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Technical Description

SIGMA CONTROL

Process Map V82.30

GL-No.: 7_7000_PAMOD_05E

Status: 01.09.2009

KAESER KOMPRESSOREN GmbH
96410 Coburg · PO Box 2143 · GERMANY · Tel. +49 (0)9561 6400 · Fax +49 (0) 9561 640130
http://www.kaeser.com

1 °C -1250 2670 KF 40045 Analog input 5 25/4095 mA/digits 0 4095 KF 40046 Analog input 6 25/4095 mA/digits 0 4095 KF 40047 Analog input 7 Raw data (corr.0 binary KM 40041 System pressure pN local mbar -6250 32767 KF 40042 Internal pressure pi mbar -6250 32767 KF 40043 Airend discharge temperature (ADT) 0.3 binary KM 40032 Operational message 32-17 Table 1.com Page 2 of 18 .4 binary KM 40035 Binary signal 2 Table 1.1 °C -1250 2670 KF 40048 Analog input 8 Raw data (corr.2 binary KM 40027 Warning 32-17 Table 1.7 .1 binary KM 40025 Alarm 80-65 Table 1.1 binary KM 40026 Warning 16-1 Table 1.2 binary KM 40030 Warning 80-65 Table 1.) 0.6 binary KM 40037 Binary signal 4 Table 1.3 .2 binary KM 40029 Warning 64-49 Table 1.1 binary KM 40024 Alarm 64-49 Table 1.1 °C -990 2040 KF 40044 Analog input 4 Raw data (corr.3 . there is I=0-25mA for 0-4095 digits © KAESER KOMPRESSOREN GmbH www.1 °C -1250 2670 KF 40049 Analog output 1 0.0 binary KM 40039 Inputs DI3.0 binary KM 40040 Outputs DO1.3 binary KM 40033 Operational message 48-33 Table 1.1 binary KM 40023 Alarm 48-33 Table 1.DI2.) 0.7 binary KM 40038 Inputs DI1.kaeser.2 binary KM 40031 Operational message 16-1 Table 1.) 0.DI0.2 binary KM 40028 Warning 48-33 Table 1.DO0.3 binary KM 40034 Binary signal 1 Table 1.SIGMA CONTROL Process Map V82.5 binary KM 40036 Binary signal 3 Table 1.1 binary KM 40022 Alarm 32-17 Table 1.1mA 0 200 KF 40050 Oil separator differential pressure mbar -4000 21000 KF 40051 System pressure pN external mbar -6250 32767 KF 40052 Current drive motor starts/h 1 KF Register 40045/40046: current number of digits.30 Table 1 1. Master Controller << == Compressor Register Description Unit min max Format 40021 Alarm 16-1 Table 1.

kaeser.com Page 3 of 18 .SIGMA CONTROL Process Map V82. Master Controller << == Compressor Register Description Unit Format 40053 Total compressor hours run x 1000 h KF 40054 Total compressor hours run x1 h KF 40055 Hours on load x 1000 h KF 40056 Hours on load x1 h KF 40057 Setpoint pressure p1 mbar KF 40058 Setpoint pressure p1 switching difference mbar KF 40059 setpoint pressure p2 mbar KF 40060 Setpoint pressure p2 switching difference mbar KF 40061 Nominal package pressure mbar KF 40062 Increased cut-out pressure pE mbar KF 40063 Remaining drive motor idle time s KF 40064 Current time free/hour KY 40065 Current time min/s KY 40066 Current date weekday/day KY 40067 Current date month / year KY 40068 Message header slave (TKS) System 1 KH 40069 Remaining oil separator service life h KF 40070 Remaining interval to oil change h KF 40071 Remaining interval to oil filter change h KF 40072 Remaining interval to air filter change h KF 40073 Remaining interval to valve inspection h KF 40074 Remaining interval to V-belts/coupling inspection h KF 40075 Remaining interval to motor bearings change h KF 40076 Remaining interval to electrical equip. inspection h KF 40077 Remaining interval to bearing lube h KF 40078 Current cut-out pressure p1(p2) mbar KF 40079 PLC software status (B&B) KY 40080 Compressor model / L2DP slave address KY 40081 Compressor start delay s KT 40082 Duty cycle permanent 1% KF 40083 Current motor speed 1/min KF 40084 Slave message footer (TFS) System KH © KAESER KOMPRESSOREN GmbH www.30 Table 1 1.

40021 10 11 fan M2 I⇞ Fan M2: overload trip 40021 11 12 access doors Access doors open 40021 12 13 motor I⇞ Drive motor: overload trip 40021 13 14 fan M3 I⇞ Fan M3: Overload trip 40021 14 15 ADT ⇞ Permissible airend discharge temperature exceeded. 40021 15 16 fan M4 I⇞ Fan M4: Overload trip © KAESER KOMPRESSOREN GmbH www.com Page 4 of 18 . 40021 9 8 blowoff prot. 40021 8 9 Sigma Control T⇞ Controller housing temperature has exceeded 70 °C.1 : Alarms (Sigma Control transmit word 0 .SIGMA CONTROL Process Map V82. Master Controller << == Compressor Table 1.4) Register Bit No. ⇞ Blow-off protection pressure setpoint exceeded.kaeser.1 1. Sigma Control display Explanation 40021 0 1 Airend rotation Direction of drive motor rotation wrong 40021 1 2 Motor T⇞ Permissible drive motor temperature exceeded (PTC or PT100) 40021 2 3 pRV ⇞ TÜV check: the opening pressure of the pressure relief valve was exceeded by 2 bar 40021 3 4 Emergency stop E M E R G E N C Y S T O P actuated 40021 4 5 separator T⇞ Permissible oil separator temperature exceeded 40021 5 6 Start T⇟ Airend temperature too low (< +2 °C) for a compressor start 40021 6 7 mains monitor Power supply fault (separate network monitoring module) 40021 7 8 oil content ⇞ Permissible oil content exceeded.30 Table 1.

30 Table 1.kaeser.1 : Alarms (Sigma Control transmit word 0 .SIGMA CONTROL Process Map V82.1 1. Master Controller << == Compressor Table 1.com Page 5 of 18 . Sigma Control display Explanation 40022 0 17 AI3/AI4 error Analog input 3 or 4 open circuit or short circuit to earth 40022 1 18 AI7/AI8 error Analog input 7 or 8 open circuit or short circuit to earth 40022 2 19 pi⇟ pi below minimum in idle mode 40022 3 20 not assigned 40022 4 21 RD T⇟ Refrigeration dryer Compressed air temperature too low.4) Register Bit No. danger of freeze-up 40022 5 22 OS dp⇞ Oil separator cartridge heavily clogged 40022 6 23 motor bearings Drive motor bearing defective 40022 7 24 WC water volume Cooling water low 40022 8 25 AI 1 open cct Analog input 1 open circuit or short to earth 40022 9 26 AI 2 open cct Analog input 2 open circuit or short to earth 40022 10 27 not assigned 40022 11 28 not assigned 40022 12 29 AI 5 open cct Analog input 5 open circuit or short to earth 40022 13 30 AI 6 open cct Analog input 6 open circuit or short to earth 40022 14 31 not assigned 40022 15 32 not assigned © KAESER KOMPRESSOREN GmbH www.

6 / DO0.SIGMA CONTROL Process Map V82.6/DO1.6/DO0.com Page 6 of 18 .7 40023 4 37 DO1.5 bar within a preset period 40023 12 45 not assigned 40023 13 46 FC VFD compressor fault (frequency converter) 40023 14 47 RS485 RS485 transmission error SC-FC (USS protocol) or HSD aggregate B 40023 15 48 HT cell High tension cell fault in power switching © KAESER KOMPRESSOREN GmbH www.1 1.7 40023 5 38 PD T⇟ Machine air outlet temperature too low 40023 6 39 PD T⇞ Machine air outlet temperature too high 40023 7 40 mains cont. Sigma Control display Explanation 40023 0 33 oil p⇟ Oil pressure too low.kaeser. stop Back pressure while drive motor stopped Back pressure in the oil separator tank caused by poor venting 40023 10 43 ADT dT/dt ⇞ Permissible rate of rise of airend discharge temperature exceeded 40023 11 44 no press.1 : Alarms (Sigma Control transmit word 0 .7 I⇞ Short circuit on binary outputs DO1.30 Table 1.6/DO1.7 I⇞ Short circuit on binary outputs DO0. off? The mains contactor does not drop out despite an OFF command 40023 8 41 mains voltage ⇟ Power supply failure - the drive motor was shut down 40023 9 42 Back press. on? The mains contactor does not pull in despite an ON command 40023 2 35 fan M7 I⇞ Control cabinet fan M7 Overload trip 40023 3 36 DO0.4) Register Bit No.buildup pi did not reach 3. Master Controller << == Compressor Table 1. 40023 1 34 mains cont.

on +Ub 40024 6 55 not assigned 40024 7 56 RD condens.1 : Alarms (Sigma Control transmit word 0 . on +Ub 40024 5 54 sh.) 40024 10 59 back press.cct AI1 Analog input 1 Short cct.cct AI5 Analog input 5 Short cct.SIGMA CONTROL Process Map V82. Sigma Control display Explanation 40024 0 49 sh.drain Refridgeration dryer (DS compressor) Condensate drain faulty 40024 8 57 Model Vague model version 40024 9 58 Condensate drain Condensate drain faulty Centrifugal separator / Aftercooler / Refridgeration dryer (AS/BS/CS compr. on +Ub 40024 1 50 sh.cct AI2 Analog input 2 Short cct.1 1.kaeser.cct AI6 Analog input 6 Short cct.com Page 7 of 18 . on +Ub 40024 2 51 aggregate A HSD aggreagte B blocked by A 40024 3 52 aggregate B HSD aggreagte A blocked by B 40024 4 53 sh. run Back pressure while drive motor runs V-belts or coupling parted 40024 11 60 softstart Softstarter defective 40024 12 61 OS dT/dt ⇞ Permissible rate of rise of oil separator temperature exceeded 40024 13 62 RD p⇞ Refrigeration dryer Refrigerant circulation pressure too high (pressure relief valve tripped) 40024 14 63 RD p⇟ Refrigeration dryer Refrigerant circulation pressure too low (pressure relief valve tripped) 40024 15 64 not assigned © KAESER KOMPRESSOREN GmbH www. Master Controller << == Compressor Table 1.4) Register Bit No.30 Table 1.

message 4 Message text freely definable from SIGMA Control display 40025 13 78 ext. Sigma Control display Explanation 40025 0 65 not assigned 40025 1 66 not assigned 40025 2 67 not assigned 40025 3 68 not assigned 40025 4 69 not assigned 40025 5 70 not assigned 40025 6 71 not assigned 40025 7 72 not assigned 40025 8 73 ext.1 1.com Page 8 of 18 . message 3 Message text freely definable from SIGMA Control display 40025 12 77 ext. message 5 Message text freely definable from SIGMA Control display 40025 14 79 p-switch Message text freely definable from SIGMA Control display 40025 15 80 T-switch Message text freely definable from SIGMA Control display © KAESER KOMPRESSOREN GmbH www.SIGMA CONTROL Process Map V82. message 2 Message text freely definable from SIGMA Control display 40025 11 76 ext.1 : Alarms (Sigma Control transmit word 0 . message 0 Message text freely definable from SIGMA Control display 40025 9 74 ext.kaeser.30 Table 1. Master Controller << == Compressor Table 1. message 1 Message text freely definable from SIGMA Control display 40025 10 75 ext.4) Register Bit No.

Master Controller << == Compressor Table 1.2 1.9) Register Bit No. 40026 3 4 OS dp↑ Oil separator cartridge clogged 40026 4 5 restart inhibit Restart inhibit for "compressor ON" activated 40026 5 6 oil content ↑ Initial warning: oil content too high 40026 6 7 motor bearings Drive motor bearings defective 40026 7 8 ADT ↑ Initial warning: maximum permissible airend discharge temperature reached soon 40026 8 9 error: SMS SMS couldn'd be transmitted 40026 9 10 buffer battery System error: buffer battery discharged 40026 10 11 oilfilter dp↑ Oil filter clogged 40026 11 12 modem problem 40026 12 13 air filter dp↑↑ Air filter clogged 40026 13 14 access doors Access doors open 40026 14 15 bus alarm ProfiBus connection error 40026 15 16 error: RAM System error: RAM defective © KAESER KOMPRESSOREN GmbH www.30 Table 1.com Page 9 of 18 .SIGMA CONTROL Process Map V82.2 : Warning Messages (Sigma Control transmit word 5 .kaeser. Sigma Control display Explanation 40026 0 1 error: FEPROM System error: flash memory defective 40026 1 2 motor T↑ Initial warning: Permissible drive motor temperature reached soon (PTC or PT100) 40026 2 3 V-belt tension V-belts too loose.

coup. h⇞ Maintenance interval for valves exceeded 40027 13 30 blt. equip. Master Controller << == Compressor Table 1.kaeser. Sigma Control display Explanation 40027 0 17 RD T↓ Refrigeration dryer Compressed air temperature too low.SIGMA CONTROL Process Map V82.9) Register Bit No.chng.h⇞ Maintenance interval for V-belts or coupling inspection exceeded 40027 14 31 motor bearing h⇞ Maintenance interval for motor bearings exceeded 40027 15 32 elect.30 Table 1.2 1.com Page 10 of 18 . danger of freeze-up 40027 1 18 RD p↓ Refrigeration dryer Low pressure in refrigerant circulation system (inlet pressure switched tripped) 40027 2 19 not assigned 40027 3 20 not assigned 40027 4 21 not assigned 40027 5 22 not assigned 40027 6 23 not assigned 40027 7 24 not assigned 40027 8 25 OS h⇞ Maintenance interval for oil separator cartridge exceeded 40027 9 26 oil change h⇞ Maintenance interval for oil change exceeded 40027 10 27 oil filter h⇞ Maintenance interval for oil filter exceeded 40027 11 28 air filter h⇞ Maintenance interval for air filter exceeded 40027 12 29 valve insp. h⇞ Maintenance interval for electrical equipment exceeded © KAESER KOMPRESSOREN GmbH www.2 : Warning Messages (Sigma Control transmit word 5 .

kaeser.com Page 11 of 18 .↓ System pressure too low (compressor only) 40028 14 47 no press.9) Register Bit No.SIGMA CONTROL Process Map V82.2 1. Master Controller << == Compressor Table 1.↑ Initial warning: Blowoff protection pressure setpoint reached soon 40028 6 39 OS cycle ↑ 40028 7 40 OS cycle ⇞ 40028 8 41 Mains voltage ↓ Power supply failure - Compressor was restarted automatically 40028 9 42 TRAP Interrupt↑ System message: TRAP interrupt 40028 10 43 ext.30 Table 1.buildup No pressure build-up after compressor start 40028 15 48 bearing lube h⇞ Motor bearings greasing maintenance intervall exceeded © KAESER KOMPRESSOREN GmbH www.2 : Warning Messages (Sigma Control transmit word 5 . 40028 11 44 oil T↓ Warning: Oil too cold for compressor to be put on load 40028 12 45 DO test The "set output" test function is activated 40028 13 46 System press.load signal? Vague external load signal Default setpoint for cut-out pressure high was exceeded. Sigma Control display Explanation 40028 0 33 fan bearing h⇞ Maintenance interval for fan bearings exceeded 40028 1 34 PD T↓ Initial warning: Package air discharge temperature soon below permissible 40028 2 35 PD T↑ Initial warning: Permissible package air discharge temperature exceeded soon 40028 3 36 motorstarts /h⇞ Drive motor Number of permissible starts per hour exceeded 40028 4 37 motorstarts /d⇞ Drive motor Number of permissible starts per day exceeded 40028 5 38 blowoff prot.

kaeser.com Page 12 of 18 . 40029 1 50 not assigned 40029 2 51 not assigned 40029 3 52 not assigned 40029 4 53 not assigned 40029 5 54 not assigned 40029 6 55 not assigned 40029 7 56 not assigned 40029 8 57 not assigned 40029 9 58 RS485 RS485 transmission error SC .9) Register Bit No.30 Table 1. FC fix-powered via K1M mains contactor 40029 14 63 FC mains VFD compressor: VFD power supply failure 40029 15 64 FC AI1 fault VFD compressor: Pressure sensor at AI1 faulty © KAESER KOMPRESSOREN GmbH www. Master Controller << == Compressor Table 1.SIGMA CONTROL Process Map V82.2 1. Sigma Control display Explanation 40029 0 49 annual maint Appears one year after last maintenance.SC point to point link or HSD aggregate B 40029 10 59 start T↓↓ Airend temperature too low (<-10°C) for compressor operation 40029 11 60 start T↓ Airend temperature too low (< +2 °C) for a compressor start 40029 12 61 Compr.T ↓ Compressor temperature (ADT or OST) did not reach the minimum required value 40029 13 62 FC MM Service Micromaster FC service.2 : Warning Messages (Sigma Control transmit word 5 .

9) Register Bit No. message 3 Message text freely definable from SIGMA Control display 40030 12 77 ext. message 0 Message text freely definable from SIGMA Control display 40030 9 74 ext. message 1 Message text freely definable from SIGMA Control display 40030 10 75 ext. message 2 Message text freely definable from SIGMA Control display 40030 11 76 ext. Sigma Control display Explanation 40030 0 65 not assigned 40030 1 66 air filter dp↑ Initial warning: Air filter clogged 40030 2 67 system press.SIGMA CONTROL Process Map V82. message 4 Message text freely definable from SIGMA Control display 40030 13 78 ext.kaeser.2 1. message 5 Message text freely definable from SIGMA Control display 40030 14 79 p-switch Message text freely definable from SIGMA Control display 40030 15 80 T-switch Message text freely definable from SIGMA Control display © KAESER KOMPRESSOREN GmbH www.com Page 13 of 18 . ↑ System pressure too high (vacuum packages only) 40030 3 68 Condensate drain Condensate drain faulty Centrifugal separator / Aftercooler / Refridgeration dryer (AS/BS/CS compr.30 Table 1.drain Refridgeration dryer (DS compressor) Condensate drain faulty 40030 8 73 ext.2 : Warning Messages (Sigma Control transmit word 5 .) 40030 4 69 RD p⇞ Refrigeration dryer Refrigerant circulation pressure too high (pressure relief valve tripped) 40030 5 70 RD T↓ Refrigeration dryer Compressed air temperature too high 40030 6 71 oil level ↓ Oil level is at minimum 40030 7 72 RD condens. Master Controller << == Compressor Table 1.

12) not displayed on Sigma Control Register Bit No.kaeser.30 Table 1.SIGMA CONTROL Process Map V82.3 : Operational Messages (Sigma Control transmit word 10 . Operational Message Explanation 40031 0 1 load control p1 Load control mode: Load control mode from setpoint pressure p1 40031 1 2 load control p2 Load control mode: Load control mode from setpoint pressure p2 40031 2 3 load control RC Load control mode: Load control from external contact 40031 3 4 load control RB Load control mode: load control from bus signal 40031 4 5 ready Load control status: drive motor ready to go on load 40031 5 6 Idle Load control status: 40031 6 7 Load run Load control status: 40031 7 8 off Load control status: 40031 8 9 compressor ON Drive motor ready to go on load (as for OM5.com Page 14 of 18 . Master Controller << == Compressor Table 1.3 1. but permanent signal) 40031 9 Controller (Sigma Control) ON The controller (Sigma Control) is switched on by the function key "I" 40031 10 11 Mode ON/OFF: clk Operating mode: compressor switched on/off by the clock 40031 11 12 Mode ON/OFF: RC Operating mode: compressor switched on/off by a remote contact 40031 12 13 Mode ON/OFF: RB Operating mode: compressor switched on/off by a bus signal 40031 13 14 Mode ON/OFF: key Operating mode: compressor switched on/off by the "I/O" function key 40031 14 15 40031 15 16 © KAESER KOMPRESSOREN GmbH www.

3 1. message 0 Message text freely definable from SIGMA Control display 40032 1 18 ext. message 3 Message text freely definable from SIGMA Control display 40032 4 21 ext. Master Controller << == Compressor Table 1. message 5 Message text freely definable from SIGMA Control display 40032 6 23 p-switch Message text freely definable from SIGMA Control display 40032 7 24 T-switch Message text freely definable from SIGMA Control display 40032 8 25 Setpoint pressure p1 System pressure setpoint p1 selected for control of load 40032 9 26 setpoint pressure p2 System pressure setpoint p2 selected for control of load 40032 10 27 power OFF → ON Interface configuration has been changed Switch off the power supply to accept the new 40032 11 28 Dyn.12) not displayed on Sigma Control Register Bit No. message 2 Message text freely definable from SIGMA Control display 40032 3 20 ext. message 1 Message text freely definable from SIGMA Control display 40032 2 19 ext.SIGMA CONTROL Process Map V82. Motor T↑ Dynamic control mode: Drive motor temperature too high for drive motor stop 40032 12 29 not assigned 40032 13 30 not assigned 40032 14 31 not assigned 40032 15 32 not assigned © KAESER KOMPRESSOREN GmbH www.3 : Operational Messages (Sigma Control transmit word 10 .com Page 15 of 18 . Operational Message Explanation 40032 0 17 ext.kaeser.30 Table 1. message 4 Message text freely definable from SIGMA Control display 40032 5 22 ext.

kaeser.SIGMA CONTROL Process Map V82.3 1.30 Table 1.3 : Operational Messages (Sigma Control transmit word 10 .12) not displayed on Sigma Control Register Bit No.com Page 16 of 18 . Master Controller << == Compressor Table 1. Operational Message Explanation 40033 0 33 machine report Monthly report of compressor status Activated only during SMS remote service 40033 1 34 not assigned 40033 2 35 not assigned 40033 3 36 not assigned 40033 4 37 not assigned 40033 5 38 not assigned 40033 6 39 not assigned 40033 7 40 not assigned 40033 8 41 not assigned 40033 9 42 not assigned 40033 10 43 not assigned 40033 11 44 not assigned 40033 12 45 not assigned 40033 13 46 not assigned 40033 14 47 not assigned 40033 15 48 not assigned © KAESER KOMPRESSOREN GmbH www.

30 Table 1.kaeser.4-1.SIGMA CONTROL Process Map V82.4 : Transmit bit assignment Register 40034 Binary signals 1 Bit Description Signal "1" Signal "0" 0 Drive motor ready for operation (SAM only!) yes no 1 Motor running yes no 2 Load run yes no 3 Idle yes no 4 Local mode ("Remote" key off) remote key off remote key on 5 Controller (Sigma Control) ON yes no 6 Group alarm yes no 7 Group warning yes no 8 Compressor ready for load yes no 9 Profibus send+receive yes no 10 11 12 13 14 15 Table 1.6) Master local 8 DUAL control mode DUAL 9 QUADRO control mode QUADRO 10 VARIO control mode VARIO 11 DYNAMIC control mode DYNAMIC 12 Continuous control mode continuous 13 14 15 Control mode setting (Bit 8 .7 1.5 : Transmit bit assignment Register 40035 Binary signals 2 Bit Description Signal "1" Signal "0" 0 Compressor ON from "I" key only yes no 1 Compressor ON from the "I" key and clock yes no 2 3 4 Compressor ON from the "I" key and ext.com Page 17 of 18 . Master Controller << == Compressor Table 1.14) Master local © KAESER KOMPRESSOREN GmbH www. contact yes no 5 6 Compressor ON from "I" key and L2DP bus yes no 7 Compressor ON setting (Bit 0 .

7 : Transmit bit assignment Register 40037 Binary signals 4 Bit Description Signal "1" Signal "0" 0 Clock key not assigned blocked 1 Remote key not assigned blocked 2 Idle key not assigned blocked 3 Automatic start after power supply ON activated 4 Actual p1(p2) pressure control value pN external pN local 5 6 7 Message acknowledgement by master activated blocked 8 9 10 11 12 13 14 15 Transfer of time + date yes no (corrupt) © KAESER KOMPRESSOREN GmbH www. contact yes no 5 6 Load-idle signal from L2DP bus yes no 7 Load control mode setting (Bit 0 .7 1.SIGMA CONTROL Process Map V82.kaeser. Master Controller << == Compressor Table 1.com Page 18 of 18 .4-1.30 Table 1.6 : Transmit bit assignment Register 40036 Binary signals 3 Bit Description Signal "1" Signal "0" 0 1 2 3 4 Load-idle signal from ext.15) Master local 8 p1 permanent yes no 9 p2 permanent yes no 10 p1/p2 from clock yes no 11 p1/p2 from timer yes no 12 13 p1/p2 from external contact yes no 14 p1/p2 from RS485 interface yes no 15 Table 1.