Assembly and operating manual

Retrofit kit

Modbus TCP
No.: 7_5250_01950 04 E

Manufacturer:

KAESER KOMPRESSOREN SE
96410 Coburg PO Box 2143 GERMANY Tel. +49-(0)9561-6400 Fax +49-(0)9561-640130
http://www.kaeser.com
/KKW/SSC 2.00 en IBA-7_5250_01950
/KKW/SSC 2.04
20140902 140136
 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 Technical specification ..................................................................................................... 3
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 4
4 Installation
4.1 Ensuring safety ................................................................................................................ 5
4.2 Scope of delivery .............................................................................................................. 5
4.3 Isolating the machine from the power supply system ...................................................... 6
4.4 Removing the EMERGENCY STOP command device .................................................... 6
4.5 Installing the communication module ............................................................................... 6
4.6 Connecting SIGMA CONTROL 2 to the bus system ........................................................ 7
4.6.1 Laying the bus conduit ........................................................................................ 7
4.6.2 Installing the RJ45 plug ...................................................................................... 8
4.6.3 Connecting the bus plug to the SIGMA CONTROL 2 ........................................ 10
4.7 Installing the EMERGENCY STOP command device ...................................................... 10
5 Initial Start-up
5.1 Switching the machine on ................................................................................................ 11
5.2 Testing the EMERGENCY OFF command device ........................................................... 11
5.3 Activating the communication module .............................................................................. 11
5.3.1 Reaction in a bus fault ........................................................................................ 12
5.4 Activating the remote control ............................................................................................ 12
6 Operation
6.1 Displays on the communication module ........................................................................... 13
6.2 Displays at SIGMA CONTROL 2 .................................................................................... 13
7 Fault Recognition and Rectification
7.1 Fault-finding and rectification ........................................................................................... 14

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 Contents

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ii Modbus TCP No.: 7_5250_01950 04 E
 List of Illustrations

Fig. 1 Insert the communication module .............................................................................................. 7

Fig. 2 Bus cable conduit with shielding ................................................................................................ 8
Fig. 3 Strip the isolation from the network cable. ................................................................................. 8
Fig. 4 Inserting the network cable conductors ...................................................................................... 8
Fig. 5 Positioning the network cable ..................................................................................................... 9
Fig. 6 Close the lid of the RJ45 plug. ................................................................................................... 9
Fig. 7 Rotating the locking piece to the stop ........................................................................................ 9
Fig. 8 Communication module Modbus TCP LEDs and interface ..................................................... 13

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 List of Illustrations

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iv Modbus TCP No.: 7_5250_01950 04 E
 List of Tables

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

Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Technical specifications Modbus TCP interface ......................................................................... 3
Tab. 4 Allocation of the Modbus TCP interface ..................................................................................... 3
Tab. 5 Modbus TCP Interface - recommended conduit ......................................................................... 3
Tab. 6 Scope of delivery ........................................................................................................................ 5
Tab. 7 Setting of the Start parameter td ............................................................................................... 12
Tab. 8 Setting of the Timeout parameter ............................................................................................... 12
Tab. 9 Communication module Modbus TCP Interpretation of LEDs ................................................. 13
Tab. 10 Warning message Bus alarm .................................................................................................... 14
Tab. 11 Fault indication in the Communication Com-Module menu. .................................................... 14

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 List of Tables

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vi Modbus TCP No.: 7_5250_01950 04 E
 1 Regarding this document
1.1 Pertinence to the product

1 Regarding this document

1.1 Pertinence to the product
This document describes the Modbus TCP retrofit kit for machine with KAESER controller. It sup
plements 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 danger Will result in death or severe injury
WARNING Warns of a potentially imminent 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 definitions (personal injury)

Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
Example:

DANGER
The type and source of the imminent danger is shown here!
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 type and source of the imminent danger is shown here!
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.

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 1 Regarding this document
1.2 Symbols and labels

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
NOTICE Warns of a potentially dangerous situation Damage to property is possible

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

Example:

NOTICE
The type and source of the imminent danger is shown here!
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

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.
The conditions relevant to safety shown here 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.
This symbol identifies important information or measures regarding the protection of the envi
ronment.

Further information Further subjects are introduced here.

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2 Modbus TCP No.: 7_5250_01950 04 E
 2 Technical Specifications
2.1 Technical specification

2 Technical Specifications
2.1 Technical specification
The retrofit kit Modbus TCP is a communication module with accessory for the installation in the
intended KAESER controls. The module is connected to the user's bus system via its bus interface.

Modbus TCP Interface

Feature Value
Bus Modbus TCP Server (Slave)
Connection 2x RJ45 socket (Cat5e, shielded), integrated 2-port switch, potential separa
tion
Baud rate [MBit/s] 10/100, full duplex or half-duplex
Input data (byte) 64
Output data (byte) 128 (process data) and 42 (diagnosis data)
Data content "Technical description SIGMA CONTROL 2 process image",
Document 7_7601_PA_0xD.

Tab. 3 Technical specifications Modbus TCP interface

Allocation of the Modbus TCP interface

Pin * Signal Wire colour Description

1 TD+ Yellow Send positive (positive transmit)
2 TD Orange Send negative (negative Transmit)
3 RD+ White Receive positive (positive receive)
4
5
6 RD- blue Receive negative (negative receive)
7
8
Enclosure Cable shield High-resistance (1 MOhm/47 nF) connected with functional
earth (FE)
* Position of pins 1 through 8, see chapter 6

Tab. 4 Allocation of the Modbus TCP interface

Recommended conduit

Feature Value
Line Network line, CAT5 shielded, copper, e.g.: 7.7629.0
Plug Bus connection plug RJ45, IP20, e.g.: 7.7628.0
Maximum cable length [m] 100

Tab. 5 Modbus TCP Interface - recommended conduit

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 3 Safety and Responsibility
3.1 Basic instructions

3 Safety and Responsibility

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.

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4 Modbus TCP No.: 7_5250_01950 04 E
 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

This retrofit kit consists of:
Item Material No. Name 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 7.7628.0 RJ45 bus connector 2
60 7.7606.00050 Communications module Modbus TCP -2P 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. 6 Scope of delivery

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 4 Installation
4.3 Isolating the machine from the power supply system

4.3 Isolating the machine from the power supply system

DANGER
Danger of fatal injury from electric shock!
Isolate the machine and external sources from all voltage.

1. Shut down the machine with the OFF key

2. Isolate the machine from all power phases.
3. Lock against unintended activation.
4. Verify the absence of any voltage.

4.4 Removing the EMERGENCY STOP command device

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 off, the absence of any voltage has been
verified.

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 Modbus TCP
Network line CAT5 2x2x0,64; bulk material, e.g. 7.7629.0
Screwdriver: Torx T9, slotted screwdriver: 2.5 3 mm blade width

Precondition The power supply is switched off, the device is locked off, the absence of any voltage has been
verified.

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.

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6 Modbus TCP No.: 7_5250_01950 04 E
 4 Installation
4.6 Connecting SIGMA CONTROL 2 to the bus system

Fig. 1 Insert the communication module

1 Communication module
2 SIGMA CONTROL 2
3 Fastening screw

4. Push the module from beneath into the bay until it latches audibly.
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.

4.6 Connecting SIGMA CONTROL 2 to the bus system

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

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 16.5mm.
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 24V DC 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.

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 4 Installation
4.6 Connecting SIGMA CONTROL 2 to the bus system

Fig. 2 Bus cable conduit with shielding

6. Push the bus cables into the screw fittings util the stripped area has contact with the springs in
the EMC screw fitting (see Fig. 2).
7. Close all installed screw fittings.

4.6.2 Installing 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. 3 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. 3).
2. Spread the conductors according to the colour coding of the contact element of the RJ45 con
nector (see Fig. 3).

Fig. 4 Inserting the network cable conductors

3. Insert the conductors into the contact elements up to the end stop.

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8 Modbus TCP No.: 7_5250_01950 04 E
 4 Installation
4.6 Connecting SIGMA CONTROL 2 to the bus system

Fig. 5 Positioning the network cable

4. Position the network cable as shown (arrows, see Fig. 5).

Fig. 6 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. 7 Rotating the locking piece to the stop

6 RJ45 plug (view from cable end)
7 Screwdriver

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 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 SIGMA CONTROL 2

Precondition The bus wiring to the bus master is ready.

1. Plug the bus plug into the bus interface of the communication module.
2. 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

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.

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10 Modbus TCP No.: 7_5250_01950 04 E
 5 Initial Start-up
5.1 Switching the machine on

5 Initial Start-up
5.1 Switching the machine on
Precondition The communication module is correctly installed and connected (see chapter 4).
The bus wiring to the bus master is ready.
The machine is parametrised in the bus master.
The bus master is operational.

1. Close the control cabinet.

2. Activate the power supply of the machine at the main disconnect switch.
3. Press ON to activate the machine.

5.2 Testing the EMERGENCY OFF command device

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 Activating the communication module

Request the required information about IP address , Subnet mask , Gateway , DNS server
from your IT department.

1. Select the 8.2.(3) < Communication Com-Module ( Modbus TCP )> menu.
2. Setting the IP address
3. Setting the Subnet mask
4. Setting the Gateway address.
5. If necessary, set other addresses.
6. Set the reaction in the event of a bus fault (see chapter 5.3.1).
7. Start the communication by placing a check mark after < Com-Module Start >.
If monitoring of the bus communication is activated at user level (check mark after Timeout ),
the number after Status Counter ( Run ) will continuously change during communication.

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 5 Initial Start-up
5.4 Activating the remote control

5.3.1 Reaction in a bus fault

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.

Configuration Start td
Factory setting 15 s

Tab. 7 Setting of the Start parameter td

SIGMA CONTROL 2 can monitor the bus communication 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 monitoring by setting a check mark .

Configuration Timeout Monitoring

Factory setting 5s Check mark activated

Tab. 8 Setting of the Timeout parameter

5.4 Activating the remote control

When the machine is tobe controlled via the bus, activate the remote control as follows:

Precondition Access level 2 is activated.

Menu Communication is selected.

1. Press DOWN repeatedly until Key remote : is displayed as active line.

2. Press Enter.
The check box for Key remote flashes.
6.1 bar 08:15 80.0 C
8 Communication Menu
1 Ethernet
2 Com-Module
Key remote : Active line

Example for menu

3. Use the UP key to activate the check box.

4. Press Enter to accept the setting.
The Remote control function is activated and can be used.
5. Press the Remote control key to enable remote mode.

Result The green LED of the Remote control key illuminates. The bus master can remotely control the
SIGMA CONTROL 2 .

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12 Modbus TCP No.: 7_5250_01950 04 E
 6 Operation
6.1 Displays on the communication module

6 Operation
6.1 Displays on the communication module

The communication module features LEDs providing information about the module status.

Fig. 8 Communication module Modbus TCP LEDs and interface

1 Communication module 5 Modbus TCP Port 2
2 LED NS: Network status 6 LED link status Port 1
3 LED Module status 7 LED link status Port 2
4 Modbus TCP Port 1

LED Colour State Meaning

2 NS off Module without voltage or no IP address
Green illuminated continuously Module in operation, active or in idle
flashes Module is waiting for connection
Red illuminated continuously Double IP address or internal fault
flashes Monitoring time exceeded (time-out)
3 MS off Module without voltage
Green illuminated continuously Module in operation
Red illuminated continuously Internal fault, module in "EXCEPTION" state
flashes Fault in the diagnosis object or IP address conflict
6, 7 off No connection.
Green illuminated continuously Connection consists, 100 Mbit/s
flashes Communication running, 100 Mbit/s
Yellow illuminated continuously Connection consists, 10 Mbit/s
flashes Communication running, 10 Mbit/s

Tab. 9 Communication module Modbus TCP Interpretation of LEDs

6.2 Displays at SIGMA CONTROL 2

In the 8.2.(3) < Communication Com-Module ( Modbus TCP )> menu, the system displays
the communication status at activated monitoring of the bus communication at user levelas follows
(set check mark after Timeout ):
In fault-free communication, the number after Status Counter ( Run ) changes continuously.

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 7 Fault Recognition and Rectification
7.1 Fault-finding and rectification

7 Fault Recognition and Rectification

7.1 Fault-finding and rectification
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 Bus alarm Bus coupling via communication module is in Check bus conduits and plug.
terrupted.
Incorrect or faulty communication module Check communication mod
ule, see below.

Tab. 10 Warning message Bus alarm

In addition to the 0015 W Bus alarm warning message, the system displays the following informa
tion for troubleshooting:
1. For displays on the communication module, see Chapter 6.
Contact KAESER Service, if the LED MS is lit up red or the LED NS is lit up red during correct
setting of the IP address.
2. Displays in the menu < Communication Com-Module >.
In the menu 8.2.(3) < Communication Com-Module ( Modbus TCP )>, 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.
2 Communication Bus coupling via communi Check bus conduits and plug.
error cation module is interrup
ted.
IP address setting or bus
parameter of module are
incorrect.
3 Firmware fault Defective module.
4 Com module Module is not activated.
deactivated
5 Com module not No KAESER communica
recognised tion module.
90 Bus monitoring fault Bus master does not re
turn the toggle bit within
the monitoring interval.
Consult KAESER Service.
Set values at the SIGMA CONTROL 2 as
parametrised at the bus master. See chap
ter 5.3 for the setting.
Consult KAESER Service.
Start the communication (see chapter 5).
Use only original KAESER communication
module.
Check bus master software.
Check time-out time, see chapter 5
Deactivate monitoring if it has been ac
tivated inadvertently. See chapter 5.

Tab. 11 Fault indication in the Communication Com-Module menu.

Result The bus communication is automatically continued as soon as the cause of the fault is remedied.

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14 Modbus TCP No.: 7_5250_01950 04 E