Assembly and Operating Manual: Retrofit Kit Ethernet/Ip

Assembly and operating manual
Retrofit kit
EtherNet/IP
No.: 7_5250_02090 01 E
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
www.kaeser.com
/KKW/SSC 2.09 en IBA-7_5250_02090
/KKW/SSC 2.09
20181023 113914
Contents
1 Regarding this document

1.1 Pertinence to the product ................................................................................................. 1
1.2 Symbols and labels .......................................................................................................... 1
1.2.1 Warnings ............................................................................................................. 1
1.2.2 Potential damage warnings ................................................................................ 2
1.2.3 Other alerts and their symbols ............................................................................ 2
2 Technical Specifications
2.1 EtherNet/IP-Module .......................................................................................................... 4
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 5
4 Installation
4.1 Ensuring safety ................................................................................................................ 6
4.2 Scope of delivery .............................................................................................................. 6
4.3 Isolating the machine/control from the power supply system ........................................... 7
4.4 Removing the EMERGENCY STOP command device .................................................... 7
4.5 Installing the communication module ............................................................................... 7
4.5.1 Machine .............................................................................................................. 7
4.5.2 SIGMA AIR MANAGER 4.0 ................................................................................ 8
4.6 Connecting the controller to the bus system .................................................................... 9
4.6.1 Laying the bus conduit ........................................................................................ 9
4.6.2 Attaching the RJ45-plug ..................................................................................... 10
4.6.3 Connecting the bus plug to the control ............................................................... 12
4.7 Installing the EMERGENCY STOP command device ...................................................... 12
5 Initial Start-up
5.1 Switching on the machine ................................................................................................ 13
5.2 Testing the EMERGENCY OFF command device ........................................................... 13
5.3 Commissioning the EtherNet/IP-Module .......................................................................... 13
5.3.1 Machine .............................................................................................................. 13
5.4 Activating the remote control ............................................................................................ 15
5.4.1 Machine .............................................................................................................. 15
6 Operation
6.1 Displays at the EtherNet/IP-Module ................................................................................. 17
6.2 Controller displays ............................................................................................................ 18
6.2.1 SIGMA CONTROL 2 ........................................................................................... 18
7 Fault Recognition and Rectification
7.1 Troubleshooting Modbus TCP/EtherNet IP-Module ......................................................... 19
7.1.1 Machine and SIGMA CONTROL 2 ..................................................................... 19
7.2 SIGMA AIR MANAGER 4.0 ............................................................................................. 20
Assembly and operating manual Retrofit kit

No.: 7_5250_02090 01 E EtherNet/IP i
Contents

ii EtherNet/IP No.: 7_5250_02090 01 E
List of Illustrations
Fig. 1 Insert the communication module .............................................................................................. 8

Fig. 2 Insert the communication module .............................................................................................. 8
Fig. 3 Bus cable conduit with shielding ................................................................................................ 9
Fig. 4 Strip the isolation from the network cable. ................................................................................. 10
Fig. 5 Inserting the network cable conductors ...................................................................................... 10
Fig. 6 Positioning the network cable ..................................................................................................... 11
Fig. 7 Close the lid of the RJ45 plug. ................................................................................................... 11
Fig. 8 Rotating the locking piece to the stop ........................................................................................ 11
Fig. 9 EtherNet/IP communication module – LEDs and interface ........................................................ 17

No.: 7_5250_02090 01 E EtherNet/IP iii
List of Illustrations

iv EtherNet/IP No.: 7_5250_02090 01 E
List of Tables
Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1

Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Formatting options ...................................................................................................................... 2
Tab. 4 Technical data EtherNet/IP-Interface ......................................................................................... 4
Tab. 5 Configuration of the EtherNet/IP-Interface ................................................................................. 4
Tab. 6 EtherNet/IP-Interface - Cabling recommendation ...................................................................... 4
Tab. 7 Scope of delivery ........................................................................................................................ 6
Tab. 8 "Switching on the Machine” action alternatives .......................................................................... 13
Tab. 9 Setting theStarttd parameter ...................................................................................................... 14
Tab. 10 Setting the Timeout parameter ................................................................................................... 15
Tab. 11 EtherNet/IP communication module – Interpretation of LEDs .................................................... 17
Tab. 12 Status of Com module at SIGMA AIR MANAGER AIR 4.0 ........................................................ 18
Tab. 13 Com-Module communication error warning message ................................................................ 19
Tab. 14 Fault displays in the Communication – Com-Module menu. ...................................................... 19
Tab. 15 Messages on SIGMA AIR MANAGER 4.0 ................................................................................ 20
Tab. 16 Fault of Com module .................................................................................................................. 20

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List of Tables

vi EtherNet/IP No.: 7_5250_02090 01 E
1.1 Pertinence to the product

1.1 Pertinence to the product
This document describes the EtherNet/IP retrofit kit for machine with KAESER controller. It supple‐
ments the user manual of the corresponding KAESER machine/controller and should always be
kept with it.
Read and comply with the instructions provided in “1 About this document“, ”3 Safety and re‐
sponsibility” and “6.1 Ensuring installation safety“ in the operating manual of the correspond‐
ing KAESER machine/controller.
1.2 Symbols and labels

➤ Please note the symbols and labels used in this document.
1.2.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of non-compliance
DANGER Warns of an imminent threat of danger Will result in death or severe injury
WARNING Warns of possible danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Tab. 1 Danger levels and their definition (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
Example:
DANGER
These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1. WARNING!
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe
injury may occur.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.

No.: 7_5250_02090 01 E EtherNet/IP 1
1.2.2 Potential damage warnings

Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
Warning notices for damages are identified by their signal term.

Signal term Meaning Consequences of non-compliance
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
Example:
NOTICE
Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.
1.2.3 Other alerts and their symbols

The meaning of names is emphasised by different formatting. Depending on the font, not all for‐
matting options can be realised.
Name Formatting Example
Operating state UPPER CASE LOAD
Item number ... Open valve 4
Indication italic ON LED
Key « ... » «ON» key
Menu option < ... > <Configuration>
Menu path <Menu 1 – Menu 2 – ...> <Configuration – Pressure control>
activated ... The minutes display flashes. 00:00:00
Tab. 3 Formatting options
This symbol identifies particularly important information.
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
Here conditions relevant to safety are named that will help you to avoid dangerous situations.
➤ This symbol denotes lists of actions comprising one stage of a task.

Operating instructions with several steps are numbered in the sequence of the operating steps.
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... as is a solution.

2 EtherNet/IP No.: 7_5250_02090 01 E
This symbol identifies important information or measures regarding the protection of the envi‐
ronment.
Further information Further subjects are introduced here.

No.: 7_5250_02090 01 E EtherNet/IP 3
2.1 EtherNet/IP-Module
2.1 EtherNet/IP-Module
EtherNet/IP-Interface
Feature Value
Controller SIGMA CONTROL 2 SIGMA AIR MANAGER 4.0
Bus EtherNet/IP-Server (Slave)
Connection 2x RJ45 ports (Cat5e, shielded), integrated 2-port switch, potential isolation
Baud 10/100, full duplex or half duplex
rate [Mbit/s]
Input data [byte] 64
Output data 128 (process data) and 42 (diagnos‐ 194 (process data)
[byte] tic data)
Data content "Technical description "Technical description
SIGMA CONTROL 2 process image", SIGMA AIR MANAGER 4.0 process im‐
document number 7_7601xPA. age", document number 7_9696_PA.
Tab. 4 Technical data EtherNet/IP-Interface
Configuration of the EtherNet/IP-Interface
Pin * Signal Conductor colour Description

1 TD+ Yellow Send positive (positive transmit)
2 TD– Orange Send negative (negative Transmit)
3 RD+ White Positive receive
4, 5, 7, 8 — — —
6 RD- Blue Negative receive
Housing Cable shield — High-impedance (1 MOhm/47 nF) connection with func‐
tional earthing (FE)
* Position of pins 1 through 8, see chapter 6
Tab. 5 Configuration of the EtherNet/IP-Interface
Recommended conduit
Feature Value
Conductor Network conductor, CAT5 shielded, CU, for example: 7.7629.0
Plug Bus plug RJ45, IP20, for example: 7.7628.1
Maximum cable length [m] 100
Tab. 6 EtherNet/IP-Interface - Cabling recommendation

4 EtherNet/IP No.: 7_5250_02090 01 E
3.1 Basic instructions

3.1 Basic instructions
Read and comply with the instructions in chapter ”3 Safety and responsibility” in the operating man‐
ual of the KAESER machine and/or controller.
■ This product may only be installed by a qualified person. See chapter “3 Assigning per‐
sonnel“ in in the operating manual of the KAESER machine and/or controller.
■ KAESER does not assume liability for any subsequent damages arising from improper in‐
stallation or use of the product.

No.: 7_5250_02090 01 E EtherNet/IP 5
4 Installation
4.1 Ensuring safety
4 Installation
4.1 Ensuring safety
Follow the instructions below for safe installation.
Warning instructions are located before a potentially dangerous task.
Disregard of warning instructions can cause serious injuries!
Complying with safety notes
Disregard of safety notes can cause unforeseeable dangers!

➤ Follow the instructions in chapter "3 Safety and Responsibility".
➤ This product may only be installed by a qualified person. See chapter “3 Assigning personnel“
in in the operating manual of the KAESER machine and/or controller.
When working on live components
Touching voltage carrying components can result in electric shocks, burns or death.
➤ Work on electrical equipment may only be carried out by authorised electricians.
➤ Switch off and lock out the power supply disconnecting (isolating) device and check that no
voltage is present.
➤ Check that there is no voltage on potential-free contacts.
4.2 Scope of delivery

The EtherNet/IP communication module is intended for the installation in suitable KAESER control‐
lers. It is connected to the user's bus system via its bus interface.
This retrofit kit consists of:

Item Material No. Description Quantity
10 7.5781.00780 Cable fitting EMC, M16 with spring 2
20 7.5819.00020 Reduction ring M 25/16 CuZn 4
30 7.5811.00010 Lock nut, CuZn M16x1.5, serrated 4
40 7.5813.00010 Lock nut, CuZn M25x1.5, serrated 4
50 7.7628.1 RJ45 bus connector 2
60 7.7606.00070 Communication Module EtherNet/IP-2P M40 1
70 7.5288.0 Screwed cable gland M16x1.5 2
80 7.0722.0 Cable tie T 18 R 10
90 − This instruction 1
Tab. 7 Scope of delivery

6 EtherNet/IP No.: 7_5250_02090 01 E
4 Installation
4.3 Isolating the machine/control from the power supply system
4.3 Isolating the machine/control from the power supply system

DANGER
Danger of fatal injury from electric shock!
➤ Isolate the machine/controller and external sources from all voltage.
Machine SIGMA AIR MANAGER 4.0

1. Shut down the machine with the «OFF» key 1. Switch SIGMA AIR MANAGER 4.0 to man‐
2. Isolate the machine from all power phases. ual mode, see SIGMA AIR MANAGER 4.0
Operating Manual Chapter 10.2.1.
3. Lock them out.
2. Isolate the machine from all power phases.
4. Verify the absence of any voltage.
3. Lock them out.
4. Verify the absence of any voltage.
4.4 Removing the EMERGENCY STOP command device

Only for machines.
If the contact block of the EMERGENCY-OFF command device impedes the installation of the
communication module, proceed as follows:
Precondition The power supply is switched off, the device is locked in the off position, and the absence of volt‐
age is checked.
1. Turn the entire contact block to the left.

2. Pull the entire contact block off the switching cabinet door.
3. Keep the contact block suspended from the SIGMA CONTROL 2.
4.5 Installing the communication module

Material Retrofit kit EtherNet/IP
Network conductor, CAT5 2x2x0,64; sold by the metre, e.g. 7.7629.0
Screwdriver (straight or offset), maximum length: 70 mm: Torx T9
Slotted screwdriver: 2.5 – 3 mm blade width
Precondition The power supply is switched off, the device is locked in the off position, and the absence of volt‐
age is checked.
4.5.1 Machine
1. Open the control cabinet door.
The bay for the installation of the communication module is located at the rear of the
SIGMA CONTROL 2. It is identified with "Com module X4" and can be access from below.
2. Use a slotted screwdriver to break out the plastic cover of the communication module bay.
3. Pick up the communication module.
The bus interface points to down and the top surface with the KAESER logo is visible.

No.: 7_5250_02090 01 E EtherNet/IP 7
4 Installation
4.5 Installing the communication module
Fig. 1 Insert the communication module

1 Communications module
2 SIGMA CONTROL 2
3 Fixing screw
4. Push the module from beneath into the bay until it latches audibly.
If the contact block of the EMERGENCY-STOP control device impedes the installation of the
communication module, proceed as described in the previous chapter.
5. Use the Torx T9 screwdriver to screw in the fixing screws.
Result The module is correctly installed when its front plate is seated solidly in the recess of the module
bay.
4.5.2 SIGMA AIR MANAGER 4.0

1. Fold-open cover of SIGMA AIR MANAGER 4.0. The bay for communication module installation
is located at the rear of the SIGMA AIR MANAGER 4.0 terminal. It is marked "Com module X1"
and is accessible from below.
2. Use a slotted screwdriver to break out the plastic cover of the module bay.
Fig. 2 Insert the communication module

8 EtherNet/IP No.: 7_5250_02090 01 E
4 Installation
4.6 Connecting the controller to the bus system
3. Push the communication module 4 into the module bay 3 from below until you feel it snap
into place. The bus interface will face downward and the top of the module with the KAESER
logo will be visible.
4. Use the Torx T9 screwdriver to screw in the fixing screws 5 .
Result The module is correctly installed when the front plate is seated firmly in the recess of the module
bay.

Interference in bus communication due to electromagnetic fields
➤ Always lay the bus cable separately from 115/230/400V~ conduits (separate bundles or
wire ducts).
4.6.1 Laying the bus conduit

4.6.1.1 Machine
1. Install an EMC fitting and a serrated lock nut in an empty bore in the machine's switching cabi‐
net. For an M25 bore, use an M25/16 reducer. If a free bore is not available, create an M16
bore with a diameter of 16.5 mm.
2. If the EMC fitting does not terminate outside of the machine:
Install a synthetic fitting and lock nut at an empty bore in the machine frame or in the cover
plate of the machine.
For an M25 bore, use an M25/16 reducer. If a free bore is not available, create an M16 bore
with a diameter of 16.5 mm.
3. If two bus cables are to be installed:
Install another EMC fitting and synthetic fitting, if required, as described above.
4. Thread the bus cables from the exterior through the screw fittings to the SIGMA CONTROL 2.
Install the bus cable(s) in the 24 VDC cable ducts (blue cables) and the existing cables to the
switching cabinet door.
5. Remove 1 cm of the bus cables' isolation at the position of the contact spring of the EMC
screw fitting.
Fig. 3 Bus cable conduit with shielding
6. Push the bus cables into the screw fittings until the stripped area has contact with the springs
in the EMC screw fitting (see Fig. 3).
7. Close all installed screw fittings.

No.: 7_5250_02090 01 E EtherNet/IP 9
4 Installation
4.6.1.2 SIGMA AIR MANAGER 4.0
1. Lead each bus cable from the outside through a metal fitting to the connection point at the
communication module.
2. Please proceed as described under 4.6.1.1 Item 5 through 7.
4.6.2 Attaching the RJ45-plug

The RJ45 plug and the network cable can be damaged if unlocked under strain.
➤ Always release strain on the RJ45 plug prior to unlocking.
Fig. 4 Strip the isolation from the network cable.

1 Orange 4 White
2 blue 5 18 mm
3 Yellow 6 5 mm
1. Strip the isolation from the network cable (stripped wires 18 mm, sheath 5 mm) (see Fig. 4).
2. Spread the conductors according to the colour coding of the contact element of the RJ45 con‐
nector (see Fig. 4).
Fig. 5 Inserting the network cable conductors
3. Insert the conductors into the contact elements up to the end stop.

10 EtherNet/IP No.: 7_5250_02090 01 E
4 Installation
Fig. 6 Positioning the network cable
4. Position the network cable as shown (arrows, see Fig. 6).
Fig. 7 Close the lid of the RJ45 plug.

4 RJ45 plug lid
5 Rotatable locking piece
5. Close the lid and manually rotate the locking piece clockwise as far as possible.
Fig. 8 Rotating the locking piece to the stop

6 RJ45 plug (view from cable end)
7 Screwdriver

No.: 7_5250_02090 01 E EtherNet/IP 11
4 Installation
4.7 Installing the EMERGENCY STOP command device
6. Insert a screwdriver with 2.5 mm blade width into the bore and rotate the locking piece clock‐
wise up to the end stop.
Contact issues with conductor ends after multiple contact creation.
➤ Cut off contacted conductor ends and again strip the conductors.
The insulation displacement contacts of the plug may be disconnected and re-contacted up
to 10 times.
Result The plug is correctly locked when the opening of the locking piece is facing sideways and the side
surfaces are flush with the plug.
4.6.3 Connecting the bus plug to the control

Precondition The bus wiring to the bus master is ready.
1. Plug the bus plug into the bus interface of the communication module.
2. Attach the bus plug with the fixing screws.
3. Machine: Use cable ties to fixate the bus cable at the cables between switching cabinet and
cabinet door.
4.7 Installing the EMERGENCY STOP command device

Only for machines.
If you had removed the contact block of the EMERGENCY-OFF command device, re-install as fol‐
lows:
1. Plug the contact block slightly turned to the left onto the EMERGENCY STOP command de‐
vice.
2. Turn the contact block to the right until it audibly latches.
3. Actuate the EMERGENCY STOP command device.
The contact block must be firmly seated and must not come off the push-button.
4. Unlatch the EMERGENCY STOP command device.

12 EtherNet/IP No.: 7_5250_02090 01 E
5 Initial Start-up
5.1 Switching on the machine
5 Initial Start-up
5.1 Switching on the machine
Precondition The following description of parametrisation refers to current SIGMA CONTROL 2 software ver‐
sions. If the settings on the machine are different, please contact KAESER SERVICE.
The communication module is correctly installed and connected (see chapter 4).
The bus wiring to the bus master is ready.
The machine/controller is parametrised in the bus master.
The bus master is operational.
1. Close the control cabinet.

2. Switch on the power supply of the machine/controller at the mains disconnect switch.
Machine SIGMA AIR MANAGER 4.0

3. Press «ON» to switch on the machine. 3. Switch SIGMA AIR MANAGER 4.0 to auto‐
matic mode, see SIGMA AIR MANAGER 4.0
Operating Manual Chapter 10.2.4.
Tab. 8 "Switching on the Machine” action alternatives
5.2 Testing the EMERGENCY OFF command device

Only for machines.
If the contact block of the EMERGENCY OFF command device has been removed, you must test
the EMERGENCY OFF command device after installation.
DANGER
A non-functional EMERGENCY OFF command device can cause severe injury or death!
➤ Operate the machine only with a functional EMERGENCY OFF command device.
1. Wait for the machine to have reached speed and let it run for a few minutes.
2. Actuate the EMERGENCY STOP command device.
Result The machine must shut down immediately.

The SIGMA CONTROL 2 displays the fault message EMERGENCY STOP.
1. Unlatch the EMERGENCY STOP command device.

2. Confirm the fault with «Acknowledge».
3. Press «ON» to activate the machine.
5.3 Commissioning the EtherNet/IP-Module

5.3.1 Machine
Precondition Access level 2 is activated.
The network parameters are known. Request the required information from your IT department

No.: 7_5250_02090 01 E EtherNet/IP 13
5 Initial Start-up
5.3 Commissioning the EtherNet/IP-Module
1. Open the 8.2 <Communication – Com-Module> menu.

2. Activate the Com-Module Start check box.
The communication module is activated. The system detects the communication module type
and displays it in the Type line.
3. Select the data exchange direction:
► SIGMA CONTROL 2 ⇆ Bus master (SIGMA CONTROL 2 sends process data and receives
control data): Send/receive or Master: Set Com module.
► SIGMA CONTROL 2 → Bus master (SIGMA CONTROL 2 sends process data): Send or
Master: Setting SAM/JSON-RPC.
4. Set the required reaction in the event of a bus fault (see next chapter, “Reaction in a PROFI‐
BUS bus fault”).
5. Set IP-Parameter as described below.
Use DHCP Do not use DHCP
1. Activate the DHCP check box. 1. Deactivate the DHCP check box.
2. Activate the Use IP settings: check box to 2. Set IP address.
apply the IP-Parameter. 3. Set Subnet mask.
The communication module is started with
4. Set the Gateway address.
the set parameters.
5. DNS Server 1-Setting address (optional).
Communication with the bus master is run‐
ning. 6. DNS Server 2-Setting address (optional).
Time-out at bus fault is activated. 7. Activate the Use IP settings: check box to
apply the IP-Parameter.
Bus communication is now monitored. The
number behind Status Counter (Run) con‐
the set parameters.
tinuously changes during communication.
Communication with the bus master is run‐
ning.
Time-out at bus fault is activated.
Bus communication is now monitored. The
number behind Status Counter (Run) con‐
tinuously changes during communication.
Reaction in a bus fault
Only for machines.
After switching on the power supply, the bus alarm can be suppressed for a definable period of
time. The setting depends on the time passing at the bus master between return of voltage and
start of communication via the bus.
Parameters Factory setting Set value

Start td 15 s
Tab. 9 Setting theStarttd parameter
SIGMA CONTROL 2 monitors the bus communication at log level (EtherNet/IP). If there is a check
box behind Communication error, this monitoring in the Send mode can be switched off by deacti‐
vating the check box.

14 EtherNet/IP No.: 7_5250_02090 01 E
5 Initial Start-up
5.4 Activating the remote control
In Send/receive or Master modes, SIGMA CONTROL 2 can monitor: Com-Module the bus commu‐
nication at user level. For this purpose, the bus master reads a value ("toggle bit") that changes
with every bus cycle and returns it without change. SIGMA CONTROL 2 returns a bus alarm if the
bit does not change for a time longer than set (Timeout). Activate the check box to enable monitor‐
ing.
Parameters Factory setting Set value

Timeout 5s
Monitoring Check box ☑ activated
Tab. 10 Setting the Timeout parameter
➤ Enter the required settings, as described above.

1. Press the Start-up – Control technology key
The Control technology menu is displayed
2. Activate the Com module option by placing a check mark "✔“ in the control box.
The communication module is activated. The system detects the communication module type
and displays it in the Detected module type line.
3. Set IP-Parameter as described below.
The IP-Parameters are displayed only if an Ethernet connection to a communication partner
(e.g. bus master) is established. If no connection is established, then “000.000.000.000“ is
displayed.
Use DHCP Do not use DHCP

1. Activate the DHCP check box. 1. Deactivate the DHCP check box.
2. Apply settings using the Apply settings key 2. Set IP address.
The communication module is started with 3. Set Subnet mask.
the set parameters.
4. Set the Gateway address.
Communication with the control electronics
5. Apply settings using the Apply settings key
is working.
the set parameters.
Communication with the control electronics
is working.

When the machine/control is controlled via the bus, activate the remote control as follows:
5.4.1 Machine
Precondition Access level 2 is activated.
The operating mode is displayed.
1. Open the menu, e.g. 8 Communication menu.

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

No.: 7_5250_02090 01 E EtherNet/IP 15
5 Initial Start-up
3. Press «Enter».
The check box Key remote will flash.
6.1bar 08:15AM 80° C Header
8 Communication Menu
▶1 Ethernet/SIGMA NETWORK
▶2 Com-Module
Key remote :☐ Active line with deactivated check box
4. Press «Up» key.

The check box Key remote is activated.
6.1bar 08:15AM 80° C Header
8 Communication Menu
▶1 Ethernet/SIGMA NETWORK
▶2 Com-Module
Key remote :☑ Active line with deactivated check box
5. Press «Enter».
The «Remote control» key is activated.
6. Press «Escape» repeatedly to leave this menu.
Proceed in the same manner to deactivate the «remote control» key.
7. Press «Remote control» key on the operating panel of SIGMA CONTROL 2.
Result SIGMA CONTROL 2 remote control is activated. The bus master can remotely control the
SIGMA CONTROL 2.

1. Press the «remote» key.
The system returns a confirmation prompt.
2. Confirm with Yes button.
The «Remote control» button illuminates in green.
Result You can control SIGMA AIR MANAGER 4.0 from a central control centre.

16 EtherNet/IP No.: 7_5250_02090 01 E
6 Operation
6.1 Displays at the EtherNet/IP-Module
6 Operation
6.1 Displays at the EtherNet/IP-Module
The communication module features LEDs providing information about the module status.
Fig. 9 EtherNet/IP communication module – LEDs and interface

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

2 NS off Module without voltage or IP address not available
Green illuminates continuously Module in operation, connection has been made
flashes Module waits for connection
Red illuminates continuously Duplicate IP address or internal fault
flashes Monitoring time exceeded (time-out)
3 MS off Module without voltage
Green illuminates continuously Module in operation, master communicates (scanner in
run status)
flashes Module not configured or master in idle (scanner in idle
status)
Red illuminates continuously Internal fault, module in "EXCEPTION" status
flashes The currently used settings do not correspond to the
saved settings
6, 7 off No connection.
Green illuminates continuously Connection established, 100 Mbit/s
flashes Communication running, 100 Mbit/s
Yellow illuminates continuously Connection established, 10 Mbit/s
flashes Communication running, 10 Mbit/s
Tab. 11 EtherNet/IP communication module – Interpretation of LEDs

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6 Operation
6.2 Controller displays
6.2 Controller displays

6.2.1 SIGMA CONTROL 2
In the 8.2 <Communication - Com-Module> menu, display the communication status as follows if
monitoring the bus communication on user level is activated (set the check mark ☑ behind
Timeout):
In fault-free communication, the number after Status Counter(Run) changes continuously.

In the Start-up – Control technology menu information on the Com module and the communication
status are displayed.
Element Meaning
Detected module type Type of installed Com module
SN Serial number of Com module, e.g.: A0:24:01:48
Status Status of Com module
Steady states ■ Module in Running (2) operation
■ Running (2) ■ The module is deactivated
■ Stopped (5) ■ The module status is unknown, no module available
■ unknown
Display temporary only
Transition states ■ The module starts
■ Starting (0) ■ The module stops
■ Stopping (1) ■ Restart requirement of module, e.g.: after setting Activate
■ Restart requested (3) Com module
■ Applying configuration (4) ■ The set configuration is transferred to the module, e.g.: after
pressing Apply settings.
Communication status Status of communication between SIGMA AIR MANAGER 4.0
■ OK Com module and control electronics
■ No connection. ■ Communication in operation
■ Internal error ■ Connection disrupted
■ Wrong module type inser‐ ■ Communication error in module
ted ■ Incorrect module type connected, e.g.: not a KAESER mod‐
ule
Tab. 12 Status of Com module at SIGMA AIR MANAGER AIR 4.0
#### is shown if information cannot be determined.

18 EtherNet/IP No.: 7_5250_02090 01 E
7.1 Troubleshooting Modbus TCP/EtherNet IP-Module

7.1 Troubleshooting Modbus TCP/EtherNet IP-Module
7.1.1 Machine and SIGMA CONTROL 2
In the event of a fault in the bus communication, the red "Communication" and the yellow "Warn‐
ing" LEDs flash at the SIGMA CONTROL 2. The system displays the following warning message:
Message Possible cause Remedy

0015 W Com-Module Bus coupling via communication module Check bus lines and plug.
communication error is interrupted.
Incorrect or faulty communication mod‐ Check communication
ule module, see below.
Tab. 13 Com-Module communication error warning message
In addition to the 0015 W Com-Module communication error warning message, the system dis‐
plays the following information for troubleshooting:
1. See chapter 6 for display on the communication module.
If one or both LEDs are illuminated red or blink red, contact KAESER SERVICE.
2. Displays in the <Communication – Com-Module> menu.
In the 8.2 <Communication – Com-Module> menu, communication faults are displayed as text
beneath the line Status or as a number after the term Error.
No.: Fault text Possible cause Remedy

1 Com-Module fault Defective module. Call KAESER SERVICE.
2 Communication error Bus coupling via communi‐ Check bus lines and plug.
cation module is interrup‐
ted.
Incorrect address settings Set the values at SIGMA CONTROL 2 as
or bus parameters in the parametrised at the bus master.
module.
3 Firmware fault. Defective module. Call KAESER SERVICE.
4 Com-Module Module is not activated. Start the communication, see chapter 5.
deactivated
5 Com-Module not No KAESER communica‐ Use only original KAESER communica‐
recognised tion module. tion module.
90 Fault bus monitoring Bus master does not return ■ Check bus master software.
the toggle bit within the ■ Check the time-out time, see chapter
monitoring interval. 5.
■ Deactivate monitoring if it has been
activated inadvertently. See chap‐
ter 5.
Tab. 14 Fault displays in the Communication – Com-Module menu.
Result The bus communication is automatically continued as soon as the cause of the fault is remedied.

No.: 7_5250_02090 01 E EtherNet/IP 19
7.2 SIGMA AIR MANAGER 4.0
7.2 SIGMA AIR MANAGER 4.0

In the event of a bus communication fault, the following diagnostic message is displayed on SIGMA
AIR MANAGER 4.0:
Message Possible cause Remedy

7xxxx Com module: Bus coupling via the communication module Check bus line and plug
Communication error is interrupted
Incorrect or faulty communication module Check communication
module, see below
Tab. 15 Messages on SIGMA AIR MANAGER 4.0
In addition to the aforementioned message, the system displays the following information for trou‐
bleshooting:
1. For displays on the communication module, see chapter 6.1.
Please contact a KAESER SERVICE technician if one or both of the LEDs are lit up or flash
red.
2. The Start-up – Control technology menu displays the communication errors and faults of the
Com module:
Indicator Possible cause Remedy

Communication status
No connection. Bus coupling via communica‐ Check bus line and plug
tion module interrupted
Incorrect slave address of the Set the slave address as parametrised at
module the bus master.
Internal error Defect module Call KAESER SERVICE
Wrong module type No KAESER communication Use only original KAESER communica‐
inserted module tion module.
Tab. 16 Fault of Com module

20 EtherNet/IP No.: 7_5250_02090 01 E

Assembly and Operating Manual: Retrofit Kit Ethernet/Ip

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Assembly and operating manual

1 Regarding this document

Assembly and operating manual Retrofit kit

Assembly and operating manual Retrofit kit

Fig. 1 Insert the communication module .............................................................................................. 8

Assembly and operating manual Retrofit kit

Assembly and operating manual Retrofit kit

Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1

Assembly and operating manual Retrofit kit

Assembly and operating manual Retrofit kit

1 Regarding this document

1.2 Symbols and labels

Tab. 1 Danger levels and their definition (personal injury)

Assembly and operating manual Retrofit kit

1.2.2 Potential damage warnings

Warning notices for damages are identified by their signal term.

Tab. 2 Danger levels and their definition (damage to property)

➤ Carefully read and fully comply with warnings against damages.

1.2.3 Other alerts and their symbols

Tab. 3 Formatting options

This symbol identifies particularly important information.

➤ This symbol denotes lists of actions comprising one stage of a task.

Assembly and operating manual Retrofit kit

Further information Further subjects are introduced here.

Assembly and operating manual Retrofit kit

Tab. 4 Technical data EtherNet/IP-Interface

Configuration of the EtherNet/IP-Interface

Pin * Signal Conductor colour Description

Tab. 5 Configuration of the EtherNet/IP-Interface

Tab. 6 EtherNet/IP-Interface - Cabling recommendation

Assembly and operating manual Retrofit kit

3 Safety and Responsibility

Assembly and operating manual Retrofit kit

Disregard of warning instructions can cause serious injuries!

Complying with safety notes

Disregard of safety notes can cause unforeseeable dangers!

When working on live components

4.2 Scope of delivery

This retrofit kit consists of:

Tab. 7 Scope of delivery

Assembly and operating manual Retrofit kit

4.3 Isolating the machine/control from the power supply system

Machine SIGMA AIR MANAGER 4.0

4.4 Removing the EMERGENCY STOP command device

1. Turn the entire contact block to the left.

4.5 Installing the communication module

Assembly and operating manual Retrofit kit

Fig. 1 Insert the communication module

4.5.2 SIGMA AIR MANAGER 4.0

Fig. 2 Insert the communication module

Assembly and operating manual Retrofit kit

4.6 Connecting the controller to the bus system

4.6.1 Laying the bus conduit

Fig. 3 Bus cable conduit with shielding

Assembly and operating manual Retrofit kit

4.6.1.2 SIGMA AIR MANAGER 4.0

4.6.2 Attaching the RJ45-plug

Fig. 4 Strip the isolation from the network cable.

Fig. 5 Inserting the network cable conductors

Assembly and operating manual Retrofit kit

Fig. 6 Positioning the network cable

4. Position the network cable as shown (arrows, see Fig. 6).

Fig. 7 Close the lid of the RJ45 plug.