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Technical Description

SIGMA CONTROL

Process Map V10.23

GL-No.: 7_7000_PAMOD_03E
GL-No.: 7_7055_PAMOD_03E

Status: 18.01.2011
File: 7_7055_PA_1023_03E.xls

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

2 binary KM 40031 Operational message 16-1 Table 1.7 .3 binary KM 40032 Operational message 32-17 Table 1.1 binary KM 40025 Alarm 80-65 Table 1.1 binary KM 40024 Alarm 64-49 Table 1.DO0.SIGMA CONTROL Process Map V10.kaeser.1 °C -990 +3270 KF 40039 p3 (inlet stage 2) mbar -4000 +21000 KF 40040 p4 (outlet stage 2) mbar -4000 +21000 KF 40041 p5 (air main pressure) mbar -4000 +21000 KF 40042 p6 (oil pressure lubrication) mbar -4000 +21000 KF 40043 p7 (oil pressure control) mbar -4000 +21000 KF 40044 T11(coolingwater outlet intercooler) 0.DI4.5 binary KM 40036 Binary signal 3 Table 1.7 .3 .2 binary KM 40029 Warning 64-49 Table 1.3 .1 binary KM 40023 Alarm 48-33 Table 1.6 binary KM 40037 Binary signal 4 Table 1.2 binary KM 40030 Warning 80-65 Table 1.23 Table 1 1.2 binary KM 40027 Warning 32-17 Table 1. Master Controller << == Compressor Register Description Unit min max Format 40021 Alarm 16-1 Table 1.DI2.7 .com Page 2 of 18 .DO2.7 binary KM 40038 T10 (coolingwater inlet) 0.3 binary KM 40034 Binary signal 1 Table 1.0 binary KM 40050 Outputs DO3.0 binary KM 40047 Inputs DI3.0 binary KM 40048 Inputs DI5.1 °C -990 +3270 KF 40045 T12 (coolingwater outlet aftercooler) 0.1 binary KM 40026 Warning 16-1 Table 1.0 binary KM 40051 System pressure pN external mbar -4000 +21000 KF 40052 Current drive motor starts/h 1 KF Register 40045/40046: © KAESER KOMPRESSOREN GmbH www.DI0.4 binary KM 40035 Binary signal 2 Table 1.1 binary KM 40022 Alarm 32-17 Table 1.2 binary KM 40028 Warning 48-33 Table 1.1 °C -990 +3270 KF 40046 Inputs DI1.0 binary KM 40049 Outputs DO1.3 binary KM 40033 Operational message 48-33 Table 1.

1 °C -990 +3270 KF 40078 Current cut-out pressure pA(pB) mbar KF 40079 PLC software status (B&B) KY 40080 Compressor model / L2DP slave address KY 40081 Compressor start delay s KF 40082 Duty cycle permanent 0.1 °C -990 +3270 KF 40077 T14 (coolingwater outlet) 0.23 Table 1 1.1 °C -990 +3270 KF 40073 T5 (air outlet temperature) 0.1 °C -990 +3270 KF 40076 T13 (coolingwater outlet airend) 0. 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 pA mbar KF 40058 Setpoint pressure pA switching difference mbar KF 40059 Setpoint pressure pB mbar KF 40060 Setpoint pressure pB 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 Display1 (p) mbar -4000 +21000 KF 40065 Display2 (p) mbar -4000 +21000 KF 40066 Display3 (T) 0.1 °C -990 +3270 KF 40072 T4 (outlet stage 2) 0.1 °C -990 +3270 KF 40067 Display4 (T) 0.kaeser.1 °C -990 +3270 KF 40074 T6 (oil temperature lubrication) 0.com Page 3 of 18 .1 °C -990 +3270 KF 40075 Motor temperature 0.SIGMA CONTROL Process Map V10.1 °C -990 +3270 KF 40070 T2 (outlet stage 1) 0.1 °C -990 +3270 KF 40071 T3 (inlet stage 2) 0.1 °C -990 +3270 KF 40068 Message header slave (TKS) System 1 KH 40069 T1 (inlet temperature) 0.1 % KF 40083 Current motor speed 1/min KF 40084 Slave message footer (TFS) System KH © KAESER KOMPRESSOREN GmbH www.

SIGMA CONTROL Process Map V10. Question the defect in menu <status > messages> standstill> 40021 8 9 Sigma Control T⇞ Controller housing temperature has exceeded 70 °C.1 : Alarms (Sigma Control transmit word 0 .23 Table 1.kaeser. Master Controller << == Compressor Table 1. 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 I/O periphery Analog input or digital output defective Question the defect in menu <status > messages> I/O periphery> 40021 5 6 T3 ⇟ run 40021 6 7 mains monitor Power supply fault (separate network monitoring module) 40021 7 8 standstill Alarms during STANDSTILL. Sigma Control display Explanation 40021 0 1 p4 rotation dir.4) Register Bit No. 40021 9 8 p5>pRV ⇞ always 40021 10 11 fan M2 I⇞ Fan M2: overload trip 40021 11 12 PD valve PD valve runtime error wiring error 40021 12 13 motor I⇞ Drive motor: overload trip 40021 13 14 fan M3 I⇞ Fan M3: Overload trip 40021 14 15 p4 / p3 ⇞ load 40021 15 16 T11< T10 ⇟ load © KAESER KOMPRESSOREN GmbH www.1 1.com Page 4 of 18 .

1 : Alarms (Sigma Control transmit word 0 .kaeser. Sigma Control display Explanation 40022 0 17 p4 ⇞ idle 40022 1 18 p4 ⇟ load 40022 2 19 p4 ⇞ always 40022 3 20 p6 ⇞ always 40022 4 21 p6 ⇟ run 40022 5 22 p7 ⇞ run 40022 6 23 bearing diag. ⇞ Drive motor bearing defective Airend bearing defective 40022 7 24 T13 ⇞ always Coolant temperature in the airend too high.4) Register Bit No. Master Controller << == Compressor Table 1. 40022 9 26 p14 ⇟ run 40022 10 27 p3 ⇟ always 40022 11 28 p3 ⇞ idle 40022 12 29 p3 ⇟ load 40022 13 30 p3 ⇞ always 40022 14 31 not assigned 40022 15 32 T14<T12T11M⇟load © KAESER KOMPRESSOREN GmbH www.1 1.com Page 5 of 18 .SIGMA CONTROL Process Map V10. 40022 8 25 p14 ⇞ always Pressure in the cooling circuit too high.23 Table 1.

1 : Alarms (Sigma Control transmit word 0 . Master Controller << == Compressor Table 1.intercl. End-position switch defective.com Page 6 of 18 . 40023 10 43 p4 / p3 ⇞ always 40023 11 44 p5 < p4 ⇟ always 40023 12 45 p5 > p4 ⇞ load 40023 13 46 FC VFD compressor fault (frequency converter) 40023 14 47 RS485 RS485 transmission error (USS protocol) 40023 15 48 HT cell High tension cell fault in power switching © KAESER KOMPRESSOREN GmbH www. Sigma Control display Explanation 40023 0 33 ECO-Dr. Condensate drain faulty intermediate cooler 40023 1 34 mains cont.23 Table 1.SIGMA CONTROL Process Map V10. End-position switch defective.kaeser.1 1.4) Register Bit No. 40023 4 37 T12<T10 ⇟ load 40023 5 38 T12 ⇞ always 40023 6 39 not assigned 40023 7 40 mains cont. off? The mains contactor does not drop out despite an OFF command 40023 8 41 mains voltage ⇟ 2nd power supply failure - the drive motor was shut down 40023 9 42 WS valve V12 cool water control valve V12 Timeout exceeded. 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 WS valve V14 cool water control valve V14 Timeout exceeded.

1 1. Master Controller << == Compressor Table 1. 40024 12 61 T6 ⇞ run 40024 13 62 not assigned 40024 14 63 T10 ⇞ always 40024 15 64 T10 ⇟ run © KAESER KOMPRESSOREN GmbH www.kaeser.com Page 7 of 18 .SIGMA CONTROL Process Map V10.4) Register Bit No.1 : Alarms (Sigma Control transmit word 0 . 40024 7 56 T4 ⇞ always 40024 8 57 Model Vague model version 40024 9 58 ECO-Dr. Sigma Control display Explanation 40024 0 49 T1 ⇞ run 40024 1 50 T2 < T1 ⇟ run 40024 2 51 T2 ⇞ always 40024 3 52 WS pump heat recovery pump overload or internal error 40024 4 53 T2T1M ⇞ always 40024 5 54 T3 ⇞ run 40024 6 55 Start T3⇟ Intake air temperature too low. End-position switch defective.23 Table 1.aftercl Condensate drain faulty Aftercooler 40024 10 59 T5 ⇟ load 40024 11 60 WS valve V10 cool water control valve V10 Timeout exceeded.

23 Table 1. Master Controller << == Compressor Table 1.4) Register Bit No. message 2 Message text freely definable from SIGMA Control display 40025 11 76 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.p4) ⇞ load 40025 5 70 T5 ⇞ always 40025 6 71 not assigned 40025 7 72 not assigned 40025 8 73 ext.p4) ⇟ load 40025 4 69 T4(T3. message 4 Message text freely definable from SIGMA Control display 40025 13 78 ext.com Page 8 of 18 . message 0 Message text freely definable from SIGMA Control display 40025 9 74 ext.1 1.1 : Alarms (Sigma Control transmit word 0 .kaeser.SIGMA CONTROL Process Map V10. message 1 Message text freely definable from SIGMA Control display 40025 10 75 ext. Sigma Control display Explanation 40025 0 65 T11 ⇞ always 40025 1 66 T4 < T3 ⇟ run 40025 2 67 T4T3M ⇞ always 40025 3 68 T4(T3. message 3 Message text freely definable from SIGMA Control display 40025 12 77 ext.

Question the defect in menu <status > messages> standstill> 40026 3 4 p4 / p3 ↑ always 40026 4 5 DHC dryer General warning DHC dryer 40026 5 6 p5 < p4 ↓ always 40026 6 7 bearing diag.com Page 9 of 18 .23 Table 1. Master Controller << == Compressor Table 1.2 : Warning Messages (Sigma Control transmit word 5 . ↑ Drive motor bearing defective Airend bearing defective 40026 7 8 p5 > p4 ↑ load 40026 8 9 error: SMS SMS couldn'd be transmitted 40026 9 10 p4 / p3 ↑ load 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 T11 ↑ always Coolant temperature in the intermediate cooler too high. 40026 14 15 bus alarm ProfiBus connection error 40026 15 16 T13 ↑ always © KAESER KOMPRESSOREN GmbH www.2 1.kaeser.9) Register Bit No. Sigma Control display Explanation 40026 0 1 error: System System error: flash memory defective Question the system error in menu <status> messages> system> 40026 1 2 motor T↑ Initial warning: Permissible drive motor temperature reached soon (PTC or PT100) 40026 2 3 standstill Warning messages during STANDSTILL.SIGMA CONTROL Process Map V10.

Master Controller << == Compressor Table 1.SIGMA CONTROL Process Map V10.9) Register Bit No. p6 <0°C too low for start of compressor 40027 1 18 not assigned 40027 2 19 p3 ↓ always 40027 3 20 p3 ↑ idle 40027 4 21 p3 ↓ load 40027 5 22 p3 ↑ always 40027 6 23 T10<T5T3 ↓ run 40027 7 24 T12<T10 ↓ load 40027 8 25 T6 ↑ run 40027 9 26 T6 ↓ run 40027 10 27 p6 ↑ always 40027 11 28 p6 ↓ run 40027 12 29 p7 ↑ run 40027 13 30 p7 ↓ run 40027 14 31 T10 ↑ always 40027 15 32 T10 ↓ run © KAESER KOMPRESSOREN GmbH www.2 : Warning Messages (Sigma Control transmit word 5 .23 Table 1.kaeser.2 1.com Page 10 of 18 . Sigma Control display Explanation 40027 0 17 Start T6↓ Oiltemp.

9) Register Bit No.2 1.com Page 11 of 18 .SIGMA CONTROL Process Map V10. 40028 11 44 T12≠T11 ↑ load 40028 12 45 DO test The "set output" test function is activated 40028 13 46 System press.2 : Warning Messages (Sigma Control transmit word 5 .load signal? Vague external load signal Default setpoint for cut-out pressure high was exceeded.23 Table 1. Sigma Control display Explanation 40028 0 33 p4 ↑ idle 40028 1 34 p4 ↓ load 40028 2 35 p4 ↑ always 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 T1 ↑ run 40028 6 39 T2 < T1 ↓ run 40028 7 40 T2 ↑ always 40028 8 41 mains voltage ↓ 1st power supply failure - compressor was restarted automatically 40028 9 42 T12 ↑ always 40028 10 43 ext.↓ System pressure too low 40028 14 47 T2T1M ↑ always 40028 15 48 T5 ↓ load © KAESER KOMPRESSOREN GmbH www.kaeser. Master Controller << == Compressor Table 1.

com Page 12 of 18 . Sigma Control display Explanation 40029 0 49 Service h ⇞ A maintenance interval counter has elapsed see menu status>messages>service 40029 1 50 T3 ↑ run 40029 2 51 T3 > T1 ↑ always 40029 3 52 T11< T10 ↓ load 40029 4 53 p14 ↓ always 40029 5 54 T4 ↑ always 40029 6 55 T14<T12T11M↓run 40029 7 56 T4T3M ↑ always 40029 8 57 T4(T3.SIGMA CONTROL Process Map V10.kaeser. Master Controller << == Compressor Table 1.23 Table 1. Start possible if T3 remains <3°C Compressor remains 900s idle max.9) Register Bit No.Sigma Control point-to-point link) 40029 10 59 Start T1↓ Inlet temperatur T1 (<-20°C) and oil temperatur T6 (<0°C) too low for compressor start 40029 11 60 Start T3↓ T1 (>-20°C) and oiltemp. T6 (>0°C) ok.2 : Warning Messages (Sigma Control transmit word 5 .p4) ↓ load 40029 9 58 RS485 RS485 transmission error (Sigma Control .2 1. 40029 12 61 T4(T3.p4) ↑ load 40029 13 62 not assigned 40029 14 63 not assigned 40029 15 64 FC AI1 fault VFD compressor: Pressure sensor at AI1 faulty © KAESER KOMPRESSOREN GmbH www.

Master Controller << == Compressor Table 1.23 Table 1. message 4 Message text freely definable from SIGMA Control display 40030 13 78 ext.SIGMA CONTROL Process Map V10.com Page 13 of 18 .kaeser. message 1 Message text freely definable from SIGMA Control display 40030 10 75 ext. message 0 Message text freely definable from SIGMA Control display 40030 9 74 ext.2 : Warning Messages (Sigma Control transmit word 5 . 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. message 3 Message text freely definable from SIGMA Control display 40030 12 77 ext.9) Register Bit No. message 2 Message text freely definable from SIGMA Control display 40030 11 76 ext.2 1.aftercl Condensate drain faulty Aftercooler 40030 4 69 T5 < T3 ↓ load 40030 5 70 T5 > T3 ↑ load 40030 6 71 not assigned 40030 7 72 not assigned 40030 8 73 ext. Sigma Control display Explanation 40030 0 65 T5 ↑ always 40030 1 66 air filter dp↑ Initial warning: Air filter clogged 40030 2 67 T5 > T1 ↑ run 40030 3 68 ECO-Dr.

h⇞ 40031 13 14 blt.12) not displayed on Sigma Control Register Bit No.coup.h⇞ 40031 1 2 not assigned 40031 2 3 not assigned 40031 3 4 not assigned 40031 4 5 not assigned 40031 5 6 not assigned 40031 6 7 check valve⇞ 40031 7 8 annual maint 40031 8 9 not assigned 40031 9 oil change h⇞ 40031 10 11 oil filter h⇞ 40031 11 12 air filter h⇞ 40031 12 13 blt. Operational Message Explanation 40031 0 1 bearing maint.kaeser.coup.23 Table 1.com Page 14 of 18 .3 : Operational Messages (Sigma Control transmit word 10 .chng.3 1.insp.SIGMA CONTROL Process Map V10.h⇞ 40031 14 15 bearingchange h⇞ 40031 15 16 electric h⇞ © KAESER KOMPRESSOREN GmbH www. Master Controller << == Compressor Table 1.

Operational Message Explanation 40032 0 17 ext.com Page 15 of 18 .SIGMA CONTROL Process Map V10.kaeser.23 Table 1. message 0 Message text freely definable from SIGMA Control display 40032 1 18 ext.12) not displayed on Sigma Control Register Bit No. Motor T↑ Dynamic control mode: Drive motor temperature too high for drive motor stop 40032 12 29 compressor ON Drive motor ready to go on load 40032 13 30 controller ON The controller (Sigma Control) is switched on by the function key "I" 40032 14 31 not assigned 40032 15 32 not assigned © KAESER KOMPRESSOREN GmbH www.pA System pressure setpoint pA selected for control of load 40032 9 26 setpointpress. message 1 Message text freely definable from SIGMA Control display 40032 2 19 ext.3 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 setpointpress.3 : Operational Messages (Sigma Control transmit word 10 . Master Controller << == Compressor Table 1. message 2 Message text freely definable from SIGMA Control display 40032 3 20 ext. message 4 Message text freely definable from SIGMA Control display 40032 5 22 ext.pB System pressure setpoint pB 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 configuration 40032 11 28 Dyn. message 3 Message text freely definable from SIGMA Control display 40032 4 21 ext.

kaeser.com Page 16 of 18 .12) not displayed on Sigma Control Register Bit No.SIGMA CONTROL Process Map V10.3 : Operational Messages (Sigma Control transmit word 10 .23 Table 1.3 1. 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.

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 .SIGMA CONTROL Process Map V10. contact yes no 5 6 Compressor ON from "I" key and L2DP bus yes no 7 Compressor ON setting (Bit 0 . Master Controller << == Compressor Table 1.23 Table 1.7 1.4 : Transmit bit assignment Register 40034 Binary signals 1 Bit Description Signal "1" Signal "0" 0 Drive motor ready for operation 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 Drive motor ready for operation yes no 9 Profibus send+receive yes no 10 11 12 13 14 15 Table 1.kaeser.4-1.14) Master local © KAESER KOMPRESSOREN GmbH www.6) Master local 8 DUAL control mode DUAL 9 QUADRO control mode QUADRO 10 11 DYNAMIC control mode DYNAMIC 12 13 14 15 Control mode setting (Bit 8 .

7 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.4-1. contact yes no 5 6 Load-idle signal from L2DP bus yes no 7 Load control mode setting (Bit 0 .SIGMA CONTROL Process Map V10.7 : 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 pA(pB) 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.kaeser.23 Table 1.com Page 18 of 18 .15) Master local 8 pA permanent yes no 9 pB permanent yes no 10 pA/pB from clock yes no 11 pA/pB from timer yes no 12 13 pA/pB from external contact yes no 14 pA/pB from RS485 interface yes no 15 Table 1. Master Controller << == Compressor Table 1.