9_5774_05USE SAM x-4 v1.14

Service manual
Master controller
SIGMA AIR MANAGER x/4 ≥1.14

Number: 9_5774 05 USE
Original instructions
/KKW/CSAM 1.03 en 01 SBA-SIGMA-AIR-MANAGER X_4
20120202 092948
Contents
1 Regarding this Document

1.1 Using the document ......................................................................................................... 1
1.2 Copyright .......................................................................................................................... 1
1.3 Licensed brands and trademarks ..................................................................................... 1
1.4 Symbols and markings ..................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Other instructions and symbols .......................................................................... 2
2 Technical Data
2.1 Master controller models .................................................................................................. 3
2.2 Connection possibilities .................................................................................................... 3
2.3 Inputs and outputs ............................................................................................................ 3
2.4 Electrical data ................................................................................................................... 4
2.5 Hardware .......................................................................................................................... 4
2.5.1 Industrial computer ............................................................................................. 4
2.5.2 Interfaces ............................................................................................................ 5
2.6 Software ........................................................................................................................... 5
2.7 Pressure transducer ......................................................................................................... 5
2.8 Control cabinet ................................................................................................................. 7
2.9 Profibus expander (PBE) ................................................................................................. 8
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 10
3.2 Specified use .................................................................................................................... 10
3.3 Improper use .................................................................................................................... 10
3.4 User's responsibilities ....................................................................................................... 11
3.4.1 Observe statutory and universally accepted regulations .................................... 11
3.4.2 Defining personnel .............................................................................................. 11
3.5 Dangers ............................................................................................................................ 11
3.5.1 Safely dealing with sources of danger ................................................................ 11
3.5.2 Using the master controller safely ...................................................................... 12
3.6 Warranty ........................................................................................................................... 12
4 Design and Function
4.1 Overview .......................................................................................................................... 14
4.2 Control panel .................................................................................................................... 14
4.2.1 Keys .................................................................................................................... 15
4.2.2 Table of light emitting diodes .............................................................................. 15
4.2.3 Display ................................................................................................................ 16
4.2.4 Password protection ........................................................................................... 17
4.3 List of menus .................................................................................................................... 17
4.3.1 Main menu level .................................................................................................. 17
4.3.2 Menu tree ............................................................................................................ 17
4.4 Operation and function ..................................................................................................... 20
4.4.1 Adaptive 3D control ............................................................................................ 20
4.4.2 Base load sequence ........................................................................................... 21
4.4.3 Shift clock mode ................................................................................................. 21
4.4.4 Power limiting ..................................................................................................... 21
4.4.5 Air main charging ................................................................................................ 21
4.4.6 EMERGENCY operation ..................................................................................... 21
4.4.7 Visualization with SIGMA AIR CONTROL basic ................................................. 22
5 Installation and Operating Conditions
5.1 Surroundings .................................................................................................................... 23
5.2 Installation conditions ....................................................................................................... 23
Service manual Master controller

Number: 9_5774 05 USE SIGMA AIR MANAGER x/4 ≥1.14 i
Contents
6 Installation
6.1 Installation ........................................................................................................................ 24
6.2 Reporting transport damage ............................................................................................ 24
6.3 Compressed air supply during installation ....................................................................... 24
6.3.1 Station with emergency operating mode ............................................................ 24
6.3.2 Stations without emergency operating mode ..................................................... 25
6.4 Installing the control cabinet ............................................................................................. 25
6.5 Identifying the machines .................................................................................................. 25
6.6 Connecting the pressure transducer ................................................................................ 26
6.6.1 Mechanical connection ....................................................................................... 26
6.6.2 Power Supply ...................................................................................................... 28
6.7 Planning cabling ............................................................................................................... 28
6.7.1 Accessories needed for a link via Profibus ......................................................... 29
6.7.2 Requirements for a link via a floating relay contact ............................................ 29
6.8 Laying cables ................................................................................................................... 30
6.8.1 Building up the Profibus network ........................................................................ 30
6.8.2 Building up the compressor station via floating relay contacts ........................... 32
6.9 Connecting the cables to the master controller ................................................................ 33
6.9.1 Connecting the equipotential bond ..................................................................... 33
6.9.2 Leading in cables and connecting the screening ................................................ 34
6.9.3 Laying the cables in the control cabinet ............................................................. 35
6.9.4 Connecting the cables ........................................................................................ 36
6.10 Connecting floating relay contact signals for sensors ...................................................... 36
6.11 Setting up the machines ................................................................................................... 36
6.11.1 Linking via Profibus ............................................................................................. 37
6.11.2 Linking via floating relay contact ......................................................................... 37
6.12 Setting the slave address on the Profibus expander ........................................................ 38
7 Initial Start-up
7.1 Overview .......................................................................................................................... 43
7.2 Configuring the master controller ..................................................................................... 43
7.2.1 Switching on the master controller ...................................................................... 43
7.2.2 Changing the display language .......................................................................... 44
7.2.3 Selecting menu options ...................................................................................... 44
7.2.4 Entering characters ............................................................................................. 44
7.2.5 Selection lists ...................................................................................................... 44
7.2.6 Password level and key lock ............................................................................... 45
7.2.7 Checking/Setting time and date .......................................................................... 46
7.2.8 Setting summer / winter ...................................................................................... 46
7.2.9 Country-specific settings ..................................................................................... 46
7.2.10 Setting up the display ......................................................................................... 47
7.3 Linking compressors to the master controller .................................................................. 47
7.3.1 Linking the machines .......................................................................................... 47
7.3.2 Settings for machines with frequency-controlled drive (FC) ............................... 48
7.3.3 Registering the Profibus expander ..................................................................... 49
7.3.4 Activating the Profibus interface ......................................................................... 49
7.3.5 Setting the operating hours and maintenance interval counters ........................ 49
7.4 Setting the required pressure ........................................................................................... 50
7.5 Setting the station parameters ......................................................................................... 50
7.5.1 Setting the parameters for the required pressure ............................................... 50
7.5.2 Setting the network pressure .............................................................................. 51
7.5.3 Configuring the restart and charging the compressed air network ..................... 51
7.5.4 Additional settings ............................................................................................... 52
7.6 Programming the shift clock ............................................................................................. 53
7.6.1 Setting the switching points ................................................................................ 53

ii SIGMA AIR MANAGER x/4 ≥1.14 Number: 9_5774 05 USE
Contents
7.6.2 Deleting a switching point ................................................................................... 53

7.6.3 Activating the clock ............................................................................................. 54
7.7 Configuring peripheral devices ......................................................................................... 54
7.7.1 Configuring alarm/warning and service messages ............................................. 54
7.7.2 Configuring further input functions ...................................................................... 55
7.7.3 Configuring further output functions .................................................................... 57
7.8 Master controller commissioning ...................................................................................... 60
7.9 Connecting a PC to the master controller ........................................................................ 60
7.9.1 System requirements .......................................................................................... 61
7.9.2 Connecting the master controller through a local network ................................. 61
7.9.3 Connecting the master controller through a modem (option) ............................. 62
7.9.4 Connecting the master controller through a null modem cable .......................... 67
7.10 Communication ................................................................................................................ 71
7.10.1 Setting the short message (option) ..................................................................... 71
7.10.2 Registering and activating SIGMA AIR CONTROL (option) ............................... 72
7.10.3 Activating send/receive Ethernet layer 4 (option) ............................................... 72
8 Operation
8.1 Displaying operating data ................................................................................................. 73
8.2 Displaying messages ....................................................................................................... 74
8.2.1 Displaying operational messages ....................................................................... 74
8.2.2 Show SMS status ............................................................................................... 75
8.2.3 Show SIGMA AIR CONTROL plus status .......................................................... 75
8.2.4 Show system status and memory access ........................................................... 75
8.3 Show input and output states ........................................................................................... 76
8.4 Calling up system information .......................................................................................... 77
9 Fault Recognition and Rectification
9.1 KAESER SERVICE ......................................................................................................... 78
9.2 Alarm, service and warning messages ............................................................................ 78
9.2.1 Controller messages ........................................................................................... 79
9.2.2 Alarm indications ............................................................................................... 79
9.2.3 Service and warning messages .......................................................................... 84
9.2.4 Notes .................................................................................................................. 85
9.3 O&O messages (operation & observation) ...................................................................... 88
9.4 System messages ............................................................................................................ 88
10 Maintenance
10.1 Maintenance tasks on electrical equipment ..................................................................... 89
10.2 Testing the control panel .................................................................................................. 89
10.3 Changing the buffer battery .............................................................................................. 89
10.3.1 Danger from batteries ......................................................................................... 89
10.3.2 Battery life ........................................................................................................... 90
10.3.3 Battery changing sequence ................................................................................ 90
11 Spares, Operating Materials, Service
11.1 Note the Nameplate ......................................................................................................... 92
11.2 Spare parts ....................................................................................................................... 92
11.3 KAESER AIR SERVICE .................................................................................................. 92
11.4 Displaying version and serial number .............................................................................. 92
12 Decommissioning, Storage and Transport
12.1 De-commissioning ............................................................................................................ 93
12.2 Disposal ........................................................................................................................... 93
13 Annex
13.1 Anchor holes for the control cabinet ................................................................................. 94

Number: 9_5774 05 USE SIGMA AIR MANAGER x/4 ≥1.14 iii
Contents
13.2 Machine assignment ........................................................................................................ 95

13.3 Profibus expander ............................................................................................................ 96
13.4 Master controller settings ................................................................................................. 96
13.4.1 Profibus expander ............................................................................................... 96
13.4.2 Summer/winter changeover ................................................................................ 98
13.4.3 Interface settings ................................................................................................ 98
13.4.4 Pressure regulation settings ............................................................................... 99
13.4.5 Linking the machines .......................................................................................... 101
13.4.6 FC characteristic ................................................................................................. 109
13.4.7 Operating hours and maintenance intervals ....................................................... 110
13.4.8 Further inputs ...................................................................................................... 114
13.4.9 Further outputs ................................................................................................... 119
13.4.10 Settings for SMS ................................................................................................. 124
13.5 Technician's settings ........................................................................................................ 125
13.6 Null modem pin connections ............................................................................................ 126
13.7 Master controller messages ............................................................................................. 126
13.7.1 Operational Messages ........................................................................................ 126
13.7.2 Defined messages .............................................................................................. 127
13.7.3 Definable messages (alarms) ............................................................................. 130
13.7.4 Definable messages (service / warning) ............................................................. 131
13.8 Machine settings .............................................................................................................. 131
13.8.1 Safety pressure switch settings .......................................................................... 131
13.8.2 Pressure range for manual operation ................................................................. 133
13.8.3 System offset for manual mode .......................................................................... 134
13.9 Examples and suggested settings ................................................................................... 135
13.9.1 Example of switching point setting ...................................................................... 135
13.9.2 Linking two small and two large machines ......................................................... 137
13.9.3 Linking 8 equally-sized machines ....................................................................... 137
13.9.4 Linking 2 equally-sized machines and an FC machine ...................................... 138
13.9.5 Connection of 5 machines in total, one of which as reserve .............................. 139
13.9.6 Example of a FC characteristic ........................................................................... 140
13.10 Installation accessories .................................................................................................... 141
13.11 Exchanging the battery .................................................................................................... 144
13.12 Electrical Diagram ............................................................................................................ 144
13.13 Menu option Settings – Overview ..................................................................................... 154

iv SIGMA AIR MANAGER x/4 ≥1.14 Number: 9_5774 05 USE
List of Illustrations
Fig. 1 Control cabinet for models 4/4 and 8/4 ...................................................................................... 7

Fig. 2 Control cabinet for models 8/8 and 16/8 .................................................................................... 7
Fig. 3 Control panel model 16/8 ........................................................................................................... 14
Fig. 4 Display arrangement .................................................................................................................. 16
Fig. 5 Pressure transducer position ...................................................................................................... 27
Fig. 6 Building up the Profibus network ................................................................................................ 30
Fig. 7 Stripping back the Profibus cable ............................................................................................... 31
Fig. 8 Connection of an inline Profibus plug ......................................................................................... 31
Fig. 9 Connection of an end of line Profibus plug ................................................................................. 32
Fig. 10 Configuration of the network with floating relay contacts ........................................................... 32
Fig. 11 Wire jumper removal .................................................................................................................. 33
Fig. 12 Cable glands with and without ferrite suppressors ..................................................................... 34
Fig. 13 Connecting the screening ........................................................................................................... 34
Fig. 14 Cable screening clamps ............................................................................................................. 35
Fig. 15 Ethernet cable screening ............................................................................................................ 35
Fig. 16 Cable routing in the control cabinet ............................................................................................ 36
Fig. 17 PBU 4+4 ..................................................................................................................................... 39
Fig. 18 PBU 4T ....................................................................................................................................... 40
Fig. 19 PBU 8 ......................................................................................................................................... 41
Fig. 20 PBU 32 ....................................................................................................................................... 42
Fig. 21 Output signal scaling .................................................................................................................. 59
Fig. 22 Buffer battery location ................................................................................................................ 90
Fig. 23 Anchor holes for model 4/4 and 8/4 cabinets ............................................................................. 94
Fig. 24 Anchor holes for model 8/8 cabinet ............................................................................................ 94
Fig. 25 Anchor holes for model 16/8 cabinet .......................................................................................... 95
Fig. 26 Null modem cable pin connections ............................................................................................. 126
Fig. 27 Example of linking eight equally-sized machines ....................................................................... 138
Fig. 28 Example for linking two equally-sized machines and a FC machine .......................................... 139

Number: 9_5774 05 USE SIGMA AIR MANAGER x/4 ≥1.14 v
List of Illustrations

vi SIGMA AIR MANAGER x/4 ≥1.14 Number: 9_5774 05 USE
List of Tables
Tab. 1 The levels of danger and their meaning ..................................................................................... 1

Tab. 2 System data ............................................................................................................................... 3
Tab. 3 Connection possibilities .............................................................................................................. 3
Tab. 4 Inputs and outputs ...................................................................................................................... 4
Tab. 5 Electrical data ............................................................................................................................. 4
Tab. 6 Buffer battery life ........................................................................................................................ 4
Tab. 7 Models I and II pressure transducers ......................................................................................... 5
Tab. 8 Models III and vacuum pressure transducers ............................................................................ 6
Tab. 9 Pressure transducers for standard master controllers ............................................................... 7
Tab. 10 Cabinet dimensions .................................................................................................................... 8
Tab. 11 Profibus expander models ......................................................................................................... 8
Tab. 12 Function keys ............................................................................................................................. 15
Tab. 13 Light emitting diodes .................................................................................................................. 15
Tab. 14 Main menu .................................................................................................................................. 18
Tab. 15 Menu option settings F1 ............................................................................................................. 19
Tab. 16 Menu option messages .............................................................................................................. 20
Tab. 17 Ambient temperatures ................................................................................................................ 23
Tab. 18 Installation .................................................................................................................................. 24
Tab. 19 Cable lengths ............................................................................................................................. 29
Tab. 20 Activating addresses .................................................................................................................. 47
Tab. 21 Activating analog input ............................................................................................................... 51
Tab. 22 Activation input ........................................................................................................................... 55
Tab. 23 Settings ...................................................................................................................................... 59
Tab. 24 Commissioning ........................................................................................................................... 60
Tab. 25 Control symbol ........................................................................................................................... 63
Tab. 29 Machine list symbol .................................................................................................................... 73
Tab. 30 Display of analog inputs ............................................................................................................. 76
Tab. 31 Display of analogue values of the PT100 inputs. ....................................................................... 76
Tab. 32 Display of analog output values ................................................................................................. 76
Tab. 33 Alarm indications ........................................................................................................................ 79
Tab. 34 Service and warning messages ................................................................................................. 84
Tab. 35 Notes .......................................................................................................................................... 85
Tab. 36 Spare buffer battery .................................................................................................................... 92
Tab. 37 Machine assignment .................................................................................................................. 95
Tab. 38 Profibus expander ...................................................................................................................... 96
Tab. 39 Profibus expander with 8 channels ............................................................................................ 97
Tab. 40 Profibus expander with 32 inputs ............................................................................................... 97
Tab. 41 Profibus expander with analog inputs and outputs ..................................................................... 97
Tab. 42 Summer/Winter changeover ....................................................................................................... 98
Tab. 43 Interface settings ........................................................................................................................ 98
Tab. 44 Pressure parameters .................................................................................................................. 99
Tab. 45 System parameters .................................................................................................................... 99
Tab. 46 Shift clock settings ...................................................................................................................... 100
Tab. 47 Factory settings for machines 1,2,3 and 4 ................................................................................. 102
Tab. 48 Factory settings for machines 5,6,7 and 8 ................................................................................. 102
Tab. 49 Factory settings for machines 9, 10, 11 and 12 ......................................................................... 103
Tab. 50 Factory settings for machines 13, 14, 15 and 16 ....................................................................... 104
Tab. 51 Settings for machines 1,2,3 and 4 .............................................................................................. 105
Tab. 52 Settings for machines 5,6,7 and 8 .............................................................................................. 106
Tab. 53 Settings for machines 9, 10, 11 and 12 ...................................................................................... 107
Tab. 54 Settings for machines 13, 14, 15 and 16 .................................................................................... 108

Number: 9_5774 05 USE SIGMA AIR MANAGER x/4 ≥1.14 vii
List of Tables
Tab. 55 FC characteristic 1 ..................................................................................................................... 109

Tab. 58 Operating and maintenance intervals ......................................................................................... 111
Tab. 59 Machine selection factory setting ............................................................................................... 114
Tab. 60 Settings for machines 1,2,3,4 ..................................................................................................... 115
Tab. 62 Settings for machines 9,10,11,12 ............................................................................................... 115
Tab. 63 Settings for machines 13,14,15,16 ............................................................................................. 115
Tab. 64 Digital inputs ............................................................................................................................... 115
Tab. 65 Input value 1 ............................................................................................................................... 116
Tab. 66 Input value 2 ............................................................................................................................... 117
Tab. 67 Input value 3 ............................................................................................................................... 117
Tab. 68 Input value 4 ............................................................................................................................... 117
Tab. 69 Input value 5 ............................................................................................................................... 117
Tab. 70 Input value 6 ............................................................................................................................... 118
Tab. 71 Input value 7 ............................................................................................................................... 118
Tab. 72 Input value 8 ............................................................................................................................... 118
Tab. 73 Factory setting (Load, Group alarm) .......................................................................................... 119
Tab. 76 Settings for machines 9,10,11,12 ............................................................................................... 119
Tab. 77 Settings for machines 13,14,15,16 ............................................................................................. 120
Tab. 78 Digital outputs ............................................................................................................................. 120
Tab. 79 Analog outputs ........................................................................................................................... 123
Tab. 80 Short message setting ................................................................................................................ 124
Tab. 81 Technician's settings .................................................................................................................. 125
Tab. 82 Operational messages ............................................................................................................... 126
Tab. 83 Defined messages ...................................................................................................................... 128
Tab. 84 Definable messages (alarms) ..................................................................................................... 130
Tab. 85 Definable messages (service/warning) ...................................................................................... 131
Tab. 86 Suggestion: safety pressure switch 4/4 and 8/4 ......................................................................... 131
Tab. 87 Suggestion: safety pressure switch 8/8 and 16/8 ....................................................................... 132
Tab. 88 Personal settings: safety pressure switch .................................................................................. 132
Tab. 89 Suggested settings: pressure range in manual mode ................................................................ 133
Tab. 90 Suggested settings: pressure range in manual mode ................................................................ 134
Tab. 91 Suggested settings: system offset (manual mode) .................................................................... 135
Tab. 92 Example of a compressor station ON/OFF clock program ......................................................... 136
Tab. 93 Linking two small and two large machines ................................................................................. 137
Tab. 94 Linking the machines .................................................................................................................. 138
Tab. 95 FC characteristic (example: 87 psig) .......................................................................................... 140
Tab. 96 FC characteristic (example: 110 psig) ........................................................................................ 141
Tab. 97 FC characteristic (example: 125 psig ......................................................................................... 141
Tab. 98 Installation accessories for SIGMA AIR CONTROL plus and communication ........................... 141
Tab. 99 Pressure transducer ................................................................................................................... 142
Tab. 100 Pressure transducer accessories ............................................................................................... 142
Tab. 101 Profibus expander models .......................................................................................................... 143
Tab. 102 Profibus fitting accessories ......................................................................................................... 143
Tab. 103 Load/idle module ........................................................................................................................ 143
Tab. 104 RC interference suppressor ....................................................................................................... 144
Tab. 105 Changing the battery .................................................................................................................. 144
Tab. 106 Main menu .................................................................................................................................. 154

viii SIGMA AIR MANAGER x/4 ≥1.14 Number: 9_5774 05 USE
1.1 Using the document

1.1 Using the document
This service manual is part of the controller.
An outline of the keys and the menu tree is found in the fold-out of this service manual.
1. Keep the service manual available as long as you work with the controller.
2. Pass the manual on to the next owner/user of the machine.
3. Make sure that every subsequent modification to the controller is also entered in the service
manual.
1.2 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.
1.3 Licensed brands and trademarks

All licensed brands and trademarks and brands and trademarks licensed to third parties mentioned
in this service manual are subject without restriction to the legislation for the brand and trademark
rights concerned and the ownership rights of the licensed owner in each case. The mere mention
of a trademark alone does not allow the conclusion to be drawn that a trademark is not protected
by the rights of a third party.
1.4 Symbols and markings

1.4.1 Warnings
Warning notices indicate three levels of danger signified by the signal word.
■ DANGER
■ WARNING
■ CAUTION
1. These show the kind of danger and its source.

The possible consequences of ignoring a warning are shown here.
The signal word "DANGER" indicates that death or severe injury can result from ignoring the
warning.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
Signal word Meaning Consequences of non-observance

DANGER Warns of an imminent threat of danger Death or serious injury may result
WARNING Warns of possible danger Death or serious injury are possible
CAUTION Warns of a possibly dangerous situa‐ Light injuries or material damage are possible
tion
Tab. 1 The levels of danger and their meaning

Number: 9_5774 05 USE SIGMA AIR MANAGER x/4 ≥1.14 1
1.4 Symbols and markings
1.4.2 Other instructions and symbols

This symbol refers to 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.
Here conditions relevant to safety are named that will help you to avoid dangerous situations.
➤ This symbol is placed by lists of actions comprising one stage of a task.

In lists of actions with several stages the sequence of actions is numbered.
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... and a remedy given.
This symbol refers to important information or measures concerning environmental protec‐
tion.
Further information Here, your attention is drawn to further topics.

2 SIGMA AIR MANAGER x/4 ≥1.14 Number: 9_5774 05 USE
2 Technical Data
2.1 Master controller models
2 Technical Data
2.1 Master controller models
The first number in the model name shows the number of machines that can be linked to the mas‐
ter controller concerned. The second number stands for the number of machines without
SIGMA CONTROL that can be directly linked.
The master controllers dealt with in this manual are called SIGMA AIR MANAGER and SAM
for short.
The following SIGMA AIR MANAGER models are available:

■ 4/4
■ 8/4
■ 8/8
■ 16/8
➤ Please enter the system data of your SIGMA AIR MANAGER here:
System data
Material number
serial number
Software
Operating system
Tab. 2 System data
Call up the software version and serial number as follows:

➤ Menu <Settings«F1»System«F1»System information«F6» >
2.2 Connection possibilities

Maximum number of machines controlled:
Model 4/4 8/4 8/8 16/8

SIGMA CONTROL 4 8 8 16
I/O via Profibus expander 4 8 8 16
I/O directly to the master controller 4 4 8 8
Tab. 3 Connection possibilities
2.3 Inputs and outputs

■ In principle, every input and output is freely assignable.
■ The number of inputs and outputs can be increased using Profibus expanders (see chap‐
ter 2.9)
■ Details on assignable and assigned inputs and outputs can be found in the circuit dia‐
grams in the attachment.

2 Technical Data
2.4 Electrical data
Model 4/4 8/4 8/8 16/8

Digital inputs (DI) for floating relay signals 4 4 24 48
Floating relay digital outputs (DO) 5 5 24 32
(as changeover contact, 230 V, 3 A)
Analog inputs (AI) 1 1 2 4
0(4)-20 mA
Analog inputs (AI) 0 0 2 4
PT100
Analog outputs (AO) 1 1 1 2
(0-20 mA, load max. 300 Ω)
Tab. 4 Inputs and outputs
2.4 Electrical data

Model 4/4 8/4 8/8 16/8
Supply voltage/phase/network frequency [V//Hz] 100–240/1/50–60
Rated current [A] 0.7–0.35 1.22–0.66
Fuses [A] 10–16
Power cable core cross-section [mm ] 2 3x1.5
Equipotential bond connection [mm2] 1x16
Enclosure protection IP54 to IEC 529
Buffer battery [V] / [Ah] 3.6/1.8
Tab. 5 Electrical data
Battery life
Model 4/4 8/4 8/8 16/8

Life [in years] without power supply 3 3 3 3
Life [in years] with power supply 10 10 10 10
Tab. 6 Buffer battery life
2.5 Hardware
2.5.1 Industrial computer
■ Industrial computer with Pentium® class processor
■ Analog inputs and outputs (0-20 mA)
■ 230/115 V relay outputs (floating contacts)
■ 24 V common negative rail digital inputs
■ Internal under-voltage monitoring of 24 V supply

2 Technical Data
2.6 Software
■ Internal temperature monitoring

■ Buffer battery for RAM and real-time clock
2.5.2 Interfaces
The SIGMA AIR MANAGER has the following interfaces:
■ RS 232 for SIGMA AIR CONTROL visualization and interface converter
■ Profibus DP Master (187.5 kbit/s) for KAESER PBE and SIGMA CONTROL
■ Ethernet for visualization and central control systems
■ PCMCIA slot for KAESER storage module, KAESER modem and updates
2.5.2.1 RS 232
■ no potential isolation
■ max. 38.4 kbit/s
■ 9-pin sub-D connection (master controller: pin and socket)
■ 4-40 UNC screw locking
■ Mating connector (screened housing)
■ Screened connector cable
■ See attachment for pin assignments
2.5.2.2 Ethernet
■ 10 Base T (Industrial Twisted Pair)

■ Potential isolation
■ max. 10 kbit/s
■ 8-pin RJ-45 connection (master controller plug and socket)
2.6 Software
■ RMOS real-time operating system
■ Controller software
■ Visualization software
■ Data base
2.7 Pressure transducer

Models I and II pressure transducers
Model I II
Measurement range [psig] 0–14.5 0–
87/145/232/290/464
Overload limit [psig] 50 double final pressure
Deviation of characteristic from final value ≤ 0.5 ≤ 0.5 (0.25 typical)
Limit setting [%]

2 Technical Data
2.7 Pressure transducer
Model I II
Air connection. male thread G 1/2 B DIN 16288 G 1/4 A DIN 3852
Stainless steel Stainless steel
Viton seals
Rated temperature range [°F] –4...+176 –13...+185
Rated temperature range [rankine] 455...635 446...644
Mean temperature range [°F] –22...+212 –40...+212
Mean temperature range [rankine] 437...671 437...671
Storage temperature range [°F] –40...+212 –40...+212
Storage temperature range [rankine] 419...671 419...671
Temperature influence / 18 rankine at zero [%] ± 0.2 ± 0.15
Temperature influence / 18 ranking over the range ± 0.2 ± 0.15
[%]
Output signal (two-wire technique) [mA] 4–20 4–20
Power supply connection PG 11 PG 9
(plug to EN 175301-803)
Enclosure stainless steel stainless steel
Enclosure protection IP 65 IP 65
Tightening torque [Nm] 17–20 17–20
Tab. 7 Models I and II pressure transducers
Pressure transducer model III and vacuum
Model III Vacuum pumps

Measurement range [psig] 0–232 –
Measurement range. psia] – 0–14.5
Overload limit [psig] 464 43.5
Deviation of characteristic from final value ≤ 1 (0.5 typical) ≤ 1 (0.5 typical)
Limit setting [%]
Air connection. male thread G 1/2 A G 1/2 A
Air connection. male thread G 1/8 A G 1/8 A
Rated temperature range [°F] –13...+176 –13...+185
Rated temperature range [rankine] 446...644 446...644
Mean temperature range [°F] –22...+212 –22...+212
Mean temperature range [rankine] 437...671 437...671
Storage temperature range [°F] –40...+212 –40...+212
Storage temperature range [rankine] 419...671 419...671
Temperature influence / 18 rankine at zero [%] ± 0.4 ± 0.4
Temperature influence / 18 rankine over the range ± 0.4 ± 0.4
[%]
Output signal (two-wire technique) [mA] 4–20 4–20

2 Technical Data
2.8 Control cabinet
Model III Vacuum pumps

Power supply connection PG 9 PG9
(plug to EN 175301-803)
Enclosure brass brass
Enclosure protection IP 65 IP 65
Tightening torque [Nm] 17–20 17–20
Tab. 8 Models III and vacuum pressure transducers
Assignment of pressure transducer to the master controller
Model 4/4 8/4 8/8 16/8

II x x x
III x
Tab. 9 Pressure transducers for standard master controllers
2.8 Control cabinet
C0200
Fig. 1 Control cabinet for models 4/4 and 8/4
C0201
Fig. 2 Control cabinet for models 8/8 and 16/8

2 Technical Data
2.9 Profibus expander (PBE)
Model 4/4 8/4 8/8 16/8

Material 1) 1) 1) 1)
Width [in] 15 15 20 32
Height [in] 20 20 28 47
Depth [in] 9 9 10 12
Weight [lb] 33 33 88 441
1)
Sheet metal, painted RAL 7035 light-grey
Tab. 10 Cabinet dimensions

Profibus expanders can be used if:
■ there are not enough inputs available in the master controller for messages from the machine,
■ cables exceed permissible lengths.
Only Profibus expanders from KAESER and any combinations thereof that are listed below may be
used:
Model PBU PBU PBU PBU PBU PBU

Profibus Expander (PBE) 8 8K 8R 32 4+4 4T
Digital inputs/outputs (DI/DO) 8 8 8 32/0 – –
Integrated output coupling relay – – 4 – – –
Analog inputs and outputs (AI/AO 0–20 mA) – – – – 4/4 –
Analog inputs (AI PT100) – – – – – 4
Maximum number of linked Profibus expanders 8 8 8 2 2 2
Maximum number of inputs and outputs 64 DI / DO 64 DI 8 AI 8 AI
created by linking several PBEs 8 AO
Tab. 11 Profibus expander models
All Profibus expanders are equipped with their own housing (exception: PBU 8 K) with integrated
power unit and require a power supply (115/230V). They have to be registered on the master con‐
troller (see chapter 7.3.3).
Profibus expander (PBE) uses
■ PBE 8:
─ Additional connection of up to eight digital inputs or outputs for further signals, for example,
from air treatment components, signal sensors or output signals from user's components.
■ PBE 8 K:
─ As for PBE 8, however, without housing. It can be integrated in machines or refrigerated
dryers.
■ PBE 8 R:
─ Typical application: LOAD/IDLE signal via coupling relay, "motor running" feedback signal
via digital inputs. Only one PBE with a cable connection (bus cable) to the master controller
is required for control of up to four conventional compressors (in one room).

2 Technical Data
■ PBE 32:
─ Additional connection of up to 32 digital inputs for further signals to the master controller, for
example from air treatment components, conventional compressors, other sensors.
■ PBE 4 + 4:
─ The additional connection of up to four analog inputs and outputs, for example system pres‐
sure to the master controller, forwarding of the required pressure to user's components.
■ PBU 4T:
─ Additional connection of up to 4 analog, two, three or four-line PT100 inputs, e.g. for sens‐
ing room temperature, cooling water temperature or the temperatures of other user's devi‐
ces.

3.1 Basic instructions

3.1 Basic instructions
Disregard of these instructions can result in serious injury.

➤ To operate the master controller safely, read the service manual carefully and take no‐
tice of its contents.
The master controller is manufactured to the latest engineering standards and acknowledged safe‐
ty regulations. Nevertheless, dangers can arise through its operation:
■ danger to life and limb of the operator or third parties,

■ Impairment of the master controller and other property.
➤ Therefore, observe the following:

■ Use the controller 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 man‐
ual.
■ In particular, immediately rectify (have rectified) any faults that could be detrimental to
safety.
3.2 Specified use

Specified use also includes compliance with the instructions in this manual.
The master controller is intended exclusively for the operation of compressors, blowers and vac‐
uum systems in industrial fields and may only be operated within its associated control cabinet.
Any other use is considered incorrect.
The manufacturer is not liable for any damages that may result there from. The user alone is liable
for any risks incurred.
➤ Adhere to the specified use given in this manual.
3.3 Improper use

Specified use also includes compliance with the instructions in this manual.
Converting or changing the master controller constitutes improper use. The manufacturer's warran‐
ty is made invalid in such cases.
1. Adhere to the specifications in the service manual.
2. Do not allow conversions or changes.

3.4 User's responsibilities
3.4 User's responsibilities

3.4.1 Observe statutory and universally accepted regulations
➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐
nance of the equipment.
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.
Authorized operators possess the following qualifications:

■ are of legal age,
■ are familiar with and adhere to the safety instructions and sections of the service manual rele‐
vant to operation,
■ have received adequate training and authorization to operate electrical and compressed air de‐
vices.
Authorized installation and maintenance personnel have the following qualifications:

■ are of legal age,
■ have read, are familiar with and adhere to the safety instructions and sections of the service
manual applicable to installation and maintenance,
■ are fully conversant with the safety concepts and regulations of electrical and compressed air
engineering,
■ are able to recognize the possible dangers of electrical and compressed air devices and take
appropriate measures to safeguard persons and property,
■ they have received adequate training in and authorization for the safe installation and mainte‐
nance of this master controller.
➤ Ensure that personnel entrusted with operation, installation and maintenance are qualified and
authorized to carry out their tasks.
3.5 Dangers
The general safety instructions in this chapter describe possible dangers and how to deal with
them. Special safety instructions are found in this service manual at the beginning of each chapter
or directly before a task instruction.
➤ Take full heed of all safety instructions.
3.5.1 Safely dealing with sources of danger

Electricity
➤ Disconnect the machine from all power supply phases.

➤ Switch off any external power sources.
External voltage is still present on the marked terminals (orange or labelled) in the master
controller when the power supply is switched off.

3.6 Warranty
➤ Check and ensure that no power is present.

➤ Before switching on again make sure that
■ no maintenance personnel are working,
■ all panels are in place,
■ all access doors are closed.
➤ Allow only qualified electricians or trained personnel under the supervision of a qualified electri‐
cian to carry out work on electrical equipment according to electrical engineering regulations.
➤ Observe all accepted safety regulations and national legislation applicable to all work carried
out on the master controller.
➤ Use fuses corresponding to machine power.
➤ Make electrical connections only with power removed and check regularly for tightness and
condition.
➤ Only use only electrical cables that are suitable and approved for the surroundings and electri‐
cal loads applied.
➤ Before every start-up by the user of machines that are linked to the master controller, make
sure there is adequate protection against electric shock from direct or indirect contact and
check regularly.
3.5.2 Using the master controller safely

Pay attention to the following points to avoid damage to the master controller:
➤ Do not remove any plugs on the master controller while the compressed air system is in opera‐
tion.
➤ Operate the master controller only when all supplies are connected.
➤ Do not short circuit the supply pins of the Profibus interface.
A short circuit can cause irreversible damage to the Profibus interface.
➤ Never modify, bypass or disable safety devices.

➤ Do not remove or obliterate labels and notices.
➤ Use only spare parts that have been approved by the manufacturer for this master controller.
3.6 Warranty
This service manual contains no independent warranty commitment. Our general terms and condi‐
tions of business apply with regard to warranty.
A condition of our warranty is the specified use of the master controller under observation of the
specific operating conditions.
Due to the large number of possible applications, it is incumbent on the user to determine whether
the master controller can be used for any specific application.
Furthermore, we accept no warranty obligation for:

■ the use of unsuitable parts or operating materials,
■ unauthorized modifications,
■ incorrect maintenance,
■ incorrect repair.

3.6 Warranty
Correct maintenance and repair means the use of genuine Kaeser spare parts.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.

4.1 Overview

4.1 Overview
The SIGMA AIR MANAGER master controller is designed for the control of compressor stations
with several compressors. The master controller reacts flexibly to fluctuating compressed air de‐
mand, so reducing energy consumption. In addition, it allows the use of various monitoring func‐
tions.
The master controller consists of the following components:

■ The central pressure transducer measures the pressure in the air main and passes the value
on to the arithmetical unit.
■ The arithmetical unit decides according to default parameters, which machines are switched to
load to keep the pressure in the air main constant. It also makes possible evaluation, visualiza‐
tion and archiving of the data.
■ The display and control panel gives information on actual pressure and other parameters and
offers various possibilities for individual settings.
■ The SIGMA AIR CONTROL basic software makes possible the visualization of important data
on an external PC.
■ The optional software SIGMA AIR CONTROL plus makes possible an evaluation and storage
of the data on an external PC.
■ The short message (SMS) option offers the possibility of sending alarm and service messages.
■ The optional send/receive protocol allows the master controller to be linked to a user's central
control system via Ethernet.
■ Network section control allows the control of a network that is divided into two sections.
Both compressors with SIGMA CONTROL and those with conventional controllers can be linked to
the master controller.
4.2 Control panel
Fig. 3 Control panel model 16/8

4.2 Control panel
4.2.1 Keys
Symbol Key Function
«Arrow keys» Move the cursor (depending on operational situation ei‐
ther field-wise or entry-wise to the left, right, up or
down).
«escape» Jump back to the next higher menu level. Exit edit mode
esc
without saving the edited parameter.
«Enter» Exit edit mode saving the edited parameter.
«ON» Switch on the compressor station.
«OFF» Switch off the compressor station (no compressed air

0 demanded).
«Automatic mode» Switch the station between manual and automatic mode.
«Shift clock» Switch the clock on or off
«Remote » Switch the station on or off from a control center.
«Machine selection» Delete from or add individual machines to the selection.

1 16
«Function keys» Select displayed functions.

F1 F6
«Acknowledgement» Confirm messages and reset the event memory (if per‐
missible).
«Information» Display help and explanatory text.

i
Tab. 12 Function keys
4.2.2 Table of light emitting diodes

Symbol Name Meaning
Compressor sta‐ The compressor station is switched on.
tion ON
Automatic mode The station runs in automatic mode.

4.2 Control panel
Symbol Name Meaning

Shift clock opera‐ The station is controlled by the shift clock.
tion
Remote mode The station can be controlled by a control center.
Machine selection This machine is selected (is available to the master controller).
1 16
Alarm Flashing: fault on a station component.

Illuminated: the alarm has been acknowledged, but the fault
has not yet been removed.
Communication Communication via a data interface is interrupted
alarm Fault between the master controller and compressor or be‐
tween the master controller and another controller.
Pressure low Network pressure has fallen below the setpoint.
Maintenance and Flashing: Maintenance work necessary.

warning indicator Illuminated: Maintenance indication acknowledged, but mainte‐
nance not yet carried out.
Controller power Power supply to the master controller is present.
ON
Help key Additional information on the actual program function is availa‐

i ble.
Tab. 13 Light emitting diodes
4.2.3 Display
The display is arranged as follows:
Fig. 4 Display arrangement

1 Header
2 Main field: machine status / message texts / settings
3 Menu selection footer (example)
The following information is displayed from left to right in the header 1 :

■ System running: represented by a rotating symbol.
■ Mode: station in automatic mode, manual mode or shut down.

4.3 List of menus
■ Pressure indication: shows the momentary network pressure.

■ Tendency: the arrow shows whether pressure is rising, is constant, or falling.
Main display area 2 : depending on operational state and setup, various events and settings are
shown.
Footer 3 : the functions and menu options that can be called up with the keys «F1» to «F6» are
shown.
4.2.4 Password protection

Access to the master controller is controlled by four levels of authority that are protected by pass‐
word.
When the master controller is switched on, the lowest level of access (Level 0) is activated. In Lev‐
el 0 parameters can be displayed and some of these can be edited.
The password sets itself back to Level 0 if no entries are made over a period of 5 minutes.
The level of authority required will be quoted in this manual for every function.
4.3 List of menus

An overview of the main menu is provided at the end of this manual.
4.3.1 Main menu level

Normally, the main menu with current information on the compressed air system is displayed.
These are distributed over numerous display frames that can be scrolled with the «F5» and «F6»
keys.
■ Large type-size display of pressure

■ Pressure/time diagram
■ Overall FAD
■ Machine overview
■ Operating data
■ Maximum, mean and minimum working pressure
See chapter 8.1 for further information on these displays.
4.3.2 Menu tree

Use the «F1» to «F4» keys to select the following menu options:

4.3 List of menus
Navigation (menu) Symbol Sub-menu options Chapter

«F1»: Settings ■ «F1»: System 7.2
■ «F2»: Control 7.4
■ «F3»: Compressor 7.3
■ «F4»: Compressed air system 7.5
■ «F5»: Shift clock 7.6
■ «F6»: Periphery 7.7
«F2»: Messages function key ■ «F1»: Alarm, service and warning messages 9.2
■ «F2»: Operational Messages 8.2.1
■ «F3»: SMS status 8.2.2
■ «F4»: SAC plus status 8.2.3
■ «F5»: System status 8.2.4
■ «F6»: Memory access 8.2.4
«F3»: Choice of language ■ «F1»+«F6»: Choice of language 7.2.2
■ «F3»: Notes
«F4»: Password ■ «F1»: Logout 7.2.6.1
■ «F2»: Password list 7.2.6.2
■ «F3»: Key lock 7.2.6.3
■ «F4»: Password allocation 7.2.6.4
Tab. 14 Main menu

4.3 List of menus
Menu options for F1 (Settings)
Menu option Sub-menu options

«F1»: System «F1»: General ■ «F1»: Date and time
settings ■ «F2»: Summer / winter
■ «F3»: Country-specific settings
■ «F4»: Operating ■ «F1»: Lamps test
panel ■ «F2»: Keys test
■ «F3»: Display test
■ «F4»: Display set‐
tings
«F3»: Interfaces ■ «F1»: Profibus
■ «F2»: RS 232
■ «F3»: Modem
■ «F4»: Ethernet
«F4»: Input/output ■ «F1»–«F4»: Digital and analog inputs and
states outputs
«F5»: Communication ■ «F1»: Short Message System (SMS)
■ «F2»: SIGMA AIR CONTROL plus
■ «F3»: SEND / RECEIVE
«F6»: System information
«F2»: Control «F1»: Further settings
«F2»: Control dynamics
«F3»: Compressor «F1»: Connection
«F2»: Hours
«F3»: FC characteristic
«F4»: Further settings
«F4»: Compressed air «F1»: Required pressure
system «F2»: Network pressure
«F3»: Restart
«F4»: Further settings
«F5»: Section control
«F5»: Shift clock

4.4 Operation and function
Menu option Sub-menu options

«F6»: Periphery «F1:» ■ «F1»: Defined messages
Alarm/Warning/ ■ «F2»: Definable messages (alarms)
external service
■ «F3»: Definable messages (service / warn‐
ing)
«F4:» ■ «F1»: Digital inputs
Further input functions ■ «F2»: Analog inputs setting
■ «F3»: Display of analog inputs
«F5:» ■ «F1»: Digital outputs
Further output func‐ ■ «F2»: Analog outputs
tions
«F6:» ■ «F1»: Digital (8 I/O)
Profibus expander ■ «F2»: Digital (32 I)
■ «F3»: Analog (4 I/4 O)
■ «F4»: PT100 (4 I)
Tab. 15 Menu option settings F1
Menu options for Messages (F2)
Menu Submenu
«F1»: Alarm, service and warning messages ■ «F1»: Current messages
■ «F2»: Event history
«F2»: Operational Messages ■ «F1»: Current messages
■ «F2»: Event history
«F3»: SMS status
«F4»: SAC plus status
«F5»: System status
«F6»: Memory access
Tab. 16 Menu option messages

The master controller was designed and developed for a number of applications. Generally, most
of the default settings can be kept or have to be changed only slightly.
4.4.1 Adaptive 3D control

The adaptive 3D control minimizes the energy requirements of the compressed air station by auto‐
matically adapting to the operating conditions.
It automatically adapts the selection of the compressors to be activated and deactivated as well as
the cut-out and cut-in pressures for the selected compressors to the current operating conditions of
the compressed air station.

4.4.2 Base load sequence

The controller will equally use machine of the same size. The standard for comparison is the num‐
ber of operating hours.
The machine with the least number of operating hours is used the most.
4.4.3 Shift clock mode

The compressed air system can be operated from a shift clock. There are 32 switching points per
week available.
Further information See chapter 7.6 for programming the clock.
4.4.4 Power limiting

If the power limiting function is activated, the system will add compressors only to the point where
the overall load capacity of the running compressors exceeds the specified power limit.
Further information See chapter 7.5.4 for further information on power limiting settings.
4.4.5 Air main charging

After the activation of the compressed air station, the air network is charged at the specified net‐
work charging speed.
Further information Air main charging, see chapter 7.5.3.
4.4.6 EMERGENCY operation

A compressed air station can run EMERGENCY operation if each compressor has its own system
pressure switch or electronic controller. This is always the case with rotary screw compressors.
Compressed air systems with rotary blowers or reciprocating air compressors may or may not have
machines provided with their own system pressure switches.
Air stations comprising machines that do not contain their own system pressure switches cannot
run in EMERGENCY operation. These compressed air systems cannot deliver compressed air
without a master controller.
Compressor stations with EMERGENCY mode (manual mode)
EMERGENCY mode can cause large pressure swings in the air main.
The air compressors linked to the master controller are automatically switched to emergency mode
if power is lost to the master controller while it is switched on (LED "Station ON" is illuminated), if
the connection to the pressure transducer is interrupted or the master controller itself fails. The
compressors then run under their internal controllers, independent of the master controller.
The machines can be manually switched to EMERGENCY operation (manual mode) for test pur‐
poses.
Compressor stations without EMERGENCY mode capability
Without a master controller no compressed air can be delivered.

The output relays trip if power to the master controller is lost, if the connection to the pressure
transducer is interrupted or the controller itself fails. This causes air compressors linked to the mas‐
ter controller to switch to idle or off. The compressed air system no longer delivers compressed air.
4.4.7 Visualization with SIGMA AIR CONTROL basic

Data from the master controller can be visualized on an external PC with SIGMA AIR CONTROL.
A web browser is used for the visualization.
The data include:

■ Status of the compressor station and/or individual machines
■ Alarm, service and warning messages
■ Minimal. maximal and momentary system pressure, required pressure and FAD
■ Graphic representation of the pressure band over time
Further information For linking a PC to the SIGMA AIR MANAGER, see chapter 7.9.

5.1 Surroundings

5.1 Surroundings
Temperature range
Ambient temperatures
Ambient temperature 0 to 104 °F
Storage temperature -13 to +131 °F
Tab. 17 Ambient temperatures
Note permissible ambient temperatures

1. Check ambient temperature.
2. Adjust equipment location to suitable ambient temperature range.
Note storage temperature
1. Check temperature of storage location.
2. Adjust storage temperature to suitable range.
5.2 Installation conditions

Installation conditions for master controllers 4/4 and 8/4
Models 4/4 and 8/4 master controllers may be operated under general or industrial conditions.
➤ Install the master controller as appropriate.
Installation conditions for master controllers 8/8 and 16/8
Models 8/8 and 16/8 master controllers may only be operated in industrial areas that are supplied
from their own supply transformer. This transformer may not supply power to a residential area out‐
side the industrial area.
➤ Install the master controller as appropriate.
Certain conditions for the installation location must be fulfilled:
■ Free access to the control cabinet.

■ Fully opening control cabinet door.
■ A free escape route must be maintained (also with the control cabinet door fully open).
■ Protection from direct sunlight, rain, splashed water or excessive dust build up must be
provided.

6 Installation
6.1 Installation
6 Installation
6.1 Installation
Link SIGMA CONTROL Conventional Chapter
Installing the control cabi‐ x x See 6.4
net
Identifying the machines x x See 6.5
Connecting the pressure x x See 6.6
transducer
Planning cabling x x See 6.7
Laying cables x x See 6.8
Building up the Profibus x − See 6.8.1
network
Building up the compres‐ − x See 6.8.2
sor station
via floating relay
contacts
Lead in the cables and x x See 6.9
connect to the
master controller
Setting up the machines x x See 6.11
Tab. 18 Installation
6.2 Reporting transport damage

1. Incorrect transport
Machine damage
➤ Protect the equipment against vibration and shock.
2. Check the master controller for visible and hidden transport damage.
3. Inform the carrier and the manufacturer in writing of any damage without delay.
6.3 Compressed air supply during installation

➤ Check the compressor station emergency operating characteristics.
■ See chapter 6.3.1 for stations with EMERGENCY mode.
■ See chapter 6.3.2 for stations without EMERGENCY mode.
6.3.1 Station with emergency operating mode

It is possible to install and start up the master controller without shutting down the complete air sys‐
tem.

6 Installation
6.4 Installing the control cabinet
Mortal danger from electric current

➤ The machine must be free of voltage before work begins.
1. Isolate the machine from all sources of voltage.

2. Make sure the machine is voltage-free.
3. Connect the machine to the master controller see chapter 6.7 to 6.10).
4. Put the machine back into operation.
5. Repeat steps 1 to 3 for any further machines.
6. Carry out settings as detailed in chapter 7.
7. Do not switch the master controller from manual to automatic mode until these settings have
been completed.
The master controller then takes over control of the machines.
Further information See chapter 4.4.6 for emergency operation.
6.3.2 Stations without emergency operating mode

The master controller is required for the supply of compressed air. The compressed air system is
not operational until initial start-up of the master controller is completed.
➤ Switch on the compressor station after commissioning the master controller.
Further information See chapter 4.4.6 for emergency operation.
6.4 Installing the control cabinet

A solid, vibration-free and load-bearing wall is required for the control cabinet.
Pay attention to the following when fitting the control cabinet:
■ The display must be level with the eyes to ensure good readability.
■ The fixing materials must be compatible with the type of wall and the weight of the control
cabinet.
■ A template for the boreholes is to be found in the annex.
■ Pay attention to the installation conditions (see chapter 5.2)
➤ Mount the control cubicle on the wall.
6.5 Identifying the machines

Same model machines have to be identified as well, because the internal pressure regulation
can be set differently.
➤ Give the machines individual numbers.

The source of alarm and service messages displayed on the master controller can be assigned
to the correct machine.

6 Installation
6.6 Connecting the pressure transducer
Machine and controller marking when in remote mode
The machines and controller must carry a warning notice when they are in remote mode.
■ Warning notice to indicate the machines.

─ WARNING: This machine is remotely controlled and can start automatically at any
time.
■ Warning notice to indicate the master controller.
─ Before starting, make sure that no one is working on the machines and that they can
be started safely.
Place the notices so they are highly visible.
1. Place warning notices on the machine.
2. Place warning notices on the master controller.

Precondition The connection point is not under pressure.
Network pressure too high.

Damage to the pressure transducer can occur.
➤ Never connect the pressure transducer to a pressurized network having a maximum
pressure exceeding the rated pressure of the pressure transducer.
1. Check the maximum network pressure.

2. Check the nominal network pressure.
6.6.1 Mechanical connection

The pressure transducer graphic (Illustration 5) shows the correct position for the transducer.

6 Installation
Fig. 5 Pressure transducer position

1 SIGMA AIR MANAGER 6 Compressed air production
2 Machine 1 7 Compressed air treatment
3 Machine 2 8 Air receiver
4 Machine 3 9 Shut-off valve
5 Machine 4 10 Pressure transducer

6 Installation
6.7 Planning cabling
➤ Pay attention to the following when connecting the pressure transducer:

■ Connect the pressure transducer either to the side or the top of the air receiver so that no
condensate can settle.
■ If the pressure transducer is connected to the main collector pipe, fit a small, additional air
receiver (item 8 order separately, see chapter 13.10 for the material number).
■ Fit the pressure transducer downstream of the air treatment components because pres‐
sure losses caused by air treatment components or pipework can occur between the ma‐
chine and the point of measurement.
■ The airflow at the point of measurement must not pulsate.
■ Pay attention to the installation depth.
■ Fit a shut-off valve between the air receiver and the pressure transducer. This allows re‐
placement of the pressure transducer without having to vent the air receiver. Do not close
the shut-off valve during operation.
■ A kit of parts for the air connection is available separately (see chapter 13.10 for the mate‐
rial number).
6.6.2 Power Supply

Avoid signal corruption.
1. Use two conductor shielded cable with minimum section 18 AWG.

2. The pressure transducer must be grounded.
■ Ground by metallic contact with the air receiver or
■ via a separate equipotential bond with minimum section 1 x 7 AWG (e.g. a ground clamp
on the transducer housing).
3. Connect the SIGMA AIR MANAGER and the pressure transducer to the same equipotential
bond. The potential difference between both grounding points must be zero.
4. Connect the cable screening to ground on the pressure transducer and to a screening connec‐
tion in the control cabinet.
5. Maintain a separation of at least 4 inches between connecting cables and power cables.

There are two methods of linking the machines to the master controller:
■ via Profibus
(for machines with SIGMA CONTROL or machines that are connected to a Profibus expander
(see chapter 6.8.1)
■ via floating relay contacts
(for conventional machines without SIGMA CONTROL; see chapter 6.8.2).
These two methods can be mixed, that is, some of the machines can be linked via a Profibus and
some via floating contacts.
Instructions on the electrical installation
A supply disconnecting device must be installed by the user. On model 16/8 this device is included
as standard.
The maximum lengths for digital input and output cables are listed below.

6 Installation
Model 4/4 and 8/4 8/8 and 16/8 Profibus ex‐

pander
Maximum cable length [ft] 330 100 100
Tab. 19 Cable lengths
■ Use galvanic isolation on cables laid outside the building to ensure lightning protection (pref‐
erably fibre optic cable).
■ See circuit diagrams in the annex for cable types, cross-sections and cable selection. Use flex‐
ible cables as far as is possible. Flexible cables must be used in the control cabinet on mod‐
els 4/4 and 8/4, except power supplies, equipotential bonds and Profibus.
■ Suppress inductive loads connected to the relay outputs of the master controller on models 4/4
and 8/4, see chapter 6.8.2.
■ If the SMS option is chosen, fit and connect a KAESER modem, see SMS instruction memo‐
randum.
6.7.1 Accessories needed for a link via Profibus

The following accessories are required for the construction of a Profibus network (see Annex
13.10)
■ Profibus cables
■ Profibus plug for SIGMA AIR MANAGER (already supplied with model 16/8)
■ Profibus plug set for SIGMA CONTROL
6.7.2 Requirements for a link via a floating relay contact

The connection to the floating relay output of the master controller is in series with the system
pressure switch in the machine.
Required contacts for machines to be connected to the SIGMA AIR MANAGER.

Models 4/4 and 8/4
■ an external load control input
■ a floating "motor running" relay contact (normally open)
Models 8/8 and 16/8

■ A "manual/automatic mode" / "load/idle" control input with a system pressure switch in manual
mode B1.1
and
─ a safety pressure switch for master controller operation B1 or
─ a blowoff protection safety relief valve pressure switch B6
■ a floating "motor running" relay contact (normally open)
■ a floating "ON and no alarm" contact (normally open).
If a machine is not equipped for connection to a master controller, it can be retrofitted. Documents
and parts for the retrofit are available separately.

6 Installation
6.8 Laying cables
6.8 Laying cables
Contact with live electric components can cause serious injury or death.
➤ Isolate the master controller and external sources from all voltage.
1. Switch off all phases of the controller and external power sources.
2. lock them out,
3. observe all accepted safety regulations and national legislation applicable to all work carried
out on the master controller.
4. Have the master controller connected to the power supply by an authorized and qualified elec‐
trician to national legislation and the regulations of the electricity company concerned.
The terminals in the master controller that could be supplied by an external voltage source
are marked:
Markings
■ Orange or
■ Label
5. Make the connections to the power supply, to the individual machines and to the pressure
transducer as detailed in the circuit diagrams.
6.8.1 Building up the Profibus network

The links to Profibus subscribers are connected in series, i.e, they are connected one after the oth‐
er. The master controller is the last in the series.
Fig. 6 Building up the Profibus network

1 Master controller
2 Machine with SIGMA CONTROL
3 Terminating resistor
1. Switch in the terminating resistor 3 at both ends of the cable.

2. See circuit diagrams in the annex for cable types, cross-sections and maximum cable lengths.

6 Installation
6.8 Laying cables
6.8.1.1 Connecting the Profibus
Fig. 7 Stripping back the Profibus cable
1. Strip back the Profibus cable as shown in fig. 7.

2. Connect the green core to the green terminal (A) in the Profibus plug.
3. Connect the red core to the red terminal (B) in the Profibus plug.
6.8.1.2 Connecting the Profibus plugs
Too tight a bend radius can cause a defect in the Profibus cable.
➤ Do not kink Profibus cables.
Subscribers in the middle of a Profibus network:

Connecting a Profibus expander to a connected subscriber in a Profibus network:
Fig. 8 Connection of an inline Profibus plug
1. Connect two Profibus cables (input and output)

2. Set the switch on the Profibus plug to OFF to deactivate the terminating resistor.
Subscribers at the end of the Profibus network
Connect the Profibus plug at the end subscriber and the master controller:

6 Installation
6.8 Laying cables
Fig. 9 Connection of an end of line Profibus plug
1. Connect one Profibus cable (input only).

2. Set the switch on the Profibus plug to ON to activate the terminating resistor.
6.8.2 Building up the compressor station via floating relay contacts

The connection of the machines via floating contacts is in the form of a star, i.e. each individual
machine is connected directly to the master controller.
Fig. 10 Configuration of the network with floating relay contacts

1 Master controller
2 Machine without SIGMA CONTROL
1. Use conventional wiring.

2. Connect each machine directly with the master controller.
6.8.2.1 Wiring changes on the machines when connecting to models 4/4 and 8/4
Interruptions to the air supply caused by unsuppressed inductive loads connected to the relay
outputs of the master controller, such as auxiliary contactors or solenoid valves.
1. Suppress inductive loads with an RC interference suppressor.

6 Installation
6.9 Connecting the cables to the master controller
2. Connect the interference suppressor in parallel with the coil (connections A1–A2). If the con‐
nections are inaccessible, e.g. solenoid valves, the suppressor can also be connected to the
corresponding terminals on the terminal strip.
3. Use an RC interference suppressor suited to the coil voltage and apparent holding power, see
chapter 13.10.
KAESER machines from 1990 onwards (with terminal 32W)
Fig. 11 Wire jumper removal
➤ Remove the jumper between the terminals (terminals 32W and 21 or 18) to allow sequencing.
Machines without terminal 32W
1. Fit terminal 32W in the terminal strip.

2. Disconnect the conductor in the cable from the network pressure switch that is connected to
terminal 21 or 18.
3. Connect the conductor to terminal 32W.
6.8.2.2 Wiring changes on the machines when connecting to models 8/8 and 16/8
KAESER machines from 1990 onwards
If a jumper is connected between the terminals for manual operation [-X1 (W) 20 or 17 and -
X1 (W) 24 (W)] on the terminal strip for connection of the master controller, then it must be re‐
moved. A more precise designation of the terminals is given in the electrical diagrams for the ma‐
chine.
➤ Remove wire jumper if necessary.

6.9.1 Connecting the equipotential bond
1. Connect the master controller housing to the user's equipotential bond with the marked bolts.
2. Keep the connection as short as possible.
3. Use an earth strap or cable with a cross-section of at least 16 mm2.

6 Installation
6.9.2 Leading in cables and connecting the screening

6.9.2.1 Models 4/4 and 8/4
Fig. 12 Cable glands with and without ferrite suppressors

1 Cable glands for screened cables 3 Cable glands for non-screened cables
2 Cable gland for power supply cable 4 Cable gland for Ethernet
1. Lead non-screened cables (for digital inputs and relay outputs) through the front cable glands
fitted with ferrite suppressors to protect them against electromagnetic interference.
2. Lead screened cables (for pressure transducer, analog outputs, Profibus and Ethernet) and the
power supply cables through the rear cable glands without ferrite suppressors.
Connecting the screening (all cables except Ethernet)
At the control cabinet:
C0246
Fig. 13 Connecting the screening
1. Strip off the cable insulation by about 0.4 in. where the cable passes through the cable gland.
2. Push the cable through the metal cable gland on the control cabinet until the stripped section
snaps in and contacts the earth clamp in the cable gland.
At the master controller:

6 Installation
Fig. 14 Cable screening clamps
1. Strip off the cable insulation by about 3/4 in. at the terminal.
2. Unscrew the spindle of the cable screening clamp completely.
3. The screening connects to the controller via the housing.
4. Use a cable screening clamp to secure the screening.
Connect the Ethernet cable screening
Fig. 15 Ethernet cable screening
1. Strip off the cable insulation by about 0.4 in. at the terminal.
2. Ensure electrical contact of the cable screening with the screening clamp next to the power
supply unit.
6.9.2.2 Models 8/8 and 16/8
1. Lead the cable through a suitable cable gland on the lower side of the control cabinet.
2. Strip the insulation off the cable screening at the clamping point for a length of 3/4 in.
3. Ensure electrical contact of the cable screening to the screening rail using a screening clamp.
6.9.3 Laying the cables in the control cabinet

Models 4/4 and 8/4
1. Bundle and bind cables carrying digital signals.
2. Bundle and bind cables connecting the compressors.
Models 8/8 and 16/8

6 Installation
6.10 Connecting floating relay contact signals for sensors
Fig. 16 Cable routing in the control cabinet

1 24 V DC
2 115/230 V AC
1. Route 24 V DC cables into the control cabinet through the left-hand duct 1 .
2. Route 115/230 V AC cables into the control cabinet through the right-hand duct 2 .
3. Route cables leading to the master controller (Profibus, Ethernet, RS232, modem cables)
through to the cabinet door, as shown in the illustration.
6.9.4 Connecting the cables

1. Make the connections to terminals and interfaces as detailed in the attached electrical dia‐
gram.
2. Fit the Profibus plug, see chapter 6.8.1.
6.10 Connecting floating relay contact signals for sensors

➤ Connect sensors according to the electrical diagram in the appendix.
6.11 Setting up the machines
Damage to drive motors can occur when the permissible motor starting frequency is exceed‐
ed on machines without idle control (piston compressors, blowers).
➤ Set the SIGMA AIR MANAGER pressure band to a width that prevents the motor switch‐
ing frequency from being exceeded.
➤ If necessary, increase the capacity of the air receiver.
Precondition The settings described in this section must be entered in full for every machine to ensure faultless
operation under control of the master controller. Make sure that the compressed air system re‐
mains in operation should the master controller fail.
➤ Carry out settings as detailed in this manual.

6 Installation
6.11 Setting up the machines
6.11.1 Linking via Profibus

The correct procedure for setting up SIGMA CONTROL machines is described in the
SIGMA CONTROL and SIGMA CONTROL 2 service manual.
Note the settings made in the appropriate form in the attachment.
The master controller software for SIGMA CONTROL as of version 72.00 was optimized as
well as for SIGMA CONTROL 2.
■ SIGMA CONTROL Slave number = machine number +2

■ SIGMA CONTROL 2 Slave number = machine number +102
If the wrong slave number is entered then either the wrong machine or no machine at is con‐
trolled.
1. Enter pressure setpoint p2 and set as default for "Manual mode pressure". In manual mode, the
pressure setpoint of each machine should be staggered by 4.35 psig to prevent all machines
starting together. The stagger time for station operation must be set. Suggestions for these set‐
tings are found in the Annex (see chapter 13.8.2).
2. Activate and set up automatic restart after a power failure.
3. Configure Profibus operation.
The following settings are recommended as parameters for bus alarms:
■ Start td: 40 sec
(maximum period that the machine waits for a signal from the Profibus after return of the
power supply. If no signal arrives before the period ends, the machine switches to self-con‐
trol).
■ Timeout: 5 sec
(Period after which the machine switches to self-control if a fault occurs in the master con‐
troller).
■ Restart: auto (not on SIGMA CONTROL 2)
auto = the machine automatically reconnects when the Profibus runs again after a bus
alarm.
■ Restart: man (not on SIGMA CONTROL 2)
man = after a bus alarm, the machine remains under its own internal control until it is con‐
nected to the bus again when the «remote» key is pressed.
4. Repeat steps 1 through 3 for any additional machines.
6.11.2 Linking via floating relay contact

Precondition The machines are provided with the required relay contacts and they are pre-wired (see chap‐
ter 6.7.2).
➤ Note the settings made here in the table in the Annex (see chapter 13.8)
Screw compressors always have an emergency mode. Piston compressors and blowers may
or may not have this emergency mode.
6.11.2.1 Stations with emergency mode capability
■ In automatic mode, the master controller takes over LOAD/IDLE control.

■ In manual mode, the machines run under the control of their own system pressure switches.

6 Installation
6.12 Setting the slave address on the Profibus expander
Models 4/4 and 8/4
When the machine is linked, the system pressure switch (-B1) remains in operation. This has the
function of an additional safety pressure switch. The system automatically runs in EMERGENCY
mode via these pressure switches if power to the master controller should fail or the master con‐
troller itself malfunction, ensuring a supply of compressed air.
➤ Setting up the pressure switch.
Further information Setting recommendation for the pressure switch: See Annex in chapter 13.8.1.
Models 8/8 and 16/8
A blow off protection safety relief valve pressure switch (-B6) or a master controller operation safe‐
ty pressure switch (-B1) is fitted on the machines to prevent:
■ machine overloading, or
■ relief valve blow off because of
─ switching points set too high,
─ defective master controller,
─ excessive pressure loss between the machine and the compressed air transducer connec‐
tion to the master controller.
➤ Set the safety pressure switch (-B1). Recommended settings: See Annex in chapter 13.8.1.
➤ The internal pressure switches for manual mode (-B1.1) must be set on a scaled basis so that
the machines switch on one after the other.
Further information Recommended settings: See Annex in chapter 13.8.2.
6.11.2.2 Stations without emergency mode capability
On such air systems, blowers and reciprocating compressors are not fitted with a pressure switch
that would ensure EMERGENCY operation.
When these machines are connected, the LOAD/IDLE switching is controlled by the master con‐
troller.
These stations will stop delivering compressed air if the master controller fails.
➤ Take suitable application-specific measures.

If more than one Profibus expander is used, each must be assigned its own slave address.
Precondition Profibus expanders have the required power supply and are wired according to their electrical dia‐
gram.

6 Installation
Profibus expander 4+4
1 8 7
L1 N + + - - RUN
Input: Output DC 24V/1,3A

BF
D/A 9 01
6
23
78
AC 100-240 V Class 2
456 X1
X1
0 1 2 3 4 5 6 7
9 01
X10
5
23
78
24V X2
06 05 04 03 02 01
456
0 1 2 3 4 5 6 7
PE N 24V
0V
0V X3 0 1 2 3 4 5 6 7
X4
0 1 2 3 4 5 6 7
4
2 3 06-C0252
Fig. 17 PBU 4+4

1 Safety cut-out 5 Terminal strip X2 for analog outputs
2 Power supply terminals 6 Terminal strip X1 for analog inputs
3 Socket for the Profibus plug 7 Setting wheel for slave address X10
4 Screening rail 8 Setting wheel for slave address X1
1. Switch off the Profibus expender via the safety cut-out 1 .

2. Set a valid slave address by means of a screwdriver on the two setting wheels.
e.g. slave address 36:
■ Set wheel 7 to «3».
(See 7.3.3 to assign slave addresses).
3. Insert the Profibus plug into the socket 3 .
4. Switch on the Profibus expander by means of the safety cut-out 1 .

6 Installation
Profibus expander 4T
1 8 7
L1 N + + - - RUN

BF
D/A 9 01
6
23
78
456 X1
X1
0 1 2 3 4 5 6 7
9 01
X10
5
23
78
24V X2
06 05 04 03 02 01
456
0 1 2 3 4 5 6 7
PE N 24V
0V
0V X3 0 1 2 3 4 5 6 7
X4
0 1 2 3 4 5 6 7
4
2 3 06-C0252
Fig. 18 PBU 4T
1 Safety cut-out 5 Termional strip X2 for PT100 inputs
2 Power supply terminals 6 Termional strip X1 for PT100 inputs
3 Socket for the Profibus plug 7 Setting wheel for slave address X10
4 Screening rail 8 Setting wheel for slave address X1


6 Installation
Profibus expander 8
7 6 5
1
L1 N + + - -

X1
0 1 2 3 4 5 6 7
4
PE N
3 X2
0 1 2 3 4 5 6 7
X3
0 1 2 3 4 5 6 7
X4
0 1 2 3 4 5 6 7
2 06-C0250
Fig. 19 PBU 8
1 Safety cut-out 5 Slave address setting wheels
2 Power supply terminals 6 Slave address setting wheels
3 Terminal strip X1 / X3 for digital outputs 7 Socket for the Profibus plug
4 Terminal strip X1 / X2 for digital inputs


6 Installation
Profibus expander 32
6 5 4
9 01
23
78
456
L1 N + + - -
X10
9 01
23
78
AC 100-240 V Class 2 456
X1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
PE N
3
33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
2 06-C0251
Fig. 20 PBU 32
1 Safety cut-out 4 Socket for the Profibus plug
2 Power supply terminals 5 Setting wheel for slave address X10
3 Terminal strip for digital inputs 6 Setting wheel for slave address X1


7 Initial Start-up
7.1 Overview
7 Initial Start-up
7.1 Overview
The master controller was designed and developed for a number of applications. Thus, a great va‐
riety of settings is possible.
Prior to delivery, the master controller is preconfigured with a standard configuration. Gener‐
ally, most of these settings can be used for many applications or need only minor modifica‐
tions. Thus, not all the steps listed below may be required for the initial start-up, depending
on the application involved.
Subjects discussed:
■ 7.2 Configuring the master controller
■ 7.3 Connecting the machines to the master controller
■ 7.4 Setting the group sequence and required pressure
■ 7.5 Setting the parameters for the compressor station
■ 7.6 Programming the clock
■ 7.7 Configuring the peripheral devices
■ 7.8 Commissioning the master controller
■ 7.9 Connecting an external PC to the master controller
■ 7.10 Communication
7.2 Configuring the master controller

The keys and LED indicators are shown in the fold-out of this service manual and in the
chapter “Design and Function.”
➤ Become familiar with the function keys.
7.2.1 Switching on the master controller

The master controller starts booting when the power supply is switched on. The boot-up is finished
when the large-font display of pressure appears (after about 25 seconds).
If nothing appears on the display, press and hold the «info» key and the «arrow up» key si‐
multaneously.
There is risk of damage to the compressed air supply through premature changeover to au‐
tomatic mode.
➤ Do not press the «Automatic» mode key until all the settings in this chapter have been
made.
1. Press the «ON» key.

2. Make sure that the compressor station is in manual mode.
3. If the automatic mode LED lights, press the «Automatic» mode key.

7 Initial Start-up
■ Compressor stations without emergency mode capability will not be delivering com‐
pressed air.
■ In compressor stations with emergency mode capability, the machines run under their
own internal control.
7.2.2 Changing the display language

1. Press «F3» in the main menu.
2. Set the required language with «F1» and «F6».
3. Press the «esc» key to return to the main menu.
7.2.3 Selecting menu options

Menu options are displayed either as an icon in the menu bar at the bottom of the display or as text
in the display.
➤ Select the required menu option with the «F1» to «F6» keys.
7.2.4 Entering characters

If characters have to be entered, a display frame opens with numbers, letters and special charac‐
ters. It is divided into several sections that can be accessed with the arrow keys.
If only numerals are to be entered, a smaller display frame opens in which only numerals, a com‐
ma, a minus sign and the C and E functions can be selected. The procedure is the same as for
character entry.
1. Use the arrow keys to select the desired characters and confirm with the «Enter» key.
2. Repeat step 1 until all characters are entered.
3. To delete a character use the arrow keys to move the cursor to C on the right of the display
frame and confirm with «Enter».
4. When all characters are entered, use the arrow keys to move the cursor to E on the right of the
display frame and confirm with «Enter».
5. Entry of characters can be cancelled with the «esc »key.
7.2.5 Selection lists

Some settings can be made using selection lists.
1. If a selection list is displayed, select the required setting with the arrow keys.
2. Confirm the setting with the «Enter» key.
If there are only two selections, no list is displayed. The other relevant setting is immediately
activated and does not have to be confirmed.
➤ Press the «Enter» key to switch between possible settings.

7 Initial Start-up
7.2.6 Password level and key lock

In this manual, the password level required will be quoted for every function.
The following passwords are entered in the master controller on delivery:

■ Password for level 1: 11
➤ Further information is given in the following chapters.
7.2.6.1 Logout
The password sets itself back to level 0 if no entries are made over a period of five minutes.
Alternatively, the password can be manually reset as follows:

1. Call up <Password «F4» > in the main menu.
2. Press «F1» (logoff).
3. Press the « esc» key to return to the main menu.
7.2.6.2 Password list
A list of the passwords together with the related password levels is displayed.
1. Call up the menu option <Password «F4» Password list «F2» >.
2. If required, enter password for level 3.
3. Press the «esc» key to close the list.
7.2.6.3 Key lock
The following keys can be locked:

■ «Remote»
■ «Shift clock»
■ «Automatic mode»
■ «ON»
■ «OFF»
■ «Machine selection»
1. Call up the menu option <Password «F4» Key lock «F3» >.
3. Select the required key with the arrow keys.
4. Press the «Enter» key until "locked" is displayed.
5. Press «esc» to return to the next higher level.
7.2.6.4 Allocating passwords
Allocate level 0 to delete a password.
1. Call up the menu option <Password «F4» Assign password «F4» >.

7 Initial Start-up

3. Enter the password and the appropriate level.
7.2.7 Checking/Setting time and date

If the clock is turned back more than 24 hours SIGMA AIR CONTROL plus is automatically
deactivated.
Automatic deactivation of SIGMA AIR CONTROL plus prevents:

■ unintentional time resetting,
■ loss of SIGMA AIR CONTROL plus data saved during the reset time.
➤ Correctly set and regularly check the clock before activating SIGMA AIR CONTROL plus; see
chapter 7.10.2.
Check/set time and date.
1. Select menu options <Settings «F1» system «F1» general settings «F1» date and time «F1» >.
2. Select date or time with the arrow keys.
3. Press «Enter».
5. Enter date and/or time (see chapter7.2.4 for entering characters).
6. When the date and time is correct press the «esc» key to return to the next higher level.
If the machine is being operated with a clock program, check the time at regular intervals for
discrepancies (generally once per year).
7.2.8 Setting summer / winter

1. Select the menu option <Settings «F1» System «F1» General settings «F1» Summer/winter
«F2» >.
2. Use the arrow keys to select the individual settings and confirm with the «Enter» key.
4. Set the options for automatic changeover.
5. When the settings are complete, press the «esc» key to return to the next higher level.
7.2.9 Country-specific settings

The units of measure and time and date format are standardized for the language selected,
but can be changed, if required.
1. Menu options <settings «F1» system«F1» general settings «F1» country-specific settings «F3»
>.
2. Use the arrow keys to select the individual settings and confirm with the «Enter» key.
4. Set the language, units of measure and date and time formats.

7 Initial Start-up
7.3 Linking compressors to the master controller
7.2.10 Setting up the display

1. Menu option <settings «F1» system «F1» general settings «F1» operating panel «F4» display
settings «F4» >.
2. Set up the:
■ Lighting
■ Lighting time delay
■ Contrast

➤ In the main menu, select <Settings «F1» compressor «F3» >.
7.3.1 Linking the machines

There are three screens for each machine that can be selected with the «F1 » and «F2» keys. The
number of each machine is displayed at the top right. The machines can be selected with the «F5»
and «F6» keys.
Precondition The electrical and mechanical connections to the machine have already been made.
Menu point <Settings «F1» Compressor «F3» > is selected.
➤ Select menu option linking «F1».

Enter the following settings for each machine linked to the master controller:
1. The type of link
2. Enter the FAD
3. Enter the power consumption
4. Enter the reference pressure for the power consumption
5. Enter the idling power consumption
6. Compressor: Set Controller, Monitored, or Monitored +. (A machine that is monitored is regu‐
lated by its internal controller.) In Monitored + mode, the SIGMA AIR MANAGER calculates the
FAD and power of the compressor; this is not the case in regular Monitored mode).
7. On machines with a conventional link, the input and output addresses still have to be assigned.
Conventional link
The employment of a Profibus expander can be necessary or provide a considerable advant‐

age under certain local conditions (see chapter 6.11.1).
Precondition Menu point <Settings «F1» Compressor «F3» Linking «F1» > is selected.
1. Select inputs and outputs for conventional connection with the «F1» key.
3. Set and activate the addresses of the inputs and outputs used according to the connections
selected in the electrical diagram.
Sign State
✓ Active

7 Initial Start-up
Sign State
x Inactive
Tab. 20 Activating addresses
4. Ignore unused inputs and outputs.

The meaning of the letter in front of the “load” output address:
■ "p" = the connected contact is open when the compressor has a fault (default setting)
■ "n" = the connected contact is closed when the compressor has a fault
Contact KAESER SERVICE if the standard settings are not used.

The meaning of the letter in front of the “load” output address:
■ "n" is the standard setting for models 4/4 and 8/4
■ "p" is the standard setting for models 8/8 and 16/8
If these standard settings are used and the machine is connected according to the circuit dia‐
gram in the Annex (EMERGENCY mode), then an EMERGENCY mode is ensured. Contact
KAESER SERVICE if the standard settings are not used.
7.3.2 Settings for machines with frequency-controlled drive (FC)

Setting the FC characteristic
If the machine has frequency-controlled drive, the input values for FAD and power consumption at
a given speed must be entered. These values are used to project an approximation curve to esti‐
mate the FAD and power consumption of the FC machine. In this way, the machine's duty cycle
can be determined.
The value of the settings for the FC machine are recorded in a data sheet that can be re‐
quested. An example is found in the Annex. In order to display the FAD, software from ver‐
sion 72.30 or 80.xx must be installed on the SIGMA CONTROL. Contact KAESER Service
for advice.
Precondition Menu point <Settings «F1» Compressor «F3» > is selected.
1. Select the menu option FC characteristic «F4».

3. Enter the following values, starting in the "max" line.
■ Maximum speed
■ Corresponding FAD at maximum working pressure (see nameplate)
■ Corresponding power consumption at maximum working pressure (see nameplate)
4. Repeat step 2 for lower speeds.
5. Press the «esc» key to return to the next higher level.
The individual FC characteristics can be selected with the «F5» and «F6» keys.
The characteristic FC curve entered is automatically added to the 0/0/0 point (speed 0 min,
FAD 0 cfm, power 0 kW).
Assigning the FC machine
The characteristic set above can now be assigned to the FC machine.

7 Initial Start-up
Precondition FC characteristic is set.

Menu point <Settings «F1» Compressor «F3» > is selected.
1. Select the menu option connection «F1».

2. Press the «F1» key twice to open the screen for the FC machines.
4. Select yes for the FC machine.
The current FAD of the FC machine is displayed.
5. Select the characteristic number.
6. Make the following settings for conventional links:
■ Select the relevant input (the «F3» key displays a list of the analog inputs).
■ Normalize the input.
7. Press the «esc» key to return to the next higher level.
7.3.3 Registering the Profibus expander

Precondition Profibus expanders are linked and configured (see chapter 6.11).
1. In the main menu, select <Settings «F1» Periphery «F6» Profibus expander «F6» >.
2. Select the linked Profibus expander:
■ Profibus expander with eight digital channels (PBE 8, PBE 8K, PBE 8R): press «F1».
■ Profibus expander with 32 digital channels (PBE 32): press «F2».
■ Profibus expander with four analog inputs and four analog outputs (PBE 4+4): press «F3».
■ Profibus expander with four PT100 inputs (PBU 4T): press «F4».
4. Activate the Profibus expander.
Only for Profibus expander with eight digital channels (PBE 8, PBE 8K, PBE 8R):
■ Individual channels are marked as input I or output O.

■ For digital outputs O, the slave address must be at least 24.
■ Further slave addresses can be selected with «F1» and «F2».
7.3.4 Activating the Profibus interface

The Profibus interface may only be activated when all the settings for this interface have
been made.
When a Profibus is used, the matching interface has to be activated.

1. Call up menu option <Settings «F1» System «F1» Interfaces «F3» Profibus «F1» >.
3. Press the «Enter» key until "Interface active: yes" is displayed.
7.3.5 Setting the operating hours and maintenance interval counters

Machines with a conventional link
No settings need to be made for machines with SIGMA CONTROL.

7 Initial Start-up
7.4 Setting the required pressure
Precondition Menu point <Settings «F1» Compressor «F3» > is selected.
1. Call up the menu option Hours «F2».

Every machine has its own screen, with the corresponding machine number displayed at the
top right. The machines can be selected with the «F5» and «F6» keys.
2. Make the following settings for each machine:
■ If required, enter password for level 3.
■ Enter the total hours and load hours for the machine.
■ Enter SIGMA AIR MANAGER as the hours source.
■ Activate the maintenance interval counter
■ Enter the default interval hours.
The hours are now counted further by the master controller.
On conventionally linked machines that are connected to the master controller without the
"motor running" feedback signal, the total hours are counted when the master controller
switches to the load mode.
7.4 Setting the required pressure

The required pressure is the pressure required by the consumers in the compressed air network
(pressure-measuring transducers).
The controller will usually maintain the required pressure with a maximum deviation of 1.5 psig.
For energy reasons, the operating pressure is to be set as low as possible, i.e., not higher as
required for the consumers within the compressed air network.
Precondition Menu point <Settings «F1» > is selected.
1. Select menu option <Controller «F2» >.

3. Specify the required pressure
4. Press the «escape» key to return to the next higher level.
Further information The required pressure can also be set in the list of machines displayed in the Machine overview
window (see chapter 8.1).
7.5 Setting the station parameters

➤ In the main menu, select <Settings «F1» Station «F4» >.
7.5.1 Setting the parameters for the required pressure

Precondition The menu option <Settings «F1» Station «F4» > is selected.
1. Select menu option “Required pressure” «F1».

3. Specify the maximum required pressure.
4. Specify the minimum required pressure.
Optionally, an external analog input for required pressure can be configured:

7 Initial Start-up
2. Enter the input number.

3. Set the input current for 0 psi.
4. Set the pressure for an input current of 20 mA.
5. Activate the analog input:
Sign State
✓ Active
x Inactive
Tab. 21 Activating analog input
6. Activate remote mode with the «remote» key.
7.5.2 Setting the network pressure

An incorrect entry of the pressure transducer's final pressure can result in problems in the
network.
1. Select menu option Network pressure «F2».

3. Select and activate analog input sensor 1.
4. If required, select and activate analog input sensor 2.
5. Determine the weighting of sensor 1 and sensor 2.
6. Enter the pressure transducer final pressure.
7. Enter the actual pressure value damping period (the period over which pressure value read‐
ings are averaged).
Problems when converting to 45 bar measure transducers?
➤ In the main menu, proceed as follows:
1. Delete all switching points for the shift clock (menu < «F1» – «F5» – «F1» >, see chapter 7.6.2)
2. Set the minimum required pressure to 1.0 bar (menu < «F1» – «F4» – «F1» >, see chapter
7.5.1)
3. Set the required pressure to 3.0 bar (menu < «F1» – «F2» >, see chapter 7.4)
4. Set the maximum required pressure to 4.0 bar (menu < «F1» – «F4» – «F1» >, see chapter
7.5.1)
5. In order to set the final pressure for the measuring transducer 45 bar, use the «UP arrow» for
the specification in the selection list.
7.5.3 Configuring the restart and charging the compressed air network
Automatic restart of the machines and recharging of the compressed air network after a power fail‐
ure is configured in this menu option.
An automatic restart after a power failure is only possible if a SIGMA CONTROL software
version 0.70 or later is installed. In earlier software versions the machines run in manual
mode when the power supply returns. Contact KAESER SERVICE for advice.

7 Initial Start-up
1. Select menu option “Restart” «F3».

3. Activate automatic restart.
4. Enter the delay period for restart.
5. Enter the air network charging speed (speed of pressure rise when charging).
Upon activation of the compressed air station ( «ON» , «Remote ON/OFF» or «Shift clock»),
the compressed air network is filled at the specified charging speed. The controller will use as
many compressors as required.
6. Specify whether minimum pressure should be monitored when the compressor station is off.
7.5.4 Additional settings

Various parameters of the compressed air station can be specified in the menu option <Further
settings>.
■ Monitoring period for motor running: the period that elapses from the absence of a motor feed‐
back signal until an alarm is triggered.
It is recommended that the default settings are used.
Contact KAESER SERVICE beforehand if the standard settings are not used.
■ Power limiting: If the power limiting function is activated, the system will add machines only to
the point where the overall load capacity of the running machines exceeds the specified power
limit.
■ The power limiting function can be activated and deactivated via a digital input. If the power
limit is exceeded at the time of activation, the machines are switched off until the value has
fallen below the limit. The switching off sequence must be the same as when switching off via
pressure.
■ Switching compressors online:
─ first: The controller will always activate these machines first and deactivate them last.
This function may be used, for instance, for machines with heat recovery.
─ last: The controller will always activate these machines last.
Their deactivation is governed by the consumption, if the machine is no longer required for
the compressed air delivery.
+ rigid: Exactly the machines defined here are activated last.
last – rigid may be used for machines designated to be reserves only.
Ensure that these machines are running sufficiently by, for example, using them first once
per week for one hour, using the timer channel A, see also chapters 7.6 and 13.9.5.
+ sequencing: If several compressors of the size (class) of the compressor designated to
be the last, a compressor of this class is switched last. The system selects the one with the
most operating hours from all suitable compressors. The other compressors of this size are
added earlier, depending on consumption. If, for example, two machines are specified un‐
der last, two machines of this size will be added last. The system selects the one with the
most operating hours from all suitable compressors.
last – sequencing may be used if, for example, the compressors of a certain class are to be
used deliberately less frequently than those of the other class(es).
1. Select the menu option <Further settings «F4» >.

3. Enter the maximum load power consumption and activate the function.

7 Initial Start-up
7.6 Programming the shift clock
4. Activate the power limiting function

■ Activate the function for general power limitation.
■ Do not activate the function for power limiting via digital input and activate input as shown
in chapter 7.7.2.2.
5. Select the machines to be activated first.
6. Select the machines to be activated last.
7.6 Programming the shift clock

Shift operation of the compressed air system can be set in the shift clock menu option.
In all, 32 switching points are available.
■ The required pressure can be changed for defined periods of time.

■ The entire compressed air system can be switched on or off.
■ Specific machines can be taken off the compressed air supply.
■ Up to 5 channels (outputs 1-4, channel A) can be selected.
Channel A will "first" use the machines entered "last" in menu 4.4. See also chapter 7.5.4.
The switching points entered are repeated weekly. During non-standard periods such as
company holidays, the compressed air system has to be switched manually.
➤ In the main menu, select <Settings «F1» Shift clock «F5» >.
7.6.1 Setting the switching points

The number of unassigned and assigned switching points is shown at the top left. The switching
point number is shown at the top right. A frame around the weekday indicates that it is selected.
You can select several weekdays at once.
2. Selecting the weekday:
■ Use the arrow keys to move the cursor to the required weekday.
■ Press «Enter».
3. Enter the switching time.
4. Enter the required pressure.
5. Specify the channels (outputs, channel A).
6. Specify the used compressors.
7. To shut down the compressed air system, enter # # # # # # # for the compressors.
8. Press«F2» key to save the switching point.
9. Repeat steps 1 through 8 to set additional switching points.
All settings apply until the next switching point is reached.
Further information See chapter 13.9.1 for examples of switching point setting.
7.6.2 Deleting a switching point

Only the settings displayed in the menu option are deleted. If several days of the week are
selected, the respective switching points for all these days are deleted.
1. Select the switching points to be deleted with the«F5 »and «F6» keys.

7 Initial Start-up
7.7 Configuring peripheral devices

3. If necessary, cancel the selection of individual weekdays.
4. Delete the selected switching point with the«F1» key.
7.6.3 Activating the clock

➤ Press the «shift clock» key.
The shift clock mode LED illuminates.

➤ Messages, input and output functions activating/configuring.
7.7.1 Configuring alarm/warning and service messages

The settings described in this section only become effective when the menu option is exited.
➤ Select from the main menu <Settings «F1» Periphery «F6» External alarms, warning and ser‐
vice messages «F1» >.
7.7.1.1 Activate predefined messages
See chapter 13.7.2 for a list of predefined messages.
Precondition Menu <Settings «F1» Periphery «F6» External alarms, warning and maintenance messages «F1»
> is selected.
1. Select menu option predefined messages «F1».

2. Searching for a message:
■ «F1» and «F2»: scroll through the message blocks
■ «F5» and «F6»: scroll through individual messages
4. Activate the message.
5. Set the time delay to prevent messages being triggered by short interference pulses.
6. Enter the input to which the message signal is connected.
7. Decide whether the message is to be triggered by an open contact 0V or closed contact 24V.
7.7.1.2 Defining own messages
External alarm and warning messages do not initiate a station shutdown.
Definable message texts can be entered in this menu option. It is differentiated between alarm and
maintenance/warning messages.
Precondition Menu <Settings «F1» Periphery «F6» External alarms, warning and maintenance messages «F1»
> is selected.
1. Select definable messages (alarm) «F2» or definable messages (maintenance/warning) «F3».

7 Initial Start-up

3. Enter the message text. (see chapter 7.2.4 for entering characters).
5. If required, select "maintenance" or "warning" type of message.
6. Set the time delay to prevent messages being triggered by short interference pulses.
7. Enter the input to which the message signal is connected.
8. Decide whether the message is to be triggered by an open contact 0V or closed contact 24V.
7.7.2 Configuring further input functions

➤ Configuring external machine selection, digital inputs and outputs.
7.7.2.1 Configuring machine selection
The machines can also be preselected from a remote control center.
If machines are externally preselected, the machine selection keys on the master controller are in‐
active. If they are pressed, a message is displayed. The LEDs in the selection keys also indicate
which machines are preselected. External preselection cannot function when the "Send/Receive"
preselection option is active.
There is a screen for every machine with the machine number at the top right. The machines can
be selected with the «F5» and «F6» keys.
Precondition The external controller must be connected to the digital inputs of the master controller (see circuit
diagram in the annex).
1. Select menu option <Settings «F1» Compressor «F3» Further settings «F5» >.
3. Enter the address of the external preselection input.
4. Activate the input (can be activated in password level 2)
Sign State
✓ Active
x Inactive
Tab. 22 Activation input
5. Negate the input as required (n = 0 V; p = 24 V).

7. Press the «remote» key to activate remote mode.
7.7.2.2 Configuring the digital inputs
In this menu option the following functions can be configured via further external inputs:
■ Remote OFF/ON: When this function is activated, the master controller can be switched off
and on from a remote contact.
■ Remote MANUAL/AUTO: When this function is activated, the master controller can be switch‐
ed between manual and automatic mode from a remote contact.

7 Initial Start-up
■ Remote shift clock: When this function is activated, clock operation in the master controller can
be switched on or off from a remote contact.
■ Switching compressors online: When this function is activated and the input signal changes,
the system will add the next possible machine, regardless of the network pressure.
■ Decrease required pressure: When this function is activated and the input signal is given, the
system will decrease the required pressure at a constant upper limit of the pressure range.
Please contact KAESER SERVICE for more information.
■ Power limiting: When this function is activated, the power limit is cut in and cut out via the input
signal.
See chapter 7.5.4 for further information on power limiting settings.
1. Select menu option <Settings «F1» Periphery «F6» Further input functions «F4» Digital inputs
«F1» >.
2. Select the required function with keys «F5 »and «F6».
4. Activate the function.
5. Enter the input to which the message signal for this function is connected.
6. Specify whether the message is to be triggered by open contact 0V or closed contact 24V.
7.7.2.3 Configuring analog inputs
Analog inputs can be freely configured. They can be used for the following applications:
■ The functional values of analog components can be displayed on the master controller.
■ If a value exceeds a preset threshold value, a message can be triggered. Inputs 16.0–16.7 and
17.0–17.7 and outputs 16.0–16.7 and 17.0–17.7 are available. Outputs are directly linked in the
software to the inputs, e.g. output 16.0 to input 16.0.
■ If a value exceeds a preset threshold value, a binary output signal can be outputted to light, for
example, a remote control lamp.
Input values at 4–20 mA and PT100 are monitored for open and short circuit.
At 4–20 mA:
■ open circuit: < 3 mA
■ short circuit: > 21 mA
1. Select menu option <Settings «F1» Periphery «F6» Further input functions «F4» Setting ana‐
log inputs «F2» >.
3. Enter description / message text (24 characters).
4. Select analog input.
5. Activate the input.
6. Enter unit of measure (8 characters).
7. For AI: Enter value at 0/4 mA, (range +/-10000 x factor (1/0.1/0.01/0.001).
8. For AI: Enter value at 20 mA, (range +/-10000 x factor (1/0.1/0.01/0.001).

7 Initial Start-up
9. For PT: Enter line compensation for two-line sensors in Ohm.

Line compensation = resistance of the line from the master controller to the PT100 sensor
and back.
■ Example:
─ Line 2 x 1.0 mm2
─ Material: copper
─ 60 m long (single length from the master controller to the PT100 sensor)
─ Line compensation =
((0.0178 Ohm mm2 / m x 2 x 60 m) / 1.0 mm2) = 2.14 Ohm
Line compensation is not needed for three and four-line sensors and the value remains at 0
Ohm.
10. Configure threshold values 1 and 2:
■ Select the comparison "smaller/larger".
■ Assign the comparison to the digital output to which the comparison result is assigned.
Example:
An alarm is to be displayed on the master controller when a dew point exceeds 41°F. The dew
point sensor is connected to analog input 1 and has a measurement range of 23°F to 95°F. Pro‐
ceed as follows:
1. Enter the designation "dew point".
2. Enter unit of measurement °C.
3. Activate the input.
4. Select analog address AI 1.
5. Enter value for 4 mA: "−5 x 1".
6. Enter value for 20 mA: “35 x 1”.
7. Select comparison ">"
8. Enter threshold value "5 x 1"
9. Enter output address 16.0.
10. Activate output.
11. Select menu option defined messages (alarm) (press <esc – esc «F1»–«F2» >).
12. Search for a non-allocated message number with «F5» and «F6».
13. Enter the message text "dew point over 41°F".
15. Enter time delay 1.
16. Enter input address 16.0.
7.7.3 Configuring further output functions

➤ Configure digital output and analog input signals.
7.7.3.1 Forwarding the signals "load" and "group alarm"
The signals "load" and "group alarm" can be assigned to a digital output for every machine to allow
them to be forwarded to other equipment.
There is a screen for every machine with the machine number at the top right. The machines can
be selected with the «F5» and «F6» keys.

7 Initial Start-up
1. Select menu option <Settings «F1» Compressor «F3» Further settings «F5» >.
2. If required, enter the password for level 3 (password level two is sufficient to activate or deacti‐
vate outputs).
3. Enter a free address for the load output and activate it.
4. Enter a free address for the group alarm output and activate it.
5. Negate the outputs, as required:
■ n = relay closes at an event
■ p = relay drops out at an event
7.7.3.2 Configuring digital outputs
Free digital outputs can be assigned the following functions in this menu option:
■ Group alarm
■ Controller operational
■ Group maintenance/group warning
■ External alarm
■ Maintenance / external warning
■ Compressor alarm
■ Compressor maintenance / warning
■ Pressure low
■ Dryer group alarm 1-8
■ Shift clock channel 1
■ REMOTE mode
■ CLOCK mode
■ AUTOMATIC mode
■ Compressor station ON
■ No compressor preselected
■ Group alarm (pulse)
■ Pressure high
1. Select menu option <Settings «F1» Periphery «F6» Further output functions «F5» Digital out‐
puts «F1» >.
2. Select the required function with keys «F5» and «F6».
4. Activate the function.
5. Enter a free output address (see circuit diagram in the Annex).
6. Decide whether the output should be open or closed when the function is active.
7.7.3.3 Configuring analog outputs
Free analog outputs can be assigned the following functions in this menu option:

7 Initial Start-up
■ System pressure
■ Required pressure
■ Delivery
■ FC set point pressure
■ Power
1. Select menu option <Settings «F1» Periphery «F6» Further output functions «F5» Analog out‐
puts «F2» >.
2. Select the required value with the «F5 »and «F6» keys.
4. Activate output.
5. Select analog output.
6. Normalize the output.
Scaling the output signal

Peripheral, analog components can work with different input currents (0–20 mA, 4–20 mA).
Example: The system pressure is to appear at the output as a 4–20 mA signal corresponding to 0 –
8 bar.
Fig. 21 Output signal scaling

I Signal range 0–20 mA III Pressure range 0 – 8 bar
II Signal range 4–20 mA IV Pressure range -2 – 8 bar
➤ Calculate the values to be set as follows:

Acceptance:
■ 0 – 8 bar ≙ 4–20 mA
■ A range of 8 bar thus represents a signal range of 16 mA.
Calculation:
■ A signal range of 20 mA therefore represents:
■ (8 bar / 16 mA) x 20 mA = 10 bar
■ 0 mA is thus => 8 bar –10 bar = -2 bar
➤ Set the following values:
Current values Pressure values

at 0 mA –2.00 bar

7 Initial Start-up
7.8 Master controller commissioning
Current values Pressure values

at 20 mA 8.00 bar
Tab. 23 Settings
7.8 Master controller commissioning

Precondition No one is working on the machine.
All enclosure panels are in place and secured.
The temperature of the machines is not below +37 °F.
All access doors on the machines are closed.
There is no bus error.
Risk of injury during an automatic machine start.

➤ Before switching on, make sure that all conditions are met.
➤ Compare the settings for initial start-up of the master controller with those listed in the
service manual.
➤ Use the commissioning checklist.
To be checked Chapter Complied?

Date and time is set 7.2.7
Machines are set up 6.11
Machines are connected 7.3.1
Required pressure is set 7.4
Tab. 24 Commissioning
Precondition All points in the checklist are complied with, see table 24.
➤ Press the «machine preselect» key for the required machines on the master controller.
Result The green «preselect» key LED lights up.
Stations with emergency mode facility Stations without emergency operating mode
1. Set the machines to remote mode. 1. Switch on the machines.
2. Press the «automatic mode» key on the 2. Start the compressed air supply by pressing
master controller. the «automatic» key on the master control‐
ler.
Result The master controller assumes control of the machines.
7.9 Connecting a PC to the master controller

To be able to use SIGMA AIR CONTROL, a PC and the master controller must be connected.
There are three methods of creating this connection:
■ through a local network (Ethernet), see chapter 7.9.2

7 Initial Start-up
■ with a modem via an analog phone connection, see chapter 7.9.3

■ directly to an RS 232 interface via a null modem cable, see chapter 7.9.4
Precondition The machines are in manual mode.
➤ Note system requirements.
7.9.1 System requirements

The following system requirements have to be met to allow visualization with
SIGMA AIR CONTROL:
■ Unicode-capable operating system, recommended is Microsoft Windows XP Professional Ser‐

vice Pack 3 or Microsoft Windows 7 Enterprise.
■ Support of the UTF 8-character coding and the Java plug-in interface from Sun via the brows‐
er.
■ Sun Java plug-in JRE 6 Update 26 (1.6.0_26) is installed.
➤ Check the list.

The current Java plug-in can be downloaded from the Sun home page under http://
java.sun.com/javase/downloads/index.jsp. Older versions are archived in http://java.sun.com/
products/archive/. Download the plug-in (JRE) for your operating system. This is required on‐
ly once for each browser computer. We recommend to use Microsoft Internet Explorer 8 or
Mozilla Firefox 5.0 as your browser. They support the aforementioned prerequisites. The use
of Internet Explorer version 5.5 is not recommended.
➤ Download required files.
The full functional capability of SIGMA AIR CONTROL can only be guaranteed for a Microsoft
Windows XP Professional Service Pack 3 or Microsoft Windows 7 Enterprise operating sys‐
tem with Microsoft Internet Explorer 8 in compatibility mode or Mozilla Firefox V5 and Java
plug-in JRE 6.0 Update 26. Although special emphasis was placed on independent browser
and operating system use during the development of SIGMA AIR CONTROL, some functions
may be impaired when it is used with systems other than those mentioned above.
➤ Avoid function impairment.
7.9.2 Connecting the master controller through a local network

➤ Connect hardware and determine settings.
7.9.2.1 Hardware interfacing
➤ Connect the master controller (0X4 Ethernet interface) to the local network:
■ via a 10Base T (industrial twisted pair) cable with a RJ45 plug or
■ via a point-to-point Ethernet connection with a crosslink cable.
7.9.2.2 Master controller settings
The IP address and the subnet mask have to be determined by the network administrator.
1. Call up menu option <Settings«F1» System«F1» Interfaces«F3» Ethernet «F4» >.


7 Initial Start-up
3. Enter the IP address of the master controller.

4. Enter the subnet mask.
5. If a router is used, enter the IP address of the relevant router.
6. Exit the selection window by pressing «esc».
7. Wait for the message "0624 write EPROM is finished. Wait for Restart needed (H)".
8. Press the «Acknowledge» key twice until the messages disappear from the display.
9. Switch the master controller off and on again to accept the settings.
7.9.2.3 Settings on the PC
No further settings need to be made on the PC.

➤ Retain settings on the PC.
7.9.2.4 Dialling into SIGMA AIR CONTROL
The user name "Kaeser1" and password "11" are preset in the shipped system. If the pass‐
word is changed, switch the master controller off and on again to make the change effective
for the SIGMA AIR CONTROL as well.
1. Start the browser and enter the master controller's Ethernet IP address.
2. Confirm with «Enter».
The SIGMA AIR CONTROL home page appears.
The left margin of the home page displays the navigation bar.
Open additional pages via the links on the navigation bar.
3. Enter user name and password as quoted above in the user name and password fields; use
correct upper and lower cases.
Result SIGMA AIR CONTROL can now be used.
7.9.3 Connecting the master controller through a modem (option)

Precondition A PCMCIA modem is installed in the controller in slot 2.
A modem connected to the phone network is installed in the PC.
➤ Check the requirements.
The IP address has to be determined by the network administrator. Take note of the user in‐
formation for the modem retrofit kit.
1. Call up menu option <Settings «F1» System «F1» Interfaces «F3» Modem «F3» >.
3. For a PC modem card PzP coupling select "PPP modem PC Card COM 3", and for a GSM
modem PzP coupling select "PPP GSM modem COM 1".
4. Enter the PPP IP address, e.g.: 192.168.212.251
6. Wait for the message "0624 write EPROM is finished. Wait for Restart needed (H)".
8. Switch the master controller off and on again to accept the changed settings.

7 Initial Start-up
7.9.3.2 Setting up the dial-up connection with modem on the PC
The dial-up connection for the following operating systems will be described:
■ Microsoft Windows XP
■ Microsoft Windows 2000
Precondition Administrator rights are available on the PC.
➤ Authorize the suitable person.
Configuring a dial-up network connection in Microsoft Windows XP
Meanings of control symbols:

Sign Meaning
◉ Radio button activated
○ Radio button passive
☑ Check box activated
☐ Check box passive
Tab. 25 Control symbol
1. In the start menu, call up the Connect with command:

< Start Connect with Show all connections Network specification Create new connection >
2. When the <New Connection Wizard> appears, click on Next.
3. Settings in the dialog window <New connection wizard – Network Connection Type>
■ Activate the connection to the network with ◉ .
■ Click Next.
4. Settings in the dialog window <New connection wizard – Network connection>
■ Activate the data connection with ◉ .
■ Click Next.
5. Settings in the dialog window <New connection wizard – Connection name>
■ Enter the connection name, e.g. SAM.
■ Click Next.
6. Settings in the dialog window <New connection wizard – Number to be dialled>
■ For the provided telephone connection to SIGMA AIR MANAGER:
─ Enter the dialling number in the appropriate field.
─ Click Next.
7. Settings in the dialog window <New connection wizard – Connection availability>
Activate the connection either for:
■ All users with the corresponding ◉ or
■ This user only with the corresponding ◉ .
■ Click Next.
8. Settings in the dialog window <New connection wizard – Completing the network connection>
■ Click Finish .
Result The dial-up network connection will be configured. The connection can be called up from the start
menu with < Start Connect with Connection name >, e.g. “SAM”.

7 Initial Start-up
Establishing the connection

To establish the connection to the master controller the user name "kaeser" and the pass‐
word "sam" are needed. These are default system settings and cannot be changed by the
user.
1. Establishing the connection in the start menu: < Start Connect with Connection name >, e.g.,
“SAM”.
2. In the <Create connection with SAM >dialog window, activate Properties.
The <SAM Properties> dialog window opens.
It contains the following tab pages:
■ General
■ Option
■ Security
■ Network
■ Common use
3. Enter the following settings in the "General" tab:
■ Click on the "General" tab.
■ Activate the field “Connection via”:
modem model with ☑.
■ Select All devices and activate the same number with ☑.
■ Activate modem configuration with Configure.
─ Select 115200 as the "maximum transfer rate (Bit/s)".
─ Activate Hardware flow control with ☑.
─ Activate Modem error check with ☑.
─ Activate Modem compression with ☑.
─ Activate Use modem loudspeaker with ☑.
─ Activate the corresponding modem configuration with OK.
■ Check the dialling number and re-enter if necessary.
4. You can leave the default settings in the register tab for options and safety.
5. Enter the following settings in the Network tab:
■ Click on the "Network" tab.
■ Activate the Internet protocol (TCP/IP) with ☑.
■ Click Properties.
─ Activate "Use following IP address" with ◉.
─ Enter the IP address: Copy the first three digits of the IP address from the master con‐
troller. Use a different number (0-255) for the last number than that of the master con‐
troller. Example: The IP address in the master controller is 192.168.212.251, the IP ad‐
dress here could be 192.168.212.252.
─ Click OK.
6. You can leave the default settings in the register tab for common use.
7. Accept the settings in the <“SAM Properties"> window with OK.
8. Enter the following in the <Connect with SAM> dialog window:
(case sensitive!)
■ Enter "kaeser" as user name.
■ Enter "sam" as password.
9. Click Select.

7 Initial Start-up
Result The dial-up network connection will be started.
Configuring a dial-up network connection in Microsoft Windows 2000

Sign Meaning
1. In the start menu, call up the Create new connection command:

< Start Settings Network and data connections Create new connection >
2. In the <Network connection wizard>, click Next .
3. Settings in <Network connection wizard – network connection type>
■ Select "Private network" with ◉.
■ Click Next.
4. Settings in <Network connection wizard – Number to dial>
■ Activate "Use dialling rules" with ☑.
■ For the provided telephone connection to SIGMA AIR MANAGER:
─ Enter the area code.
─ Enter the number.
─ Enter the country code.
─ Click Next.
5. Settings in <Network connection wizard – Connection availability>
For the connection you may choose either
■ "For all users" with the corresponding ◉, or
■ "This user only" with the corresponding ◉.
■ Click Next.
6. Settings in <Network connection wizard – Finishing>
■ Enter the name of the connection, e.g. SAM, in the appropriate field.
■ Click Finish .
menu with < Start Settings Network and data connections Connection name >, e.g. “SAM”.

user.
1. Establish the connection in the start menu: < Start Settings Network and data connections
Create new connection >

7 Initial Start-up
2. In the <Create connection with SAM> window, click Properties .

The <SAM Properties> dialog window opens.
■ General
■ Option
■ Security
■ Network
■ Common use
■ Activate the field “Connection via”:
modem model with ☑.
■ Select All devices and activate the same number with ☑.
─ Activate Modem error check with ☑.
─ Activate Modem compression with ☑.
─ Activate Use modem loudspeaker with ☑.
─ Activate the corresponding modem configuration with OK.
■ Check the dialling number and correct if necessary.
4. You can leave the default settings in the register tabs Options and Security.
─ Click OK.
7. Accept the settings in the <“SAM Properties"> window with OK.
8. Enter the following in the dialog window <Connect with SAM>:
(case sensitive!)
9. Click Connect .
Result The dial-up connection will be started.

7 Initial Start-up
2. Confirm with «Enter».
The SIGMA AIR CONTROL home page appears; call up further pages with the links in the
navigation bar.
7.9.4 Connecting the master controller through a null modem cable

Precondition The master controller (0X2 RS232 interface) and the PC must be connected with a null modem ca‐
ble.
➤ Check the requirements.

The null modem cable connections are listed in the annex chapter 13.6. The connection can
be established only with a fully wired null modem cable.
The parameters to be set have to be determined by the network administrator. Settings

changed in the Modem menu option are not active until the menu option has been exited and
the master controller has been restarted.
1. Call up menu option <Settings «F1» System «F1» Interfaces «F3» Modem «F3» >.
3. Select "PPPNull ModemCOM 1" for ptp link.
4. Enter the PPP IP address, e.g.: 192.168.212.251
6. Wait for the message "0624 write EPROM is finished". Wait for Restart needed (H)".
8. Switch the master controller off and on again to accept the changed settings.
7.9.4.2 Setting up the dial-up connection with null modem on the PC
The dial-up connection for the following operating systems will be described:
■ Microsoft Windows XP
■ Microsoft Windows 2000
Precondition Administrator rights are necessary on the PC.
➤ Authorize the suitable person.

7 Initial Start-up
Configuring a dial-up network connection in Microsoft Windows XP

Sign Meaning
1. In the start menu, call up the Connect with command:

< Start Connect with Show all connections Network specification Create new connection >
2. When the <New Connection Wizard – Welcome> appears, click on Next.
3. Settings in <New connection wizard – Network connection type>
■ Activate “Create additional connection” with ◉.
■ Click Next.
4. Settings in the dialog window <New connections wizard – Advanced connection options>
■ Activate "Create direct connection with another computer" with ◉.
■ Click Next.
5. Settings in the dialog window <New connections wizard – host or guest?>
■ Activate "Guest" with ◉.
■ Click Next.
6. Settings in the dialog window <New connection wizard – Connection name>
■ Enter the connection name, e.g. SAM.
■ Click Next.
7. Settings in the dialog window <New connection wizard – Select device>
■ Select "Communication cable between 2 computers (COM1)" in the device selection field.
■ Click Next.
8. Settings in the dialog window <New connection wizard – Connection availability>
Activate the connection either as:
■ "All users" with ◉, or
■ "This user only" with ◉.
■ Click Next.
9. Settings in the dialog window <New connection wizard – Completing the network connection>
■ Click Finish .
menu with < Start Connect with Connection name >, e.g. “SAM”.

user.
1. Establishing the connection in the start menu: < Start Connect with Connection name >, e.g.,
“direct with SAM”.

7 Initial Start-up
2. In the <Create direct connection to SAM >dialog windows, click on Properties.

The <SAM direct properties> dialog window will open.
■ General
■ Options
■ Security
■ Network
■ Common use
─ Activate the corresponding null modem configuration with OK.
─ Click OK.
7. Accept the settings in the dialog window <SAM direct properties> with OK.
8. Enter the following information in the <Create direct connection with SAM> :
(case sensitive!)
9. Click select.
Configuring a dial-up network connection in Microsoft Windows 2000

Sign Meaning

7 Initial Start-up
1. In the start menu, call up the Create new connection command:

< Start Settings Network and data connections Create new connection >
2. Click Next in the Network connection wizard.
3. Settings in <Network connection wizard – network connection type>
■ Activate "Connect directly to another computer" with ◉.
■ Click Next.
4. Settings in the dialog window <Network connection wizard – host or guest>
■ Activate "Guest" with ◉.
■ Click Next.
5. Settings in the <Network connection wizard – select device>
■ Click Next.
6. Settings in <Network connection wizard – Connection availability>
Activate the connection either as:
■ "For all users" with the corresponding ◉, or
■ "This user only" with the corresponding ◉.
■ Click Next.
7. Settings in <Network connection wizard – Finishing>
■ Enter the name of the connection, e.g. "SAM direct", in the appropriate field.
■ Click Finish .
menu with < Start Settings Network and data connections Connection name >, e.g. “SAM direct”.

user.
1. Establishing the connection in the start menu: < Start Settings Network and data connections
Create new connection >, e.g., "SAM direct".
2. In the <Create direct connection to SAM >dialog windows, click on Properties.
The <SAM direct properties> dialog window opens.
■ General
■ Options
■ Security
■ Network
■ Common use
─ Activate the corresponding null modem configuration with OK.

7 Initial Start-up
7.10 Communication

─ Click OK.
7. Accept the settings in the <“SAM direct Properties"> window with OK.
8. Enter the following information in the <Create direct connection with SAM> :
(case sensitive!)
9. Click Connect .
2. Confirm with the «Enter» key.
The SIGMA AIR CONTROL home page appears; call up further pages with the links in the
navigation bar.
7.10 Communication
The functions in the Communication menu are optionally available.
➤ Select from the main menu < Settings «F1» System «F1» Communication «F5» >.
7.10.1 Setting the short message (option)

Short messages can be sent to an authorized KAESER service representative with the short mes‐
sage (SMS) option.

7 Initial Start-up
7.10 Communication
Precondition Either a KAESER PC card modem or a KAESER GSM modem is installed in the master controller.
➤ See service manual "SIGMA AIR MANAGER SMS".
Further information Modem retrofit kits are available. See Annex in chapter 13.10, table 98.
7.10.2 Registering and activating SIGMA AIR CONTROL (option)

Precondition A KAESER PC card with SIGMA AIR CONTROL software installed in the master controller and the
release code on hand.
Detailed information on installation, operation and registration is found in the
SIGMA AIR CONTROL plus service manual.
Data loss from switching off the controller power supply or setting back the clock.
➤ The SIGMA AIR CONTROL plus must be deactivated before taking these actions.
1. Deactivate the SIGMA AIR CONTROL plus before interrupting the power supply.
2. Deactivate the SIGMA AIR CONTROL plus before setting back the clock.
Further information SIGMA AIR CONTROL plus as retrofit kit, see Annex in chapter 13.10, table 98.
7.10.3 Activating send/receive Ethernet layer 4 (option)

The master controller can send and receive data via Ethernet, making a link to a user's control cen‐
ter possible.
Precondition Release code for send/receive to hand.
➤ See service manual "SIGMA AIR MANAGER send/receive".
Further information Send/Receive Ethernet Layer 4 is optionally available. See Annex in chapter 13.10, table 98.

8 Operation
8.1 Displaying operating data
8 Operation
8.1 Displaying operating data
The current data of the compressed air system is shown in the main menu. These are distributed
over six display windows that can be scrolled with the «F5» and «F6» keys.
Precondition The basic settings of the main menu are specified.
1. Select large font display of pressure.

The current system pressure is displayed in large font.
2. Select the "pressure/time diagram".
A profile of system pressure over the preceding 15 minutes is displayed graphically.
3. Select "Overall FAD".
The values in this display are not measured values, they are computed values.
In conventional connections, only machines with the "motor running" feedback signal are
shown.
The following values are displayed:

■ The overall power consumption of the machines in the compressed air station since the
last reset.
■ The overall delivery of the machines in the compressed air station since the last reset.
■ The specific capacity of all machines in the compressed air station since the last reset.
■ Date and time of the last reset in the line above the word "Reset".
The display of these three values can be reset at the same time, by using "Reset" and the
password.
4. Select "List of machines".
In this display, the required pressure can be set and the computed momentary FAD of the
compressor station is shown. (these two figures are shown in the "Operational data" display on
model 16/8).
The status of the machines is shown in the "List of machines". The following symbols are used:
Symbol Meaning
1 Machine 1 is preselected
[4] Machine 4 is activated last
2 Machine 2 is only monitored, load and idle are internally controlled.
1 Machine 1 is not available to the master controller.
Remote/clock/location Type of deselection:

Remote: remote contact, for example, a control center.
Clock: operated with shift clock, machine has been deselected
Location: machine itself (local mode)
Machine running under load
Machine running in idle mode

8 Operation
8.2 Displaying messages
Symbol Meaning
Machine ready for operation, waiting for command
Compressor has a fault
Tab. 29 Machine list symbol
5. Select "Current operating data".

The values in this display are not measured values, they are computed values. In convention‐
al connections, only machines with the "motor running" feedback signal are shown.
Displayed are:
■ Type 16/8 only: Required pressure
■ Power: the current power consumption of the machines
■ Delivery: the current delivery of the machines
■ Specific: the current specific power consumption of the station's running machines
■ Switchings: idle/load swtichings of the station's machines (moving average of the last 7
days)
■ Consumption: the current compressed air consumption of the station
6. Select "Pressure values"
The following values are displayed:
■ Maximum system pressure, together with the respective time of occurrence
■ Mean system pressure since last reset
■ Minimum system pressure, together with the respective time of occurrence
■ Date and time of the last reset in the line above the word "Reset".
■ The display of these three values can be reset at the same time, by using "Reset" and the
password (password level 2).

➤ Note the list of messages in the Annex.
8.2.1 Displaying operational messages

Operational messages are stored in the master controller's event memory.
They do not have to be acknowledged.
A differentiation is made between the following messages:

■ Current messages
■ Event memory (the last 100 messages are stored)
1. Call up menu option <message «F2» operational messages «F2» >.

8 Operation
2. Select a menu option:

■ Current messages «F1»
■ event memory «F2»
The events (messages) are shown with the following data:
─ Message number
─ Message coming K, KG or message gone G
─ Time and date of the event.
─ Message text
─ Type of message (O = operational message)
3. Use the arrow keys to scroll through the events.
8.2.2 Show SMS status

When the short message (SMS) option is activated the current status as an SMS is shown.
➤ Call up menu option <message«F2» SMS status «F3» >.
The following data are shown:
■ SMS being processed: yes or no
■ Active SMS channel
■ Error code (hexadecimal)
■ Message number
■ Type of message: Alarm, warning or maintenance
■ Message from slave (slave 2 = Sequencer; SIGMA CONTROL: Slave 3–18 = machines 1–
16; SIGMA CONTROL 2: Slave 103–118 = machines 1–16)
8.2.3 Show SIGMA AIR CONTROL plus status

When the SIGMA AIR CONTROL plus option is activated, the current status of
SIGMA AIR CONTROL plus is shown in this window.
➤ Call up menu option <message«F2» SAC plus status «F4» >.
■ SAC plus activated yes or no
■ Remaining memory
■ Circular buffer mode.: yes or no
■ Error code (hexadecimal)
8.2.4 Show system status and memory access

System internal information is shown in these displays that may only be used by an authorized
KAESER service representative.
Precondition Authorized KAESER Service Representative
➤ Call up pictures if required.

8 Operation
8.3 Show input and output states
8.3 Show input and output states

The states of the digital and analog inputs and outputs are shown in the inputs/outputs menu op‐
tion.
➤ Select from the main menu <settings«F1»system«F1»inputs and outputs«F4» >.
Show digital inputs
➤ Select menu option <digital inputs«F1» >.

The states of the digital inputs are shown.
This allows the correct wiring of the floating relay inputs to be checked.
■ “0”: no volts
■ “1”: 24 volts
Show digital outputs
➤ Select menu option <digital outputs«F2» >.

The states of the digital outputs are shown. This checks whether an output is activated or not.
Show analog inputs
➤ Select menu option <analog inputs«F3» >.

The analog values in digits are shown.
Analog value of 0 to 20 mA inputs. Indication

Direct on the master controller (AI0, AI1, AI16, AI17) 0 is equivalent to 0 mA
3276 is equivalent to 20 mA
On a Profibus expander (AI36-AI50) 0 is equivalent to 0 mA
Tab. 30 Display of analog inputs
➤ Display the analog values of the PT100 inputs.
Analogue values of the PT100 inputs. Indication

Direct on the master controller (PT0, PT1, PT8, PT9) −2000 is equivalent to −328.0 °F
+2300 is equivalent to 446.0 °F
To a Profibus expander (PT52-PT66) −2000 is equivalent to −148.0 °F
+4500 is equivalent to +842.0 °F
Tab. 31 Display of analogue values of the PT100 inputs.
Show analog outputs
➤ Select menu option <analog outputs «F4» >.

The analog values in digits and mA are shown:
Analog values of outputs Indication

Direct on the master controller (AO0, AO8): 0 is equivalent to 0 mA

8 Operation
8.4 Calling up system information
Analog values of outputs Indication

Models 4/4 and 8/4 1023 is equivalent to 20 mA
Models 8/8 and 16/8 4096 is equivalent to 20 mA
On a Profibus expander (AO36-AO50) 0 is equivalent to 0 mA
Tab. 32 Display of analog output values
8.4 Calling up system information

➤ Select from the main menu <settings«F1»system«F1»system information«F6» >.
■ Material number
■ serial number
■ Details of the software used
■ Details of the operating system used.

9.1 KAESER SERVICE

9.1 KAESER SERVICE
The messages valid for your master controller are dependent on how the compressor station
is equipped. Self-definable messages (see chapter7.7.1) cannot be considered in this overall
description.
1. Do not attempt fault rectification measures other than those given in this manual.
2. Inform KAESER SERVICE if the fault cannot be rectified by the measures suggested.
9.2 Alarm, service and warning messages

Alarm, service and warning messages are displayed on the master controller and stored in the
event memory. The messages are displayed in a display frame (message window) that overlays
the current displayed information. The messages are identified by a Δ at the top left of the mes‐
sage window.
New messages that are not acknowledged are displayed together with the following data:
■ Message (event) number
■ Date and time
■ Message text
■ Type of message:
─ A=Alarm
─ S=Service
─ W=Warning
─ N=Note
Messages must be acknowledged.
➤ Use the «acknowledgement» key to acknowledge messages.

A differentiation is made between events (messages) that are current and the event memory in
which the last 100 events are saved.
1. Select menu option <message«F2»alarm, service and warning messages«F1» >.

2. Select a menu option:

■ Current messages «F1» or
■ event memory «F2»
Every message is displayed with three time stamps:
■ first time stamp: message coming
■ second time stamp: message acknowledged
■ third time stamp: message gone
The following data are shown in addition:
■ message (event) number
■ message has come (C, CG or CGQ), message acknowledged (Q) or message gone (G)
■ date and time
■ message text
■ type of message (A, S, W, N)
3. Use the arrow keys to scroll through the events.
9.2.1 Controller messages

The following messages can appear on the master controller (in the master controller's message
text x represents a number).
Message numbers 191–256 and 369–384 can be activated or deactivated (see chapter 7.7.1)
Interruption of air supplies
Switching the power supply to the master controller off and on again will interrupt the com‐
pressed air supply on compressor stations without emergency mode for about 40 seconds.
With most events, the master controller continues running in its current operating mode. If the mes‐
sage has an asterisk (*) however, machines with EMERGENCY mode switch to their own internal
control. Machines without EMERGENCY mode do not supply compressed air if these messages
appear.
9.2.2 Alarm indications

No. Message Possible cause Remedy
1–16 Compressor x Profibus line or plug ■ Check bus cable/bus plug.
bus alarm (diagnosis) defective; incorrect ■ Check machine slave number.
slave number; ma‐
■ Check power supply to the ma‐
chine without power.
chine.
17–32 Compressor x Profibus line or plug ■ Check bus cable/bus plug.
bus alarm (from SC) defective; incorrect ■ Check machine slave number.
slave number; ma‐
■ Check power supply to the ma‐
chine without power.
chine.
33–46 Bus expander slave x Profibus line or plug ■ Check bus cable/bus plug.
bus alarm (diagnosis) defective; incorrect ■ Check machine slave number.
slave number; ex‐
■ Check power supply to the expand‐
pander without power.
er.
49 Profibus DP not run‐ Consult KAESER service.
ning


50 Profibus DP Consult KAESER service.
Planning error
57 SMS could not be sent ■ Check phone connection.
(CODE) ■ Check SMS settings (see chap‐
ter7.10.1)
■ Always quote the code number
when inquiring at KAESER.
■ Acknowledge message
58 SAC plus group error Code not equal to 80: ■ Consult KAESER service.
Internal error ■ Acknowledge the message.
58 SAC plus group error Code 80 = buffer over‐ ■ Acknowledge message
(80) flow: ■ Re-activate SAC plus.
System heavily over‐ ■ Contact KAESER Service if this er‐
loaded with simultane‐ ror occurs repeatedly.
ous demand for large
amounts of data via
SAC plus
59 SND / RCV alarm Communication via Check Ethernet connection.
the send/receive pro‐
tocol is faulty
60 SAC plus storage me‐ Storage medium de‐ ■ Acknowledge message
dium fective or nonexistent ■ Replace storage medium.
(CODE)
61 SAC plus drive fault Storage medium not ■ Acknowledge message
(DWNo.;CODE) from KAESER; defec‐ ■ Replace storage medium.
tive or not installed.
62 GSM modem alarm or Modem not operation‐ ■ Put the modem in operation.
incorrect PIN. al (no power; no con‐ ■ Correct the PIN in the master con‐
nection to the master troller.
controller; no recep‐
■ Acknowledge the message and re-
tion). Master controller
activate "send GSM PIN"
PIN incorrect.
65–80 Compressor x Machine not ready for ■ Remove fault on the machine.
Group alarm operation. ■ For conventional connection: Check
the cable


81–96 Compressor x "motor running" or ■ Check feedback contact and wiring.
does not switch to "load" feedback sig‐ ■ Remove reason for the machine not
load. nals from the machine starting.
not switching correct‐
ly.
Possible causes:
Feedback contact or
cable defective.
Machine not starting,
e.g. because of back‐
pressure or active idle
key.
99 Highest pressure ex‐ The set highest pres‐ Find and remove the cause of pressure
ceeded. sure ph was exceeded undercut.
for longer than the set
time tph.
100 Summer/winter system An error occurred dur‐ ■ Check clock time and correct if nec‐
changeover faulty. ing internal clock reset essary.
from summer to winter ■ Consult KAESER service.
or vice versa.
101 System EEPROM An error occurred ■ Consult KAESER service.
read error while reading from the ■ Acknowledge message
EEPROM.
102 System EEPROM An error occurred ■ Consult KAESER service.
write faulty. when writing to the ■ Acknowledge message
EEPROM.
113 + Pressure transducer x The connection to the ■ Remove the cause of the interrup‐
115 (*) open circuit pressure transducer is tion.
interrupted. ■ Acknowledge message
■ Switch the station back to automat‐
ic mode or switch on again.
114 + Pressure transducer x The connection to the ■ Remove the cause of the short cir‐
116 (*) short circuit pressure transducer is cuit.
short circuited. ■ Acknowledge message
117 Minimum pressure un‐ Pressure was less Find and remove the cause of pressure
der cut. than minimum pres‐ undercut.
sure pt for a longer
period than set for
time tpt.
118 (*) No pressure transduc‐ No pressure transduc‐ ■ Connect at least one transducer to
er activated. er assigned to an ana‐ an analog input in the network pres‐
log input. sure menu (see chapter 7.5.2).
■ Acknowledge alarm message.


119 FC compressor speed Check the cable at the respective ana‐
open circuit log input.
120 FC compressor speed Check the cable at the respective ana‐

short circuit log input.
121 Required pressure ■ Check the cable at the respective

from AI analog input.
open circuit ■ Acknowledge message
122 Required pressure ■ Check the cable at the respective
from AI analog input.
short circuit ■ Acknowledge message
123 Input value X from AI Check the cable at the respective ana‐
open circuit log input.
124 Input value X from AI Check the cable at the respective ana‐
short circuit log input.
125 Input value X from PT Check line to the PT100 input.

Sensor fault.
127 Network section Valve control, the ■ Check valve control, the valve itself
Valve does not open. valve itself or position or position sensing contact.
sensing contact. ■ Change the time-out setting for the
Time-out for the valve valve function.
function set too short.
128 Network section Valve control, the ■ Check valve control, the valve itself
Valve does not close. valve itself or position or position sensing contact.
sensing contact. ■ Change the time-out setting for the
Time-out for the valve valve function.
function set too short.
130 (*) System An error occurred in ■ Switch the master controller's pow‐
FLASH error the master controller's er supply off.
internal FLASH mem‐ ■ Leave the power supply off.
ory.
■ Consult KAESER service.
RAM error the master controller's er supply off.
internal RAM memory. ■ Leave the power supply off.
132 (*) System The master control‐ ■ Maintain ambient temperature be‐
Temperature too high. ler's ambient tempera‐ low 104 °F.
ture has exceeded the ■ Acknowledge message
permissible 104°F.
133 (*) System The master control‐ ■ Maintain ambient temperature
Temperature too low. ler's ambient tempera‐ above 32 °F.
ture has undercut the ■ Acknowledge message
permissible 32 °F.


135 (*) System There is not enough ■ Switch the master controller's pow‐
HEAP error internal memory for er supply off and on again.
the master controller ■ Consult KAESER service.
program.
TRAP error the master controller's er supply off.
program. ■ Leave the power supply off.
137 System The PCMCIA slots ■ Maintain ambient temperature be‐
PC card slots deacti‐ were deactivated be‐ tween 32 and 104 °F.
vated. cause temperature ■ Switch the master controller's pow‐
was either too high or er supply off and on again.
too low.
138 (*) System GDT fault There is not enough ■ Switch the master controller's pow‐
internal resource for er supply off.
the master controller ■ Leave the power supply off.
program.
■ Consult KAESER SERVICE.
139 System application er‐ There is a problem in ■ Note the complete message, espe‐
ror. a subroutine in the cially the numbers in the brackets.
(DW No.; CODE) master controller's ■ Consult KAESER SERVICE.
program.
140 (*) System application er‐ There is a problem in ■ Note the complete message, espe‐
ror. a subroutine in the cially the numbers in the brackets.
(DW No.; CODE) master controller's ■ Consult KAESER SERVICE.
program.
141 System output test The relays on outputs ■ Check relay connections.
Card 1 with error 0.0 to - 0.7 defective ■ Acknowledge message
at the coil end (open
■ Switch the master controller's pow‐
circuit or short circuit).
er supply off and on again.
143 System output test The relays on outputs ■ Check relay connections.
Card 3 with error 8.0 to - 8.7 defective ■ Acknowledge message
at the coil end (open
■ Switch the master controller's pow‐
circuit or short circuit).
er supply off and on again.
161– Message text may be Component connect‐ Remove the fault in the connected com‐
176 defined. ed reports a fault. ponent.
191 UPS battery Battery soon dis‐ Ensure power supply is available.
charged.
Battery defective. Replace battery.
192 Power failure Power supply has
failed.
SAM is working from
the battery.


193– Cyclone separator x Cyclone separator re‐ Remove the fault on the condensate
208 condensate drain ports fault. drain.
209– Dryer x Dryer reports a fault. Remove the fault in the dryer.
216 High dew point.
224 Fault
240 Condensate drain x
241– Air receiver x Air receiver reports a Remove the fault on the condensate
242 condensate drain fault. drain.
243– Filter x Filter reports a fault. Remove the fault on the condensate
250 Condensate drain drain.
251– Condensate treatment Connected compo‐ Remove the fault in the connected com‐
256 x nent reports a fault. ponent.
Tab. 33 Alarm indications
9.2.3 Service and warning messages

No. Message Possible cause Action
257– Compressor x Machine reports service see machine / machine mainte‐
272 Group maintenance message nance instructions
Acknowledge message.
273– Compressor x The maintenance interval Carry out maintenance on the
288 Carry out maintenance. entered in the master con‐ machine.
troller for the machine has Reset maintenance interval
expired. counters (see 7.3.5).
289 System The buffer battery in the Change the buffer battery soon‐
Change the SAM buffer master controller is dis‐ est (see chapter 10.3).
battery. charged.
369– Filter x Connected component re‐ Carry out maintenance according

384 Pressure differential x ports maintenance. to manual.
385– Compressor x Machine reports service see machine / machine service

400 Group warning message. manual.
Acknowledge message.
401– Compressor x Press the remote key on the ma‐
416 Not in REMOTE mode. chine again.
417– Compressor x Machine power or FAD not Enter power and FAD.
432 Data incomplete. entered.
481– Message text may be Connected component ini‐ Carry out maintenance according
488 defined. tiates a service message. to manual.
Tab. 34 Service and warning messages

9.2.4 Notes
579 Input already as‐ Select a spare input from the DI
signed. list.
580 Delay period too The period entered is too long and Enter an acceptable period.
long. cannot be accepted by the master
(0s to 999s) controller.
581 Input nonexis‐ Select a spare input from the DI

tent. list.
583 Output non-exis‐ Select a spare output from the DO
tent. list.
584 Output already Select a spare output from the DO
assigned. list.
585 Output non-exis‐ Select a spare output from the DO
tent. list.
586 Input non-exis‐ Select a spare input from the DI
tent. list.
591 Slave cannot be Activate Profibus (see chap‐
activated be‐ ter 7.3.4).
cause the Profi‐
bus is inactive.
592 Deactivation not Deactivate all the slave's inputs
possible. and outputs.
Slave is in use.
593 Deactivation not Deactivate all slaves.
possible.
At least 1 slave
is active.
594 Analog input Select a spare input from the AI
nonexistent. list.
595 Undiscovered An error occurred in the master con‐ Consult KAESER SERVICE.
compile time er‐ troller's program.
ror.
596 Values must be Two equal values have been entered; Enter acceptable values.
different. they must differ. The master controller
cannot accept these values.
597 Value below The value entered is too small and Enter an acceptable value.
lower limit! cannot be accepted by the master
Minimum: < # # controller.
# > psi
609 No weekdays The switching point cannot be saved Select weekday(s).
selected. as no weekday has been defined.
610 Given switching The switching point to be deleted is Acknowledge message
time not entered. nonexistent.


611 Not enough All 32 shift clock switching points have Set up the shift clock so that the
spare switching been assigned. maximum of 32 switching points
points. are used.
612 Time reset to Time switches from winter to summer Acknowledge message
summer time. time automatically.
613 Time reset to Time switches from summer to winter Acknowledge message
winter time. time automatically.
614 Keys locked. The depressed key is locked. Unlock key (see chapter 7.2.6.3).
615 Compressor The «machine preselect »key has not See menu Connect to compres‐
non-existent been assigned to a machine. sors (chapter 7.3.1).
616 Compressor pre‐ «Machine preselection» by key is cur‐ ■ Check if the remote key can
selection rently not possible as remote prese‐ be deactivated.
Controlled by lection via a relay contact or control ■ Use the preselection key as
REMOTE center is active. required
617 No switching An attempt is made to activate the Set up switching points (see chap‐
points entered shift clock although no switching ter 7.6).
points have been set up.
618 Manual/Auto‐ Manual/Automatic is currently not pos‐ ■ Check if the «Remote »key
matic sible as remote Manual/Automatic is can be deactivated.
Controlled by active via a relay contact or control ■ Use the «Automatic» key as
REMOTE centre required.
619 OFF/ON ON or OFF by key is currently not pos‐ ■ Check if the «Remote »key
Controlled by sible as remote ON/OFF is active via a can be deactivated.
REMOTE relay contact or control center ■ Use «ON» or «OFF» keys as
required.
620 Shift clock The shift clock cannot be activated/de‐ ■ Check if the «Remote »key
Controlled by activated by the «clock» key because can be deactivated.
REMOTE the clock is active via a floating relay ■ Use the «clock» key as re‐
contact or control center. quired.
621 SMS will be sent Acknowledge the message.
(CODE)
622 SMS channel 2 SMS couldn’t be transmitted on chan‐ ■ Check settings for SMS chan‐
activated. nel 1 nel 1.
Channel 2 was used ■ Possibly temporary problems
at the provider.
623 Write EEPROM The master controller is saving data to Acknowledge message and wait
running. the internal EEPROM memory. till message 624 is displayed.
Do not switch Switching off will cause data loss.
off!
624 Write EEPROM See also message 623 ■ Switch to manual operation.
finished. Data save complete. Switch the mas‐ ■ Switch the power supply off
Power off/on ter controller off and on again to ac‐ and on again.
cept the data. ■ Switch to automatic mode
again.


625 SAC plus invalid A false registration code was entered Use the specific registration code
registration for SIGMA AIR CONTROL plus . of the master controller.
code.
626 SAC plus is de‐ See also message 629 Acknowledge message
activated. Data saving on SAC plus storage me‐
Shutdown is dium is finished. The master controller
possible. can be switched off if necessary.
627 SAC plus Save SAC plus data if desired. Acknowledge message
Free memory
less than 30%
628 SAC plus circu‐ Save SAC plus data if desired. Oldest Acknowledge message
lar buffer active. data is deleted.
629 SAC plus is de‐ The master controller is saving data to Acknowledge message and wait
activated. the SACplus storage medium. Switch‐ till message 626 is displayed.
Do not switch ing off will cause data loss.
off!
630 SAC plus is de‐ The master controller clock was set ■ Acknowledge message If the
activated. back by more than 24 hours. clock was set back acciden‐
Clock set back! SIGMA AIR CONTROL plus will be tally, correct and re-activate
deactivated to prevent the accidental SIGMA AIR CONTROL plus.
deletion of data. ■ Re-activate SACplus if the set
back of time was deliberate.
Recent data will be deleted.
633 SND/RCV regis‐ A false registration code was entered Use the specific registration code
tration code in‐ for the send/receive protocol option. of the master controller.
valid.
636 SMS will be de‐ After setting up modem communica‐ Acknowledge message
activated tion to KLink the SMS function will be
(KLink connec‐ automatically deactivated. Only SMS
tion) or KLink can be used through a mo‐
dem.
637 Required pres‐ A required pressure read off from an ■ Check external source of re‐
sure from AI in‐ analog input is outside the permissible quired pressure.
valid range. ■ For limits, see "Required
pressure" menu (chap‐
ter 7.5.1).
638 Current pressure An error occurred in the master con‐ ■ Switch the master controller's
remains con‐ troller's program. power supply off.
stant. ■ Leave the power supply off.
■ Consult KAESER SERVICE.
Tab. 35 Notes

9.3 O&O messages (operation & observation)
9.3 O&O messages (operation & observation)

Messages concerning operation and observation are displayed on the master controller, but not
stored in the event memory. The messages are identified by a ! at the top left of the message win‐
dow. They have to be acknowledged with the «escape »key. Mostly, they refer to either too large or
too small entry value.
➤ Acknowledge messages with the «Escape» key.
9.4 System messages

A message with text similar to the following is shown across the complete display: "critical system
error occurred... system halted”
■ The complete master controller system is stopped, all outputs are deactivated.
■ On compressor stations with emergency operation capability, the machines run under their
own internal control.
■ Stations without this capability cannot supply compressed air.
1. If such a message appears, write it down in full and then contact KAESER SERVICE.
2. Leave the station running in emergency mode.
3. On stations without an emergency mode capability, try to remove the fault by switching the
power supply to the master controller off and then on again.

10 Maintenance
10.1 Maintenance tasks on electrical equipment
10 Maintenance
10.1 Maintenance tasks on electrical equipment
Maintenance talks on electrical equipment may only be carried out by the following persons:
■ trained technicians
■ by technicians trained to maintain the master controller and by service personnel instruct‐
ed by and under the supervision of such a trained technician
■ an authorized KAESER service representative
1. Check personnel for specialized suitability.
2. Assign suitable personnel to maintenance tasks.
3. Instruct on correct maintenance procedures in accordance with the service manual.
4. Document maintenance tasks carried out.
Enter completed maintenance tasks in the list in the service manual.
10.2 Testing the control panel

The LEDs, keys and the display can be checked for correct function.
1. Select menu <settings«F1»system«F1»general settings«F1»control panel«F4» >.
2. Press the «F1» key to carry out the LED test; if required, enter the password for Level 1.
All LEDs on the master controller will light up for approximately five seconds. Any unlit lamps
are defective.
3. To carry out the key test, press the «F2» key and then the key to be tested; if required, enter
the password for Level 2.
An image of the key that has been pressed appears on the display. The actual key function is
not triggered. The arrow keys cannot be tested.
4. To test the display, press and hold «F3».
As long as «F3 » is pressed the display turns black and defective pixels can be recognized.
10.3 Changing the buffer battery

➤ Follow instructions carefully.
10.3.1 Danger from batteries
There is danger of acid burns if batteries are overheated or damaged.

➤ Store the battery in a cool and dry place.
➤ Dispose of damaged buffer batteries correctly.

10 Maintenance
10.3.2 Battery life

Under normal operating conditions the buffer battery in the master controller has a life of approxi‐
mately 10 years. Unused buffer batteries can be stored for five years.
Data loss from flat battery

➤ Heed warning messages from the controller concerning the buffer battery charge level.
➤ Exchange the buffer battery only when the master controller is switched on.
If the battery is discharged and a power failure occurs the event memory settings and clock
time are lost after approximately one hour.
➤ Heed the charging time for unused buffer batteries.
10.3.3 Battery changing sequence
Cable crack from incorrect handling.

➤ Never remove the battery plug from its socket by pulling on the cable.
Fig. 22 Buffer battery location

1 Side cover
2 Buffer battery
3 Battery cable plug
Precondition New battery to hand.

The master controller is switched on.
1. Remove the securing pins on the side cover 1 of the master controller with a screwdriver.
2. Remove the side cover 1 . The battery 2 is fixed to the side cover.
3. Carefully withdraw the plug on the battery cable 3 from the socket.
4. Remove the battery 2 from the fixing.
5. Insert a new battery.

10 Maintenance
6. Plug the battery cable 3 into the socket:

■ Blue cable (-) above
■ Red cable (+) below
7. Push extra cable into the master controller's housing.
8. Replace the cover and fix with the securing pins.
9. Check date, time and settings, correcting if required. (see chapters 7.2.7 to 7.2.9)
Used batteries are hazardous waste
➤ Dispose of the old battery in accordance with local environment protection regulations.

11.1 Note the Nameplate

11.1 Note the Nameplate
The nameplate contains all information to identify your controller. 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 Spare parts

Name Voltage Capacity Order number
[V] [Ah]
Lithium buffer battery 3.6 1.8 7.7704.0
Tab. 36 Spare buffer battery
11.3 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.
11.4 Displaying version and serial number

➤ Select menu <settings«F1»system«F1»system information«F6» >

12.1 De-commissioning

12.1 De-commissioning
De-commissioning is necessary, for example, under the following circumstances:
■ The master controller is temporarily not needed,
■ The master controller is to be moved to another location,
1. Isolate the master controller (power supply disconnecting device) from all power phases.
2. Switch off external power sources.
12.2 Disposal
Precondition The master controller is decommissioned.
1. The master controller is completely disconnected.

2. The battery has been removed (see 10.3) and properly disposed of.
3. Hand the master controller over to an authorized disposal expert.

13 Annex
13.1 Anchor holes for the control cabinet
13 Annex
13.1 Anchor holes for the control cabinet
See instructions in chapter 6.4
Fig. 23 Anchor holes for model 4/4 and 8/4 cabinets

1 15 in. 4 12 in.
2 13.4 in 5 13.3 in.
3 7.5 in. 6 ∅ 0.3 in.
Fig. 24 Anchor holes for model 8/8 cabinet

1 19.7 in. 4 27.5 in.
2 18.1 in. 5 ∅ 0.3 in.
3 26 in.

13 Annex
13.2 Machine assignment
Fig. 25 Anchor holes for model 16/8 cabinet

1 31.5 in. 4 47.25 in.
2 30 in. 5 ∅ 0.3 in.
3 45.7 in.
13.2 Machine assignment

No. Model Machine Year of manufacture Electrical diagram Bus address / slave
number number number
1
2
3
4
5
6
7
8
9
10
11

13 Annex
13.3 Profibus expander
No. Model Machine Year of manufacture Electrical diagram Bus address / slave
number number number
12
13
14
15
16
Tab. 37 Machine assignment
13.3 Profibus expander

See instructions in chapter 7.3.3
The following Profibus expanders are connected to the master controller:
Model Material number Profibus address
Tab. 38 Profibus expander
13.4 Master controller settings

The master controller factory settings are listed below. Enter alterations in the empty fields.
➤ Enter changes in the prepared list.
Result These entries simplify the task of determining the cause if any problems should arise.
13.4.1 Profibus expander


13 Annex
13.4.1.1 Profibus expander with 8 channels
active XX.0 XX.1 XX.2 XX.3 XX.4 XX.5 XX.6 XX.7

Slave 20 − I I I I I I I I
Slave 24 − I I I I O O O O
+ ≙ Yes, − ≙ No, I ≙ Input, O ≙ Output
Tab. 39 Profibus expander with 8 channels
13.4.1.2 Profibus expander with 32 inputs
active
Slave 28 −
Slave 32 −
+ ≙ Yes, − ≙ No
Tab. 40 Profibus expander with 32 inputs
13.4.1.3 Profibus expander with analog inputs and outputs
active
Slave 36 −
Slave 44 −
Slave 52 −
Slave 60 −
+ ≙ Yes, − ≙ No

13 Annex
active
+ ≙ Yes, − ≙ No
Tab. 41 Profibus expander with analog inputs and outputs
13.4.2 Summer/winter changeover

Date / time
Name Factory settings
Switchover active +
Hours offset (h) 1
Winter → summer changeover
Relative weekday second
Weekday Sunday
Month March
Time 2
Summer → winter changeover
Relative weekday first
Weekday Sunday
Month November
Time 3
+ ≙ Yes, − ≙ No
Tab. 42 Summer/Winter changeover
13.4.3 Interface settings

Profibus
Interface active +
RS 232
Connections −
Bit rate 9.600
Data format D8/S1/P none
Modem
ptp link PPP null modem
COM1
PPP-IP address 192.168.212.251
Ethernet
IP address 169.254.100.100
+ ≙ Yes, − ≙ No

13 Annex
Profibus
Subnet mask 255.255.0.0
IP router address 0.0.0.0
+ ≙ Yes, − ≙ No
Tab. 43 Interface settings
13.4.4 Pressure regulation settings

13.4.4.1 Pressure parameters
Date / time
Name Unit Factory
setting
Required pressure [psig] 110
Pressure low
Pressure low dpt [psig] 7
Pressure low dpt [s] 10
Pressure low dpt active +
Pressure low pt [psig] 0.00
Pressure low pt [s] 10
Pressure low pt active −
Pressure high
Pressure high ph [psig] 145 / 232
Pressure high ph [s] 60
Pressure high ph active −
Tab. 44 Pressure parameters
13.4.4.2 System parameters
Date / time
Name Unit Factory set‐
ting
Required pressure
Maximum required pres‐ [psig] 110
sure
Minimum required pres‐ [psig] 60
sure
Analog input 1
Required pressure 0 psig [mA] 4
+ = Yes, − = No

13 Annex
Date / time
Name Unit Factory set‐
ting
Required pressure at 20 [psig] 232
mA:
System pressure
Analog input 1 0
Weighting [%] 100
Analog input 2 0
Weighting [%] 0
Final pressure of pres‐ [psig] 145 / 232
sure transducer
Actual pressure value [s] 1
damping
Restart
Automatic restart +
Delay period for restart [s] 60
Minimum pressure with Active –
air system OFF
Network charging with [psig/min] 14.5
Further settings
Monitoring period for mo‐ [s] 60
tor running
Power limiting [kW] 500
Power limiting active −
Activate compressors, #
first
Activate compressors, #
first rigid
+ = Yes, − = No
Tab. 45 System parameters
13.4.4.3 Shift clock
Date / time
Name
Switching point Weekday Time Pressure Channel Compressors

13 Annex
Date / time
Name
Switching point Weekday Time Pressure Channel Compressors
Tab. 46 Shift clock settings
13.4.5 Linking the machines


13 Annex
Factory settings for model x/4 / x/8
Machine 1 2 3 4
Connection
None X X X X
SIGMA CONTROL − − − −
Conventional − − − −
Compressor
Controlled X X X X
Monitored − − − −
Delivery[cfm] 0 0 0 0
Power consumption [kW] 0 0 0 0
at pressure [psig] 0 0 0 0
Idle consumption [kW] 0 0 0 0
Inputs
Engine running 0.0 / 1.0 0.1 / 1.2 0.2 / 1.4 0.3 / 1.6
Active − − − −
No alarm 0.0 / 1.1 0.0 / 1.3 0.0 / 1.5 0.0 / 1.7
Load 0.0 0.0 0.0 0.0
Outputs
Load 0.1 / 4.5 0.2 / 4.6 0.3 / 4.7 0.4 / 4.0
Negative +/− +/− +/− +/−
Automatic 0.0 / 4.1 0.0 / 4.2 0.0 / 4.3 0.0 / 4.4
FC machine − − − −
Characteristic curve No. − − − −
Conventional connection
Analog input AI 0 AI 0 AI 0 AI 0
Speed = 0 at [mA] 4 4 4 4
Speed at 20 mA 4000 4000 4000 4000
+ ≙ Yes, − ≙ No
Tab. 47 Factory settings for machines 1,2,3 and 4
Machine 5 6 7 8
Connection
+ ≙ Yes, − ≙ No

13 Annex
Machine 5 6 7 8
None X X X X
Compressor
Controlled X X X X
Idle consumption [kW] 0 0 0 0
Inputs
Engine running 0.0 / 2.0 0.0 / 2.2 0.0 / 2.4 0.0 / 2.6
No alarm 0.0 / 2.1 0.0 / 2.3 0.0 / 2.5 0.0 / 2.7
Load 0.0 0.0 0.0 0.0
Outputs
Load 0.0 / 12.5 0.0 / 12.6 0.0 / 12.7 0.0 / 12.0
Negative − − − −
Automatic 0.0 / 12.1 0.0 / 12.2 0.0 / 12.3 0.0 / 12.4
Speed = 0 at [mA] 4 4 4 4
Speed at 20 mA 4000 4000 4000 4000
+ ≙ Yes, − ≙ No
Tab. 48 Factory settings for machines 5,6,7 and 8
Machine 9 10 11 12
Connection
None X X X X
+ ≙ Yes, − ≙ No

13 Annex
Machine 9 10 11 12
Compressor
Controlled X X X X
Power consumption in 0 0 0 0
idle [kW]
Inputs
Engine running 0.0 0.0 0.0 0.0
No alarm 0.0 0.0 0.0 0.0
Load 0.0 0.0 0.0 0.0
Outputs
Load 0.0 0.0 0.0 0.0
Automatic 0.0 0.0 0.0 0.0
Speed = 0 at [mA] 4 4 4 4
Speed at 20 mA 4000 4000 4000 4000
+ ≙ Yes, − ≙ No
Tab. 49 Factory settings for machines 9, 10, 11 and 12
Machine 13 14 15 16
Connection
None X X X X
Compressor
Controlled X X X X
+ ≙ Yes, − ≙ No

13 Annex
Machine 13 14 15 16
Power consumption in 0 0 0 0
idle [kW]
Inputs
Engine running 0.0 0.0 0.0 0.0
No alarm 0.0 0.0 0.0 0.0
Load 0.0 0.0 0.0 0.0
Outputs
Load 0.0 0.0 0.0 0.0
Automatic 0.0 0.0 0.0 0.0
Speed = 0 at [mA] 4 4 4 4
Speed at 20 mA 4000 4000 4000 4000
+ ≙ Yes, − ≙ No
Tab. 50 Factory settings for machines 13, 14, 15 and 16
13.4.5.1 Personal settings
Settings for the machines 1, 2, 3, and 4
Machine 1 2 3 4
Date and time
Connection
None
SIGMA CONTROL
Conventional
Compressor

13 Annex
Machine 1 2 3 4
Date and time
Controlled
Monitored
Delivery[cfm]
Power consumption [kW]
at pressure [psig]
Idle consumption [kW]
Inputs
Engine running
Active
No alarm
Active
Load
Active
Outputs
Load
Active
Negative
Automatic
Active
FC machine
Characteristic curve No.
Analog input
Active
Speed = 0 at [mA]
Speed at 20 mA
Tab. 51 Settings for machines 1,2,3 and 4
Settings for the machines 5, 6, 7 and 8
Machine 5 6 7 8
Date and time
Connection
None
SIGMA CONTROL
Conventional
Compressor
Controlled

13 Annex
Machine 5 6 7 8
Date and time
Monitored
Delivery[cfm]
at pressure [psig]
Inputs
Engine running
Active
No alarm
Active
Load
Active
Outputs
Load
Active
Negative
Automatic
Active
FC machine
Analog input
Active
Speed = 0 at [mA]
Speed at 20 mA
Tab. 52 Settings for machines 5,6,7 and 8
Settings for the machines 9, 10, 11 and 12
Machine 9 10 11 12
Date and time
Connection
None
SIGMA CONTROL
Conventional
Compressor
Controlled
Monitored

13 Annex
Machine 9 10 11 12
Date and time
Delivery[cfm]
at pressure [psig]
Inputs
Engine running
Active
No alarm
Active
Load
Active
Outputs
Load
Active
Negative
Automatic
Active
FC machine
Analog input
Active
Speed = 0 at [mA]
Speed at 20 mA
Tab. 53 Settings for machines 9, 10, 11 and 12
Settings for machines 13, 14, 15 and 16
Machine 13 14 15 16
Date and time
Connection
None
SIGMA CONTROL
Conventional
Compressor
Controlled
Monitored
Delivery[cfm]

13 Annex
Machine 13 14 15 16
Date and time
at pressure [psig]
Inputs
Engine running
Active
No alarm
Active
Load
Active
Outputs
Load
Active
Negative
Automatic
Active
FC machine
Analog input
Active
Speed = 0 at [mA]
Speed at 20 mA
Tab. 54 Settings for machines 13, 14, 15 and 16
13.4.6 FC characteristic
FC characteristic 1
Plotting points Speed Delivery Power

[rpm] [cfm] [kW]
Factory setting 0 0.000 0.00
min
2
3
4
5

13 Annex

[rpm] [cfm] [kW]
6
7
max
Tab. 55 FC characteristic 1
FC characteristic 2

[rpm] [cfm] [kW]
min
2
3
4
5
6
7
max
FC characteristic 3

[rpm] [cfm] [kW]
min
2
3
4
5
6
7
max
13.4.7 Operating hours and maintenance intervals


13 Annex
Date / time
Name Factory
settings
Machine 1
Source SC
Total hours: [h] 0
Hours on load [h] 0
Preset (maintenance in‐ [h] 500
terval)
Remaining (maintenance [h] 500
interval)
Active (y/n) −
Machine 2
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Machine 3
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Machine 4
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Machine 5
Source SC
Total hours: [h] 0

13 Annex
Date / time
Name Factory
settings
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Machine 6
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Machine 7
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Machine 8
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Machine 9
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)

13 Annex
Date / time
Name Factory
settings
interval)
Active (y/n) −
Machine 10
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Machine 11
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Machine 12
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Machine 13
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −

13 Annex
Date / time
Name Factory
settings
Machine 14
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Machine 15
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Machine 16
Source SC
Total hours: [h] 0
Hours on load [h] 0
terval)
interval)
Active (y/n) −
Tab. 58 Operating and maintenance intervals
13.4.8 Further inputs

13.4.8.1 External machine selection
Factory setting
Machine all
External selection 0.0
Active −

13 Annex
Machine all
Negative −
Tab. 59 Machine selection factory setting
Personal setting
Machine 1 2 3 4
Date and time
External selection
Active
Negative
Tab. 60 Settings for machines 1,2,3,4
Machine 5 6 7 8
Date and time
External selection
Active
Negative
Machine 9 10 11 12
Date and time
External selection
Active
Negative
Machine 13 14 15 16
Date and time
External selection
Active
Negative
13.4.8.2 Digital inputs
Factory setting
Remote ON/OFF
Function active −
Input 0.0

13 Annex
Factory setting
Active at: 24 V
Remote MANUAL/AUTO
Function active −
Input 0.0
Active at: 24 V
Remote SHIFT CLOCK
Function active −
Input 0.0
Active at: 24 V
Switching compressors
online
Function active −
Input 0.0
Active at: 24 V
Decrease required pres‐
sure:
Function active −
Input 0.0
Active at: 24 V
Power limiting
Function active −
Input 0.0
Active at: 24 V
Tab. 64 Digital inputs
13.4.8.3 Analog inputs
Input value 1 Unit Active Input
at 0 mA at 20 mA
Line compensation
Threshold value 1 Output Active
Input value
Input value
Tab. 65 Input value 1

13 Annex
at 0 mA at 20 mA
Line compensation
Input value
Input value
at 0 mA at 20 mA
Line compensation
Input value
Input value
at 0 mA at 20 mA
Line compensation
Input value
Input value
at 0 mA at 20 mA
Line compensation
Input value

13 Annex

Input value
at 0 mA at 20 mA
Line compensation
Input value
Input value
at 0 mA at 20 mA
Line compensation
Input value
Input value
at 0 mA at 20 mA
Line compensation
Input value
Input value

13 Annex
13.4.9 Further outputs

13.4.9.1 Load and group alarm signals
Factory setting
Machine all
Load 0.0
Active −
Negative −
Group alarm 0.0
Active −
Negative −
Tab. 73 Factory setting (Load, Group alarm)
Personal settings
Machine 1 2 3 4
Date and time
Load
Active
Group alarm
Active
Negative
Machine 5 6 7 8
Date and time
Load
Active
Group alarm
Active
Negative
Machine 9 10 11 12
Date and time
Load
Active
Group alarm
Active

13 Annex
Machine 9 10 11 12
Date and time
Negative
Machine 13 14 15 16
Date and time
Load
Active
Group alarm
Active
Negative
13.4.9.2 Digital outputs
Factory setting
Group alarm
Function active −
Output 0.0
Active at: 24 V
Controller operational
Function active −
Output 0.0
Active at: 24 V
Group maintenance/group warning
Function active −
Output 0.0
Active at: 24 V
External alarm
Function active
Output
Active at:
Maintenance/external warning
Function active −
Output 0.0
Active at: 24 V
Compressor alarm
+ = Yes, − = No

13 Annex
Factory setting
Function active −
Output 0.0
Active at: 24 V
Compressor maintenance / warning
Function active −
Output 0.0
Active at: 24 V
Pressure low
Function active −
Output 0.0
Active at: 24 V
Group alarm dryer 1
Function active −
Output 0.0
Active at: 24 V
Group alarm dryer 2
Function active −
Output 0.0
Active at: 24 V
Group alarm dryer 3
Function active −
Output 0.0
Active at: 24 V
Group alarm dryer 4
Function active −
Output 0.0
Active at: 24 V
Group alarm dryer 5
Function active −
Output 0.0
Active at: 24 V
Group alarm dryer 6
Function active −
Output 0.0
Active at: 24 V
Group alarm dryer 7
Function active −
+ = Yes, − = No

13 Annex
Factory setting
Output 0.0
Active at: 24 V
Group alarm dryer 8
Function active −
Output 0.0
Active at: 24 V
Timer channel 1
Function active −
Output 0.0
Active at: 24 V
Timer channel 2
Function active −
Output 0.0
Active at: 24 V
Timer channel 3
Function active −
Output 0.0
Active at: 24 V
Timer channel 4
Function active −
Output 0.0
Active at: 24 V
REMOTE mode
Function active −
Output 0.0
Active at: 24 V
CLOCK mode
Function active −
Output 0.0
Active at: 24 V
AUTOMATIC mode
Function active −
Output 0.0
Active at: 24 V
Compressor station ON
Function active −
Output 0.0
+ = Yes, − = No

13 Annex
Factory setting
Active at: 24 V
No compressor preselected
Function active −
Output 0.0
Active at: 24 V
Group alarm (pulse)
Function active −
Output 0.0
Active at: 24 V
Pressure high
Function active −
Output 0.0
Active at: 24 V
+ = Yes, − = No
Tab. 78 Digital outputs
13.4.9.3 Analog outputs
Factory setting
System pressure
Output active +
Analog output 0
I = 0 mA 0.00 psig
I = 20 mA 232.00 psig
Required pressure
Output active −
Analog output 0
I = 0 mA 0.00 psig
I = 20 mA 232.00 psig
Free air delivery
Output active −
Analog output 0
I = 0 mA 0 cfm
I = 20 mA 1766 cfm
FC setpoint pressure
Output active −
Analog output 0
+ = Yes, − = No

13 Annex
Factory setting
I = 0 mA 0.00 psig
I = 20 mA 232.00 psig
Power
Output active −
Analog output 0
I = 0 mA 0.000 kW
I = 20 mA 500,000 kW
+ = Yes, − = No
Tab. 79 Analog outputs
13.4.10 Settings for SMS

Date / time
SMS active −
Language SMS German
Send air system data −
Call-repeat blocking 60
time [min]
Subsidiary CBG
Dial initialization ATX 3 DT0,
Sender
Telephone number
Contact person
SAM's phone number
Send GSM PIN −
GSM PIN −1
Sign-of-life active −
Weekday
Time of sending:
Channel 1
Protocol TAP
Auto re-dial 3
Pause [min] 1
Call-center's phone num‐ 01712521002
ber
Customer Service phone 017118637270
number
+ ≙ Yes, − ≙ No

13 Annex
13.5 Technician's settings
Date / time
Channel 2
Protocol TAP
Auto re-dial 3
Pause [min] 1
Call-center's phone num‐ 01712521001
ber
Customer Service phone 017118637270
number
+ ≙ Yes, − ≙ No
Tab. 80 Short message setting
13.5 Technician's settings

Technician's settings

13 Annex
13.6 Null modem pin connections
Technician's settings
Tab. 81 Technician's settings
13.6 Null modem pin connections

Plug: 2x9 pin sub-D (socket)
Fig. 26 Null modem cable pin connections

A PC COM 1/2
B Master controller RS232, 0x2
13.7 Master controller messages

13.7.1 Operational Messages
No. Message text Remarks
1 Transmission test The transmission test is sent through the SMS.
signal
33 SAM OFF mode The compressed air system is switched off. No compressed air is sup‐
plied.
34 SAM MANUAL Only on compressor stations with emergency mode capability.
mode The station is in emergency mode. The air compressors are controlled
independently of the master controller by their own pressure regula‐
tion.
35 SAM AUTO mode The compressed air system is operational, compressed air is being
supplied. The master controller takes over control of the machines.

13 Annex
No. Message text Remarks

36 SAM start delay The power supply to the master controller has just returned. The air
mode system is in start delay mode and is not yet supplying compressed air.
When the "restart delay period" has expired, compressed air will be
supplied again.
37 SAM air main The air system has just been switched on. The air main will be charg‐
charging mode ed. The compressed air supply is only used to charge the air main.
38 SAM shift clock The required pressure and compressors in use are specified by the
mode internal shift clock. They can change depending on the shift clock.
39 SAM remote mode The following functions can be controlled in remote control operation:
Remote ON/OFF
Remote shift clock
Remote manual/automatic
40 SAM power ON The master controller's power supply has been switched on.
mode
41 SAM network sec‐ Both sections and the compressor station are off.
tion control
Both sections off
42 SAM network sec‐ Section 1 is operating; section 2 is switched off.
tion control
Section 1 in opera‐
tion
43 SAM network sec‐ Section 2 is operating; section 1 is switched off.
tion control
Section 2 in opera‐
tion
44 SAM network sec‐ Both sections are operating together.
tion control
Both in operation.
49 SMS function acti‐ Short message system (SMS) option has been activated. The master
vated controller can send short messages.
50 SAC plus activated Data recording with SIGMA AIR CONTROL plus has been switched
on and should be running.
51 SAC plus activated SIGMA AIR CONTROL plus data recording is running.
52 SND / RCV activat‐ Send/receive protocol option has been switched on.
ed
53 SND/RCV active Communication with the send/receive protocol and remote control
and remote mode (e.g. control centre) is running.
65– Compressor x dese‐ The machine has been deselected by either the preselect key, the in‐
80 lected ternal shift clock, the external preselect contact or the send/receive
preselection (green LED off). It is neither controlled nor monitored by
the master controller.
Tab. 82 Operational messages
13.7.2 Defined messages


13 Annex
No. Message Active Time delay Input Active at:

Input OFF
Factory setting − 0s 0.0 0V yes
191 UPS battery (A)
192 Power failure (A)
193 Cyclone separator 1 condensate drain (A)
209 Dryer 1 high dew point (A)
217 Dryer 1 alarm (A)
225 Dryer 1 condensate drain 1 (A)
(A) = alarm, (W) = Warning

13 Annex

Input OFF
241 Air receiver 1 condensate drain (A)
242 Air receiver 2 condensate drain (A)
243 Filter 1 condensate drain (A)
251 Condensate treatment 1 (A)
369 Filter 1 pressure drop 1 (W)

13 Annex

Input OFF
Tab. 83 Defined messages
13.7.3 Definable messages (alarms)

Active Input Text Time delay Active at:

Input OFF
Factory setting − 0.0 0s 0V yes
Message 161
Message 162
Message 163
Message 164
Message 165
Message 166
Message 167
Message 168
Message 169
Message 170
Message 171
Message 172
Message 173
Message 174
Message 175
Message 176

13 Annex
13.8 Machine settings
Active Input Text Time delay Active at:

Input OFF
Factory setting − 0.0 0s 0V yes
Message 177
Tab. 84 Definable messages (alarms)
13.7.4 Definable messages (service / warning)

Active Input Text Type Time delay Active at:

Input OFF
Factory setting − 0.0 W 0s 0V yes
Message 481
Message 482
Message 483
Message 484
Message 485
Message 486
Message 487
Message 488
Tab. 85 Definable messages (service/warning)

13.8.1 Safety pressure switch settings
Suggestions for models 4/4 and 8/4 [psig]
The reference point is the maximum working pressure.

➤ Adjust the safety pressure switch (-B1) setpoints as follows:
Machine number Cut-in pressure Cut-out pressure

Maximum working pressure 14.5 psig to 36 psig
Machine 1/5 ON − 1.45 OFF + 0.73
Machine 2/6 ON − 2.2 OFF + 0.73
Machine 3/7 ON − 2.9 OFF + 0.73
Machine 4/8 ON − 3.6 OFF + 0.73
Maximum working pressure 36 psig to 87 psig
Machine 1/5 ON − 2.9 OFF + 2.9

13 Annex

Machine 4/8 ON − 11.6 OFF + 2.9
Machine 2/6 ON − 10.2 OFF + 4.4
Machine 3/7 ON − 14.5 OFF + 4.4
Machine 4/8 ON – 18.9 OFF + 4.4
Machine 1/5 ON − 58 OFF + 14.5
Machine 2/6 ON − 72.5 OFF + 14.5
Machine 3/7 ON − 87 OFF + 14.5
Machine 4/8 ON − 101.5 OFF + 14.5
Tab. 86 Suggestion: safety pressure switch 4/4 and 8/4
Suggestions for models 8/8 and 16/8 [psig]
The reference point is the maximum working pressure.

➤ Adjust the safety pressure switch (-B1) setpoints as follows:

Maximum working pressure 14.5 psig to 36 psig
all ON − 1.45 OFF + 0.73
all ON − 2.9 OFF + 2.9
all ON − 5.8 OFF + 4.4
all ON − 58.0 OFF + 14.5
Tab. 87 Suggestion: safety pressure switch 8/8 and 16/8
Personal settings
Date / time
Switching point ON OFF ON OFF ON OFF
Unit
Machine 1 [psig]
Machine 2 [psig]
Machine 3 [psig]
Machine 4 [psig]
Machine 5 [psig]
Machine 6 [psig]

13 Annex
Date / time
Unit
Machine 7 [psig]
Machine 8 [psig]
Machine 9 [psig]
Machine 10 [psig]
Machine 11 [psig]
Machine 12 [psig]
Machine 13 [psig]
Machine 14 [psig]
Machine 15 [psig]
Machine 16 [psig]
Tab. 88 Personal settings: safety pressure switch
13.8.2 Pressure range for manual operation

To avoid simultaneous cut-in of machines in manual mode. system pressure p2 and/or system
pressure switch −B1.1 have to be set.
Suggested setting [psig]:

Maximum working pressure 14.5 psig
Machine 1/5/9/13 ON 13.5 OFF 14.5
Machine 2/6/10/14 ON 13.2 OFF 14.2
Machine 3/7/11/15 ON 12.9 OFF 13.9
Machine 4/8/12/16 ON 12.6 OFF 13.6
Maximum working pressure 110 psig
Machine 1/5/9/13 ON 101.5 OFF 108.8
Machine 2/6/10/14 ON 97.2 OFF 104.4
Machine 3/7/11/15 ON 92.8 OFF 100.1
Machine 4/8/12/16 ON 88.5 OFF 95.7
Machine 1/5/9/13 ON 135 OFF 145
Machine 2/6/10/14 ON 130.5 OFF 140.7
Machine 3/7/11/15 ON 126.2 OFF 136.3
Machine 4/8/12/16 ON 121.8 OFF 132
Machine 1/5/9/13 ON 178.4 OFF 190
Machine 2/6/10/14 ON 174 OFF 184.2

13 Annex

Machine 3/7/11/15 ON 169.7 OFF 179.8
Machine 4/8/12/16 ON 165.3 OFF 175.5
Machine 1/5/9/13 ON 319 OFF 362.6
Machine 2/6/10/14 ON 304.6 OFF 348.1
Machine 3/7/11/15 ON 290 OFF 333.6
Machine 4/8/12/16 ON 275.6 OFF 319
Machine 1/5/9/13 ON 391.6 OFF 464
Machine 2/6/10/14 ON 377 OFF 449.6
Machine 3/7/11/15 ON 362.6 OFF 435.1
Machine 4/8/12/16 ON 348.1 OFF 420.6
Tab. 89 Suggested settings: pressure range in manual mode
Personal settings
Date / time
Unit
Machine 1 [psig]
Machine 2 [psig]
Machine 3 [psig
Machine 4 [psig]
Machine 5 [psig]
Machine 6 [psig]
Machine 7 [psig]
Machine 8 [psig]
Machine 9 [psig]
Machine 10 [psig]
Machine 11 [psig]
Machine 12 [psig]
Machine 13 [psig]
Machine 14 [psig]
Machine 15 [psig]
Machine 16 [psig]
Tab. 90 Suggested settings: pressure range in manual mode
13.8.3 System offset for manual mode

tv = time delay for switching on machines after a power failure

13 Annex
13.9 Examples and suggested settings
Date / time
Name
Time delay tv [s] tv [s] tv [s] tv [s] tv [s] tv [s]
Machine 1
Machine 2
Machine 3
Machine 4
Machine 5
Machine 6
Machine 7
Machine 8
Machine 9
Machine 10
Machine 11
Machine 12
Machine 13
Machine 14
Machine 15
Machine 16
Tab. 91 Suggested settings: system offset (manual mode)

➤ Note suggested settings.
13.9.1 Example of switching point setting

Guidelines for establishing the switching points

■ The compressor station comprises the following machines:
─ 2 small machines (1, 2)
─ 2 mid-sized machines (3, 4)
─ 2 large machines (5, 6)
■ Required pressure for the compressor station 97 psig
■ Compressor station ON:
─ Weekdays 6:30–17:00
─ Fridays 6:30-15:00
■ Compressor station OFF:
─ Saturday
─ Sunday
─ Midday 12:00–13:00

13 Annex
No. Day Time Function Compressors

1–5 Mon – Fri 06:30 ON 1-2-3-4-5-6-#-#
6–10 Mon – Fri 12:00 OFF #-#-#-#-#-#-#
11–15 Mon – Fri 13:00 ON 1-2-3-4-5-6-#-#
16–19 Mon – Thu 17:00 OFF #-#-#-#-#-#-#
20 Fri 15:00 OFF #-#-#-#-#-#-#
Tab. 92 Example of a compressor station ON/OFF clock program
Precondition The menu item <Settings «F1» – Shift clock «F5» > is selected.
If a # is entered in the first place of a group sequence, the group sequence #-#-#-#-#-#-# is
automatically set when the «F2 » key (new) is pressed.
➤ Enter password for level 2 if necessary.
Switching points 1-5
1. Select the days Mon, Tue, Wed, Thur and Fri.

2. Enter switching time 06:30:00.
3. Enter pressure setpoint 6.70.
4. Enter compressors 1-2-3-4-5-6–#-#.
5. Press «F2» to save the switching points.

2. Enter compressors #-#-#-#-#-#-#.
3. Do not change the other settings.

2. Enter compressors 1-2-3-4-5-6–#-#.
1. Remove the check mark from Fri by placing the cursor over Fri and pressing «Enter».
Only Mon to Thur are still selected.
2. Enter switching time 17:00.
3. Enter compressors #-#-#-#-#-#-#.
Switching point 20
1. Remove the selection for Mon to Thur.

13 Annex
2. Select Fri for the day.

5. Press«F2» key to save the switching point.
13.9.2 Linking two small and two large machines

Machine number Small Large Connection
Machine 1 x Profibus
Tab. 93 Linking two small and two large machines
➤ Link every machine to the master controller (see 7.3).
13.9.3 Linking 8 equally-sized machines

See chapter 6 and 7 for instructions.
Keep the pressure switch settings for manual mode in mind.
Example:
There are 8 compressors of the same size, each with a 110 psig maximum pressure. Four are
equipped with SIGMA CONTROL. The compressor station is made up as follows:

13 Annex
Fig. 27 Example of linking eight equally-sized machines

1 Machines without SIGMA CONTROL 5 Machines with SIGMA CONTROL (Profi‐
(conventional link) bus link)
Overview: Linking the machines

Compressor, link Profibus ad‐ "Motor run‐ "No alarm" Output for Output for
dress ning" input input load automatic
Machine 1; conventional None 1.0 1.1 4.5 4.1
Machine 5; Profibus 7 None None None None
Tab. 94 Linking the machines
13.9.4 Linking 2 equally-sized machines and an FC machine

Software requirement:
■ The SIGMA AIR MANAGER software must be at least version 0.18.
■ The SIGMA AIR MANAGER software of the FC machine must be at least version 72.20.
Principle:

13 Annex
The FC machine receives the pressure set-point and current pressure value from the master con‐
troller.
in the event of a master controller break-down, the machines regulate themselves using their inter‐
nal pressure transducers.
Fig. 28 Example for linking two equally-sized machines and a FC machine

1 SIGMA AIR MANAGER 6 Air receiver
2 Machine with SIGMA CONTROL 7 Pressure transducer
3 Machine with SIGMA CONTROL 8 Profibus cable
4 Machine with SIGMA CONTROL and fre‐ 9 Compressed air line
quency converter (communication via USS
protocol)
5 Air Treatment
1. Link every machine to the master controller. (see chapter 7.3)

2. Assign a characteristic to the FC machine. (see chapter 7.3.2)
13.9.5 Connection of 5 machines in total, one of which as reserve

See chapters 7.5.4 and 7.6.1 for instructions.
Setting parameters
■ The compressor station comprises the following machines:
─ 4 new machines (1, 2, 3, 4)
─ One old machine to be used as reserve (5)
■ In order for the reserve machine not be deactivated for a very long time, it is to be used every
week on Friday between 10:00 and 12:00 AM.

13 Annex
Settings of the reserve machine
Precondition The menu option <Settings «F1» Station «F4» – Other settings «F4» > is selected.
Enter password for level 2 if necessary.
➤ Switching compressors online: Finally, enter #-#-#-#-5–#-#-#-#.
Setting the shift clock – switching points 1
Precondition The menu item <Settings «F1» – Shift clock «F5» > is selected.
Enter password for level 2 if necessary.
1. Select Fr for the day.

3. Enter channels #-#-#-#-A.
4. Enter compressors 1–2–3–4–5–6–#-#.
Setting the shift clock – switching points 2

2. Enter channels #-#-#-#-#.
13.9.6 Example of a FC characteristic

See chapter 7.3.2 for instructions.
Example of a compressor with SIGMA CONTROL:
SFC 55 compressor, nominal pressure 110 psig.
Example: 87 psig
Pressure Frequency range FAD

[psig] [Hz] (Vmax-Vmin)
[cfm]
15 25 35 50 70
87 Free air delivery [cfm] 83 146 205 292 399 316
Power [kW] 16 24.7 34 48.7 73.1
Specific power requirement 6.78 6.00 5.86 5.88 6.47
[kW/cfm]
Speed [rpm] 900 1500 2100 3000 4200
Tab. 95 FC characteristic (example: 87 psig)

13 Annex
13.10 Installation accessories
Example: 110 psig

[cfm]
15 25 35 50 67
110 FAD [cfm] 83 144 204 291 381(**) 298
Power [kW] 17.9 27.4 37.5 53.7 75.6(***)
[kW/cfm]
Speed [rpm] 900 1500 2100 3000 4020(*)
(*)
= highest speed. (**) = FAD at (*). (***) = power at (*)
Tab. 96 FC characteristic (example: 110 psig)
Example: 125 psig

[cfm]
15 25 35 50 64
125 FAD [cfm] 81 144 203 291 367 286
Power [kW] 19.5 29.3 39.7 57.1 75.6
[kW/cfm]
Speed [rpm] 900 1500 2100 3000 3840
Tab. 97 FC characteristic (example: 125 psig
1. In the speed line of the table 96. start with the highest speed and enter the FAD and power at
nominal pressure.
2. Enter the remaining values in relation to decreasing speed.
The zero point is added automatically.

SIGMA AIR CONTROL plus and communication
Description Part number Remarks

for model 4/4 7.7740.2 PCMCIA plug-in card (compact flash and adapter) with
SAC plus and memory extension to be installed by the
user (can be retrofitted).
for model 8/4 7.7741.2
for model 8/8 7.7741.2
for model 16/8 7.7742.2
Modem kit for PCMCIA slot 7.7750.2 Analog 56k PC card modem, to be retrofitted by the
user.

13 Annex

GSM modem kit 7.7752.0 GSM modem for retrofitting by the user to interface
RS232.
Send/receive protocol 7.7760.0 For link to external control center
(Ethernet layer 4)
Tab. 98 Installation accessories for SIGMA AIR CONTROL plus and communication
Pressure transducer
Description Part number Pressure range

For model I 7.4599.0 0-14.5 psi
For model II 7.3397.1 0-87 psi
7.2816.3 0-145 psi
7.2817.3 0-232 psi
7.4762.0 0-290 psi
7.6689.0 0-494 psi
For model III 7.7040.1 0-232 psi
For vacuum 7.7046.0 0-14.5 psi (absolute)
Tab. 99 Pressure transducer
Pressure transducer fitting parts and lines

Fitting set straight, elbow G 1/4, G1/2 with shut- for air receiver connection
off valve and accessories
up to 16 bar 8.0484.10050
up to 45 bar 8.0484.00090
Fitting set G 1/4, G1/2 with shut-off valve and ac‐ 1 quart air receiver for con‐
cessories nection to pipework
up to 15 bar 204465.0
Connecting cable for pressure transducer 7.2679.0 Shielded, 2 x 0.75 mm2,
for indoor installation,
PVC sheath, grey, 6 mm diam‐
eter
Tab. 100 Pressure transducer accessories

13 Annex
Profibus expander and compressor retrofit kit

PBE 4+4 7.7777.0 Scope of delivery:
PBU 4T 7.7778.0 Sheet metal control cabinet
Power supply:
PBU 8 7.7775.0
115/230V, 1ph, 50-60 Hz
PBE 8R 7.7775.00010
PBU 8R/4+4 7.7779.0
PBU 32 7.7776.0
PBU 8K on request For installation in machines
without SIGMA CONTROL
Retrofit kit for floating relay contacts on request For installation in machines
without SIGMA CONTROL
Tab. 101 Profibus expander models
Profibus fitting parts and lines

Connecting cable for Profibus 7.4666.0 Shielded, 1 x 2 x 0.64/2.55,
for indoor installation,
PVC sheath. violet, 8mm diameter.
Profibus connector plug for 7.4664.20010 35° cable exit
SIGMA AIR MANAGER (not required for model 16/8)
Profibus connecting plug set for 7.5250.00300 For PG and M fittings including EMC
SIGMA CONTROL fittings.
Setting communications module Profibus DP 7.5250.01880 Module, bus connector, fittings
for SIGMA CONTROL 2
Tab. 102 Profibus fitting accessories
Load/idle control module
Description Pressure Part number Remarks

Module for external 115 psi 7.7006.00003 Digital input for load control
load/idle control 160 psi 7.7006.00013 via SIGMA AIR MANAGER.
(7.7005.1 or 7.7005.2) 217 psi 7.7006.00023 For machines with SIGMA CONTROL BASIC
(7.7005.1 or 7.7005.2)
without frequency converter.
SFC module with exter‐ 115 psi 7.7706.00033 as 7.7006.00003 but for machines with frequen‐
nal load/idle control cy converter (SFC)
Module for external 115 psi 7.7056.00002 Digital input for load control via
load/idle control 160 psi 7.7056.00012 SIGMA AIR MANAGER.
(7.7005.3). 217 psi 7.7056.00022 For machines with SIGMA CONTROL BASIC
(7.7005.3) without frequency converter.

13 Annex
13.11 Exchanging the battery
Description Pressure Part number Remarks

SFC module with exter‐ 115 psi 7.7056.00035 as 7.7056.00002 but for machines with frequen‐
nal load/idle control cy converter (SFC)
Tab. 103 Load/idle module
RC interference suppressor

RC interference sup‐ 7.2812.1 For suppression of inductive loads connected to the relay
pressor outputs of the master controller.
Coil voltage: 110–230 V AC/DC
Coil capacity: 15 VA
Tab. 104 RC interference suppressor
13.11 Exchanging the battery

Exchanging the battery
Date / time
Name
Tab. 105 Changing the battery
13.12 Electrical Diagram

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex
13.13 Menu option Settings – Overview
13.13 Menu option Settings – Overview

Menu option Settings «F1» to «F4»
Navigation (menu) Symbol Sub-menu options Chapter

«F1»: Settings «F1»: System 7.2
«F2»: Control 7.4
«F3»: Compressor 7.3
«F4»: Compressed air system 7.5
«F5»: Shift clock 7.6
«F6»: Periphery 7.7
«F2»: Messages function key «F1»: Alarm, service and warning messages 9.2
«F2»: Operational Messages 8.2.1
«F3»: SMS status 8.2.2
«F4»: SAC plus status 8.2.3
«F5»: System status 8.2.4
«F6»: Memory access 8.2.4
«F3»: Choice of language «F1»+«F6»: Choice of language 7.2.2
«F3»: Notes
«F4»: Password «F1»: Log-off 7.2.6.1
«F2»: Password list 7.2.6.2
«F3»: Key lock 7.2.6.3
«F4»: Password allocation 7.2.6.4
Tab. 106 Main menu


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Service manual

SIGMA AIR MANAGER x/4 ≥1.14

1 Regarding this Document

Service manual Master controller

Service manual Master controller

7.6.2 Deleting a switching point ................................................................................... 53

Service manual Master controller

13.2 Machine assignment ........................................................................................................ 95

Service manual Master controller

Fig. 1 Control cabinet for models 4/4 and 8/4 ...................................................................................... 7

Service manual Master controller

Service manual Master controller

Tab. 1 The levels of danger and their meaning ..................................................................................... 1

Service manual Master controller

Tab. 55 FC characteristic 1 ..................................................................................................................... 109

Service manual Master controller

1 Regarding this Document

1.3 Licensed brands and trademarks

1.4 Symbols and markings

1. These show the kind of danger and its source.

Signal word Meaning Consequences of non-observance

Tab. 1 The levels of danger and their meaning

Service manual Master controller

1.4.2 Other instructions and symbols

➤ This symbol is placed by lists of actions comprising one stage of a task.

Further information Here, your attention is drawn to further topics.

Service manual Master controller

The following SIGMA AIR MANAGER models are available:

Tab. 2 System data

Call up the software version and serial number as follows:

2.2 Connection possibilities

Model 4/4 8/4 8/8 16/8

Tab. 3 Connection possibilities

2.3 Inputs and outputs

Service manual Master controller

Model 4/4 8/4 8/8 16/8

Tab. 4 Inputs and outputs

2.4 Electrical data

Tab. 5 Electrical data

Model 4/4 8/4 8/8 16/8

Tab. 6 Buffer battery life

Service manual Master controller

■ Internal temperature monitoring

■ 10 Base T (Industrial Twisted Pair)

2.7 Pressure transducer

Service manual Master controller

Tab. 7 Models I and II pressure transducers

Pressure transducer model III and vacuum

Model III Vacuum pumps

Service manual Master controller

Model III Vacuum pumps

Tab. 8 Models III and vacuum pressure transducers

Assignment of pressure transducer to the master controller

Model 4/4 8/4 8/8 16/8

Tab. 9 Pressure transducers for standard master controllers

2.8 Control cabinet

Fig. 1 Control cabinet for models 4/4 and 8/4

Fig. 2 Control cabinet for models 8/8 and 16/8

Service manual Master controller

Model 4/4 8/4 8/8 16/8