SERVICE MANUAL USA

SIGMA CONTROL
Article---No.: 7.7000.0 / 7.7001.0

Index: 080801
GL---Nr.: BA---7.7000.0---00
Table of Contents
Chapter --- Page

1 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.2 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.3 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 2

3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 3
3.1 Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 3
3.2 Finding the best Type of Pressure Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 4
3.3 DUAL Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 5
3.4 QUADRO Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 6
3.5 VARIO Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 7

4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.1 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.2 Sigma Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.3 Emergency Stop Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 9
4.4 Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 10
4.4.1 Key functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.5 Light Emitting Diodes (LEDs) and Plain Text Display . . . . . . . . . . . . . . . . . . . . . 4 --- 12
4.5.1 LED functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 13
4.5.1.1 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 14
4.6 Switching the Compressor Package On and Off . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.6.1 Switching on locally: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.6.2 Switching off locally: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.6.3 Switching on and off in remote (control center) . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.6.4 Switching on and off with the timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.7 Resetting alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 15
4.8 Resetting Service Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 16
4.9 Alarm and Service Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 17

5 SIGMA CONTROL Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 24

5.1 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 24
5.2 Password Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 25
5.3 Display and Setup Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 25
5.4 Display Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 25

6 Display Level on the Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 28

6.1 Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 28
6.1.1 Display of Status Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 29
6.1.1.1 Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 29
6.1.1.2 Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 30
6.1.1.3 Printout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 31

i
 Table of Contents
Chapter --- Page

6.2 Analog Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 32

6.2.1 Display of Analog Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 33
6.3 Hour Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 34
6.3.1 Display of Hour Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 35
6.4 Service Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 36
6.4.1 Display of Service Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 37
6.4.2 Resetting the service hour counter (maintenance interval counter) . . . . . . . . 6 --- 38

7 Display and Setup Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 40

7.1 Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 40
7.1.1 Display and setup of panel test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 41
7.1.1.1 Lamps test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 41
7.2 Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 42
7.2.1 Display and setup of the timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 43
7.2.2 General description of the timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 44
7.2.2.1 The yearly schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 44
7.2.2.2 The weekly schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 44
7.2.2.3 The daily schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 44
7.3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 48
7.3.1 Display and setup of configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 49
7.3.1.1 Load/save data submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 49
7.3.1.2 General submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 49
7.3.1.3 Password submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 50
7.3.1.4 Pressure settings submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 50
7.3.1.5 Pressure control submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 51
7.3.1.6 Motor temperature submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 51
7.3.1.7 Function selection submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 51
7.4 PG Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 52
7.4.1 Display and setup of PG functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 53
7.5 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 54
7.5.1 Display and setup of interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 55
7.6 History (Event Information Memory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 56
7.7 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 57

ii
Technical Specification

1 Technical Specification

1.1 Power Supply

Power supply for SIGMA CONTROL
Rated voltage . . . . . . . . . . . . . . . . . . . . . . . . 24 V DC (stabilized)
Current . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 A (standard controller)
Current . . . . . . . . . . . . . . . . . . . . . . . . 2.5 A (with expansion card)
Auxiliary voltage for sensors (from the controller)
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 V DC

Note All voltages are generated in the compressor package

1.2 Sensors
Pressure transducer:
Output signal of sensor . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 20 mA
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . two wire
Resistance thermometer
Sensing resistor . . . . . . . . . . . . . . . . . . . . . PT100 to DIN IEC 751
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . two wire

1.3 Hardware
- industrial computer with Intel9 processor
- analog inputs and outputs (0---20mA and PT100)
- 230/115 V relay outputs (floating contacts)
- 24 V common negative rail transistor outputs (short circuit and overload proof)
- 24 V common negative rail digital inputs
- internal undervoltage monitoring of 24 V supply
- internal temperature monitoring
- 3 serial interface:
RS 232 (modem)
RS 485 (master---slave control)
Profibus DP
- real---time clock
- buffer battery for RAM and real---time clock

1.4 Software
- real---time operating system
- soft PLC
- visualization software
- user software

1 --- 1
 Safety

2 Safety Regulations

- Do not pull out or push in components (plugs) on SIGMA CONTROL when the compressor
package is operational. This can cause damage to the controller.
- Do not apply other voltages to the electronic outputs on the output plug pins (i.e. external
feed via wire links, etc.).
- Do not run the compressor package with supplies removed from SIGMA CONTROL as irre-
versible damage could occur (e.g. feed to the digital outputs with no power supply con-
nected to the unit).

2 --- 2
General

3 General

3.1 Brief description

The SIGMA CONTROL electronic controller comprises an industrial computer with an Intel pro-
cessor, a user interface with a background illuminated plain text display, keys, some with inte-
grated LEDs, digital and analog inputs and outputs. Power to the controller is provided by a
24 V DC power supply unit.
The controller is provided with a clear, easily understood user interface that allows call---up of in-
formation or parameter settings to be made:
- LEDs indicate the most important operational states.
- various functions can be keyed.
- the plain text display provides information on current events to the user in the selected lan-
guage
- an event information memory records the last 100 events with date and time, e.g. alarm,
maintenance and operational messages.
SIGMA CONTROL controls, regulates, protects and monitors the compressor package.
The control function provides:
- automatic changeover from load to idle or standstill ensuring optimum utilization of the drive
motor, matched to the user’s current air demand.
- automatic start after a power supply failure.
The protective function provides:
- automatic shutdown at overload, excess pressure, excess temperature, etc., that is, faults
that could cause to damage to the compressor package.
The monitoring function provides:
- punctual maintenance prompts for oil filter, air filter, V---belts, motor bearings, electrical com-
ponents and other internal components. All these functions are monitored by the service
hour counter and maintenance due is displayed as warning or as service messages in the
plain text display.
All important data can be transferred by the integrated software via the Profibus or the RS 232
modem.
All parameters needed to operate KAESER screw compressor and vacuum packages are en-
tered in SIGMA CONTROL. Depending on compressor model they are set up at the factory.
These parameters can be displayed or changed in the software with the help of various menus or
sub ---menus (see also chapter 5).
Parameter settings and changes are entered in the display and setup level of the software menu
after input of a password. At this level the type of drive, type of pressure regulation (Dual, Quadro
or Vario control), the model and basic status according to model can be entered.

3 --- 3
 General

3.2 Finding the best Type of Pressure Regulation

SIGMA CONTROL is provided with various types of regulation. This means that the compressor
package can be operated at maximum efficiency depending on the user’s air demand.
 select the type of regulation in the ‘configuration’ menu.
 reset the ‘utilization from’ parameter in the ‘statistic’ menu.
 Run the compressor package for a longer period of time (at least four weeks, or more).
 Evaluate the ‘utilization from’ parameter.
Repeat this procedure for all types of pressure regulation.

DUAL control QUADRO control VARIO control

Utilization (%)

Note The type of pressure regulation with maximum utilization is the most effi-
cient.

3 --- 4
General

3.3 DUAL Control

p
max
p
Pressure

min

1 2 3 4 5
Load t1 t2
Motor power

Idle
Standstill
Time
In DUAL Control (combined idle and start ---stop) the compressor normally runs in load, idle or
standstill.
The controller regulates the compressor package between load and idle.
If the compressor package runs in idle for longer than the preset period (1) to (2), for example t1
= 6 min, the drive motor is stopped completely (2). When the lower switching point p min (3) is
reached the compressor package is automatically started again. Pressure rises to the upper
switching point p max (4), and the compressor package switches to idle. If the pressure falls again
within a shorter period (4) to (5), for example t2 = 3 min, to p min (5) again then the compressor is
automatically switched from idle to load.

3 --- 5
 General

3.4 QUADRO Control

p
max
Pressure

pmin

Full load
Motor power

Idle
Standstill
1 2 1 3 1 4 1 2 1 4 5 1
Time
tp rise
tp decay

Running period
Idle/
standstill period

Run ---on period

Stop point for the running period or idle / standstill period

p max upper switching point

p min lower switching point

tprise pressure rise time (the time during which the air system pressure rises
from the lower to the upper switching point)
tpdecay pressure decay time (the time during which the air system pressure decays
from the upper to the lower switching point)

Functional description
Two fixed periods --- the running period and idle/standstill period --- are taken as the criterium
for selection of the operating mode of the compressor package when the air system pressure
reaches the upper switching point. These two periods are set according to the maximum per-
missible cut ---in frequency of the drive motor.
The running period starts every time the compressor package is switched on. It lasts as long as
the drive motor runs and stops when the compressor package switches to standstill.
The idle/standstill period starts every time the operating mode changes from full load to idle. It
runs during idle and also when the compressor package is switched to standstill after the idle
period. It stops when the compressor package switches to full load.
Every switching off point is delayed by the run ---on period, during which time the compressor
package vents.
The following switching cycles are possible:
- If the air system pressure decays to the lower switching point, the compressor package
switches to full load (1) irrespective of its previous operating mode. If the drive motor was at
standstill the opening of the inlet valve is delayed to allow an unloaded compressor package
start.

3 --- 6
General

- If the air system pressure rises to the upper switching point and the running period has al-
ready expired, the compressor package is switched off after the run ---on period has expired
(2).
- If the air system pressure rises to the upper switching point before the running period has
expired then the pressure decay time of the previous switching cycle is taken as the criterium
for the selection of the operating mode:
-- If the pressure decay time tp decay was longer than the period set for the idle/standstill
period, the compressor package is switched to standstill after the run ---on period has ex-
pired (3).
-- If the pressure decay time tp decay was shorter than the period set for the idle / standstill
period, the idle mode is selected (4), that is, the inlet valve closes and the compressor is
vented with running motor. When the running period expires the compressor package
switches to standstill only after the run ---on period has also expired (5).

3.5 VARIO Control

Functional Description:
In Vario Control the idle period is automatically extended or shortened depending on the number
of motor starts. The number of motor starts occurring during the preceding hour are recorded
and evaluated.
The higher the motor switching frequency the longer the idle period.
The lower the motor switching frequency the shorter the idle period.

3 --- 7
 General

3 --- 8
Operation

4 Operation

4.1 Control Panel

1 SIGMA CONTROL panel

2 Emergency Stop pushbutton

4.2 Sigma Control

Sigma Control (1) is fitted in the control cabinet in the compressor package and serves as the
control panel. It has 11 keys and 9 LEDs. Operation of the compressor package is determined by
the settings programmed into the controller.

4.3 Emergency Stop Pushbutton

The Emergency Stop pushbutton shuts down the compressor package immediately.
If the Emergency Stop pushbutton is pressed because of an existing hazard, then this must be
eliminated before the compressor package is reset. To accomplish this the following procedure
must be carried out:
 Unlatch the Emergency Stop pushbutton by turning the button in the direction of the arrow.
 Acknowledge the alarm message on Sigma Control by pressing the acknowledge (reset)
key.

4 --- 9
 Operation

4.4 Function Keys

7
11 8
10 9
6
1

5 2

4 3
1 ON key (”I”) 6 Menu select key --- DOWN
2 OFF key (”0”) 7 Men select key --- UP
3 Timer ON/OFF key 8 Escape key
4 Remote ON key 9 Return key
5 Load/idle key 10 Info --- event key
11 Acknowledge (reset) key

4 --- 10
Operation

4.4.1 Key functions

Symbol Item Description Function

1 ON key The compressor is switched on and runs in the prese-
lected operating mode:
local control --- remote control (control centre) --- timer
control
2 OFF key (”0”) The compressor is switched off irrespective of operating
mode.

3 Timer ON/OFF key Pressing the key causes the compressor to be switched
on and off by the integrated timer.
The LED illuminates in timer mode.
4 Remote ON key Pressing the key switches between local and remote con-
trol of the compressor package.
The LED illuminates in remote mode.
5 Load/idle key Pressing the key switches the compressor into idle mode.
Pressing again switches back to the preselected mode.

6 Menu select key --- Ç Menus are scrolled downwards

or
a selected parameter is reduced.
7 Menu select key Å Menus are scrolled upwards
or
a selected parameter is increased.
8 Escape key Pressing the ‘esc’ key:
--- causes a jump back to the next higher level
--- exits change mode without saving the changed param-
eter.
If the “esc” key is held down longer than 10 s a jump back
to the main menus is triggered.
9 Enter key (save) Affects the message in the third line of the display (12):
--- jump into the selected menu
or
--- exits the change mode and saves the changed
parameter.
10 Info --- event key Display of the event information memory:
can be selected in every menu.
The display jumps back to the last menu position with the
‘esc’ key (8).
11 Acknowledge (reset) Acknowledges alarm messages and resets the alarm
key memory (if permitted).

4 --- 11
 Operation

4.5 Light Emitting Diodes (LEDs) and Plain Text Display

13
14 12
15

16 19

17
18

20 21
12 Four ---line display 17 Load LED
13 Alarm LED 18 Idle LED
14 Communication alarm LED 19 Compressor ON LED
15 Warning --- maintenance LED 20 Remote ON LED
16 Power ON LED (to controller) 21 Timer ON LED

4 --- 12
Operation

4.5.1 LED functions

Symbol Item Description Function

•
EDU  & 12 Four---line display Alpha numerical display with 4 lines with 16 characters
(,17 /$67  S see 4.5 (columns) each and green background illumination.
*HVDPW 
/DVW 

13 Alarm LED The red LED flashes if the compressor package is shut
down because of an alarm.
If the alarm is acknowledged with the key (11), the LED
illuminates permanently. It extinguishes when the fault
causing the alarm is remedied and the alarm is reset.
14 Communication The red LED illuminates if communication via the data
alarm LED interface is interrupted.
In remote mode the compressor package is automati-
cally switched to local mode.
If data communication returns the compressor pack-
age is automatically switched to remote mode again.
When the acknowledge key (11) is pressed, the LED
extinguishes if the alarm is no longer present.
15 Warning/mainte- The yellow LED flashes when maintenance is due or if
nance LED there is a maintenance warning.
If the message is acknowledged with the key (11), the
LED illuminates permanently until the maintenance is
completed and (if necessary) the service counter is
reset.
16* Power ON LED The green LED illuminates when power is available
(main disconnect and automatic cutout for the control
transformer are both switched on and 24 V DC is pres-
ent at the output of the power supply unit).
17* Load LED The green LED illuminates when the compressor is
running under load and compressed air is being sup-
plied.
18* Idle LED The green LED illuminates permanently when the
compressor is running but no compressed air is being
supplied. The LED flashes if idle mode is selected with
the idle key (5).
19* Compressor ON LED The compressor is switched on.
LEDs 17 and 18 must be taken into consideration to
determine the operational status of the compressor
package:
* Compressor in If both LEDs (16) and (19) are on-- and both
standby LEDs (17) and (18) are off, the package is at stand-
still and in standby.
It can start at any moment.
20 Remote ON LED The green LED illuminates when the compressor pack-
age is in remote control mode.

21 Timer ON LED The green LED illuminates when the compressor pack-
age is controlled by the timer.

4 --- 13
 Operation

4.5.1.1 Display
The display (12, see chapter 4.5) used for entry and readout of data and is provided with four
lines of 16 characters each.
Example:

 SVL •F 5

$03 PD[
SPD[  SVL
$03 PLQ F

Line 1 -- header
The current air system pressure and airend discharge temperature are displayed in the header.
These values are always shown:
- in the main menu
- in configuration levels, in which parameter changes can be made even if the compressor is
running.
The letters ‘R’, ‘S’ and ‘F’ in column 16 identify internal operational modes of the controller and
are shown for servicing reasons. ‘R’ means, that the controller is in ‘RUN mode’ and is working
perfectly. If the letters ‘S’ or ‘F’ appear, there is an internal fault.
Line 2
The letter ‘i’ always appears in line 2, column 16, if information that can be called up with the info
key ‘i’ is available for text in line 3.
Line 3 -- active line
All actions, such as jumps to submenus, or changes to values are made in line 3. If it is possible
to jump to a submenu or if a parameter can be entered the ‘enter (§)’ sign is displayed in
column 16.
Line 4
The signs ‘D9F’ appear in line 4, column 16 and indicate the direction in which the lines can be
scrolled:
- D --- upwards scroll only
- 9 --- downwards scroll only
- F --- scroll in both directions

4 --- 14
Operation

4.6 Switching the Compressor Package On and Off

Attention! Do not switch the compressor package on and off with the main disconnect.
Always switch on with the ON key (1) and off with the OFF key (2).

4.6.1 Switching on locally:

 Switch on the main disconnect.
The controller runs a selftest. The test sequence can be seen in the display (12). When the
selftest is completed the green LED (16) illuminates permanently.
 Press the ON key (1) --- LED (19) illuminates.
LEDs 17 and 18 must be taken into consideration to determine the operational status of the com-
pressor package:

Attention! If LED (19) is on-- and both LEDs (17) and (18) are off, the compressor is at
standstill and in standby.
The compressor can start at any moment.

4.6.2 Switching off locally:

 Press the OFF key (2) --- LED (19) extinguishes.
 Lock the main disconnect in the ”off” position in accordance with applicable lock out/tag out
procedures (example: OSHA CFR 29 § 1910.147) to ensure the compressor does not restart.

4.6.3 Switching on and off in remote (control center)

Remote control of the compressor package is switched with Remote ON key (4) on the controller.
Control via the floating contacts ‘Cont’ at the binary inputs or via the Profibus ‘Bus’ can be se-
lected in the ‘Configuration ---Function select ---Remote---Select’ menu.

4.6.4 Switching on and off with the timer

If required, the compressor package can be controlled by the timer. The procedure is the same
as for switching on and off locally. Subsequently the periods during which the compressor is to
run or be switched off are entered in the ‘Timer ---> Compressor---ON/OFF’ menu. The Timer ON
key (3) is then pressed.
See chapter 7.2.2 for setting up the timer.

4.7 Resetting alarm messages

If an alarm occurs, the compressor package is shut down automatically and the red LED (13) on
SIGMA CONTROL flashes.
The bottom line of the display (12) shows the current alarm.
A list of possible alarms (faults) that could occur during operation of the compressor package is
given in chapter 4.9.
 Remove the fault.
 Reset the alarm with the reset key (11) --- LED (13) extinguishes.
The compressor package can now be started again.

Attention! If the compressor was shut down with the latched Emergency Stop pushbut-
ton, ensure that the pushbutton is unlatched by turning in the direction of the
arrow before acknowledging the alarm.

4 --- 15
 Operation

4.8 Resetting Service Messages

The yellow LED (15) on SIGMA CONTROL flashes when a maintenance routine is due.
Maintenance due is shown in the display (12).
A list of service messages that can be displayed during operation is given in chapter 4.9).
 Carry out the maintenance.
 Acknowledge the service message with the reset key (11) --- LED (15) extinguishes.

Note A warning is given before maintenance is due. This serves the coordination
of maintenance and service personnel and provision of any service ma-
terials(lubricants, spare parts, etc.) required.

When the associated maintenance is completed the remaining interval (3)

must be reset to the predetermined maintenance interval (4).

 Reset the service hour counter, see chapter 6.4.2.

4 --- 16
Operation

4.9 Alarm and Service Messages

Message2 Type1 Fault Remedy

A 0.6/A 0.7 A The conductor between output 0.6 Check load circuit, wiring and con-
or output 0.7 and load circuit is nections; change defective load cir-
short ---circuited. cuit
A 1.6/A 1.7 A The conductor between output 1.6 Check load circuit, wiring and con-
or output 1.7 and load circuit is nections; change defective load cir-
short ---circuited. cuit
access doors A The access doors were opened du- Close the doors
ring compressor operation.
ADT C W Initial warning: Make sure compressor space
The maximum permissible airend dis- ventilation is sufficient
charge temperature (ADT) will be Keep room temperature below 104•F
reached soon.
Clean cooler
Cooling air exhaust of compressor
package too near the wall
Top ---off the oil
Replace oil filter
ADT A The maximum permissible airend Make sure compressor space
discharge temperature (ADT) was ventilation is sufficient
exceeded. Keep room temperature below 104•F
Clean cooler
Cooling air exhaust of compressor
package too near the wall
Top up the oil
Replace oil filter
AE1 nocont A There is no continuity in the conduc- Check sensor, wiring and connec-
tor between analog input 1 and the tions;
air main pressure transducer. change defective sensor3
AE2 nocont A There is no continuity in the conduc- Check sensor, wiring and connec-
tor between analog input 2 and the tions;
internal pressure transducer. change defective sensor3
AE5 nocont A There is no continuity in the conduc- Check sensor, wiring and connec-
tor between analog input 5 and pres- tions;
sure transducer. change defective sensor3
AE6 nocont A There is no continuity in the conduc- Check sensor, wiring and connec-
tor between analog input 6 and pres- tions;
sure transducer. change defective sensor3
AI 3 nocont A There is no continuity in the conduc- Check sensor, wiring and connec-
tor between analog input 3 and the tions; change defective sensor3
resistance thermometer measuring
the airend discharge temperature.
AI 4 nocont A There is no continuity in the conduc- Check sensor, wiring and connec-
tor between analog input 4 and the tions; change defective sensor3
resistance thermometer measuring
the drive motor temperature.
1 AÆ alarm message WÆ warning message
2 Symbols: high: C / too high: / low: 8 / too low:
3 Contact authorized KAESER agency

4 --- 17
 Operation

Message2 Type1 Fault Remedy

AI 7 nocont A There is no continuity in the conduc- Check sensor, wiring and connec-
tor between analog input 7 and sen- tions; change defective sensor3
sor.
AI 8 nocont A There is no continuity in the conduc- Check sensor, wiring and connec-
tor between analog input 8 and sen- tions; change defective sensor3
sor.
airend rotation A The airend rotors rotate in the wrong Swap phases: power supply phases
direction. L1 and L2 must be changed over
airend T dT/s A The nominal rate of rise of tempera- Check airend and pipes to the air-
ture at the airend discharge (ADT) end 3
was exceeded (temperature measu- Top ---off the oil
red with resistance thermometer).
air filter dp C W Initial warning: Order replacement parts
The air filter is clogged. Prepare maintenance
air filter h C W Initial warning: Order replacement parts
the set service interval for the air filter Prepare maintenance
check will expire soon.
air filter h W The prescribed service interval for Clean air filter cartridge
the air filter has expired. Replace cartridge after fifth cleaning
AMP low W The air system pressure has fallen Check pressure transducer,
below the ‘low’ set value. conductors and connections;
Measured with pressure transducer. Replace defective sensor3
Air demand is too high; check con-
sumers
bearings temp. A Overheating of the bearings on the Grease the drive motor bearings
drive motor shaft. Change bearings when damaged 3
blowoff prot. W Initial warning: Change oil separator cartridge
The set point of the pressure relief Check pressure transducer;
valve on the oil separator will be re- change defective transducer3
ached shortely.
blowoff prot. A The set point of the pressure relief Change oil separator cartridge
valve on the oil separator has been Check transducer, wiring and con-
exceeded. nections;
change defective transducer3
Check minimum pressure/check
valve, control valve, inlet valve;
change defective valve3
Open shut ---off valve in the venting
line
buffer battery W The battery in the controller for reten- Change the controller battery3
tion of data is discharged.
comp. M I S Compressor shut down because of Investigate cause of shutdown;
drive motor overload. Reset reset overload trip
1 AÆ alarm message WÆ warning message
2 Symbols: high: C / too high: / low: 8 / too low:
3 Contact authorized KAESER agency

4 --- 18
Operation

Message2 Type1 Fault Remedy

comp. M T C W Initial warning: Ensure sufficient ventilation
Drive motor very hot Install exhaust fan
(temperature sensed with PTC sen- Drive motor dirty, clean motor
sor and trip).
comp. M T PTC A Drive motor overheating Ensure sufficient ventilation
(temperature sensed with PTC sen- Install exhaust fan
sor and trip). Drive motor dirty, clean motor
comp. M T C W Initial warning: Ensure sufficient ventilation
Drive motor very hot Install exhaust fan
(temperature sensed with PTC sen- Drive motor dirty, clean motor
sor and trip).
comp. M T A Drive motor overheating Ensure sufficient ventilation
(temperature sensed with resistance Install exhaust fan
thermometer). Drive motor dirty, clean motor
configuration W Invalid input. Check last setting
cooling water p A No cooling water pressure. Check throttling valve3
No inlet water pressure
No water shut ---off valve
door open W The mainrtenance doors are open. Close the doors
E0.3 nocont A There is no continuity in the conduc- Check pressure switch, wiring and
tor between input 0.3 and the direc- connections;
tion of rotation pressure switch. change defective pressure switch3
E---comp h W Initial warning: Have electrical components checked
The set service interval for electrical by a qualified electrician
components and electrical installa-
tion check will expire soon.
E---comp h W The set service interval for electrical Have electrical components checked
components and electrical installa- by a trained electrician
tion check has expired.
EMERGENCY A The emergency stop pushbutton was Unlatch and reset pushbutton
STOP depressed.
ext. load fault W Maximum set pressure of compres- Check setting of the external load
sor exceeded during active ’remote’ signal;
mode operation. change defective sensor3
ext. alarm 1 A An alarm message has been recei- Remove fault on external equipment
ved from external equipment connec- Change defective equipment
ted to the controller.
external maint. W A service message has been recei- Carry out maintenace on external
ved from external equipment connec- equipment
ted to the controller.
fan motor 2 A Fan motor 2 shut down because of Investigate cause; reset overload trip
overload.

1 AÆ alarm message WÆ warning message

2 Symbols: high: C / too high: / low: 8 / too low:
3 Contact authorized KAESER agency

4 --- 19
 Operation

Message2 Type1 Fault Remedy

fan motor 3 A Fan motor 3 shut down because of Investigate cause; reset overload trip
overload.

fan motor 4 A Fan motor 4 shut down because of Investigate cause; reset overload trip
overload.

flash memory W Internal controller memory error. Change the controller3

local on BUS W The compressor is centrally con- Press the remote key
trolled via the BUS connection and
was switched to local mode with the
‘remote’ key.
M bearings h C W Initial warning: Order replacement parts
The set service interval for Prepare maintenance
the drive motor shaft bearings will
expire soon.
M bearings h W The set service interval for Carry out maintenance3
replacement of the drive motor shaft Replace defective motor3
bearings has expired.

mains cont. off A The contactor does not open at ‘off’ Check mains contactor and wiring;
command. change defective contactor

mains cont. on A The contactor does not close at ‘on’ Check mains contactor and wiring;
command. change defective contactor

mains voltage A Power supply voltage falls below ra- Use a more stable power supply
ted voltage during compressor start. Use a different motor start system3
max. oil level A Oil level too high. Drain off some oil
min. oil level A Oil level too low. Top ---off the oil
OCO sensor A Oil carry---over sensor defective. Check sensor, wiring and connec-
tions3
Change defective sensor3
oil carry---over C W Initial warning: Check oil carry---over sensor, wiring
The max. oil carry---over value allo- and connections3
wed for pure air will be reached Check the scavenge tube in the oil
soon. separator tank
Check the dirt trap in the scavenge
tube
Check the oil separator cartridge
oil change h C W The set service interval for the oil Order oil
change will expire soon. Prepare maintenance
oil change h W The set service interval for the oil Carry out oil change
change has expired.

oil filter dp C W Initial warning: Clogged oil filter

Oil filter clogged. Prepare maintenance
1 AÆ alarm message WÆ warning message
2 Symbols: high: C / too high: / low: 8 / too low:
3 Contact authorized KAESER agency

4 --- 20
Operation

Message2 Type1 Fault Remedy

oil filter h C W Initial warning: Order replacement parts
The set service interval for the oil fil- Prepare maintenance
ter check will expire soon.
oil filter h W The set service interval for the oil fil- Change the oil filter
ter check has expired.

oil---leak mon. h W Initial warning: Carry out visual check of leak ---oil
The set service interval for the sliding collector bottle
ring seal check will expire soon. Empty leak ---oil collector bottle
oil---leak mon. W The set service interval for the sliding Empty leak ---oil collector bottle
ring seal check has expired. If the oil loss is high, change the
sliding ring seal3
oil T/pressure A No changeover to load when the mi- Check temperature switch, wiring
nimum oil temperature is reached. and connections. Change defective
No changeover to load when the mi- switch
nimum oil pressure is reached. Check pressure switch, wiring and
connections. Change defective
switch
oil too cold W The compressor will not start as oil is Ambient temperature must be higher
too cold. than 38•F
(temperature measurement with PTC Fit auxiliary heating system 3
thermistor sensor and trip device).
ON---OFF /h W The maximum permissible switching Extend idle period
frequency of the drive motor was ex- Increase size of air receiver
ceeded during the last 60 minutes.
Check pressure transducer;
change defective transducer3
Increase diameter of pipework
between compressor and air receiver
ON---OFF /day W The maximum permissible daily Extend idle period
switching frequency of the drive mo- Increase size of air receiver
tor was exceeded during the last 24
hours. Check pressure transducer;
change defective transducer3
Increase diameter of pipework be-
tween compressor and air receiver
PDT A Package discharge temperature be- Two ---speed cooling fan running at
low permissible value. high speed only --- switch to lower
speed

PDT A Package discharge temperature Two ---speed cooling fan running at

above permissible value. low speed only --- switch to higher
speed
Check fan motor3
Check sensor, regulator3
Check frequency converter3
Clean cooler
Top ---off the oil
1 AÆ alarm message WÆ warning message
2 Symbols: high: C / too high: / low: 8 / too low:
3 Contact authorized KAESER agency

4 --- 21
 Operation

Message2 Type1 Fault Remedy

PDT 8 W Initial warning: Two ---speed cooling fan running at
Package discharge temperature is high speed only --- switch to lower
too low. speed
PDT C W Initial warning: Two ---speed cooling fan running at
Package discharge temperature too low speed only --- switch to higher
high. speed
Check fan motor3
Clean the cooler
Top ---off the oil
Profibus L2DP The bus connection via the Profi- Check bus wiring and plug, check
bus---DP interface is interrupted. interface configuration3
RAM memory W Internal RAM memory defective. Check controller3
separator dp C W Initial warning: Order replacement parts
The oil separator is clogged. Prepare maintenance
separator h C W Initial warning: Order replacement parts
The set service interval for the oil Prepare maintenance
separator check expire soon.
separator h W The set service interval for the oil Change oil separator cartridge
separator check has expired.

separator T A The permissible air temperature at Check trip device at oil separator air
the oil separator discharge was ex- discharge
ceeded Check sensor and wiring of trip
(temperature measurement with PTC device, change defective trip device
thermistor sensor and trip device).
sh.cct AI3 A Short circuit in cable between ana- Check sensor, wiring and connec-
logue input 3 and airend discharge tions;
temperature sensor. change defective sensor3
sh.cct AI4 A Short circuit in cable between ana- Check sensor, wiring and connec-
logue input 4 and a sensor. tions;
change defective sensor3
sh.cct AI7 A Short circuit in cable between ana- Check sensor, wiring and connec-
logue input 7 and a sensor. tions;
change defective sensor3
sh.cct AI8 A Short circuit in cable between ana- Check sensor, wiring and connec-
logue input 8 and drive motor tem- tions;
perature sensor. change defective sensor3
start voltage 8 W First power supply failure during Check wiring of power supply con-
compressor start. tactor
Use a more stable power supply
start voltage A Second power supply failure during Check wiring of power supply con-
compressor start. tactor
Use a more stable power supply
set output! The ‘ON’ key was pressed when the Leave the ‘set output’ test mode
controller was in test mode ‘set out-
put’ (PG functions).
1 AÆ alarm message WÆ warning message
2 Symbols: high: C / too high: / low: 8 / too low:
3 Contact authorized KAESER agency

4 --- 22
Operation

Message2 Type1 Fault Remedy

temperature min. A The air temperature at the airend dis- Ambient temperature must be higher
charge (ADT) needed to start the than 38•F
compressor is too low (temperature Fit auxiliary heating system 3
measured with resistance thermome-
ter).
TRAP Interrupt C

V---belts h W Initial warning: Carry out visual check

The set service interval for the V--- Order replacement parts
belts check will expire soon.
Prepare service routine
V---belts h W The set service interval for the V--- Change and tension the V---belts
belts check has expired.

V---belt tens. h C W Initial warning: Carry out visual check

The set service interval for the V---belt Prepare service routine
tension check will expire soon.
V---belt tens. h W The set service interval for the V---belt Tension the V---belts, replace, if
tension check has expired. required
V---belt tension W The V---belt tension is too low. Tension the V---belts
The V---belt tension is checked using
a limit switch.
1 AÆ alarm message WÆ warning message
2 Symbols: high: C / too high: / low: 8 / too low:
3 Contact authorized KAESER agency

4 --- 23
 Menus --- General

5 SIGMA CONTROL Menus

When the compressor package is switched on details of the software installed are initially dis-
played on the Sigma Control. The software is then downloaded and the main menu appears in
the display.

5.1 Main menu

The main menu shows the current air main pressure, the airend discharge temperature, the type
of controller (via ON/OFF key, timer or remote operation), total hours run and load hours.

 SVL •F 5
2 21NH\ORDGS
3 WRWDO K
4 ORDG K F

1 Display of current outlet pressure and airend discharge temperature

2 Operational message (current state of the compressor package)
3 Total number of operating hours
3 Number of hours on load
The following information can be displayed in the second line (operational messages):

e.g. ON---key/load ---p1

pressure regulation p1 pressure range p1 (air main press.)
p2 pressure range p2 (air main press.)
RC Remote Contact (external load
contact)
RB Remote Bus (external load signal)
state of air supplies
idle in idle run
load on load
off standby: motor off, the motor starts
when air is demanded
change compressor state with:
Key ‘O’ and ‘I’ ---key on unit front
timer internal timer
RC Remote Contact
RB Remote Bus
state of compressor ON compressor running
OFF compressor stopped
alarm a malfunction exists

The ‘esc’ key allows a jump ---back to the main menu from all other menus and submenus.

5 --- 24
Menus --- General

5.2 Password Protection

Authority to access the menus and submenus is divided into several levels and protected by
password.
When the controller is switched on the lowest level of access (level 0) is started. There are four
levels available for the customer. The password for level 4 is to be found in the documents sup-
plied with the compressor package or can be obtained from an authorized Kaeser distributor.
In level 4 the customer/user can create passwords for the first three levels (level 1 to level 3) and
thus allow access to authorized persons. See chapter 7.3.1.3 for entry of the password.

5.3 Display and Setup Level

If the main menu is scrolled with the ‘D’ key, all menus in the display and setting level in which
programmed parameters can be changed are shown. These menus are:
- panel test
- timer
- configuration
- PG functions
- interfaces
- event information

5.4 Display Level

If the main menu is scrolled with the ‘9’ key, all menus in the display level in which programmed
parameters can only be read are shown. These menus are:
- status data
- measured data
- hour counter
- service hours
See following pages for overall list of menus and submenus in the display and setup level.
For an explanation of the abbreviated messages in the display, see list of abbreviations in
chapter 7.7).

5 --- 25
5 --- 26
Test menu Version menu
System check Version display automatiic
Hardware version
VIN Op. system version

L
Compressor version
5 esc
sec.

Panel test Timer Configuration PG functions Interfaces History (event info)

§
§
§
§
§

esc esc esc esc esc esc

--- Lamps test --- Compressor ON/OFF --- Data backup --- Input/output status --- RS 232 --- The last 100 events
--- Dry contact --- Compressor model --- Set outputs --- RS485 are stored and
--- Sequencer --- General --- Profibus displayed
--- Print --- Password

§
--- Pressure settings §

§
--- Type of press. control
--- Time values
--- Airend discharge temp.
--- Drive motor temp.
--- Function selection
--- Power switching

§
110p si 185 F Display and setup level

•
ON ---key /load ---p1
total 13000h
Display level
load 12034h

Main menu
Display and Setup Level
Menus --- General
 Display Level
110p si 185 F Display and setup level

•
ON ---key /load ---p1
total 13000h Display level
load 12034h

Main menu
Menus --- General

Status data Analog data Hour counter Service hours

§
§
§
§

esc esc esc

Messages Statistics Print --- Total hours --- Oil filter

--- Air main pressure --- Load hours --- Oil separator
--- Cut ---out pressure --- Total utilization --- Air filter
--- Airend discharge temp --- Number of motor starts --- Oil filling
--- Differential pressure --- Motor hours --- V---belts
across oil separator --- Airend hours --- V---belt tension

§
§

§
--- Internal pressure --- Sigma hours --- Motor bearing change
esc esc --- Motor temperatur --- Valve operations --- Electrical components
--- Airend discharge temp. --- Regulating hours
--- Utilization display before start
All alarm and service --- Settings
--- Differential pressure
§
§

messages are dis- --- Air main pressure --- Message memory
--- Internal pressure across oil filter
played --- Messages
--- Motor starts/time --- Air outlet temperature
--- Messages via timer
--- Last run on load --- Analog inputs
--- lLast run in idle --- Analog output
--- Last motor off --- Airend discharge
temperature rise Info key
esc esc Additional information (help) or the event information memory
L

(history)
Return key
§

Initiates jump to next submenu, enters parameters and

passwords

Menu selection key --- UP

§
Scrolls display text downwards
esc
Menu selection key --- DOWN
Scrolls display text upwards

Escape key
esc Returns to next higher level and to the main menu

5 --- 27
 Display Level

6 Display Level on the Control Panel

Data on status and measurements, the hour counter and service hours are displayed at the dis-
play level

6.1 Status Data

Status data

§
HVF

Messages Statistics Printout

§ § §
HVF HVF HVF

--- All operational, --- Display of utilization --- Parameters

alarm and service --- Air main pressure --- Message memory
messages are --- Internal pressure --- Messages
displayed --- Motor starts/time --- Messages via
--- Last run on load timer
--- Last run in idle
--- Last motor stop
HVF --- Last alarm HVF
--- Last service
--- Alarms activated
--- Maintenance due
--- Operational messages
activated
§
HVF

6 --- 28
Display Level

6.1.1 Display of Status Data

 Press the 9 key until ‘status data’ appears in the third line of the display.
 Press the § key.
Three further readouts are displayed:
- messages
- statistics
- printout

6.1.1.1 Messages
 Activate messages menu by pressing the § key.
All current operational, alarm and service messages are displayed,
for example:
- controller ON
- compressor ON
- ready to switch on
- p regn. p1 (pressure regulation)
- alarm air filter
- maintenance air filter
- maintenance V---belt tension
- maintenance oil separator
etc.
The following readouts are possible,
for example:

 SVL •F 5

2 : & 4  4
3  5
9EHOW WHQVLRQ 6

1 Current discharge pressure and airend discharge temperature

2 Type of message
W Warning/service message
A Alarm message
B Operational message
3 Message status
C Message activated, not acknowledged
G message (alarm) cleared, reset
Q Message (alarm) acknowledged
4 Time of occurrence of service, alarm or operational message
5 Date of occurrence of service, alarm or operational message
6 Activated service, alarm or operational message

6 --- 29
 Display Level

6.1.1.2 Statistics
 Activate display of statistics menu by pressing the § key.
Evaluated statistics are displayed,
for example:
- utilization
- minimum and maximum air main pressure (pmin or pmax)
- minimum and maximum internal pressure (pmin or Pmax)
- number of motor starts
- last run on load, last run in idle
- last alarm or service
- activated alarm, service and operational messages
The following readouts are possible,
for example:

 SVL •F 5

2
$03 PD[
3 SPD[ SVL
4 $03 PLQ F

1 Current discharge pressure and airend discharge temperature

2 Description of statistic
3 Value (percent, minimum or maximum value)
4 Next value

These statistics can be reset individually.

 Select submenu reset: no of the individual statistic by pressing the § key.
 Select the reset: yes with the D key.
 Press the § key.
 Exit the submenu with the ‘esc’ key.

6 --- 30
Display Level

6.1.1.3 Printout
 Activate the printout menu by pressing the § key.
All messages to be printed are displayed,
for example:
- settings
- message memory
- current messages
- messages via timer
The following readouts are possible,
for example

 SVL •F 5

2 VHWWLQJV
3 SULQW Q
4 PVJ PHPRU\ F

1 Current discharge pressure and airend discharge temperature

2 Message to be printed
3 Activation of printout
4 Next printout

6 --- 31
 Display Level

6.2 Analog Data

Analog data

--- Air main pressure

--- Cut ---out pressure
--- Airend discharge temp
--- Differential pressure
across oil separator
--- Internal pressure
--- Motor temperature
--- Airend discharge temp.
before start
--- Differential pressure
across oil filter
--- Air outlet temperature
--- Analog inputs
--- Analog output
--- Airend discharge
temperature rise

6 --- 32
Display Level

6.2.1 Display of Analog Data

 Press the 9 key until ‘analog data’ appears in the third line of the display.
 Press the § key.
All analog data of the compressor package are displayed,
for example:
- current air main pressure
- current cut ---out pressure
- airend discharge temperature (ADT)
- differential pressure across oil separator (dp)
- internal pressure (pi)
- motor temperature
- airend discharge temperature before start
- differential pressure across oil filter (dp)
- air outlet temperature
- analog inputs 5, 6, 7 and 8
- analog output
- airend discharge temperature rise (dT/s)
The following readouts are possible,
for example:

 SVL •F 5

2 $03
3 S  SVL
4 WHPSHUDWXUH F

1 Current discharge pressure and airend discharge temperature

2 Analog value
3 Value
4 Next analog value

6 --- 33
 Display Level

6.3 Hour Counter

Hour counter

§
HVF

--- Total hours

--- Load hours
--- Total utilization
--- Number of motor starts
--- Motor hours
--- Airend hours
--- Sigma hours
--- Valve operations
--- Regulating hours

6 --- 34
Display Level

6.3.1 Display of Hour Counter

 Press the 9 key until ‘hour counter’ appears in the third line of the display.
 Press the § key.
All hours run are displayed, such as
- total hours
- load hours
- total utilization
- number of motor starts
- motor hours
- airend hours
- Sigma hours
- load valve ON
- regulator hours
The following readouts are possible,
for example:

110 SVL •F 5

2 WRWDO KRXUV
3  K
4 ORDG KRXUV F

1 Current discharge pressure and airend discharge temperature

2 Counter
3 Count value
4 Next counter

6 --- 35
 Display Level

6.4 Service Hours

Service hours

§
HVF

--- Oil filter

--- Oil separator
--- Air filter
--- Oil filling
--- V---belts
--- V---belt tension
--- Motor bearings
--- Electrical components

6 --- 36
Display Level

6.4.1 Display of Service Hours

 Press the 9 key until ‘service hours’ appears in the third line of the display.
 Press the § key.
All service hours until next service are displayed,
for example:
- oil filter
- oil separator
- air filter
- oil filling
- V---belts
- V---belt tension
- motor bearings
- electrical components (E---comp.:)
The following readouts are possible,
for example:

 SVL •F 5

2 RLO ILOWHU
4 K K 3
5 RLO VHSDUDWRU F

1 Current discharge pressure and airend discharge temperature

2 Service hour counter
3 Remaining time to next service
4 Service interval
5 Next service hour counter

6 --- 37
 Display Level

6.4.2 Resetting the service hour counter (maintenance interval counter)

Attention! When the corresponding maintenance has been carried out, reset the re-
maining time (3) to the prescribed service interval (4).

The remaining times of the individual service hour counters can be reset individually.
 Press the 9 key until the required service hour counter (e.g. oil filter) appears in the third line
of the display,
for example:

 SVL •F 5

RLO ILOWHU §
K K F

 Press the § key.

 SVL •F 5

RLO ILOWHU
UHVHW Q §
RLO ILOWHU F

 Activate submenu reset n for the corresponding service by pressing the § key.
 set reset y with the D key.
 Press the § key.
Reset the remaining time to the prescribed value.
 Exit the submenu with the ‘esc’ key.
Initial warning intervals can be changed in the above submenu.

6 --- 38
Display Level

6 --- 39
 Display and Setup Level

7 Display and Setup Level

In the display and setup level the panel test, timer configuration, PG functions, interfaces and his-
tory (event information memory) are displayed and their settings can be changed.

7.1 Panel Test

Panel test

§
HVF

--- Lamps test

HVF

7 --- 40
Display and Setup Level

7.1.1 Display and setup of panel test

 Press the D until ‘panel test’ appears in the third line of the display.
 Press the § key.
The following display appears:

 SVL •F 5

2 ODPSV WHVW
3 WHVW Q §
F

1 Current discharge pressure and airend discharge temperature

2 Test to be carried out
3 Activation of test

7.1.1.1 Lamps test

 Press the § key.
 Configuration can be changed from ‘test n’ to ‘test y’ by pressing the D key.
 Press the § key.
@ All LEDs on the control panel should flash.
The display jumps back to ‘test n’ automatically after 10 seconds.

7 --- 41
 Display and Setup Level

7.2 Timer

Timer

§
HVF

--- Compressor ON/OFF

--- Dry contact
--- Sequencer
--- Print

§
HVF

7 --- 42
Display and Setup Level

7.2.1 Display and setup of the timer

 Press the D key until ‘timer’ appears in the third line of the display.
 Press the § key.
All settings affecting the timer can be displayed and changed.
Example:
- Compressor ON/OFF
- Dry contact
- Sequencer
- Printer
The following readouts are possible,
for example:

 SVL •F 5

FRPS 212)) 1 Current discharge pressure and
airend discharge temperature
2 GU\ FRQWDFW §
2 Various timer channels
VHTXHQFHU F

 Scroll the menus up or down with the D9 keys.

 Scroll the timer channel to be changed into the third line and activate with the § key.
For example ‘compressor ON/OFF’ (timer channel for the compressor package):

1 Current discharge pressure and

 SVL •F 5
airend discharge temperature
2 212)) GD\ 2 Daily schedule
3 212)) ZHHN § 3 Weekly schedule
4 212)) \HDU F 4 Yearly schedule

 Scroll the menus up or down with the D9 keys.

 Scroll the schedule to be changed into the third line and activate with the § key.
For example: compressor daily schedule (‘ON/OFF day’)

1
1 Current discharge pressure and
airend discharge temperature
 SVL •F 5 2 First time period
2 212)) GD\  3 Cut ---in point of the compressor in
hours and minutes
3 21  §
4 2))  F
4 Cut ---out point of the compressor in
hours and minutes

 The on and off times of the compressor can be changed by pressing the § key.

7 --- 43
 Display and Setup Level

7.2.2 General description of the timer

The timer has four channels that are allocated fixed tasks:
- Channel 1 (compressor ON/OFF) switches the compressor package on and off.
- Channel 2 (dry contact) can be parameterized to an output A0.3.....A0.4 and is available for
any external task.
- Channel 3 (sequencer) controls the sequencer. The sequencer rotates two compressors that
are operated in pressure---cascade control between duty and standby within set time
periods.
- Channel 4 (printout) controls a timed printout of service and alarm messages if the timed
printout option via the timer is selected in the ‘print’ menu.
Four time periods for each day, each week and each year can be programmed for each channel.
A yearly schedule (month, day of the month, hour, minute), a weekly schedule (weekday, hour,
minute) and a daily schedule (hour, minute) is available to the user for the input of switching
points. The switching points in the yearly and weekly schedules are entered as periods (with start
and end) and the switching points in the daily schedule are entered as points in time.

7.2.2.1 The yearly schedule

An interruption of the cyclic daily schedule may be required if, for example, a public holiday oc-
curs on a working day, or if a different schedule is required during holiday periods. These periods
can be started and ended at any convenient date and time. If no further such period is scheduled
to follow the end of the first period, the program returns to the weekly schedule. As it is not poss-
ible to enter the year in the periods, they are not unique, but repeat every year if they are not de-
leted. The following conditions must be fulfilled to enable a correctly scheduled sequence of pro-
grammed periods:
- The periods entered must contain all information required (start date, start time, end date,
end time, required operational state).

7.2.2.2 The weekly schedule

All periods that are repeated during a weekly cycle are entered in the weekly schedule. If the
overriding yearly schedule is not active, a current period in the weekly schedule can be activated.
The following conditions must must be fulfilled:
- The periods entered must contain all information required (start weekday, start time, end
weekday, end time, required operational state).

7.2.2.3 The daily schedule

If the overriding yearly or weekly schedule is not active, the daily schedule is effective. The pro-
grammed operational state of a switching point remains active until it is overridden by the oper-
ational state of a following switching point or the weekly/yearly schedule activates.
- Only the switching points must entered.

Attention! When the ‘timer’ key is pressed (3, see chapter 4.4) only the command from
the timer in channel 1 (compressor ON/OFF) is used to control the com-
pressor package. The timer function itself is not influenced, that is, the timer
runs permanently in the background.

7 --- 44
Display and Setup Level

Example:
It is intended to run a compressor from 05:30 to 12:00 and from 13:00 to 21:10 daily.
It is shut down at weekends from 14:00 Fridays to 05:30 Mondays, during company holidays
from 11 July to 26 July, and over the New Year from 12:00 on December 24 to 05:30 on January
1.
Menu: timer -- compressor ON/OFF -- ON/OFF day:
- ON/OFF day 1
ON: 05:30:00
OFF: 12:00::00
- ON/OFF day 2
ON: 13:00:00
OFF: 21:10::00
Enter ‘0’ for day 3 and day 4 switching points.
Menu: timer -- compressor ON/OFF -- ON/OFF week:
- ON/OFF week 1
1: Friday
1: 14:00:00

1 : Sunday
1 : 23:59:59

1: comp. OFF

- ON/OFF week 2
2: Monday
2: 00:00:00

2 : Monday
2 : 05:30:00

2: comp. OFF
Enter ‘0’ for week 3 and week 4 switching points.
Menu: timer -- compressor ON/OFF -- ON/OFF year:
- ON/OFF year 1
1: 11.07.# #
1: 00:00:00

1 : 26.07.# #
1 : 23:59:59

1: comp. OFF

- ON/OFF year 2
2: 24.12.# #
2: 12:00:00

2 : 31.12.# #
2 : 23:59:59

2: compr. OFF

7 --- 45
 Display and Setup Level

- ON/OFF year 3
3: 01.01.# #
3: 00:00:00

3 : 02.01.# #
3 : 05:30:00

3: comp. OFF
Enter ‘0’ for year 4.

Note ‘> ’ is the start of the period

‘< ’ is the end of the period
‘# ’ without meaning

7 --- 46
Display and Setup Level

7 --- 47
 Display and Setup Level

7.3 Configuration

Configuration

§
HVF

--- Load/save data

--- General
--- Password
--- Pressure settings
--- Type of press. control
--- Timing values
--- Drive motor temp.
--- Function selection

7 --- 48
Display and Setup Level

7.3.1 Display and setup of configuration

 Press the D key until ‘configuration’ appears in the third line of the display.
 Press the § key.
All settings affecting configuration can be displayed and changed,
for example:
- load/save data (from level 6) - Pressure control (p control)
- General - Timing values (from level 6)
- Password - Motor temperature
- Pressure settings - Function selection
The following readouts are possible,
for example:

 SVL •F 5

ORDGVDYH GDWD 1 Current discharge pressure and
2 JHQHUDO § airend discharge temperature
SDVVZRUG F 2 Display of the various menus

 Scroll the menus up or down with the D9 keys.

 Scroll the menu required into the third line and activate with the § key.

7.3.1.1 Load/save data submenu

Example:

1 Current discharge pressure and

airend discharge temperature
 SVL •F 5 2 Load/save setup data
2 VHWXS GDWD 3 Save prompt
3 VDYH " Q § 4 Load prompt
4 ORDG " Q F

 Scroll the menus up or down with the D9 keys.

 Scroll the function required to the third line of the display, activate with the § key and change
the ‘n’ setting to ‘y’.

7.3.1.2 General submenu

The following parameters are displayed and can be changed:
- Serial number (display only)
- Weekday
- Date

7 --- 49
 Display and Setup Level

- Time
- Summer/Winter
- Language
- Date format (dd.mm.yy)
- Time format (hh:mm:ss)
- Unit of pressure (bar, hPa, MPa, psi, atü)
- Unit of temperature (EC, K, EF)
- Motor starts count: per day
- Inhibit keys
- Preselection keys: idle/remote/timer

7.3.1.3 Password submenu

Staggered access to the functions of the menu tree is possible with the help of a password.
When the password menu is selected the cursor blinks over the place at the extreme left. All the
available characters can now be scrolled with the UP/DOWN keys. The required character is se-
lected with the § key and the cursor moves one place to the right. This procedure is repeated
until all places are occupied by the password. The password is checked by pressing the § key, if
it is correct the corresponding level (e.g. level 5) is displayed. Subsequently the password menu
is exited with the ‘esc’ key.
 Press the D key until ‘password’ appears in the third line of the display.
 Press the § key.
 Enter 5---character password with the help of the D9 keys.
 Press the § key.

7.3.1.4 Pressure settings submenu

- AMP (air system pressure)
This submenu is subdivided into:
- AMP p1
- AMP low
AMP p1
 Press the 9 key until the ‘AMP p1’ appears in the third line of the display and the press the §
key.
The required air system pressure is displayed. The minimum pressure is computed by the con-
troller.
AMP low
If the pressure falls below a set value a warning message is displayed but only if the ‘AMP low’
function is activated.
To activate AMP low:
 Press the 9 key until the ‘AMP low’ appears in the second line of the display and ‘activate’
appears in the third line.
 Press the § key.
 Change ‘n’ to ‘y’ with the 9 key and enter with § .

7 --- 50
Display and Setup Level

7.3.1.5 Pressure control submenu

The following types of control can be set:
- Dual control
- Quadro control
- Vario control
To activate/deactivate type of pressure control:
 Press the 9 key until the required type of pressure control appears in the third line of the dis-
play.
 Press the § key.
 Change ‘n’ to ‘y’ with the D9 keys and enter with § .

7.3.1.6 Motor temperature submenu

This submenu contains the preset motor temperature above which a warning message is dis-
played.

7.3.1.7 Function selection submenu

The following functions can be displayed or set:
- DO standard (standard digital output)
- remote select (display only)
- automatic restart
- pressure increase (display only)
- external load signal (display only)

7 --- 51
 Display and Setup Level

7.4 PG Functions

PG functions

§
HVF

--- I/O status

--- Set outputs

7 --- 52
Display and Setup Level

7.4.1 Display and setup of PG functions

 Press the D key until ‘PG functions’ (Programming functions) appears in the third line of the
display.
 Press the § key.
The current signal states of the digital inputs and outputs are displayed.
The following readouts are possible,
for example:

 SVL •F 5

§
2 ,2 VWDWXV
F

1 Current discharge pressure and airend discharge temperature

2 Activate status of digital inputs and outputs

7 --- 53
 Display and Setup Level

7.5 Interfaces

Interfaces

§
HVF

--- RS 232
--- RS485
--- Profibus

7 --- 54
Display and Setup Level

7.5.1 Display and setup of interfaces

 Press the D key until ‘interfaces’ appears in the third line of the display.
 Press the § key.
- The RS232 interface allows data transfer to/from the programming computer (AS511),
modem, printer, etc.
- The RS485 interface allows data transfer between two sequenced compressors (master/
slave).
- The Profibus---DP interface allows integration into a master control system (control centre,
PC, PLC).

 SVL •F 5

2 56 [§
56 [8

1 Current discharge pressure and airend discharge temperature

2 List of interfaces

7 --- 55
 Display and Setup Level

7.6 History (Event Information Memory)

History (event info)

§
HVF

--- The last 100 events

are stored and
displayed

7 --- 56
 Display and Setup Level

7.7 List of Abbreviations

(n) compressor ”n” (where ”n” is F FAULT
a number) FC frequency converter
(n+ 1) compressor ”n+ 1”(the next fil. filter
number) Fr Friday
A alarm or alarm message funct. function
act. active G fault rectified, reset alarm
AD airend discharge grl. general
ADA air demand analysis grp. group
add. additional h hours
addr. address H or hys. hysteresis
ADP airend discharge pressure hi high
ADT airend discharge tempera- HT high tension
ture I input or current
AI analog input ID identity
AM air system inh. inhibit
AMC air system charging init. initial
AMP air system pressure IS interlock switch
an . analog L/i load/idle
AO analog output lo low
auto. automatic M motor
avail. available, already existing maint. maintenance
B operational message max. maximum
bitad. bit address min minute
BP back pressure min. minimum
bytad. byte address modcontrol modulation control
C alarm activated, Mo Monday
not yet acknowledged mon. monitor
c/o changeover MOPS motor overload protection
char. character switch
comp. compressor msg. message
config. configuration mxx maximum recorded or
conn. connection highest reached
cont. contactor n no (negative answer to a
COP cut ---off pressure question)
corr. correction negn. negation
D data bits no. number
DC Dual Control nocont. no continuity
dbits. data bits NU not used
del. delay O output
DI digital input occu. occupancy
dig. digital OCO oil carry---over
DO digital output op. operation
DOL direct ---online opl. operational
DoR direction of rotation optl. optional
dp delta p OS oil separator
(pressure differential or drop) P parity
dT delta T p pressure, usually airmain
(temperature differential or pressure
drop) pA pressure alarm
dtrans. data transfer PDT package discharge
E---comp. electrical components temperature
EM---STOP EMERGENCY STOP param. parameter
ena. enable pd period
equip. equipment PG programming function
ext. external

7 --- 57
Display and Setup Level

pi internal pressure Sa Saturday

(in oil separator) seqr. sequencer
PL partial load sh.cct short circuit
PLV partial load valve sig. signal
prot. protection sp. speed
psel. pre---select st. start
pt low pressure Su Sunday
PS power switching sw. switch
PU power unit t time value
PW pressure warning T temperature
PWH pressure warning hysteresis TA temperature alarm
Q alarm acknowledged tdel. time delay
QC quadro control tens. tension
R RUN Th Thursday
RAM random access memory util. utilization
RB remote bus UV unloading valve
RC remote contact V rate of rise or fall
red. reduction VC Vario control
ref. reference W warning, or maintenance
regn. regulation message
RS rated speed We Wednesday
S STOP or stop bit y yes
s or sec. second(s) Y---delta star---delta (wye---delta)
S/N serial number

7 --- 58