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Technical Description

SIGMA CONTROL

Process Map V10.23

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

Status: 18.01.2011
File: 7_7055_PA_1023_03E.xls

KAESER KOMPRESSOREN GmbH


96410 Coburg PO Box 2143 GERMANY Tel. +49 (0)9561 6400 Fax +49 (0) 9561 640130
http://www.kaeser.com
SIGMA CONTROL Process Map V10.23 Table 1

1. Master Controller << == Compressor

Register Description Unit min max Format


40021 Alarm 16-1 Table 1.1 binary KM
40022 Alarm 32-17 Table 1.1 binary KM
40023 Alarm 48-33 Table 1.1 binary KM
40024 Alarm 64-49 Table 1.1 binary KM
40025 Alarm 80-65 Table 1.1 binary KM
40026 Warning 16-1 Table 1.2 binary KM
40027 Warning 32-17 Table 1.2 binary KM
40028 Warning 48-33 Table 1.2 binary KM
40029 Warning 64-49 Table 1.2 binary KM
40030 Warning 80-65 Table 1.2 binary KM
40031 Operational message 16-1 Table 1.3 binary KM
40032 Operational message 32-17 Table 1.3 binary KM
40033 Operational message 48-33 Table 1.3 binary KM
40034 Binary signal 1 Table 1.4 binary KM
40035 Binary signal 2 Table 1.5 binary KM
40036 Binary signal 3 Table 1.6 binary KM
40037 Binary signal 4 Table 1.7 binary KM
40038 T10 (coolingwater inlet) 0,1 C -990 +3270 KF
40039 p3 (inlet stage 2) mbar -4000 +21000 KF
40040 p4 (outlet stage 2) mbar -4000 +21000 KF
40041 p5 (air main pressure) mbar -4000 +21000 KF
40042 p6 (oil pressure lubrication) mbar -4000 +21000 KF
40043 p7 (oil pressure control) mbar -4000 +21000 KF
40044 T11(coolingwater outlet intercooler) 0,1 C -990 +3270 KF
40045 T12 (coolingwater outlet aftercooler) 0,1 C -990 +3270 KF
40046 Inputs DI1.3 - DI0.0 binary KM
40047 Inputs DI3.3 - DI2.0 binary KM
40048 Inputs DI5.7 - DI4.0 binary KM
40049 Outputs DO1.7 - DO0.0 binary KM
40050 Outputs DO3.7 - DO2.0 binary KM
40051 System pressure pN external mbar -4000 +21000 KF
40052 Current drive motor starts/h 1 KF

Register 40045/40046:

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SIGMA CONTROL Process Map V10.23 Table 1

1. Master Controller << == Compressor

Register Description Unit Format


40053 Total compressor hours run x 1000 h KF
40054 Total compressor hours run x1 h KF
40055 Hours on load x 1000 h KF
40056 Hours on load x1 h KF
40057 Setpoint pressure pA mbar KF
40058 Setpoint pressure pA switching difference mbar KF
40059 Setpoint pressure pB mbar KF
40060 Setpoint pressure pB switching difference mbar KF
40061 Nominal package pressure mbar KF
40062 Increased cut-out pressure pE mbar KF
40063 Remaining drive motor idle time s KF
40064 Display1 (p) mbar -4000 +21000 KF
40065 Display2 (p) mbar -4000 +21000 KF
40066 Display3 (T) 0,1 C -990 +3270 KF
40067 Display4 (T) 0,1 C -990 +3270 KF
40068 Message header slave (TKS) System 1 KH
40069 T1 (inlet temperature) 0,1 C -990 +3270 KF
40070 T2 (outlet stage 1) 0,1 C -990 +3270 KF
40071 T3 (inlet stage 2) 0,1 C -990 +3270 KF
40072 T4 (outlet stage 2) 0,1 C -990 +3270 KF
40073 T5 (air outlet temperature) 0,1 C -990 +3270 KF
40074 T6 (oil temperature lubrication) 0,1 C -990 +3270 KF
40075 Motor temperature 0,1 C -990 +3270 KF
40076 T13 (coolingwater outlet airend) 0,1 C -990 +3270 KF
40077 T14 (coolingwater outlet) 0,1 C -990 +3270 KF
40078 Current cut-out pressure pA(pB) mbar KF
40079 PLC software status (B&B) KY
40080 Compressor model / L2DP slave address KY
40081 Compressor start delay s KF
40082 Duty cycle permanent 0,1 % KF
40083 Current motor speed 1/min KF
40084 Slave message footer (TFS) System KH

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SIGMA CONTROL Process Map V10.23 Table 1.1

1. Master Controller << == Compressor

Table 1.1 : Alarms (Sigma Control transmit word 0 - 4)

Register Bit No. Sigma Control display Explanation

40021 0 1 p4 rotation dir. Direction of drive motor rotation wrong

40021 1 2 motor T Permissible drive motor temperature


exceeded (PTC or PT100)

40021 2 3 pRV TV check: the opening pressure of the


pressure relief valve was exceeded by 2
bar
40021 3 4 EMERGENCY STOP E M E R G E N C Y S T O P actuated

40021 4 5 I/O periphery Analog input or digital output defective


Question the defect in menu
<status > messages> I/O periphery>
40021 5 6 T3 run

40021 6 7 mains monitor Power supply fault (separate network


monitoring module)

40021 7 8 standstill Alarms during STANDSTILL.


Question the defect in menu
<status > messages> standstill>
40021 8 9 Sigma Control T Controller housing temperature has
exceeded 70C.

40021 9 8 p5>pRV always

40021 10 11 fan M2 I Fan M2: overload trip

40021 11 12 PD valve PD valve


runtime error
wiring error
40021 12 13 motor I Drive motor: overload trip

40021 13 14 fan M3 I Fan M3: Overload trip

40021 14 15 p4 / p3 load

40021 15 16 T11< T10 load

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SIGMA CONTROL Process Map V10.23 Table 1.1

1. Master Controller << == Compressor

Table 1.1 : Alarms (Sigma Control transmit word 0 - 4)

Register Bit No. Sigma Control display Explanation

40022 0 17 p4 idle

40022 1 18 p4 load

40022 2 19 p4 always

40022 3 20 p6 always

40022 4 21 p6 run

40022 5 22 p7 run

40022 6 23 bearing diag. Drive motor bearing defective


Airend bearing defective

40022 7 24 T13 always Coolant temperature in the airend too


high.

40022 8 25 p14 always Pressure in the cooling circuit too high.

40022 9 26 p14 run

40022 10 27 p3 always

40022 11 28 p3 idle

40022 12 29 p3 load

40022 13 30 p3 always

40022 14 31 not assigned

40022 15 32 T14<T12T11Mload

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SIGMA CONTROL Process Map V10.23 Table 1.1

1. Master Controller << == Compressor

Table 1.1 : Alarms (Sigma Control transmit word 0 - 4)

Register Bit No. Sigma Control display Explanation

40023 0 33 ECO-Dr.intercl. Condensate drain faulty


intermediate cooler

40023 1 34 mains cont. on? The mains contactor does not pull in despite
an ON command

40023 2 35 fan M7 I Control cabinet fan M7


Overload trip

40023 3 36 WS valve V14 cool water control valve V14


Timeout exceeded.
End-position switch defective.
40023 4 37 T12<T10 load

40023 5 38 T12 always

40023 6 39 not assigned

40023 7 40 mains cont. off? The mains contactor does not drop out despite
an OFF command

40023 8 41 mains voltage 2nd power supply failure -


the drive motor was shut down

40023 9 42 WS valve V12 cool water control valve V12


Timeout exceeded.
End-position switch defective.
40023 10 43 p4 / p3 always

40023 11 44 p5 < p4 always

40023 12 45 p5 > p4 load

40023 13 46 FC VFD compressor fault (frequency converter)

40023 14 47 RS485 RS485 transmission error


(USS protocol)

40023 15 48 HT cell High tension cell fault in power switching

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SIGMA CONTROL Process Map V10.23 Table 1.1

1. Master Controller << == Compressor

Table 1.1 : Alarms (Sigma Control transmit word 0 - 4)

Register Bit No. Sigma Control display Explanation

40024 0 49 T1 run

40024 1 50 T2 < T1 run

40024 2 51 T2 always

40024 3 52 WS pump heat recovery pump


overload or internal error

40024 4 53 T2T1M always

40024 5 54 T3 run

40024 6 55 Start T3 Intake air temperature too low.

40024 7 56 T4 always

40024 8 57 Model Vague model version

40024 9 58 ECO-Dr.aftercl Condensate drain faulty


Aftercooler

40024 10 59 T5 load

40024 11 60 WS valve V10 cool water control valve V10


Timeout exceeded.
End-position switch defective.
40024 12 61 T6 run

40024 13 62 not assigned

40024 14 63 T10 always

40024 15 64 T10 run

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SIGMA CONTROL Process Map V10.23 Table 1.1

1. Master Controller << == Compressor

Table 1.1 : Alarms (Sigma Control transmit word 0 - 4)

Register Bit No. Sigma Control display Explanation

40025 0 65 T11 always

40025 1 66 T4 < T3 run

40025 2 67 T4T3M always

40025 3 68 T4(T3,p4) load

40025 4 69 T4(T3,p4) load

40025 5 70 T5 always

40025 6 71 not assigned

40025 7 72 not assigned

40025 8 73 ext. message 0 Message text freely definable from SIGMA


Control display

40025 9 74 ext. message 1 Message text freely definable from SIGMA


Control display

40025 10 75 ext. message 2 Message text freely definable from SIGMA


Control display

40025 11 76 ext. message 3 Message text freely definable from SIGMA


Control display

40025 12 77 ext. message 4 Message text freely definable from SIGMA


Control display

40025 13 78 ext. message 5 Message text freely definable from SIGMA


Control display

40025 14 79 p-switch Message text freely definable from SIGMA


Control display

40025 15 80 T-switch Message text freely definable from SIGMA


Control display

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SIGMA CONTROL Process Map V10.23 Table 1.2

1. Master Controller << == Compressor

Table 1.2 : Warning Messages (Sigma Control transmit word 5 - 9)

Register Bit No. Sigma Control display Explanation

40026 0 1 error: System System error: flash memory defective


Question the system error in menu
<status> messages> system>
40026 1 2 motor T Initial warning:
Permissible drive motor temperature reached
soon (PTC or PT100)
40026 2 3 standstill Warning messages during STANDSTILL.
Question the defect in menu
<status > messages> standstill>
40026 3 4 p4 / p3 always

40026 4 5 DHC dryer General warning DHC dryer

40026 5 6 p5 < p4 always

40026 6 7 bearing diag. Drive motor bearing defective


Airend bearing defective

40026 7 8 p5 > p4 load

40026 8 9 error: SMS SMS couldn'd be transmitted

40026 9 10 p4 / p3 load

40026 10 11 oilfilter dp Oil filter clogged

40026 11 12 modem problem

40026 12 13 air filter dp Air filter clogged

40026 13 14 T11 always Coolant temperature in the intermediate


cooler too high.

40026 14 15 bus alarm ProfiBus connection error

40026 15 16 T13 always

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SIGMA CONTROL Process Map V10.23 Table 1.2

1. Master Controller << == Compressor

Table 1.2 : Warning Messages (Sigma Control transmit word 5 - 9)

Register Bit No. Sigma Control display Explanation

40027 0 17 Start T6 Oiltemp. p6 <0C


too low for start of compressor

40027 1 18 not assigned

40027 2 19 p3 always

40027 3 20 p3 idle

40027 4 21 p3 load

40027 5 22 p3 always

40027 6 23 T10<T5T3 run

40027 7 24 T12<T10 load

40027 8 25 T6 run

40027 9 26 T6 run

40027 10 27 p6 always

40027 11 28 p6 run

40027 12 29 p7 run

40027 13 30 p7 run

40027 14 31 T10 always

40027 15 32 T10 run

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SIGMA CONTROL Process Map V10.23 Table 1.2

1. Master Controller << == Compressor

Table 1.2 : Warning Messages (Sigma Control transmit word 5 - 9)

Register Bit No. Sigma Control display Explanation

40028 0 33 p4 idle

40028 1 34 p4 load

40028 2 35 p4 always

40028 3 36 motorstarts /h Drive motor


Number of permissible starts per hour
exceeded
40028 4 37 motorstarts /d Drive motor
Number of permissible starts per day
exceeded
40028 5 38 T1 run

40028 6 39 T2 < T1 run

40028 7 40 T2 always

40028 8 41 mains voltage 1st power supply failure -


compressor was restarted automatically

40028 9 42 T12 always

40028 10 43 ext.load signal? Vague external load signal


Default setpoint for cut-out pressure high was
exceeded.
40028 11 44 T12T11 load

40028 12 45 DO test The "set output" test function is activated

40028 13 46 System press. System pressure too low

40028 14 47 T2T1M always

40028 15 48 T5 load

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SIGMA CONTROL Process Map V10.23 Table 1.2

1. Master Controller << == Compressor

Table 1.2 : Warning Messages (Sigma Control transmit word 5 - 9)

Register Bit No. Sigma Control display Explanation

40029 0 49 Service h A maintenance interval counter has


elapsed
see menu status>messages>service
40029 1 50 T3 run

40029 2 51 T3 > T1 always

40029 3 52 T11< T10 load

40029 4 53 p14 always

40029 5 54 T4 always

40029 6 55 T14<T12T11Mrun

40029 7 56 T4T3M always

40029 8 57 T4(T3,p4) load

40029 9 58 RS485 RS485 transmission error


(Sigma Control - Sigma Control point-to-point
link)
40029 10 59 Start T1 Inlet temperatur T1 (<-20C) and oil
temperatur T6 (<0C) too low for
compressor start
40029 11 60 Start T3 T1 (>-20C) and oiltemp. T6 (>0C) ok.
Start possible if T3 remains <3C
Compressor remains 900s idle max.
40029 12 61 T4(T3,p4) load

40029 13 62 not assigned

40029 14 63 not assigned

40029 15 64 FC AI1 fault VFD compressor:


Pressure sensor at AI1 faulty

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SIGMA CONTROL Process Map V10.23 Table 1.2

1. Master Controller << == Compressor

Table 1.2 : Warning Messages (Sigma Control transmit word 5 - 9)

Register Bit No. Sigma Control display Explanation

40030 0 65 T5 always

40030 1 66 air filter dp Initial warning:


Air filter clogged

40030 2 67 T5 > T1 run

40030 3 68 ECO-Dr.aftercl Condensate drain faulty


Aftercooler

40030 4 69 T5 < T3 load

40030 5 70 T5 > T3 load

40030 6 71 not assigned

40030 7 72 not assigned

40030 8 73 ext. message 0 Message text freely definable from SIGMA


Control display

40030 9 74 ext. message 1 Message text freely definable from SIGMA


Control display

40030 10 75 ext. message 2 Message text freely definable from SIGMA


Control display

40030 11 76 ext. message 3 Message text freely definable from SIGMA


Control display

40030 12 77 ext. message 4 Message text freely definable from SIGMA


Control display

40030 13 78 ext. message 5 Message text freely definable from SIGMA


Control display

40030 14 79 p-switch Message text freely definable from SIGMA


Control display

40030 15 80 T-switch Message text freely definable from SIGMA


Control display

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SIGMA CONTROL Process Map V10.23 Table 1.3

1. Master Controller << == Compressor

Table 1.3 : Operational Messages (Sigma Control transmit word 10 - 12)


not displayed on Sigma Control
Register Bit No. Operational Message Explanation

40031 0 1 bearing maint.h

40031 1 2 not assigned

40031 2 3 not assigned

40031 3 4 not assigned

40031 4 5 not assigned

40031 5 6 not assigned

40031 6 7 check valve

40031 7 8 annual maint

40031 8 9 not assigned

40031 9 oil change h

40031 10 11 oil filter h

40031 11 12 air filter h

40031 12 13 blt.coup.chng.h

40031 13 14 blt.coup.insp.h

40031 14 15 bearingchange h

40031 15 16 electric h

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SIGMA CONTROL Process Map V10.23 Table 1.3

1. Master Controller << == Compressor

Table 1.3 : Operational Messages (Sigma Control transmit word 10 - 12)


not displayed on Sigma Control
Register Bit No. Operational Message Explanation

40032 0 17 ext. message 0 Message text freely definable from SIGMA


Control display

40032 1 18 ext. message 1 Message text freely definable from SIGMA


Control display

40032 2 19 ext. message 2 Message text freely definable from SIGMA


Control display

40032 3 20 ext. message 3 Message text freely definable from SIGMA


Control display

40032 4 21 ext. message 4 Message text freely definable from SIGMA


Control display

40032 5 22 ext. message 5 Message text freely definable from SIGMA


Control display

40032 6 23 p-switch Message text freely definable from SIGMA


Control display

40032 7 24 T-switch Message text freely definable from SIGMA


Control display

40032 8 25 setpointpress.pA System pressure setpoint pA selected for


control of load

40032 9 26 setpointpress.pB System pressure setpoint pB selected for


control of load

40032 10 27 power OFF ON Interface configuration has been changed


Switch off the power supply to accept the
new configuration
40032 11 28 Dyn. Motor T Dynamic control mode:
Drive motor temperature too high for drive
motor stop
40032 12 29 compressor ON Drive motor ready to go on load

40032 13 30 controller ON The controller (Sigma Control) is switched on


by the function key "I"

40032 14 31 not assigned

40032 15 32 not assigned

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SIGMA CONTROL Process Map V10.23 Table 1.3

1. Master Controller << == Compressor

Table 1.3 : Operational Messages (Sigma Control transmit word 10 - 12)


not displayed on Sigma Control
Register Bit No. Operational Message Explanation

40033 0 33 machine report Monthly report of compressor status Activated


only during SMS remote service

40033 1 34 not assigned

40033 2 35 not assigned

40033 3 36 not assigned

40033 4 37 not assigned

40033 5 38 not assigned

40033 6 39 not assigned

40033 7 40 not assigned

40033 8 41 not assigned

40033 9 42 not assigned

40033 10 43 not assigned

40033 11 44 not assigned

40033 12 45 not assigned

40033 13 46 not assigned

40033 14 47 not assigned

40033 15 48 not assigned

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SIGMA CONTROL Process Map V10.23 Table 1.4-1.7

1. Master Controller << == Compressor

Table 1.4 : Transmit bit assignment Register 40034


Binary signals 1

Bit Description Signal "1" Signal "0"


0 Drive motor ready for operation yes no
1 Motor running yes no
2 Load run yes no
3 Idle yes no
4 Local mode ("Remote" key off) remote key off remote key on
5 Controller (Sigma Control) ON yes no
6 Group alarm yes no
7 Group warning yes no
8 Drive motor ready for operation yes no
9 Profibus send+receive yes no
10
11
12
13
14
15

Table 1.5 : Transmit bit assignment Register 40035


Binary signals 2

Bit Description Signal "1" Signal "0"


0 Compressor ON from "I" key only yes no
1 Compressor ON from the "I" key and clock yes no
2
3
4 Compressor ON from the "I" key and ext. contact yes no
5
6 Compressor ON from "I" key and L2DP bus yes no
7 Compressor ON setting (Bit 0 - 6) Master local
8 DUAL control mode DUAL
9 QUADRO control mode QUADRO
10
11 DYNAMIC control mode DYNAMIC
12
13
14
15 Control mode setting (Bit 8 - 14) Master local

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SIGMA CONTROL Process Map V10.23 Table 1.4-1.7

1. Master Controller << == Compressor

Table 1.6 : Transmit bit assignment Register 40036


Binary signals 3

Bit Description Signal "1" Signal "0"


0
1
2
3
4 Load-idle signal from ext. contact yes no
5
6 Load-idle signal from L2DP bus yes no
7 Load control mode setting (Bit 0 - 15) Master local
8 pA permanent yes no
9 pB permanent yes no
10 pA/pB from clock yes no
11 pA/pB from timer yes no
12
13 pA/pB from external contact yes no
14 pA/pB from RS485 interface yes no
15

Table 1.7 : Transmit bit assignment Register 40037


Binary signals 4

Bit Description Signal "1" Signal "0"


0 Clock key not assigned blocked
1 Remote key not assigned blocked
2 Idle key not assigned blocked
3 Automatic start after power supply ON activated
4 Actual pA(pB) pressure control value pN external pN local
5
6
7 Message acknowledgement by master activated blocked
8
9
10
11
12
13
14
15 Transfer of time + date yes no (corrupt)

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