1 Regarding this document

1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alerts and their symbols ............................................................................ 2
2 Technical Specifications
2.1 Nameplate ........................................................................................................................ 4
2.2 Options ............................................................................................................................. 4
2.3 Weight .............................................................................................................................. 4
2.4 Temperature ..................................................................................................................... 5
2.5 Ambient conditions ........................................................................................................... 5
2.6 Ventilation ........................................................................................................................ 5
2.7 Pressure ........................................................................................................................... 6
2.8 Mass flow rate .................................................................................................................. 6
2.8.1 Mass flow rate m [g/s] at maximum working pressure of 14.0 bar (abs): ......... 7
2.9 Cooling oil ........................................................................................................................ 7
2.10 Cooling oil charge ............................................................................................................ 8
2.11 Motors and Power ............................................................................................................ 8
2.11.1 Compressor drive motor ..................................................................................... 8
2.11.2 Fan motor ........................................................................................................... 8
2.11.3 Fan motor ........................................................................................................... 9
2.12 Noise emission [dB(A)] ..................................................................................................... 9
2.13 Power Supply ................................................................................................................... 9
2.14 Power supply specifications ............................................................................................. 10
2.14.1 Grounded conductor specification ...................................................................... 10
2.15 Water cooling ................................................................................................................... 11
2.15.1 Water cooling (plate-type heat exchanger) ......................................................... 12
2.15.2 Water cooling (Bundled pipe heat exchanger) ................................................... 13
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 15
3.2 Specified use .................................................................................................................... 15
3.3 Improper use .................................................................................................................... 15
3.4 User's responsibilities ....................................................................................................... 15
3.4.1 Observe statutory and universally accepted regulations .................................... 15
3.4.2 Defining personnel .............................................................................................. 16
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 16
3.5 Dangers ............................................................................................................................ 17
3.5.1 Safely dealing with sources of danger ................................................................ 17
3.5.2 Safe machine operation ...................................................................................... 19
3.5.3 Organisational Measures .................................................................................... 21
3.5.4 Danger Areas ...................................................................................................... 21
3.6 Safety devices .................................................................................................................. 21
3.7 Safety Signs ..................................................................................................................... 22
3.8 In emergency ................................................................................................................... 23
3.8.1 Correct fire fighting ............................................................................................. 23
3.8.2 Treating injuries from handling cooling oil .......................................................... 24
3.9 Warranty ........................................................................................................................... 24
3.10 Environment protection .................................................................................................... 25
4 Design and Function
4.1 Enclosure ......................................................................................................................... 26
Service Manual Screw Compressor

ESD_2C_10357405_10–LIN_00 E ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 i
Contents
4.2 Function description ......................................................................................................... 26

4.3 Frequency converter ........................................................................................................ 27
4.4 Floating relay contacts ..................................................................................................... 27
4.5 Options ............................................................................................................................. 28
4.5.1 Water cooling ...................................................................................................... 28
4.5.2 Machine mountings ............................................................................................. 28
4.5.3 Cooling air filter mat ............................................................................................ 28
4.6 Operating modes .............................................................................................................. 29
4.6.1 Operating modes ................................................................................................ 29
4.7 Variable speed with frequency converter (SFC) .............................................................. 29
4.8 Safety Devices ................................................................................................................. 29
4.9 Operating panel SIGMA CONTROL 2 ............................................................................ 30
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 33
5.2 Installation conditions ....................................................................................................... 33
5.2.1 Determining location and clearances .................................................................. 33
5.2.2 Ensuring the machine room ventilation ............................................................... 34
5.2.3 Exhaust duct design ........................................................................................... 35
5.3 Operating the machine in a compressed gas network ..................................................... 35
6 Installation
6.1 Ensuring safety ................................................................................................................ 37
6.2 Reporting Transport Damage ........................................................................................... 38
6.3 Checking the tightness ..................................................................................................... 38
6.4 Installing gas connections ................................................................................................ 38
6.4.1 Installing inlet and outlet gas connections .......................................................... 38
6.5 Connecting the power supply ........................................................................................... 39
6.6 Connecting the external pressure transducer .................................................................. 40
6.7 Options ............................................................................................................................. 40
6.7.1 Anchoring the machine ....................................................................................... 40
6.7.2 Connecting the cooling water ............................................................................. 41
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 42
7.2 Instructions to be observed before commissioning or re-commissioning ......................... 43
7.3 Checking installation and operating conditions ................................................................ 43
7.4 Commissioning the Frequency Converter ....................................................................... 44
7.5 Filling with cooling oil ....................................................................................................... 44
7.6 Filling cooling oil into the airend ....................................................................................... 44
7.7 Setting the motor overload protection switch ................................................................... 46
7.8 Evacuating the machine ................................................................................................... 46
7.9 Starting the machine for the first time .............................................................................. 46
7.10 Checking the direction of rotation ..................................................................................... 47
7.11 Setting the display language ............................................................................................ 47
8 Operation
8.1 Switching on and off ......................................................................................................... 48
8.1.1 Switching on ....................................................................................................... 48
8.1.2 Switching off ....................................................................................................... 48
8.2 Switching off in an emergency and switching on again .................................................... 49
8.3 Switching on and off from a remote control centre ........................................................... 49
8.4 Switching on and off with the clock .................................................................................. 50
8.5 Interpreting operation messages ...................................................................................... 51
8.6 Acknowledging alarm and warning messages ................................................................. 51

ii ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E
Contents
9 Fault Recognition and Rectification

9.2 Other faults ....................................................................................................................... 53
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 55
10.2 Linde regulations .............................................................................................................. 56
10.3 Following the maintenance plan ....................................................................................... 56
10.3.1 Logging maintenance work ................................................................................. 56
10.3.2 Resetting maintenance interval counters ............................................................ 57
10.3.3 Regular maintenance tasks ................................................................................ 57
10.3.4 Regular service tasks ......................................................................................... 58
10.4 Check the oil collecting tank ............................................................................................. 58
10.5 Control cabinet: Clean or renew the filter mat .................................................................. 59
10.6 Cooler maintenance ......................................................................................................... 59
10.7 Water-cooling Maintenance ............................................................................................. 60
10.8 Cleaning or Renewing the Cooling Air Filter Mat ............................................................. 61
10.9 Motor maintenance .......................................................................................................... 62
10.10 Checking the Coupling ..................................................................................................... 63
10.11 Checking the pressure relief valve ................................................................................... 64
10.12 Checking the overheating safety shutdown function ........................................................ 65
10.13 Checking the cooling oil level ........................................................................................... 65
10.14 Venting the machine (de-pressurising) ............................................................................ 66
10.15 Replenishing the cooling oil ............................................................................................. 68
10.15.1 Venting the machine (de-pressurising) ............................................................... 68
10.15.2 Topping up with cooling oil and trial run ............................................................. 69
10.16 Changing the cooling oil ................................................................................................... 70
10.17 Changing the oil filter ....................................................................................................... 74
10.18 Changing the oil separator cartridge ................................................................................ 75
10.19 Assembling flexible pipe connections .............................................................................. 78
10.20 Documenting maintenance and service work .................................................................. 79
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 80
11.2 Ordering consumable parts and operating fluids/materials .............................................. 80
11.3 KAESER AIR SERVICE .................................................................................................. 80
11.4 Service Addresses ........................................................................................................... 81
12 Decommissioning, Storage and Transport
12.1 Putting Out of Operation .................................................................................................. 82
12.2 Packing ............................................................................................................................ 82
12.3 Storage ............................................................................................................................. 82
12.4 Transport .......................................................................................................................... 83
12.4.1 Safety .................................................................................................................. 83
12.4.2 Transport with a forklift truck ............................................................................... 83
12.4.3 Transport with a crane ........................................................................................ 83
12.5 Disposal ........................................................................................................................... 84
13 Annex
13.1 Pipeline and instrument flow diagram (P&I diagram) ....................................................... 85
13.2 Dimensional drawing ........................................................................................................ 88
13.3 Electrical Diagram ............................................................................................................ 90

ESD_2C_10357405_10–LIN_00 E ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 iii
Contents

iv ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E
List of Illustrations
Fig. 1 Mass flow rate and regulating range .......................................................................................... 7

Fig. 2 Correct use of RCD .................................................................................................................... 10
Fig. 3 Location of safety signs .............................................................................................................. 22
Fig. 4 Enclosure overview .................................................................................................................... 26
Fig. 5 Machine layout ........................................................................................................................... 27
Fig. 6 Machine mountings .................................................................................................................... 28
Fig. 7 Cooling air filter mat (option K3) ................................................................................................. 28
Fig. 8 Keys - overview .......................................................................................................................... 30
Fig. 9 Indicators - overview .................................................................................................................. 31
Fig. 10 RFID sensor field ........................................................................................................................ 32
Fig. 11 Recommended machine placement and dimensions [mm] ........................................................ 34
Fig. 12 Gas connection .......................................................................................................................... 38
Fig. 13 Connecting the cooling water ..................................................................................................... 41
Fig. 14 Inlet valve oil filling port .............................................................................................................. 45
Fig. 15 Coupling ..................................................................................................................................... 45
Fig. 16 Switching On and Off ................................................................................................................. 48
Fig. 17 Switching off in an emergency ................................................................................................... 49
Fig. 18 Switching on and off from a remote control centre ..................................................................... 50
Fig. 19 Switching on and off with the clock ............................................................................................ 51
Fig. 20 Acknowledging messages .......................................................................................................... 52
Fig. 21 Cooling oil collecting tank ........................................................................................................... 58
Fig. 22 Switching cabinet ventilation ...................................................................................................... 59
Fig. 23 Cleaning the cooler .................................................................................................................... 60
Fig. 24 Cooling air filter mat ................................................................................................................... 61
Fig. 25 Compressor motor maintenance ................................................................................................ 62
Fig. 26 Checking the coupling ............................................................................................................... 64
Fig. 27 Checking the cooling oil level ..................................................................................................... 66
Fig. 28 Venting the machine ................................................................................................................... 67
Fig. 29 Replenishing the cooling oil ........................................................................................................ 68
Fig. 30 Changing the cooling oil, oil separator tank ............................................................................... 71
Fig. 31 Changing the cooling oil, oil cooler ............................................................................................. 72
Fig. 32 Changing the cooling oil, airend ................................................................................................. 73
Fig. 33 Changing the oil filter .................................................................................................................. 74
Fig. 34 Open the enclosure (oil separator cartridge changing) .............................................................. 76
Fig. 35 Changing the oil separator cartridge .......................................................................................... 76
Fig. 36 Open the enclosure (oil separator cartridge changing) .............................................................. 77
Fig. 37 Assembling flexible pipe connections ......................................................................................... 78
Fig. 38 Transport with a forklift truck ...................................................................................................... 83
Fig. 39 Transport with a crane ................................................................................................................ 84

ESD_2C_10357405_10–LIN_00 E ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 v

vi ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E
List of Tables
Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1

Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Options ....................................................................................................................................... 4
Tab. 5 Machine weight .......................................................................................................................... 5
Tab. 6 Temperature ............................................................................................................................... 5
Tab. 7 Ambient conditions ..................................................................................................................... 5
Tab. 8 Ventilation ................................................................................................................................... 5
Tab. 9 Ambient conditions ..................................................................................................................... 6
Tab. 10 Mass flow rate and regulating range .......................................................................................... 7
Tab. 11 Mass flow rate ........................................................................................................................... 7
Tab. 12 Cooling oil recommendation ....................................................................................................... 7
Tab. 13 Cooling oil charge ....................................................................................................................... 8
Tab. 14 Compressor drive motor ............................................................................................................. 8
Tab. 15 Fan motor (option K1) ................................................................................................................ 8
Tab. 16 Fan motor (Option K2/K9) .......................................................................................................... 9
Tab. 17 Noise emission [dB(A)] ............................................................................................................... 9
Tab. 18 Connection data ......................................................................................................................... 11
Tab. 19 Cooling water temperature (ΔT=10K) ........................................................................................ 12
Tab. 20 Specification: Heat exchanger (Option K2) ................................................................................ 12
Tab. 21 Cooling water quality .................................................................................................................. 12
Tab. 22 Cooling water temperature (ΔT=10K) ........................................................................................ 13
Tab. 23 Specification: Heat exchanger (Option K9) ................................................................................ 13
Tab. 24 Cooling water quality .................................................................................................................. 14
Tab. 25 Inspection intervals according to Ordinance on Industrial Safety and Health ............................ 16
Tab. 26 Danger Areas ............................................................................................................................. 21
Tab. 27 Safety Signs ............................................................................................................................... 22
Tab. 28 Keys ........................................................................................................................................... 30
Tab. 29 Indicators .................................................................................................................................... 31
Tab. 30 RFID sensor field ........................................................................................................................ 32
Tab. 31 Re-commissioning after storage ................................................................................................. 43
Tab. 32 Installation conditions checklist .................................................................................................. 43
Tab. 33 Machine identification ................................................................................................................. 50
Tab. 34 Remote control identification ...................................................................................................... 50
Tab. 36 Other faults and actions. ............................................................................................................ 53
Tab. 37 Advise others that the machine is being serviced. ..................................................................... 55
Tab. 38 Regular maintenance tasks ........................................................................................................ 57
Tab. 39 Regular service tasks ................................................................................................................. 58
Tab. 40 Dimensions of the flexible pipe connection ................................................................................ 78
Tab. 41 Logged maintenance tasks ........................................................................................................ 79
Tab. 42 Consumable parts ...................................................................................................................... 80

ESD_2C_10357405_10–LIN_00 E ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 vii
List of Tables

viii ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E
1.1 Using this document

The operating manual is a component of the product. It describes the machine as it was at the time
of first delivery after manufacture.
➤ Keep the operating manual in a safe place throughout the life of the machine.
➤ Supply any successive owner or user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Further documents

Further documents included with this operating manual are:
■ Certificate of acceptance / operating instructions for the pressure vessel
■ Declaration of Conformity in accordance with the applicable directive
■ Operating manual for SIGMA CONTROL 2
Missing documents can be requested from KAESER.

➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you provide the data from the nameplate when ordering documents.
1.3 Copyright
This service manual is copyright protected. Queries regarding use or duplication of the documenta‐
tion should be referred to KAESER. Correct use of information will be fully supported.
1.4 Symbols and labels

➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of disregard
DANGER Warns of an imminent danger Will result in death or severe injury
WARNING Warns of a potentially imminent danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Tab. 1 Danger levels and their definition (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
Example:

ESD_2C_10357405_10–LIN_00 E ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 1
DANGER
The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1. WARNING!
If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe
injury may occur.
2. Always read and comply with warning instructions.
1.4.2 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 disregard
NOTICE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
Example:
NOTICE
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.
1.4.3 Other alerts and their symbols

This symbol identifies particularly important information.

2 ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E
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.
Option H1 ➤ 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 relating to one option only are marked with an option code (e.g., H1 indicates that
this section applies only to machines with screw-in machine feet). Option codes used in this
service manual are explained in chapter 2.2.
Information referring to potential problems are identified by a question mark.
The cause is named 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.

2.1 Nameplate
2.1 Nameplate
The model designation and important technical information are given on the machine's nameplate.
The nameplate is located on the outside of the machine:

■ above the cooler, or
■ on the rear of the machine.
➤ Enter here the nameplate data as a reference:
Feature Value
Rotary screw compressor
Article No.
Serial No.
Year of manufacture
Rated power
Rated motor speed
Maximum working pressure (abs)
Ambient temperature
Tab. 3 Nameplate
2.2 Options
The table contains a list of possible options.
➤ Enter options here as a reference:
Option Option code Available?

SIGMA CONTROL 2 C3
Adjustable machine mountings H1
Air cooling K1
Water cooling K2
(Plate-type heat exchanger)
Cooling air filter mat K3
Water cooling K9
(Bundled pipe heat exchanger)
Tab. 4 Options
2.3 Weight
The weight given is the maximum. The actual weights of individual machines are dependent on
equipment fitted.

2.4 Temperature
ESD 442
Weight [kg] 5825
Tab. 5 Machine weight
2.4 Temperature
ESD 442
Minimum cut-in tempera‐ 3
ture [°C]
Typical airend discharge 65–100
temperature during oper‐
ation [°C]
Maximum airend dis‐ 110
charge temperature (au‐
tomatic safety shut-down)
[°C]
Tab. 6 Temperature
2.5 Ambient conditions

ESD 442
Maximum elevation amsl* 1000
[m]
Permissible ambient tem‐ 3 – 45
perature [°C]
Permissible cooling air 3 – 45
temperature [°C]
Permissible gas intake 276 – 318
temperature [K]
Humidity of the intake absolutely dry
gas
* Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 7 Ambient conditions
2.6 Ventilation
Values given are minimum guidelines.
ESD 442
Inlet aperture Z see fig‐ 5.2
ure 11 [m2]

2.7 Pressure
ESD 442
Extractor for forced venti‐ 75000
lation:
Flow rate [m3/h] at
100 Pa
Tab. 8 Ventilation
2.7 Pressure
ESD 442
Intake pressure [bar] 1.05 (abs) ± 0.05
(abs)
Operating pressure [bar] 14.0 (abs) ± 0.1
(abs)
Relationship: >5
Operating pressure/
Intake pressure
Pressure relief valve acti‐ 16.0
vating pressure [bar]
(abs)
Any other operating conditions are excluded and require consulting with the manufacturer.
Tab. 9 Ambient conditions
2.8 Mass flow rate

Figure shows the mass flow rate 1 depending on the 4-20 mA signals specified by the customer.

2.9 Cooling oil
Fig. 1 Mass flow rate and regulating range

1 m 4 I1
mass flow rate 20 mA ≙ 50 Hz
2 mmax 5 I2
maximum mass flow rate at signal 4 4 mA ≙ 20 Hz
3 mmin 6 I
minimum mass flow rate at signal 5 Amperage
Signal [mA] Frequency [Hz] Mass flow rate [g/s]

4 20 31.1
20 50 79.5
Tab. 10 Mass flow rate and regulating range
2.8.1 Mass flow rate m [g/s] at maximum working pressure of 14.0 bar (abs):
p1 [bar] (abs) ESD 442
m min m max
14.0 31.1 79.5
*at 1.05 bar (abs) suction pressure, 298 K inlet temperature
Tab. 11 Mass flow rate
2.9 Cooling oil

➤ In order to protect any possible warranty claims, the cooling oil should only be obtained
from LINDE AG.
HCF 12
Description Synthetic oil

2.10 Cooling oil charge
HCF 12
Viscosity at 40 °C 43.3 cst
Viscosity at 7.45 cst
100 ℃
Flash point 268℃
Density at 20 ℃ 839 kg/m3
Pour point -57 ℃
Tab. 12 Cooling oil recommendation
2.10 Cooling oil charge

ESD 442
Total charge [litres] 120
Topping up volume [l] 20
(minimum–maximum)
Tab. 13 Cooling oil charge
2.11 Motors and Power

2.11.1 Compressor drive motor
ESD 442
Rated power [kW] 250
Rated speed [min ] -1 1792
Protection rating IP 55
Motor bearing re-greas‐ 1500
ing interval [h]
Grease requirement,
each bearing [g]*
h = operating hours
* Copy the data from the motor nameplate into the table.
Tab. 14 Compressor drive motor
2.11.2 Option K1
Fan motor
ESD 442
Oil cooler Air cooler
Rated power [kW] 5.5 2.2
Rated speed [min ] -1 970 1165
h = operating hours

2.12 Noise emission [dB(A)]
ESD 442
Oil cooler Air cooler
Protection rating IP 55 IP 55
Motor bearing re-greas‐ 4000 4000
ing interval [h]
Grease requirement,
each bearing [g]*
h = operating hours
Tab. 15 Fan motor (option K1)
2.11.3 Option K2/K9

Fan motor
ESD 442
Rated power [kW] 0.3
Rated speed [min-1] 1460
Protection rating IP 54
Tab. 16 Fan motor (Option K2/K9)
2.12 Noise emission [dB(A)]

ESD 442
Sound pressure lev‐ 77
el [dB(A)]
Noise pressure level as per ISO 2151 and the basic standard ISO 9614-2, tolerance: ±3 dB(A) at
maximum machine working pressure
Tab. 17 Noise emission [dB(A)]
2.13 Power Supply

Basic requirements
The machine is designed for an electrical supply according to National Electric Code (NEC)
NEC-670, particularly NFPA 79, edition 2007, section 4.3
The machine requires a symmetrical three-phase power supply.
In a symmetrical three-phase supply the phase displacement and voltages are equal for all phases.
This machine may only be supplied from a grounded TN or TT three-phase supply in which the
neutral point is grounded.
Connection to an IT network is not permitted without further measures being taken (ground leak
detection, specially designed frequency converter, etc.).
The machine may not be connected to a three-phase supply in which one of the phases is groun‐
ded, as this can lead to dangerous voltage surges.
The machine requires an industrial power supply that is separate from the public power supply.

2.14 Power supply specifications
Further requirements
RCD Type A:
A Type A RCD cannot detect residual DC currents in the event of a UPS system, Frequency Con‐
verter, or other types of device in which DC is utilized faults. Because of the presence of these DC
residual currents, a Type A device is ineffective at sensing AC residual currents or pulsating DC
currents therefore the device may not trip if a fault occurs.
RCD Type B:
Type B devices not only detect AC residual currents but also DC (smooth) residual and DC pulse
residual currents, which allows the RCD to be applied with all types of residual current. Type B de‐
vices are recommended in applications of 3 phase systems before circuits with rectifiers. They
should not be used in DC only systems or where a frequency of other than 50 Hz or 60 Hz is used.
Fig. 2 Correct use of RCD

A RCD Type A (Pulse current sensitive)
B RCD Type B (Universal current sensitive)
Further information The wiring diagram in chapter 13.3 contains further details of the power supply connection.
2.14 Power supply specifications

The following multi-strand copper core wires are given according to 2012 NEC 310.15, Ta‐
ble 310.16 for 40 °C ambient temperature.
If other local conditions prevail, like for example high temperature, the cross section should be
checked and adjusted according to 2012 NEC 110.14©, 220.3, 310.15, Table 310.16, 430.6,
430.22, 430.24 and other local codes.
Dual element time delay fuses are selected according to 2012 NEC 240.6, 430.52 and Ta‐
bles 430.52, 430.248 and 430.250.
We strongly suggest using a separate copper conductor for the equipment GROUNDING. NEC
Table 250.122 will point out the ”minimum size”, however, we recommend a ground conductor the
same size as the power leads, if local codes allow.
2.14.1 Grounded conductor specification

All grounded conductors should be sized in accordance with NEC code and local regulations. With
the leakage currents present in frequency converter applications, a ground conductor sized no
smaller than 6 AWG is recommended.

2.15 Water cooling
If the ground conductor on the supply side is smaller than 6 AWG, use one of the following options:
■ Use a multi-core conductor (including ground conductor) appropriately sized to handle the FLA
of the compressor with a minimum 6 AWG ground,
■ If the ground wire is separate from the current-carrying conductors, a size 6 AWG wire should
be used,
■ Use a second ground conductor equal to the supply line ground,
■ Use a ground fault interrupt device to disconnect the feeders when a fault condition occurs
Mains voltage: 480V±10%/3/60Hz
ESD 442
Pre-fuse [A] 600
Supply 2x4 xMCM 400
Consumption [A] 443
Tab. 18 Connection data
2.15 Option K2/K9

Water cooling
Cooling oil may contaminate the cooling water if a leak occurs.
➤ A special heat exchanger must be used for heating drinking water.
The specific heat capacity and required volume flow rate of the cooling water changes if anti‐
freeze is added.
➤ Consult KAESER Service to ensure optimum cooling-system performance.
➤ Comply with the specified minimum requirements for the cooling water in order to avoid
downtimes due to corrosion, calcification and contamination.
It is imperative that measures for cooling water treatment and filtration are implemented and
performed.
KAESER can provide the names of companies specialising in cooling water analysis and the
supply of suitable treatment devices.
The following design types are available:

■ Option K2 Water cooling with plate heat exchanger: Chapter 2.15.1
■ Option K9: Water cooling with bundled pipe heat exchanger: Chapter 2.15.2
Open cooling system
An open cooling system may be a cooling circuit with open cooling towers for cooling via evapora‐
tion. As a portion of the cooling water evaporates, it must be replenished regularly. During evapora‐
tion, the material content of the cooling water concentrates and the contact with ambient air can
contaminate the cooling water. When replenishing cooling water, you must ensure the minimum re‐
quirements for the cooling water.
Closed cooling system
In a closed cooling system, the cooling water has not contact with the atmosphere. Thus, it cannot
be contaminated by the atmosphere or enriched with oxygen, for example.

2.15 Water cooling
Continuous-flow cooling system
A continuous-flow cooling system is an open cooling system. Ground, surface or drinking water cir‐
culate once through the cooling system.
Further information The dimensional drawing in chapter 13.2 gives the flow direction, size and location of the connec‐
tion ports.
2.15.1 Option K2
Water cooling (plate-type heat exchanger)
The primary winding of the heat exchanger is connected to the machine. The specifications
refer to the secondary side of the heat exchanger.
2.15.1.1 Design data
Cooling water temperature rise 10 K
ESD 442
Maximum permissible in‐ 40
let temperature [°C]
Flow rate [m3/h] 22.7
Pressure drop [bar] 2.0
Tab. 19 Cooling water temperature (ΔT=10K)
Heat exchanger specification
ESD 442
Material 1.4401
Braze Copper (Cu)
Maximum working pres‐ 10
sure [bar]
Max. permissible dis‐ 70
charge temp. [°C]
Maximum flow rate [m3/h] 23
Unsuitable cooling medi‐ Sea water
um Consult KAESER on the suitability of water.
Tab. 20 Specification: Heat exchanger (Option K2)
2.15.1.2 Cooling water quality
Characteristics/content Closed cooling sys‐ Open cooling system

tem
pH value 7,5–9,0 7,5–9,0
Total hardness [°dH] 0–20 0–20
Carbonate hardness [°dH] <20 <4
* CFU: colony-forming units

2.15 Water cooling

tem
Chlorides (Cl) [mg/l] <100 <100
Iron (Fe), dissolved [mg/l] <0,5 <0,2
Sulphate (SO4) [mg/l] <300 <300
HCO3/SO4 ratio >1 >1
Electrical conductivity [µS/cm] 10–800 10–1500
Ammonia (NH4 ) [mg/l]
+ <1 <1
Manganese (Mn), dissolved [mg/l] <0,1 <0,1
Glycol [%] 20–40 —
Solids (particle size) [mm] <0,1 <0,1
Bacterial count [CFU*/ml] 10 000 10 000
Suspended solids [ppm] <20 <20
(portion of undissolved matter)
Tab. 21 Cooling water quality
2.15.2 Option K9
Water cooling (Bundled pipe heat exchanger)
The primary winding of the heat exchanger is connected to the machine. The specifications
refer to the secondary side of the heat exchanger.
2.15.2.1 Design data
Cooling water temperature rise 15 K
ESD 442
Maximum permissible in‐ 40
let temperature [°C]
Flow rate [m3/h] 15.2
Pressure drop [bar] 1.2
Tab. 22 Cooling water temperature (ΔT=10K)
Heat exchanger specification
ESD 442
Material (Tube interior) CuNi10Fe
Maximum working over‐ 10
pressure [bar]
Maximum permissible 70
outlet temperature [°C]
Maximum flow rate [m3/h] 16.3

2.15 Water cooling
ESD 442
Unsuitable cooling medi‐ Salt water
um Consult KAESER on the suitability of water.
Tab. 23 Specification: Heat exchanger (Option K9)
2.15.2.2 Cooling water quality

tem
pH value 6,0 – 9,0 6,5 – 9,0
Total hardness [°dH] 0 – 20 0 – 20
Carbonate hardness [°dH] <20 <4
Chlorides (Cl) [mg/l] <500 <250
Dissolved iron (Fe) [mg/l] <0,5 <0,2
Sulphate (SO4) [mg/l] <300 <300
HCO3/SO4 ratio >1 >1
Electrical conductivity [µS/cm] 10 – 2500 10 – 2500
Ammonia (NH4 ) [mg/l]
+ <2 <1
Manganese (Mn), dissolved [mg/l] <0,1 <0,1
Glycol [%] 20 – 40 —
Solid particles [mm] <0,2 <0,2
(Particle size)
Bacterial count [CFU*/ml] 10 000 10 000
Suspended solids [ppm] <20 <20
(portion of undissolved matter)
Tab. 24 Cooling water quality

3.1 Basic instructions

The machine is manufactured to the latest engineering standards and acknowledged safety regula‐
tions. Nevertheless, dangers can arise through its operation:
■ danger to life and limb of the operator or third parties,
■ damages to the machine and other material assets.
Disregard of warning or safety instructions can cause serious injuries!
➤ Use this machine only if it is in a technically perfect condition and only for the purpose for
which it is intended; observe all safety measures and the instructions in the service manual.
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety!
3.2 Specified use

The machine is intended solely for industrial use in generating compressed gas and in refrigeration
engineering. Any other use is considered incorrect. The manufacturer is not liable for any damages
that may result from incorrect use. The user alone is liable for any risks incurred.
➤ Comply with the specifications listed in this service manual.
➤ Operate the machine only within its performance limits and under the permitted ambient condi‐
tions (see chapter 2).
3.3 Improper use

Improper usage can cause damage to property and/or (severe) injuries.
➤ Only use the machine as intended.
➤ Never direct compressed gas at persons or animals.
➤ Use hot cooling air for heating purposes only if there is no risk to the health of humans or ani‐
mals. If necessary, hot cooling air should be treated by suitable means.
➤ Do not allow the machine to take in toxic, acidic, flammable of explosive gases or vapours.
➤ Do not operate the machine in areas in which specific requirements with regard to explosion
protection are in force.
3.4 User's responsibilities

3.4.1 Observe statutory and universally accepted regulations
These are, for example, nationally applied European directives and/or valid national legislation,
safety and accident prevention regulations.
➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐
nance of the machine.

3.4 User's responsibilities
3.4.2 Defining personnel

Suitable personnel are experts who, by virtue of their training, knowledge and experience as well
as their knowledge of relevant regulations can assess the work to be done and recognize the pos‐
sible dangers involved.
Authorised operators possess the following qualifications:

■ are of legal age,
■ are conversant with and adhere to the safety instructions and sections of the service manual
relevant to operation,
■ they have received adequate training and authorization to operate electrical and compressed
gas and cryogenics devices,
Authorised installation and maintenance personnel have the following qualifications:

■ are of legal age,
■ must have read, be conversant with and adhere to the safety instructions and sections of the
service manual applicable to installation and maintenance,
■ are familiar with the safety concepts and regulations of electrical and gas pressure engineering
and the cryogenics safety regulations in the case of refrigeration engineering,
■ are able to recognize the possible dangers of electrical and compressed gas and cryogenics
devices and take appropriate measures to safeguard persons and property,
■ have received adequate training in and authorization for the safe installation and maintenance
of this machine.
➤ Ensure that personnel entrusted with operation, installation and maintenance are qualified and
authorised to carry out their tasks.
3.4.3 Adherence to inspection schedules and accident prevention regulations

The machine is subject to local inspection schedules.
Examples of German inspection schedules
➤ Recurring inspections according to BGR 500, chapter 2.11:

The user must ensure that the machine's safety devices are checked for function as required
or at least annually.
➤ Oil changing according to BGR 500, chapter 2.11:
The user must ensure that the cooling oil is changed as required or at least annually and the oil
change must be documented. This requirement may be waived if an oil analysis proves that
the oil is still usable.
➤ Keep to inspection intervals in accordance with the Ordinance on Industrial Safety and Health
with maximum intervals as laid down in §15.
Inspection Inspection interval Inspecting authority

Installation and equip‐ Before commissioning Approved supervisory body
ment inspection
Internal inspection Every 5 years after installation or the last Approved supervisory body
inspection

3.5 Dangers
Inspection Inspection interval Inspecting authority

Strength test Every 10 years after installation or the last Approved supervisory body
inspection
Tab. 25 Inspection intervals according to Ordinance on Industrial Safety and Health
3.5 Dangers
Basic instructions
The following describes the various forms of danger that can occur during machine operation.
Basic safety instructions are found in this service manual at the beginning of each chapter in the
section entitled 'Safety'.
Warning instructions are found before a potentially dangerous task.
3.5.1 Safely dealing with sources of danger

The following describes the various forms of danger that can occur during machine operation.
Electricity
Touching voltage carrying components can result in electric shocks, burns or death.
➤ Allow only qualified and authorised electricians or trained personnel under the supervision of a
qualified and authorised electrician to carry out work on electrical equipment according to elec‐
trical engineering regulations.
➤ Before commissioning or re-commissioning the machine, the user must ensure adequate pro‐
tection against electric shock from direct or indirect contact.
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply isolator and check that no voltage is present.
➤ Switch off any external power sources.
These could be connections to floating relay contacts or the electrical machine heating, for ex‐
ample.
➤ Use fuses corresponding to machine power.
➤ Check regularly that all electrical connections are tight and in order.
Forces of compression
Compressed gas is contained energy. Uncontrolled release of this force can cause serious injury or
death. The following information concerns work on components that could be under pressure.
➤ Close shut-off valves or otherwise isolate the machine from the gas network to ensure that no
compressed gas can flow back into the machine.
➤ De-pressurise all pressurised components and enclosures.
➤ Do not carry out welding, heat treatment or mechanical modifications on pressurised compo‐
nents (e.g. pipes and vessels) as this influences the component's resistance to pressure.
The safety of the machine is then no longer ensured.
Spring force
Springs under tension or compression store energy. Uncontrolled release of this force can cause
serious injury or death.

3.5 Dangers
Minimum pressure / check valves, pressure relief valves and inlet valves are powerfully spring-loa‐
ded.
➤ Do not open or dismantle valves.
Rotating components
Touching the fan wheel, the coupling or the belt drive while the machine is switched on can result
in serious injury.
➤ Do not open the enclosure while the machine is activated.
➤ Switch off and lock out the power supply disconnecting device and check that no voltage is
present.
➤ Wear close-fitting clothes and a hair net if necessary.
➤ Make sure all covers and safety guards are in place and secured before re-starting.
Temperature
High temperatures are generated during compression. Touching hot components may cause inju‐
ries.
➤ Avoid contact with hot components.
These include, for example, compressor airends or blocks, oil and compressed air lines, cool‐
ers, oil separator tanks, motors and machine heaters.
➤ Wear protective clothing.
➤ When welding is taking place on or near the machine take adequate measures to ensure that
no parts of the machine or any oil vapours can ignite because of sparks or heat.
Noise
The enclosure absorbs the machine noise to a tolerable level. This function will be effective only if
the enclosure is closed.
➤ Operate the machine only with intact soundproofing.
➤ Wear hearing protection if necessary.
The blowing-off of the pressure relief valve can be particularly loud.
Operating fluids/materials
The used operating fluids and materials can cause adverse health effects. Suitable safety meas‐
ures must be taken in order to prevent injuries.
➤ Strictly forbid fire, open flame and smoking.
➤ Follow safety regulations when dealing with lubricants and chemical substances.
➤ Avoid contact with skin and eyes.
➤ Do not inhale oil mist or vapour.
➤ Do not eat or drink while handling cooling and lubricating fluids.
➤ Keep suitable fire extinguishing agents ready for use.
➤ Use only KAESER approved operating materials.
Unsuitable spare parts
Unsuitable spare parts compromise the safety of the machine.

➤ Use only spare parts approved by the manufacturer for use in this machine.
➤ Use only genuine KAESER replacement parts on pressure bearing parts.

3.5 Dangers
Conversion or modification of the machine
Modifications, additions to and conversions of the machine or the controller can result in unpredict‐
able dangers.
➤ Do not convert or modify the machine!
➤ Obtain written approval by the manufacturer prior to any technical modification or expansion of
the machine, the controller, or the control programs.
Extension or modification of the gas compressor station
If dimensioned appropriately, pressure relief valves reliably prevent an impermissible rise in pres‐
sure. New dangers may arise if you modify or extend the compressed gas station.
➤ When extending or modifying the compressed gas system:
Check the blow-off capacity of pressure relief valves on gas receivers and compressed gas
lines before installing a new machine.
➤ If the blow-off capacity is insufficient:
Install pressure relief valves with larger blow-off capacity.
3.5.2 Safe machine operation

Information on conduct that will help in handling the machine safely is given here.
Personal protective equipment
When working on the machine you may be exposed to dangers that can result in accidents with
severe adverse health effects.
➤ Wear protective clothing as necessary.
Suitable protective clothing (examples):

■ Safety workwear
■ Protective gloves
■ Safety boots
■ Eye protection
■ Ear protection
Transporting
The weight and size of the machine require safety measures during its transport to prevent acci‐
dents.
➤ Use suitable lifting gear that conforms to local safety regulations.
➤ Allow transportation only by personnel trained in the safe movement of loads.
➤ Attach lifting gear only to suitable lifting points.
➤ Be aware of the centre of gravity to avoid tipping.
➤ Make sure the danger zone is clear of personnel.
➤ Do not step onto machine components to climb up the machine.
Installation
➤ Use only electrical cables that are suitable and approved for the surroundings and electrical
loads applied.

3.5 Dangers
➤ Never dismantle pressure lines until they are fully vented.

➤ Only use pressure lines that are suitable and approved for the maximum working pressure and
the intended medium.
➤ Do not allow connection pipes to be placed under mechanical stress.
➤ Do not induce any forces into the machine via the connections, so that the compressive forces
must be balanced by bracing.
Installation
A suitable installation location for the machine prevents accidents and faults.
➤ Install the machine in a suitable compressor room.
➤ Ensure sufficient and suitable lighting such that the display can be read and work carried out
comfortably and safely.
➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
➤ If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain and
splashing water.
➤ Do not operate in areas in which specific requirements regarding explosion protection are in
force.
For instance, the requirements of ATEX directive 94/9/EC "Equipment and Protective Systems
intended for use in Potentially Explosive Atmospheres".
➤ Ensure adequate ventilation.
➤ Place the machine in such a manner that the working conditions in its environment are not im‐
paired.
➤ Comply with limit values for ambient temperature and humidity.
➤ Clean inlet gas with no damaging contaminants.
Damaging contaminants are for instance: explosive or chemically instable gases and vapours,
acid or base forming substances such as ammonia, chlorine or hydrogen sulfide.
➤ Do not position the machine in warm cooling outlet air from other machines.
Commissioning, operation and maintenance
During commissioning, operation and maintenance you may be exposed to dangers resulting from,
e.g., electricity, pressure and temperature. Careless actions can cause accidents with severe ad‐
verse effects for your health.
➤ Allow maintenance work to be carried out only by authorised personnel.
➤ Wear close-fitting, flame-resistant clothing. Wear protective clothing as necessary.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Check that there is no voltage on potential-free contacts.
➤ Allow the machine to cool down.
➤ Do not open the cabinet while the machine is switched on.
➤ Do not open or dismantle any valves.
➤ Use only spare parts approved by KAESER for use in this machine.

3.6 Safety devices
➤ Carry out regular inspections:

for visible damages,
of safety installations,
of the EMERGENCY STOP command device,
of any components requiring monitoring.
➤ Pay particular attention to cleanliness during all maintenance and repair work. Cover compo‐
nents and openings with clean cloths, paper or tape to keep them clean.
➤ Do not leave any loose components, tools or cleaning rags on or in the machine.
➤ Components removed from the machine can still be dangerous.
Do not attempt to open or destroy any components taken from the machine.
Decommissioning, storage, disposal
Improper handling of old operating fluids and components represent a danger for the environment.
➤ Drain out fluids and dispose of according to environmental regulations.
These include, for example, compressor oil and cooling water.
➤ Have refrigerant disposed of by authorized bodies only.
➤ Dispose of the machine in accordance with local environmental regulations.
3.5.3 Organisational Measures

➤ Designate personnel and their responsibilities.
➤ Give clear instructions on reporting faults and damage to the machine.
➤ Give instructions on fire reporting and fire-fighting measures.
3.5.4 Danger Areas

The table gives information on the areas dangerous to personnel.
Only authorised personnel may enter these areas.
Activity Danger area Authorised personnel

Transport Within a 3 m radius of the machine. Installation personnel for transport
preparation.
No personnel during transport.
Beneath the lifted machine. No personnel!
Installation Within the machine. Installation personnel
Within 1 m radius of the machine and its sup‐
ply cables.
Operation Within a 1 m radius of the machine. Operating personnel
Maintenance Within the machine. Maintenance personnel
Within a 1 m radius of the machine.
Tab. 26 Danger Areas
3.6 Safety devices

Various safety devices ensure safe working with the machine.
➤ Do not change, bypass or disable safety devices.

3.7 Safety Signs
➤ Regularly check safety devices for their correct function.

➤ Do not remove or obliterate labels and notices.
➤ Ensure that labels and notices are clearly legible.
Further information More information on safety devices is contained in chapter 4, section 4.8.
3.7 Safety Signs

The diagram shows the positions of safety signs on the machine. The table lists the various safety
signs used and their meanings.
Fig. 3 Location of safety signs
Item Symbol Meaning

8 Danger of fatal injury from touching electrically live components!
➤ Switch off and lock out the supply disconnecting device and check that no volt‐
age is present.
9 Machine starts automatically!
Severe injury could result from rotating components, electrical voltage and air pres‐
sure.
➤ Isolate from the power supply and lock out before opening any machine enclo‐
sure or guard.
11 Injury and/or contamination can result from breathing compressed air!
Contamination of food can result from using untreated compressed air for food pro‐
cessing!
➤ Never breathe untreated compressed air.
➤ Air from this compressor must meet OSHA 29CFR1910.134 and
FDA 21CFR178.3570 standards, if used for breathing or food processing. Use
proper compressed air treatment.

3.8 In emergency
Item Symbol Meaning

13 Hot surface can cause burns!
➤ Let the machine cool down.
➤ Wear long-sleeved garments (not synthetics such as polyester) and protective
gloves.
15 Bearing damage due to re-greasing in standstill!
➤ Re-grease the bearings only with the motor running.
➤ For lubrication interval and volume required,please refer to service manual.
23 Serious injury or death can result from loosening or opening component that is un‐
der pressure and heavily spring loaded!
➤ Do not open or dismantle the valve.
➤ Call for authorized KAESER Service representative if a fault occurs.
24 Serious injury or death can result from loosening or opening component under pres‐
sure!
➤ De-pressurize all pressurized components and enclosures.
➤ Secure that machine keeps de-pressurized.
➤ Check that machine is de-pressurized.
25 Ear damage and burns can result from loud noise and/or oil mist when the safety
relief valve opens!
➤ Wear ear protection and protective clothing.
➤ Close all access doors and cover panels.
27 Risk of electric shock!
If the interrupter has tripped current-carrying components of the controller should be
examined and replaced if damaged to reduce the risk of fire or electric shock.
28 Risk of electric shock!
To maintain overcurrent short-circuit, and ground-fault protection, the manufactur‐
er's instructions for setting the interrupter must be followed to reduce the risk of fire
or electric shock.
29 Danger of falling or damage to the machine!
➤ Do not sit or walk on the enclosure.
➤ Do not place or store any load on the enclosure.
Tab. 27 Safety Signs
3.8 In emergency
3.8.1 Correct fire fighting
Suitable measures
Calm and prudent action can safe lives in the event of a fire.
➤ Keep calm.
➤ Give the alarm.

3.9 Warranty
➤ Shut off supply lines if possible.

Mains disconnecting device (all poles)
Cooling water (if present)
Heat recovery (if present)
➤ Warn and move endangered personnel to safety.
➤ Help incapacitated persons.
➤ Close the door(s).
➤ When trained accordingly: Attempt to extinguish the fire.
Extinguishing substances
➤ Suitable extinguishing media:

Foam
Carbon dioxide
Sand or soil
➤ Unsuitable extinguishing media:
Strong jet of water
3.8.2 Treating injuries from handling cooling oil

Eye contact:
Cooling oil can cause irritation.

➤ Rinse open eyes thoroughly for a few minutes under running water.
➤ Seek medical help if irritation persists.
Skin contact:
Cooling oil may irritate after prolonged contact.

➤ Wash thoroughly with skin cleaner, then with soap and water.
➤ Contaminated clothing should be dry-cleaned before reuse.
Inhalation:
Cooling oil mist may make breathing difficult.

➤ Clear air passages of oil mist.
➤ Seek medical help if difficulty with respiration continues.
Ingestion
➤ Wash out the mouth immediately.

➤ Do not induce vomiting.
➤ Seek medical aid.
3.9 Warranty
This service manual contains no independent warranty commitment. Our general terms and condi‐
tions apply with regard to warranty.

3.10 Environment protection
A condition of our warranty is that the machine is used solely for the purpose for which it is inten‐
ded and under the conditions specified.
Due to the multitude applications for which the machine is suitable the obligation lies with the user
to determine its suitability for his specific application.
Furthermore, we accept no warranty obligation for:

■ the use of unsuitable parts or operating materials,
■ un-authorised modifications,
■ incorrect maintenance,
■ incorrect repair.
Correct maintenance and repair includes the use of genuine KAESER spare parts and operating
materials.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.
3.10 Environment protection

The operation of this machine may cause dangers for the environment.
➤ Do not allow cooling oil to escape to the environment or into the sewage system.
➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐
ment protection regulations.
➤ Observe national regulations.
This applies particularly to parts contaminated with compressor cooling oil.

4.1 Enclosure

4.1 Enclosure
Fig. 4 Enclosure overview

1 Control cabinet door 3 Access door
2 Latch 4 Panel (removable)
When closed, the enclosure serves various functions:

■ Sound insulation
■ Protection against contact with components
■ Cooling air flow
The enclosure is not suitable for the following uses:

■ Walking on, standing or sitting on.
■ As resting place or storage of any kind of load.
Safe and reliable operation is only assured with the enclosure closed.
Access doors are hinged to swing open and removable panels can be lifted off.
Latches are released by a key supplied with the machine.
4.2 Function description

The description uses an air-cooled machine as an example.

4.3 Frequency converter
Fig. 5 Machine layout

1 Inlet valve 5 Airend
2 Minimum pressure/check valve 6 Control cabinet
3 Compressor drive motor 7 Oil separator tank
4 Oil filter 9 Oil/gas cooler
Gas delivered to the machine by pipeline is drawn into the airend 5 and compressed.
The airend is driven by an electric motor 3 .
Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between the ro‐
tors themselves and between them and the airend casing. This direct cooling in the compression
chamber ensures a very low airend discharge temperature.
Cooling oil recovered from the compressed gas in the oil separator tank 7 gives up its heat in the
oil cooler 9 . The oil then flows through the oil filter 4 and back to the point of injection. Pressure
within the machine keeps the oil circulating. A separate pump is not necessary. A thermostatic
valve maintains optimum cooling oil temperature.
Compressed gas, freed of cooling oil in the oil separator tank 7 , flows through the minimum pres‐
sure / check valve 2 into the gas cooler 9 . The minimum pressure/check valve ensures that there
is always a minimum internal pressure sufficient to maintain cooling oil circulation in the machine.
The cooler brings down the compressed gas temperature to only 5 K to 10 K above ambient.
4.3 Frequency converter

The machine is equipped with a frequency converter that regulates motor speed in proportion to
the gas demand.
4.4 Floating relay contacts

Floating relay contacts are provided for the transfer of signals, messages.
Information on location, loading capacity and type of message or signal is found in the electrical
diagram.
If the floating relay contacts are connected to an external voltage source, voltage may be
present even when the machine is isolated from the power supply.

4.5 Options
4.5 Options
The options available for your machine are described below.
4.5.1 Option K2/K9

Water cooling
Stainless steel plate-type heat exchanger (Option K2) or bundled pipe heat exchangers (Option
K9) are used in machines with water cooling.
4.5.2 Option H1
Machine mountings
These mountings allow the machine to be anchored firmly to the floor.
Fig. 6 Machine mountings
4.5.3 Option K3
Cooling air filter mat
The mat filters the cooling air and keeps the cooler surface clean.
Fig. 7 Cooling air filter mat (option K3)

1 Cooling air filter mat

4.6 Operating modes
4.6 Operating modes

4.6.1 Operating modes
The machine operates in the following modes:
■ LOAD:
The inlet valve is open. The airend delivers gas into the gas network.
The compressor motor runs under full load.
■ STANDSTILL:
The inlet valve is closed. The minimum pressure/check valve shuts off the oil separator from
the gas discharge line. The venting valve is open.
The drive motor is stopped.
4.7 Variable speed with frequency converter (SFC)

When the machine runs in LOAD, the frequency converter compensates for deviations between
SETPOINT pressure and ACTUAL pressure by changing the speed of the drive motor and, there‐
by, the airend.
The speed of the airend determines the rate of compressed gas delivery and the absolute working
pressure.
These changes in speed match the gas delivery to the gas consumption and keep system pressure
as constant and as close as possible to the SETPOINT pressure.
This functions within the control range of the machine between minimum and maximum delivery
(Vmin und Vmax).
4.8 Safety Devices

The following safety devices are provided and may not be changed:
■ EMERGENCY STOP control device:
Stops the machine immediately in an emergency situation. The motor remains stopped. The
pressure system is vented.
■ Pressure relief valve:
The pressure relief valve protects the system against excessive pressure. This is factory set.
■ Enclosures and guards for moving parts and electrical connections
Protect against accidental contact.

4.9 Operating panel SIGMA CONTROL 2

Keys
Fig. 8 Keys - overview
Item Description Function

1 «OFF» Switch the machine off.
2 «ON» Switch on the machine.
3 «Escape» Returns to the next higher menu option level.
Exits the edit mode without saving.
4 «Enter» Jumps to the selected submenu.
Exits the edit mode and saves.
5 «DOWN» Scrolls down the menu options.
Reduces a parameter value.
6 «Right» Jumps to the right.
7 «Left» Jumps to the left.
8 «UP» Scrolls up the menu options.
Increases a parameter value.
9 «Events and information» Operating mode:
Displays the event memory.
10 «Acknowledgement» Acknowledges alarms and warning messages.
If permissible: Resets the fault counter (RESET).
11 «LOAD/IDLE» Toggles the compressor between LOAD and IDLE operating
modes (key inactive for gas compressors).
12 «Remote control» Switches remote control on and off.
13 «Shift clock» Switches clock control on and off.
Tab. 28 Keys

Indicators
Fig. 9 Indicators - overview

14 Indicator field or dis‐ Graphic display with 8 lines and 30 characters.
play
15 Alarm Flashes red when an alarm occurs.
Lights continuously when acknowledged.
16 Communication Continuous red illumination if a communication connection (Ethernet,
USS, COM modules) has a fault.
17 Warning Flashes in yellow in the following events:
■ maintenance work due,
■ Warning message
Lights continuously when acknowledged.

18 Controller voltage Lights green when the power supply is switched on.
19 LOAD Lights green when the compressor is running under LOAD.
20 IDLE Lights green when the compressor is running in IDLE.
Flashes when the «LOAD/IDLE» toggle key is pressed (key inactive
for gas compressors).
21 Remote control The LED lights when the machine is in remote control.
22 Shift clock The LED lights when the machine is in clock control.
23 Machine ON Lights green when the machine switched on.
Tab. 29 Indicators

RFID sensor field
RFID is the abbreviation for “Radio Frequency Indentification” and enables the identification of per‐
sons or objects.
Placing a suitable transponder in front of the RFID sensor field of the controller will automatically
activate the communication between transponder and SIGMA CONTROL 2 .
A suitable transponder is theKAESER RFID equipment card. Two of them have been provided with
the machine.
Typical application:
■ Users log on to the machine.
(no manual input of the password required.)
Fig. 10 RFID sensor field

24 RFID RFID sensor field for the communication with a suitable RFID transponder.
Tab. 30 RFID sensor field
Further information More information about the use of RFID technology is provided in the SIGMA CONTROL 2 operat‐
ing manual.

5.1 Ensuring safety

5.1 Ensuring safety
The conditions in which the machine is installed and operated have a decisive effect on safety.
Warning instructions are located before a potentially dangerous task.
Disregard of warning instructions can cause serious injuries!
Complying with safety notes
Disregard of safety notes can cause unforeseeable dangers!

➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapours or parts of the machine.
➤ Do not store inflammable material in the vicinity of the machine.
➤ The machine is not explosion-proof!
Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
For instance, the requirements of ATEX directive 94/9/EC "Equipment and Protective Systems
intended for use in Potentially Explosive Atmospheres".
➤ Ensure sufficient and suitable lighting such that the display can be read and work carried out
comfortably and safely.
➤ Ensure that required ambient conditions are maintained.
Required ambient conditions may be:

■ Maintain ambient temperature and humidity
■ Ensure the appropriate composition of the air within the machine room:
─ clean with no damaging contaminants (e.g., dust, fibres, fine sand)
─ free of explosive or chemically unstable gases or vapours
─ free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen sulfide.
5.2 Installation conditions

5.2.1 Determining location and clearances
The machine is intended for installation in an appropriate machine room. Information on distances
from walls and ventilation is given below.
The distances quoted are recommended distances and ensure unhindered access to all ma‐
chine parts.
➤ Please consult KAESER if you cannot comply with these recommendations.
Precondition The floor must be level, firm and capable of bearing the weight of the machine.

Fig. 11 Recommended machine placement and dimensions [mm]

A Exhaust fan
B Exhaust duct cover
Z Inlet air opening
1. NOTICE!
Ambient temperature too low!
Frozen condensate and highly viscous cooling oil can cause damage when starting the ma‐
chine.
➤ Make sure that the temperature of the machine is at least +3 °C before starting.
➤ Heat the machine room adequately or install an auxiliary heater.
2. Ensure adequate lighting so that all work on the machine can be carried out without danger or
hindrance.
3. Ensure that the indicators can be read without glare and that the controller display cannot be
damaged by direct sunlight (UV radiation).
4. Ensure that all intake and exhaust apertures of the enclosure remain opened.
5. If installed outdoors, the machine must be protected from frost, direct sunlight, dust and rain.
5.2.2 Ensuring the machine room ventilation

Adequate ventilation of the machine room has several tasks:
■ It prevents subatmospheric pressure in the machine room.
■ It evacuates the exhaust heat of the machine and thus ensures the required operating condi‐
tions.
➤ Consult with KAESER if you cannot ensure the conditions for an adequate ventilation of
the machine room.
1. Ensure that the volume of air flowing into the machine room is at least equivalent to that being
removed from it by the machine and exhaust fan.

5.3 Operating the machine in a compressed gas network
2. Make sure that the machine and exhaust fan can only operate when the inlet aperture is ac‐
tually open.
3. Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely
through the room.
4. Ensure clean air in order to support the proper functioning of the machine.
5.2.3 Exhaust duct design

The machine can only overcome the air resistance at the cooling air inlet and exhaust determined
by the duct design. Any additional air resistance will reduce airflow and deteriorate machine cool‐
ing.
➤ Consult the KAESER service representative before deciding on:
■ the design of the exhaust air ducting
■ the intersection between the machine and the exhaust air duct
■ the length of the ducting
■ the number of duct bends
■ the design of flaps or shutters

High pressure side
If the compressor is integrated in a gas network the pressure side may not exceed 17 bar (a).
Initial filling of a fully vented gas network generally creates very a high rate of flow through treat‐
ment devices. These devices cannot function correctly under such conditions and compressed gas
quality suffers.
Gas inlet side
The compressor is designed for inlet pressures between 1.05 ± 0.05 bar (a). When starting, a
maximum inlet pressure of ≤ 2.5 bar (a) can be tolerated for a short period (5 - 10 minutes).
Inlet pressure monitoring is the responsibility of the user.
➤ The manufacturer must be consulted if higher inlet pressures are to be conditioned.

➤ The machine is delivered without a gas inlet filter.
The inlet gas must be:

■ clean
■ dry
■ pure
■ chemically inert
■ free of solid particles larger than 3 — 4 µm
■ incombustible
■ non-toxic
➤ The pressure dew point that will not be exceeded during compression.
➤ The user must install a fine filtration system in the gas feed line to exclude solid particles
including welding beads, dust and attrition from pipework and valves.
Filter porosity: ≤10 µm at 100 % efficiency
➤ The pressure loss of the intake filter may not exceed 0.05 bar.
If this value is exceeded due to excessive filter contamination, a pressure differential
monitoring installed by the user shall trigger an alarm or switch off the machine in time
before the system falls below permissible intake pressure.
Oil return line
The compressor oil fed to the helium compressor from an external source must have a minimum
fineness of 100% for solids ≥39 µm according to ISO standard 4548/12.
➤ If necessary, a suitable oil fine filter must be installed by the user.
Chapter 13.1 provides more information about the connection of the oil scavenge line to the
user's oil fine filter.

6 Installation
6.1 Ensuring safety
6 Installation
6.1 Ensuring safety
Follow the instructions below for safe installation.

➤ Follow the instructions in chapter 3 'Safety and Responsibility'.
➤ Installation work may only be carried out by authorized personnel.
➤ Make sure that no one is working on the machine.
➤ Ensure that all service doors and panels are locked.
When working on live components
Dangerous voltages persist in the frequency converter and intermediate circuit capacitors for some
time after power is switched off.
Live components are exposed when the frequency converter cabinet is opened.
➤ Work on electrical equipment may only be carried out by authorized electricians.
➤ Before starting work on the frequency converter or intermediate circuit capacitors, wait at least
5 minutes.
When working on pressure system
CAUTION
For transport and short-term storage, the machine is filled in the factory with gas with an
overpressure of 0.5 bar.
Compressed gas is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following safety concerns relate to any work on components that could be under
pressure.
➤ Check all machine gas hose connectors with a hand-held pressure gauge to ensure that all
read zero.

6 Installation
6.2 Reporting Transport Damage
When working on the drive system
in serious injury.
Further information Details of authorized personnel are found in chapter 3.4.2.

Details of dangers and their avoidance are found in chapter 3.5.

1. Check the machine for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage without delay.
6.3 Checking the tightness

For transport and short-term storage, the machine is filled in the factory with gas with an overpres‐
sure of 0.5 bar.
If the machine is de-pressurised prior to installation, a leak test may need to be performed on-site.
➤ Use a manual pressure gauge to measure the gas pressure.
Did the protective gas escape?
➤ Perform leak test. If required, consult with the manufacturer.
6.4 Installing gas connections

6.4.1 Installing inlet and outlet gas connections
Precondition The gas network and the machine are fully de-pressurised.
Fig. 12 Gas connection

1 Axial compensator or flexible hose
2 Shut-off valve

6 Installation
6.5 Connecting the power supply
1. WARNING!
Serious injury or death can result from loosening or opening components under pressure.
➤ The machine is charged with 0.5 bar gauge pressure.
2. A shut-off valve must be installed by the user in the connection line.
3. Make the compressed gas connection with an axial compensator or flexible pressure line.
4. Pressure relief valve with 6 bar blow-off pressure to be installed at customer site.
5. Receiver to be installed in the intake section at customer site.
The receiver accepts the venting volume without increasing inlet pressure to > 5 bar (a)
Further information The dimensional drawing in chapter 13.2 provides the size and position of the connection ports.
6.5 Connecting the power supply

Precondition The supply isolating device is switched off,
the device is locked off,
the absence of any voltage has been verified.
The voltage in the intermediate circuit capacitors of the frequency converter is reduced.
1. The power supply must only be connected by authorized installation personnel or an author‐
ized electrician.
2. Carry out safety measures as stipulated in relevant regulations and in national accident pre‐
vention regulations. In addition, observe the regulations of the local electricity supplier.
3. Test the overcurrent protection cut-out to ensure that the time it takes to disconnect in re‐
sponse to a fault is within the permitted limit.
4. Select supply cable conductor diameters and fusing in accordance with local regulations.
5. The user must provide the machine with a lockable power supply disconnecting device.
This could be, for example, a load disconnect switch with fused input. If a circuit breaker is
used it must be suitable for the motor starting characteristics.
6. Check that the tappings on the control voltage transformer are connected according to the sup‐
ply voltage.
If not, change the tappings to suit the power supply voltage.
7. If applicable:
Check that the tappings on the control voltage transformer in the frequency converter cabinet
are connected according to the supply voltage.
If not, change the tappings to suit the power supply voltage.
8. DANGER!
Danger of fatal injury from electric shock!
➤ Switch off and lock out the power supply disconnecting device and verify the absence of
voltage.
9. Connect the machine to the power supply.
10. Ensure that the cabinet again complies with the requirements of degree of protection IP54.
Further information Further specifications for electrical connections are to be found in the electrical diagram in chap‐
ter 13.3 and in the frequency converter operating instructions.

6 Installation
6.6 Connecting the external pressure transducer
6.6 Connecting the external pressure transducer

Material Retrofit kit: Retrofit kit "External pressure transducer SC USS"
Use suitable screened, copper-core cable (e.g.:LIYCY 2 x 0.75 mm2 for ambient temperatures up
to 30 °C and laying method C).
Precondition The supply disconnecting device is switched off.

The disconnecting device is locked off.
A check has been made that no voltage is present.
Cable length between the machine and the pressure transducer: < 50 m
By means of a pressure transducer, the pressure in the gas network can be measured at any se‐
lected location and this signal used to regulate the compressor.
This ensures optimum compressor regulation with regard to the network pressure at the selected
location.
Safety monitoring of the machine's internal pressure is unaffected.
Your authorized KAESER Service Technician will be glad to provide support on planning and
executing an individual solution.
1. Install the isolating transformer in the control cabinet.
2. Connect the power supply for the isolating amplifier.
3. Make the connection between the output of the isolating amplifier and the analog input of the
frequency controller.
4. Install the pressure transducer at the selected location in the gas network.
5. Using a suitable cable, connect the pressure transducer to the isolating amplifier input.
➤ Connect as large an area of the screening as possible to the mounting plate in the control
cabinet or use an EMC fitting to make contact.
6. When commissioning the machine with SIGMA CONTROL 2 , activate the < Network actual
pressure > setting in the < FC USS > menu.
Further information The electrical diagram in chapter 13.3 contains further details of the pressure transducer connec‐
tion.
6.7 Options
6.7.1 Option H1
Anchoring the machine
➤ Use appropriate fixing bolts to anchor the machine.
Further information Details of the fixing holes are contained in the dimensional drawing in chapter 13.2.

6 Installation
6.7 Options
6.7.2 Option K2/K9

Connecting the cooling water
➤ Take the electrochemical series into consideration and choose suitable materials for wa‐
ter connections.
➤ Keep the effect of pressure surges on the coolers as low as possible.
➤ Install an expansion tank to act as a pulsation damper if pressure surges cannot be avoi‐
ded.
➤ Avoid a low inlet temperature for the cooling water as it can cause condensation. If re‐
quired, contactKAESER for suitable insulation measures.
Temperature-controlled cooling water supply systems, to which numerous machines are connec‐
ted, regulate the water flow rate according to the difference in temperature between the supply and
the return water. Individual machines may not receive an adequate flow under this system. Break‐
downs are the result.
➤ KAESER can advise on how to ensure the cooling water supply via suitable control
valves.
Fig. 13 Connecting the cooling water

A Cooling water outlet 12 Connection port with plug
B Cooling water inlet 17 Pressure relief valve
10 Shut-off valve
1. The user is to provide the following fittings:

■ Dirt traps (grid size according to permissible particle size.
■ Shut-off valves 10 and connection ports 12 for maintenance and venting
■ Pressure relief valve 17 to prevent build-up of excessive pressure.
Activating pressure and blow-off capacity of the safety valve are governed by the user's in‐
stallation design. The technical specification of the cooler must be taken into account.
2. Connect the cooling water lines to the fittings.
3. Open the shut-off valve on the cooling water outlet A .
4. Slowly open the cooling water inlet shut-off valve B to gradually fill the cooler with water.
5. Bleed air from the water lines.
Further information The dimensional drawing in chapter 13.2 gives the flow direction, size and location of the connec‐
tion ports.

7 Initial Start-up
7.1 Ensuring safety
7 Initial Start-up
7.1 Ensuring safety
Follow the instructions below for safe installation.
Please take note of all safety instructions

➤ Installation work may only be carried out by authorized personnel.
➤ Make sure that no one is working on the machine.
➤ Ensure that all service doors and panels are locked.
➤ Work on electrical equipment may only be carried out by authorized electricians.
5 minutes.
When working on the compressed air system
CAUTION
For transport and short-term storage, the machine is filled in the factory with gas with an
overpressure of 0.5 bar.
pressure.
read zero.

7 Initial Start-up
7.2 Instructions to be observed before commissioning or re-commissioning
in serious injury.
Further information Details of authorized personnel are found in chapter 3.4.2.

7.2 Instructions to be observed before commissioning or re-commis‐

sioning
Incorrect or improper commissioning can cause injury to persons and damage to the machine.
➤ Commissioning may only be carried out by authorised installation and service personnel who
have been trained on this machine.
Special measures for re-commissioning after storage
Storage period Remedy

longer than:
3 months ➤ Manually fill the airend with cooling oil.
12 months ➤ Change the oil filter.
➤ Change the oil separator cartridge.
➤ Change the cooling oil.
➤ Have the motor bearings checked by an authorised KAESER Service Techni‐
cian.
➤ Have the frequency converter smoothing capacitors formed by an authorised
KAESER Service Technician.
36 months ➤ Have the overall technical condition checked by an authorised KAESER Serv‐
ice Technician.
Tab. 31 Re-commissioning after storage
7.3 Checking installation and operating conditions

➤ Check and confirm all the items in the checklist before initially starting the machine.
To be checked See Complied?

chapter
➤ Are the operators fully conversant with safety regulations? –
➤ Have all the positioning conditions been fulfilled? 5
➤ Is a user's lockable power supply disconnecting device installed? 6.5
➤ Does the power supply conform to the specifications on the name‐ 2.1
plate?

7 Initial Start-up
7.4 Commissioning the Frequency Converter
To be checked See Complied?

chapter
➤ Are the power supply cable conductor cross-sections and fuse ratings 2.14
adequate?
➤ Fan motor overload protection switch set according to the mains volt‐ 7.7
age?
➤ Have all electrical connections been checked for tightness? –
➤ Has the check been repeated after 50 operating hours?
➤ Is a shut-off valve fitted to gas outlet? 6.4
➤ Is the connection the gas network made with a flexible pressure line 6.4
or axial compensator?
➤ Sufficient cooling oil in the separator tank? 10.13
(oil level indicator outside the red zone)
➤ Is there sufficient cooling oil in the machine? 7.5
➤ Is there sufficient cooling oil in the airend? 7.6
➤ Is the machine firmly anchored to the floor? 6.7.1
(option H1)
➤ Supply of cooling water ensured? 6.7.2
(Option K2/K9)
➤ Are all access doors closed and latched and all removable panels in –
place and secured?
Tab. 32 Installation conditions checklist
7.4 Commissioning the Frequency Converter

The frequency converter parameters are preset. Adjustment of parameters to suit operating condi‐
tions on site is done by trained and authorised personnel.
Changes to the factory settings may influence the whole machine. The machine may break down
or be damaged.
➤ Allow only trained and authorised personnel to make parameter changes.
7.5 Filling with cooling oil

The machine must be charged with cooling oil prior to commissioning, see chapter 10.15.
For the required cooling oil charge volume please see chapter 2.10.
7.6 Filling cooling oil into the airend

Before starting the compressor for the very first time and before re-starting after a shutdown period
of more than 3 months it is necessary to manually add a quantity of cooling oil into the airend. In
order to avoid that the cooling oil exceeds the permissible level, drain the required quantity from
the de-pressurised oil separator tank.
Chapter 10.16 provides detailed information on how to drain cooling oil from the oil separator tank.

7 Initial Start-up
7.6 Filling cooling oil into the airend
Material 4 l Cooling oil from separator tank

The machine is fully vented, the pressure gauge on the oil separator tank reads 0 bar.
Fig. 14 Inlet valve oil filling port

1 Screw plug
2 Inlet valve
1. Unscrew the filler plug from the inlet valve.

2. Pour the stipulated amount of cooling oil into the airend and replace the filler plug.
3. See the LINDE operating manual for cleaning instructions..
Fig. 15 Coupling
1 Airend 3 Safety screen
2 Coupling 4 Arrow showing direction of rotation
1. Remove the safety screen 3 .

2. Turn the airend 1 by turning the coupling 2 by hand in the direction indicated by the arrow 4 .
3. Replace the safety screen 3 .

7 Initial Start-up
7.7 Setting the motor overload protection switch
7.7 Setting the motor overload protection switch

Electrical diagram in chapter 13.3 gives the setting values for the motor overload protection switch.
In direct on-line starting, the current for the fan motor is fed via the motor overload protection
switch.
To prevent the motor overload protection switch from being triggered by voltage fluctuations,
temperature influences or component tolerances, the setting can be higher than the rated
motor current.
➤ Check the motor overload protection switch setting.
The overload protection switch shuts the machine down despite being correctly set?
➤ Contact KAESER Service.
7.8 Evacuating the machine

Before initial start-up the compressor must be evacuated and then filled with gas.
After a long transport or storage, the protective gas may have escaped, see also chapter 6.3.
➤ Perform a leak test before commissioning. If required, consult with the manufacturer.
Evacuation
1. Close the user's shut-off valves at the inlet and outlet ends.
2. Evacuate the machine to a minimum vacuum of ≤5 mbar using the hose couplings of the evac‐
uation connections, see chapter 13.1.
3. Open the user's inlet and outlet shut-off valves.
Filling with gas
1. Fill the machine with gas via the evacuation connections hose couplings as described in chap‐
ter 13.1.
7.9 Starting the machine for the first time

Precondition No personnel are working on the machine
All access doors are closed.
All removable panels in place and secured.
1. Open the user's inlet and outlet shut-off valves.

2. Switch on the power supply isolating device.
After the controller has carried out a self-test, the green Control voltage LED is lit continuously.
3. If required:
Change the display language as described in chapter 7.11.
4. Press the «ON »key.
The drive motor runs up and after a short time the machine switches to LOAD and delivers
gas.

7 Initial Start-up
7.10 Checking the direction of rotation
➤ Watch for any faults occurring in the first hours of operation.

➤ After the first 50 operating hours, check all electrical connections and tighten where nec‐
essary.
7.10 Checking the direction of rotation

The machine is designed for a clockwise phase sequence.
In frequency-controlled compressors, the direction of rotation of the fan motor may be incorrect
even if the compressor motor is correct.
Ideally, the direction of phase rotation should be measured with a phase sequence meter.
Alternatively, start the machine very briefly and observe the direction of rotation of the motor cool‐
ing fan.
1. Check the direction of phase rotation with a phase sequence meter at the inlet lines of the fan
motor.
2. If the fan motor is incorrect, change the machine supply phases L1 and L2.
You do not have a phase sequence meter?
➤ Switch the machine on and off again the moment the drive motor begins to turn.
➤ Compare the direction of rotation of the fan with the arrow on the motor casing.
7.11 Setting the display language

The controller can display text messages in several languages.
You can set the language for texts on the display. This setting will be retained even when the ma‐
chine is switched off.
1. In operating mode, switch to the main menu with the «Return» key.
2. Press the «UP» or «DOWN» keys until the current language is shown as active line (inverse):
6.1 bar 80.0 °C
–––––––– Deutsch –––––––– Current language (active line)
▶1 xxxxxxxxxx Submenu
3. Use the «Return» key to switch to setting mode.

The language display flashes.
4. Move to the required language with «UP »or «DOWN».
5. Confirm the setting with the «Enter» key.
Result The display texts are now in the selected language.
Further information Detailed information can be found in the SIGMA CONTROL 2 operating manual.

8 Operation
8.1 Switching on and off
8 Operation
Always switch the machine on with the «ON» key and off with the «OFF» key.
A power supply disconnecting device has been installed by the user.
Fig. 16 Switching On and Off

1 Machine ON LED (green) 11 «LOAD/IDLE» toggle key
2 «ON» key 19 LOAD LED
3 «OFF» key 20 IDLE LED
8 Control voltage LED (green)
8.1.1 Switching on
Precondition No personnel are working on the machine.
All access doors and panels are closed and secure.
1. Switch on the power supply isolating device.

After the controller has carried out a self-test, the green Control voltage LED is lit continuously.
2. Press the «ON »key.
The green Machine ON LED is lit continuously.
If a power failure occurs, the machine is not prevented from re-starting automatically when
power is resumed.
It can re-start automatically as soon as power is restored.
Result The compressor motor starts as soon as system pressure is lower than the setpoint pressure (cut-
off pressure).
8.1.2 Switching off

1. Press the «OFF» key.
The machine switches off.
2. Switch off and lock out the power supply disconnecting device.
3. The machine may be started again after at least 20 seconds in standstill.

8 Operation
8.2 Switching off in an emergency and switching on again
Result The Control voltage LED extinguishes. The machine is switched off and disconnected from the
mains supply.

The EMERGENCY STOP push-button is located below the control panel.
Fig. 17 Switching off in an emergency

9 EMERGENCY STOP control device:
Switching off
➤ Press the EMERGENCY STOP control device.
Result The EMERGENCY STOP button remains latched after actuation.

The compressor's pressure system is vented and the machine is prevented from automatically re-
starting.
Switching on
Precondition The fault has been rectified
1. Turn the EMERGENCY STOP device in the direction of the arrow to unlatch it.
2. Acknowledge any existing alarm messages.
Result The machine can now be started again.
8.3 Switching on and off from a remote control centre

Precondition A link to the remote control centre exists.

8 Operation
8.4 Switching on and off with the clock
Fig. 18 Switching on and off from a remote control centre

1 «Remote control» key
2 Remote control LED
1. Attach an easily seen notice to the machine that warns of remote operation.
Remote control: danger of unexpected starting!

➤ Make sure the power supply disconnecting device is switched off before commencing any
work on the machine.
Tab. 33 Machine identification
2. Label the starting device in the remote control centre as follows:

➤ Before starting, make sure that no one is working on the machine and that it can be safely
started.
Tab. 34 Remote control identification
3. Press the «remote control» key.

The remote control LED lights. The machine can be remotely controlled.
8.4 Switching on and off with the clock

Precondition The clock is programmed.

8 Operation
8.5 Interpreting operation messages
Fig. 19 Switching on and off with the clock

1 «Clock» key
2 Clock LED
1. Attach an easily seen notice warning of time-controlled operation:
Clock control: danger of unexpected starting!

2. Press the «clock» key.

The clock LED lights. The machine is switched on and off by the clock.
8.5 Interpreting operation messages

The controller will automatically display operation messages informing you about the current opera‐
tional state of the machine.
Operating messages are identified with the letter O .
Further information Detailed information can be found in the SIGMA CONTROL 2 operating manual.
8.6 Acknowledging alarm and warning messages

Messages are displayed on the "new value" principle:
■ Message coming: LED flashes
■ Message acknowledged: LED illuminates
■ Message going: LED off
or

■ Message going: LED flashes
■ Message acknowledged: LED off

8 Operation
Fig. 20 Acknowledging messages

10 LED Warning (yellow)
11 LED Alarm (red)
12 Key«Acknowledge»
Alarm message
An alarm shuts the machine down automatically. The red alarm LED flashes.
The system displays the appropriate message.
➤ Acknowledge the message with the «acknowledge» key.

Alarm LED extinguishes.
The machine is again ready for operation.
If the machine was switched off with the EMERGENCY Stop button:
➤ Unlatch the EMERGENCY STOP button (turn in direction of the arrow) before acknowl‐
edging the alarm message.
Further information A list of possible alarm messages occurring during operation can be found in the service manual
SIGMA CONTROL 2 .
Warning message
If maintenance work is to be carried out or if the warning is displayed before an alarm, the yel‐
low warning LED flashes.
Precondition The danger of an alarm is passed,

maintenance has been carried out.
➤ Acknowledge the message with the «Acknowledge» key.

The warning LED extinguishes.
Further information A list of possible alarm messages occurring during operation can be found in the service manual
SIGMA CONTROL 2 .


There are 3 types of fault:
■ Warning:
─ Warning messages W
■ Fault (with indication):
─ Alarm messages A
─ System messages Y
─ Diagnostic messages D
■ Other faults (without indication): See chapter 9.2
The messages valid for your machine are dependent on how the individual machine is equipped.
1. Do not attempt fault rectification measures other than those given in this manual!
2. In all other cases:
Have the fault rectified by an authorized KAESER service representative.
Further information Detailed information for the various messages can be found in the service manual
SIGMA CONTROL 2 .
9.2 Other faults

Alarm Possible cause Remedy
Machine runs but produces no Inlet valve not opening or only Contact KAESERservice.
compressed gas. opening partially.
Venting valve not closing. Contact KAESERservice.
Pressure system leaking. Check pipework and connec‐
tions for leaks and tighten any
loose fittings.
Gas demand exceeds the deliv‐ Check the gas network for
ery capacity of the compressor. leaks.
Shut down the consumer(s).
Hose coupling or maintenance Remove coupling or mainte‐
hose still plugged into the nance hose.
quick-release coupling on the
oil separator tank.
Inlet valve defective. Contact KAESERservice.
Compressor switches between Gas receiver too small. Increase size of receiver.
LOAD into STANDSTILL more Flow into the gas network is re‐ Increase gas pipe diameter.
than twice per minute. stricted. Check filter elements.
The differential between cut-in Check switching differential.
and cut-out pressure is too
small.

9.2 Other faults
Alarm Possible cause Remedy

Cooling oil leaking into the floor Hose coupling or maintenance Remove coupling or mainte‐
pan. hose still plugged into the nance hose.
quick-release coupling on the
oil separator tank.
Oil cooler leaking. Contact KAESERservice.
Leaking joints. Tighten joints.
Replace seals.
Cooling oil consumption too Unsuitable oil is being used. Use recommended cooling oil.
high. Oil separator cartridge split. Change the oil separator car‐
tridge.
Oil level in the oil separator Drain off oil until the correct lev‐
tank too high. el is reached.
Oil return line clogged. Check dirt trap in the return
line.
Tab. 36 Other faults and actions.

10 Maintenance
10.1 Ensuring safety
10 Maintenance
10.1 Ensuring safety
Follow the instructions below to ensure safe machine maintenance.

➤ Allow maintenance work to be performed by authorised personnel only.
➤ Use one of the safety signs below to advise others that the machine is currently being serv‐
iced:
Sign Meaning
Don't activate the machine.
Warning:
The machine is being serviced.
Tab. 37 Advise others that the machine is being serviced.
➤ Before switching on, make sure that nobody is working on the machine and all access doors
and panels are closed.
➤ Work on electrical equipment may only be carried out by authorised electricians.
➤ Switch off and lock out the power supply disconnecting (isolating) device and check that no
voltage is present.
5 minutes.
When working on the compressed air system
pressure.

10 Maintenance
10.2 Linde regulations
➤ Vent all pressurized components and enclosures.
read zero.
in serious injury.
➤ Switch off and lock out the power supply disconnecting (isolating) device and check that no
voltage is present.
Further information Details of authorised personnel are found in chapter 3.4.2.

10.2 Linde regulations

➤ Linde regulations have priority and should be observed in all maintenance and service work.
10.3 Following the maintenance plan

10.3.1 Logging maintenance work
The maintenance intervals given are those recommended for KAESER original components
with average operating conditions.
➤ In adverse conditions, perform maintenance work at shorter intervals.
Adverse conditions are, e.g.:

■ high temperatures
■ much dust
■ high number of load changes
■ low load
➤ Adjust the maintenance intervals with regard to local installation and operating condi‐
tions.
➤ Document all maintenance and service work.
This enables the frequency of individual maintenance tasks and deviations from our recom‐
mendations to be determined.
Further information A prepared list is provided in chapter 10.20.

10 Maintenance
10.3 Following the maintenance plan
10.3.2 Resetting maintenance interval counters

According to the way a machine is equipped, sensors and/or maintenance interval counters moni‐
tor the operational state of important functional devices. Required maintenance work is shown on
SIGMA CONTROL 2 .
Precondition Maintenance performed and

maintenance message acknowledged.
➤ Reset the maintenance interval counter as described in the SIGMA CONTROL 2 operating
manual.
10.3.3 Regular maintenance tasks

The table below lists maintenance tasks required.
The compressor must be evacuated and then filled with gas after commencing any mainte‐
nance or service work requiring an opening of the pressure system.
➤ Detailed information can be found in chapter 7.8.
➤ Take note of the controller's service messages and carry out tasks punctually, taking ambient
and operating conditions into account.
Interval Maintenance task See chapter

weekly Check the cooling oil level. 10.13
Check the oil collecting tank. 10.4
Control cabinet: 10.5
Check the filter mat
Up to 1,000 h Clean the cooler. 10.6
Check the cooling air filter mat 10.8
Up to 8,000 h Change the cooling air filter mat 10.8
At least annually Control cabinet: 10.5
Change the filter mat.
Display: Maintain the motor bearings. 10.9
SIGMA CONTROL 2 Check the coupling. 10.10
Display: Change the oil filter. 10.17
SIGMA CONTROL 2
At least annually
Display: Change the oil separator cartridge. 10.18
SIGMA CONTROL 2 Change the cooling oil. 10.16
Every 3 years at least
Annually Check the pressure relief valve. 10.11
Check the overheating safety shutdown function. 10.12
Check the cooler for leaks. 10.6
Maintain the water-cooling system. 10.7
Check that all electrical connections are tight. –
h = operating hours
Tab. 38 Regular maintenance tasks

10 Maintenance
10.4 Check the oil collecting tank
10.3.4 Regular service tasks

The table below lists necessary service tasks.
➤ Only an authorised KAESER service technician should carry out service work.
➤ Have service tasks carried out punctually taking ambient and operating conditions into ac‐
count.
Interval Service task

Up to 24,000 h Fan motor:
At the latest every Replace the motor bearings.
3 years Check hoses.
■ Valve revision:
■ Minimum pressure/check valve
■ Combined venting and auxiliary valve
■ Inlet valve
Up to 32,000 h ■ Change the coupling.
■ Check the airend.
■ Compressor drive motor
Replace the motor bearings.
h = operating hours
Tab. 39 Regular service tasks
10.4 Check the oil collecting tank

A certain amount of oil diffuses through the airend shaft seal. This oil is led to a collecting tank.
Fig. 21 Cooling oil collecting tank
➤ Check the oil level and empty when necessary.

If the oil collecting tank must be frequently emptied:
➤ Contact KAESER service.
Dispose of the old oil in accordance with local environment protection regulations.

10 Maintenance
10.5 Control cabinet: Clean or renew the filter mat
10.5 Control cabinet: Clean or renew the filter mat

A filter mat is placed behind every ventilation grille. Filter mats protect the control cabinet from in‐
gress of dirt. If the filter mats are clogged, adequate cooling of the components is no longer ensur‐
ed. In such a case, clean or replace the filter mats.
Material Warm water and household detergent

Spare parts (as required)
Precondition The power supply isolator is switched off (all poles),

the absence of voltage has been verified.
Fig. 22 Switching cabinet ventilation

1 Ventilation grille
2 Filter mat
Frequency-controlled machines (SFC) have ventilation grilles and filter mats in both the machine
and the frequency converter control cabinets. Maintain all filter mats at the same time.
1. Carefully remove the ventilation grille and take out the filter mat.
2. Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash with lukewarm
water and household detergent.
3. Replace the filter mat if cleaning is not possible or if the change interval has expired.
4. Insert the filter mat in the frame and latch in the ventilation grille.
10.6 Option K1
Cooler maintenance
Regularly clean the cooler. This ensures reliable cooling of the machine and the compressed gas.
The frequency is mainly dependent on local operating conditions.
A leaking cooler results in loss of cooling oil and compressed gas.
Clogged coolers are indicative of unfavourable ambient conditions. Such ambient conditions
clog the cooling air ducts in the machine's interior and the motors resulting in increased wear
and tear.
➤ Have the authorised KAESER Service clean the cooling air ducts.

10 Maintenance
10.7 Water-cooling Maintenance
Material Brush and vacuum cleaner

Face mask (as required)

The machine has cooled down.
Fig. 23 Cleaning the cooler

1 Cooler
2 Brush
Cleaning the cooler
Do not use sharp objects to clean the cooler. It could be damaged.

Avoid creating clouds of dust.
➤ Dry brush the oil and gas coolers and use a vacuum cleaner to suck up the dirt.
The gas and oil coolers can no longer be properly cleaned?
➤ Have stubborn clogging removed by an authorized KAESER Service Technician.
Check the cooler for leaks
➤ Carry out visual inspection: Did cooling oil escape?

Is a cooler leaking?
➤ Have the defective cooler repaired immediately by KAESER Service.
➤ Check the gas- and oil cooler for leaks
10.7 Option K2/K9

Water-cooling Maintenance
Cooler clogging causes overheating and machine damage.
➤ Observe the airend discharge temperature to detect any tendency to rise.
Check the cooler regularly for leaks and contamination. Frequency of checking is dependant on the
characteristics of the cooling water.

10 Maintenance
10.8 Cleaning or Renewing the Cooling Air Filter Mat

Checking for leaks
Pressure in the cooling oil circuit is generally higher than that in the cooling water system. If a leak
occurs, oil will run into the cooling water.
1. Check the cooler visually for leaks.
2. Have an authorised KAESER Service Technician check the cooler for internal leaks at least
once a year.
Cleaning
➤ An authorised KAESER Service Technician should clean the cooler when the airend discharge
temperature is 10 °C above the annual average.
➤ Check the gas- and oil cooler for leaks
10.8 Option K3
Cleaning or Renewing the Cooling Air Filter Mat
The filter mat help to keep the cooler clean. If the filter mat is clogged, adequate cooling of the
components is no longer ensured.
Material Warm water and household detergent

Spare parts (as required)
Precondition The machine is switched off.
Fig. 24 Cooling air filter mat

1 Cooling air filter mat
2 Retaining frame
3 Fixing

10 Maintenance
10.9 Motor maintenance
Removal
1. Open the fixing 3

by turning 90° anti-clockwise with a screwdriver.
2. Remove the frame 2 .
Cleaning
➤ Renew the mat if cleaning is not possible or has already been carried out five times.
➤ Beat the mat 1 or use a vacuum cleaner to remove loose dirt.

If necessary, wash the mat in lukewarm water (about 40 °C) and household detergent then
rinse thoroughly.
Refitting
➤ Replace the frame and close the fixings.

Use a screwdriver to turn the fixings 90° clockwise until they latch.
10.9 Motor maintenance

Use only the high temperature grease ESSO UNIREX N3 for the motor bearings. Bearing
damages caused by the use of other brands of grease are excluded from the warranty.
Material Bearing grease: ESSO UNIREX N3

Cleaning cloths
Fig. 25 Compressor motor maintenance

1 Grease nipple (drive motor)
2 Grease nipple (fan motor K1)
Compressor drive motor:
Nipples for re-greasing the motor bearings are located on the outside of the machine.
The lines to the bearings are pre-filled with bearing grease.

10 Maintenance
10.10 Checking the Coupling
The required quantity of grease is stated on the motor nameplate.
Precondition Motor running
1. Clean the nipple 1 with a cloth before greasing.

2. Grease both bearings with a grease gun.
3. Reset the maintenance interval counter.
Option K1 Fan motor:
Nipples for re-greasing the motor bearings are located on the outside of the machine.
The lines to the bearings are pre-filled with bearing grease.
The required quantity of grease is stated on the motor nameplate.
Precondition Motor running
1. Clean the nipple 2 with a cloth before greasing.

2. Grease both bearings with a grease gun.
3. Reset the maintenance interval counter.
Option K2/K9 Fan motor:
➤ Have the fan motor bearings checked by a KAESER Service Technician during the regular
maintenance calls.
10.10 Checking the Coupling

A defective coupling is recognisable by:
■ noisy running,
■ surface cracks,
■ colour change.
WARNING
Danger of injury from rotating coupling!
➤ Never switch the machine on without the safety screen in place over the coupling.

10 Maintenance
10.11 Checking the pressure relief valve
Fig. 26 Checking the coupling

1 Safety screen
2 Coupling
Check for uneven or noisy running
Precondition The machine is running
➤ Check the coupling for noisy or uneven running
Make a visual check for damage
Precondition The power supply disconnecting device is switched off.

The disconnecting device is locked in the off position.
The machine has cooled down.
1. Remove the securing screws and take off the safety screen.
2. Turn the coupling my hand and look for damage or colour change.
3. Refit the safety screen.
4. Close all access doors and replace all enclosure panels.
Has the coupling cracks or colour changes?
➤ Have a damaged coupling changed by an authorised KAESER Service Technician.
10.11 Checking the pressure relief valve

In order to check the pressure relief valve, the machine's working pressure is raised above the acti‐
vating pressure of the valve.
Blow off protection and air system pressure monitoring are switched off during the test. In normal
operation, the blow-off protection will switch off the machine before the pressure relief valve re‐
sponds. During the inspection, the blow-off protection will switch off the machine only when the ac‐
tivating pressure of the pressure relief valve has been exceeded by 1 bar.

10 Maintenance
10.12 Checking the overheating safety shutdown function
➤ Follow the detailed description of this procedure in the SIGMA CONTROL 2 operating
manual
➤ Never operate the machine without a correctly functioning pressure relief valve.
➤ Have a defect pressure relief valve replaced immediately.
WARNING
Excessive noise is caused when the pressure relief valve blows off!
➤ Close all access doors; replace and secure all removable panels.
➤ Wear hearing protection.
Precondition The machine is switched off.
1. Close the user's shut-off valve at the inlet and outlet ends.
2. Read off the activating pressure on the valve.
(the activating pressure is usually to be found at the end of the part identification)
3. Log on to SIGMA CONTROL 2 with access level 2.
4. Observe the display of pressure on SIGMA CONTROL 2 and call up the test function.
5. WARNING!
Risk of burns due to released cooling oil and gas when blowing off the pressure relief valve!
➤ Wear eye protection.
6. End the test as soon as the pressure relief valve blows off or working pressure exceeds the
activating pressure of the pressure relief valve by nearly 1 bar.
7. If necessary, vent the machine and replace the defective pressure relief valve.
8. Deactivate the test function
9. Open the user's shut-off valve at the inlet and outlet ends.
10.12 Checking the overheating safety shutdown function

The machine should shut down if the airend discharge temperature reaches a maximum of 110 °C.
➤ Check the safety shutdown function as described in the SIGMA CONTROL 2 operating man‐
ual.
The machine does not shut down?
➤ Have the safety shutdown function checked by an authorised KAESER Service Techni‐
cian.
10.13 Checking the cooling oil level

In frequency-controlled compressors (SFC) the oil level indicator is only accurate when the
machine is running at or near maximum speed.
The lower the pressure at the compressed gas outlet, the higher the speed.
SIGMA CONTROL 2 displays this value.
Precondition The machine has been running at least 5 minutes under LOAD.

10 Maintenance
10.14 Venting the machine (de-pressurising)
Fig. 27 Checking the cooling oil level

1 Minimum oil level
2 Maximum oil level
3 Optimum oil level
1. CAUTION!
Danger of burning - hot surfaces!
➤ Wear long-sleeved clothing and protective gloves.
2. Check the oil level with machine running under LOAD.
Result As soon as the minimum level is reached: Replenish the cooling oil.

Venting takes place in three stages:
■ Isolate the compressor from the gas network.
■ Vent the oil separator tank.
■ Gas is vented manually from the gas cooler.
The machine must be isolated from the gas network and completely vented before undertak‐
ing any work on the pressure system.
Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.

CAUTION
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.

10 Maintenance
Fig. 28 Venting the machine

1 Hose coupling (gas cooler venting) 7 Shut-off valve
2 Pressure gauge A Shut-off valve open
3 Hose coupling (oil separator tank venting) B Shut-off valve closed
6 Male hose fitting 8 Maintenance hose
Isolate the compressor from the gas network
➤ Close the user's shut-off valve at the inlet and outlet ends.
If no shut-off valve is provided, the complete gas network must be vented.
Vent the oil separator tank
The oil circulation vents automatically as soon as the machine is stopped.

➤ Check that the oil separator tank pressure gauge reads 0 bar.
After automatic venting the pressure gauge does not read 0 bar?
➤ Make sure that the shut-off valve is closed or that the complete gas network is vented.
➤ With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Disconnect the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact
KAESER Service.
Vent gas manually from the gas cooler
After shutting down the compressor and venting the oil separator tank, the machine is still un‐
der pressure from the gas network or the section from the shut-off valve to the minimum pres‐
sure/check valve.
1. With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 1 .
2. Slowly open the shut-off valve 7 to release pressure.
3. Disconnect the male hose fitting 6 and close the shut-off valve 7 .

10 Maintenance
10.15 Replenishing the cooling oil

The machine must be isolated from the compressed gas network and completely vented be‐
fore undertaking any work on the pressure system.
Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.
Precondition The supply disconnecting device is switched off,

the absence of voltage has been verified.
Fig. 29 Replenishing the cooling oil

1 Hose coupling (gas cooler venting) 6 Male hose fitting
2 Pressure gauge 7 Shut-off valve
3 Hose coupling (oil separator tank venting) A Shut-off valve open
4 Oil filler port with plug B Shut-off valve closed
5 Cooling oil level indicator 8 Maintenance hose
1. Vent the machine as described in section 10.15.1.

2. Fill with cooling oil and test run as described in section 10.15.2.
10.15.1 Venting the machine (de-pressurising)

Venting takes place in three stages:
■ Isolate the compressor from the gas system.
■ Vent the oil separator tank.
■ Gas is vented manually from the gas cooler.
CAUTION
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.

10 Maintenance
Isolate the compressor from the gas system.
➤ Close the user's shut-off valve at the inlet and outlet ends.
If no shut-off valve is provided, the complete gas network must be vented.
Vent the oil separator tank.
The oil circulation vents automatically as soon as the machine is stopped.

➤ Check that the oil separator tank pressure gauge reads 0 bar.
After automatic venting the pressure gauge does not read 0 bar?
➤ Make sure that the shut-off valve is closed or that the complete gas network is vented.
➤ With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Disconnect the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact
the KAESER Service.
Vent gas manually from the gas cooler.
After shutting down the compressor and venting the oil separator tank, the machine is still un‐
der pressure from the gas network or the section from the shut-off valve to the minimum pres‐
sure/check valve.
2. Slowly open the shut-off valve 7 to release pressure.
3. Disconnect the male hose fitting 6 and close the shut-off valve 7 .
10.15.2 Topping up with cooling oil and trial run

Replenishing the cooling oil
A sticker on the oil separator tank specifies the type of oil used.
1. WARNING!
Compressed gas!
Compressed gas and devices under gas pressure can injure or cause death if the contained
energy of the gas is released suddenly or uncontrolled.
➤ Vent all pressurized components and chambers completely.
2. NOTICE!
The machine could be damaged by unsuitable oil.
➤ Never mix different types of oil.
➤ Never top up with a different type of oil to that already used in the machine.
3. Slowly unscrew the filler plug 4 .
4. Top up to bring the oil to the correct level.
5. Renew the filler plug's gasket if necessary and screw the plug into the filler port.
Start the machine and carry out a trial run
1. Close all access doors, replace and secure all removable panels.

10 Maintenance
10.16 Changing the cooling oil
3. After approx. 10 minutes of operation: Check the cooling oil level and top up if necessary.
4. Switch off the machine and check visually for leaks.

Drain the oil completely from the following components:
■ Oil separator tank
■ Oil cooler
■ Compressor block
➤ Always change the oil filter and oil separator cartridge when changing the oil.
➤ Contact KAESER Service if condensate is detected in the cooling oil. It is necessary to
adjust the airend discharge temperature to suit operating conditions.
Gas pressure helps to expel the oil. This compressed gas can be taken either from the compressor
itself or from an external source.
An external source of compressed gas is necessary in the following cases:

■ The machine is not operational.
■ The machine is to be restarted after a long period of standstill.
The machine must be isolated from the gas network and completely vented before undertak‐
ing any work on the pressure system.
Material Cooling oil

Cooling oil receptacle
The maintenance hose with hose coupling and shut-off valve is stowed beneath the oil separator
tank.
CAUTION
There is risk of burns from hot components and oil!
➤ Wear long-sleeved clothing and gloves.

10 Maintenance
Fig. 30 Changing the cooling oil, oil separator tank

1 Hose coupling (air cooler venting) A Shut-off valve open
2 Pressure gauge B Shut-off valve closed
3 Hose coupling (oil separator tank venting) 8 Maintenance hose
4 Oil filler port with plug 9 Hose coupling (oil drain)
5 Cooling oil level indicator 10 Shut-off valve (venting line)
6 Plug-in nozzle 11 Shut-off valve (oil drain)
7 Shut-off valve
Oil change using the internal pressure Changing the cooling oil with the help of exter‐
nal gas
Machine has been running at least 5 minutes The power supply isolating device is switched
under LOAD. off,
The machine is fully vented, the device is locked off,
the pressure gauge on the oil separator tank the absence of any voltage has been verified.
reads 0 bar. The machine is fully vented,
1. Close the shut-off valve 10 in the venting the pressure gauge on the oil separator tank
line. reads 0 bar.
2. Start the machine and watch the oil separa‐ External source of gas pressure available.
tor tank pressure gauge 2 until it reads 3– 1. Close the shut-off valve 10 in the venting
5 bar. line.
3. Switch off and lock out the power supply 2. With the shut-off valve closed, insert the
disconnecting device and verify the absence male hose fitting 6 into the hose cou‐
of any voltage. pling 3 .
4. Wait at least 2 minutes to allow the oil to 3. Connect the maintenance hose to the exter‐
flow back to the separator tank. nal gas supply.
4. Open the shut-off valve 7 until the pressure
gauge on the oil separator tank reads 3–
5 bar.
5. Close the shut-off valve 7 and remove the
male hose fitting from the coupling.
Draining the oil from the separator tank
1. Have an oil receptacle ready.


10 Maintenance
3. Place the other end of the maintenance hose in the oil receptacle and secure it in place.
4. Open the shut-off valve 11 .
5. Slowly open the shut off valve 7 in the maintenance hose to release oil and close immediately
when air escapes.
6. Close the shut-off valve 11 and unplug the male hose fitting.
Draining the oil from the cooler
Fig. 31 Changing the cooling oil, oil cooler

1 Oil cooler 6 Plug-in nozzle
2 Hose coupling (oil drainage) 7 Shut-off valve
3 Shut-off valve

4. Open the shut-off valve 3 .
5. Slowly open the shut-off valve 7 and allow cooling oil and gas to escape completely until the
pressure gauge on the oil separator tank reads 0 bar.

10 Maintenance
Draining the oil from the airend
Fig. 32 Changing the cooling oil, airend

1 Airend gas discharge point 4 Safety screen
2 Hose coupling (oil drainage) 5 Coupling
3 Shut-off valve

2. With the shut-off valve closed, insert the male hose fitting 6 (Fig. 30) into the hose coupling 2 .
4. Open shut-off valves 3 and 7 (Fig. 30)
5. Remove the coupling safety screen 4 and turn the coupling 5 by hand at least five revolutions
until all the oil has run out.
6. Fit the safety screen again.
Result The cooling oil is drained from the airend.

A small amount of cooling oil may flow back into the oil cooler and oil separator tank as a result of
turning the coupling.
Remove this by repeating the steps for draining oil from the separator tank and oil cooler.
Filling with cooling oil
1. WARNING!
Compressed gas!
Compressed gas and devices under pressure can injure or cause death if the contained ener‐
gy is released suddenly.
2. Slowly open the filler plug 4 (Fig. 30).
3. Fill with cooling oil.
4. Check the filler plug and ring seal for damage and screw the plug back in again.
Starting the machine and performing a trial run

10 Maintenance
10.17 Changing the oil filter
3. Switch on the power supply and reset the maintenance interval counter.
4. Start the machine and check the oil level again after about 10 minutes, topping up if necessary.
➤ Dispose of used oil in accordance with environment protection regulations.
10.17 Changing the oil filter

Material Spares
Cooling oil receptacle

The machine is fully vented,
the pressure gauge on the oil separator tank reads 0 bar.
CAUTION
There is risk of burns from hot components and oil!
➤ Wear long-sleeved clothing and gloves.
Fig. 33 Changing the oil filter

1 Oil filter
2 Direction to unscrew
Changing the oil filter
1. WARNING!
Compressed gas!
Compressed gas and devices under pressure can injure or cause death if the contained ener‐
gy is released suddenly.

10 Maintenance
10.18 Changing the oil separator cartridge
2. Unscrew the oil filter anti-clockwise, catch oil spillage and dispose of in accordance with envi‐
ronmental protection regulations.
3. Lightly oil the new filter's O-ring.
4. Turn the oil filter clockwise by hand to tighten.
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
Starting the machine and performing a trial run
4. After approx. 10 minutes of operation: Check the cooling oil level and top up if necessary.

The oil separator cartridge cannot be cleaned.
The life of the oil separator cartridge is influenced by:

■ contamination in the inlet gas;
■ and adherence to the changing intervals for:
─ Cooling oil
─ Oil filter
Material Spares
Cleaning cloth

The machine is fully vented,
the pressure gauge on the oil separator tank reads 0 bar.

10 Maintenance
Opening the machine enclosure
Fig. 34 Open the enclosure (oil separator cartridge changing)

1 Access panel
2 Cover plate
1. Remove enclosure panels 1 .

2. Remove the cover plate 2 .
Changing the oil separator cartridge
➤ Lift the oil separator cartridge with lifting tackle or the aid of at least one other person.
Fig. 35 Changing the oil separator cartridge

1 Screw fitting 6 Clamping nut
2 Dirt trap 7 Gasket
3 Screw fitting 8 Oil separator cartridge
4 Air pipe 9 Minimum pressure/check valve
5 Fixing screw
1. WARNING!
Compressed gas!
Compressed gas and devices under gas pressure can injure or cause death if the contained
energy of the gas is released suddenly or uncontrolled.

10 Maintenance
2. Unscrew the fitting 1 and carefully put the parts to one side, then pull out the copper pipe from
the dirt trap 2 .
3. Loosen the fitting 3 and disconnect the air pipe 4 completely if necessary.
4. Unscrew the tank cover fixing screws 5 .
5. Use the nut 6 to lift the cover and swing it to the side.
6. Take out the old oil separator cartridge 8 together with the gaskets 7 and dispose of accord‐
ing to environmental protection regulations.
7. Clean all sealing faces.
8. Insert the new cartridge and gaskets.
9. Swing the cover over the tank and lower with the nut 6 until it rests on the tank rim.
The nut 6 becomes free and can be turned by hand when the cover is resting on the tank.
10. Screw the cover with nuts 5 .
11. Renew the O-ring and strainer in the dirt trap 2 .
12. Secure the air pipe 4 with a new self-locking nut.
➤ Follow the instructions in chapter 10.19 concerning flexible pipe connections.
13. Replace and tighten all fittings.

➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.
Closing the enclosure
Fig. 36 Open the enclosure (oil separator cartridge changing)

1 Access panel
2 Cover plate
1. Fit the cover plate 2 .

2. Replace enclosure panels 1 .
Starting the machine and carrying out a trial run
1. Close all access doors; replace and secure all removable panels.
4. After approx. 10 minutes of operation: Switch off the machine and check visually for leaks.

10 Maintenance
10.19 Assembling flexible pipe connections
10.19 Assembling flexible pipe connections

With the machine depressurized, the clamping bolts must be freely movable by hand and par‐
allel with the pipe.
All clamping bolts must be equally loaded.
➤ Replace the self-locking nuts.
Fig. 37 Assembling flexible pipe connections

1 Pipe 6 Self-locking nut
2 Seal holder 7 Pipe clamp halves
3 Seal 8 Self-locking nut
4 Sleeve d Pipe diameter (outside)
5 Tensioning bolt s Dimension of the flexible pipe joint under
tension.
Precondition The pipe 1 must be deburred and the sealing face clean and undamaged.
1. Slide the seal holder 2 and gasket 3 over the pipe 1 .

2. Slide the pipe end 1 into the bush 4 without pretension.
3. Slide the gasket 3 with seal holder 2 up the sealing face of the bush 4 taking care of pipe
alignment.
4. Tighten up the clamping bolts 5 with the self-locking nuts 6 .
5. Lay the pipe clamp halves 7 over the seal holder 2 and bush 4 and tighten the self-locking
nuts 8 until the dimension s is reached.
Pipe diameter: d [mm] Clamp diameter: s [mm]

42.0 83.0 ± 2%
89.0 124.0 ± 2%
114.0 152.0 ± 2%
Tab. 40 Dimensions of the flexible pipe connection

10 Maintenance
10.20 Documenting maintenance and service work
10.20 Documenting maintenance and service work

Machine number:
➤ Enter maintenance and service work carried out in the list.
Date Maintenance task carried out Operating hours Signature
Tab. 41 Logged maintenance tasks

11.1 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.
11.2 Ordering consumable parts and operating fluids/materials

KAESER consumable parts and operating materials are original Kaeser products. They are selec‐
ted for use in KAESER machines.
Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐
chine or impair its proper function.
Personal injury may result from machine damage.
WARNING
There is risk of personal injury or damage to the machine resulting from the use of unsuita‐
ble spares or operating fluids/materials.
➤ Use only original KAESER parts and operating fluids/materials.
➤ Have an authorised KAESER Service Technician carry out regular maintenance.
Machine
Name Quantity Number

Filter mat (control cabinet) 6 1100
Filter mat (Option K3) 4 1050
Oil filter 2 1200
Oil separator cartridge 1 1450
Cooling oil 1 1600
Bearing grease [g] 100 9.0915.0
400 6.3234.0
Tab. 42 Consumable parts
11.3 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 gas compressor station
■ The security of genuine KAESER spares
■ Increased legal certainty as all regulations are kept to.

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

Your advantage:
lower costs and higher compressed gas availability.

Addresses of KAESER agents are given at the end of this manual.

12.1 Putting Out of Operation

12.1 Putting Out of Operation
This is necessary 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.
Temporarily putting out of operation
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.
Putting out of operation for a longer period
Precondition Before putting out of operation, the machine should be run under LOAD for at least 30 minutes.
Switch off the mains disconnecting device,
the disconnect device is locked in the off position,
check that no voltage is present.
Machine fully vented (no pressure).
1. Allow the machine to cool down completely.

2. Disconnect all air and electrical connections.
12.2 Packing
A wooden crate is required for overland transport to protect the machine from mechanical damage.
Other measures must be taken for the transport of machines by sea or air. Please contact
KAESER SERVICE for more information.
Material Desiccant
Plastic sheeting
Wooden crate
Precondition The machine is decommissioned.

The machine is dry and cooled down.
1. Place sufficient desiccant silica gel or desiccant clay) in the machine.

2. Wrap the machine fully in plastic sheeting.
3. Protect the machine in a wooden crate against mechanical damages.
12.3 Storage
Moisture can lead to corrosion, particularly on the surfaces of the airend and in the oil separator
tank.
Frozen moisture can damage components, valve diaphragms and gaskets.

12.4 Transport
The following measures also apply to machines not yet commissioned.

Please consult with KAESER if you have questions to the appropriate storage and commis‐
sioning.
1. NOTICE!
Moisture and frost can damage the machine!
➤ Prevent ingress of moisture and formation of condensation.
➤ Maintain a storage temperature of >0 °C.
2. Store the machine in a dry, frost-proof room.
12.4 Transport
12.4.1 Safety
Weight and centre of gravity determine the most suitable method of transportation. The centre of
gravity is shown in the drawing in chapter 13.2.
➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐
tures.
Precondition Transport only using a forklift truck or lifting gear and only by personnel trained in the safe trans‐
portation of loads.
➤ Make sure the danger area is clear of personnel.
12.4.2 Transport with a forklift truck

Precondition The forks are fully under the machine.
Fig. 38 Transport with a forklift truck
➤ Drive the forks completely under the machine or pallet and lift carefully.
12.4.3 Transport with a crane

Suitable lifting gear ensures correct transportation.
The lifting slings must be fed under the machine.
The slings may not bear on the side of the machine enclosure.

12.5 Disposal
Examples of unsuitable fixing points:

■ Pipe sockets
■ Flanges
■ Attached components such as cyclone separators, condensate drains or filters
■ Rain protection covers
➤ Please consult with KAESER if you have questions to the appropriate lifting gear.
Precondition The lifting gear complies with local safety regulations.

No pressure should bear on the sides of the machine cabinet.
Fig. 39 Transport with a crane

1 Lifting gear
2 Slings
1. NOTICE!
The machine can be damaged by incorrect attachment of the lifting gear!
➤ Do not attach the lifting gear to any of the machine components.
2. Use the lifting gear correctly and lift the machine carefully.
12.5 Disposal
When disposing of a machine, drain out all liquids and remove old filters.
Precondition The machine is decommissioned.
1. Completely drain the cooling oil from the machine.

2. Remove used ail filter and separator cartridge.
3. Hand the machine over to an authorised disposal expert.
➤ Components contaminated with cooling oil must be disposed of in accordance with local
environment protection regulations.

13 Annex
13.1 Pipeline and instrument flow diagram (P&I diagram)
13 Annex

13 Annex
13 Annex
13 Annex
13.2 Dimensional drawing
13.2 Dimensional drawing

Die Zeichnung bleibt unser ausschließliches Eigentum. Sie wird nur zu dem vereinbarten Zweck anvertraut und darf zu keinem anderen Drawings remain our exclusive property. They are entrusted only for the agreed purpose. Copies or any other Entwicklungsbedingte
Zweck verwendet werden. Kopien oder sonstige Vervielfältigungen einschließlich Speicherung, Verarbeitung oder Verbreitung unter reproduction, including storage, treatment and dissemination by use of electronic systems must not be made for any Änderungen vorbehalten.
Verwendung elektronischer Systeme dürfen nur zu dem vereinbarten Zweck angefertigt werden. Weder Original noch Vervielfältigungen other than the agreed purpose. Neither originals nor reproductions may be given to or made available to third parties. Zeichnung darf nur über
dürfen Dritten ausgehändigt oder in sonstiger Weise zugänglich gemacht werden. CAD geändert werden.
Option:
37 3/4 40 1/2
Air cooling
1/2
Machine mountings
Gas discharge
ANSI 3" / 300lbs
Z
1/8
25 7/8
8 3/8
7 1/8
11 3/8 1 7/8
H1
5 1/4
3 7/8
4 5/8
Cooling air outlet
ESD_2C_10357405_10–LIN_00 E
64 5/8
67
K1
H1
Code:
CG
13
13.2
ATTENTION!
33 1/2
CG : Centre of gravity
Annex
78 23 5/8
CG
35 1/4 17 1/4
position marginally dependent on design

2
Z
30 5/8
Minimum width of door is total width of unit + 100 mm

14 3/4 9 7/8
Dimensional drawing
Gas inlet

19 7/8 ±0,4
ANSI 4" / 150lbs
Demounting height for separating cartridge

90
°
122
CG
72 7/8
ESD 442/14 bar (abs) SFC SIGMA CONTROL 2

Oil return line
90
°
33 1/2
for motor bearings

Swagelok SS 400-1-2
Relubrication equipment
62 1/4
70 1/8 ±0,4
9 7/8
Y
B
90
90
°
°
84 1/8
5 1/8
90
86 3/8 °
24 1/4
90 1/8
32 1/2
38 1/4 35 3/8
16
Status
11
10248151 D 00
Dokument TZD
Dokument TZM
10248151 USE 00
FREIGEGEBEN
13 3/4
40
A2
5
Original
Änderungs-Nr. Projektion Maßstab
Bezeichnung
79
Gez.
Bearb.
24 7/8 11 3/4
ESD.2C SFC K1
Y
Dimension and connection dim.

Datum
as required
2 x dia.75
1 5/8
7 1/8
1 5/8
5 3/4
30.08.2013 MALTER1
23.05.2013 MALTER1
B
Freigeg. 03.09.2013 DRESSEL4

4 x dia.26
Electrical connections
Name
USE
5 7/8
2 1/2
3 7/8
Sprache
A
29 1/8 3 7/8
2 x dia.75
Electrical connections as required
Blatt
1 von 1
Cooling air inlet
Stand 12.11.2012
89
13 Annex
13.3 Electrical Diagram

13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex
13 Annex

Order-No.: 10357405

4. Service manual Sigma Control

Service manual
Controller
SIGMA CONTROL 2 SCREW FLUID 1.1.3

9_9450 03USE
Manufacturer:
KAESER KOMPRESSOREN
/KKW/SSC 2.03 en 01 BA-SIGMA CONTROL FLUID
/KKW/SSC 2.03 01
20130805 113302
Quick user guide
Controller
SIGMA CONTROL 2 SCREW FLUID 1.1.3

9_9450 03 USE
Manufacturer:
KAESER KOMPRESSOREN
Contents
1. Important settings ............................................................................................................. 1

2. Setting the contrast and the brightness ............................................................................ 2
3. Setting the display language ............................................................................................ 3
4. Logging on with Equipment Card ..................................................................................... 4
5. Adjusting the system setpoint pressure ........................................................................... 6
6. Activating the «clock» key. ............................................................................................... 7
7. Activating the «<Remote control»> key ........................................................................... 10
8. Changing the control mode .............................................................................................. 13
9. Outputting important operational states of the machine ................................................... 14
10. Resetting maintenance interval counters ......................................................................... 15
11. Safety relief valve checking .............................................................................................. 17
12. Checking the temperature sensor and overheating shutdown function ........................... 20
13. Interpreting operation messages ...................................................................................... 22
14. Interpreting diagnostic messages .................................................................................... 25
15. Interpreting fault messages .............................................................................................. 26
16. Interpreting warning messages ........................................................................................ 32
17. Interpreting system messages ......................................................................................... 36
Quick user guide Controller

9_9450 03 USE SIGMA CONTROL 2 SCREW FLUID 1.1.3 i
Contents

ii SIGMA CONTROL 2 SCREW FLUID 1.1.3 9_9450 03 USE
1 Important settings
1 Important settings
In this chapter, important or often used settings are explained in brief. Detailed information on func‐
tion, configuration, fault removal and important instructions concerning safe operation are found in
subsequent chapters.
Setting and other work on the machine may only be carried out by the following persons:
■ persons trained on the machine/controller and persons instructed by and under the su‐
pervision of a specialist,
■ trained technicians,
■ authorized service personnel.

9_9450 03 USE SIGMA CONTROL 2 SCREW FLUID 1.1.3 1
2 Setting the contrast and the brightness
2 Setting the contrast and the brightness

The display settings for contrast and brightness are set to the highest possible values by default.
Change the settings if adverse lighting conditions make it difficult to read the displayed information.
Optimizing the contrast settings:

■ Press and hold the «Information» key.
■ At the same time, press the «Left» or «Right» key.
Optimizing the brightness settings:

■ Press and hold the «Information» key.
■ At the same time, press the «UP» or «DOWN» key.
Precondition The display shows the operating mode.
1. Press «Enter».
The main menu is displayed.
2. Press and hold the «Information» key.
89 psi 08:15 176 °F
Main menu
········· Deutsch ········· Active line with current language
3. Press «UP» or «DOWN» to adjust the contrast.

4. Press «Left» or «Right» to adjust the brightness.
Result The settings for contrast and brightness have been adjusted.

2 SIGMA CONTROL 2 SCREW FLUID 1.1.3 9_9450 03 USE
3 Setting the display language
3 Setting the display language

1. Press «Enter».
2. Press the «UP» or «DOWN» keys until the current language is shown as active line.
89 psi 08:15 176 °F
Main menu
········· Deutsch ········· Active line with current language
3. Use the «Enter» key to switch to setting mode.

The currently set language flashes.
4. Move to the required language with «UP »or «DOWN».
5. Confirm the setting with «Enter».
6. Press «Escape» repeatedly to return to the main menu.
Result The display texts are now in the selected language.

4 Logging on with Equipment Card

Proceed as follows:
■ Take the plastic sleeve from the control cabinet.
■ Remove one Equipment Card.
■ Note the number on the reverse side of the Equipment Card.
■ Safely store the number.
■ Log on with Equipment Card
➤ Proceed in the prescribed sequence of actions.
Remove the Equipment Card from the control cabinet.
The supplied Equipment Cards are stored in a plastic sleeve.

This plastic sleeve is attached to the rear of the controller in the control cabinet.
The number shown on the rear of the Equipment Card is also the user name.
The user name is required for a manual log on without Equipment Card.
Fig. 1 KAESER Equipment Card

1 KAESER Equipment Card
2 Number of the KAESER Equipment Card
1. Open the control cabinet.

2. Remove the plastic sleeve from the rear of the controller.
3. Remove one Equipment Card from the plastic sleeve.
4. Note the number shown on the backside of the Equipment Card.
5. Store this information at a suitable location.
Log on with Equipment Card
Use a supplied KAESER Equipment Card to log on at the controller.

Two of them have been provided with the machine.

Fig. 2 RFID reader
1. Hold the Equipment Card for a short time in front of the RFID reader.
The data are read.
Your user name and access level are displayed.
2. Press «Enter» to confirm the log-on.
The operating mode is displayed.
Result You are logged on.
Further information See chapter 7.2.6 for a manual log-on to the controller.

5 Adjusting the system setpoint pressure
5 Adjusting the system setpoint pressure

Precondition Access level 2 is activated.
The display shows the operating mode.
1. Press «Enter».
2. Select the < Configuration ➙ Pressure control ➙ Pressure settings > menu.
The pA switching value is displayed in the active line.
89 psi 08:15 176 °F
5.2.2 Pressure settings Current menu
Setpoint pressure Parameter to be adjusted
pA SP : 116 psi ¦ SD : - 7 psi Active line, setting for switching point pA
pB SP : 1127 psi ¦ SD : - 7 psi Setting for switching point pB
·········
System pressure low ☐
↓< 73 psi ¦ SD : 7 psi
3. Press «Enter» to switch into setting mode.

The current value flashes.
4. Use «UP» or «DOWN» to adjust the setting for the switching point pA .
5. Press «Enter» to accept the setting.
6. Press the «Right» key once.
7. Press «Enter» to switch into the setting mode for the switching differential.
The current value flashes.
8. Use «UP» or «DOWN» to adjust the setting for the switching differential.
10. If necessary, adjust the value for switching point pB in the same way.
Further information See chapter 7.4 for the adjustment of the machine's pressure parameters.

6 Activating the «clock» key.

Activating/deactivating the check box
Check box Check box for reset Status

☑ ☒ activated
☐ ☐ deactivated
Tab. 1 Check box status
Precondition Password level 2 is activated.

Select the clock compressor menu
1. Press «Enter».
2. Select < Compressor clock >.
The display for setting the Compressor clock timing program appears.
89 psi 08:15 176 °F
6 Compressor clock Menu
Key clock: ☐
Reset: ☐
·········
01 n.a. 00:00 off Enter switching point 01 (active line)
02 n.a. 00:00 off Enter switching point 02
03 n.a. 00:00 off Enter switching point 03
Entering switching points

The n.a. column flashes in the active line.
2. Use «UP» to specify the settings for the weekdays.
Column time, hours display, 00 : 00 flashes in the active line.
6. Use «UP» to specify the settings for the hours.
Column time, hours display, 00 : 00 flashes in the active line.
8. Use «UP» to specify the settings for the minutes.

9. Press «Enter» to accept the settings.

The display stops flashing and the time (hours/minutes) is set.
89 psi 08:15 176 °F
6 Compressor clock Current menu
Key clock: ☐
Reset: ☐
·········
01 Mon-Fri 06:30 on example for weekdays
02 Mon-Fri 12:00 off example for time
03 Mon-Fri 13:00 on For example, compressor ON action

Column action on/off flashes.
12. Use «UP» to specify the settings for the compressor ON action.
The compressor ON action is set for the first switching point.
14. Specify further switching points in the same manner.
Result Weekdays, time and the compressor ON / compressor OFF actions are set for all switching points.
Activating the «clock» key.
1. Use «UP» key to change to line Key clock .

The check box flashes in the active line.
89 psi 08:15 176 °F
Key clock: ☑ Active line with check box
Reset: ☐ Resetting all current switching points
·········
01 Mon-Fri 06:30 on
02 Mon-Fri 12:00 off
03 Mon-Fri 13:00 on
3. Use the «UP» key to activate the check box.

The «clock» key is activated.
6. Press the «clock» key.
■ Proceed in the same manner to deactivate the «clock» key.
■ All defined switching points will be reset simultaneously if you activate the reset check
box.

Result The machine runs according to the defined switching points of the clock program.
Further information See chapter 7.5 for configuration of starting and stopping the machine.
See chapter 7.8.2 for configuration of load changeover based on a clock program.

7 Activating the «<Remote control»> key

Further settings have to be made to allow the machine to be remotely controlled.
➤ Refer to the section "Additional information" in this chapter.
Activating/deactivating the check box

Check box Status
☑ activated
☐ deactivated
The following menus are used to activate the «Remote control» key:
■ Menu <Compressor ON>
■ Menu <Load control>
The function will be available as soon as the «Remote control» key in one of the menus has been
activated.

Activating the «Remote control» key in the Compressor ON menu
1. Press «Enter».
2. Select < Configuration ➙ Compressor start ➙ Compressor on >.
3. Press «DOWN» repeatedly until Key remote is displayed as active line.
The check box for «Remote control» key will flash.
89 psi 08:15 176 °F
5.4.1 Compressor on Menu
Local mode: Key
Remote mode: Key
------------------------------
RC DI 1.12 ☐
Key remote: ☐ Active line with check box
Key clock: ☐
5. Press the «UP» key.

The activated check box is displayed.

6. Press «Enter» to save the setting.

The «Remote control» key is activated and can be used.
89 psi 08:15 176 °F
Local mode: Key
Remote mode: Key
------------------------------
RC DI 1.12 ☐
Key remote: ☑ Active line with check box
Key clock: ☐

8. Press the «Remote control» key to enable remote mode.
Proceed in the same manner to deactivate the «Remote control» key.
Activating the «Remote control» key in the load control menu

1. Press «Enter».
2. Select < Configuration ➙ Pressure control ➙ Load control >.
3. Press «UP» repeatedly until Key remote is displayed as active line.
The check box for «Remote control» key will flash.
89 psi 08:15 176 °F
5.2.3 Load control Menu
Local mode pA
·········
Remote mode: pA
Key remote: ☐ Active line with check box
·········
▶1 pA/pB Clock



89 psi 08:15 176 °F
Local mode pA
·········
Remote mode: pA
Key remote: ☑ Active line with check box
·········
▶1 pA/pB Clock

Proceed in the same manner to deactivate the «Remote control» key.
Further information See chapter 7.5 for configuration of starting and stopping the machine.
See chapter 7.9 for configuration of load changeover under master control.

8 Changing the control mode
8 Changing the control mode

The standard setting of the control mode depends on the machine type.
As an example, the change from DUAL to QUADRO control mode is described below.

1. Press «Enter».
2. Select the < Configuration ➙ Control mode > menu.
Local mode is displayed as active line.
89 psi 08:15 176 °F
5.3 Control mode Current menu
Local mode: DUAL Active line with control mode to be adjusted
------------------------------
▶1 Venting period
·········
▶3 DUAL
▶4 QUADRO

The display for DUAL control mode flashes.
89 psi 08:15 176 °F
5.3 Control mode Current menu
Local mode: QUADRO Active line with changed control mode
------------------------------
▶1 Venting period
·········
▶3 DUAL
▶4 QUADRO
4. Use «UP» to select QUADRO.

6. Press «Esc» repeatedly to return to the main menu.
Result The regulating mode DUAL has been switched to QUADRO.
Further information See chapter 4.7 for the functions of the control modes.
See chapter 7.6 for the parameters of the control modes.

9 Outputting important operational states of the machine
9 Outputting important operational states of the ma‐

chine
Important operational machine states can be assigned via floating relay contacts as a binary signal
on the outputs DOR 1.05 – DOR 1.07. Further outputs are optionally available. You can assign ev‐
ery output only once.

Configuration ➙ I/O Periphery ➙ DO Functions menu
1. Press «Enter».
2. Select the < Configuration ➙ I/O periphery ➙ DO functions > menu.
A list of available messages and their assigned outputs is displayed.
Controller on line is displayed as being active.
3. Select the required message with the «UP» or «DOWN» keys.
89 psi 08:15 176 °F
5.7.1 DO functions Menu
Controller on Active line
DOR 1.05 ☐ ¦ Logic : +
DOT 1.02 ☐ ¦ Logic : +
Compressor on
DOR 1.03 ☐ ¦ Logic : +
DOT 1.02 ☐ ¦ Logic : +
Assigning a message to an output

The display flashes.
2. Select a free output with the «UP» or «DOWN» key.
A message is now sent via the assigned output.
Further information See chapter 7.11 for the configuration and use of the controller's inputs and outputs.

10 Resetting maintenance interval counters

Example: Resetting the maintenance counter for the oil filter.
Precondition Maintenance has been performed.

Warning message has been acknowledged.
Access level 2 is activated.
Maintenance menu
1. Press «Enter».
2. Select the < Maintenance > menu.
The maintenance counter for Oil filter is displayed in the active line.
3. Press «DOWN» once.
The Reset check box flashes.
89 psi 08:15 176 °F
4 Maintenance Menu
Oil filter
6000 h ¦ 0005 h Reset: ☐ Active line, maintenance interval, remaining service
life
·········
Oil separator
6000 h ¦ 3000 h Reset: ☐
·········
6. Use «UP» or«DOWN» to activate the Reset check box.

89 psi 08:15 176 °F
4 Maintenance Menu
Oil filter
6000 h ¦ 6000 h Reset: ☒ Active line, maintenance interval, remaining new
service life
·········
Oil separator
6000 h ¦ 3000 h Reset: ☐
·········

The remaining service life of the new oil filter complies with the defined maintenance interval of
3000 h (depending on the machine type).
Result The check box for Reset is deactivated automatically.

89 psi 08:15 176 °F

4 Maintenance Menu
Oil filter
6000 h ¦ 6000 h Reset: ☐ Active line, check box is deactivated
·········
Oil separator
6000 h ¦ 3000 h Reset: ☐
·········
Further information See chapter 8.9 for setting the maintenance intervals.
See chapter 10 for the maintenance of the controller.

11 Safety relief valve checking

Overview
■ Preparing the test
■ Performing the test
■ Correct conclusion of the test
■ Resetting
When the check mode is activated, monitoring of internal pressure (blow-off protection – if
provided) and regulation of network pressure are deactivated.
The measured value of internal pressure pi is used to describe the following check.
Check box Status

☑ activated
☐ deactivated
Danger of injury from pressurized components!

➤ Perform the following actions in the sequence provided.
Preparing the test
1. Note the activating pressure of the safety relief valve from the machine's nameplate.
2. Press the «OFF» key to shut down the machine.
3. Close the user's shut-off valve between the machine and the air distribution network.
4. Log on to SIGMA CONTROL 2 with access level 2 (see chapter 7.2.6).
5. In operating mode, switch to the main menu with the «Enter» key.
6. Select the < Machine test ➙ TÜV inspection > menu.
Safety relief valve is displayed as an active line.
89 psi 08:15 176 °F
9.1 TÜV inspection Menu
Safety valve: ☐ Active line with check box
pRV: 232 psi¦ pi 0 psi Relief valve activating pressure (example)
Reset: ☐
·········
Performing the test
1. Press «Enter».


The test mode is now activated.
The monitoring of internal and network set point pressures is deactivated!
89 psi 08:15 176 °F
Safety valve: ☑ Active line with check box
pRV: 232 psi¦ pi 36 psi Safety relief valve activating pressure
Reset: ☐
·········
4. Excessive noise is caused when the safety relief valve blows off!
5. Risk of burns due to released cooling oil and compressed air when blowing off
the safety relief valve!
6. Press and hold the «ON» key.
The machine switches to load, the machine's internal pressure pi rises.
7. Monitor on the display the pressure rise pi during the check.
8. If the internal pressure pi increases to more than 10% above the correct opening pressure of
the safety relief valve, shut down the machine with the «OFF» key and replace the safety relief
valve.
If the alarm message pRV ⇞ appears, the safety relief valve is defective. The permissible
internal pressure was exceeded by 30 psi.
➤ Have the safety relief valve replaced.
Avoid oil mist:
➤ Release the «ON» key immediately when the safety relief valve responds, in order to pre‐
vent unnecessary oil mist.
Correct conclusion of the test

The check box in the active line flashes.
2. Use the «DOWN» key to deactivate the check box.
The test mode is deactivated and the test is completed.
5. Open the shut-off valve from the machine.
Result The machine is ready for operation.

Resetting
If the test is canceled when opening the safety relief valve, SIGMA CONTROL 2 will indicate the
highest measured value as internal pressure.
Activate the check box for reset in order to reset the stored value.
➤ Activate the check box.
Further information See chapter 8.10 to test the safety relief valve.

12 Checking the temperature sensor and overheating shutdown
function
12 Checking the temperature sensor and overheating

shutdown function
The machine should shut down if the airend discharge temperature (ADT) reaches a maximum of
230°F.
SIGMA CONTROL 2 will simulate a higher temperature for checking this function.
For this purpose, SIGMA CONTROL 2 automatically determines an offset value to be displayed.
During the test mode, this offset is added to the actual airend discharge temperature to cause the
machine to shut down prematurely.
In standard operation, SIGMA CONTROL 2 generates the "overtemperature" fault message when
the maximum airend discharge temperature is reached. Since the modified test temperature is 2 K
below the fault message switching point for overtemperature, the system will not generate a fault
message in test mode.
Overview
■ Shut down the machine and allow to cool down slightly
■ Resetting
Performing the test
Precondition Machine has cooled down approximately 40°F.
1. Log on to SIGMA CONTROL 2 with access level 2. (see section 7.2.6).

Pressure relief valve is displayed in the active line.
4. Press «DOWN» repeatedly until Airend discharge temperature ADT ⇞ is displayed as active
line.
89 psi 08:15 163 °F Fallen airend discharge temperature
·········
Airend discharge temperature ADT ⇞ : ☐ Active line
Offset : 0 °C ¦ ADT ⇞ 0.0 °C
Reset: ☐

12 Checking the temperature sensor and overheating shutdown
function

The Offset display changes to 95°F.
The Airend discharge temperature ADT ⇞ display changes to 226°F.
89 psi 08:15 163 °F
·········
Airend discharge temperature ADT Active line
⇞: ☑
Offset : 35 °C ¦ ADT ⇞ 108 °C Offset, airend discharge temperature in test mode
Reset: ☐
8. Press the «ON» key to switch the machine to LOAD.

The machine switches to LOAD and the airend discharge temperature rises again.
The machine will switch off as soon as the airend discharge temperature attains a value of
226°F.
➤ Abort the test and contact KAESER Service as soon as possible.

The offset is reset to 32°F.
Resetting
SIGMA CONTROL 2 will display the highest measured value if the test for switching off at overtem‐
perature is aborted.
Activate the Reset check box in order to reset the stored value.
➤ Activate the Reset check box.
Further information See chapter 8.11 for testing the temperature sensor.

13 Interpreting operation messages

Operating messages are identified with the letter O.
The message numbers are not numbered consecutively.
Messages 0081 to 0095 are customer-specific and undefined. Complete them with your defined
message text and interpretation.
Message Meaning
0001 O The machine is regulated by system setpoint pressure pA.
Load control pA
0002 O The machine is regulated by system setpoint pressure pB.
Load control pB
0003 O The machine is regulated via the remote contact.
Load control RC
0004 O The machine is remotely regulated via the bus connection.
Load control RB
0005 O The machine is switched on and in READY operating mode.
ready
0006 O The machine is switched on and in IDLE operating mode.
Idle
0007 O The machine is switched on and in LOAD operating mode.
On load
0008 O The machine is switched off.
off The power supply is connected.
0009 O The machine is switched on.
Compressor on
0010 O The power supply is connected.
Controller on The controller is powered.
0011 O The machine can be switched on although the machine tempera‐
Cold start release ture is below the permissible starting temperature.
The machine can be switched on only as long as the message is
displayed.
0025 O The value for pA is output.
Setpoint pressure pA
0026 O The value for pB is output.
Setpoint pressure pB
0027 O Request:
Power OFF → ON Switch the power supply off and on.
0028 O Control mode DYNAMIC:

DYNAMIC motor temperature ↑ The temperature of the compressor motor is too high.

Message Meaning
0081 O
0082 O
0083 O
0084 O
0085 O
0086 O
0087 O
0088 O
0089 O
0090 O
0091 O
0092 O
0093 O
p-Switch pi
0094 O
T-Switch ADT
0095 O
p-Switch pN
0200 O The internal voltage monitoring reports low voltage fault IOSlot1
IOSlot1 Undervoltage error 50

Message Meaning
Tab. 4 Operational messages

14 Interpreting diagnostic messages
14 Interpreting diagnostic messages

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 troubleshooting.

15 Interpreting fault messages

Alarm messages are identified with the letter A.
Messages 0081 to 0095 are customer-specific and may differ from the suggested values. Com‐
plete them with your defined message text, possible causes, and remedies.
Message Possible cause Remedy

0001 A The compressor drive motor Change over
Direction of rotation is turning in the wrong direc‐ phase lines L1 and
tion. L2.
0002 A Compressor drive motor over‐ Clean the motor.
Motor temperature ⇞ heated. Keep ambient con‐
ditions within
specified limits.
0003 A The activating pressure of the Change the safety
pRV ⇞ pressure relief valve on the oil relief valve.
separator tank has been ex‐
ceeded.
0004 A EMERGENCY STOP push Unlatch the push
EMERGENCY STOP button actuated. button.
0005 A Maximum air temperature at Check the line to
Oil separator Temperature ⇞ the oil separator tank outlet is the trip relay.
exceeded.
0007 A Fault in main power supply. Have the main
Power supply monitor power supply
checked.
0009 A Permissible enclosure tem‐ Keep ambient con‐
SIGMA CONTROL 2 T⇞ perature for ditions within
SIGMA CONTROL 2 exceed‐ specified limits.
ed. Control cabinet:
Check filter mats
and fan.
0010 A The activating pressure of the Change the oil
Blow-off protection ⇞ safety relief valve on the oil separator car‐
separator tank has been ex‐ tridge.
ceeded. Open the shut-off
valve in the venting
line.
0011 A Overload shut-down of the Investigate cause
Oil-/air cooler fan Overcurrent first fan motor. of shut-down.
Reset the overload
relay.
0012 A Door open / interlocked panel Fit and secure all
Access doors removed while the machine is panels and close
running. access doors.


Compressor motor overcurrent compressor drive motor. of shut-down.
Change the oil
separator car‐
tridge.
Oil-/air cooler fan Overcurrent second fan motor. of shut-down.
Reset the overload
relay.
0015 A Maximum permissible airend Keep ambient con‐
Airend discharge temperature ADT ⇞ discharge temperature (ADT) ditions within
exceeded. specified limits.
Clean the cooler.
Check the cooling
oil level.
Oil-/air cooler fan Overcurrent third fan motor. of shut-down.
Reset the overload
relay.
0019 A – –
Internal pressure pi ⇟
0021 A Refrigeration dryer: Contact an author‐
Refrigeration dryer T ⇟ Compressed air temperature ized KAESER
too low. service representa‐
tive.
0022 A Oil separator cartridge clog‐ Change the oil
Oil separator Δp ⇞ ged. separator car‐
tridge.
0023 A Drive motor bearings over‐ Re-grease the mo‐
Motor bearings heated. tor bearings.
0024 A Cooling water pressure is too Check cooling wa‐
Water-cooling water shortage low. ter supply.
0034 A Main contactor does not Check main con‐
Mains contactor on? close. tactor and wiring.
0035 A Overload shut-down of the Contact an author‐
Cabinet fan I ⇞ control cabinet fan motor. ized KAESER
service representa‐
tive.
0038 A Package discharge (PD) tem‐ Contact an author‐
PD temperature ⇟ perature too low. ized KAESER
tive.


0039 A Package discharge (PD) tem‐ Check the cooling
PD temperature ⇞ perature too high. oil level.
Clean the cooler.
Check the fan mo‐
tor.
Mains contactor off? open. tactor and wiring.
0041 A Second power failure. Check power sup‐
Mains voltage ⇟ ply voltage.
Check the door in‐
terlock switch.
0042 A Back pressure in the oil sepa‐ Check venting line.
Back pressure stop rator tank caused by defective
venting.
0043 A The rate of rise of the airend Check the cooling
Airend discharge temperature ADT rise dT/dt⇞ discharge temperature (ADT) oil level.
is too fast.
0044 A The machine produces no Check the machine
No pressure buildup compressed air. for leaks.
The working pressure does Check coupling /
not rise above 50 psi within a V-belts
default period.
0045 A Thermostatic valve defective Contact an author‐
Compressor T ↓↓ ized KAESER
tive.
0048 A Fault in the high voltage cell. Contact an author‐
High-voltage cell ized KAESER
tive.
0051 A Aggregate A failed. Contact an author‐
Aggregate A ized KAESER
tive.
0052 A Aggregate B failed. Contact an author‐
Aggregate B ized KAESER
tive.
0056 A Refrigerated dryer: Refrigerated dryer:
RD condensate drain The condensate drain is de‐ Check condensate
fective. drain and conden‐
sate conduits.
0057 A Compressor model uncertain. Contact an author‐
Model? ized KAESER
tive.


0058 A The condensate drain is de‐ Check condensate
Condensate drain fective. drain and conden‐
sate conduits.
0059 A Drive belts or coupling bro‐ Drive belt:
Back pressure run ken. Replace drive
belts.
Coupling:
Contact an author‐
ized KAESER
tive.
0061 A The rate of rise of the airend Check the cooling
Oil separator rise dT/dt ⇞ discharge temperature is too oil level.
fast.
0062 A Refrigerated dryer: Clean the refriger‐
Refrigeration dryer p ⇞ Pressure too high in the re‐ ant condenser.
frigerant circuit. Check the fan mo‐
Safety pressure switch trip‐ tor.
ped.
Maintain operating
conditions.
0063 A Refrigerated dryer: Contact an author‐
Refrigeration dryer p ⇟ Refrigerant lost; pressure in ized KAESER
the refrigerant circuit too low. service representa‐
Inlet pressure switched trip‐ tive.
ped.
0081 A
0082 A
0083 A
0084 A
0085 A
0086 A
0087 A
0088 A
0089 A
0090 A


0091 A
0092 A
0093 A
p-Switch pi
0094 A
T-Switch ADT
0095 A
p-Switch pN
0097 A High-voltage cell does not ac‐ Check high-voltage
High-voltage cell on? tivate. cell and wiring.
0098 A High-voltage cell does not de‐ Check high-voltage
High-voltage cell off? activate. cell and wiring.
Mains contactor on? close. tactor and wiring.
Mains contactor off? open. tactor and wiring.
Compressor motor overcurrent compressor drive motor. of shut-down.
Change the oil
separator car‐
tridge.
Oil-/air cooler fan Overcurrent first fan motor. of shut-down.
Reset the overload
relay.
0200 A Frequency converter fault Contact an author‐
Compressor motor USS alarm ized KAESER
tive.
tive.
tive.
0205 A Communications error Check connection
Compressor motor USS alarm and line path.
Compressor motor FC Motor overload alarm ized KAESER
tive.


Compressor motor FC Motor overload alarm ized KAESER
tive.
Tab. 5 Fault messages and remedies

16 Interpreting warning messages

Warning messages are identified with the letter W.
plete them with your defined message text, possible causes, and remedies.

0002 W Drive motor overheating. Clean the motor.
Motor temperature ↑ Keep ambient conditions
within specified limits.
0004 W Increased differential Change the oil separator car‐
Oil separator Δp ↑ pressure of the oil sepa‐ tridge.
rator cartridge.
Oil separator cartridge
clogged.
0007 W Drive motor bearing de‐ Contact KAESER Service.
Motor bearings fective.
0008 W Maximum airend dis‐ Clean the cooler.
Airend discharge temperature ADT ↑ charge temperature will Check the cooling oil level.
soon be reached.
Replace the oil filter cartridge.
Ensure adequate ventilation.
Keep surrounding tempera‐
ture within recommended lim‐
its.
0011 W Increased pressure dif‐ Change the oil filter.
Oil filter Δp ↑ ferential of the oil filter.
Oil filter clogged.
0013 W Air filter clogged. Change the air filter.
Air filter Δp ↑
0015 W The bus link via the Pro‐ Check the bus cables and
Bus alarm fibus DP interface is in‐ plugs.
terrupted.
0024 W The maximum permissi‐ Have the main contactor re‐
Mains contactor operations ⇞ ble number of switching placed by an authorized
cycles has been ex‐ KAESER service representa‐
ceeded. tive.
0025 W Oil separator cartridge: Change the oil separator car‐
Oil separator h ⇞ Maintenance interval tridge.
has elapsed.
0026 W Cooling oil: Change the cooling oil.
Oil change h ⇞ Maintenance interval
has elapsed.
0027 W Oil filter: Change the oil filter.
Oil filter h ⇞ Maintenance interval
has elapsed.


0028 W Air filter: Change the air filter.
Air filter h ⇞ Maintenance interval
has elapsed.
0029 W Valves: Contact KAESER Service.
Valve inspection h ⇞ Maintenance interval
has elapsed.
0030 W Belt tension/coupling: Carry out a visual inspection.
Belt/coupling inspection h ⇞ Maintenance interval Re-tension the drive belt.
has elapsed.
0031 W Motor bearing of com‐ Contact KAESER Service.
Motor bearings h ⇞ pressor motor:
Maintenance interval
has elapsed.
0032 W Electric components and Inspect and reset the mainte‐
Electrical equipment h ⇞ installation: nance interval counter.
has elapsed.
0033 W Motor bearing of fan mo‐ Contact KAESER Service.
Fan bearings h ⇞ tors:
has elapsed.
0034 W Package discharge (PD) Contact KAESER Service.
PD temperature ↓ temperature too low.
0035 W Compressed air dis‐ Clean the cooler.
PD temperature ↑ charge temperature too Check the cooling oil level.
high.
0036 W The permissible number Extend the idle period.
Motor starts/h ⇞ of motor starts was ex‐ Increase the capacity of the
ceeded in the last 60 mi‐ air receiver.
nutes.
Increase the cross-section of
piping between compressor
and air receiver.
Motor starts/d ⇞ of motor starts was ex‐ Increase the capacity of the
ceeded in the last air receiver.
24 hours.
and air receiver.
0038 W The safety relief valve's Change the oil separator car‐
Blow-off protection ↑ activating pressure will tridge.
soon be reached. Open the shut-off valve in the
venting line.
0041 W 1. Power failure: Check power supply.
Mains voltage ↓ The machine is auto‐ Check the door interlock
matically restarted. switch.


0043 W Ambiguous external Check settings of the external
External load signal? load signal: controller. Take into account
Increased cut-out pres‐ pressure drops across filters
sure exceeded. and dryer.
The external load con‐
trol has not switched to
idle.
0044 W Cooling oil temperature Check temperature switch,
Oil temperature ↓ too low. line and connection.
Check the oil circuit.
Increase room temperature.
0046 W Network pressure has Check air demand.
System pressure ↓ fallen below the set Check cable runs and sensor
“system pressure low” connections.
value.
Check the 'system pressure
Air consumption too low' warning value.
high.
0047 W The compressor cannot Check for air leaks.
No pressure buildup build-up to working pres‐ Check the value for internal
sure. pressure given in the <Analog
data> menu against the read‐
ing on the oil separator tank
pressure gauge.
0048 W Re-grease the motor Re-grease the motor bear‐
Bearing lube h ⇞ bearings. ings.
has elapsed.
0049 W Last maintenance was Carry out the necessary
Annual maintenance 1 year ago. maintenance and reset the
corresponding maintenance
interval counter.
0059 W The airend temperature Keep ambient conditions
Start temperature ↓↓ is too low (< 14°F) for within specified limits.
the machine to be oper‐
ated.
Start temperature ↓ is too low (< 36°F). within specified limits.
0061 W The airend discharge Contact KAESER Service.
Compressor T ↓ temperature (ADT) did
not reach the minimum
value within the speci‐
fied time.
0066 W Initial warning: Change the air filter element
Air filter Δp ⇡ Air filter clogged. soon.
0068 W The condensate drain is Check the condensate drain
Condensate drain defective. and drain line.


0069 W Refrigerated dryer de‐ Immediately contact KAESER
Error operation without RD → Call fective. service.
service! Compressed air supply
with undried air is acti‐
vated.
0070 W Refrigerated dryer: Maintain operating conditions.
Refrigeration dryer T ↑ Compressed air temper‐ Clean the refrigerant liquefier.
ature too high.
Clean the cooler.
Install an extractor fan.
0071 W Cooling oil level too low. Replenish the cooling oil.
Oil level ↓
0072 W Refrigerated dryer: Check condensate drainage
RD condensate drain The condensate drain is
defective.
0081 W
0082 W
0083 W
0084 W
0085 W
0086 W
0087 W
0088 W
0089 W
0090 W
0091 W
0092 W
0093 W
p-Switch pi
0094 W
T-Switch ADT
0095 W
p-Switch pN
Tab. 6 Warning messages and remedies

17 Interpreting system messages
17 Interpreting system messages

System messages are identified with the letter Y.
Message Possible Remedy

cause
0001 Y System error Contact an authorized KAESER service
Hardware watchdog reset representative.
Internal software error representative.
Filesystem Read/Write failure representative.
CPU load too high representative.
RAM out of memory representative.
RFID error: switch SIGMA representative.
CONTROL power supply OFF → ON!
Tab. 7 System messages and remedies

Contents
1 Regarding this Document

1.1 Using this document ......................................................................................................... 1
1.2 Copyright .......................................................................................................................... 1
1.2.1 Software .............................................................................................................. 1
1.3 Updating the operating manual ........................................................................................ 1
1.4 Symbols and labels .......................................................................................................... 2
1.4.1 Warnings ............................................................................................................. 2
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alerts and their symbols ............................................................................ 3
2 Technical Data
2.1 SIGMA CONTROL 2 Controller ....................................................................................... 4
2.1.1 User interface with display, CPU and interfaces ................................................. 4
2.1.2 Input/output modules .......................................................................................... 5
2.1.3 Sensors ............................................................................................................... 7
3.2 Specified use .................................................................................................................... 9
3.3 Improper use .................................................................................................................... 9
4.1 The controller ................................................................................................................... 10
4.2 Operating panel ................................................................................................................ 11
4.3 Display ............................................................................................................................. 14
4.3.1 Operating mode .................................................................................................. 14
4.3.2 Main menu .......................................................................................................... 15
4.3.3 Setting parameters ............................................................................................. 15
4.3.4 Activating keys with check boxes ....................................................................... 16
4.4 Access rights .................................................................................................................... 16
4.4.1 Secure storage of the RFID Equipment Cards ................................................... 17
4.5 Checking the machine status with KAESER CONNECT ................................................ 17
4.6 Menus – overview ............................................................................................................ 18
4.6.1 Operating mode .................................................................................................. 18
4.6.2 Menu structure .................................................................................................... 19
4.7 Operating modes and control modes ............................................................................... 30
4.7.1 Operating modes ................................................................................................ 30
4.7.2 Control modes .................................................................................................... 31
4.7.3 Frequency-controlled drive (SFC) ....................................................................... 32
4.7.4 MODULATING control ........................................................................................ 33
5.1 Maintaining ambient conditions ........................................................................................ 34
5.2 Installation conditions ....................................................................................................... 34
6 Installation
6.1 Reporting Transport Damage ........................................................................................... 35
6.2 Machine identification ....................................................................................................... 35
7 Initial Start-up
7.1 Outline .............................................................................................................................. 36
7.2 Configuring the controller ................................................................................................. 36
7.2.1 Selecting menu options ...................................................................................... 36
7.2.2 Changing the display language .......................................................................... 37
7.2.3 Noting the number of the KAESER Equipment Card ......................................... 38
7.2.4 Controlling access to the SIGMA CONTROL 2 with the Equipment Card .......... 38
7.2.5 Generating a password for the SIGMA CONTROL 2 ........................................ 38
Service manual Controller

9_9450 03USE SIGMA CONTROL 2 SCREW FLUID 1.1.3 i
Contents
7.2.6 Controlling access to the SIGMA CONTROL 2 via manual input ....................... 40
7.2.7 Generating a password for KAESER CONNECT .............................................. 42
7.2.8 Checking/setting the time and date .................................................................... 42
7.2.9 Setting display formats ....................................................................................... 44
7.2.10 Setting and activating summer/winter time ......................................................... 47
7.3 Using KAESER CONNECT ............................................................................................. 47
7.3.1 Calling up KAESER CONNECT for SIGMA CONTROL 2 ................................. 48
7.3.2 Displaying the system status .............................................................................. 49
7.3.3 Display graphs .................................................................................................... 51
7.3.4 Displaying messages .......................................................................................... 53
7.3.5 Viewing the IO modules assigment ................................................................... 54
7.3.6 Creating additional user accounts ...................................................................... 54
7.3.7 Settings ............................................................................................................... 57
7.3.8 Performing a data backup ................................................................................... 58
7.3.9 Closing KAESER CONNECT: ............................................................................ 58
7.4 Adjusting the pressure parameters of the machine .......................................................... 59
7.4.1 Displaying pressure parameters ......................................................................... 60
7.4.2 Configuring the pressure parameters for compressors ...................................... 61
7.4.3 Activating/deactivating the «LOAD/IDLE» key .................................................... 64
7.5 Configuring machine start and stop ................................................................................. 65
7.5.1 Automatic start/stop in programmed clock mode ................................................ 65
7.5.2 Setting up the holiday period .............................................................................. 68
7.5.3 Starting the machine remotely (Remote ON/OFF) ............................................. 69
7.5.4 Activating/deactivating the idle phase (Venting period function) ........................ 72
7.5.5 Activating/deactivating and adjusting the "Automatic restart after a power 73
failure" function ...................................................................................................
7.6 Activating and adjusting the control modes ...................................................................... 74
7.6.1 Selecting a control mode .................................................................................... 75
7.6.2 Adjusting the idle time of DUAL mode ................................................................ 76
7.6.3 Adjusting the minimum running and unloaded period in QUADRO control 76
mode ...................................................................................................................
7.7 Activating the settings for the refrigerated dryer .............................................................. 77
7.7.1 Setting the CLOCK mode ................................................................................... 78
7.7.2 Output messages ................................................................................................ 79
7.7.3 Fault in the refrigerated dryer ............................................................................. 80
7.7.4 Fault in the refrigerated dryer – activate fault mode ........................................... 80
7.8 Configuring the machine for local mode ........................................................................... 82
7.8.1 Selecting the < Configuration ➙ Pressure control ➙ Load control > menu ........ 82
7.8.2 Configuring the system pressure setpoint changeover using the clock 82
program ..............................................................................................................
7.8.3 Configuring the system pressure setpoint changeover using the clock .............. 85
7.9 Configuring the machine for master control ..................................................................... 87
7.9.1 List of the various master controllers .................................................................. 87
7.9.2 Configuring Profibus mode (SIGMA AIR MANAGER or VESIS) ........................ 88
7.9.3 Configuring the Profibus interface without SIGMA AIR MANAGER or VESIS .. 97
7.9.4 Configuring for master control of two machines in master/slave operation 98
(Ethernet interface) .............................................................................................
7.9.5 Configuring for master control using the LOAD remote contact (e.g., 104
SIGMA AIR MANAGER BASIC) .........................................................................
7.9.6 Configuring for master control with local/LOAD remote contact ......................... 107
7.9.7 Configuring setpoint pressure pre-selection via remote contact ......................... 110
7.9.8 Configuring master control of compressors regulated by pressure switch ......... 112
7.9.9 Examples of time settings for equal overall load ................................................ 120
7.10 Configuring email ............................................................................................................. 121

ii SIGMA CONTROL 2 SCREW FLUID 1.1.3 9_9450 03USE
Contents
7.11 Configuring input and output signals ................................................................................ 123

7.11.1 Outputting important operational states of the machine ..................................... 124
7.11.2 Displaying analog input values ........................................................................... 125
7.11.3 Displaying additional binary input signals ........................................................... 129
7.12 Activating remote acknowledgement ............................................................................... 133
7.12.1 Selecting the < Configuration ➙ Acknowledgement > menu .............................. 134
7.12.2 Setting the remote acknowledgement function ................................................... 134
7.12.3 Activating the «Remote control» key .................................................................. 134
7.12.4 Assigning an input .............................................................................................. 135
7.13 Linking to an external pressure transducer ...................................................................... 136
7.13.1 Selecting the < Configuration ➙ Pressure control > menu ................................. 137
7.13.2 Assigning an input to an external sensor ............................................................ 137
7.14 Commissioning the machine ............................................................................................ 138
8 Operation
8.1 Switching on and off ......................................................................................................... 140
8.1.1 Switching on ....................................................................................................... 140
8.1.2 Switching off ....................................................................................................... 140
8.2 Switching off in an emergency and switching on again .................................................... 141
8.3 Acknowledging alarm and warning messages ................................................................. 141
8.4 Displaying messages ....................................................................................................... 143
8.4.1 Selecting the Status menu .................................................................................. 144
8.5 Displaying the current operating mode ............................................................................ 145
8.6 Adjusting working pressure .............................................................................................. 146
8.7 Displaying analog data ..................................................................................................... 147
8.8 Displaying operating data ................................................................................................. 148
8.8.1 Interpreting operation messages ........................................................................ 149
8.9 Setting the maintenance interval ...................................................................................... 151
8.10 Safety relief valve checking .............................................................................................. 152
8.11 Checking the temperature sensor and overheating shutdown function ........................... 154
9.2 Interpreting alarm messages ............................................................................................ 157
9.3 Interpreting system messages ......................................................................................... 162
9.4 Interpreting diagnostic messages .................................................................................... 162
9.5 Interpreting warning messages ........................................................................................ 162
10 Maintenance
10.1 Maintenance Work ........................................................................................................... 167
11.1 Note the nameplate .......................................................................................................... 168
11.2 KAESER AIR SERVICE .................................................................................................. 168
11.3 Service Addresses ........................................................................................................... 168
11.4 Displaying the version number, machine model, part number and serial number ........... 168
12.1 De-commissioning ............................................................................................................ 170
12.2 Packing ............................................................................................................................ 170
12.3 Storage ............................................................................................................................. 170
12.4 Transporting ..................................................................................................................... 170
12.5 Disposal ........................................................................................................................... 170

9_9450 03USE SIGMA CONTROL 2 SCREW FLUID 1.1.3 iii
Contents

iv SIGMA CONTROL 2 SCREW FLUID 1.1.3 9_9450 03USE
Fig. KAESER Equipment Card .......................................................................................................... 4

Fig. RFID reader ................................................................................................................................ 5
Fig. 1 System structure ........................................................................................................................ 10
Fig. 2 Keys – overview ......................................................................................................................... 11
Fig. 3 Indicators – overview .................................................................................................................. 12
Fig. 4 RFID sensor field ........................................................................................................................ 13
Fig. 5 KAESER CONNECT for SIGMA CONTROL 2 .......................................................................... 17
Fig. 6 Header ........................................................................................................................................ 18
Fig. 7 Back of the KAESER Equipment Card ....................................................................................... 38
Fig. 8 Login window .............................................................................................................................. 48
Fig. 9 KAESER CONNECT ................................................................................................................. 49
Fig. 10 Language selection .................................................................................................................... 49
Fig. 11 Status display ............................................................................................................................. 50
Fig. 12 Main menu .................................................................................................................................. 50
Fig. 13 Status menu with submenus ...................................................................................................... 51
Fig. 14 Pressure/temperature graphs ..................................................................................................... 52
Fig. 15 Arrow keys .................................................................................................................................. 52
Fig. 16 Messages ................................................................................................................................... 53
Fig. 17 User administration menu .......................................................................................................... 55
Fig. 18 "Log on for write access" window ............................................................................................... 55
Fig. 19 Creating a new user ................................................................................................................... 56
Fig. 20 Settings ...................................................................................................................................... 57
Fig. 21 Data backup ............................................................................................................................... 58
Fig. 22 Header ........................................................................................................................................ 59
Fig. 23 Pressure rise in frequency-controlled (SFC) machines .............................................................. 63
Fig. 24 Profibus plug wiring .................................................................................................................... 89
Fig. 25 Electrical diagram example with SIGMA AIR MANAGER ......................................................... 90
Fig. 26 Communication interface ............................................................................................................ 92
Fig. 27 Insert the communication module. ............................................................................................. 92
Fig. 28 Front plate of the PROFIBUS communication module ............................................................... 93
Fig. 29 Direct connection of two SIGMA CONTROL 2 .......................................................................... 100
Fig. 30 LOAD remote contact ................................................................................................................. 105
Fig. 31 Wiring diagram for local/LOAD remote contact: ......................................................................... 107
Fig. 32 Machine with pressure switch regulation .................................................................................... 113
Fig. 33 Function diagram ........................................................................................................................ 116
Fig. 34 Switching on and off ................................................................................................................... 140
Fig. 35 Switching off in an emergency ................................................................................................... 141
Fig. 36 Acknowledging messages .......................................................................................................... 142

9_9450 03USE SIGMA CONTROL 2 SCREW FLUID 1.1.3 v

vi SIGMA CONTROL 2 SCREW FLUID 1.1.3 9_9450 03USE
List of Tables
Tab. 1 Danger levels and their definitions (personal injury) .................................................................. 2

Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 User interface ............................................................................................................................. 4
Tab. 4 Display data ................................................................................................................................ 4
Tab. 5 Interfaces .................................................................................................................................... 5
Tab. 6 RFID ........................................................................................................................................... 5
Tab. 7 SC2IOM-1 .................................................................................................................................. 5
Tab. 8 SC2IOM-2 .................................................................................................................................. 6
Tab. 9 SC2IOM-3 .................................................................................................................................. 6
Tab. 10 Power supply specifications ....................................................................................................... 6
Tab. 11 Cable lengths ............................................................................................................................. 7
Tab. 12 Degree of protection, IOM .......................................................................................................... 7
Tab. 13 IOM dimensions ......................................................................................................................... 7
Tab. 14 Pressure transducer ................................................................................................................... 7
Tab. 15 Resistance thermometer ............................................................................................................ 7
Tab. 16 Keys ........................................................................................................................................... 11
Tab. 17 Indicators .................................................................................................................................... 12
Tab. 18 RFID sensor field ........................................................................................................................ 13
Tab. 19 Reset check box status .............................................................................................................. 16
Tab. 20 Check box status ........................................................................................................................ 16
Tab. 21 Menu structure ........................................................................................................................... 20
Tab. 22 Status menu ............................................................................................................................... 22
Tab. 23 Configuration menu .................................................................................................................... 23
Tab. 24 Pressure control menu ............................................................................................................... 24
Tab. 25 I/O periphery menu ..................................................................................................................... 25
Tab. 26 Communication menu ................................................................................................................ 26
Tab. 27 Profibus ...................................................................................................................................... 27
Tab. 28 Modbus ....................................................................................................................................... 27
Tab. 29 Modbus TCP .............................................................................................................................. 28
Tab. 30 DEVICENET ............................................................................................................................... 28
Tab. 31 PROFINET ................................................................................................................................. 28
Tab. 32 Connections menu ..................................................................................................................... 29
Tab. 33 Components menu ..................................................................................................................... 29
Tab. 34 Power switching module – menu ................................................................................................ 30
Tab. 36 Remote control identification ...................................................................................................... 35
Tab. 38 Display language ....................................................................................................................... 37
Tab. 39 Date formats ............................................................................................................................... 44
Tab. 40 Time formats .............................................................................................................................. 44
Tab. 41 Units of pressure ........................................................................................................................ 45
Tab. 42 Units of temperature ................................................................................................................... 46
Tab. 43 Display illumination ..................................................................................................................... 46
Tab. 44 Arrow keys and functions ........................................................................................................... 52
Tab. 45 Compressor pressure parameters .............................................................................................. 59
Tab. 46 Setting limits for system setpoint pressure (* Cut-in pressure min) ............................................ 61
Tab. 47 Pressure condition for LOAD ..................................................................................................... 61
Tab. 48 Pressure condition for IDLE ...................................................................................................... 61
Tab. 49 Example: Activated output .......................................................................................................... 62
Tab. 50 Settings for machine start and stop. ........................................................................................... 65
Tab. 51 Example of a machine ON/OFF timer program .......................................................................... 66
Tab. 52 Local operating mode (local mode) ............................................................................................ 82
Tab. 53 Example of system pressure changeover switching points ........................................................ 83
Tab. 54 Master control – overview ........................................................................................................... 87

9_9450 03USE SIGMA CONTROL 2 SCREW FLUID 1.1.3 vii
List of Tables
Tab. 55 Profibus DP pin connection ........................................................................................................ 88

Tab. 56 Master-slave configuration procedure ........................................................................................ 99
Tab. 57 Function diagram ........................................................................................................................ 115
Tab. 58 Example switching points ........................................................................................................... 117
Tab. 59 Example for a clock program for equal duty cycling during the day ........................................... 120
Tab. 60 Example for a clock program for equal duty cycling during the week ........................................ 121
Tab. 61 Assigned output signals ............................................................................................................. 124
Tab. 62 Logic ........................................................................................................................................... 132
Tab. 63 Transmission of sensor value ..................................................................................................... 136
Tab. 64 Checklist of installation conditions .............................................................................................. 138
Tab. 65 Information of a message ........................................................................................................... 143
Tab. 66 Message type and status abbreviations ..................................................................................... 143
Tab. 67 Operating mode display ............................................................................................................. 145
Tab. 68 Possible operating modes .......................................................................................................... 146
Tab. 69 Operational messages ............................................................................................................... 149
Tab. 70 Check box status ........................................................................................................................ 152
Tab. 71 Alarm messages and remedies .................................................................................................. 157
Tab. 72 System messages and remedies ............................................................................................... 162
Tab. 73 Warning messages and remedies .............................................................................................. 163

viii SIGMA CONTROL 2 SCREW FLUID 1.1.3 9_9450 03USE

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.
1.2 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 support‐
ed.
1.2.1 Software
The software used in SIGMA CONTROL 2 contains copyright-protected software which is licensed
by GNU General Public License in versions 2 and 3.
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>/ SIGMA CONTROL 2 COPYING
The licenses can be also found under this address:
http://www.gnu.org/licenses/gpl-2.0.txt
http://www.gnu.org/licenses/gpl.txt
Within three years from receipt of SIGMA CONTROL 2, you may obtain the complete source code
by sending a corresponding order to the following address:
Technical Office Electrical Design
KAESER KOMPRESSOREN
96450 Coburg, Postfach 2143
Germany
This offer is valid for anybody having this information.
1.3 Updating the operating manual

The page <http://www.kaeser.com/sc2manual> of our website provides frequently updated ver‐
sions of this operating manual.
Be prepared to provide the part number and the serial number of the machine in which the
SIGMA CONTROL 2 is installed.
Both numbers can be found on the nameplate of the machine.
➤ Download the operating manual in your language.

9_9450 03USE SIGMA CONTROL 2 SCREW FLUID 1.1.3 1

➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of non-compliance
DANGER Warns of an imminent danger Will result in death or severe injury
WARNING Warns of a potentially imminent danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Tab. 8 Danger levels and their definitions (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
Example:

If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1. The type and source of the imminent danger is shown here!
If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe
injury may occur.
2. Always read and comply with warning instructions.
1.4.2 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
NOTICE Warns of a potentially dangerous situation Damage to property is possible
Tab. 9 Danger levels and their definition (damage to property)
Example:

2 SIGMA CONTROL 2 SCREW FLUID 1.1.3 9_9450 03USE

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.
1.4.3 Other alerts and their symbols

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 are identified by a question mark.
The cause is named 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.

2 Technical Data
2.1 SIGMA CONTROL 2 Controller
2 Technical Data
Industrial computer
■ Internal temperature monitoring
■ Internal undervoltage monitoring
■ Battery-buffered real-time clock
─ Battery life span more than 10 years
─ Battery replaceable
2.1.1 User interface with display, CPU and interfaces

User interface
Feature Value
Material Plastics
Width [in] 7.5
Height [in] 5.1
Depth [in] 1.8
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] 24
Current [A] 0.3
Voltage source Input/output module
Tab. 10 User interface
Display
Feature Value
Graphical display [px] 255 x 128
Width [in] 3.2
Height [in] 1.6
Maximum number of lines/characters 8/30
Colors Black/white with gray levels
Lighting LED backlit
px ≙ pixel
Tab. 11 Display data

2 Technical Data
Interfaces
Interface Connection Marking

Ethernet 10/100 Base T RJ 45 socket X1
IO bus 9-pole SUB-D pins X2
RS485–FC (USS interface) 9-pole SUB-D socket X3
COM modules, Module optional for: X4
slot for communications module Profibus, Modbus,
Profinet, Devicenet
SD card, SD card slot SD/SDHC card X5
The positions of the interfaces X1–X5 are marked on the rear of the controller.
Tab. 12 Interfaces
Identification with RFID Equipment Card
Feature Value
Hardware on the SIGMA CONTROL 2 controller RFID write/read device
Hardware (external) KAESER Equipment Card
Recognition distance [in] Max. 2
Frequency [MHz] 13.56
Tab. 13 RFID
2.1.2 Input/output modules

There are three different types of input/output modules with different amounts of inputs and out‐
puts.
The actually available number of input/output modules depends on the machine type and the avail‐
able options.
Refer to the machine's wiring diagram for the input/output modules installed in your equipment.
Every input/output module is equipped with:

■ Internal temperature monitoring
■ Internal undervoltage monitoring
■ LED indication of operational status
IOM 1
Input/Output Input/output module 1
Internal, into available in External, into
the control parallel on the compres‐
cabinet both sides sor interior
Digital input (DI), 24 VDC 4 10 2
Analog input current (AII), 0–20 mA – 1 2
Analog 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

2 Technical Data

Analog output current (AOI), 0–20 mA – – –
Tab. 14 SC2IOM-1
IOM 2
Digital input (DI), 24 VDC 6 – 2
Analog input resistor (AIR), PT100 – 3 –
Analog output current (AOI), 0–20 mA – 1 –
Tab. 15 SC2IOM-2
IOM 3
Digital input (DI), 24 VDC 6 – 2
Analog input resistor (AIR), PT100 – 3 8
Analog output current (AOI), 0–20 mA – 1 –
Tab. 16 SC2IOM-3
2.1.2.1 Power supply specifications
Power is provided by the power supply unit within the machine.

Feature Value
Rated power supply (stabilized) [V DC] 24
Current consumption SIGMA CONTROL 2 2,4
with IOM 1 [A]
Current consumption IOM 2 [A] 2,5
IOM ≙ input/output module

2 Technical Data
Feature Value
Current consumption IOM 3 [A] 1,6
IOM ≙ input/output module
Tab. 17 Power supply specifications
2.1.2.2 Maximum cable lengths
Input/Output Conductor length [ft]

Analog input current (AII), ＜ 100
Analog input resistor (AIR)
Analog output current (AOI)
Digital input (DI), ＜ 330
Digital output relay (DOR)
Digital output resistor (DOT) ＜ 100
Tab. 18 Cable lengths
2.1.2.3 Input/output modules – degree of protection
Feature Value
Degree of protection within the machine IP 54
Degree of protection within the control cabinet IP 20
Tab. 19 Degree of protection, IOM
2.1.2.4 Input/output modules – dimensions
Feature Value
Width [in] 4.9
Height [in] 9.8
Depth [in] 1.7
Tab. 20 IOM dimensions
2.1.3 Sensors
Pressure transducer
Feature Value
Output signal [mA] 0/4–20
Connection Twin cable
Tab. 21 Pressure transducer
Resistance thermometer
Feature Value
Sensing resistance (to DIN IEC 751) PT100

2 Technical Data
Feature Value
Connection Twin cable
Tab. 22 Resistance thermometer


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 ener‐
gy and, if not installed and used in accordance with the instructions, may cause harmful inter‐
ference 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:
➤ Close and lock the door of the equipment properly.
➤ Place the equipment as far as possible from the interfered radio or television receiver.
Changes or modifications not expressly approved by KAESER could void the user's authority
to operate the equipment.
This device complies with Industry Canada licence-exempt RSS standard(s).

Operation is subject to the following two conditions:
■ this device may not cause interference and
■ this device must accept any interference, including interference that may cause unde‐
sired operation of the device
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.
3.2 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.
3.3 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.

4.1 The controller

4.1 The controller
SIGMA CONTROL 2 controls, regulates, monitors, and protects the machine.
All parameters needed to operate KAESER rotary screw compressors 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 Identification (RFID):
Identification with the KAESER 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 analog inputs and outputs with their own power supply.
Fig. 3 System structure

1 Machine enclosure 6 Inputs/outputs in the interior of the control
2 Control cabinet cabinet
3 SIGMA CONTROL 2 7 Inputs/outputs in the interior of the com‐
4 Input/output module pressor
5 IO bus 8 Inputs/outputs for external sensors
9 Compressor
Function
The control and regulating function allows:

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

4.2 Operating panel
■ Optimum utilization of the drive motor in relation to the user's actual air demand.
■ Automatic restart of the machine after a power failure (can be deactivated).
The monitoring function allows:

■ 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. high
current, high pressure, or high temperature.
4.2 Operating panel

Keys
Fig. 4 Keys – overview
Position Name Function

1 «OFF» Switches the machine off.
2 «ON» Switches the machine on.
3 «Esc» Returns to the next higher menu option level.
Exits the edit mode without saving.
4 «Enter» Jumps to the selected menu option.
Exits the edit mode and saves.
5 «Down» Scrolls down the menu options.
Reduces a parameter value.
6 «Right» Jumps to the right.
Moves the cursor position to the next right field.

4.2 Operating panel

7 «Left» Jumps to the left.
Moves the cursor position to the next left field.
8 «Up» Scrolls up the menu options.
Increases a parameter value.
9 «Information» Operating mode:
Displays the event memory.
10 «Acknowledgement» Confirms/acknowledges alarms and warning messages.
If permissible: Resets the fault counter (RESET).
11 «LOAD/IDLE» Toggles between the LOAD and IDLE operating modes.
12 «Remote control» Switches the remote control on and off.
13 «Timer control» Switches the timer control on and off.
Tab. 23 Keys
Indicators
Fig. 5 Indicators – overview

14 Display Graphic display with 8 lines and 30 characters per line.
15 Fault Flashes red to indicate a machine fault.
Continuous red light after acknowledgement.
16 Communications Continuous red light to indicate a faulty communication connection,
error or an external fault message without machine shut-down.

4.2 Operating panel

17 Warning Flashes in yellow in the following events:
■ Maintenance work due
■ Warning message
Continuous yellow light after acknowledgement.

18 Controller voltage Continuous green light when voltage is applied to the controller.
19 LOAD Continuous green light when the machine is running in LOAD.
20 IDLE Continuous green light when the machine is running in IDLE.
Flashes when the «LOAD/IDLE» toggle key is pressed.
21 Remote control Continuous green light when the machine is in remote control.
22 Timer control Continuous green light when the machine is controlled by the tim‐
er.
23 ON Continuous green light when the machine switched on.
Tab. 24 Indicators
RFID sensor field
RFID is the abbreviation for “Radio Frequency IDentification” and enables the identification of per‐
sons or objects.
Placing a suitable transponder in front of the RFID sensor field of the controller will automatically
activate the communication between transponder and SIGMA CONTROL 2 .
A suitable transponder is the KAESER RFID Equipment Card. Two of them have been provided
with the machine.
Typical application:
■ Users log on to the machine.
(no manual input of the password required.)
The KAESER RFID Equipment Cards are carefully packed in a plastic sleeve.
This plastic sleeve is attached to the rear of the controller inside the control cabinet.
Fig. 6 RFID sensor field

24 RFID RFID sensor field for communication with a suitable RFID transponder
Tab. 25 RFID sensor field

4.3 Display
4.3 Display
Use the display to read information and to enter data. The display comprises 8 lines, each of
30 characters.
During operation, the display will indicate the operating mode.
Pressing «Enter» or one the arrow keys opens the main menu. Here, you can set the language to
be used for the display of texts or open the various submenus.
4.3.1 Operating mode

89 psi 08:15 176 °F
------------------------------
Alarm Current operating mode
------------------------------
Key – off ¦ # – off Operating parameters
------------------------------
Run 2500 h ¦ Load 2490 h Operating parameters
Maintenance in 500 h
Header
The header 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 on the title bar:

■ Working pressure
■ Time
■ Airend discharge temperature
Lines 3 and 5: Operational state
Depending on the settings, either the current state of the machine or a menu text is shown in line 3.
The following parameters with their current values are displayed in line 5:
■ Remote control: yes/no
■ Timer control: yes/no
■ Pressure control
Lines 7 and 8: Machine state
The following parameters with their current values are displayed in lines 7 and 8:
■ The hours during which the machine was activated
■ The hours during which the machine ran in operating mode LOAD.
■ Remaining working hours of the machine before the next maintenance

4.3 Display
4.3.2 Main menu

89 psi 08:15 176 °F
········· Deutsch ········· Language
▶1 Status Submenu
▶2 Performance data Submenu (shown here as the active line)
▶3 Operating data Submenu
▶4 Maintenance Submenu
▶5 Configuration Submenu
▶6 Compressor clock Submenu
Description
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 recognize subordinate menus in the menu structure by the number preced‐
ing their designation. The menu structure is explained in chapter 4.6.2.
Active line
The active line is always shown as white text on a dark background. Do not confuse this with the
header which is also shown with white lettering on a black background.
Press «Enter» to open a menu in the active line. This opens the selected menu.
Here, you can change parameters.
Further information For the setting of parameters see chapter 4.3.3.
4.3.3 Setting parameters

In order to set a parameter in the active line of the selected menu, you must always switch to
setting mode.
You move to setting mode by:

Press «Enter». The value of the parameter will flash indicating that it can be changed.
Changing 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 a single parameter.
In this case, you must first select the specific parameter with the «Left» or «Right» keys.

4.4 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 will flash.
You then press «UP». The check box is activated and flashes.
Press «Enter» to save the settings.
The parameters no longer flash and are reset. The check box for Reset is again deactivated.
Check box Reset Status

☒ activated
☐ deactivated
Tab. 26 Reset check box status
4.3.4 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.
Check box Status

☑ activated
☐ deactivated
4.4 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.
Throughout this operating manual, the RFID Equipment Card will be simply called the "Equip‐
ment Card".
When the controller is switched on, the lowest level of access (level 0) is activated.
You have access to a further level: Level 2.
In level 2, you can display and specify further parameters and, for instance, reset the system pres‐
sure or the maintenance counters.
The access level will automatically return to level 0 after 10 minutes without any key being pressed.

4.5 Checking the machine status with KAESER CONNECT
4.4.1 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 behind the controller inside the control cabinet.
If you lose both Equipment Cards, you can register a new Equipment Card only after having en‐
tered the user name and the password. A new Equipment Card may be registered by
KAESER Service subject to a fee, if the user name and the password are lost.
4.5 Checking the machine status with KAESER CONNECT

Using a PC with web browser, you can call up a visualization of your machine's controller and thus
check the energy efficiency of the machine. KAESER CONNECT does not require additional and
expensive special software applications. KAESER CONNECT selectively visualizes the current sta‐
tus of your controller in your country's language.
Fig. 7 KAESER CONNECT for SIGMA CONTROL 2

1 Language selection 5 IO display
2 System status 6 User administration
3 Graphs 7 Settings
4 Messages 8 Data backup
KAESER CONNECT functions:

■ System status
─ Mapping of the local menu
■ Graphs
─ Graphic representation of the main pressure and airend discharge temperature along the
time axis.
─ Graphic representation of the compressor status (STOP, IDLE, LOAD) and RPM along the
time axis.

4.6 Menus – overview
■ Messages
─ Current messages
─ Message history (event memory)
■ IO display
─ Assignment of the input/output modules
■ User administration
─ Creating and activating new user accounts
─ Deactivating existing user accounts
─ Changing passwords
■ Settings
─ Unit display format
─ Date display format
─ Time display format
■ Data backup
─ Writing data to your own PC.
Further information For the installation of Ethernet cables, the Login, and other procedures, please see chapter 7.3.
Header
■ Please note the designations in the menu's header. The designations cover user-friendly func‐
tions such as:
■ Activating write mode:
─ You can switch from read mode to write mode to create a new user account, for example.
■ Closing KAESER CONNECT:
─ Logout function in the header.
■ Contact KAESER Service:
─ Display of authorized KAESER Service addresses.
Fig. 8 Header
1 Machine designation 3 Logout
2 Write mode 4 Contact KAESER Service

4.6.1 Operating mode
When the machine is switched on, details of the software are displayed, for example,

Compressor Machine model

PN : SN : Part number and serial number of the machine
EN : Equipment number of the machine
SIGMA CONTROL 2 MCS MCS: Main Control System

PN : SN : Part number and serial number of the controller
Software : Software version
Subsequently, the software is loaded and the current operating mode is displayed (example):
89 psi 08:15 176 °F
------------------------------
Alarm Current operating mode
------------------------------
Key – off ¦ # – off Operating parameters
------------------------------
Run 2500 h ¦ Load 2490 h Operating parameters
The following parameters are displayed:

■ Operating mode of the machine
■ Information on the «LOAD/IDLE» keys, «Remote control» or «Timer»
■ Value for the system setpoint pressure pA
■ Number of operating hours and hours of the machine being in LOAD mode.
The operations menu provides the most important parameters during the machine's operation.
4.6.2 Menu structure

Pressing «Enter» or one of the arrow keys opens 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
Navigation Function/submenu
1 Status ■ Messages
─ Status report
─ Current warnings
Current faults
■ Statistics
■ Current pressure regulation
■ Current operating mode
■ DI/DO display
■ Diagram:
Nominal pressure/airend discharge temper‐
ature
For details of the <Status> menu, see table 29

“Status menu”.
2 Performance data Display of the following measured data:
■ System pressure pNloc
■ ADT (airend discharge temperature)
Increased speed ADT
■ Δp/Oil separator
■ Starting temperature
■ Temperature MCS (Main Control System)
■ Temperature, first IOM
3 Operating data Operating hours
■ Compressor
■ Load
■ Motor
■ Airend
■ SIGMA CONTROL 2
kWh counter
■ Active
■ Counting pulses
■ kWh
■ Reset
Load valve ON

4 Maintenance ■ Oil filter
■ Oil separator
■ Oil change
■ Air filter
■ Valve inspection
■ Belts / coupling inspection
■ Bearing lubrication
■ Motor bearings
■ Electrical equipment
■ Annual maintenance
5 Configuration For details of the <Configuration> menu, see ta‐
ble 30 “Configuration menu”.
6 Compressor clock Activate/deactivate compressor timer
Delete/reset the existing clock program
Entering weekdays and times:
■ Switching point 01:
■ Switching point 10
7 User ■ Name
Password
■ Current access level
8 Communication ■ Ethernet
■ COM module
Activating/deactivating the
«Remote control» key
For details of the <Communication> menu, see
table 33 “Communication menu”.
9 Machine test ■ TÜV check (safety relief valve)
10 Components ■ Compressor motor
─ Power switching
For details of the <Components> menu, see ta‐

ble 40 “Components menu”.
Tab. 28 Menu structure

4.6.2.1 Status menu
1.1 Messages ■ Current messages
■ Message history (event memory)
─ Compressor messages
─ Diagnostic messages
─ System messages
Status report
Current warnings
Current faults
1.2 Statistics ■ Overall load
■ pNloc actual system pressure
─ maximal
─ minimal
■ Total number of motor starts
■ Motor starts per day
Motor starts per hour
■ Total number of motor starts below mini‐
mum temperature
■ Last load run
■ Last idle run
■ Last motor OFF
1.3 Current pressure control ■ SIGMA CONTROL 2
■ Cut-out pressure
■ Actual system pressure
1.4 Current operating mode ■ Compressor ON
Load control
■ Regulating mode
Idle time
■ Acknowledgement
1.5 DI/DO status ■ First I/O module
─ DI/DO display
■ Second I/O module
─ DI/DO display
■ Third I/O module
─ DI/DO display
■ Fourth I/O module
─ DI/DO display
■ Fifth I/O module
─ DI/DO display
■ Sixth I/O module
─ DI/DO display

1.6 pN/ADT curve Diagram:
Nominal pressure/airend discharge temperature
Tab. 29 Status menu
4.6.2.2 Configuration menu
5.1 General Machine model
Date and time
Date format
Time format
Pressure unit
Temperature unit
Display illumination
System data
■ SIGMA CONTROL 2 MCS:
─ Software
─ KAESER:
Part number
Serial number
─ Controller manufacturer:
Part number
Serial number
Date of manufacture
■ Compressor:
─ Equipment number
─ Part number
─ Serial number
■ IO modules:
─ First IOM
5.2 Pressure control ■ Pressure sensors
■ Pressure settings
■ Load control
■ Actual system pressure
For details of the <Pressure control> menu, see

table 31 “Pressure control menu”.
5.3 Control mode Local mode
■ Venting period
■ DUAL
■ QUADRO
■ Mod.valves

5.4 Compressor start ■ Compressor ON
■ Compressor OFF
Auto start
Cut-in lock
Start temperature
5.5 Acknowledgement Remote operation
«Remote control» key
Acknowledging the remote contact
5.6 ADT ■ AIR 1.00
Conduit correction
■ Rate of rise of the airend discharge temper‐
ature
5.7 I/O periphery ■ DO functions
■ Analog values
■ External messages
■ Switch
For details of the <I/O periphery> menu, see ta‐

ble 32 “I/O periphery menu”.
5.8 Timer ■ ON
■ OFF
■ DOR 1.03
5.9 Refrigeration dryer ■ Control mode
─ Compressor standby
─ Compressor clock/FK/FB off
■ Temperature high
■ Temperature low
■ Activate fault mode
Tab. 30 Configuration menu
Pressure control menu
5.2.1 Pressure sensors ■ System pressure pNloc
■ Internal pressure pi
5.2.2 Pressure settings ■ pRV Safety relief valve opening pressure
■ Pressure increase
■ Nominal pressure
■ System setpoint pressure
■ System pressure low
■ Minimum cut-in pressure

5.2.3 Load control ■ Set local mode
■ Set remote operation
Activate/deactivate «Remote control» key
■ Timer operating mode pA/pB
■ Remote contact operating mode pA/pB
■ Assign load mode remote contact
■ Assign local load remote contact:
■ Activate/deactivate the IDLE key
5.2.4 Network actual pressure Actual system pressure (pNloc)
AII
Tab. 31 Pressure control menu
I/O periphery menu
5.7.1 DO functions Controller on
ON
Motor running
IDLE
LOAD
Group fault
Group warning
Remote operation
Timer active
EMERGENCY-OFF
■ Timer contact (enter timing program)

5.7.2 Analogue values Configure display of measured values
■ Display 1 (p)
■ Display 2 (p)
■ Display 3 (T)
■ Display 4 (T)
■ Display 5 (I)
■ Display 6 (I)
5.7.3 External messages Configure display of external messages
■ External message 1

5.7.4 Switch Configuring the switching points for pressure
and temperature
■ System pressure pNloc
■ Internal pressure pi
■ Airend discharge temperature (ADT)
■ Inlet temperature
■ Compressed air outlet temperature (PD)
Tab. 32 I/O periphery menu
4.6.2.3 Communication menu
8.1 Ethernet ■ IP configuration
─ IP address
─ Subnet mask
─ Gateway
─ DNS Server 1
─ DNS Server 2
─ Network restart
■ Connections
─ SIGMA CONTROL 2
─ Control technology
Restart
Time-out
Cycle time
For details of the <Connections > menu, see ta‐
ble 39 "Connections menu".
■ Email
─ Activate/deactivate email
Compressor number
Language
Interval
─ Sender address
Sender name
Telephone number contact person
Recipient address
─ SMTP server
User name
─ Port
Interval

8.2 Com-Module The following communications module may be
used optionally:
Profibus
Modbus
Modbus TCP
DeviceNet
Profinet
Details regarding the <Com modules> menu are
provided in tables 34, 35, 36, 37, 38.
Tab. 33 Communication menu
4.6.2.4 COM module – menu
Navigation Function
8.2 Com-Module Profibus:
Status
Start Com module
Slave number
Reset
Bus fault
Start time
Time-out
Tab. 34 Profibus
Navigation Function
8.2 Com-Module Modbus:
Status
Start Com module
Slave number
Reset
Bus fault
Start time
Time-out
Baud rate
Stop bits
Parity
Time-out
Modus
Tab. 35 Modbus

Navigation Function
8.2 Com-Module Modbus TCP:
Status
COM module start
Reset
Bus fault
Start time
Time-out
Use P settings
IP address
Subnet mask
Gateway
DNS Server 1
DNS Server 2
Tab. 36 Modbus TCP
Navigation Function
8.2 Com-Module DeviceNet
Status
Start Com module
Slave number
Reset
Bus fault
Start time
Time-out
Tab. 37 DEVICENET
Navigation Function
8.2 Com-Module Profinet:
Status
COM module start
Reset
Bus fault
Start time
Time-out
Permit IP configuration
IP address
Subnet mask
Gateway
DNS Server 1
DNS Server 2
Station name
Tab. 38 PROFINET

4.6.2.5 Menu: Connections
8.1.2 Connections ■ SIGMA CONTROL 2
─ Status
─ Mode: Master/Slave
Port
─ IP address of communication partner
─ Communication alarm
■ Control technology
─ JSON-RPC active
─ IP address
─ Port
Tab. 39 Connections menu
4.6.2.6 Menu: Components
10.1 Compressor motor ■ Power switching
─ Star-delta start
─ Direct start
─ High-voltage cell
─ SFC USS
─ Softstart
Mains contactor hysteresis, total

For details of the <Power switching module>
menu, see table 41 “Power switching module –
menu”.
Tab. 40 Components menu

4.7 Operating modes and control modes
4.6.2.7 Menu: Power switching
10.1.1 Power switching ■ Star-delta start
─ Temperature, warm start
─ Star time at warm start
Star time at cold start
Star/Delta changeover time
─ Overload relay
─ Main contactor
─ Star contactor
─ Delta contactor
■ Direct start
─ Acceleration time
─ Overload relay
─ Main contactor
■ High-voltage cell
─ Acceleration time
─ ready
─ Main contactor
■ SFC USS
─ Service mode
─ Main contactor
■ Softstart
─ Ready
─ Engine running
─ Run-up over
─ Start
─ Reset
─ Main contactor
Tab. 41 Power switching module – menu

4.7.1 Operating modes
STOP
The machine is connected to the power supply.

The Controller on LED lights green.
The machine is switched off. The ON LED is extinguished.
READY
The machine has been activated with the «ON» key:

■ The ON LED lights green.

■ The drive motor is stopped.

■ The inlet valve is closed.
■ The minimum pressure/check valve shuts off the oil separator from the air distribution network.
■ The venting valve is open.
The compressor motor starts as soon as system pressure is lower than the set point pressure (cut-
off pressure).
In addition, timing and/or remote control may affect the start of the motor.
LOAD
The compressor motor runs under load.

■ The inlet valve is open.
■ The airend delivers compressed air to the air distribution network.
IDLE
The compressor motor runs unloaded with low power consumption.

■ The inlet valve is closed.
■ The minimum pressure/check valve shuts off the oil separator from the air distribution network.
■ The venting valve is open.
A small volume of air circulates through the bleed hole in the inlet valve, through the airend and
back to the inlet valve via the venting line.
4.7.2 Control modes

Using the selected control mode, the controller switches the machine between its various opera‐
tional states in order to compensate for air being drawn off by consumers, and to maintain the sys‐
tem pressure between the set minimum and maximum values. The control mode also rules the de‐
gree of energy efficiency of the machine.
The machine-dependant venting phase between the LOAD and READY operating modes ensures
load changes at minimum material stresses.
The controller SIGMA CONTROL 2 can operate in the following modes:

■ DUAL
■ QUADRO
■ VARIO
■ DYNAMIC
Option C1 ■ MODULATING control
DUAL
In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to
maintain the machine working pressure between the preset minimum and maximum values. When
maximum pressure is reached, the machine switches to IDLE. When the preset idling time has
elapsed, the machine is READY.
The idling time is factory preset according to the maximum starting frequency of the compressor
motor. The shorter the idling time setting, the sooner (and more frequently) the drive motor is stop‐
ped.

QUADRO
Unlike the DUAL regulating mode, the machine will switch from LOAD to READY in QUADRO
mode after periods with low compressed air consumption.
After periods with a high compressed air consumption, the machine will switch from LOAD to
READY after passing through IDLE.
In this control mode, the controller requires two specified times: The running time and the idling/
standstill time.
The shorter these times are set, the sooner (and more frequently) the motor is stopped.
VARIO
The VARIO mode is based on the DUAL control mode. Unlike the DUAL regulating mode, the
idling time is automatically lengthened or shortened to compensate for higher or lower machine
starting frequencies.
CONTINUOUS
Unlike the DUAL control mode, the machine is switched back and forth between LOAD and IDLE,
to maintain the machine working pressure between the preset minimum and maximum values.
When maximum pressure is reached, the machine switches to IDLE. However, the machine does
not switch to READY.
DYNAMIC
Unlike the DUAL regulating mode, the machine will switch from LOAD to READY in DYNAMIC
mode at low drive motor temperature.
And from LOAD via IDLE to READY at a high drive motor temperature.
The lower the drive motor temperature, the sooner (and, therefore, more often and longer) it is
stopped.
Option C1 MODULATING control
The MODULATING control is an additional mechanical regulation. It continuously changes the de‐
livery volume within the machine's control range.
A control valve, the proportional controller, changes the degree of opening of the inlet valve when
the machine transports compressed air into the air network (LOAD)
The load and power consumption of the drive motor rises and falls with the air demand.
4.7.3 Frequency-controlled drive (SFC)

If the machine runs in LOAD, the frequency converter compares the ACTUAL value with the TAR‐
GET value of the system pressure and regulates, depending on the difference, the speed of the
compressor motor and the airend.
The speed of the airend determines the rate of compressed air delivery and the working pressure.
If air consumption rises, the frequency converter increases motor speed and therefore increases
the volume of air delivered.
If air consumption drops, the converter reduces motor speed and therefore reduces the volume of
air delivered.
The network pressure remains constant – within the control range of the converter – regardless of
fluctuating air demand.

If the network pressure exceeds the TARGET value:
Outside the frequency converter's range of control the machine reverts to the selected control
mode.
DUAL:
The minimum controllable speed is reached and the machine switches to IDLE. The drive motor
runs unloaded with low power consumption.
When the preset idling time has elapsed, the machine switches to READY.
VARIO/QUADRO/CONTINUOUS:
The minimum controllable speed is reached and, depending on the air demand at the time, the ma‐
chine switches either to READY or to IDLE.
DYNAMIC:
The minimum controllable speed is reached and, depending on the air temperature of the drive mo‐
tor, the machine switches either to READY or to IDLE.
If the network pressure falls below the TARGET value:
The frequency converter runs the motor up to a speed at which air delivery matches the air de‐
mand.
The inlet valve opens and the machine delivers compressed air.
The frequency converter varies the speed of the drive motor according to the air demand. The
power consumption of the drive motor rises and falls according to air demand.
4.7.4 MODULATING control

With the help of a mechanical control valve (the proportional controller), the opening and closing of
the inlet valve is continuously varied in relation to the actual air demand. The airend delivers com‐
pressed air to the distribution network.
The load and power consumption of the drive motor rises and falls with the air demand.
To ensure optimal control on large compressors, the control air for the proportional controller is tak‐
en from an external air receiver.

5.1 Maintaining ambient conditions

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

The installation and operating conditions depend the machine into which the controller is installed.
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.

6 Installation
6 Installation
1. Check the machine for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage without delay.
6.2 Machine identification

If the machine is run in sequenced operation its identification as detailed in the installation diagram
is to be taken into account.
Identifying the machine for operation in remote mode.
➤ Attach the following notice to warn of remote machine operation (suggestion):

➤ Label the starting device in the remote control center as follows (suggestions):

➤ Before starting, make sure that no one is working on the machine and that it can be safely
started.
Tab. 43 Remote control identification
Identifying the machine for clock control mode operation
➤ Attach the following notice to warn of remote machine operation (suggestion):
Clock control: danger of unexpected starting!


7 Initial Start-up
7.1 Outline
7 Initial Start-up
7.1 Outline
SIGMA CONTROL 2 was designed and developed for a number of applications. Potential settings
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.
The following sections explain the large number of practical applications, but only one configuration
is relevant for any specific use.
7.2: Configuring the controller (display format, units, languages, etc.)
7.3: Using KAESER CONNECT
7.4: Adjusting the pressure parameters of the machine and possible modules
7.5: Configuring machine start and stop
7.6: Activating and adjusting the control modes
7.8: Configuring the machine for local mode
7.9: Configuring the machine for master control
7.10: Configuring email
7.11: Configuring input and output signals
7.12: Activating remote acknowledgement
7.13: Linking to an external pressure transducer
7.14: Commissioning the machine
7.2 Configuring the controller

All controller settings are explained in detail in the following sections. The most common set‐
tings are summarized for experienced users in the section titled "Important settings" in the
front of this manual.
➤ Carry out settings as required:
■ 7.2.1: Selecting menu options (introduction)
■ 7.2.2: Changing the display language
■ 7.2.3: Note the number of the KAESER Equipment Card
■ 7.2.4: Control access to SIGMA CONTROL 2 with the Equipment Card
■ 7.2.5: Generate password for SIGMA CONTROL 2
■ 7.2.6: Control access to SIGMA CONTROL 2 via manual input
■ 7.2.7: Generate password for KAESER CONNECT
■ 7.2.8: Set time and date
■ 7.2.9: Set display formats (date, time, units of pressure, and temperature)
■ 7.2.10: Activate summer/winter time
■ 7.3.6: Add user accounts
7.2.1 Selecting menu options

All menu options can be selected with the «DOWN», «UP» and «Enter» keys.

7 Initial Start-up
Example: Select the > Configuration ➙ General > menu option
1. Press «Enter».
2. Press the «UP» or «DOWN» key until Configuration is displayed as the active line.
3. In order to open the < Configuration > menu, press «Enter» once.
4. Use the «DOWN» or «UP» keys to select a submenu in the < Configuration > menu, < General
> or < Pressure control > for instance.
5. Press «UP» repeatedly until General is displayed as the active line.
6. Press «Enter».
The current menu is the < General > submenu in the < Configuration > menu.
7. Use the «DOWN» or «UP» keys to select a menu option in the < General > submenu, <
System information > for instance.
7.2.2 Changing the display language

The controller can display text messages in the following languages:
Arabian 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 ...
English Hebrew Lithuanian Swedish ...
English Indonesian Dutch Slovenian ...
(USA)
Tab. 45 Display language
Some of the units, as well as clock and date format, will be adjusted according to the language
selected.
1. Press «Enter».
2. Press the «UP» key once.
The set language is displayed as the active line.
3. Use the «Enter» key to switch to setting mode.
The currently set language flashes.
4. Use the «DOWN» or «UP» keys to select the desired language.
6. Press «Esc» repeatedly to return to the Main Menu.
The display texts are now in the selected language.

7 Initial Start-up
7.2.3 Noting the number of the KAESER Equipment Card

The number of your KAESER Equipment Card is identical to the user name displayed on the
SIGMA CONTROL 2 after you have successfully logged in using your Equipment Card.
Fig. 9 Back of the KAESER Equipment Card

1 Back of the KAESER Equipment Card
2 Number of your Equipment Card
1. Hold your KAESER Equipment Card with its back upward.

2. Note your user name (the number of your Equipment Card).
3. Store this information in a suitable location.
The Equipment Card is damaged or lost?
➤ If you know your user name and password, you can manually log onto the
SIGMA CONTROL 2.
7.2.4 Controlling access to the SIGMA CONTROL 2 with the Equipment Card
Use the Equipment Card to quickly and easily check the advanced access rights to the
SIGMA CONTROL 2 .
Advanced access rights let you:
■ Read additional data
■ Change other settings
1. Hold the Equipment Card in front of the controller's reader.
(see also chapter 4.2)
Your user name and access level will be displayed.
2. Press «Enter» to confirm the access right.
The Equipment Card is damaged or lost?
➤ Manually enter the user name and password, see chapter 7.2.6.
7.2.5 Generating a password for the SIGMA CONTROL 2

In the event that your Equipment Card is damaged or lost, you must manually log on to
SIGMA CONTROL 2.
Prerequisite for this is that you know your:

■ User name and
■ Password

7 Initial Start-up
If you have noted your user name and stored it in a suitable location, you can now generate a
password on the SIGMA CONTROL 2. Note this generated password as well, and store it in a suit‐
able location. If your Equipment Card is damaged or lost, you can use these two to manually log
onto the SIGMA CONTROL 2 without an Equipment Card.
Precondition The customer is logged on with the Equipment Card

1. Press «Enter».
2. Use the «DOWN» key to select the <User> menu.
The Name line is displayed as the active line.
89 psi 08:15 176 °F
7 User Menu
Name : E00019895 Active line, display of your Equipment Card's num‐
ber
Password: ****************
[Logout]
------------------------------
Current access level: 2 Display access level 2
3. Press «DOWN» twice.

[Logout] is displayed as the active line.
89 psi 08:15 176 °F
7 User Menu
Name : E00019895
Password: ****************
[Logout] Active line
------------------------------
4. Press «Enter».
[Login] is displayed as the active line.
89 psi 08:15 176 °F
7 User Menu
Name : E00019895
Password: ****************
[Login] Active line
------------------------------

7 Initial Start-up
5. Hold the Equipment Card in front of the controller's reader.

89 psi 08:15 176 °F
Log-on successful. Menu
Password change with key Prompt, whether the password is to be changed
------------------------------
Name : E00019895
Level: 2
6. Press the «Right» key.

The generated password is displayed in a new screen.
89 psi 08:15 176 °F
Password changed Menu
Please note your new password:
xFNDQRCnDn Note the new password
Name : E00019895
Level: 2
7. Note the generated password.

8. Store the password at a suitable location, if it should become necessary to manually log on
without your Equipment Card.
7.2.6 Controlling access to the SIGMA CONTROL 2 via manual input

In the event that your Equipment Card is damaged or lost, you must manually log on to
SIGMA CONTROL 2.
Precondition The Equipment Card is damaged or lost.

User name (number of Equipment Card) must be known
A password was generated at the SIGMA CONTROL 2 before the Equipment Card was damaged
or lost.
1. Press «Enter».
2. Use the «DOWN» key to select the <User> menu.
The Name line is displayed as the active line.

7 Initial Start-up

A column with alphanumeric characters is displayed.
89 psi 08:15 176 °F
7 User Menu
Name : E00019895
Password: ****************
[Login] Active line
------------------------------
4. Repeatedly press «DOWN» or «UP» until the requested character is displayed.

The cursor jumps to the next position.
6. Complete the remaining characters of the name.
The user name has been entered.
89 psi 08:15 176 °F
7 User Menu
Name : E00019895 Active line, user name
Password: ****************
[Login]
------------------------------

The Password line is displayed as the active line.
A column with alphanumeric characters is displayed.
89 psi 08:15 176 °F
7 User Menu
Name : E00019895
Password: **************** Active line, password
[Login]
------------------------------
10. Repeatedly press «DOWN» or «UP» until the requested character is displayed.
The cursor jumps to the next position.
12. Complete the remaining characters of the password.

7 Initial Start-up

The [Login] line is displayed as the active line.
89 psi 08:15 176 °F
7 User Menu
Name : E00019895
Password: ****************
[Login] Active line
------------------------------

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 generated password.
7.2.7 Generating a password for KAESER CONNECT

You also need a password to access KAESER CONNECT for the SIGMA CONTROL 2.
This password is also generated at the SIGMA CONTROL 2.
Entering the password is necessary to

■ Log on to KAESER CONNECT
■ Activate the write mode in the User accounts menu
➤ Proceed as described for "Generating a password for the SIGMA CONTROL 2”, see chap‐
ter 7.2.5.
7.2.8 Checking/setting the time and date

Checking/setting the time
➤ When operating the machine with a timer program, check the time settings at least once
a year.
1. Press «Enter».
2. Select the < Configuration ➙ General > menu.

7 Initial Start-up
3. Press the «DOWN» key repeatedly until the current time is displayed as the active line.
89 psi 08:15 176 °F
5.1 General Menu
▶1 System information
·········
Model:
·········
Date/time
13:04:11 08:15:37 Current time

The hours display flashes. 00: 00: 00.
6. Use «UP» or «DOWN» to change the hour setting.
The minutes display flashes. 00: 00: 00.
8. Use «UP» or «DOWN» to change the minute setting.
The seconds display flashes. 00: 00: 00 .
10. Use «UP» or «DOWN» to change the second setting.
11. Press «Enter» to save the settings.
Checking/setting the date
Precondition Password level 2 is activated,

the < Configuration ➙ General > menu is selected (see 7.2.1).
1. Press the «DOWN» key repeatedly until the current date is displayed as the active line.
89 psi 08:15 176 °F
5.1 General Menu
▶1 System information
·········
Model:
·········
Date/time
13:04:11 08:15:37 Current date

The day display flashes. 00: 00: 00.
3. Use «UP» or «DOWN» to change the day setting.
The month display flashes. 00: 00: 00.
5. Use «UP» or «DOWN» to change the month setting.
The year display flashes. 00: 00: 00 .

7 Initial Start-up
7. Use «UP» or «DOWN» to change the year setting.

8. Press «Enter» to save the settings.
7.2.9 Setting display formats

When setting the language, several display formats will automatically adjust to local usage.
Setting the date format
Select your preferred format.

Format Example:
DD.MM.YY 30.07.10
YY-MM-DD 10–07–30
MM/DD/YY 07/30/10
Tab. 46 Date formats

Menu < Configuration> General > is selected (see 7.2.1).
1. Press the «DOWN» key repeatedly until Date format is displayed as the active line.
89 psi 08:15 176 °F
5.1 General Menu
Date/time
13:04:11 08:15:37
Europe/Berlin
·········
Date format DD.MM.YY Current date format
Time format hh:mm:ss

DD.MM.YY flashes.
3. Change the format with the «DOWN» or «UP» keys.
Setting the time format
Select your preferred format for the time display:

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. 47 Time formats

7 Initial Start-up

1. Press the «DOWN» key repeatedly until Time format is displayed as the active line.
89 psi 08:15 176 °F
5.1 General Menu
Date/time
13:04:11 08:15:37
Europe/Berlin
·········
Date format DD.MM.YY
Time format hh:mm:ss Current time format

hh:mm:ss flashes.
3. Change the format with the «DOWN» or «UP» keys.
Setting the pressure display units
Select your preferred display of the pressure unit:

Format Example:
bar 5.5 bar
hPa 5523 hPa
MPa 0.55 MPa
psi 80 psi
at 5.6 at
"Hg 162.9 "Hg
Tab. 48 Units of pressure

1. Press the «DOWN» key repeatedly until Pressure unit is displayed as the active line.
89 psi 08:15 176 °F
5.1 General Menu
·········
Pressure unit bar Current unit of pressure
Temperature unit °C
·········
Display lighting

The bar parameter flashes.

7 Initial Start-up
3. Change the unit with the «DOWN» or «UP» keys.

Setting the temperature display units
Select your preferred display of the temperature unit:

Format Example:
°C 46 °C
K 319 K
°F 114 °F
Tab. 49 Units of temperature

1. Press the «DOWN» key repeatedly until Temperature unit is displayed as the active line.
89 psi 08:15 176 °F
5.1 General Menu
·········
Pressure unit bar
Temperature unit °C Current unit of temperature
·········
Display lighting

The °C parameter flashes.
3. Change the unit with the «DOWN» or «UP» keys.
Setting the display illumination
Select your personal mode for the display illumination:
Mode 1 2 3
Display automatic ON OFF
Function The illumination extin‐ Permanent setting Permanent setting
guishes after the time- Illumination "on" Illumination "off"
out has elapsed.
Tab. 50 Display illumination

1. Press «DOWN» repeatedly until Display lighting is displayed.

7 Initial Start-up
7.3 Using KAESER CONNECT
2. Press «DOWN» once until Mode is displayed as the active line.

89 psi 08:15 176 °F
5.1 General Menu
·········
Pressure unit bar
Temperature unit °C
·········
Display lighting
Mode: auto. ¦ Timeout : 1 min Active line

The on display flashes.
4. Use «UP» to select the auto. mode.
6. Enter the setting for time-out in the same manner.
Result The display illumination is set for automatic operation with deactivation after one minute without
user intervention.
7.2.10 Setting and activating summer/winter time

The system automatically switches between summer and winter time.

Using a PC with web browser, KAESER CONNECT enables you to view the following of the
SIGMA CONTROL 2:
■ System status
■ Graphs
■ Messages
■ IO display
■ User administration
■ Settings
■ Data backup
Thus, KAESER CONNECT provides an excellent option for an easy and quick check of the energy
efficiency of your compressors.
The following functions are not available with KAESER CONNECT:
■ Remotely starting the machine

■ Remotely changing parameters

7 Initial Start-up
7.3.1 Calling up KAESER CONNECT for SIGMA CONTROL 2

Precondition The password for KAESER CONNECT has already been generated, see chapter 7.2.7
The IP address of your controller is known.
1. Use an Ethernet cable to connect the PC and the SIGMA CONTROL 2.

2. In the web browser, enter the controller's IP address.
The Login window opens.
Fig. 10 Login window

1 Login window 3 Generated password
2 User name 4 «Login» key
3. Enter the user name.

4. Enter the generated password.
5. Click «Login».
KAESER CONNECT for SIGMA CONTROL 2 is displayed.

7 Initial Start-up
Fig. 11 KAESER CONNECT

1 Language selection 5 User administration
2 System status 6 Settings
3 Graphs 7 Data backup
4 Messages
6. Click the «Arrow key» 1 to open the language selection.

The Language selection 2 window opens.
Fig. 12 Language selection

1 «Arrow key» Language selection 3 Select a language
2 Language selection window 4 Selected language
7. Select the required language 3 .

KAESER CONNECT is displayed in the selected language.
7.3.2 Displaying the system status

Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed.
1. Select the <System status> menu.

The system displays the status information.

7 Initial Start-up
Fig. 13 Status display

1 <System status> menu
2 Display SIGMA CONTROL 2 with status information
2. Check the status information.

The entire local menu can be displayed at your PC.
1. Simply click in the display of the operating mode.
The <main menu> is displayed.
Fig. 14 Main menu
2. You now may click the <Status> menu.

The system displays the corresponding <submenus>.

7 Initial Start-up
Fig. 15 Status menu with submenus

1 Messages 6 pN / ADT curve
2 Statistics 7 pN / n curve
3 Current pressure regulation 8 «Scroll down» key
4 Current operating mode 9 «Scroll up» key
5 DI/DO display
3. Navigate through the submenus by additional clicks in the display.

4. Click «Scroll up» 9 to start the upward scroll.
Data not visible prior to the scroll action are now displayed.
5. Click «Scroll down» 8 to start the downward scroll.
6. To move back between the menus, click «esc» as often as required.
7.3.3 Display graphs

When starting this menu, the recorded data from the last 60 minutes are loaded. The last 20 mi‐
nutes are displayed in a graph. The system updates the graph every ten seconds whilst the current
time is displayed.
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 following graphs can be displayed:

■ System pressure
■ Machine status
─ OFF
─ IDLE
─ LOAD
■ Speed
The display of the Speed is implemented only for machines with frequency converter.

7 Initial Start-up
1. Select the <Graphs> menu.

The system displays graphs.
Fig. 16 Pressure/temperature graphs

1 <Graphs> menu 4 Speed
2 System pressure 5 Machine status
3 Airend discharge temperature
2. Check pressure development

3. Check airend discharge temperature.
7.3.3.1 Zoom and arrow key functions
Use the Zoom-in 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. 17 Arrow keys

1 «Start» Display of oldest data
2 «Scroll left» Shift the display area by 1/3 to the left
3 «Zoom-out» Time range is enlarged

7 Initial Start-up

4 «Scroll right» Shift the display area by 1/3 to the right
5 «End» Display of newest data
Tab. 51 Arrow keys and functions
1. Click the «Start» 1 arrow key.

The oldest data are displayed.
2. Click the «Scroll right» 4 arrow key.
The display area is shifted to the right by 1/3.
3. Draw a rectangle with the mouse pointer pressed.
4. Release the mouse pointer.
The selected area is enlarged (zoom-in function).
5. Click the «Zoom-out» 3 arrow key.
Time range is enlarged (zoom-out function).
7.3.4 Displaying messages

The following messages are shown:
■ Current messages
■ Compressor messages
■ System messages
■ Diagnostic messages
1. Open menu <Messages>.

Menu <Messages> is displayed.
Fig. 18 Messages
1 Menu < Messages > 4 System messages
2 Current messages 5 Diagnostic messages
3 Compressor messages
2. Check messages.

7 Initial Start-up
7.3.5 Viewing the IO modules assigment

The assignment of the I/O modules is displayed in the <IO display> menu.
➤ Select the <IO display> menu.
The assignment of the input/output modules is displayed.
7.3.6 Creating additional user accounts

Use the <User administration> menu to create additional user accounts for other employees.
In order to be able to create user accounts, you must active the write mode 2 . The system
will prompt you to enter and confirm your user name and your password (see chapter 7.2.7).
Subsequently, the write mode is activated.
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.
1. Select the <User administration> menu.

The system displays the <User administration> menu.

7 Initial Start-up
Fig. 19 User administration menu

1 <User administration> menu 3 User list
2 Activate write mode 4 User account
2. Activate the write mode 2 .

The Log on for write access window opens.
Fig. 20 "Log on for write access" window

1 Log on for write access window 4 «OK» key
2 User name 5 «Esc» key
3 Password
3. Enter your own user name.

4. Enter your own password.
5. Click «OK».

7 Initial Start-up
Fig. 21 Creating a new user

1 <User administration> menu 6 User type
2 New user name 7 Status
3 Password 8 «Add» key
4 Confirm the password 9 «Update» key
5 Access level
6. Enter the new user name 2 for an additional employee.

7. Enter the new password 3 .
8. Confirm the new password 4 .
9. Select access level 2 5 .
10. Select the user type Customer 6 .
11. Select the status Activated 7 .
12. Click «Add» 8 .
The new user name has been added to the user list.
Result A new user account has been created and activated.
Updating user accounts
Similar to the creation of new user accounts, you can also update existing user accounts.
■ Changing the password
■ Changing the access level
■ Changing the status
As an example, we show here how to change a password.

7 Initial Start-up
Precondition The system displays the <User administration> menu.

Write mode is activated.
1. Click on the existing user account.

2. Enter the new password.
3. Confirm the new password.
4. Click «Update» 9 .
Result The existing user account has been updated.
7.3.7 Settings
Settings via KAESER CONNECT apply only to your PC and your Browser.
The following settings are available:

■ Units
■ Date format
■ Time format
Fig. 22 Settings
1 <Settings> menu
2 Unit of pressure
3 Unit of temperature
Converting units to US values:
1. Select the <Settings> menu.

The system displays the <Settings> menu.
2. Click the arrow key for the unit of pressure.
A selection list of units of pressure is displayed.
3. Select the desired unit.
4. Click the arrow key for the unit of temperature.
A selection list of units of temperature is displayed.
5. Select the desired unit.
6. Set additional units and date and time formats.

7 Initial Start-up
7.3.8 Performing a data backup

In order to use KAESER CONNECT to easily back up data from the SIGMA CONTROL 2 to your
own PC, use the <Data backup> menu.
You can choose to either perform a full backup or partial backups:

■ Full
■ Log files
■ Settings
■ User data
1. Open the <Data backup> menu.

The system displays the <Data backup> menu.
Fig. 23 Data backup

1 <Data backup> menu
2 Selection
3 «Data backup» key
2. Select 2 .
3. Click the «Data backup» 3 key.
Result Data is saved to your PC.
7.3.9 Closing KAESER CONNECT:

To close KAESER CONNECT for SIGMA CONTROL 2, click Logout 3 in the header.

7 Initial Start-up
7.4 Adjusting the pressure parameters of the machine
Fig. 24 Header
1 Machine designation 3 Logout
2 Activation Write mode 4 Contact KAESER Service
➤ Click Logout.
The logout message is displayed.
Result You have closed KAESER CONNECT for SIGMA CONTROL 2.

This section contains instructions for how to display and adjust the pressure parameters of the ma‐
chine.
This section is divided into the following sections:

■ 7.4.1: Displaying pressure parameters
■ 7.4.2: Configuring the pressure parameters
"Display:" means that the parameter will only be shown.

"Setting:" means that the parameter can also be changed.
Parameter Explanation
pRV Display:
Activating pressure of the safety relief valve on the oil separator tank
pE Pressure increase
Setting:
■ pE SP: Switching point for pressure increase; upper safety limit for machine
maximum pressure; in an external LOAD control; this value is used to switch
the machine from LOAD to IDLE in the event of a fault.
■ pE SD: Switching differential of pressure increase
ΔpFC Limiting value for machines with frequency-controlled drive (SFC).
Setting:
■ dp FC: Limit of the lowest delivery quantity. When the value [switching point
system setpoint pressure +dp FC] is exceeded, the compressor switches from
LOAD to IDLE.
Nominal Display:
pressure The compressor is designed for this pressure (maximum system pressure setpoint)

7 Initial Start-up
Parameter Explanation
Setpoint Setpoint pressure can be regulated to two values: pA and pB
pressure
Setting:
■ Switching point pA or control pressure pA in machines with frequency converter
(SFC)
■ Switching point pB or control pressure pB in machines with frequency converter
(SFC)
System A warning message is displayed when the limit value for the system pressure is
pressure low reached.
Setting:
■ SD: Switching differential for system pressure low,
SP: Switching point for system pressure low
■ Option: Configure the output signal,
Warning message displayed or an additional output signal is sent, e.g., to a
control center
Cut-in Display:
pressure min For design reasons, pressure can only be built up above this value.
Tab. 52 Compressor pressure parameters
➤ Parameters correspond to the following specifications
7.4.1 Displaying pressure parameters

The < Configuration ➙ Pressure control > menu is selected.
Opening the menu for pressure parameters
1. Press «DOWN» or «UP» repeatedly until Pressure settings is displayed as the active line.
2. Press «Enter».
The system displays the pressure parameters.
89 psi 08:15 176 °F
5.2.2 Pressure settings Menu
pA SP : 116 psi ¦ SD : - 7 psi Active line
pB SP : 109 psi ¦ SD : - 6 psi
·········
↓ < 73 psi ¦ SD : 7 psi
ta : 600 s ¦ DOR 1.04 ☐

7 Initial Start-up
Displaying compressor parameters
1. Press «DOWN» repeatedly until Setpoint pressure is displayed.

89 psi 08:15 176 °F
·········
Setpoint pressure Active line
pA SP : 116 psi ¦ SD : - 7 psi Current system setpoint pressure pA and switching
differential
pB SP : 109 psi ¦ SD : - 6 psi Current system setpoint pressure pB and switching
differential
·········
2. Display further parameters with «UP» and «DOWN».
7.4.2 Configuring the pressure parameters for compressors

7.4.2.1 Adjusting the system setpoint pressure: pA and pB
The pressure parameters can only be set within certain limits:

Rated machine pressure ≥ SP pA /pB ≥ minimum cut-in pressure* + switching differential
Tab. 53 Setting limits for system setpoint pressure (* Cut-in pressure min)
The machine switches to LOAD under the following condition:

System pressure ≤ SP: pA /pB - switching differential
Tab. 54 Pressure condition for LOAD
The machine switches to IDLE under the following condition:

System pressure = System setpoint pressure
Tab. 55 Pressure condition for IDLE
1. Select < Configuration ➙ Pressure control ➙ Pressure settings > (see Section 7.4.1)
2. Press «UP» or «DOWN» repeatedly until the following is displayed as the active line:
89 psi 08:15 176 °F
·········
Setpoint pressure
pA SP : 116 psi ¦ SD : - 7 psi Active line with current value for system setpoint
pressure pA
·········

7 Initial Start-up

The 116 psi parameter flashes.
4. Use «UP» or «DOWN» to adjust the system setpoint pressure pA.
6. Adjust the switching differential in the same way.
7. Adjust the pB and the switching differential in the same manner, if necessary.
Result The settings for the system setpoint pressure pA and pB are adjusted.
7.4.2.2 Adjusting the value for “System pressure low”
If the system pressure falls to the sys.press.low value, SIGMA CONTROL 2 will display a warning
message for the system pressure being too low.
The switching differential influences the pressure at which the message can be acknowledged or
the optionally activated output will again switch:
Message Output
73 psi message appears Active
80 psi messages disappears Inactive
Tab. 56 Example: Activated output
2. Press the «DOWN» key repeatedly until the following is displayed as the active line:
89 psi 08:15 176 °F
·········
↓ < 73 psi ¦ SD : 7 psi Current value system pressure low, current switch‐
ing differential
ta : 600 s ¦ DOR 1.04 ☐
·········
Cut-in pressure min 73 psi

4. Use «UP» or «DOWN» to adjust the setting.
6. Adjust the switching differential if necessary in the same way.
7.4.2.3 Adjusting pressure rise pE
The value for pressure rise pE serves as a safety limit value when the machine is externally con‐
trolled. When the system set pressure reaches the value pE (for example, when the external con‐
trol functions incorrectly) the machine switches to IDLE.
The warning message ext.load signal? is displayed.

7 Initial Start-up
89 psi 08:15 176 °F
pRV 232 psi
·········
Pressure rise
pE SP : 122 psi ¦ SD : - 7 psi Active line with current switching point pressure rise,
current switching differential
ΔpFC : 44 psi
·········

6. Adjust the switching differential if necessary in the same way.
7.4.2.4 Adjusting pressure rise: Machine with variable frequency drive (SFC)
The pressure rise value dpfC is the limit from which the machine switches to IDLE.
This value can be between 2.9 psi and 5.8 psi. The factory setting is 2.9 psi.
The pressure rise is added to the system setpoint pressure. In this way, the system setpoint pres‐
sure can be changed without having to adjust the parameter again.
Fig. 25 Pressure rise in frequency-controlled (SFC) machines

1 System pressure 4 LOAD switching point:
2 IDLE switching point: (System setpoint pressure + dpFC) -
System setpoint pressure + dpFC switching differential
3 System setpoint pressure pA or pB 5 Pressure rise dpFC
6 System pressure band width

7 Initial Start-up
2. Press «DOWN» repeatedly until the following is displayed:

89 psi 08:15 176 °F
Pressure rise
pE SP : 122 psi ¦ SD : - 7 psi Pressure increase
ΔpFC : 3 psi Active line with pressure rise dpFC
·········
Nominal pressure 116 psi
·········

7.4.3 Activating/deactivating the «LOAD/IDLE» key

In order to prevent unauthorized users from switching the machine to IDLE, you can deactivate the
«LOAD/IDLE» key on the operating panel.

The < Configuration ➙ Pressure control ➙ Load control > menu is selected (see Section 7.2.1).
1. Press «UP» or «DOWN» repeatedly until < Key idle > is displayed as the active line.
The check box < Key idle > will flash.
89 psi 08:15 176 °F
pA/pB DO DOR1.04 ☐
·········
Load RC DI1.13 ok ☑
loc.-load RC DI1.09 ☑
·········
Key idle : ☑ Active line with check box
3. Press «UP».
The deactivated check box is displayed.

7 Initial Start-up
7.5 Configuring machine start and stop

The «IDLE» key is deactivated.
89 psi 08:15 176 °F
pA/pB DO DOR1.04 ☐
·········
Load RC DI1.13 ok ☑
loc.-load RC DI1.09 ☑
·········
Key idle : ☐ Active line with deactivated check box
Result Thus, it is ensured that unauthorized users can press the «IDLE» key without the machine switch‐
ing to IDLE.

➤ In addition to manually starting the machine locally, you have the following alternatives:
Function State on delivery, setting See

Automatic start/stop in programmed clock mode No clock (time) program entered 7.5.1
Holidays Not set 7.5.2
Remote start, e.g. from a control centre. Deactivated 7.5.3
IDLE (venting) Activated 7.5.4
Automatic restart after power failure (after delay period). Activated 7.5.5
Tab. 57 Settings for machine start and stop.
7.5.1 Automatic start/stop in programmed clock mode

Overview
■ If not activated, enter password for level 2
■ Select the <Compressor clock> menu
■ Set/adjust the time program
■ Activate the «Clock» key
7.5.1.1 Selecting the compressor clock menu

1. Press «Enter».

7 Initial Start-up
2. Select < Compressor clock >.

The display for setting the Compressor clock timing program appears.
89 psi 08:15 176 °F
Key clock : ☐ Compressor clock is activated
Reset: ☐ All current switching points are reset
·········
01 n.a. 00:00 off Active line
02 n.a. 00:00 off
03 n.a. 00:00 off
7.5.1.2 Setting the clock program (example)
When setting a timer program for the first time, note the switching times on a sheet of paper
first.
In addition to individual week days, the controller has the following cycles:
■ Mon-Thu
■ Mon-Fri
■ Mon-Sat
■ Mon-Sun
■ Sat-Thu
You can also program an OFF time (shutdown periods) (see section 7.5.2).
Example:
■ Machine ON: Weekdays 6:30 – 17:00, Fridays 6:30 – 15:00.
■ Machine OFF: Sat – Sun and during midday break from 12:00 – 13:00.
The following switching points result:

No. Day Time Function
1 Mon-Fri 06:30 ON
2 Mon-Fri 12:00 OFF
3 Mon-Fri 13:00 ON
4 Mon-Thu 17:00 OFF
5 Fri 15:00 OFF
Tab. 58 Example of a machine ON/OFF timer program

the «Clock» key is activated,
the "clock" menu is selected.

7 Initial Start-up
1. Press «DOWN» repeatedly until the 01 switching point is displayed as the active line.
89 psi 08:15 176 °F
·········
01 n.a. 00:00 off Active line with switching point 01
02 n.a. 00:00 off Switching point 02:

The n.a. column flashes in the active line.
3. Use «UP» to specify the settings for the weekdays.
The column time, display for hours, 00: 00 in the active line flashes.
9. The column time, display for minutes, 00: 00 in the active line flashes.
89 psi 08:15 176 °F
·········
01 Mon-Fri 06:30 on Switching point 01 is set
02 Mon-Fri 12:00 off Switching point 02 is set
03 Mon-Fri 13:00 on Switching point 03 is set
04 Mon-Thu 17:00 off Switching point 04 is set
05 Fri 15:00 off Switching point 05 is set

The Action on/off column flashes.
14. Use «UP» to specify the settings for the action Compressor ON.
The Compressor ON function is set for the first switching point.
Result Weekdays, time, and the Compressor ON/Compressor OFF functions are set for all switching
points.

7 Initial Start-up
7.5.1.3 Activating the «Compressor timer» key
1. Press «UP» repeatedly until Key clock is displayed as active line.

89 psi 08:15 176 °F
Key clock : ☑ Active line with deactivated check box
Reset: ☐
·········
01 Mon-Fri 06:30 on Switching point 01:
02 Mon-Fri 12:00 off Switching point 02:
03 Mon-Fri 13:00 on Switching point 03:

The «Clock» key is activated and can be used.
6. Press «Clock» to enable the operation with a timing program.
7.5.2 Setting up the holiday period

In addition to the fixed cycles of a timing program or timer, you can also specify a longer lasting
standstill time. For example, you may specify a standstill period for vacation shut-down by defining
the following:
1. Press «Enter».
2. Select < Configuration ➙ Compressor start ➙ Compressor off >.
3. Press «DOWN» repeatedly until Holidays is displayed as active line.
89 psi 08:15 176 °F
5.4.2 Compressor off Menu
Venting period : ☐
·········
Holidays : ☐ Active line
Start : 23.12.12
00:00
End : 07.01.13

The check box flashes.

7 Initial Start-up

89 psi 08:15 176 °F
Venting period : ☐
·········
Holidays : ☑ Active line with deactivated check box
Start : 23.12.12
00:00 Time for start
End : 07.01.13
6. Press Enter to accept the setting.

You may manually adjust the start and end of vacation shut-down (date) in the setting mode.
Adjust the times for start and end (hours and minutes) of the vacation shut-down in the same
manner described in chapter 7.5.1.2 (timing program) for the times of the switching points.
Result You have set a standstill time 23.12.12–07.01.13 for your machine.
7.5.3 Starting the machine remotely (Remote ON/OFF)

If the machine is to be started and stopped remotely, the following settings have to be set:
Overview
■ Make the electrical connection (a spare input for the remote contact is to be found in the elec‐
trical wiring diagram for the machine, DI 1.0 being preferred).
■ Switch machine start to remote mode.
■ Press the «Remote» key.
■ If necessary, activate the «Clock » key and configure the clock program (see section7.5.1.2).
■ If required, assign the remote contact to another input.
■ Press the «Remote» key.
7.5.3.1 Switch machine start to Remote mode
Two methods are available to start the machine remotely:
■ Method A: Starting the machine with the input signal from the remote control center.
■ Method B: Starting the machine from the remote control center in addition to a configured
ON/OFF clock program.
The machine can be started from the remote control center even though the clock is activated
and the program has selected compressor OFF at this point in time.
Precondition The electrical connection has been made.

Password level 2 is activated.
1. Press «Enter».
2. Select the < Configuration ➙ Compressor start ➙ Compressor on > menu.
3. Press «UP» repeatedly until Remote mode is displayed as active line.

7 Initial Start-up

Key flashes.
89 psi 08:15 176 °F
Local mode : Key
Remote mode : Key Active line
·········
current Key
·········
RC DI 1.12 ok ☑
5. Press «DOWN» repeatedly until Key+RC is displayed.

89 psi 08:15 176 °F
Local mode : Key
Remote mode : Key+RC Active line
·········
current Key
·········
RC DI 1.12 ok ☑
Result The machine start is set to remote operation with Key+RC.
7.5.3.2 Activating/deactivating the «Remote control» key
Precondition The electrical connection has been made.

Password level 2 is activated.
1. Press «Enter».
2. Select the < Configuration ➙ Compressor start ➙ Compressor on > menu.
3. Press «DOWN» repeatedly until Key remote is displayed as active line.
The check box for the remote control key will flash.
89 psi 08:15 176 °F
Local mode : Key
Remote mode : Key+RC
·········
RC DI 1.12 ok ☑
Key remote : ☐ Active line with check box
Key clock : ☐

7 Initial Start-up

89 psi 08:15 176 °F
Local mode : Key
·········
RC DI 1.12 ok ☑
Key remote : ☑ Active line with deactivated check box
Key clock : ☐ The Clock key is not activated.

8. If method B with the timer program is selected, the «Clock» key must be activated in the same
manner.
7.5.3.3 Assigning another input
Inputs already assigned cannot be further assigned.
1. Press the «DOWN» key repeatedly until the following is displayed as active line:
89 psi 08:15 176 °F
Local mode : Key
·········
RC DI 1.12 ok ☑ Remote contact DI 1.12 (preset)
Key remote : ☑
Key clock : ☐

Display for input flashes.
3. Select another input with the «UP» or «DOWN» keys.
The input has now been assigned.
5. Press the «Remote control» key to enable the machine to be started from the remote control
centre.
If an input is rejected it means it is already assigned.
➤ Select a different input.

7 Initial Start-up
7.5.4 Activating/deactivating the idle phase (Venting period function)

After receiving the OFF signal from the remote control center, an additional idling phase (Venting
period) can be activated before the machine is stopped completely. The duration of the idling
phase can be timed and/or regulated by internal pressure.

1. Press «Enter».
2. Select the < Configuration ➙ Compressor start ➙ Compressor off > menu.
The check box for "Venting period" is displayed in the active line.
89 psi 08:15 176 °F
Venting period : ☐ Actual setting: Venting period deactivated
·········
Holidays : ☐
Start : 01.01.12
00:00
End : 01.01.12

The check box for the "Venting period" function will flash.
89 psi 08:15 176 °F
Venting period : ☑ Actual setting: Venting period activated
·········
Holidays : ☐
Start : 01.01.12
00:00
End : 01.01.12

The check box for the "Venting period" function is activated.
The function can be deactivated in the same manner.
You may also activate the Venting period function by pressing the «OFF» key on the controller.
➤ Press the «OFF» key.
Result The "Venting period" function is activated.
Press the «OFF» key twice to immediately shut the machine off.
➤ Press the «OFF» key twice.
Result The machine is switched off without venting (idle time).

7 Initial Start-up
7.5.5 Activating/deactivating and adjusting the "Automatic restart after a power fail‐
ure" function
'Autostart:' is activated as standard.
To avoid overloading the main power supply through several machines starting simultaneously, a
delay period determining the restart of each machine can be entered.
Overview
■ Select the < Configuration ➙ Compressor start > menu.
■ Activate/deactivate the restart function
or
set the restart delay.

The < Configuration ➙ Compressor start > menu option is selected.
1. Press «Enter».
The Compressor start menu is displayed.
89 psi 08:15 176 °F
5.4 Compressor start Menu
▶1 Compressor on Active line
▶2 Compressor off
·········
Autostart: : ☑ Automatic restart activated
Target 10 s ¦ Actual 0 s
·········
Deactivating/activating automatic restart
1. Press «DOWN» repeatedly until Autostart: is displayed as the active line.

89 psi 08:15 176 °F
▶1 Compressor on
▶2 Compressor off
·········
Autostart: : ☐ Automatic restart is deactivated
Target 10 s ¦ Actual 0 s Set/expiring delay period.
·········

The check box for the "Autostart" function will flash.
The check box for the "Autostart" function is deactivated.

7 Initial Start-up
7.6 Activating and adjusting the control modes

Activate the “Autostart” function in the same manner.
Result Automatic restart after a power failure is now deactivated.
Setting up the automatic restart delay period
If you operate several machines, it is better to start them in sequence.

Time for restart: Use the set times (IDLE to LOAD) of the other machines as base.

The < Compressor start > menu is selected.
1. Press «DOWN» repeatedly until the delay time for the restart is displayed as the active line.
89 psi 08:15 176 °F
▶1 Compressor on
▶2 Compressor off
·········
Autostart: : ☑ Automatic restart is activated
Target 10 s ¦ Actual 0 s Set/expiring delay period.
·········

The display for the delay time Setpoint flashes.
3. Change the time using the «DOWN» or «UP» keys.
89 psi 08:15 176 °F
▶1 Compressor on
▶2 Compressor off
·········
Autostart: : ☑
Target 12 s ¦ Actual 0 s Active line
·········

Result Delay time for restart after a main power failure has been adjusted from 10 s to 12 s.

The controller is provided with various control modes that can bring about different capacity utiliza‐
tion depending on machine application. Chapter 4.7 provides a comprehensive description of all
control modes.

7 Initial Start-up
7.6.1 Selecting a control mode

The following control modes are possible:
■ DUAL
■ QUADRO
■ VARIO
■ DYNAMIC
■ CONTINUOUS
The standard setting of the control mode depends on the machine type.

1. Press «Enter».
2. Select the < Configuration ➙ Control mode > menu.
Local mode is displayed as the active line.
89 psi 08:15 176 °F
5.3 Control mode Menu
Local mode : DUAL Active line
------------------------------
▶1 Venting period Venting period menu
·········
▶2 DUAL
▶3 QUADRO

The display for DUAL control mode flashes.
89 psi 08:15 176 °F
5.3 Control mode Menu
Local mode : QUADRO Active line
------------------------------
▶1 Venting period Venting period menu
·········
▶2 DUAL
▶3 QUADRO
4. Use «UP» to change the regulating mode to QUADRO .


7 Initial Start-up
7.6.2 Adjusting the idle time of DUAL mode

The machine is READY when the specified idle time has elapsed.
The shorter the period, the more often the machine will switch from IDLE to READY.
SIGMA CONTROL 2 will take into account the maximum motor switching capacity.
Depending on the machine type, the machine's motor may not fall below a minimum idling or
standstill time.

The control mode is selected.
1. Press «Enter».
2. Select the < Configuration ➙ Control mode ➙ DUAL > menu. (See section 7.6.1)
The setting for idle time is shown in the active line.
89 psi 08:15 176 °F
5.3.2 DUAL Menu
Idle period
Target 240 s ¦ Actual 0 s Active line

The current idle time of 240 s flashes.
89 psi 08:15 176 °F
5.3.2 DUAL Menu
Idle period
Target 300 s ¦ Actual 0 s Active line with changed idle time, (example: 300
seconds)
4. Use «UP» to change to the desired idle time.

7.6.3 Adjusting the minimum running and unloaded period in QUADRO control
mode
When the minimum running period has elapsed, the machine switches from IDLE to READY. De‐
pending on the setting for the unloaded period, the machine switches first from LOAD to IDLE or
directly to READY.

7 Initial Start-up
7.7 Activating the settings for the refrigerated dryer

QUADRO control mode is selected.
1. Press «Enter».
2. Select the < Configuration ➙ Control mode ➙ QUADRO > menu.
3. Press «DOWN» repeatedly until Target is displayed as the active line.
89 psi 08:15 176 °F
5.3.3 QUADRO Menu
Min. run period
Target 240 s ¦ Actual 0 s Active line setpoint value for minimum run-time
·········
Unloaded period
Target 240 s ¦ Actual 100 s

The setpoint value 240 s flashes.
89 psi 08:15 176 °F
5.3.3 QUADRO Menu
Min. run period
Target 260 s ¦ Actual 0 s Active line with changed setpoint value for minimum
run-time
·········
Unloaded period
Target 260 s ¦ Actual 100 s Changed setpoint value for unloaded period
5. Use «UP» to change the minimum run-time.

7. Change the unloaded period accordingly.
Further information See chapter 4.7 for an overview of the control modes.

Overview:
■ Set the operating mode
■ Output messages

7 Initial Start-up
■ Procedures following a fault of the refrigerated dryer:

─ Compressed air quality has priority
Call KAESER Service immediately
■ Procedures following a fault of the refrigerated dryer:
─ Compressed air quantity has priority,
Activate fault mode without refrigerated dryer
➤ It is mandatory to follow the procedures indicated according to the priorities established for the
compressed air quality or compressed air quantity!
7.7.1 Setting the CLOCK mode

You may select either CONTINUOUS or CLOCK mode for controlling the refrigerated dryer.
If the CLOCK setting is used, the refrigerated dryer is shut-down under timing control whenever
compressed air is not required.
The operating temperature in the refrigerated dryer is kept constant within narrow limits under this
method of control by cycling the refrigerant circulation.
2. Select the < Configuration ➙ Refrigeration dryer > menu.
The < Refrigeration dryer > menu is displayed.
89 psi 08:15 176 °F
5.9 Refrigeration dryer Menu
Control mode Active line
Compressor ready:
Continuous
Compressor Clk/RC/RB off:
off
·········

The Continuous line is displayed as being active.
Display flashes.
89 psi 08:15 176 °F
Control mode
Compressor ready:
Continuous Active line
off
·········
5. Press «UP» once.

The Clock mode is displayed.

7 Initial Start-up

89 psi 08:15 176 °F
Control mode
Compressor ready:
Timer Active line
off
·········
Result The CONTINUOUS operating mode has been switched to CLOCK.
7.7.2 Output messages

If required, you can activate messages regarding the operating temperature of the refrigerated dry‐
er as a binary signal.
You can assign to DOR or DOT.
If you have correctly parameterized, ok will be displayed.

The < Configuration ➙ Refrigeration dryer > menu is selected.
1. Press «DOWN» repeatedly until Temperature ↑ is displayed as the active line.

89 psi 08:15 176 °F
Temperature ↑ Active line, temperature high
DOR 1.07 ☐ ¦ Logic : +
DOT 1.01 ☐ ¦ Logic : +
Temperature ⇟
DOR 1.03 ☐ ¦ Logic : +
DOT 2.01 ☐ ¦ Logic : +

4. Choose a spare DOR with the «UP» key.
89 psi 08:15 176 °F
Temperature ↑ Temperature high
DOR 1.05 ☐ ¦ Logic : + Active line, example: DOR selected
DOT 1.01 ☐ ¦ Logic : +
Temperature ⇟
DOR 1.03 ☐ ¦ Logic : +
DOT 2.01 ☐ ¦ Logic : +

7 Initial Start-up

8. Press «UP».
ok is displayed in the active line.
89 psi 08:15 176 °F
Temperature ↑ Temperature high
DOR 1.05 ok ☑ ¦ Logic : + Active line
DOT 1.01 ☐ ¦ Logic : +
Temperature ⇟ Temperature low
DOR 1.03 ☐ ¦ Logic : +
DOT 2.01 ☐ ¦ Logic : +
10. Proceed in the same manner when configuring the Temperature ⇟ message.
Upon activation of the check box, err is displayed.
➤ The parameterization is incorrect.
➤ Assign another and/or free output.
7.7.3 Fault in the refrigerated dryer

After a fault occurs in the refrigerated dryer, the SIGMA CONTROL 2 will shut the machine down.
No compressed air is delivered.
Because compressed air quality is decisive factor (dried compressed air), you must call KAESER
Service immediately. An authorized KAESER service representative eliminates the fault and exe‐
cutes a reset.
Precondition The operator decides: Compressed air quality has a higher priority than the compressed air quanti‐
ty
1. Keep machine shut down because the required compressed air quality is no longer delivered.
2. Immediately contact KAESER service.
An authorized KAESER service representative eliminates the fault and executes a reset.
The machine is ready for the delivery of high-quality, dried compressed air.
7.7.4 Fault in the refrigerated dryer – activate fault mode
Higher residual humidity in the compressed air!

Higher residual humidity in the compressed air accelerates corrosion.
➤ Carefully assess a "Fault mode without refrigerated dryer" in respect to the further use of
the compressed air.

7 Initial Start-up
After a fault occurs in the refrigerated dryer, the SIGMA CONTROL 2 will shut the machine down.
In order to ensure compressed air delivery for a defined period of time, the operator can activate
the "fault mode without refrigerated dryer" function. The quality of the compressed air (dried com‐
pressed air) is compromised in this case. The 0069 Error operation without RD → Call service!
warning message is displayed. The 0069 warning message remains active for the entire time of
operation in fault mode.
Precondition The operator decides: Compressed air quantity has a higher priority than the compressed air quali‐
ty
The < Configuration ➙ Refrigeration dryer > menu is selected.
1. Press «DOWN» repeatedly until Error operation without RD is displayed as the active line.
89 psi 08:15 176 °F
·········
Error operation without RD Active line
active: ☐
Run time max.: 8h Running time (fixed)
Actual
2. Press the «DOWN» key.

The check box for activation of the fault mode is displayed as the active line.
89 psi 08:15 176 °F
·········
Error operation without RD
active: ☐ Active line
Actual

4. Press «UP».
89 psi 08:15 176 °F
·········
Error operation without RD
active: ☑ Active line
Actual

7 Initial Start-up
7.8 Configuring the machine for local mode
Result "Fault mode without refrigerated dryer" is activated.

The compressor provides compressed air for connected consumers.
The compressed air delivered in this mode contains a higher residual humidity because the func‐
tion of the refrigerated dryer is defective.

In local mode, the machine is regulated with the system setpoint pressure pA or pB. The controller
is provided with the following modes of operation:
Operating Description See

mode section
pA The machine is controlled by the system setpoint pressure pA. 7.8.3.3
pB The machine is controlled by the system setpoint pressure pB.
pA/pB Clock The changeover between the system setpoint pressures pA and pB 7.8.2
is regulated by a timer program.
pA/pB Cycle The changeover between the system setpoint pressures pA and pB 7.8.3
is regulated by a programmed time pulse.
Tab. 59 Local operating mode (local mode)
➤ Adjust the system setpoint pressure as described in Section 7.4.

Overview
■ Enter access level 2.
■ Select < Configuration >.
■ Set/adjust the clock program (see section 7.8.2)
or
Set/adjust the clock (see section 7.8.3)
■ Local mode
7.8.1 Selecting the < Configuration ➙ Pressure control ➙ Load control > menu
The < Load control > menu is displayed.
7.8.2 Configuring the system pressure setpoint changeover using the clock program
Note the configuration sequence:
➤ First, determine the clock program.
➤ Then select the operating mode.
Overview
■ Set the day of the week for the first switching point (delete any existing clock program).
■ Enter the time of the first switching point.

7 Initial Start-up
■ Select the system setpoint pressure for the first switching point pA or pB.
■ Define further switching points.
■ Select the pA/pB Clock operating mode, see Section 7.8.3.3.
When setting a clock program for the first time, note first the switching times on a sheet of
paper.
In addition to individual weekdays, the controller has the following cycles:

■ Mon-Thu
■ Mon-Fri
■ Mon-Sat
■ Mon-Sun
■ Sat-Thu
Example:
■ Peak load period: Weekdays 06:30 – 17:00, Fridays 06:30 – 16:00;
■ Low load period: Midday from 12:00 – 13:00 and the remaining period.
The clock program is established with the following switching points (maximum 10 switching points
available):
No. Weekday Time System setpoint pres‐

sure
01 Mon-Fri 06:30 pA on
02 Mon-Fri 12:00 pB on
03 Mon-Fri 13:00 pA on
04 Mon-Thu 17:00 pB on
05 Fri 16:00 pB on
Tab. 60 Example of system pressure changeover switching points
Setting the day of the week for the first switching point

The < Configuration ➙ Pressure settings ➙ Load control > menu is selected (see Section 7.8.1).
1. Press «DOWN» repeatedly until pA/pB Clock is displayed as the active line.
2. Press «Enter».
The system displays the setting options for the switching points.
89 psi 08:15 176 °F
5.2.3.1 pA/pB Clock Menu
·········
01 n.a. 00:00 pA
02 n.a. 00:00 pA
03 n.a. 00:00 pA
04 n.a. 00:00 pA
05 n.a. 00:00 pA

7 Initial Start-up

n.a. flashes in the active line.
89 psi 08:15 176 °F
·········
01 Mon-Fri 06:30 pA Active line (settings for weekdays, time, pA)
02 Mon-Fri 12:00 pB (Settings for weekdays, time, pB)
03 Mon-Fri 13:00 pA
04 Mon-Thu 17:00 pB
05 Fri 16:00 pB
4. Use «DOWN» or «UP» to set the weekdays and confirm by pressing «Enter».
6. Press «Enter» once.
The column time, display for hours, 00: 00 in the active line flashes.
7. Use «UP» or «DOWN» to change the hour setting.
9. Column, minutes display, 00 00 flashes in the active line.
10. Use «DOWN» or «UP» to set the time (minutes) and confirm by pressing «Enter».
12. Press «Enter».
The display for the system setpoint pressure pA/pB flashes.
13. Use «UP» or «DOWN» to change the setting for pA or pB.
Deleting the existing clock program
Take the following steps to delete an existing clock program:

The < Configuration ➙ Pressure settings ➙ Load control > menu is selected.
1. Press «DOWN» repeatedly until pA/pB Clock is displayed as the active line.
2. Press «Enter».
The current clock program is displayed.
3. Press the «UP» repeatedly until Reset is displayed as the active line.
89 psi 08:15 176 °F
Reset: ☐ Active line
·········
01 Mon-Fri 06:30 pA
02 Mon-Fri 12:00 pB
03 Mon-Fri 13:00 pA
04 Mon-Thu 17:00 pB

7 Initial Start-up

The Reset check box flashes.
5. Press «UP».
The check box is activated.
Result The clock program is now deleted.
Selecting the operating mode

2. Press «Enter» and use the «DOWN» or «UP» key to select pA or pB (not required in this ex‐
ample).
3. Set up the remaining switching points in the same way.
The clock program is now finished.
4. Select the pA/pB Clock operating mode, see Section 7.8.3.3.
7.8.3 Configuring the system pressure setpoint changeover using the clock
Overview
■ Delete the old clock configuration, if necessary
■ Set clock periods pA and pB
■ Select starting time for pA or pB.
■ Select the pA/pB Cycle operating mode, see Section 7.8.3.3.
7.8.3.1 Setting clock periods pA and pB
Keep to the order of the configuration. The operating mode pA/pB Cycle must not be activat‐
ed when configuring the timer period.
➤ Configure the clock first and then select the operating mode or select another operating
mode first.

The < Configuration ➙ Pressure control ➙ Load control > menu is selected.
1. Press «DOWN» repeatedly until the Settings pA / pB menu section is displayed as the active
line.
pA flashes.
3. Press the «UP» repeatedly until the desired clock period is displayed as the active line.

7 Initial Start-up

89 psi 08:15 176 °F
pA/pB Cycle
pA : 10 h – 10 h pB : 18 h – 18 h Active line, manually set setpoint value – automati‐
cally elapsing value (example)
1.Start pA ¦ 00:00
·········
5. Set the timer period for pB in the same manner.

Result The timer period for the system setpoint pressure pA and pB is set.
7.8.3.2 Setting starting time for pA or pB

The starting time h flashes.
89 psi 08:15 176 °F
pA/pB Cycle
pA : 10 h – 10 h pB : 18 h – 18 h
1.Start pA ¦ 06:30 Active line, starting time
·········
4. Press «UP» to set the hours.

The starting time min flashes.
6. Press «UP» to set the minutes.
Result The starting time for pA is set.
The period is to start with pB.

➤ Press «Enter» and specify the first start pB with «UP».
7.8.3.3 Selecting local mode

The clock program or timer is set up.

7 Initial Start-up
7.9 Configuring the machine for master control
1. Press «UP» repeatedly until Local mode is displayed as the active line.
Operating mode flashes.
89 psi 08:15 176 °F
Local mode pA/pB Cycle Active line
·········
Remote mode : pA
Key remote : ☐
·········
current pA/pB Cycle Display of the current operating mode
3. Press the «UP» or «DOWN» key to select the required operating mode (pA, pB, pA/pB Clock
or pA/pB Cycle).
The actual operating mode is displayed.
Result The clock is fully configured.

7.9.1 List of the various master controllers
The machine controller is provided with several methods of working under other controllers.
Method Description Section

Master control with Profibus The controller (and therefore the compressor) 7.9.2
(requires an additional module) receives the instruction LOAD, IDLE or local
operation via the Profibus master (e.g.
SIGMA AIR MANAGER or VESIS). The system
setpoint pressures pA and pB are irrelevant for
the LOAD/IDLE signals.
Master control of two compressors with 2 The SIGMA CONTROL 2 controllers operate 7.9.4
SIGMA CONTROL 2 via Ethernet inter‐ as master and slave. The slave receive the
face command to switch between the two system
setpoint pressures pA and pB from the master.
Master control via LOAD remote contact. LOAD remote contact 7.9.5
Master control via a LOAD remote con‐ An input signal from a superordinate controller
tact is another method of controlling the switches the machine to LOAD or IDLE. The
machine externally. There are 2 possibil‐ setpoint pressure settings pA and pB have no
ities: relevance.
Local/LOAD remote contact: 7.9.6
Using two inputs, a master controller (e.g.
MVS 8000) switches the machine between
LOAD/IDLE and local operation.

7 Initial Start-up
Method Description Section

Setpoint pressure pre-selection pA/pB remote contact: 7.9.7
An input contact provides the signal to switch
from the system setpoint pressure pA to pB.
Master control of compressors regulated On machines with the same FAD, 7.9.8.1
by pressure switch SIGMA CONTROL 2 controls the pressure
There are two possibilities of linking to a switch via a floating relay output.
machine regulated by pressure switch: On machines supplying an unequal FAD, the 7.9.8.2
pressure ranges are matched to each other.
Tab. 61 Master control – overview
Further information Examples of clock programs for equal machine loading are given in section 7.9.9.
7.9.2 Configuring Profibus mode (SIGMA AIR MANAGER or VESIS)

Overview
■ Profibus DP-V0 Retrofit Kit required
■ Establishing the electrical connection
■ Set the remote operating mode pB.
■ Configure the Profibus interface
■ Activate the «Remote control» key
Precondition Profibus DP-V0 Retrofit Kit required
Making the electrical connections
Pin Connections
1 Spare
2 Spare
3 Profibus connection B
4 TTL signal RTS
5 Ground
6 +5 V for bus terminal
7 Spare
8 Profibus connection A
9 Spare
Tab. 62 Profibus DP pin connection

7 Initial Start-up
Wiring the interface plug
Fig. 26 Profibus plug wiring

1 Terminal 1A 4 Terminal 2B
2 Terminal 1B 5 Slide switch, terminating resistor
3 Terminal 2A

7 Initial Start-up
Wiring possibilities for master control (excerpt)
Fig. 27 Electrical diagram example with SIGMA AIR MANAGER
7 Initial Start-up
1. Connect the bus subscribers one after the other according to the pin assignment below.
2. Connect the screening to the plug housings at both ends.
3. Switch in the terminating resistor in the plugs of the first and last subscribers to the Profibus.
Result The terminals for the remaining bus conduit (2A/2B) are switched off.
Setting the remote operating mode pB.
When automatic mode is changed to manual mode at the master controller,

SIGMA CONTROL 2 changes into the set remote mode. In such a case it is preferable to set
the operating mode to "remote mode pB".
➤ Note that multiple machines may be set to local operation when you set the system set‐
point pressure pB.

Menu < Configuration ➙ Pressure control ➙ Load control > is selected.
1. Press «DOWN» repeatedly until Remote mode is displayed as the active line.
The operating mode display flashes.
89 psi 08:15 176 °F
Local mode pA
·········
Remote mode : pB Active line
Key remote : ☑
·········
▶1 pA/pB Clock
3. Use «UP» or «DOWN» to set pB operating mode.

Remote operating mode pB is set.
5. Adjust the system setpoint pressure pB, if necessary.
Further information See chapter 7.4 for system setpoint pressure adjustment.
7.9.2.1 Inserting the communication module
The SIGMA CONTROL 2 communication interface is sealed with a plastic cover when shipped
from the factory. Before you can insert the communication module in the X4 interface, you must
remove the plastic cover from the SIGMA CONTROL 2 . The designation of the interfaces is pro‐
vided on the rear of the SIGMA CONTROL 2.
Material Small screwdriver

Torx screwdriver, size 9
Precondition The machine is disconnected from the power supply.

The absence of voltage has been verified.
➤ Work carefully.

7 Initial Start-up
Proper removal of the plastic cover
Fig. 28 Communication interface

1 Designation of the interfaces 6 Communication interface X4 (customer in‐
2 Rear side of the controller terface)
SIGMA CONTROL 2 7 Plastic cover
3 Ethernet interface X1 8 Fin
4 IO BUS X2 9 Communication interface X4 without plastic
5 RS485–FC (USS interface) X3 cover
1. Place the screwdriver next to the fin.

2. Insert the tip into the slot between the plastic cover and the enclosure of the
SIGMA CONTROL 2.
3. Press the screwdriver down until the fin breaks.
4. Break all other fins in the same manner.
5. Remove the plastic cover.
Inserting and fixing the communication module

Align the communication module until both cable connectors are at the same height.
Precondition The plastic cover is removed.
Fig. 29 Insert the communication module.

1 Bay, interface X4 5 Cable connector, communication module
2 Cable connector, interface X4 6 Communication module
3 Guiding plate 7 Front plate
4 Recess, module bay

7 Initial Start-up
1. Align the communication module.

2. Insert the communication module into the bay of interface X4 until it latches (see Fig. 29)
The module is correctly installed when its front plate is seated solidly in the recess of the mod‐
ule bay.
3. Tighten both screws.
7.9.2.2 Activating operation via Profibus
Overview:
■ Set the slave number
■ Set reaction for a bus fault
■ Activate the communications module
■ Activate the remote mode
Precondition The communication module is plugged and screwed into the X4 interface.
The bus is wired to the bus master.
The machine's voltage supply is activated.
The machine is parameterized as a slave in the bus master.
The bus master is operational.
Fig. 30 Front plate of the PROFIBUS communication module

1 PROFIBUS communication module 3 Status
2 Operation indicator 4 PROFIBUS interface
➤ Proceed as shown.
Setting the slave number
You only need to set the slave address for the communication with the
SIGMA AIR MANAGER.
The other parameters do not require adjustment.
When connected to a SIGMA AIR MANAGER, the slave address is determined as follows:
Compressor number used at the SIGMA AIR MANAGER +102.

7 Initial Start-up
2. Select the < Communication ➙ Com-Module > menu.

The < Com-Module > menu is displayed.
89 psi 08:15 176 °F
8.2 Com-Module Menu
Status Counter 0 Active line
Com module not recognised
·········
Type None
Com-Module Start : ☐
Reset: ☐
3. Press «DOWN» six times.

The Slave line is displayed as the active line.
89 psi 08:15 176 °F
8.2 Com-Module Menu
Type Profibus Detected communication module
Reset: ☐
Slave No. : 103 Active line
·········
Bus alarm

The Slave display flashes.
89 psi 08:15 176 °F
8.2 Com-Module Menu
Reset: ☐
Slave No. : 102 Active line
·········
Bus alarm
Result Slave address 102 is set.
Setting the reaction for a bus fault
Exchange of data with a Profibus connection takes place in fixed cycles. The Profibus connection
can be monitored with the help of the cycle time:
The bus connection is considered to be interrupted if no data is exchanged between the bus mas‐
ter and the controller (as bus subscriber) after the expiry of a set time period (time-out).
Time-out monitoring is activated. You may neither adjust nor deactivate time-out for
SIGMA AIR MANAGER.

7 Initial Start-up
After switching on the power supply, the bus alarm can be suppressed temporarily.
■ Settings for SIGMA AIR MANAGER without SIGMA AIR CONTROL PLUS
─ Start: 30 seconds
■ Settings for SIGMA AIR MANAGER with SIGMA AIR CONTROL PLUS
─ Start: 40 seconds
1. Press «DOWN» five times.

The Start line is displayed as the active line.
89 psi 08:15 176 °F
8.2 Com-Module Menu
Reset: ☐
Slave No. : 102
·········
Bus alarm
Start td : 30 s Active line
Timeout : 5 s ☑

Activate the communications module
1. Press «UP» five times.

The Com-Module Start line is displayed as the active line.
89 psi 08:15 176 °F
8.2 Com-Module Menu
Status Counter 0
Com module not recognised
·········
Type None
Com-Module Start : ☐ Active line
Reset: ☐
3. Press «UP».

7 Initial Start-up

The communication module is activated.
89 psi 08:15 176 °F
8.2 Com-Module Menu
Status Counter 1 Status counter 1 is displayed.
No error
·········
Com-Module Start : ☑ Active line
Reset: ☐
Activate the «Remote control» key
2. Select < Communication >.
The < Communication > menu is displayed.
89 psi 08:15 176 °F
8 Communication Menu
▶1 Ethernet Active line
▶2 Com-Module
Key remote : ☐

The «Remote control» key is displayed as the active line.
5. Press «UP» once.
The «Remote control» key is activated.
89 psi 08:15 176 °F
▶1 Ethernet
▶2 Com-Module
Key remote : ☑ Active line
7. In order to activate the remote control, press «Remote control» on the operating panel of
SIGMA CONTROL 2.
Result The green LED of the «Remote control» key illuminates.

7 Initial Start-up
The bus master can remotely control the SIGMA CONTROL 2.
7.9.3 Configuring the Profibus interface without SIGMA AIR MANAGER or VESIS
Contact KAESER Service for information on configuring the Profibus interface if Profibus is to
be used.
Overview
■ Selecting the Profibus interface
■ Assigning the slave address
■ If necessary, setting suppression time for bus fault
■ Activating the communications module
■ Assigning an output contact for the bus fault message (spare output can be found in the electri‐
cal diagram)
Precondition Communications module from Profibus DP-V0 retrofit kit is installed.

The electrical connection to the bus master is made.
The required data has been provided by KAESER.
Selecting the Profibus interface
1. Press «Enter».
2. Press «DOWN» repeatedly until < Communication > is displayed as the active line.
3. Press «Enter».
The < Com-Module > menu is displayed as the active line.
89 psi 08:15 163 °F
▶1 Ethernet
▶2 Com-Module Active line
Key remote : ☑

7 Initial Start-up
5. Press «Enter».
The Status line is displayed as the active line.
89 psi 08:15 176 °F
8.2 Com-Module Menu
Status Counter 0 Active line
No error
------------------------------
Type Profibus Displayed communication module
Slave No. 103
Assigning the slave address
The permissible address length is between 3 and 126.

For the configuration of the Profibus interface without SIGMA AIR MANAGER or VESIS, the
rule "compressor number +102” does not apply.
1. Press the «DOWN» key repeatedly until Slave is displayed as the active line.
The slave display flashes.
89 psi 08:15 176 °F
8.2 Com-Module Menu
Status Counter 0
No error
------------------------------
Type Profibus
Slave No. 103 Active line, current slave address assigned
3. Set the slave address with «UP» or «DOWN».

Result The slave address is assigned.
Further steps
Proceed with the further configuration as outlined in chapter 7.9.2:

➤ If required, also set the suppression time for the bus fault.
7.9.4 Configuring for master control of two machines in master/slave operation

(Ethernet interface)
Two machines with SIGMA CONTROL 2 work as master/slave in the same air network. The mas‐
ter controls the machine configured as a slave and provides the signal for the system pressure set‐
point.

7 Initial Start-up
Example: Two machines with different delivery quantities

Local operating mode of the master: Local mode pA/pB Clock.
■ Toggles between system pressure setpoints pA and pB by a clock program.
■ At peak load times, pressure is regulated to system set-point pressure pA.
During periods of low air demand, pressure is regulated to system setpoint pB (e.g., at week‐
ends).
■ The machine with the lesser air delivery is the slave.
In times with lower air demand, the machine with the smaller delivery is used more frequently.
Example: Two machines with equal delivery quantities

■ Local operating mode of the master: Local mode pA/pB Cycle.
(Toggles between system pressure setpoints pA and pB by a clock).
The clock ensures even loading of both machines. The system pressure setpoints are set the
same for both machines.
■ During timer period 1, the master regulates to pA and signals the slave for pB.
During timer period 2, the master regulates to pB and signals the slave to pA.
If two machines 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 63 .
Controller Procedure Chapter

Both Establishing the electrical connection 7.9.4.1
Both Set system pressure setpoints pA and pB. The pressure for switch‐ 7.9.4.2and7.9.4.3
ing points pA and pB is measured directly at the compressor. Pres‐
sure losses in the network do not need to be taken into account.
Master Either set up switching times for the clock program 7.9.4.2
or set switching times for the clock 7.9.4.2
Master Set the type of LOAD control (clock program or clock) in local mode. 7.9.4.2
Slave Set remote mode: pA/pB SC2 7.9.4.3
Slave Activate the «Remote control» key 7.9.4.3
Both Set IP addresses for Ethernet 7.9.4.2and7.9.4.3
Both Activate controller as master or slave 7.9.4.2and7.9.4.3
Tab. 63 Master-slave configuration procedure
7.9.4.1 Establishing the electrical connection
Prepare the following for the Ethernet connection:
■ Ethernet cable, 100 m maximum, depending on connection.

■ For each machine with SIGMA CONTROL 2 :
─ Ethernet connector set
■ For connecting the machines to a network (LAN):
─ 2 Ethernet connection plugs
➤ Make the electrical connections as shown in the table below.

7 Initial Start-up
Installing the Ethernet cable
Use a cross-link Ethernet cable for the direct connection of two machines.
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-link cable
➤ Install the Ethernet cable between the two machines.

For connecting the machines to a network (LAN):
➤ Install the Ethernet cable from each machine to the next LAN connection.
Connecting 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. Install the Ethernet bus plug at the cable end.
4. Push the bus plug into the Ethernet interface X1 of the SIGMA CONTROL 2 until it latches.
For connecting the machines to a network (LAN):
Connect the Ethernet cable for each machine to the LAN connection.
1. Install the Ethernet bus plug at the cable end.
2. Push the bus plug into the LAN socket until it latches.
7.9.4.2 Configuring the controller of machine 1 as master
Precondition The electrical connection is made.

7 Initial Start-up
Set the switching points pA and pB
The switching point pA is displayed as the active line.
The display of switching point pA flashes.
3. Use «UP» or «DOWN» to set the required value.
The switching point pB is displayed as the active line.
6. Proceed as described for switching point pA.
Deactivating the «Remote control» key
1. Select the < Configuration ➙ Pressure control ➙ Load control > menu.
Local mode line is displayed as the active line.
2. Press «DOWN» three times.
4. Press «UP» key to deactivate the check box.
Setting the times
SIGMA CONTROL 2 provides the following options for selecting times:
■ Clock program, or
■ Timer
1. Decide your desired method.

2. Apply the corresponding settings (table).

7 Initial Start-up
Setting a clock program Setting the timer

1. Select the < Configuration ➙ Pressure 1. Select the < Configuration ➙ Pressure
control ➙ Load control > menu. control ➙ Load control > menu.
2. Press «DOWN» five times. 2. Press «DOWN» eight times to define the
3. Press «Enter» to open the < pA/pB Clock > timer period for system setpoint pressure pA
menu. and pB.
4. Press «Enter» to switch into the setting 3. Press «Enter» to switch into the setting
mode for the first switching point. mode for the system setpoint pressure pA.
5. Use «UP» or «DOWN» to set the week‐ 4. Use «UP» or «DOWN» to set the timer peri‐
days. od for the system setpoint pressure pA.
6. Press «Enter» to accept the setting. 5. Press «Enter» to accept the setting.
7. Press «Right» to set the time. 6. Press the «Right» key.
8. Press «Enter» to switch into the time setting 7. Press «Enter» to switch into the setting
mode. mode for system setpoint pressure pB.
9. Use «UP» or «DOWN» to set the hours. 8. Use «UP» or «DOWN» to set the timer peri‐
od for the system setpoint pressure pB.
10. Press «Right» to set the minutes.
11. Use «UP» or «DOWN» to set the minutes.
12. Press «Enter» to accept the time settings.
11. Press «Enter» to switch into the setting
13. Press «Right» to set the system setpoint
mode for the first start of system setpoint
pressure.
pressure pA or pB.
14. Press «Enter» to switch into the setting
12. Use «UP» or «DOWN» to set the first start
mode for system setpoint pressure pA or
of system setpoint pressure pA.
pB.
15. Press «UP» or «DOWN» to set the system
setpoint pressure. 14. Press «Right» to set the starting time.
16. Press «Enter» to accept the setting. 15. Press «Enter» to switch into the setting
mode for the starting time.
16. Use «UP» or «DOWN» to set the hours.
17. Press «Right» to set the minutes.
18. Use «UP» or «DOWN» to set the minutes.
19. Press «Enter» to accept the settings for the
starting time.
IP configuration
If the controllers of both machines are linked directly, they must have different IP addresses.
Example:
■ Controller machine 1 (Master mode): 169.254.100.101
■ Controller machine 2 (Slave mode): 169.254.100.102
1. Select < Communication ➙ Ethernet ➙ IP configuration >.

2. Enter IP address for the slave.
3. Select < Communication ➙ Ethernet ➙ Connections ➙ SIGMA CONTROL 2 >.
6. Use «UP» to et the controller of machine 1 to “Master”.

7 Initial Start-up

8. Press «DOWN» four times.
10. Enter the IP address of the communication partner (slave).
7.9.4.3 Configuring the controller of machine 2 as slave
Precondition The electrical connection is made.

The < Configuration ➙ Pressure control ➙ Pressure settings > menu option is selected.
Set the switching points pA and pB
The switching point pA is displayed as the active line.
The display of switching point pA flashes.
3. Use «UP» or «DOWN» to set the required value.
The switching point pB is displayed as the active line.
6. Set the switching point pB in the same manner.
Activating the «Remote control» key
4. Press «UP» to activate the check box.
Setting the remote operating mode
Remote mode line is displayed as the active line.
4. Use «UP» or «DOWN» to set the required value for pA/pB SC2.
IP configuration
If the controllers of both machines are linked directly, they must have different IP addresses.

7 Initial Start-up
Example:
■ Controller machine 1 (Master mode): 169.254.100.101
■ Controller machine 2 (Slave mode): 169.254.100.102
1. Select < Communication ➙ Ethernet ➙ IP configuration >.

2. Enter IP address for the master.
3. Select < Communication ➙ Ethernet ➙ Connections ➙ SIGMA CONTROL 2 >.
6. Use «UP» to set the controller of machine 2 to “Slave”.
10. Enter the IP address of the communication partner (master).
7.9.5 Configuring for master control using the LOAD remote contact (e.g.,
SIGMA AIR MANAGER BASIC)
Overview
■ Making the electrical connection for LOAD remote contact
■ Setting the LOAD remote contact operating mode and assign the input
■ Adjusting the pressure increase pE, if necessary.
■ Activating the «Remote control» key
➤ Configuring master control as described below.

7 Initial Start-up
7.9.5.1 Making the electrical connection for remote LOAD contact
Machine (example)
Fig. 32 LOAD remote contact

1 Electrical connection DI 1.12 4 LOAD remote contact closed (LOAD)
2 LOAD remote contact open (IDLE) 5 SIGMA AIR MANAGER BASIC contacts
3 Electrical connection DI 1.12
➤ Making the electrical connection for DI 1.13 according to the diagram.
7.9.5.2 Setting the remote LOAD contact operating mode and assigning the input for LOAD remote contact

Set the LOAD remote contact operating mode
1. Press «UP» or «DOWN» repeatedly until Remote mode is displayed as the active line.
The Remote operation display flashes.
89 psi 08:15 176 °F
Local mode
·········
Remote mode : Load RC Active line, current operating mode
Key remote : ☐
·········
3. Use «UP» to select the LOAD remote contact operating mode.

Result The remote LOAD contact operating mode is set.

7 Initial Start-up
Assigning the input for LOAD remote contact
The input for the LOAD remote contact is preassigned.

Setting is only necessary if you deliberately want to use a different input.
1. Press «DOWN» repeatedly until Load RC is displayed as the active line.

The digital input display flashes.
89 psi 08:15 176 °F
pA/pB DO DOR 1.04 ☐
·········
Load RC DI 1.13 ok ☑ Active line; standard DI 1.13
loc.-load RC DI 1.09 ☐
·········
Key idle : ☑
3. Use the «UP» or «DOWN» keys to select the input for the LOAD remote contact.
5. Activate the check box for DI 1.13 .
ok is displayed.
Result The operating mode is now configured.
7.9.5.3 Adjusting pressure increase pE.
➤ Adjust the pressure increase pE as described in section 7.4.2.3.
Further information Detailed information on the pressure parameters is provided in chapter 7.4.2.
7.9.5.4 Activating the «Remote control» key

1. Press «UP» repeatedly until Key remote is displayed as the active line.
The check box for Remote control flashes.
89 psi 08:15 176 °F
Local mode
·········
Remote mode : Load RC
·········

7 Initial Start-up

7.9.6 Configuring for master control with local/LOAD remote contact

Overview
■ Making the electrical connection
■ Setting the local/LOAD remote contact operating mode and assign the input.
■ Configuring the local operating mode, if necessary.
■ Activating the «Remote control» key
➤ Configuring master control as described below.
7.9.6.1 Making the electrical connection
Use the input “Controller On (DOR 1.03) for the "alarm machine X" message to prevent line
breaks!
➤ Wire the "motor running” and "Controller on” (DOR 1.03) messages from the compressor
to the MVS 8000 controller.
■ Contact A open: SIGMA CONTROL 2 controls with system setpoint pressurepB

■ Contact A closed: SIGMA CONTROL 2 controls using a remote contact input.
■ DI 1.13: LOAD/IDLE external
■ DI 1.09: LOAD control – switchover local/LOAD remote contact.
Fig. 33 Wiring diagram for local/LOAD remote contact:

A Changeover between automatic and manual modes
B LOAD/IDLE contact
➤ Make the electrical connection according to the diagram.
7.9.6.2 Setting the local/LOAD remote contact operating mode and assigning the input


7 Initial Start-up
Set local/LOAD remote contact operating mode:
1. Press «UP» repeatedly until Remote mode is displayed as the active line.
Remote mode flashes.
89 psi 08:15 176 °F
·········
Remote mode : loc.-load RC Active line, current operating mode
Key remote : ☐
·········
current pA
3. Use «UP» to select the loc.-load RC operating mode.

Result The local/LOAD remote contact operating mode is set.
Assigning an input for the local/LOAD remote contact for switching the pressure control
1. Press «DOWN» repeatedly until loc.-load RC is displayed as the active line.

DI flashes.
89 psi 08:15 176 °F
pA/pB DO DOR 1.04 ☐ No input assigned
·········
Load RC DI 1.13 ok ☑
loc.-load RC DI 1.09 ok ☑ Active line
·········
Key idle : ☑
3. Use «UP» to select a new input for local/LOAD remote contact.

Result The input for local/LOAD remote contact operating mode is assigned.
7.9.6.3 Setting local operating mode pB
System setpoint pressure pB is normally set for local operation.

➤ When setting the system setpoint pressure pB, bear in mind that, under certain circum‐
stances, more than one compressor may be operating in local mode (see section 7.4 for
adjusting the system setpoint pressure).


7 Initial Start-up

Setpoint pressure flashes.
89 psi 08:15 176 °F
Local mode pB Active line, current operating mode
·········
Remote mode : loc.-load RC
Key remote : ☐
·········
current pB
3. Use «UP» to select the pB operating mode.

5. Adjust the system setpoint pressure pB if necessary (see section 7.4).
Result The local operating mode pB is set.
7.9.6.4 Activating the «Remote control» key

1. Press «UP» or «DOWN» repeatedly until Key remote is displayed as the active line.
The check box for Key remote flashes.
89 psi 08:15 176 °F
·········
Remote mode : loc.-load RC
·········
current pB

Result The master control is fully configured.
7.9.6.5 Setting the LOAD remote contact operating mode and assigning the input


7 Initial Start-up
Setting the LOAD remote contact operating mode

1. Press «DOWN» repeatedly until Remote mode is displayed as the active line.
Remote mode flashes.
89 psi 08:15 176 °F
·········
Remote mode : Load RC Active line
Key remote : ☐
·········
▶1 pA/pB Clock
·········
3. Use «UP» to select the Load RC operating mode.

Result The LOAD remote contact operating mode is set.
Assigning an input for the LOAD remote contact for switching the pressure control
1. Press «DOWN» repeatedly until Load RC is displayed as the active line.

DI flashes.
89 psi 08:15 176 °F
·········
pA/pB RC DI 1.05 ☐
pA/pB DO DOR 1.04 ☐
·········
Load RC DI 1.13 ok ☑ Active line
loc.-load RC DI 1.09 ☐
3. Use «UP» to select a new input for LOAD remote contact.

Result The input for LOAD remote contact is assigned.
7.9.7 Configuring setpoint pressure pre-selection via remote contact

The signal to changeover from setpoint pressure pA to setpoint pressure pB comes from an input
contact. If there is a signal at the input then system pressure is regulated on setpoint pressure pB.
Overview
■ Setting up remote contact mode pA/pB

7 Initial Start-up
■ Assigning the remote contact input

■ Activating the «remote control» key
➤ Configure the setpoint pressure pre-selection as described.
7.9.7.1 Setting up remote contact mode pA/pB

The electrical connections are made,
1. Press «UP» repeatedly until Remote mode is displayed as the active line.
Display for remote mode flashes.
89 psi 08:15 176 °F
·········
Remote mode : pA/pB RC Active line, current operating mode
Key remote : ☐
·········
▶1 pA/pB Clock
·········
3. Use the «UP» key to select operating mode pA/pB RC.

Result Operating mode pA/pB remote contact is selected.
7.9.7.2 Assigning the remote contact input
A spare input can be found in the machine circuit diagram.

1. Press «UP» repeatedly until pA/pB RC is displayed as the active line.
DI flashes.
89 psi 08:15 176 °F
·········
pA/pB RC DI 1.05 ok ☑ Active line
pA/pB DO DOR 1.04
·········
Load RC DI 1.13 ok ☑
loc.-load RC DI 1.09 ok ☑ No input assigned
3. Use the «UP» key to select input pA/pB RC.

Result The input for remote contact has now been assigned.

7 Initial Start-up
7.9.7.3 Activating the «remote control» key

1. Press «UP» repeatedly until Key remote is displayed as the active line.
Check box flashes.
89 psi 08:15 176 °F
·········
Remote mode : pA/pB RC
·········
current pB

The «remote control» key can be used.
5. Press the «remote control» key to enable remote mode.
Result The operating mode is now configured.
7.9.8 Configuring master control of compressors regulated by pressure switch

➤ Configure the master control as previously described.
7.9.8.1 Configuring master control via floating relay contact
Requirement:
A machine with SIGMA CONTROL 2 (e.g. series BSD) and a conventional machine without
SIGMA CONTROL 2 of the same capacity are to run in sequence as base load or peak load ma‐
chines.
Proposal:
■ Set/adjust the clock program or clock on SIGMA CONTROL 2 .
■ Select local mode with time control pA/pB Clock or clock pA/pB Cycle.
■ Set the system setpoint pressures pA and pB analogous to the required values. They must be
identical to the pressure switch settings on the machine without SIGMA CONTROL 2 .
■ To make the setpoint changeover between the two machines possible, a floating relay contact
must be assigned to the selected local operating mode. An auxiliary contactor can be ener‐
gized via this contact to activate the pressure switches for pA and pB on the compressor with‐
out SIGMA CONTROL 2 . See the example wiring diagram below.
Overview
■ Making the electrical connection
■ Setting the system setpoint pressure pA and pB.
■ Configuring/adjusting the local operating mode

7 Initial Start-up
■ Assigning the floating relay contact

■ Setting local operating mode
Establishing the electrical connection
■ Contact A open: SIGMA CONTROL 2 controls with system setpoint pressure pB

■ Contact A closed: SIGMA CONTROL 2 controls with system setpoint pressure pA
■ B 1.1: Pressure switch for system setpoint pressure pB
■ B 1.2: Pressure switch for system setpoint pressure pA
-K3 A1
A2
07-S0629
Fig. 34 Machine with pressure switch regulation

A Floating relay contact SIGMA CONTROL 2
➤ Make the electrical connection according to the diagram.
Setting the system setpoint pressure pA and pB.
Precondition Access level 2 is activated,

The electrical connections are made.
1. Select menu < Configuration ➙ Pressure control ➙ Pressure settings > (see section 7.4.1).

7 Initial Start-up

Setpoint pressure pA flashes.
89 psi 08:15 176 °F
Setpoint pressure
pA SP : 124 psi ¦ SD : - 7 psi Active line
·········
System pressure low
↓ < 73 psi ¦ SD : 7 psi :
3. Use «UP» or «DOWN» to adjust the value.

5. Adjust the switching differential pA in the same manner.
6. If necessary, adjust the value for pB in the same way.
Configuring local mode
➤ Set the clock program or clock as described in section 7.8.
Assigning the floating relay contact (activate)

The electrical connection made (select spare contact from the machine's electrical diagram).

89 psi 08:15 176 °F
·········
pA/pB RC DI 1.10 ☐
pA/pB DO DOR 1.03 ☐ Active line, no output assigned
·········

Output display flashes.
4. Use «DOWN» or «UP» to select the required output (DOR).
This output can now be used for the changeover between the two pressure switches.
Setting local mode

7 Initial Start-up
The Local operation display flashes.
89 psi 176 °F
Local mode pA Active line, current local operating mode
·········
Remote mode : pA
Key remote : ☐
·········
▶1 pA/pB Clock
4. Use «UP» or «DOWN» to set pA/pB Clock or pA/pB Cycle operating mode.
5. Press «Enter» to accept the operating mode.
The actual operating mode is displayed.
7.9.8.2 Configuring the master control without an electrical connection
Requirement:
A high-capacity machine with SIGMA CONTROL 2 (e.g., BSD) is to work as base load machine. A
second machine (e.g., SK) without SIGMA CONTROL 2 is to supply air in times of low demand.
Proposal:
■ Select the system setpoint pressures pA and pB of the BSD machine for the switching point of
the SK machine's pressure switch to be in between. When pB is activated for the periods of
low demand, the SK machine automatically functions as the base load machine.
■ Set the required values for a clock program on SIGMA CONTROL 2 .
■ Select local mode pA/pB SC2 Clk.
■ Activate the compressor timer
Function diagram:
Time period t1–t7: high compressed air demand Time period t8–t14: low compressed air demand
t1 t8:
Air demand rises. Air demand rises.
System pressure pNloc drops. System pressure pNloc drops.
t2 t9:
BSD switches to LOAD. SK switches to LOAD.
t3: t10:
System setpoint pressure pA reached. System setpoint pressure pB reached.
BSD switches to IDLE. SK switches to IDLE.
t4: t11:
BSD switches to LOAD. BSD switches to LOAD.
Air demand not covered. Air demand not covered.
t5: t12:
SK also switches to LOAD. SK switches to LOAD.
System pressure pNloc starts to rise. System pressure pNloc starts to rise.

7 Initial Start-up
Time period t1–t7: high compressed air demand Time period t8–t14: low compressed air demand
t6: t13:
SK switches to IDLE. SK switches to IDLE.
t7: t14:
BSD switches to IDLE. BSD switches to IDLE.
Tab. 64 Function diagram
Fig. 35 Function diagram

SD Switching differential
p Pressure
t Time
Setting the system setpoint pressure pA and pB.
The < Pressure settings > menu is displayed.
2. Press «DOWN» repeatedly until Setpoint pressure pA SP is displayed as the active line.
89 psi 08:15 176 °F
Setpoint pressure
pA SP : 123 psi ¦ SD : - 7 psi Active line with system set-point pressure pA and
switching differential
pB SP : 119 psi ¦ SD : - 7 psi System pressure setpoint pB and switching differen‐
tial.
·········
System pressure low
< 73 psi ¦ SD : 7 psi

The display for system setpoint pressure pA flashes.
4. Use «UP» or «DOWN» to adjust the value.

7 Initial Start-up

6. Adjust the switching differential in the same way.
7. If necessary, adjust the values for system setpoint pressure pB in the same manner.
Configuring the clock program
The clock program for the example is set up using the following switching points: A maximum of 10
switching points are available:
No. Weekday Time System setpoint pressure

01 Mon-Fri 06:30 pA On
02 Mon-Fri 17:00 pB On
Tab. 65 Example switching points
Overview
■ Set the day of the week for the first switching point.
■ Set the time for the first switching point
■ Set the system setpoint pressure for the first switching point
■ Define further switching points.

The < Configuration ➙ Pressure settings ➙ Load control > menu is selected.
➤ Configure the switching program as described below.
Enter the weekday for the first two switching points
1. Press the «DOWN» key repeatedly until < pA/pB Clock > is displayed as the active line.
89 psi 08:15 176 °F
Local mode pA
·········
Remote mode : pA/pB SC2
Key remote : ☑
------------------------------
▶1 pA/pB Clock Active line
2. Press «Enter».
The < pA/pB Clock > menu is displayed.
3. If you want to delete an existing clock program, press «UP» until Reset: is displayed as the
active line.
The check box will flash.

7 Initial Start-up
5. Press «UP».
The check box is activated.
89 psi 08:15 176 °F
Reset: ☒ Active line, delete existing clock program
·········
01 n.a. 00:00 pA First switching point deleted
02 n.a. 00:00 pA Second switching point deleted
03 n.a. 00:00 pA Third switching point deleted
04 n.a. 00:00 pA Fourth switching point deleted

You have deleted the existing clock program.
All switching points are reset to pA .
The Reset check box is deactivated automatically.
7. Press the «DOWN» key repeatedly until the switching point 01 is displayed as the active line.
The Weekdays column flashes.
9. Press «UP» repeatedly until Mon-Fri appears.
89 psi 08:15 176 °F
Reset: ☐
·········
01 Mon-Fri 00:00 pB Active line, First switching point, set weekdays
02 Mon-Fri 00:00 pB Weekday Second switching point
03 n.a. 00:00 pB
04 n.a. 00:00 pB
11. Enter the weekdays for the second switching point in the same manner.
Result The weekdays for the first two switching points are set.
Set the time for the first two switching points
1. Press the «UP» key repeatedly until the switching point 01 is displayed as the active line.
The column time, display for hours, 00 : 00 in the active line flashes.
The column time, display for minutes, 00 : 00 in the active line flashes.

7 Initial Start-up

89 psi 08:15 176 °F
5.2.3.1 pA/pB Clock Weekday setting.
Reset: ☑
·········
01 Mon-Fri 06:30 pB Active line, time, first switching point
02 Mon-Fri 17:00 pB Time, second switching point
03 n.a. 00:00 pB
04 n.a. 00:00 pB
8. Enter the time for the second switching point in the same manner.
Result The times for the first two switching points are set.
Selecting the system setpoint pressure pA or pB for the first two switching points.
1. Press the «UP» key repeatedly until the switching point 01 is displayed as the active line.
2. Press the «Right» key twice.
The column for system setpoint pressure pA or pB is displayed.
The column for the system setpoint pressure flashes.
4. Use «UP» to specify the settings for the system setpoint pressure pA or pB.
89 psi 08:15 176 °F
5.2.3.1 pA/pB Clock Weekday setting.
Reset: ☑ Current start time
·········
01 Mon-Fri 06:30 pA System setpoint pressure for the first switching point
02 Mon-Fri 17:00 pB System setpoint pressure for the second switching
point
03 n.a. 00:00 pB
04 n.a. 00:00 pB
6. Enter the system setpoint pressure for the second switching point in the same manner.
Result Select the system setpoint pressure pA or system setpoint pressure pB for the first two switching
points.
Setting local mode
1. Select the < Configuration ➙ Pressure settings ➙ Load control > menu.
The Local mode mode is displayed as the active line.

7 Initial Start-up

The Local operation display flashes.
89 psi 08:15 176 °F
Local mode pA/pB Clock Active line
········· Current local mode
Remote mode : pA/pB SC2
Key remote : ☐
------------------------------
▶1 pA/pB Clock
3. Press «UP» repeatedly until Local mode pA/pB Clock appears.

Result The current local mode pA/pB Clock is set.
7.9.9 Examples of time settings for equal overall load

Requirement:
Two machines of the same capacity are to be equally loaded. Versions A, B and C describe the
different possibilities of achieving this requirement.
A detailed description for configuring a clock or timer program can be found in chapter 7.8.
Variant A: Daily switch between system set-point pressure pA and system set-point pressure pB
after 24 hours
The compressors start with a system set-point pressure pB at 00:00 hours. A timer triggers the
switch between system set-point pressurepA and system set-point pressure pB (local operating
mode: Local mode pA/pB Cycle).
Precondition The setpoint pressure pA/pB is configured the same for both machines.
➤ Establish a cycle with the following switching points:

■ Cycle time pA: 24 h
■ Cycle time pB: 24 h
■ Start pB: 01:00:00
Variant B: Equal duty cycle during the day
A timer triggers the switch between system set-point pressure pA and system set-point pressure
pB (local operating mode pA/pB Clock).
➤ The clock program is set up using the following switching points:
No. Weekday Time System set-point pressure

01 Mon-Sun 00:00 pA On
02 Mon-Sun 06:00 pB On

7 Initial Start-up
7.10 Configuring email

03 Mon-Sun 12:00 pA On
04 Mon-Sun 18:00 pB On
Tab. 66 Example for a clock program for equal duty cycling during the day
Variant C: Equal duty cycle during the week
A timer triggers the switch between system set-point pressure pA and system set-point pressure
pB (local operating mode: pA/pB SC2 Clk).
➤ The clock program is set up using the following switching points:

01 Mon 00:00 pA On
02 Mon 21:00 pB On
03 Tue 18:00 pA On
04 Wed 15:00 pB On
05 Thu 12:00 pA On
06 Fri 09:00 pB On
07 Sat 06:00 pA On
08 Sun 03:00 pB On
Tab. 67 Example for a clock program for equal duty cycling during the week

SIGMA CONTROL 2 uses email to send information (messages) to an email address.
For this purpose, an Ethernet connection with an SMTP server is required.
Overview
■ Select the menu < Communication ➙ Ethernet >.
■ Configure and activate the email function.
■ Set interval and suppress repeats.
Select menu
1. Select the menu < Communication ➙ Ethernet >.

7 Initial Start-up

E-mail submenu line is displayed as being active.
89 psi 08:15 176 °F
8.1 Ethernet Menu
▶1 IP configuration
▶2 Connections
▶3 E-mail Active line, submenu email
Configure and activate the email function

E-mail submenu is displayed as being active.
1. Press «Enter».
The display shows Email function as the active line.
The check box for the email function flashes.
3. Press «UP» to deactivate the email function.
The email function is deactivated.
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8.1.3 E-mail Menu
active: ☐ Active line; deactivate/activate email function
Compressor number: 1
Language: Deutsch Setting the language
------------------------------
Sender address:
status-kaeser@mdex.de
5. Set:
■ Compressor number
■ Language
■ Sender address
■ Sender's name
■ Telephone number of contact person
■ Recipient address
■ SMTP server:
─ Username
─ Password
6. Reactivate the email function.

7 Initial Start-up
7.11 Configuring input and output signals
Further setting options:
■ SMTP port
■ Timeout
■ Interval (repeats)
Result The email functions are configured and activated.
Suppress repeat messages (setting an interval)
To suppress messages repeating at short intervals, a period of 0 – 900 minutes can be set during
which a repeat of the same message is suppressed, i.e. is not sent.

E-mail submenu is displayed as being active.
1. Press «Enter».
2. Press «DOWN» repeatedly until Interval: is displayed as the active line.
The value for the time of suppression flashes.
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8.1.3 E-mail Menu
Password
·········
Port 25 ¦ Timeout 10 s
Interval: 5 min Active line
4. Use the «UP» or «DOWN» keys to set the desired duration of suppression.
Result Suppression interval is set.

The controller's binary and analog inputs and outputs can be used for other requirements.
This chapter deals with the various options in the following sections:
■ 7.11.1: Outputting important operational states of the compressors.
■ 7.11.2: Displaying analog input values
■ 7.11.3: Displaying additional binary input signals
The controller only allows assignment of spare inputs and outputs.

Any assignment of a preassigned input or output is discarded by the controller.
When delivered from the factory, the outputs DO0.3 to DO0.5 are available for assignment.
Further spare outputs can be found in the machine circuit diagram.
➤ Configure the inputs and outputs as described in the following.

7 Initial Start-up
7.11.1 Outputting important operational states of the machine

Important operational machine states can be made available as a binary signal via floating con‐
tacts.
Each output can be assigned only once.
The following messages can be returned:

Message Explanation Output
Controller on Controller is powered up
Compressor on The machine is switched on.
Motor running Compressor motor running
IDLE The machine is running in IDLE mode
ON LOAD The machine is running in LOAD mode
Group alarm Fault has occurred
Group warning Warning message has appeared
Remote mode Remote mode is activated
Clock active The clock is activated
Clock contact The clock contact is closed.
EMERGENCY STOP The «EMERGENCY OFF» button has been pressed
Tab. 68 Assigned output signals
Overview
Navigate to the < Configuration ➙ I/O periphery ➙ DO functions > menu for the configuration:
■ Access level 2 is activated.
■ Assigning a message to an output
7.11.1.1 Selecting the < Configuration ➙ I/O periphery > menu
2. Select < Configuration ➙ I/O periphery ➙ DO functions >.
A list of available messages and their assigned outputs is displayed.
89 psi 08:15 176 °F
Controller on Active line
DOR 1.05 ☐ ¦ Logic : +
DOT 1.02 ☐ ¦ Logic : +
Compressor on
DOR 1.03 ☐ ¦ Logic : +
DOT 1.02 ☐ ¦ Logic : +
7.11.1.2 Assigning a message to an output
1. Select the required message with the «DOWN» key.

7 Initial Start-up

The display of the selected message flashes.
89 psi 08:15 176 °F
Controller on
DOR 1.05 ok ☑ ¦ Logic : + Active line with assigned output
DOT 1.02 ☐ ¦ Logic : +
Compressor on
DOR 1.03 ☐ ¦ Logic : +
DOT 1.02 ☐ ¦ Logic : +
3. Select a free output with the «UP» or «DOWN» key.

7. Activate the check box.
If the message is correctly assigned to the output and activate, ok is displayed.
9. If necessary, set Logic.
A message is now sent via the assigned output.
You are missing an organized display of assigned output signals?
➤ Enter the selected output in table 68.
7.11.2 Displaying analog input values

The < Performance data > menu can display up to six values from analog measuring sensors of
pressure or temperature, for example.
Of these, two each are assigned to pressure and temperature transducers; two further inputs can
be assigned to freely selectable sensor types. A list of standard analog data that can be displayed
is found in chapter 8.7.
Overview
Navigate to the < Configuration ➙ I/O periphery ➙ Analogue values > menu for the configuration.
■ Select < Configuration ➙ I/O periphery ➙ Analogue values >.
■ Select display (display 1–6)
■ Edit sensor designation and unit of measure
■ Assigning the analog input
■ Selecting the type of signal (4–20 mA / 0–20 mA)
■ Assign a value range to the measurement signal (calibration)
Example:
The configuration is explained with the following example:
The signal value from a flow measuring device is to be displayed in the measured <data menu>.
■ Sensor designation: Volume flow 01.
■ The sensor is connected to analog input AII 1.03.

7 Initial Start-up
■ The sensor has a measuring range of 0 – 50 m3/h.

■ The sensor is operated with 4–20 mA.
7.11.2.1 Selecting the Analog data menu

The electrical connection is made.
1. Select menu < Configuration ➙ I/O periphery ➙ Analogue values > (see chapter 7.11).
89 psi 08:15 176 °F
5.7.2 Analogue values Menu
▶1 AnMod Active line
▶2 AI
▶3 AO

The menu for analog measuring devices is displayed as the active line.
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5.7.2 Analogue values Menu
▶1 AnMod
▶2 AI Active line
▶3 AO
3. Press «Enter».
The menu for pressure transducers, temperature sensors, and freely selectable sensor types is
displayed.
89 psi 08:15 176 °F
5.7.2.2 AI Menu
▶1 AI_p_1 Pressure transducer 1
▶2 AI_p_2 Pressure transducer 2
▶3 AI_T_1 Temperature sensor 1
▶4 AI_T_2 Temperature sensor 2
▶5 AI_I_1 Active line, flow rate sensor
▶6 AI_I_1 Freely selectable sensor type
5. Press «Enter».
Result The < AI_I_1 > menu is displayed.

7 Initial Start-up
7.11.2.2 Editing sensor designation and unit of measure
The display shows the line for the sensor designation as the active line.
2. Use the «UP» and «DOWN» keys to select characters from the character set in order to assign
a name to the sensor signal. There are 20 characters to choose from.
89 psi 08:15 176 °F
5.7.2.2.5 AI_I_1 Menu
Flow rate The line for sensor designation
AII 1.02 ☐ 0
·········
20mA : 16000
4mA : 0

5. Press the «Right» key twice.
The Unit display of the sensor flashes.
7. Use the «UP» and «DOWN» keys to select characters from the character set in order to assign
the unit to the sensor signal.
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5.7.2.2.5 AI_I_1 Menu
Volume flow 01. The line for sensor designation
AII 1.02 ☐ 0 m3/h Unit of measure
·········
20mA : 16000
4mA: 0
Result Editing sensor designation and unit of measure.
7.11.2.3 Assigning the analog input
1. Press «left» twice, until AII 1.02 is displayed.

The display of the analog input flashes.
3. Use «UP» to select AII 1.03.

7 Initial Start-up

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5.7.2.2.5 AI_I_1 Menu
AII 1.03 ☐ 0 m3/h Active line
·········
20mA : 16000
4mA: 0

The check box of the analog input flashes.
7. Activate the check box for AII 1.03.
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5.7.2.2.5 AI_I_1 Menu
AII 1.03 ok ☑ 123 m3/h Active line; the measured value is displayed
·········
20mA : 16000
4mA : 0

ok is displayed.
The measured value is displayed in the active line.
7.11.2.4 Determining the type of current signal (0/4–20 mA)

2. Press «Right» once to set the type of current signal.
As 4 -20 mA is preset, no further setting is needed.
7.11.2.5 Assigning a value range to the measurement signal (calibration)
The factory setting is a range from 0-16,000 that represents a signal current between 4–20 mA.
This value range has to be adapted to represent the measurement range of the sensor of 0–29
cfm.
1. Press «DOWN» once until 20 mA is displayed as the active line.

7 Initial Start-up

Quality range flashes.
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5.7.2.2.5 AI_I_1 Menu
AII 1.03 ok ☑ 123 m3/h Measured value prior to calibration
·········
20mA : 16000¦ 4mA: 0 Signal top range/signal bottom range
3. Press and hold the «DOWN» key and to set the top of the range to 50.
The quantity reduces initially in steps of units, then tens, hundreds and finally in thousands.
4. Using this method, reduce the value to 100 and then set to 50 with the «DOWN» key.
5. Press the «Enter» key to accept the value.
89 psi 08:15 176 °F
5.7.2.2.5 AI_I_1 Menu
AII 1.03 ok ☑ -12 m3/h Measured value after calibration
·········
20mA : 50¦ 4mA: 0 Signal top range/signal bottom range
6. Set the value for the bottom range (4 mA) to zero accordingly.
The measured value adjusts to the calibration.
Result The signal value from the sensor can now be displayed in the < Performance data > menu (see
chapter 8.7).
7.11.3 Displaying additional binary input signals

As well as the defined fault and warning messages there are six additional, freely selectable input
signals that can be used to display messages. A list of the defined fault and warning messages is
provided in chapters 9.2 and 9.5. Information on spare inputs is given in the machine circuit dia‐
gram.
An input signal can be classified as either a fault, a service 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
Navigate to the < Configuration ➙ I/O periphery ➙ External messages > menu for the configura‐
tion.
■ Enter the message text

7 Initial Start-up
■ Assign and activate the input

■ Set the time delay
■ Set the logic
■ Assign and activate the output
■ Select the message type (operational, fault, warning)
■ Activate the message.
7.11.3.1 Selecting the < External messages > menu
Precondition Access level 2 is activated,

The electrical connections are made.
2. Select < Configuration ➙ I/O periphery ➙ External messages > (see Section 7.11.1.1)
The External messages menu is displayed.
89 psi 08:15 176 °F
5.7.3 External messages Menu
▶1 External message 1 Active line with external message No. 1
▶2 External message 2
7.11.3.2 Entering the message text
External message 1 is shown as example.

1. Press «Enter».
External message 1 is displayed as the active line.
The display of the character set flashes.
3. Enter the individual message text.
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5.7.3.1 External message 1 Menu
External message 1 Message number
DI 1.11 ☐ No input assigned
td : 0 s ¦ Logic + Logic
DOR 1.04 ☐
Warning ☑ Message type (operational, alarm, warning)
7.11.3.3 Assign and activate the input
1. Press «DOWN» repeatedly until "Input" is displayed as the active line.

7 Initial Start-up

Input flashes.
3. Select the relevant input with the «UP» or «DOWN» keys.
89 psi 08:15 176 °F
External message 1 Message name
DI 1.11 ok ☑ Input is selected and activated
DOR 1.04 ☐
Alarm ☑ Example: Fault message type

ok is displayed.
The input is assigned and activated.
7.11.3.4 Setting the time delay
The delay can be set between 0.01 and 600 seconds. The delay is counted down from 600
with the «DOWN» key and counted upwards from zero in 0.01 second increments with the
«UP» key.
2. Press «Enter» to switch into the setting mode for the time delay.
The display for the delay time flashes.
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External message 1
DI 1.11 ok ☑
td :1 s ¦ Logic + Active line, set time delay
DOR 1.04 ☐
Alarm ☑
3. Select the required delay time with the «UP» key.

Result The delay time is set.

7 Initial Start-up
7.11.3.5 Setting the logic
Possible logic settings

Message at Symbol
24 V +
0V -
Tab. 69 Logic

2. Press «Enter» to switch into the logic setting mode.
The Logic display flashes.
3. Use «UP» to set the desired behavior, see table 69.
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External message 1
DI 1.11 ok ☑
td : 1 s ¦ Logic + Active line, set logic
DOR 1.04 ☐

For messages at 24 V, the logic is set with the + symbol.
7.11.3.6 Assign and activate the output
1. Press «DOWN» repeatedly until "Output" is displayed as the active line.

The Output display flashes.
3. Select the output with the «UP» or «DOWN» keys.
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DI 1.11 ok ☑
DOR 1.04 ok ☑ Output is selected and activated


7 Initial Start-up
7.12 Activating remote acknowledgement

ok is displayed.
The output is assigned and activated.
7.11.3.7 Selecting the message type (operational, alarm, warning)
1. Press «DOWN» once until message type is displayed as the active line.
The display of Message type flashes.
3. Use «UP» to select the corresponding message type.
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DI 1.11 ok ☑
DOR 1.04 ok ☑
Result The input signal is available as external message 1 and/or as output.

When warning or fault messages are routed to a remote control center via an output it makes
sense to have these messages acknowledged by the control center.
Acknowledging the message without correcting the cause, however, can lead to machine damage.
Safety-relevant messages such as "Emergency-Off" cannot be acknowledged with this function.
The following conditions must be fulfilled:

■ The "Remote acknowledgement" function and the «Remote control» key are activated.
■ A controller input has been assigned for the acknowledgement signal.
Overview
■ Select the < Configuration ➙ Acknowledgement > menu.
■ Set the "Remote acknowledgement" function.
■ Activate the «Remote control» key
■ Assigning an input
■ Press the «Remote control» key.
Machine damage can result from acknowledging a fault message without remedying its
cause!
➤ Find the fault and then decide to acknowledge or not.

7 Initial Start-up
7.12.1 Selecting the < Configuration ➙ Acknowledgement > menu

2. Select the < Configuration ➙ Acknowledgement > menu.
Remote mode line is displayed as the active line.
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5.5 Acknowledgement Menu
Remote mode : Key Active line with "Key" setting
Key remote : ☐ The Remote control key is deactivated.
·········
RC ack DI 1.11 ☐
7.12.2 Setting the remote acknowledgement function

Key flashes.
2. Press «UP».
The Key+RC menu is displayed.
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Remote mode : Key+RC Active line with "Key + Remote contact" setting
Key remote : ☐
·········
RC ack DI 1.11 ☐
Result The Remote acknowledgement function is set.
7.12.3 Activating the «Remote control» key

Key remote line is displayed as the active line.
The check box for Key remote will flash.

7 Initial Start-up
3. Press «UP».
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Key remote : ☑ Active line with activated check box for the Remote
control key
·········
RC ack DI 1.11 ☐
Result The «Remote control» key is activated.
7.12.4 Assigning an input

1. Press «DOWN» repeatedly until the active line is displayed.
89 psi 08:15 176 °F
Key remote : ☑
·········
RC ack DI 1.11 ☐ Active line
2. Press «Enter».
DI flashes.
3. Use «UP» to select the desired input.
The input has now been assigned.
The check box for input will flash.
7. Press «UP».

7 Initial Start-up
7.13 Linking to an external pressure transducer

ok is displayed,
the input is assigned and activated.
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Key remote : ☑
·········
RC ack DI 1.13 ok ☑ Active line, input for Load RC assigned and activat‐
ed.
9. Press the «Remote control» key to enable remote acknowledgement.
Result Should a warning message occur, it can now be acknowledged from a control center.

If the air system is operated with an air receiver, the pressure in the receiver can be regulated by
an external pressure transducer.
Transmission of sensor value Assignment to an input
Profibus connection Not necessary
(from a master controller)
External pressure transducer is connected to Assign AII
SIGMA CONTROL 2 .
Characteristics, pressure transducer:
■ 4–20 mA
■ 0–232 psig
USS protocol Assign FC USS
(External pressure transducer connected to the fre‐
quency converter)
Tab. 70 Transmission of sensor value
The controller processes the options in the following sequence:

■ Profibus value
■ Pressure according to the assigned external transducer
■ The local system pressure transducer (pNloc) remains active.
Overview
Example: External pressure transducer is connected to SIGMA CONTROL 2 .
■ Select the < Configuration ➙ Pressure control > menu.
■ Assigning an input

7 Initial Start-up
7.13.1 Selecting the < Configuration ➙ Pressure control > menu

2. Select the < Configuration ➙ Pressure control > menu.
< Pressure settings > sub-menu line is displayed as the active line.
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5.2 Pressure control Menu
▶1 Pressure sensors
▶2 Pressure settings Active line
▶3 Load control
▶4 Network actual pressure

< Network actual pressure > sub-menu is displayed as the active line.
4. Press «Enter».
The < Network actual pressure > menu is displayed.
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5.2.4 Network actual pressure Menu
pNloc 89 psi Active line (local sensor)
AII 1.01 ☐ 0 psi
7.13.2 Assigning an input to an external sensor

pNloc flashes.
2. Press the «UP» key once.
The AII is displayed.
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5.2.4 Network actual pressure
AII 89 psi Active line (external sensor)
AII 1.01 ☐ 0 psi

7 Initial Start-up
7.14 Commissioning the machine

Input AII (analog value via frequency converter) is displayed.
The line for activating the input is displayed.
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5.2.4 Network actual pressure
AII 89 psi
AII 1.01 ok ☑ 89 psi Active line
7. Press «UP».
Result The input for the external transducer is now activated.
You have connected an external pressure transducer to a frequency converter (USS proto‐
col).
➤ Assign the input FC USS to the pressure transducer.

Checking the controller settings Section Complied?
➤ Language correctly set? 7.2.2
➤ Date and time correct? 7.2.8
➤ Display format correctly set? 7.2.9
➤ System pressure setpoint correctly set? 7.4
Tab. 71 Checklist of installation conditions

7 Initial Start-up
1. Check and confirm all the items in the checklist before starting the machine.
When power is applied to the machine the controller boots and carries out a self test.
The display and the Controller on LED illuminate.
The actual system pressure (pNloc), the time and the airend discharge temperature are dis‐
played in the first line of the display.
89 psi 08:15 122 °F
·········
Alarm
·········
Key - off ¦ pA - off
·········
Run 0 h Load 0 h
2. Continue the commissioning process as described in chapter "Commissioning" of the ma‐

chine's operating manual.

8 Operation
8 Operation
Always switch the machine on with the «ON» key and off with the «OFF» key.
A power supply disconnecting device should be installed by the user.
Fig. 36 Switching on and off

1 Machine ON LED 11 «LOAD/IDLE» toggle key
2 «ON» key 19 LOAD LED
3 «OFF» key 20 IDLE LED
8 Controller voltage LED
8.1.1 Switching on
Precondition No personnel are working on the machine.
All access doors and panels are closed and secure.
1. Switch on the power supply disconnecting device.

The Controller voltage LED lights green.
2. Press the «ON» key.
The ON LED lights green.
If a power failure occurs, the machine is not prevented from restarting automatically when
power is resumed.
It can restart automatically as soon as power is restored.
Result The compressor motor starts as soon as system pressure is lower than the setpoint pressure (cut-
off pressure).
8.1.2 Switching off

1. Press the «OFF» key.
The machine switches to IDLE and the IDLE LED flashes. The SIGMA CONTROL 2 displays
Stopping . The ON LED extinguishes as soon as the automatic shut-off action is completed.
2. Switch off and lock out the power supply disconnecting device.

8 Operation
Result The Controller voltage LED extinguishes. The machine is switched off and disconnected from the
power supply.
In rare cases, if you need to shut the machine down immediately and cannot wait until the
automatic shut-down process is finished:
➤ Press «OFF» once again.

The EMERGENCY STOP push-button is located below the control panel.
Fig. 37 Switching off in an emergency

9 EMERGENCY STOP control device:
Switching off
➤ Press the EMERGENCY STOP control device.
Result The EMERGENCY STOP button remains latched after actuation.

The compressor's pressure system is vented and the machine is prevented from automatically re-
starting.
Switching on
1. Turn the EMERGENCY STOP device in the direction of the arrow to unlatch it.
2. Acknowledge any existing alarm messages.
Result The machine can now be started again.

Messages are displayed on the "new value" principle:
■ Message acknowledged: LED illuminates
■ Message going: LED off
or

8 Operation
■ Message going: LED flashes

■ Message acknowledged: LED off
Fig. 38 Acknowledging messages

10 Warning LED (yellow)
11 Alarm LED (red)
12 «Acknowledge» key
Alarm message
An alarm shuts the machine down automatically. The Alarm LED flashes red.

The Alarm LED extinguishes.
The machine is again ready for operation.
If the machine was switched off with the EMERGENCY STOP button:
➤ Unlatch the EMERGENCY STOP button (turn in direction of the arrow) before acknowl‐
edging the fault message.
Further information Please refer to the 9.2 operating manual for a list of possible fault messages during operation.
Warning message
If maintenance work is to be carried out or if the warning is displayed before an alarm, the Warning
LED flashes yellow.
Precondition The danger of a fault has been eliminated,

maintenance has been carried out.

The Warning LED extinguishes.
Further information Please refer to the 9.5 operating manual for a list of possible warning messages during operation.

8 Operation
8.4 Displaying messages

The following information can be called up in the < Status ➙ Messages > menu:
■ Current messages
─ Last fault
─ Last warning
─ Number of currently registered fault and/or warnings
■ The message history stores the last 1000 events, these include fault and warning messages.
─ Compressor messages
─ Diagnostic messages
─ System messages
The information (message) is shown in three lines of the display.

Line Submenu/Segment/Text
1 Selected submenu:
■ Compressor messages
■ Diagnostic messages
■ System messages
2 Segment:
■ Message number
■ Type of message
■ Message status
■ Message date
■ Message time
3 Text:
■ message text
■ –
Tab. 72 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/service message
S Fault message
Message status c Message has come
g Message gone
a Message acknowledged (reset)
Date 21.01.11 (example) Date
Time 16:10:31 (example) Time
Tab. 73 Message type and status abbreviations

8 Operation
8.4.1 Selecting the Status menu

2. Select the < Status ➙ Messages > menu.
The <messages> menu is displayed.
The number of current faults and warnings is displayed in the two bottom lines.
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1.1 Messages Menu
▶1 Current messages Active line
▶2 Message history
Status report 01:00 ☐
------------------------------
current Alarms 2 Number of currently registered faults
Warnings2 Number of currently registered warnings
Displaying the last fault/warning
2. Select the < Status ➙ Messages ➙ Current messages > menu.
The third line displays the last fault or warning message.
89 psi 08:15 176 °F
1.1.1 Current messages Menu
0021 S q 16.04.13 13:32:49 Active line
Refrigeration dryer T ⇟
0015 W q 21.01.11 13:06:43
Bus alarm
0911 D q 21.01.11 13:07:47
AIR1.3 — Sensor fault
Displaying the message history
2. Select the < Status ➙ Messages ➙ Message history > menu.
The <message history> menu is displayed.
The messages in the three submenus are displayed in the order of their occurrence.
89 psi 08:15 176 °F
1.1.2 Message history Menu
▶1 Compressor messages Active line with Compressor messages submenu
▶2 Diagnostic messages Diagnostic messages
▶3 System messages System messages

8 Operation
8.5 Displaying the current operating mode
3. Press «Enter».
The <compressor messages> menu is displayed.
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1.1.2.1 Compressor messages Menu
0021 S q 16.04.13 13:32:49 Last compressor message
Refrigeration dryer T ⇟ Message text for fault message 0021
0008 S k 20.01.11 13:33:25
Diagnostics group alarm Message text for message 0008
0042 S q 19.01.11 13:11:19
Back pressure stop Message text for message 0042
8.5 Displaying the current operating mode

The operating mode is displayed in 4 segments (example):
On/off switching via Machine state LOAD control via State of the LOAD control
Key on pA Idle
Tab. 74 Operating mode display
2. Select < Status >.
The < Status > menu is displayed.
3. Press the «DOWN» key repeatedly until < Current operating mode > is displayed as the active
line.
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1 Status Menu
▶1 Messages
▶2 Statistics
▶3 Current pressure control
▶4 Current operating mode Active line
▶5 DI/DO status

8 Operation
8.6 Adjusting working pressure
4. Press «Enter».
The < Current operating mode > submenu is displayed.
89 psi 08:15 176 °F
1.4 Current operating mode Menu
Compressor on Key Active line
Load control pA
·········
Control mode DUAL
Idle period Remains 140 s
·········
Abbreviation of operating modes
Segment Display Meaning

On/off switching via Key «ON» key on the control panel
Clk Internal clock
RC Remote contact (external LOAD signal)
RB Remote bus (external bus signal)
cRC Clock or remote contact (external LOAD signal)
Holidays Holidays (see chapter 7.5.2)
Machine state on Switched on
off Switched off
AL Alarm
There is a fault registered
LOAD control via pA System setpoint pressure pA
pB System setpoint pressure pB
pE Raised system pressure pE (at a dubious LOAD signal)
Load RC Remote contact (external LOAD signal)
Load RB Remote bus (external bus signal)
State of the LOAD control Idle IDLE
Load LOAD
ready Compressor motor off and machine ready
Compressor motor starts at compressed air demand
off Compressor motor is off
Tab. 75 Possible operating modes
8.6 Adjusting working pressure

➤ Adjust the pressure parameter to suit the compressor and application.
Further information A detailed explanation of all pressure parameter settings is given in chapter 7.4.

8 Operation
8.7 Displaying analog data
8.7 Displaying analog data

The following information can be called up in the < Performance data > menu option:
■ Local system pressure
Rise rate, airend discharge temperature
■ Differential pressure, oil separator cartridge
■ Start temperature, compressor motor
■ Temperature MCS ( SIGMA CONTROL 2 )
■ Temperature, first IOM
The data for the actual pressure can be displayed in < Configuration ➙ Pressure control ➙
Network actual pressure >.
Displaying analog data

2. Select the < Performance data > menu.
An overview of the analog data is displayed.
89 psi 08:15 176 °F
2 Performance data Menu
System pressure pNloc 89 psi Local System pressure pNloc
·········
ADT T 176 °F Airend discharge temperature
dT/dt 32 °F /s Increase of airend discharge temperature
Oil separator Δp 0 psi Differential pressure, oil separator cartridge
·········
3. Press «DOWN» to display additional analog data.

89 psi 08:15 176 °F
2 Performance data Menu
·········
Starting temperature 32 °F Temperature of compressor motor
·········
·········
MCS T 98 °F Temperature of the controller (Main Control System)
First IOM T 32 °F Temperature, first I/O module

8 Operation
8.8 Displaying operating data

The following information can be called up in the <Operating data> menu option:
■ <Operating hours>
─ Compressor: Total machine running time
─ Load run: Machine running time in LOAD mode
─ Compressor motor: Running time of compressor motor (adjustable)
─ Airend: Running time of airend (adjustable)
─ SIGMA CONTROL 2 : Controller running time
Displaying operating data
2. Select < Operating data >.
The Operating data menu is displayed.
89 psi 08:15 176 °F
3 Operating data Menu
▶1 Operating hours Active line
▶2 kWh counter
·········
Load valve on 383 Total number of switching actions
Changing the operating hours
The running times of the compressor motor and the airend can be adjusted. This may be required
after a replacement, for example.
1. Select the < Operating data ➙ Operating hours > menu.

The Operating hours menu is displayed.
89 psi 08:15 176 °F
3.1 Operating hours Menu
Compressor 3050 h Active line
On load 3030 h
Motor 3050 h
Compressor block 3050 h
SIGMA CONTROL 2 3050 h
2. Press «DOWN» repeatedly until Compressor block is displayed as the active line.

8 Operation

The display of the running time flashes (e.g., 3050h).
89 psi 08:15 176 °F
3.1 Operating hours Menu
Compressor 3050 h
On load 3030 h
Motor 3050 h
Compressor block 0 h Active line
SIGMA CONTROL 2 3050 h
4. Use «DOWN» or «Up» to set the value for operating hours to zero.
Result The operating hours for the new airend are set to 0 h .
8.8.1 Interpreting operation messages

Operating messages are identified with the letter O.
Messages 0081 to 0095 are customer-specific and undefined. Complete them with your defined
message text and interpretation.
Message Meaning
0001 O The machine is regulated by system setpoint pressure pA.
Load control pA
0002 O The machine is regulated by system setpoint pressure pB.
Load control pB
0003 O The machine is regulated via the remote contact.
Load control RC
0004 O The machine is remotely regulated via the bus connection.
Load control RB
0005 O The machine is switched on and in READY operating mode.
ready
0006 O The machine is switched on and in IDLE operating mode.
Idle
0007 O The machine is switched on and in LOAD operating mode.
On load
0008 O The machine is switched off.
off The power supply is connected.
0009 O The machine is switched on.
Compressor on

8 Operation
Message Meaning
0010 O The power supply is connected.
Controller on The controller is powered.
0011 O The machine can be switched on although the machine tempera‐
Cold start release ture is below the permissible starting temperature.
The machine can be switched on only as long as the message is
displayed.
0025 O The value for pA is output.
Setpoint pressure pA
0026 O The value for pB is output.
Setpoint pressure pB
0027 O Request:
Power OFF → ON Switch the power supply off and on.
0028 O Control mode DYNAMIC:

DYNAMIC motor temperature ↑ The temperature of the compressor motor is too high.
0081 O
0082 O
0083 O
0084 O
0085 O
0086 O
0087 O
0088 O
0089 O
0090 O
0091 O
0092 O
0093 O
p-Switch pi

8 Operation
8.9 Setting the maintenance interval
Message Meaning
0094 O
T-Switch ADT
0095 O
p-Switch pN
Tab. 76 Operational messages
8.9 Setting the maintenance interval

Example: Changing the oil change service interval.

Select menu “ Maintenance ”
1. Press «Enter».
2. Select < Maintenance >.
The maintenance interval “Oil filter” is displayed as the active line.
89 psi 08:15 176 °F
4 Maintenance
Oil filter Active line, description of maintenance interval
3000 h ¦ 0150 h Reset: ☐ Preset interval 3000 h
·········
Oil separator
3000 h ¦ 0150 h Reset: ☐
·········

8 Operation
8.10 Safety relief valve checking
3. Press «DOWN» repeatedly until the maintenance interval for Oil change is displayed as the ac‐
tive line.
89 psi 08:15 176 °F
4 Maintenance
Oil separator
3000 h ¦ 0150 h Reset: ☐
·········
Oil change Maintenance interval description
3000 h ¦ 0150 h Reset: ☐ Active line, preset interval
·········

Maintenance interval display flashes.
5. Use the «UP» key to set the new value for the maintenance interval.
Simply keep the «UP» key pressed to quickly change the maintenance interval in increments
of 10, 100 or 1000.

Overview
■ Preparing the test
■ Resetting
When the check mode is activated, monitoring of internal pressure (blow-off protection – if
provided) and regulation of network pressure are deactivated.
The measured value of the internal pressure pi is used to describe the test below.
Check box Status

☑ Activated
☐ Deactivated
Danger of injury from pressurized components!

➤ Perform the following actions in the sequence provided.
Preparing the test
1. Note the activating pressure of the safety relief valve from the machine's nameplate.
2. Press the «OFF» key to shut down the machine.
3. Close the user's shut-off valve between the machine and the air distribution network.
4. Log on to SIGMA CONTROL 2 with access level 2 (see chapter 7.2.6).

8 Operation
Pressure relief valve is displayed as the active line.
89 psi 08:15 176 °F
Safety valve: ☐ Active line with check box
pRV : 232 psi¦ pi 0 psi Relief valve activating pressure (example)
Reset: ☐
·········
Performing the test

The monitoring of internal and network setpoint pressures is deactivated!
89 psi 08:15 176 °F
Safety valve: ☑ Active line with check box
pRV :232 psi¦ pi 36 psi Relief valve activating pressure
Reset: ☐
·········
4. Excessive noise is caused when the safety relief valve blows off!
5. Risk of burns due to released cooling oil and compressed air when blowing off
the safety relief valve!
6. Press and hold the «ON» key.
The machine switches to load, the machine's internal pressure pi rises.
7. Monitor on the display the pressure rise pi during the check.
8. If the internal pressure pi increases to more than 10% above the correct opening pressure of
the safety relief valve, shut down the machine with the «OFF» key and replace the safety relief
valve.

8 Operation
8.11 Checking the temperature sensor and overheating shutdown function
If the alarm message pRV ⇞ appears, the safety relief valve is defective. The permissible
internal pressure was exceeded by 30 psi.
➤ Have the safety relief valve replaced.
Avoid oil mist:
➤ Release the «ON» key immediately when the safety relief valve responds, in order to pre‐
vent unnecessary oil mist.

5. Open the shut-off valve from the machine.
Result The machine is ready for operation.
Resetting
If the test is canceled when opening the safety relief valve, SIGMA CONTROL 2 will indicate the
highest measured value as internal pressure.
8.11 Checking the temperature sensor and overheating shutdown func‐

tion
The machine should shut down if the airend discharge temperature (ADT) reaches a maximum of
230 °F.
SIGMA CONTROL 2 will simulate a higher temperature for checking this function.
For this purpose, SIGMA CONTROL 2 automatically determines an offset value to be displayed.
During the test mode, this is added to the actual airend discharge temperature to cause the ma‐
chine to shut down prematurely.
In standard operation, SIGMA CONTROL 2 generates the "overtemperature" fault message when
the maximum airend discharge temperature is reached. Since the modified test temperature is 4 °F
below the fault message switching point for overtemperature, the system will not generate a fault
message in test mode.
Overview
■ Shut down the machine and allow to cool down slightly
■ Perform the test
■ Resetting
Performing the test
Precondition Machine cooled down by approximately 40 °F

8 Operation
1. Log on to SIGMA CONTROL 2 with password level 2. (see section 7.2.6).

Safety valve is displayed in the active line.
4. Press «DOWN» repeatedly until Airend discharge temperature ADT ⇞ is displayed as the ac‐
tive line.
89 psi 08:15 163 °F Fallen airend discharge temperature ( 163 °F )
·········
Airend discharge temperature ADT ⇞ : ☐ Active line
Offset : 0 °F ¦ ADT ⇞ 0.0 °F
Reset: ☐

The Offset display changes to 95 °F.
The Airend discharge temperature ADT ⇞ display changes to 226 °F.
89 psi 08:15 163 °F
·········
Airend discharge temperature ADT Active line
⇞: ☑
Offset : 95 °F ¦ ADT ⇞ 226 °F Offset, airend discharge temperature in test mode
Reset: : ☐
8. Press the «ON» key to switch the machine to LOAD.

The machine switches to LOAD and the airend discharge temperature rises again.
The machine will switch off as soon as the airend discharge temperature attains a value of
226 °F.
➤ Abort the test and contact KAESER Service as soon as possible.


8 Operation

The offset is reset to 32 °F.
Resetting
SIGMA CONTROL 2 will display the highest measured value if the test for switching off at overtem‐
perature is aborted.


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 9.2 and 9.4.
■ Fault on the controller:
The machine is shut down, see chapter 9.3.
■ Warning:
The yellow LED illuminates, the machine is not shut down, see chapter 9.5.
The messages valid for your machine are dependent on the controller and individual equipment fit‐
ted.
1. Do not attempt fault rectification measures other than those given in this manual!
2. In all other cases:
Have the fault rectified by an authorized KAESER service representative.
9.2 Interpreting alarm messages

If an input signal is classified as an alarm, the controller will display the alarm upon the sig‐
nal's arrival.
Consequences
■ The red LED flashes:
■ The controller switches the machine off.
Alarm messages are identified with the letter A.
plete them with your defined message text, possible causes and remedies.

0001 A The compressor drive motor Change over phase
Direction of rotation is turning in the wrong di‐ lines L1 and L2.
rection.
0002 A Compressor drive motor Clean the motor.
Motor temperature ⇞ overheated. Keep ambient condi‐
tions within specified
limits.
0003 A The activating pressure of Change the safety
pRV ⇞ the safety relief valve on the relief valve.
oil separator tank has been
exceeded.
0004 A EMERGENCY STOP push Unlatch the push
EMERGENCY STOP button actuated. button.


0005 A Maximum air temperature at Check the line to the
Oil separator Temperature ⇞ the oil separator tank outlet trip relay.
is exceeded.
0007 A Fault in main power supply. Have the main power
Power supply monitor supply checked.
0008 A A diagnostic message has For more details, see
Diagnostics group alarm occurred. the text of the diag‐
nostic message.
0009 A Permissible enclosure tem‐ Keep ambient condi‐
SIGMA CONTROL 2 T⇞ perature for tions within specified
SIGMA CONTROL 2 ex‐ limits.
ceeded. Control cabinet:
Check filter mats and
fan.
0010 A The activating pressure of Change the oil sepa‐
Blow-off protection ⇞ the safety relief valve on the rator cartridge.
oil separator tank has been Open the shut-off
exceeded. valve in the venting
line.
0011 A Overload shut-down of the Investigate cause of
Oil-/air cooler fan Overcurrent first fan motor. shut-down.
Reset the overload
relay.
0012 A Door open / interlocked Fit and secure all
Access doors panel removed while the panels and close ac‐
machine is running. cess doors.
Compressor motor overcurrent compressor drive motor. shut-down.
Change the oil sepa‐
rator cartridge.
Oil-/air cooler fan Overcurrent second fan motor. shut-down.
Reset the overload
relay.
0015 A Maximum permissible air‐ Keep ambient condi‐
Airend discharge temperature ADT ⇞ end discharge temperature tions within specified
(ADT) exceeded. limits.
Clean the cooler.
Check the cooling oil
level.
Oil-/air cooler fan Overcurrent third fan motor. shut-down.
Reset the overload
relay.
0019 A – –
Internal pressure pi ⇟


0021 A Refrigerated dryer: Contact
Refrigeration dryer T ⇟ Compressed air tempera‐ KAESER Service.
ture too low.
0022 A Oil separator cartridge clog‐ Change the oil sepa‐
Oil separator Δp ⇞ ged. rator cartridge.
0023 A Drive motor bearings over‐ Re-grease the motor
Motor bearings heated. bearings.
0024 A Cooling water pressure is Check cooling water
Water-cooling water shortage too low. supply.
0034 A Main contactor does not Check main contac‐
Mains contactor on? close. tor and wiring.
0035 A Overload shut-down of the Contact
Cabinet fan I ⇞ control cabinet fan motor. KAESER Service.
0038 A Package discharge (PD) Contact
PD temperature ⇟ temperature too low. KAESER Service.
0039 A Package discharge (PD) Check the cooling oil
PD temperature ⇞ temperature too high. level.
Clean the cooler.
Check the fan motor.
Mains contactor off? open. tor and wiring.
0041 A Second power failure. Check power supply
Mains voltage ⇟ voltage.
Check the door inter‐
lock switch.
0042 A Back pressure in the oil Check venting line.
Back pressure stop separator tank caused by
defective venting.
0043 A The rate of rise of the air‐ Check the cooling oil
Airend discharge temperature ADT rise dT/dt⇞ end discharge temperature level.
(ADT) is too fast.
0044 A The machine does not pro‐ Check the machine
No pressure buildup duce compressed air. for leaks.
The working pressure does Check coupling and
not rise above 50 psi within V-belt.
the preset period.
0045 A Thermostatic valve defec‐ Contact
Compressor T ↓↓ tive KAESER Service.
0048 A Fault in the high voltage Contact
High-voltage cell cell. KAESER Service.
0051 A Aggregate A failed. Contact
Aggregate A KAESER Service.
0052 A Aggregate B failed. Contact
Aggregate B KAESER Service.


0056 A Refrigerated dryer: Refrigerated dryer:
RD condensate drain The condensate drain is de‐ Check condensate
fective. drain and conden‐
sate conduits.
0057 A Compressor model uncer‐ Contact
Model? tain. KAESER Service.
0058 A The condensate drain is de‐ Check condensate
Condensate drain fective. drain and conden‐
sate conduits.
0059 A Drive belt or coupling bro‐ Drive belt:
Back pressure run ken. Replace drive belt.
Coupling:
Contact
KAESER Service.
0061 A The rate of rise of the air‐ Check the cooling oil
Oil separator rise dT/dt ⇞ end discharge temperature level.
is too fast.
0062 A Refrigerated dryer: Clean the refrigerant
Refrigeration dryer p ⇞ Pressure too high in the re‐ liquefier.
frigerant circuit. Check the fan motor.
Safety pressure switch trip‐
Maintain operating
ped.
conditions.
0063 A Refrigerated dryer: Contact
Refrigeration dryer p ⇟ Refrigerant lost; pressure in KAESER Service.
the refrigerant circuit too
low. Inlet pressure switched
tripped.
0081 A
0082 A
0083 A
0084 A
0085 A
0086 A
0087 A
0088 A
0089 A


0090 A
0091 A
0092 A
0093 A
p-Switch pi
0094 A
T-Switch ADT
0095 A
p-Switch pN
0097 A High-voltage cell does not Check high-voltage
High-voltage cell on? activate. cell and wiring.
0098 A High-voltage cell does not Check high-voltage
High-voltage cell off? deactivate. cell and wiring.
Mains contactor on? close. tor and wiring.
Mains contactor off? open. tor and wiring.
Compressor motor overcurrent compressor drive motor. shut-down.
Change the oil sepa‐
rator cartridge.
Oil-/air cooler fan Overcurrent first fan motor. shut-down.
Reset the overload
relay.
0200 A Frequency converter fault Contact
Compressor motor USS alarm KAESER Service.
0205 A Communications error Check connection
Compressor motor USS alarm and line path.
Compressor motor FC Motor overload alarm KAESER Service.
Compressor motor FC Motor overload alarm KAESER Service.
Tab. 78 Alarm messages and remedies

9.3 Interpreting system messages
9.3 Interpreting system messages

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


0001 Y System error Contact KAESER Service.
Hardware watchdog reset
Internal software error
Filesystem Read/Write failure
CPU load too high
RAM out of memory
RFID error: switch SIGMA CONTROL power supply
OFF → ON!
Tab. 79 System messages and remedies
9.4 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 KAESER service with troubleshooting.
9.5 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.
plete them with your defined message text, possible causes and remedies.


0002 W Drive motor overheating. Clean the motor.
Motor temperature ↑ Keep ambient conditions
within specified limits.
0004 W Increased differential Change the oil separator car‐
Oil separator Δp ↑ pressure of the oil sepa‐ tridge.
rator cartridge.
Oil separator cartridge
clogged.
0007 W Drive motor bearing de‐ Contact KAESER Service.
Motor bearings fective.
0008 W Maximum airend dis‐ Clean the cooler.
Airend discharge temperature ADT ↑ charge temperature will Check the cooling oil level.
soon be reached.
Replace the oil filter cartridge.
Ensure adequate ventilation.
Keep surrounding tempera‐
ture within recommended lim‐
its.
0011 W Increased pressure dif‐ Change the oil filter.
Oil filter Δp ↑ ferential of the oil filter.
Oil filter clogged.
0013 W Air filter clogged. Change the air filter.
Air filter Δp ↑
0015 W The bus link via the Pro‐ Check the bus cables and
Bus alarm fibus DP interface is in‐ plugs.
terrupted.
0025 W Oil separator cartridge: Change the oil separator car‐
Oil separator h ⇞ Maintenance interval tridge.
has elapsed.
0026 W Cooling oil: Change the cooling oil.
Oil change h ⇞ Maintenance interval
has elapsed.
0027 W Oil filter: Change the oil filter.
Oil filter h ⇞ Maintenance interval
has elapsed.
0028 W Air filter: Change the air filter.
Air filter h ⇞ Maintenance interval
has elapsed.
0029 W Valves: Contact KAESER Service.
Valve inspection h ⇞ Maintenance interval
has elapsed.
0030 W Belt tension/coupling: Carry out a visual inspection.
Belt/coupling inspection h ⇞ Maintenance interval Re-tension the drive belt.
has elapsed.


0031 W Motor bearing of com‐ Contact KAESER Service.
Motor bearings h ⇞ pressor motor:
has elapsed.
0032 W Electric components and Inspect and reset the mainte‐
Electrical equipment h ⇞ installation: nance interval counter.
has elapsed.
0033 W Motor bearing of fan mo‐ Contact KAESER Service.
Fan bearings h ⇞ tors:
has elapsed.
0034 W Package discharge (PD) Contact KAESER Service.
PD temperature ↓ temperature too low.
0035 W Compressed air dis‐ Clean the cooler.
PD temperature ↑ charge temperature too Check the cooling oil level.
high.
Motor starts/h ⇞ of motor starts was ex‐ Increase the capacity of the
ceeded in the last 60 mi‐ air receiver.
nutes.
and air receiver.
Motor starts/d ⇞ of motor starts was ex‐ Increase the capacity of the
ceeded in the last air receiver.
24 hours.
and air receiver.
0038 W The safety relief valve's Change the oil separator car‐
Blow-off protection ↑ activating pressure will tridge.
soon be reached. Open the shut-off valve in the
venting line.
0041 W 1. Power failure: Check power supply.
Mains voltage ↓ The machine is auto‐ Check the door interlock
matically restarted. switch.
0043 W Ambiguous external Check settings of the external
External load signal? load signal: controller. Take into account
Increased cut-out pres‐ pressure drops across filters
sure exceeded. and dryer.
The external load con‐
trol has not switched to
idle.
0044 W Cooling oil temperature Check temperature switch,
Oil temperature ↓ too low. line and connection.
Check the oil circuit.
Increase room temperature.


0046 W Network pressure has Check air demand.
System pressure ↓ fallen below the set Check cable runs and sensor
“system pressure low” connections.
value.
Check the 'system pressure
Air consumption too low' warning value.
high.
0047 W The compressor cannot Check for air leaks.
No pressure buildup build-up to working pres‐ Check the value for internal
sure. pressure given in the <Ana‐
log data> menu against the
reading on the oil separator
tank pressure gauge.
0048 W Re-grease the motor Re-grease the motor bear‐
Bearing lube h ⇞ bearings. ings.
has elapsed.
0049 W Last maintenance was Carry out the necessary
Annual maintenance 1 year ago. maintenance and reset the
corresponding maintenance
interval counter.
Start temperature ↓↓ is too low (< 14°F) for within specified limits.
the machine to be oper‐
ated.
Start temperature ↓ is too low (< 35°F). within specified limits.
0061 W The airend discharge Contact KAESER Service.
Compressor T ↓ temperature (ADT) did
not reach the minimum
value within the speci‐
fied time.
0066 W Initial warning: Change the air filter element
Air filter Δp ⇡ Air filter clogged. soon.
0068 W The condensate drain is Check the condensate drain
Condensate drain defective. and drain line.
0069 W Refrigerated dryer de‐ Immediately contact KAESER
Error operation without RD → Call fective. service.
service! Compressed air supply
with undried air is acti‐
vated.
0070 W Refrigerated dryer: Maintain operating condi‐
Refrigeration dryer T ↑ Compressed air temper‐ tions.
ature too high. Clean the refrigerant liquefier.
Clean the cooler.
Install an extractor fan.
0071 W Cooling oil level too low. Replenish the cooling oil.
Oil level ↓


0072 W Refrigerated dryer: Check condensate drainage
RD condensate drain The condensate drain is
defective.
0081 W
0082 W
0083 W
0084 W
0085 W
0086 W
0087 W
0088 W
0089 W
0090 W
0091 W
0092 W
0093 W
p-Switch pi
0094 W
T-Switch ADT
0095 W
p-Switch pN
Tab. 80 Warning messages and remedies

10 Maintenance
10.1 Maintenance Work
10 Maintenance
10.1 Maintenance Work
The SIGMA CONTROL 2 and the I/O modules are maintenance-free. Use basic safety instructions
and safety instructions for working on live components.


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 inquiry and order for spares.
11.2 KAESER AIR SERVICE

KAESER AIR SERVICE offers:
■ authorized KAESER service representatives 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 spare parts,
■ increased legal certainty as all regulations are kept to.
➤ Why not sign a KAESER AIR SERVICE maintenance agreement!
Result Your advantage:

lower costs and higher compressed air availability.

Addresses of KAESER representatives are given at the end of this manual.
11.4 Displaying the version number, machine model, part number and
serial number
2. Select the < Configuration ➙ General ➙ System information > menu.
89 psi 08:15 176 °F
5.1.1 System information Menu
▶1 SIGMA CONTROL 2 MCS Active line
▶2 Compressor
▶3 IO modules

11.4 Displaying the version number, machine model, part number and serial number
3. Press «Enter» to open the submenu.

The system information is displayed.
89 psi 08:15 176 °F
5.1.1.1 SIGMA CONTROL 2 MCS Menu
Software 1.1.3 Software
·········
Kaeser
PN 7.7601.0 Part number
SN x.xx.xx Serial number
·········
4. Keep pressing the «DOWN» key to display further settings.

89 psi 08:15 176 °F
5.1.1.1 SIGMA CONTROL 2 MCS Menu
SN x.xx.xx
·········
Prodrive Manufacturer
PN 6309.1000.7900 Part number
SN 10.34.000.961 Serial number
MFGDT 2010/08 Manufacturing date

12.1 De-commissioning

12.1 De-commissioning
12.2 Packing
12.3 Storage
12.4 Transporting
12.5 Disposal

Order-No.: 10357405

5. Spare Parts List

Spare parts
Screw compressor
ESD 442 SFC / 14 bar ESD.2C / 1204/1205

No.: TTL-ESD_2C_10357405_10_00 E
Manufacturer:
KAESER KOMPRESSOREN
/KKW/GBASE 1.00 en ERSATZTEILE 10357405_10 ESD.2C
20130903 115349
Contents

1.1 Safely dealing with sources of danger ............................................................................. 1
1.2 Spares for service and repair ........................................................................................... 3
1.3 ESD 442 SFC / 14 bar .................................................................................................... 3
Spare parts Screw compressor

No.: TTL-ESD_2C_10357405_10_00 E ESD 442 SFC / 14 bar ESD.2C / 1204/1205 i
Contents

ii ESD 442 SFC / 14 bar ESD.2C / 1204/1205 No.: TTL-ESD_2C_10357405_10_00 E

No.: TTL-ESD_2C_10357405_10_00 E ESD 442 SFC / 14 bar ESD.2C / 1204/1205 iii

iv ESD 442 SFC / 14 bar ESD.2C / 1204/1205 No.: TTL-ESD_2C_10357405_10_00 E
List of Tables
Tab. 1 Advise others that the machine is being serviced. ..................................................................... 1

Tab. 2 Machine data .............................................................................................................................. 3

No.: TTL-ESD_2C_10357405_10_00 E ESD 442 SFC / 14 bar ESD.2C / 1204/1205 v
List of Tables

vi ESD 442 SFC / 14 bar ESD.2C / 1204/1205 No.: TTL-ESD_2C_10357405_10_00 E
1.1 Safely dealing with sources of danger


➤ Allow maintenance work to be carried out only by authorised personnel.
➤ Use one of the safety signs below to advise others that the machine is currently being serv‐
iced:
Symbol Meaning
Don't activate the machine.
Warning:
The machine is being serviced.
Tab. 1 Advise others that the machine is being serviced.
➤ Before switching on, make sure that nobody is working on the machine and all access doors
and panels are closed.
Electricity
➤ Allow only qualified and authorised electricians or trained personnel under the supervision of a
qualified and authorised electrician to carry out work on electrical equipment according to elec‐
trical engineering regulations.
➤ Before commissioning or re-commissioning the machine, the user must make sure there is ad‐
equate protection against electric shock from direct or indirect contact.
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply isolator and check that no voltage is present.
➤ Switch off any external power sources.
These could be connections to floating relay contacts or the electrical machine heating, for ex‐
ample.
➤ Use fuses corresponding to machine power.
➤ Check regularly that all electrical connections are tight and in proper condition.
Forces of compression
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following information concerns work on components that could be under pressure.
➤ Close shut-off valves or otherwise isolate the machine from the distribution network to ensure
that no compressed air can flow back into the machine.
➤ Do not carry out welding, heat treatment or mechanical modifications on pressurised compo‐
nents (e.g. pipes and vessels) as this influences the component's resistance to pressure.
The safety of the machine is then no longer ensured.

No.: TTL-ESD_2C_10357405_10_00 E ESD 442 SFC / 14 bar ESD.2C / 1204/1205 1
Spring forces
Springs under tension or compression store energy. Uncontrolled release of this energy can cause
serious injury or death.
Minimum pressure / check valves, pressure relief valves and inlet valves are powerfully spring-loa‐
ded.
Rotating components
in serious injury.
➤ Do not open the enclosure while the machine is switched on.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of any
voltage.
➤ Wear close-fitting clothes and a hair net if necessary.
➤ Ensure that all covers and safety guards are in place and secured before re-starting.
Temperature
High temperatures are generated during compression. Touching hot components may cause inju‐
ries.
➤ Avoid contact with hot components.
➤ Wear protective clothing.
Noise
The enclosure absorbs the machine noise to a tolerable level. This function will be effective only if
the enclosure is closed.
➤ Operate the machine only with intact sound insulation.
➤ Wear hearing protection if necessary.
Operating fluids/materials
The used operating fluids and materials can cause adverse health effects. Suitable safety meas‐
ures must be taken in order to prevent injuries.
➤ Follow safety regulations when dealing with oils, lubricants and chemical substances.
➤ Avoid contact with skin and eyes.
➤ Do not inhale oil mist or vapour.
➤ Do not eat or drink while handling cooling and lubricating fluids.
➤ Use only KAESER approved operating materials.
Unsuitable spare parts
Unsuitable spare parts compromise the safety of the machine.

➤ Use only spare parts approved by the manufacturer for use in this machine.
➤ Use only genuine KAESER replacement parts on pressure bearing parts.

2 ESD 442 SFC / 14 bar ESD.2C / 1204/1205 No.: TTL-ESD_2C_10357405_10_00 E
1.2 Spares for service and repair
Conversion or modification of the machine
Modifications, additions to and conversions of the machine or the controller can result in unpredict‐
able dangers.
➤ Do not convert or modify the machine!
➤ Obtain written approval by the manufacturer prior to any technical modification or expansion of
the machine, the controller, or the control programs.
1.2 Spares for service and repair

With the help of the following pages, you can plan your material requirement according to operating
conditions and order the spare parts you need.
This document is protected by copyright. Any queries regarding the use or duplication of this docu‐
ment should be referred to KAESER.
Correct use of information will be fully supported.
➤ During work, please comply with the safety instructions provided in the current operating
manual for this machine.
➤ Make sure that any service or repair tasks not described in this manual are carried out by
an authorised KAESER Service Technician.
Model ESD 442 SFC / 14 bar

Equipment 4823271/4824071
Material / serial number ESD.2C / 1204/1205
Year of manufacture 2013
Miscellaneous
Tab. 2 Machine data
When ordering spare parts for a component, please indicat the material and serial numbers of the
machine and the position number and designation of the spare parts.
1.3 ESD 442 SFC / 14 bar

1.3 ESD 442 SFC / 14 bar
1.3 ESD 442 SFC / 14 bar

1.3 ESD 442 SFC / 14 bar

Order-No.: 10357405

6. Performance test by helium #100714

KAESER KOMPRESSOREN AG
P.O.Box 2143 • 96410 Coburg • Germany • Phone +49 9561 6400
Fax +49 9561 640130
Inspection certificate to EN 10204 3.1

Test report to EN 10204 2.2
Customer: Linde Kryotechnik AG

Dättlikonerstrasse 5
8422 Pfungen
Machine : Screw compressor

Model : ESD 442 SFC / 14 bar
Serial number : 1205
Year of manufacture : 2013
Kaeser part number : ESD.2C
Kaeser job number : 10357405
Date of test : 30.08.2013
Technical specification: M-SD 1014-7
Type of test: Performance test by helium
We herewith certify that the components subject to pressure of Helium Screw

Compressor Unit has been submitted to a performance test by helium.
Gas inlet temperature : --- K

Gas suction pressure : --- bar (abs)
Outlet pressure : --- bar (a)
Mass throughput : --- g/s
Total power consumption : --- kW
M. Kiesewetter-QA /QESM/F-100714-Performance test by helium - 4 / June 3rd, 2013

Fax +49 9561 640130
Frequency Gas inlet Gas suction Outlet Mass Total power

temperature pressure pressure throughput consumption
20 Hz 299,1 K 1,05 bar (abs) 14 bar 29,72 g/s 108,2 kW
Comments:
We confirm that the package/part meets the order requirements.
Coburg, 19.09.2013
(manufacturer’s competent examiner)
M. Kiesewetter-QA /QESM/F-100714-Performance test by helium - 4 / June 3rd, 2013

Order-No.: 10357405

7. Measurement record for units with suction side gas supply

Helium unit
Measurement record
for helium screw compressor units
Compressor unit Type/Serial-No.: ESD 442 SFC 14,0 bar(a) HE a.c. /480V 60Hz / 1205 - Linde CH, Proj. Florence12, USA
Mat.No.: ESD.2C Equipment-No.: 4824071

Airend Type/Serial-No.: Sigma 38 Helium / 1014 EQ.-No. 788085
Motor Type/Serial-No.: 1LG6318-4AA96-Z Make: Siemens
-1
Rated power [kW]: 250 Speed [min ]:
Warranty terms
Suction temperature TA: 298 K
Suction pressure pA: 1,05 bar (abs) Rate of mass flow m: 31,1 g/s Tol.: +5 / -2 %
Unit outlet pressure pe: 14,0 bar (abs) Power input PIN: 111,6 kW Tol.: +/- 3 %
Measurement results
Ambient pressure pU: 0,984 bar (abs) Ambient temperature TU: 298 K
Suction temperature TA: 299,6 K Discharge temp. T(END): 327 K
Unit outlet temperature T(OUT): --- K
Gas meter inlet temperature TB1: 299,1 K Gas meter outlet temp. TB2: --- K
Suction pressure pA: 1,05 bar (abs) Unit outlet pressure pe: 14,0 bar (abs)
Gas meter working pressure pB: 5,74 bar (abs)
Gas meter working volume VB: 10,0 m³
Duration of measurement t: 5,18 min

Compressor speed nK: 595 min-1 Deviation
Package power input PIN: 108,2 kW 20 Hz -3,05 %
Pressure ratio:
pB 5,74
Z = = = 5,467
pA
1,05
Free gas delivery (referring to inlet conditions ) [m³/min]
VB TA 10,0 299,60
VA = x Z x = x 5,467 x = 10,571
t TB
5,18 299,10
Density at inlet conditions [kg/m³]
TN pA 273,15 1,05
ρA = ρN x x = 0,1785 x x = 0,1687
TA pN 299,60 1,013
Rate of mass flow [g/s]
1000 1000
m = x VA x ρA = x 10,571 x 0,1687 = 29,72
60 60
Remarks: Deviation
For TA = 298,0 K and res. ρA = 0,1696 mass flow will result in approx. m = 29,88 g/s -3,93 %
Date: 30.08.13 Name: M. Skrobek

Helium unit
Measurement record

-1
Warranty terms
Measurement results

Pressure ratio:
pB 5,78
Z = = = 5,505
pA
1,05
VB TA 21,0 300,50
VA = x Z x = x 5,505 x = 22,019
t TB
5,25 300,50
TN pA 273,15 1,05
ρA = ρN x x = 0,1785 x x = 0,1682
TA pN 300,50 1,013
1000 1000
m = x VA x ρA = x 22,019 x 0,1682 = 61,72
60 60
Remarks: Deviation

Helium unit
Measurement record

-1
Warranty terms
Measurement results

Pressure ratio:
pB 5,94
Z = = = 5,657
pA
1,05
VB TA 25,0 301,00
VA = x Z x = x 5,657 x = 27,604
t TB
5,12 301,20
TN pA 273,15 1,05
ρA = ρN x x = 0,1785 x x = 0,1679
TA pN 301,00 1,013
1000 1000
m = x VA x ρA = x 27,604 x 0,1679 = 77,25
60 60
Remarks: Deviation

Order-No.: 10357405

8. Quality-Dimensions-Material-Surface #100713
• Fax +49 9561 640130
Inspection certificate to EN 10204 3.1

Test report to EN 10204 2.2
Declaration of compliance with the order 2.1
Customer: Linde Kryotechnik AG

Dättlikonerstrasse 5
8422 Pfungen
Machine : Screw compressor

Model : ESD 442 SFC / 14 bar
Serial number : 1205
Year of manufacture : 2013
Kaeser part number : ESD.2C
Kaeser job number : 10357405
Date of test : 29.08.2013
Technical specification: M-SD 1014-7
Type of test: Material certificate airend
Component Part number Material

Airend casing 212886.00010 EN-GJL 300
Male rotor 204877.0 EN-GJL-250
Male rotor shaft 204876.0 C45
Female rotor 204866.00010 GGG 50
These components were manufactured to KAESER works drawings and tested to KAESER
quality standards.
The quality (dimensions, surface finish, material) complies with requirements.
We hereby certify that the above named equipment/part complies with regulations.
Coburg, 19.09.2013
Competent Examiner
M. Kiesewetter-QA /QESM/F-100713-Material certificate airend- 3 / June 3rd, 2013

Esd 442 SFC

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Project: Florence12 / L.

Compressor-Typ: ESD 442 SFC / 14 bar (a), ac, Helium

3. Service manual compressor

4. Service manual Sigma Control

5. Spare Parts List

6. Performance test by helium #100714

7. Measurement record for units with suction side gas

Compressor-Typ: ESD 442 SFC / 14 bar (a), ac, Helium

position marginally dependent on design

Minimum width of door is total width of unit + 100 mm

Demounting height for separating cartridge

for motor bearings

Dimension and connection dim.

Freigeg. 03.09.2013 DRESSEL4

Electrical connections as required

Compressor-Typ: ESD 442 SFC / 14 bar (a), ac, Helium

Compressor-Typ: ESD 442 SFC / 14 bar (a), ac, Helium

3. Service manual compressor

ESD 442/14 bar (abs) SFC SIGMA CONTROL 2

1 Regarding this document

Service Manual Screw Compressor

4.2 Function description ......................................................................................................... 26

Service Manual Screw Compressor

9 Fault Recognition and Rectification

Service Manual Screw Compressor

Service Manual Screw Compressor

Fig. 1 Mass flow rate and regulating range .......................................................................................... 7

Service Manual Screw Compressor

Service Manual Screw Compressor

Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1

Service Manual Screw Compressor

Service Manual Screw Compressor

1 Regarding this document

1.2 Further documents

Missing documents can be requested from KAESER.

1.4 Symbols and labels

Tab. 1 Danger levels and their definition (personal injury)

Service Manual Screw Compressor

1.4.2 Potential damage warnings

Warning notices for damages are identified by their signal term.

Tab. 2 Danger levels and their definition (damage to property)

➤ Carefully read and fully comply with warnings against damages.

1.4.3 Other alerts and their symbols

Service Manual Screw Compressor

Further information Further subjects are introduced here.

Service Manual Screw Compressor

The nameplate is located on the outside of the machine:

➤ Enter here the nameplate data as a reference:

Option Option code Available?

Service Manual Screw Compressor

Tab. 5 Machine weight

2.5 Ambient conditions

Tab. 7 Ambient conditions

Service Manual Screw Compressor

Tab. 9 Ambient conditions

2.8 Mass flow rate

Service Manual Screw Compressor

Fig. 1 Mass flow rate and regulating range

Signal [mA] Frequency [Hz] Mass flow rate [g/s]

Tab. 10 Mass flow rate and regulating range

Tab. 11 Mass flow rate

2.9 Cooling oil

Service Manual Screw Compressor